CN102016735A - 利用压电式换能器的工业过程装置 - Google Patents
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Abstract
一种用于接合至工业过程的过程装置(200),用于监测或控制所述过程,包括构造为物理地接合至所述工业过程的装置壳体(202)。过程变量传感器(18)构造为测量过程变量,并且接合至该过程变量传感器(18)的测量电路提供与所感测的过程变量相关的输出。压电式换能器(68)提供与所述工业过程中的压力脉动相关的电输出(210)。所述壳体中的电子线路包括构造为接收来自压电传感器的电输出的输入装置。
Description
技术领域
本发明涉及用来接合至工业过程控制和监测系统类型的工业过程装置。
背景技术
在工业设置中,控制系统用来监测和控制工业和化学过程等的存量。典型地,控制系统采用分布在工业过程中的关键位置处并由过程控制环接合至位于控制室中的控制电路的现场设备执行这些功能。术语“现场设备”涉及执行分布式控制或过程监测系统中的功能的任何设备,包括用在工业过程的测量、控制和监测中的所有设备。
一些现场设备包括过程变量传感器。典型地,换能器将输入转化成具有不同形式的输出。换能器的类型包括多种分析装置、压力传感器、电热调节器、热电偶、应变仪、流量变送器、定位器、传动装置、螺线管、指示灯和其它的。其它的现场设备包括控制元件,并用来控制工业过程。这种过程装置的例子包括阀控制器、阀位置控制器、加热器控制器、泵控制器等。
在多种过程装备中,过程装置经历脉动。这些脉动会在过程的正常操作期间出现。
发明内容
一种用于接合至工业过程的过程装置,用于监测或控制所述过程,包括构造为物理地接合至所述工业过程的装置壳体。过程变量传感器构造为测量过程变量,并且接合至过程变量传感器的测量电路提供与所感测的过程变量相关的输出。压电式换能器提供与所述工业过程中的压力脉动相关的电输出。所述壳体中的电子线路包括构造为接收来自压电传感器的电输出的输入装置。在一种结构中,所述电输出用来向所述过程装置提供动力。
附图说明
图1为用于监测或控制工业过程的过程监测或控制系统的简图。
图2示出了包括用于执行诊断的脉动传感电路的过程装置的剖面图和简化结构图。
图3示出了过程装置的剖面图和简化结构图,该过程装置包括用在用于该过程装置的发电的脉动传感电路。
图4为包括用于与压电式换能器一起使用的隔膜的传感器模块的底部俯视图。
图5为示出用于与压电式换能器一起使用的隔膜的剖视图。
图6为包括位于安装凸缘中的压电式换能器的过程装置的平面图。
图7为包括位于过程联接器中的压电式换能器的过程装置的平面图。
图8为其中压电式换能器接合至远离过程装置的位置处的过程流体的结构的简图。
具体实施方式
存在多种利用过程中的机械振动用于诊断或捕获能量的现有技术。然而,这些脉动通常是从过程元件接收到,如管道系统、固定架等,而不是从过程流体,例如,从在过程管道中运送的过程流体直接地接收脉动。这些压力脉动可以多种源引起,例如,泵、管道阻塞等。在一些情况中,内部压力脉动不会导致传递至管道系统本身、支架或其它元件的外部机械振动。通常,可用的最大能量在过程容器的内部,例如,在过程管道系统的内部。在一个方面中,本发明包括从过程中捕获这种能量,并利用它诊断和/或进行能量捕获。如在此使用的那样,“压力脉动”是过程流体中的任何类型的压力变化。压力脉动可以被以压力波、移动波前(travelingwavefront)等形式载送。在一种结构中,压力脉动可以包括单个压力脉冲,在其它结构中,压力脉动可以为周期性的或重复的波形,或者具有延长周期的其它波形。
图1为根据本发明的包括过程装置16的工业过程控制器监测系统10的简图。如下文更详细地讨论的那样,过程装置10包括压电式换能器(在图1中未示出),其构造为响应于系统10中的压力脉动而移动,且由此产生电输出。
