Industrial process device utilizing piezoelectric transducer

• US 9,921,120 B2
• Filed: 07/31/2012
• Issued: 03/20/2018
• Est. Priority Date: 04/22/2008
• Status: Active Grant

• Current Assignee: Rosemount Incorporated (Emerson Electric Company)
• Original Assignee: Rosemount Incorporated (Emerson Electric Company)
• Inventors: Hedtke, Robert C.
• Primary Examiner(s): Shah, Manish S
• Assistant Examiner(s): MILLER, ROSE MARY
• Application Number:
  US13/562,772
• Publication Number:
  US 20130079895A1
• Time in Patent Office: 2,058 Days
• Field of Search: 73660, 7386118-86124, 310338, 310339, 310329, 310327
• CPC Class Codes: G01H 11/08 using piezoelectric devices
• CPC Class Codes: G01L 9/00 Measuring steady of quasi-steady pressure of fluid or fluent solid material by electric or magnetic pressure-sensitive elements G01L11/004 takes precedence; Transmitting or indicating the displacement of mechanical pressure-sensitive elements, used to measure the steady or quasi-steady pressure of a fluid or fluent solid material, by electric or magnetic means measuring differences of two or more pressure values G01L13/00; measuring two or more pressure values simultaneously G01L15/00
• CPC Class Codes: G01L 9/0008 using vibrations
• CPC Class Codes: G01L 9/0022 of a piezoelectric element
• CPC Class Codes: G05B 11/01 electric

Abstract

A process device for coupling to an industrial process for use in monitoring or controlling the process includes a device housing configured to physically couple to the industrial process. A process variable sensor is configured to measure a process variable and measurement circuitry coupled to the process variable sensor provides an output related to the sensed process variable. A piezoelectric transducer provides an electrical output related to pressure pulsations in the industrial process. Electrical circuitry in the housing includes an input configured to receive the electrical output from the piezoelectric sensor.

Claims

1. A process device for coupling to an industrial process for use in monitoring or controlling the process, comprising:

a device housing configured to physically couple to the industrial process;

a process variable sensor configured to measure a process variable;

measurement circuitry coupled to the process variable sensor having an output related to the sensed process variable;

a piezoelectric sensor having an electrical output related to pressure pulsations in the industrial process;

electrical circuitry in the housing having an input configured to receive the electrical output from the piezoelectric sensor;

a memory which stores nominal signal values comprising known signals from the piezoelectric sensor representative of pressure pulsations during nominal operation of the process arising due to operation of a component in the industrial process; and

output circuitry configured to provide an output related to the process variable sensed by the process variable sensor;

wherein the electrical circuitry is configured to diagnose operation of the industrial process based upon the electrical output from the piezoelectric sensor by comparing the electrical output from the piezoelectric sensor with nominal signal values stored in the memory and responsively providing an output indicative of a life expectancy of the component in the industrial process.

2. The apparatus of claim 1 wherein the process device is powered with the electrical output.

3. The apparatus of claim 1 including an analog to digital converter having a digital output related to the electrical output.

4. The apparatus of claim 1 including a microcontroller configured to perform diagnostics based upon the electrical output from the piezoelectric sensor.

5. The apparatus of claim 1 wherein the nominal signal values stored in the memory comprise amplitude values.

6. The apparatus of claim 1 wherein the nominal signal values stored in the memory comprise frequency values.

7. The apparatus of claim 1 wherein the nominal signal values stored in the memory comprise a signature.

8. The apparatus of claim 1 wherein the piezoelectric sensor is configured to receive a control signal which causes movement of the piezoelectric sensor.

9. The apparatus of claim 8 wherein movement of the piezoelectric sensor induces pressure pulsations in the process fluid which are sensed by the process variable sensor, the electrical circuitry further configured to diagnose process device operation based upon the sensed pressure pulsations.

10. The apparatus of claim 1 wherein the electrical circuitry includes power storage circuitry configured to store power from the piezoelectric sensor.

11. The apparatus of claim 10 wherein the power storage circuitry comprises a capacitor.

12. The apparatus of claim 11 wherein the capacitor comprises a supercapacitor.

13. The apparatus of claim 1 wherein the piezoelectric sensor is mounted in the housing of the process device.

14. The apparatus of claim 1 wherein the piezoelectric sensor is mounted in a sensor module of the process device.

15. The apparatus of claim 1 wherein the piezoelectric sensor is carried on a mounting flange used to couple the process device to the industrial process.

16. The apparatus of claim 1 wherein the piezoelectric sensor is positioned at a location which is spaced apart from the device housing.

17. The apparatus of claim 1 wherein the piezoelectric sensor couples to the process fluid through a resonant pipe.

18. The apparatus of claim 1 wherein the piezoelectric sensor couples to process fluid through a diaphragm.

19. A method for sensing pulsations in a process device coupled to an industrial process of the type used in monitoring a process variable of industrial process, the method comprising:

physically coupling a piezoelectric sensor to the industrial process;

receiving pressure pulsations from the industrial process through the physical coupling;

sensing a process variable with a process variable sensor;

providing a process variable output based upon the sensed process variable;

coupling the pressure pulsations to the piezoelectric sensor and providing an electrical output from the piezoelectric sensor in response to the pressure pulsations;

storing nominal signal values in a memory, the nominal signal values comprising comprising known signals from the piezoelectric sensor representative of pressure pulsations during nominal operation of the process arising due to operation of a component in the industrial process;

providing the electrical output to circuitry of the process device; and

providing an output related to the sensed process variable;

diagnosing operation of the industrial process based upon the electrical output by comparing the electrical output from the piezoelectric sensor with nominal signal values stored in the memory and responsively providing an output indicative of a life expectancy of the component in the industrial process.

20. The method of claim 19 including powering the electrical circuitry with the electrical output.

21. The method of claim 19 including digitizing the electrical output.

22. The method of claim 19 wherein the nominal signal values stored in the memory comprise amplitude values.

23. The method of claim 19 wherein the nominal signal values stored in the memory comprise frequency values.

24. The method of claim 19 wherein the nominal signal values stored in the memory comprise a signature.

25. The method of claim 19 including providing a control signal to the piezoelectric sensor which causes movement of the piezoelectric sensor.

26. The method of claim 25 wherein the movement of the piezoelectric sensor induces pressure pulsations in the process fluid and sensing the pressure pulsations with the process variable sensor, the method further including diagnosing process device operation based upon the sensed pressure pulsations.

27. The method of claim 19 wherein the piezoelectric sensor is mounted in the housing of the process device.

28. The method of claim 19 wherein the piezoelectric sensor is mounted in a sensor module of the process device.

29. The method of claim 19 wherein the piezoelectric sensor is carried on a mounting flange used to couple the process device to the industrial process.

30. The method of claim 19 wherein the piezoelectric sensor is positioned at a location which is spaced apart from the device housing.

31. The method of claim 19 wherein the piezoelectric sensor couples to process fluid through a resonant pipe.

32. The method of claim 19 wherein the piezoelectric sensor couples to process fluid through a diaphragm.