Hydraulic piston position sensor signal processing

• US 6,722,261 B1
• Filed: 12/11/2002
• Issued: 04/20/2004
• Est. Priority Date: 12/11/2002
• Status: Active Grant

• Current Assignee: Rosemount Incorporated (Emerson Electric Company)
• Original Assignee: Rosemount Incorporated (Emerson Electric Company)
• Inventors: Johnson, James A., Lovegren, Eric R., Brown, Gregory C.
• Primary Examiner(s): Lazo, Thomas E.
• Application Number:
  US10/316,777
• Time in Patent Office: 496 Days
• Field of Search: 91/1, 913/61, 92/5.R, 604/59, 324/642
• US Class Current: 92/5.00R
• CPC Class Codes: F15B 15/2869 using electromagnetic radiation, e.g. radar or microwaves
• CPC Class Codes: G01D 5/48 using wave or particle radiation means G01D5/26 takes precedence

Abstract

A piston position in a cylinder of a hydraulic assembly is measured using microwave pulses. The microwave pulses are launched along a conductor coupled to the piston or cylinder. A sliding member is slidably coupled to the conductor and moves with the piston or cylinder. Position is determined as a function of a reflection from the end of the conductor and the sliding member. Various aspects include signal processing, fudicial pulse identification control and input/output circuitry, and a three conductor configuration.

Claims

1. An apparatus for measuring relative position of a hydraulic piston in a cylinder, comprising:

an antenna rod extending in a direction of movement of the piston fixedly coupled to the cylinder, the rod configured to carry a microwave pulse between a coupling and a distal end of the rod;

a sliding member slidably coupled to the piston, the sliding member configured to cause a partial reflection of the microwave pulse;

a fudicial member coupled to a proximal end of the antenna rod and configured to generate a fudicial reference reflection in response to a microwave pulse;

microwave transceiver circuitry coupled to the antenna rod configured to generate and receive microwave pulses; and

computation circuitry configured to calculate piston position;

wherein an amplitude of a fudicial reference reflection is related to piston position when the piston is proximate the fudicial member and the computation circuitry calculates piston position based upon the amplitude of the fudicial reference pulse when the piston is proximate the fudicial member.

2. The apparatus of claim 1 wherein the antenna rod includes a reference conductor surrounded by an outer conductor.

3. The apparatus of claim 1 including a controller configured to provide a control signal to a hydraulic actuator as a function of piston position.

4. The apparatus of claim 1 including a programmable discrete input/output line.

5. The apparatus of claim 1 including a digital computation device configured to process a signal which is a function of a reflected microwave pulse and a pulse delayed within the transducer circuitry.

6. The apparatus of claim 1 wherein a relationship between piston position and amplitude of the fudicial reference reflection is substantially monotonic.

7. The apparatus of claim 1 wherein the calculation circuitry calculates piston position using a look-up table.

8. The apparatus of claim 1 wherein the calculation circuitry calculates piston position using a polynomial equation.

9. The apparatus of claim 1 wherein the computation circuitry calculates piston position based upon a time delay of the microwave pulse reflected by the sliding member.

10. An apparatus for measuring relative position of a hydraulic piston in a cylinder, comprising:

an antenna rod extending in a direction of movement of the piston fixedly coupled to the cylinder, the rod configured to carry a microwave pulse between a coupling and a distal end of the rod, the antenna rod comprising a reference conductor at least partially within an outer conductor;

a sliding member slidably coupled to the outer conductor of the antenna rod and slidable as the piston moves within the cylinder to cause a partial reflection of the microwave pulse;

microwave transceiver circuitry coupled to the antenna rod configured to generate and receive microwave pulses; and

computation circuitry configured to calculate piston position as a function of reflected microwave pulses carried on the outer conductor and reflected microwave pulses carried on the reference conductor of the antenna rod.

11. The apparatus of claim 10 wherein the outer conductor has a tubular shape.

12. The apparatus of claim 10 including switching circuitry configured to selectively couple the microwave transceiver to the outer conductor of the antenna rod.

13. The apparatus of claim 10 wherein the reference conductor comprises an elongate conductor extending along an interior of the outer conductor.

14. The apparatus of claim 13 wherein the reference conductor extends along a center of the outer conductor.

15. The apparatus of claim 10 wherein the outer conductor has a tubular shape.

16. The apparatus of claim 10 further comprising a fudicial member coupled to the antenna rod to generate a fudicial reference reflection and wherein piston position is calculated as a function of amplitude of a reflected fudicial reference pulse when the piston is proximate a fudicial member.

17. The apparatus of claim 10 including a controller which provides a control signal to a hydraulic actuator as a function of piston position.

18. The apparatus of claim 10 including a programmable discrete input/output line.

19. The apparatus of claim 10 including a digital computation device configured to process a signal which is a function of a reflected microwave pulse and a delayed microwave pulse.

