Variable power control for process control instruments

• US 6,686,831 B2
• Filed: 09/18/2001
• Issued: 02/03/2004
• Est. Priority Date: 01/23/2001
• Status: Active Grant

• Current Assignee: Schneider Electric Systems USA, Inc. (Schneider Electric SE)
• Original Assignee: Invensys Systems Incorporated (Invensys PLC)
• Inventors: Cook, Warren E., Kostadinov, Vladimir
• Primary Examiner(s): NGUYEN, MATTHEW VAN
• Application Number:
  US09/954,205
• Publication Number:
  US 20020097031A1
• Time in Patent Office: 868 Days
• Field of Search: 323/266, 323/268, 323/273, 323/275, 340/310.01, 340/310.02, 340/310.06, 340/825.77
• US Class Current: 323/273
• CPC Class Codes: G05B 19/0423 Input/output
• CPC Class Codes: G05B 2219/25428 Field device
• CPC Class Codes: G05B 2219/31121 Fielddevice, field controller, interface connected to fieldbus
• CPC Class Codes: G05B 2219/33192 Radio link, wireless
• CPC Class Codes: G05B 2219/33208 Superposition of control signals on supply lines
• CPC Class Codes: G05B 2219/34312 Power supply for servo delivered by, derived from 4-20-mA current loop

Abstract

A process control instrument includes a sensor/actuator portion and a transmitter portion connected to the sensor/actuator portion. The transmitter portion is operable to communicate with other process variable transmitters through a communication network. The transmitter includes a processing module and a power module operable to generate a power output supplied to at least the transmitter portion, wherein the power module is operable to adjust the power output based on a power control signal. Moreover, the power control signal may be generated by a controller device remote from the process control instrument and communicated to the process control instrument over the communication network. Additionally, the power module includes a power control module for adjusting the power output. This power control module includes an amplitude limiter operable to limit a power input to the process control instrument according to a controllable amplitude limit, and a power rate of change unit operable to limit a rate of change of the power input to the process control instrument according to a controllable adjustment rate limit.

Claims

1. A process control instrument comprising:

a sensor/actuator portion;

a transmitter portion connected to the sensor/actuator portion and operable to communicate with other process variable transmitters through a communication network, wherein the transmitter portion includes;

a processing module; and

a power module operable to generate a power output, wherein the power module is operable to adjust the power output supplied to at least the transmitter portion based on a power control signal.

2. The process control instrument of claim 1 wherein the power control signal is generated by a controller remote from the process control instrument and communicated to the process control instrument over the communication network.

3. The process control instrument of claim 1 wherein the power module comprises a power control module for adjusting the power output.

4. The process control instrument of claim 3 wherein the power control module comprises:

a limiter operable to limit a power input to the process control instrument according to a controllable limit; and

a power rate of change unit operable to limit a rate of change of the power input to the process control instrument according to a controllable adjustment rate limit.

5. The process control instrument of claim 4 wherein the controllable limit is automatically controlled by software.

6. The process control instrument of claim 4 wherein the controllable limit is controlled by human intervention.

7. The process control instrument of claim 4 wherein the controllable limit is automatically controlled by circuitry.

8. The process control instrument of claim 4 wherein the controllable adjustment rate limit is automatically controlled by software.

9. The process control instrument of claim 4 wherein the controllable adjustment rate limit is controlled by human intervention.

10. The process control instrument of claim 4 wherein the controllable adjustment rate limit is automatically controlled by circuitry.

11. The process control instrument of claim 4 wherein the controllable adjustment rate limit equals 1 mA/ms.

12. The process control instrument of claim 1 wherein the power output of the power module is an electric current supplied to at least the transmitter portion of the process control instrument.

13. The process control instrument of claim 1 wherein:

the communication network comprises a hard-wired communication pathway operable to supply a bus power to the power module, and

the power module uses the bus power as a source for the power output.

14. The process control instrument of claim 13 wherein the hard-wired communication pathway is configured in a bus-with-spurs topology.

15. The process control instrument of claim 13 wherein the hard-wired communication pathway is configured in a daisy-chain topology.

16. The process control instrument of claim 13 wherein the hard-wired communication pathway is configured in a tree topology.

