CN117791224A

CN117791224A - Intelligent catheter plug

Info

Publication number: CN117791224A
Application number: CN202311269838.6A
Authority: CN
Inventors: 雅各布·D·霍尔姆; 布莱恩·M·阿菲亚斯
Original assignee: Rosemount Inc
Current assignee: Rosemount Inc
Priority date: 2022-09-29
Filing date: 2023-09-27
Publication date: 2024-03-29

Abstract

The invention relates to an intelligent catheter plug, comprising: a plug body having an externally threaded region, the plug body having a diameter and a thread pitch for engaging a catheter port; at least one electrical component mounted with respect to the plug body and configured to electrically couple with and provide an indication related to the field device.

Description

Intelligent catheter plug

Technical Field

The present invention relates to a smart catheter plug and a method of communicating a status of a field device using the smart catheter plug.

Background

A field device is a device that can be coupled to a process, such as a manufacturing or refining process, to support the process by providing one or more functions of measuring and controlling parameters associated with the process. The field device is so named because it can be installed in the field. "field" is typically an external area in a process device that may be subject to extreme weather, vibration, humidity changes, electromagnetic or radio frequency interference, or other environmental challenges. Thus, the robust physical packaging of such field devices provides them with the ability to operate in the "field" once for long periods of time (such as years).

In the process control industry, field devices such as process variable transmitters are used to remotely sense process variables. The process control industry uses field devices, such as actuators, to remotely control physical parameters of a process, such as flow, temperature, etc. The process variable may be transmitted from a field device, such as a process variable transmitter, to a control room for providing information about the process to a controller. The controller may then transmit control information to a field device, such as an actuator, to modify a parameter of the process. For example, information related to the pressure of the process fluid may be transmitted to a control room and used to control a process such as oil refining.

One environment in which field devices are particularly useful is process control and monitoring. In such environments, process fluids (such as petrochemicals, slurries, pharmaceutical compounds, etc.) may be processed and delivered to various locations within a processing facility. However, process control and monitoring environments are a challenge for many devices because the environment itself may have highly flammable or explosive gases present therein. Therefore, in some such environments, it is important to house the electronic equipment used therein in an explosion-proof housing. When so contained, even if the electrical circuitry of the device generates a spark or has electrical components with surface temperatures high enough to ignite the environment, the generated ignition will be contained entirely within the housing and cannot escape into the surrounding environment. This is important to ensure the safety of the process control devices and workers therein.

One example of an explosion proof rating is ATEX certification of Ex-d standards EN60079-0 and EN60079-1 for potentially explosive environments. Generally, explosion proof housings are relatively heavy in order to be mechanically strong enough to accommodate an internal explosion without rupture. Typically, such explosion proof containers are very strong metal housings designed to withstand the explosion pressure. These housings typically include a conduit port for coupling a process wire to the device. When less than all of the conduit ports of the field device are required at section Cheng Jiexian, the unused conduit ports must be plugged with conduit plugs.

Disclosure of Invention

According to an aspect of the present invention, there is provided a smart catheter plug comprising: a plug body having an externally threaded region, the plug body having a diameter and a thread pitch for engaging a catheter port; at least one electrical component mounted with respect to the plug body and configured to electrically couple with and provide an indication related to the field device.

According to another aspect of the present invention, a method of communicating a status of a field device using a smart catheter plug installed into a catheter port of the field device, wherein the smart plug includes at least one electrical component electrically coupled with the field device is provided.

Drawings

Fig. 1 and 2 are a cross-sectional view and a perspective view, respectively, of a smart catheter plug according to an embodiment of the present invention.

Fig. 3 and 4 are a cross-sectional view and a perspective view, respectively, of a smart catheter plug according to another embodiment of the present invention.

Fig. 5 and 6 are a cross-sectional view and a perspective view, respectively, of a smart catheter plug according to another embodiment of the present invention.

Fig. 7 and 8 are schematic perspective and cross-sectional views of a smart catheter plug according to another embodiment of the invention.

