Local device and process diagnostics in a process control network having distributed control functions

• US 6,026,352 A
• Filed: 10/07/1998
• Issued: 02/15/2000
• Est. Priority Date: 10/04/1996
• Status: Expired due to Term

• Current Assignee: Fisher Controls International LLC (Emerson Electric Company)
• Original Assignee: Fisher Controls International LLC (Emerson Electric Company)
• Inventors: Larson, Brent H., Brown, Larry K., Burns, Harry A.
• Primary Examiner(s): Shah, Kamini
• Application Number:
  US09/167,766
• Time in Patent Office: 496 Days
• Field of Search: 702/122, 702/182, 364/140, 364/188, 364/138, 364/172, 340/870.11, 709/103
• US Class Current: 702/182
• CPC Class Codes: G05B 19/0425 Safety, monitoring
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/25428 Field device
• CPC Class Codes: G05B 2219/31211 Communicate diagnostic data from intelligent field device controller to central
• CPC Class Codes: G05B 2219/33326 Analyzer, diagnostic for servovalve
• CPC Class Codes: G05B 2219/33331 Test, diagnostic of field device for correct device, correct parameters
• CPC Class Codes: G05B 2219/34427 Diagnostic, monitoring incorporated in controller
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

A field device for use in a process control network having a plurality of devices communicatively coupled by a two-wire, all-digital communication bus includes a connector that connects the field device to the two-wire, all-digital bus to enable all-digital communication over the bus, a memory that stores a diagnostic test routine having a series of device or process diagnostic test instructions, and a controller that performs the device or process diagnostic test instructions stored in the memory to implement a device or process diagnostic test using the field device. A data collection unit within the field device collects diagnostic data generated during the diagnostic test and a communication unit communicates the collected diagnostic data over the bus to a host device for processing. The controller may include a program language interpreter adapted to interpret the diagnostic test instructions which may be provided to the field device from another one of the devices via the bus.

Claims

1. A field device for use in a process control system including a plurality of field devices mutually coupled by a two-wire, digital, powered bus, the bus supplying a field device control signal to the field device, the field device comprising:

a pneumatically operated fluid control valve having an actuator connected to a pneumatic pressure line, wherein said actuator is adapted to cause the fluid control valve to move to a position ranging from an open position to a closed position;

a position sensor coupled to the fluid control valve that senses the position of the fluid control valve;

a pressure sensor coupled to the pneumatic pressure line that senses a pneumatic pressure within the pneumatic pressure line;

an electrical to pneumatic transducer coupled to the actuator by the pneumatic pressure line adapted to control the pneumatic pressure in the pneumatic pressure line as a function of an electrical signal;

an electronic controller communicatively coupled directly to the electrical to pneumatic transducer, the pressure sensor, and the position sensor other than through the bus, the electronic controller including a control logic that determines the electrical signal based on feedback signals indicative of a pressure sensed by the pressure sensor and a position sensed by the position sensor and based on the field device control signal; and

a digital interface coupled to the two-wire, digital, powered bus and coupled to the electronic controller, the digital interface including;

a power circuit adapted to be coupled to the bus that supplies power derived from the powered bus to the electronic controller and the electrical to pneumatic transducer, and

a two-way communication circuit adapted to receive a field device control signal from the bus and to transmit signals indicative of a status of the field device to the bus.

2. A field device according to claim 1, further including a pneumatic relay coupled on the pneumatic pressure line between the electrical to pneumatic transducer and the valve and the pressure sensor is coupled to the pneumatic pressure line between the electrical to pneumatic transducer and the pneumatic relay.

3. A field device according to claim 2, including a further pressure sensor coupled to the pneumatic pressure line between the pneumatic relay and the valve.

4. A field device according to claim 1, further including a pneumatic relay coupled on the pneumatic pressure line between the electrical to pneumatic transducer and the valve and the pressure sensor is coupled to the pneumatic pressure line between the pneumatic relay and the valve.