过程装置16示出为接合至构造为运送过程流体14的过程管道系统12。过程接口元件18构造为接合至所述过程,并用于至过程装置16的输入或输出。例如,如果过程装置构造为过程控制变送器,则接口元件18可以包括一些类型的过程变量传感器,如构造为感测过程变量的压力传感器、流量传感器、温度传感器等。另一方面,如果过程装置16构造为过程控制装置,则接口元件18例如可以为用来控制所述过程的阀、加热器、马达、泵等。过程装置16经由过程控制回路22接合至远程设置的电路,如控制室20。过程控制回路22图示为两线过程控制回路,并且例如可以包括构造为根据工业标准操作的过程控制回路。示例性的工业标准包括4-20mA协议、协议、FieldBus协议和其它协议。在一些实施方式中,装置16采用无线过程控制回路通信,并且可以或不可以接合至有线回路22。图1还示出了在过程流体中载送的压力脉冲72。
图2为示出本发明的一种示例性实施方式的简化剖视图,其中,过程装置16通过诸如凸缘等等之类的过程联接器50接合至过程管道系统。现场设备16包括接合至过程接口18的接口电路52。当构造为变送器时,接口电路52可以进行初始处理,并与过程变量传感器一起运转。类似地,当构造为过程控制器时,接口电路52用来控制过程接口18。现场设备16包括根据存储在存储器62中的编程指令操作的微控制器60。微控制器60还接合到本身接合至过程控制回路22的I/O电路64。在一些结构中,I/O电路64还提供用来向过程装置16的一些或所有电路供电的功率输出。
压电式换能器68安装在过程装置16的装置壳体70中。压电式换能器68直接地或通过一个或多个其它元件间接地物理地接合至所述过程,以便由压电式换能器68接收从工业过程14发出的压力脉动72。这些脉动引起换能器68运动,所述运动产生作为所接收的脉动的函数的电输出信号74。在图2的结构中,压电式换能器68向模数转换器76提供电输出信号74。模数转换器76接收输出信号74,并向微控制器60提供数字化信号80。微控制器60可以采用任何期望的技术处理数字化信号,且不限于在此讨论的。
在一种示例性结构中,微控制器60监测脉动信号72的幅度、频谱含量和/或特征(时间和/或频率)。信号72可以与已知的表示所述过程10的额定操作的信号进行比较。诸如幅度、频谱含量和/或特征之类的额定信号值例如可以存储在存储器62中。
在另一种示例性结构中,输出信号74中的某个水平或阈值可以表示所述过程10的特定故障,如破损或正出故障的泵或支架。类似地,某个频率或频率组可以暗示特定的故障,如正出故障或已出现故障的叶轮。脉动信息还可以用来提供与过程装置10或过程10中的其它装置由于暴露至脉动引起的预期寿命下降相关的预测信息。在过程装置16的操作期间,如果脉动信号72以预定的方式从存储的额定值改变,而由微控制器60执行的编程指令可以用来进行在所述过程中已经出现某些类型的故障的判断,这允许进行进一步的研究。例如,微控制器60可以提供表示应当由操作人员调查的元件故障或潜在故障的输出信号。所述信息还可以用于其它目的,如提供工业过程中的诸如阀控制器等之类的其它元件的操作的指示。如果过程联接器50已经变松,则脉动信号72也将改变。在另一个例子中,如果脉动信号72将要突然降低,或者甚至完全消失,这可以是过程10已经不正确地关闭或处于不期望有的状态的指示。在2003年7月29日授权给Eyrurek的美国专利No.6,601,005中示出诊断技术的各种例子,在此通过引用将其结合在其全文中。
图3为过程装置16的另一简化结构图,示出了本发明的另一种示例性结构。在图3中,与图2中示出的元件类似的元件保留它们的标记。在图3的结构中,脉动信号72由压电式换能器68接收。来自压电式换能器68的电流输出信号74提供至能量存储电路82。能量存储电路82可以为任何合适的用于存储电能的装置,例如可以包括用来存储来自压电式换能器68的能量的电容器和整流电路、电池等等。能量存储电路82提供可以向过程装置16提供动力的功率输出信号。在这种结构中,可以不要求I/O电路64提供功率输出信号。而且,在一些结构中,过程装置16构造为通过无线连接操作,I/O电路64用于无线通信。能量存储电路82可以为过程装置16提供所有的动力,或者可以为装置16提供补充或备用动力。