17. The process control instrument of claim 13 wherein the hard-wired communication pathway is configured in a point-to-point topology.

18. A process control system comprising:

process control instruments, each of which includes a power control module that controls a maximum available power level for the process control instrument, wherein the power control module is operable to adjust the maximum available power level for the process control instrument based on a power control signal;

a communication network electrically connected to the process control instruments and operable to conduct communication signals among the process control instruments; and

a power supply operable to supply power to the process control instruments through the communication network.

19. The process control system of claim 18 further comprising a control station operable to generate the power control signal and control power distribution among the process control instruments.

20. The process control system of claim 19 wherein the control station is further operable to determine power loads of the process control instruments and distribute functions among the process control instruments to balance the power loads of the process control instruments.

21. The process control system of claim 20 wherein the control station distributes functions among the process control instruments to balance power consumption among at least one of individual process control instruments, groups of process control instruments, and segments of the communication network.

22. The process control system of claim 19 wherein the control station is further operable to control power distribution of a limited quantity of power among the process control instruments.

23. The process control system of claim 18 wherein the power control module comprises:

an amplitude limiter operable to limit the available power level of the process control instrument according to a controllable amplitude limit; and

a power rate of change unit operable to limit a rate of change of the available power level of the process control instrument according to a controllable adjustment rate limit.

24. The process control system of claim 23 wherein the controllable amplitude limit is automatically controlled by software.

25. The process control system of claim 23 wherein the controllable amplitude limit is controlled by human intervention.

26. The process control system of claim 23 wherein the controllable amplitude limit is automatically controlled by circuitry.

27. The process control system of claim 23 wherein the controllable adjustment rate limit is automatically controlled by software.

28. The process control system of claim 23 wherein the controllable adjustment rate limit is controlled by human intervention.

29. The process control system of claim 23 wherein the controllable adjustment rate limit is automatically controlled by circuitry.

30. The process control system of claim 23 wherein the controllable adjustment rate limit equals 1 mA/ms.

31. The process control system of claim 18, wherein the power control module supplies electric current to the process control instrument.

32. The process control system of claim 18 wherein:

the communication network comprises a hard-wired communication pathway operable to supply a bus power to the power control module, and

the power control module uses the bus power as a source for the available power level.

33. The process control system of claim 32 wherein the hard-wired communication pathway is configured in a bus-with-spurs topology.

34. The process control system of claim 32 wherein the hard-wired communication pathway is configured in a daisy-chain topology.

35. The process control system of claim 32 wherein the hard-wired communication pathway is configured in a tree topology.

36. The process control system of claim 32 wherein the hard-wired communication pathway is configured in a point-to-point topology.

37. A process control system power management method, comprising:

determining initial power requirements of power-consuming functions distributed among process control instruments which are electrically connected together by a network;

determining initial power loads of the process control instruments;

determining an available power level supplied by a power supply connected to the network; and

distributing the power-consuming functions among the process control instruments, based on at least one of the initial power requirements, the initial power loads, and the available power level, to balance power loads among the process control instruments.

38. The process control system power management method of claim 37 wherein distributing the power-consuming functions among the process control instruments is achieved using a control station connected to the network.

39. The process control system power management method of claim 37 further comprising determining line losses of network branches connecting the process control instruments.

40. The process control system power management method of claim 39 wherein distributing the power-consuming functions among the process control instruments is further based on the line losses of the network branches.

41. The process control system power management method of claim 37 wherein distributing the power-consuming functions among the process control instruments comprises producing a balance of the power loads with respect to individual process control instruments.

42. The process control system power management method of claim 37 wherein distributing the power-consuming functions among the process control instruments comprises producing a balance of the power loads with respect to segments of the network.

43. The process control system power management method of claim 37 wherein distributing the power-consuming functions among the process control instruments comprises producing a balance of the power loads with respect to a limited amount of power supplied by the power supply.

44. A process control system power management method comprising:

determining initial power requirements of power-consuming functions distributed among process control instruments which are electrically connected together by a network;

determining initial power loads of the process control instruments;

determining an available power level supplied by a power supply connected to the network; and

controlling power control modules associated with the process control instruments, based on at least one of the initial power requirements, the initial power loads, and the available power level, to adjust a power level available to individual process control instruments and to balance power loads among the process control instruments.