20. An apparatus for measuring relative position of a hydraulic piston in a cylinder, comprising:

an antenna rod extending in a direction of movement of the piston fixedly coupled to the cylinder, the rod configured to carry a microwave pulse between a coupling and a distal end of the rod;

a sliding member slidably coupled to the piston, the sliding member configured to cause a partial reflection of the microwave pulse;

a fudicial member coupled to a proximal end of the antenna rod configured to generate a fudicial reference reflection in response to a microwave pulse;

microwave transceiver circuitry coupled to the antenna rod configured to generate and receive microwave pulses;

computation circuitry configured to calculate a piston position as a function of the partial reflection of the microwave pulse from the sliding member; and

control circuitry configured to provide a control signal to a hydraulic actuator in response to a command input and the piston position, the control signal a function of at least one of an integral or derivative of the piston position.

21. The apparatus of claim 20 including a pressure sensor configured to sense pressure of hydraulic fluid from the hydraulic actuator and wherein the control signal is further a function of the sensed pressure.

22. The apparatus of claim 20 wherein the antenna rod includes a reference conductor in an outer conductor.

23. The apparatus of claim 20 wherein piston position is calculated as a function of amplitude of a microwave pulse reflected from a fudicial member when the piston is proximate the fudicial member.

24. The apparatus of claim 20 including a programmable discrete input/output line.

25. The apparatus of claim 20 including a digital computation device configured to process a signal which is a function of a reflected microwave pulse and a delayed microwave pulse.

26. The apparatus of claim 20 wherein the control circuitry provides cushioning in the control signal as the piston approaches an end of the cylinder.

27. An apparatus for measuring relative position of a hydraulic piston in a cylinder, comprising:

an antenna rod extending in a direction of movement of the piston fixedly coupled to the cylinder, the rod configured to carry a microwave pulse between a coupling and a distal end of the rod;

a sliding member slidably coupled to the piston, the sliding member configured to cause a partial reflection of the microwave pulse;

a fudicial member coupled to a proximal end of the antenna rod configured to generate a fudicial reference reflection in response to a microwave pulse;

microwave transceiver circuitry coupled to the antenna rod configured to generate and receive microwave pulses;

computation circuitry configured to calculate a piston position as a function of the partial reflection of the microwave pulse from the sliding member; and

control circuitry including an input/output (I/O) connection having a plurality of programmable functions.

28. The apparatus of claim 27 wherein the input/output connection comprises a switched output.

29. The apparatus of claim 27 wherein the input/output connection comprises a voltage level output.

30. The apparatus of claim 27 wherein the input/output connection comprises a current level output.

31. The apparatus of claim 27 wherein the input/output connection comprises an input for receiving a set point for a limit switch function.

32. The apparatus of claim 27 wherein the input/output connection provides an alarm condition output.

33. The apparatus of claim 32 wherein the alarm condition is selected from the group of conditions consisting of excessive temperature, sub-operating temperature, measurement out of range, self-test failure, antenna open circuit, antenna short circuit, maximum velocity exceeded and electronic cushioning failure.

34. The apparatus of claim 27 including an input for use in programming a function of the input/output connection.

35. The apparatus of claim 27 including a controller configured to provide a control signal to a hydraulic actuator as a function of piston position.

36. The apparatus of claim 27 including a digital computation device configured to process a signal which is a function of a reflected microwave pulse and a delayed microwave pulse.

37. An apparatus for measuring relative position of a hydraulic piston in a cylinder, comprising:

an antenna rod extending in a direction of movement of the piston fixedly coupled to the cylinder, the rod configured to carry a microwave pulse between a coupling and a distal end of the rod;

a sliding member slidably coupled to the piston, the sliding member configured to cause a partial reflection of the microwave pulse;

a fudicial member coupled to a proximal end of the antenna rod configured to generate a fudicial reference reflection in response to a microwave pulse;

microwave transceiver circuitry coupled to the antenna rod configured to generate and receive microwave pulses; and

computation circuitry configured to calculate piston position as a function of a time delay in microwave pulses reflected from the sliding member, the computation circuitry including a digital computation device configured to digitally process a signal received from the microwave transceiver.

38. The apparatus of claim 37 wherein the computation circuitry controls operation of the microwave transceiver.

39. The apparatus of claim 38 including a digital to analog converter configured to convert a digital output from the computation circuitry to an analog signal which controls operation of the microwave transceiver.

40. The apparatus of claim 37 wherein the computation circuitry controls a scan range of the microwave transceiver.

41. The apparatus of claim 37 wherein the computation circuitry controls a resolution of the microwave transceiver.

42. The apparatus of claim 37 wherein the computation circuitry controls an update rate of the microwave transceiver.

43. The apparatus of claim 37 wherein the computation circuitry adjusts for a distance between the microwave transceiver and the antenna rod.

44. The apparatus of claim 37 wherein the computation circuitry controls a transmit power of the microwave transceiver.

45. The apparatus of claim 37 including a controller configured to provide a control signal to a hydraulic actuator as a function of piston position.

46. The apparatus of claim 37 including a programmable discrete input/output line.