通常,采用这种技术不能从过程中捕获动力,除非存在动能。例如,加压容器可以包括大量势能。然而,如果压力保持恒定,则不能捕获能量。一种方案是捕获通过如由水“击”作用、泵脉动等引起的过程压力噪声产生的能量。采用本发明,可以采用压电效应捕获这种能量。典型的压电元件具有相对低的电流输出。然而,给一个足够的输入力,可以产生足够的用在过程控制装置中的动力。在多种结构中,压电式换能器可以用来捕获来自过程流体中的压力脉动的动力。压电式换能器可以集成到压力传感器模块或过程连接中,以由此消除外部接线。在该结构中可以电池电容器或其它能量存储装置,如图3中示出的能量存储装置82。所述电池可以全部或部分地补充由压电式换能器提供的能量。而且,当存在足够的多于能量时,压电式换能器可以用来向该电池充电。这也可以通过减少放电来延长电池寿命。在另一种示例性结构中,控制信号可以从微控制器60施加至压电式换能器68,以引起换能器68运动,并提供压力脉动。在这种结构中,所产生的压力信号可以由过程装置的压力传感器感测,以诊断或检验变送器操作。所述信号的幅度也可以用来提供管线压力的指示。虽然图示了单个压电式换能器68,但可以使用多个电路。
图4示出了用在本发明的一种实施方式中的压力模块150的底部仰视图。压力模块150包括用于接合至过程压力的高压侧的隔膜152和用于接合至过程压力的低压侧的隔膜154。可以使用例如嵌入图2和3中示出的接口电路52的压力传感器,并且其配置为测量由过程流体施加在隔膜152和154之间的压力差。这种压力差流入可以表示过程流体的流量。隔膜156可以用来将压电式换能器68接合至过程流体。例如,压电式换能器68可以安装至隔膜156,使得隔膜156的运动引起压电式换能器68运动。这允许换能器68直接感测过程流体中的脉冲。
图5为模块150的侧面剖视图,更详细地示出了隔膜156。如图5所示,压电传感器68物理地接合至隔膜156。传感器68示出定位在形成在模块150中的腔170中。电连接载送来自换能器68的输出74。在图5的结构中,当在过程流体中出现脉动时,隔膜156将运动。隔膜156的这种运动引起换能器68的作为结果产生的运动,其产生电输出。如上所述,输入信号可以施加至换能器68,产生隔膜156的运动,其在过程流体中引起脉动。
图6为本发明的另一示例性实施方式的平面图,其中示出了过程变量变送器,其包括变送器电子组件壳体202和传感器模块204。安装凸缘206用来将变送器传感器模块204安装至工业过程的管道系统。凸缘206例如可以包括阀等等。在图5的结构中,压电式换能器68安装在凸缘206中,并且例如可以采用如图5中图示的采用隔膜的技术接合至过程流体。电连接210从凸缘206延伸至用来接合电信号的变送器电子组件壳体202和/或从换能器68延伸。
图7为以类似于图6中示出的方式构造的变送器200的平面图,相应地已经保留了标记。然而,在图7的结构中,变送器200包括一些类型的过程联接器220,如用于感测温度、压力等的探测器。图7中的结构中的联接器,联接器220图示为包括压电式换能器68。换能器68可以采用任何适合的技术,例如,包括图5中示出的隔膜156,接合至所述过程。
在图6和7的结构中,压电式换能器安装在“浸湿(wetted)”元件中。这种结构会是有利的,因为它们可以在现场修理或升级,而不改变变送器本身。而且,这些结构不需要占用变送器壳体内的其它空间。
图8示出了本发明的另一示例性结构,其中压电传感器68通过共振导管232接合至过程管道系统230。换能器68如上文中讨论的那样通过电连接234接合至过程装置。在图8的结构中,压电式换能器与过程装置分离。换能器68可以包括用于提供放大或信号处理的电子组件,并且可以构造为例如拧在容器上的带螺纹端口上。在一种结构中,换能器68(包括其相关的电子组件)的直径在1至2英寸之间,高度在1至2英寸之间,且像管堵头。这种结构是有优势的,因为可以在现场修理或对它进行升级,并增加在过程测量点可能不同于最佳过程噪声位置时捕获的能量。可选的管262中的共振可以构造为利用在任何封闭波介质中出现的驻波。例如,该构造可以用来在压电式换能器68上放大或集中过程流体中的脉动。在共振导管的例子中,公式为L=Vs/F,其中L为导管的长度,Vs为声速,F为声频。在一种结构中,感兴趣的脉动频率将通常在60至80赫兹的范围内,且共振导管232的长度可以在0.5和1米之间。
虽然可以采用其它结构,但在一种实施方式中,电路可以包括用于存储来自压电式换能器的电荷的超级电容器。当捕获的能量足以向所述装置供给动力时,可以使用提取的能量,而不是来自电池的能量。而且,当提取的能量仍较大时,多于的电荷例如可以存储在超级电容器中。然而,如果换能器68产生的能量不足以向所述装置供给动力,则可以使用来自电池的能量。因此,在这种结构中,捕获的能量不是代替该装置中的电池,而是延长电池寿命。