5. A field device according to claim 1, wherein the pneumatic pressure line includes a pressure supply line that is coupled to an input of the electrical to pneumatic transducer and the pressure sensor is coupled to the pneumatic pressure supply line to measure the pressure supplied to the input of the electrical to pneumatic transducer.

6. A field device according to claim 1, further comprising:

a second control logic for execution in the electronic controller for executing and controlling a diagnostic valve test protocol in response to a diagnostic test request received from the bus and for generating valve diagnostic data corresponding to variations in pressure measured by the pressure sensor and variations in valve position measured by the position sensor, and a storage coupled to the electronic controller for storing the valve diagnostic data.

7. A field device according to claim 6, further comprising:

a third control logic for execution in the electronic controller for digitally transmitting valve diagnostic data to the bus.

8. A field device according to claim 7, wherein the field device executes the diagnostic test protocol independently of operations of other field devices on the bus.

9. A field device according to claim 1, wherein the digital interface communicates via the two-wire, digital, powered bus using a Fieldbus standard communication protocol.

10. A process control system comprising:

a control console for generating commands and receiving data;

a two-wire, digital, powered bus coupled to the control console; and

a plurality of field devices mutually coupled by the two-wire, digital, powered bus,

the bus supplying commands including a field device control signal to the field devices, one of the field devices including;

a pneumatically operated fluid control valve having an actuator coupled to a pneumatic pressure line to cause the fluid control valve to move to a position ranging from an open position to a closed position;

a position sensor coupled to the fluid control valve for sensing the position of the fluid control valve;

a pressure sensor coupled to the pneumatic pressure line for sensing the pneumatic pressure within the pressure line;

an electrical to pneumatic transducer coupled to the valve by the pneumatic pressure line for controlling the pneumatic pressure in the pneumatic pressure line as a function of an electrical signal;

an electronic controller communicatively coupled directly to the electrical to pneumatic transducer, the pressure sensor, and the position sensor other than through the bus, the electronic controller including a control logic that determines the electrical signal based on feedback signals indicative of a pressure sensed by the pressure sensor and a position sensed by the position sensor and based on the field device control signal; and

a digital interface coupled to the two-wire, digital, powered bus and coupled to the electronic controller, the digital interface including;

a circuit for supplying power derived from the powered bus to the field device including the electronic controller and the electrical to pneumatic transducer, and

a two-way communication circuit for receiving signals including the field device control signal from the bus and transmitting signals indicative of a status of the field device to the bus.

11. A process control system according to claim 10, further including a pneumatic relay coupled on the pneumatic pressure line between the electrical to pneumatic transducer and the valve and the pressure sensor is coupled to the pneumatic pressure line between the electrical to pneumatic transducer and the pneumatic relay.

12. A process control system according to claim 10, further including a pneumatic relay coupled on the pneumatic pressure line between the electrical to pneumatic transducer and the valve and the pressure sensor is coupled to the pneumatic pressure line between the pneumatic relay and the valve.

13. A process control system according to claim 10, wherein the pneumatic pressure line includes a pressure supply line that is coupled to an input of the electrical to pneumatic transducer and the pressure sensor is coupled to the pressure supply line to measure the pressure supplied to the input of the electrical to pneumatic transducer.

14. A process control system according to claim 10, further comprising:

a second control logic for execution in the electronic controller for executing and controlling a diagnostic valve test protocol in response to a diagnostic test request received from the bus and for generating valve diagnostic data corresponding to variations in pressure measured by the pressure sensor and variations in valve position measured by the position sensor; and

a storage coupled to the electronic controller for storing the valve diagnostic data.

15. A process control system according to claim 14, further comprising:

a third control logic for execution in the electronic controller for digitally transmitting valve diagnostic data to the bus.

16. A process control system according to claim 15, wherein the field device executes the diagnostic test protocol independently of operations of other field devices on the bus.

17. A process control system according to claim 10 wherein:

the control console includes an operating logic for generating and transmitting a plurality of diagnostic test commands for a plurality of field devices; and

the plurality of field devices each includes further operating logic for executing the diagnostic test commands independently of operations of other field devices on the bus so that the operations are executed in parallel.