Fig. 9 is a schematic perspective view of a shroud of a smart catheter plug in accordance with an embodiment of the present invention.

FIG. 10 is a front view of a smart catheter plug attached to a field device in accordance with an embodiment of the present invention.

Fig. 11 is a schematic diagram of different alarm colors (illustrated as different shades of gray) of a smart catheter plug according to an embodiment of the present invention.

Detailed Description

One challenge of field devices may sometimes be determining whether the field device is operating as intended. In many applications, field devices are installed in the field and connected to process and control systems without any feedback that the device is starting, powering on, and running. A field device with an LCD screen will provide at least some visual feedback to the instrument technician that the field device is powered on and operating, but a field device without an LCD display will not provide such local feedback to the instrument technician.

The embodiments described herein generally provide a smart catheter plug that uses the form factor (e.g., diameter, pitch, etc.) of a standard catheter plug, as well as some electronics and a glass top cover to provide an indication of the status of a field device. The smart catheter plug is electrically coupled to a field device junction box (field device terminal block). In a particularly simple embodiment, the LED simply turns on when the field device receives power. In another example, the smart catheter plug employs an integrated circuit configured to drive the LED status based on the field device analog output. For example, the integrated circuit may cause the LED to display blue if in a normal state and red if the field device is in a highly alarm state. More advanced embodiments include providing a small microcontroller to increase the number of states that are indicated. The microcontroller driving the LEDs may be located on the printed circuit board of the smart catheter plug or may be placed on the field device junction box PCA. Some example functions that the smart catheter plug may indicate include, but are not limited to: power on state, start-up and normal operation (process variable within limits), alarms, faults, field device health, no power (in the case of small batteries or capacitors provided on the printed circuit board of the smart plug).

The embodiments described below primarily utilize existing techniques and manufacturing processes such as glass to metal seals, machined metal bodies, and PCA. Glass to metal seals provide reliability and robustness, but also provide a fire-resistant joint. The glass seal and the welding process maintain the fire/explosion-proof state of the field device housing. In at least some embodiments, the electronics are simple and readily available. Glass caps are commercially available from Fusite/Therm-o-dic or Schott.

Fig. 1 and 2 are a cross-sectional view and a perspective view, respectively, of a smart catheter plug according to an embodiment of the present invention. In the illustrated embodiment, a simple conduit plug body 100 is welded to a metallic glass top cover 102 at weld 104. The printed circuit board 106 is disposed within the catheter plug body 100 and may be mounted in the catheter plug body 100 by plastic, solder, and/or epoxy. In embodiments where it is not necessary to maintain an explosion proof rating of the field device housing, conduit plug body 100 and header body 104 may be formed solely of plastic. As shown in fig. 2, the smart catheter plug still includes the wrench flats of a standard catheter plug for installation into the field device housing. As shown in fig. 1, one or more LEDs 108 are disposed on the printed circuit board 106 and directed to provide illumination through the glass 110. A pair of conductors 112 extend from the printed circuit board 106 to field device wiring sections, such as field device terminal blocks within a field device housing (not shown).

Fig. 3 and 4 are a cross-sectional view and a perspective view, respectively, of a smart catheter plug according to another embodiment of the present invention. In the embodiment shown in fig. 3, the LED 208 with the metal cap 220 and the glass top cover 222 is provided as a subassembly with soldered pins 224 extending from the glass top cover 222 to the printed circuit board 206. The metal cap 220 is then welded or soldered to the metal conduit plug body at the interface 226. The LED(s) 208 are configured to direct light through the glass 210 to provide one or more visual indications related to the field device. As shown in fig. 3, component or logic chip(s) 228 are disposed on a surface 230 of the printed circuit board 206. Component 228 can comprise a simple integrated circuit that drives the state of LED(s) 208 based on the field device state. In addition, component 228 may also include a small microcontroller configured to provide additional indications related to the field device. Although only the component 228 is shown on the surface 230, it is expressly contemplated that additional components may be provided on opposite sides of the printed circuit board 206. Wires or connectors 212 extend from the printed circuit board 206 to field device wiring sections, such as a junction box (not shown). The printed circuit board 206 may be attached to the catheter plug body 200 in any suitable manner, including but not limited to epoxy, solder, or mechanically (e.g., using clamps). Note that in embodiments where only LEDs driven with an analog power supply of the field device are required, the printed circuit board 206 may be omitted.