虽然已经参照优选的是实施方式描述了本发明,但本领域技术人员将会认识到,在不偏离本发明的精神和范围的条件下,可以在形式和细节方面进行改变。虽然分开图示了图2和3的实施方式,但压电式换能器68可以同时用于诊断以及发电。
Claims (16)
1.一种用于接合至工业过程的过程装置,用于监测或控制所述过程,包括:
装置壳体,构造为物理地接合至所述工业过程;
过程变量传感器,构造为测量过程变量;
测量电路,接合至过程变量传感器,具有与所感测的过程变量相关的输出;
压电式换能器,具有与所述工业过程中的压力脉动相关的电输出;和
所述壳体中的电子线路,具有构造为接收来自压电传感器的电输出的输入装置,所述电输出用来向所述过程装置提供动力。
2.一种用于感测接合至工业过程的用于监测工业过程的过程变量的类型的过程装置中的脉动的方法,该方法包括下述步骤:
将压电式换能器物理地接合至所述工业过程;
通过所述物理接合从所述工业过程接收压力脉动;
采用过程变量传感器感测过程变量;
基于所感测的过程变量提供过程变量输出;
将所述压力脉动接合至压电式换能器,并响应于压力脉动提供来自压电式换能器的电输出;以及
将所述电输出提供至所述过程装置的电子线路,所述电输出用于向所述电子线路提供功率。
3.根据权利要求1或2所述的过程装置或方法,其中,所述电子线路构造为基于所述电输出诊断所述工业过程的运转。
4.根据权利要求3所述的过程装置或方法,其中,所述诊断基于所述工业过程中的脉动的频率。
5.根据权利要求3所述的过程装置或方法,其中,所述诊断基于所述工业过程中的所述脉动的特征。
6.根据权利要求3所述的过程装置或方法,其中,所述电子线路基于所述脉动和存储在存储器中的数据提供诊断输出。
7.根据权利要求1或2所述的过程装置或方法,其中,所述压电式换能器构造为接收引起压电式换能器运动的控制信号。
8.根据权利要求7所述的过程装置或方法,其中,所述压电式换能器的运动引起所述过程流体中的由过程变量传感器感测的压力脉动,所述电子线路还构造为基于所感测到的压力脉动诊断变送器操作。
9.根据权利要求1或2所述的过程装置或方法,其中,所述电子线路包括能量存储电路,所述能量存储电路被构造以存储来自压电式换能器的能量。
10.根据权利要求9所述的过程装置或方法,其中,所述能量存储电路包括电容器。
11.根据权利要求1或2所述的过程装置或方法,其中,所述压电式换能器安装在所述过程装置的壳体中。
12.根据权利要求1或2所述的过程装置或方法,其中,所述压电式换能器安装在所述过程装置的传感器模块中。
13.根据权利要求1或2所述的过程装置或方法,其中,所述压电式换能器安装在用来将所述过程装置接合至所述工业过程的安装凸缘上。
14.根据权利要求1或2所述的过程装置或方法,其中,所述压电式换能器定位在与所述装置壳体隔离的位置处。
15.根据权利要求1或2所述的过程装置或方法,其中,所述压电式换能器通过共振导管接合至所述过程流体。
16.根据权利要求1或2所述的过程装置或方法,其中,所述压电式换能器通过隔膜接合至所述过程流体。
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Also Published As
Publication number | Publication date |
---|---|
WO2009131667A1 (en) | 2009-10-29 |
US9921120B2 (en) | 2018-03-20 |
EP2269127A1 (en) | 2011-01-05 |
EP2269127B1 (en) | 2016-03-16 |
JP2011520185A (ja) | 2011-07-14 |
US20090260438A1 (en) | 2009-10-22 |
US8250924B2 (en) | 2012-08-28 |
JP5318194B2 (ja) | 2013-10-16 |
US20130079895A1 (en) | 2013-03-28 |
CN102016735B (zh) | 2014-09-03 |
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