Input channel diagnostics

• US 9,256,211 B2
• Filed: 02/15/2012
• Issued: 02/09/2016
• Est. Priority Date: 02/01/2008
• Status: Active Grant

• Current Assignee: Rockwell Automation, Inc.
• Original Assignee: Rockwell Automation, Inc.
• Inventors: Meagher, Thomas Bruce, Creech, Gerald Robert
• Primary Examiner(s): Nguyen, Vincent Q
• Application Number:
  US13/397,209
• Publication Number:
  US 20120146663A1
• Time in Patent Office: 1,455 Days
• Field of Search: 324/525, 324/522, 324/73.1, 324/76.11
• US Class Current: 1/1
• CPC Class Codes: G05B 9/02 electric

Abstract

This invention relates to input channel diagnostics for an industrial process control system. The invention provides improved apparatus and methods relating to fault containment, overload protection and input channel diagnostics.

Claims

1. A method of internally testing an input channel for a safety critical system, the method comprising:

adding a subliminal perturbation signal to an input signal to be applied to an input circuit;

detecting an output signal from the input circuit; and

assessing operability of the input channel by determining whether addition of said subliminal perturbation signal causes a change in said output signal.

2. The method of claim 1 wherein the subliminal perturbation signal is determined to be a subliminally scaled amplitude of an operating value of the output signal.

3. The method of claim 1 further comprising storing an input channel identity value locally on at least one channel processor.

4. The method of claim 3 further comprising comparing the input channel identity value to the detected output signal to detect individual channel independence faults.

5. The method of claim 1 wherein the input signal is passed from an input circuit that includes one or more series resistors that have a total resistance that is at least two orders of magnitude greater than the resistance of a conditioned sensor signal source.

6. The method of claim 5 wherein the series resistors resistance is three orders of magnitude greater than the resistance of the conditioned sensor signal source.

7. The method of claim 5 further comprising low pass noise filtering the conditioned sensor signal source by positioning a low value capacitor in parallel with a signal source voltage.

8. The method of claim 5 further comprising passing the input signal through a fuse that is oriented in series with the one or more series resistors and has an operating threshold that is lower than an operating threshold of the one or more series resistors.

9. The method of claim 8 further comprising providing a load termination wetting current and a voltage attenuation by a Zener diode oriented in series with the fuse and in parallel with one or more series resistors.

10. A method of internally testing an input channel for a safety critical system, the method comprising:

adding a perturbation signal to an input signal to be applied to an input circuit;

detecting an output signal from the input circuit;

determining whether addition of said perturbation signal causes a change in said output signal;

passing the input signal from an input circuit that includes one or more series resistors that have a total resistance that is at least two orders of magnitude greater than the resistance of a conditioned sensor signal source; and

passing the input signal through a fuse that is oriented in series with the one or more series resistors and has an operating threshold that is lower than an operating threshold of the one or more series resistors.

11. The method of claim 10 further comprising providing a load termination wetting current and a voltage attenuation by a Zener diode oriented in series with the fuse and in parallel with one or more series resistors.