Field transmitter with diagnostic self-test mode

• US 6,834,258 B2
• Filed: 12/31/2002
• Issued: 12/21/2004
• Est. Priority Date: 12/31/2002
• Status: Active Grant

• Current Assignee: Rosemount Incorporated (Emerson Electric Company)
• Original Assignee: Rosemount Incorporated (Emerson Electric Company)
• Inventors: Schulte, John P., Wang, Rongtai
• Primary Examiner(s): Barlow, John
• Assistant Examiner(s): PRETLOW, DEMETRIUS R
• Application Number:
  US10/335,380
• Publication Number:
  US 20040128110A1
• Time in Patent Office: 721 Days
• Field of Search: 702/104, 702/182, 702/183, 702/185, 714/30, 714/733
• US Class Current: 702/183
• CPC Class Codes: G01D 21/00 Measuring or testing not otherwise provided for
• CPC Class Codes: G01D 3/08 with provision for safeguarding the apparatus, e.g. against abnormal operation, against breakdown
• CPC Class Codes: G05B 23/0221 Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods

Abstract

A field transmitter for transmitting signals representative of process variables has both a normal operating mode and a diagnostic self-test mode. The field transmitter has a physical sensor for sensing a process variable and generating a physical sensor signal which is representative of the process variable. A signal processing circuit converts the sensor signal to a measurement which is transmitted to a control room. The field transmitter also has a surrogate sensor for producing a surrogate sensor signal which is independent of the process variable. During the diagnostic self-test mode, the surrogate sensor is connected to the signal processing circuit in place of the physical sensor. If the output of the signal processing circuit does not correspond to an expected value, a diagnostic code is produced.

Claims

1. A field transmitter for transmitting signals representative of process variables, the field transmitter comprising:

a physical sensor for sensing a process variable and generating a physical sensor signal which is representative of the process variable;

a surrogate sensor for producing a surrogate sensor signal which is independent of the process variable;

a signal processing circuit which converts an input signal to a measurement;

means for supplying the physical parameter sensor as the input signal to the signal processing circuit during a normal mode and supplying the surrogate sensor as the input signal to the signal processing circuit during a diagnostic mode;

means for transmitting an output signal over a communication link as a function of the measurement produced during the normal mode; and

means for performing a diagnostic evaluation based upon the measurement produced during the diagnostic mode.

2. The field transmitter of claim 1, further comprising:

means for providing an excitation signal to the physical sensor during the normal mode and the surrogate sensor during the diagnostic mode.

3. The field transmitter of claim 1, wherein the physical sensor comprises a capacitive pressure sensor.

4. The field transmitter of claim 3 wherein the surrogate sensor comprises a reference capacitor.

5. The field transmitter of claim 3, wherein the surrogate sensor comprises a plurality of reference capacitors.

6. The field transmitter of claim 1, wherein the physical sensor comprises a temperature sensor.

7. The field transmitter of claim 6, wherein the surrogate sensor comprises a reference voltage source.

8. The field transmitter of claim 7, wherein the surrogate sensor produces a zero voltage input signal.

9. The field transmitter of claim 1 wherein the physical sensor produces a variable capacitance as a function of the process variable.

10. The field transmitter of claim 9, wherein the signal processing circuit comprises a capacitance-to-digital (C/D) converter.

11. The field transmitter of claim 10 wherein the C/D converter includes a sigma delta modulator.

12. The field transmitter of claim 1 wherein the physical sensor produces a variable voltage as a function of the process variable.

13. The field transmitter of claim 12, wherein the signal processing circuit comprises a voltage-to-digital (V/D) converter.

14. The field transmitter of claim 13 wherein the V/D converter includes a sigma delta modulator.

15. The field transmitter of claim 1 and further comprising:

means for storing an expected value of the measurement during the diagnostic mode.

16. The field transmitter of claim 15 wherein the means for performing a diagnostic evaluation produces a diagnostic code bases on a comparison of the measurement during the diagnostic mode and the expected value.