Fig. 5 and 6 are a cross-sectional view and a perspective view, respectively, of a smart catheter plug according to another embodiment of the present invention. As shown in fig. 5, the smart plug 300 includes a conduit plug body 302, the conduit plug body 302 having an externally threaded portion 330 and a cavity 332 therein. The smart plug 300 uses a packaging design with an O-ring 334 between the catheter plug body 302 and the glass tube 336. Potting 338 is dispensed into chamber 332 and forms an environmental seal with O-ring 334. A 10 mm potting along the length of the glass tube 336 is required to create an adequate fire seal. This is easy to achieve because a typical catheter plug is 5/8 inch high. The printed circuit board 306 is attached to the catheter plug body 302 in any suitable manner, including by epoxy, solder (depending on material selection), or via ultrasonic welding, or fixed plastic (held-in-place plastics) in the catheter plug body 302 or potting 338. As shown in fig. 5, one or more LEDs 308 are disposed on the printed circuit board 306 and are configured to generate light in the direction of the glass tube 336. One or more electrical components 328 are disposed on a side of the printed circuit board 306 opposite the LEDs 308. A plurality of wires or connectors 312 extend from the printed circuit board 306 to field device wiring sections (not shown).

While the above embodiments have primarily provided LEDs that provide indications related to field devices, it is expressly contemplated that embodiments may include additional components on a printed circuit board to provide additional functionality. For example, a humidity sensor on a printed circuit board may be used to detect humidity within the field device housing, and the visual indication provided by the one or more LEDs may include an indication of the humidity level inside the field device housing. In another example, an alarm may be triggered if the humidity content increases significantly, i.e. a situation that typically results in a malfunction. In yet another example, the vibration sensor/accelerometer is mounted to the printed circuit board of the smart plug and would provide a warning if the field device and thus its mounting point is experiencing significant vibrations. In another example, an early wetness warning/corrosion junction box detector may be provided to sense and provide an indication of a wetness/corrosion junction box. Furthermore, while the indication has been described with respect to driving one or more LEDs to display different colors, it is also expressly contemplated that one or more LEDs may also communicate visual information by flashing a code instead of or in combination with changing colors.

Additional features that may be included in a smart plug according to the various embodiments described above include the provision of a buzzer within the field device to indicate status and/or communicate an alarm. An RF antenna disposed in the smart plug is used to provide an RF path that typically passes through the metal field device housing. The RF antenna may be configured for any suitable RF communication, but in one particular embodiment is a Bluetooth Low Energy (BLE) antenna. In another embodiment, a small LCD is mounted to the printed circuit board of the smart plug and viewable through glass. The small LCD may also include a backlight to enhance visibility and/or provide additional visual indications (e.g., by color or flashing codes).

Fig. 7 and 8 are schematic perspective and cross-sectional views of a smart catheter plug according to another embodiment of the invention. The smart catheter plug 400 includes a housing 402, the housing 402 preferably being formed of two portions 404, 406, the two portions 404, 406 threadably engaging one another at an interface 408 to provide an explosion-proof housing. The housing 402 also includes external NPT threads 410, which external NPT threads 410 are configured to be threaded into a conduit of a field device. Hex bolt 412 is attached to threads 410 so that a technician may use a wrench or other suitable tool to threadably engage NPT threads 410 into a conduit of a field device.

