Device in a process system for validating a control signal from a field device

• US 6,047,220 A
• Filed: 12/29/1997
• Issued: 04/04/2000
• Est. Priority Date: 12/31/1996
• Status: Expired due to Term

• Current Assignee: Rosemount Incorporated (Emerson Electric Company)
• Original Assignee: Rosemount Incorporated (Emerson Electric Company)
• Inventors: Eryurek, Evren
• Primary Examiner(s): Grant, William
• Assistant Examiner(s): Marc, McDieunel, Marc, McDieunel
• Application Number:
  US08/998,906
• Time in Patent Office: 827 Days
• Field of Search: 700/10, 700/12, 700/271, 700/287, 700/28, 700/33, 700/29
• US Class Current: 700/28
• CPC Class Codes: G05B 13/0285 using neural networks and fuzzy logic
• CPC Class Codes: G05B 19/042 using digital processors G05B19/05 takes precedence
• CPC Class Codes: G05B 19/418 Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
• CPC Class Codes: G05B 2219/25428 Field device
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A device in a process control system includes a memory for storing a series of sensed process variables and command outputs representative of a learned process cycle. Comparison circuitry compares recent process information to learned process information stored in the memory and responsively provides a validity output signal. A method includes learning a cycle of a process to provide learned process information which comprises stored process variables and stored control signals over a time period, measuring a process variable in the process and responsively calculating the control output, storing the process variable in the control output to provide recent process information, and comparing the recent process information to the learned process information and responsively providing a validity output signal.

Claims

1. A method for validating a control output from a field device in a process, the method comprising:

learning a cycle of the process to provide a learned process information, the learned process information comprising stored process variables and stored control outputs over a specified time period;

measuring a current process variable in the process and calculating the current control output for the process as a function of the current process variable to provide current process information; and

comparing the current process information to the learned process information in a validation circuit and providing a validity signal, the validity signal indicating that the current control output has exceeded a predetermined boundary derived from the learned process information.

2. The method of claim 1 wherein the steps are performed in the field device.

3. The method of claim 1 wherein the process variable is measured at a first location and the control output is calculated at a second location and the comparing is performed at the second location.

4. The method of claim 1 wherein process variable measured in a first location, the control output calculated at a second location and the comparing is performed at a third location.

5. The method of claim 1 wherein the learned process information is modeled in a fuzzy logic algorithm.

6. The method of claim 1 wherein the learned process information is modeled by a neural network.

7. The method of claim 1 wherein the learned process information is modeled by a regression algorithm.

8. A two-wire device of the type used in the process control industry, comprising:

a process variable input receiving a process variable;

a control circuit for calculating a control output as a function of the sensed process variable and the setpoint;

a memory for storing a series of sensed process variables and command outputs representative of a learned process cycle;

an output circuit for formatting the control output onto the two wires; and

a validation circuit which compares the learned process cycle to the sensed process variable and command output to responsively provide a validation signal representative of a state of the control system, the validation signal indicating that the current control output has exceeded a predetermined boundary derived from the learned process information.

9. The device of claim 8 including a compensation circuit compensating the process variable.

10. The device of claim 8 wherein the learned process cycle is modeled in a fuzzy logic algorithm.

11. The device of claim 8 wherein the learned process cycle is modeled by a neural network.

12. The device of claim 8 wherein the learned process cycle is modeled by a regression algorithm.

13. The device of claim 8 wherein the process variable input comprises a sensor for sensing a process variable.

14. The device of claim 8 wherein the device is wholly powered through the two-wire loop.

15. The device of claim 8 wherein the device comprises a transmitter.