17. The field transmitter of claim 1 wherein the signal processing circuit and the means for supplying are incorporated in an integrated circuit.

18. The field transmitter of claim 17 wherein the surrogate sensor is incorporated in the integrated circuit.

19. A field transmitter comprising:

a sensor;

a signal processor for producing a measurement output as a function of an input from the sensor;

a communication interface for providing a transmitter output as a function of the measurement output;

a diagnostic self-test circuit for providing, during a diagnostic mode, a diagnostic input to the signal processor in place of the input from the sensor; and

means for providing a diagnostic output based upon the measurement output of the signal processor in response to the diagnostic input.

20. The field transmitter of claim 19 wherein the sensor provides a variable capacitance input to the signal processor as a function of a sensed parameter.

21. The field transmitter of claim 20 wherein the diagnostic self-test circuit provides a reference capacitance input to the signal processor during the diagnostic mode.

22. The field transmitter of claim 21 wherein the diagnostic self-test circuit includes a plurality of selectable gain and linearization capacitors.

23. The field transmitter of claim 20 wherein the signal processor is a sigma delta capacitance-to-digital (C/D) modulator.

24. The field transmitter of claim 19 wherein the sensor provides a variable voltage input to the signal processor as a function of a sensed parameter.

25. The field transmitter of claim 24 wherein the diagnostic self-test circuit provides a reference voltage input to the signal processor during the diagnostic mode.

26. The field transmitter of claim 19 wherein the signal processor and the diagnostic self-test circuit are incorporated in an integrated circuit.

27. The field transmitter of claim 26 wherein the diagnostic self-test circuit generates the diagnostic input within the integrated circuit.

28. A field transmitter having a normal operating mode in which a sensor produces a sensor signal which is a function of a sensed parameter, a signal processor converts the sensor signal to a measurement value, and a communication interface transmits a transmitter output as a function of the measurement value, characterized by:

a diagnostic self-test circuit which substitutes a known surrogate signal for the sensor signal during a diagnostic mode; and

means for producing a diagnostic output based upon the measurement value produced by the signal processor during the diagnostic mode.

29. The field transmitter of claim 28 wherein the signal processor and the diagnostic self-test circuit are incorporated in an integrated circuit.

30. The field transmitter of claim 29 wherein the diagnostic self-test circuit generates the surrogate signal in the integrated circuit.

31. A field transmitter having a normal mode and a diagnostic self-test mode, the field transmitter comprising:

a sensor for sensing a parameter and producing a sensor signal;

a sigma delta modulator for producing a data signal as a function of the sensor signal during the normal mode and as a function of a surrogate signal during the diagnostic self-test mode;

a data processor for selecting the normal and diagnostic self-test modes, controlling transmission of a transmitter output as a function of the data signal produced during the normal mode, and causing transmission of a diagnostic code is the data signal produced during the diagnostic self-test mode indicates a malfunction.

32. A method of operating a field transmitter to provide a diagnostic self-test, the method comprising:

initiating a diagnostic self-test mode in which a known surrogate input replaces a sensor input to signal processing circuitry of the field transmitter; and

comparing an output of the signal processing circuitry with an expected output based upon the known surrogate input.

33. A method of claim 32 and further comprising:

producing a diagnostic code indicating a result of the diagnostic self-test based upon the comparing of the output of the signal processing circuitry with the expected output.

34. An integrated circuit for use in a field transmitter which produces an output as a function of a parameter sensed by a sensor, the integrated circuit comprising:

a signal processor for producing a measurement output as a function of an input from the sensor; and

a diagnostic self-test circuit for providing, during a diagnostic mode, a known diagnostic input to the signal processor in place of the input from the sensor, so that the measurement output of the signal processor during the diagnostic mode is a function of the known diagnostic input.

35. The integrated circuit of claim 34 wherein the diagnostic self-test circuit generates the diagnostic input within the integrated circuit.