45. The process control system power management method of claim 44 wherein controlling the power control modules associated with the process control instruments is achieved using a control station connected to the network.

46. The process control system power management method of claim 44 further comprising determining line losses of network branches connecting the process control instruments.

47. The process control system power management method of claim 46 wherein controlling the power control modules associated with the process control instruments is further based on the line losses of network branches.

48. The process control system power management method of claim 44 wherein controlling the power control modules associated with the process control instruments comprises producing a balance of the power loads with respect to individual process control instruments.

49. The process control system power management method of claim 44 wherein controlling the power control modules associated with the process control instruments comprises producing a balance of the power loads with respect to segments of the network.

50. The process control system power management method of claim 44 wherein controlling the power control modules associated with the process control instruments comprises producing a balance of the power loads with respect to a limited amount of power supplied by the power supply.

51. A process control system power management method, comprising:

determining at least one of;

initial power requirements of power-consuming functions distributed among process control instruments which are connected by a network, initial power loads of the process control instruments, and an available power level supplied by a power supply connected to the network; and

distributing the power-consuming functions among the process control instruments, based on at least one of the initial power requirements of the power-consuming functions the initial power loads of the process control instruments, and the available power level supplied by the power supply, to balance power loads among the process control instruments.

52. The process control system power management method of claim 51, further comprising:

determining the initial power requirements of the power-consuming functions distributed among the process control instruments which are connected by a network;

determining the initial power loads of the process control instruments; and

determining the available power level supplied by a power supply connected to the network.

53. The process control system power management method of claim 51 wherein distributing the power-consuming functions includes using a control station connected to a network, which connects the process control instruments for distributing the power-consuming functions among the process control instruments.

54. The process control system power management method of claim 51 further comprising determining line losses of network branches connecting the process control instruments.

55. The process control system power management method of claim 54 wherein distributing the power-consuming functions among the process control instruments is further based on the line losses of the network branches.

56. The process control system power management method of claim 51 wherein distributing the power-consuming functions among the process control instruments comprises producing a balance of the power loads with respect to individual process control instruments.

57. The process control system power management method of claim 51 wherein distributing the power-consuming functions among the process control instruments comprises producing a balance of the power loads with respect to segments of a network to which the process control instruments are connected.

58. The process control system power management method of claim 51 wherein distributing the power-consuming functions among the process control instruments comprises producing a balance of the power loads with respect to a limited amount of power supplied by a power supply.

59. A process control system power management method comprising:

determining at least one of;

initial power requirements of power-consuming functions distributed among process control instruments which are connected together by a network, initial power loads of the process control instruments, and an available power level supplied by a power supply connected to the network; and

controlling power control modules associated with the process control instruments, based on at least one of the initial power requirements of the Power-consuming functions the initial power loads of the process control instruments, and the available power level supplied by the power supply, to adjust a power level available to each of the process control instruments and to balance power loads among the process control instruments.

60. The process control system power management method of claim 59, further comprising:

determining the initial power requirements of power-consuming functions distributed among the process control instruments which are connected together by a network;

determining the initial power loads of the process control instruments; and

determining the available power level supplied by a power supply connected to the network.

61. The process control system power management method of claim 59 wherein controlling the power control modules includes using a control station connected to a network, which connects the process control instruments for controlling the power control modules associated with the process control instruments.

62. The process control system power management method of claim 59 further comprising determining line losses of network branches connecting the process control instruments.

63. The process control system power management method of claim 62 wherein controlling the power control modules includes using the line losses of the network branches for controlling the power control modules associated with the process control instruments.

64. The process control system power management method of claim 59 wherein controlling the power control modules associated with the process control instruments comprises producing a balance of the power loads with respect to individual process control instruments.

65. The process control system power management method of claim 59 wherein controlling the power control modules associated with the process control instruments comprises producing a balance of the power loads with respect to segments of the network.

66. The process control system power management method of claim 59 wherein controlling the power control modules associated with the process control instruments comprises producing a balance of the power loads with respect to a limited amount of power supplied by a power supply.