As shown in fig. 8, the smart catheter plug 400 includes at least one printed circuit board 414, which printed circuit board 414 may contain any or all of the circuit components described above. The printed circuit board 414 includes at least one LED that provides an indication of the status of the device, process, or any combination thereof. In one particular example, the LEDs are mounted in the center of the circular circuit board 414 and are arranged to be displayed from the window 416. In the example shown in fig. 8, a shield 418 is interposed between the circuit board and the window 416. The shroud 418 includes an aperture therethrough that is aligned with the position of the LED such that the illumination of the LED may pass through the aperture of the shroud 418 and exit the window 416. However, other components of the circuit board 414 are obscured from view through the window 416.

Fig. 9 is a schematic perspective view of a shroud of a smart catheter plug in accordance with an embodiment of the present invention. The shroud 418 generally includes a circular platform 420, the circular platform 420 having a plurality of standoffs 422 extending downwardly therefrom. The standoffs 422 help create the correct spacing between the circular platform 420 and the printed circuit board 414. Fig. 9 shows an aperture 424 disposed in the center of the circular platform 420 to allow the centrally located LED to emit light therethrough. However, in embodiments where the LED is not located in the center of the printed circuit board, the aperture 424 will be placed in a different location so that the LED can still emit light through. In the illustrated example, the circular platform 420 includes an opaque surface to prevent light from passing through. In some embodiments, the circular platform itself may be opaque.

As shown in fig. 9, the shroud 418 may include additional features. One such feature may be the shape of the shield 418. For example, the shield 418 may be provided with a concave shape to enhance LED visibility. In addition, the shield 418 may have or include a metalized surface to provide reflectivity and to enhance visibility. The shield 418 may be designed to enclose and/or protect the printed circuit board 414 (shown in fig. 8). The shield 418 may include one or more mechanical features to physically attach to the printed circuit board 414. For example, the shield 418 may include a snap feature to snap to the printed circuit board 414 and retain the printed circuit board 414. Additionally or alternatively, the shroud 418 may include one or more mechanical features to mount and retain itself within the housing 402. For example, the shroud 418 may include a snap feature to fit and retain into the housing 402. Furthermore, the shield 418 may include overmolding for environmental protection and to prevent high vibration.

FIG. 10 is a front view of a smart catheter plug attached to a field device in accordance with an embodiment of the present invention. As shown in fig. 10, the smart catheter plug 400 is attached to a field device 440 and has a centrally located LED 442, the LED 442 being shown through a window 416 of the smart catheter plug 400.

Fig. 11 is a schematic diagram of different alarm colors (illustrated as different shades of gray) of a smart catheter plug according to an embodiment of the present invention. In the illustrated example, the color of the LED may indicate nominal operation, such as by lighting in green, when the system is in region 470. If the system becomes slightly above or below the nominal range, as indicated by regions 472, 474, respectively, an appropriate warning, such as a saturation warning, may be generated by illuminating the LED with blue light. If the system further enters either of the regions 476, 478, an alarm may be indicated by illuminating an LED in red. Of course, other color schemes may be employed, in combination with LED blinking and/or blinking codes that indicate particular device or process conditions.

Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.

Claims

1. An intelligent catheter plug, comprising:

a plug body having an externally threaded region, the plug body having a diameter and a pitch for engaging a catheter port;

at least one electrical component mounted with respect to the plug body and configured to electrically couple with a field device and provide an indication related to the field device.

2. The smart catheter plug of claim 1, wherein the at least one electrical component comprises a light emitting diode.

3. The smart catheter plug according to claim 2, wherein the indication is selected from the group consisting of a power status, normal operation, alarm status, fault, and field device health.

4. The smart catheter plug of claim 1, wherein the smart catheter plug is configured to maintain an explosion-proof rating.

5. The smart catheter plug of claim 1, further comprising at least one sensor disposed on a printed circuit board of the smart catheter plug, wherein the at least one sensor is configured to sense a condition associated with the field device, and wherein the indication provided by the smart catheter plug is based on the sensed condition.

6. The smart catheter plug of claim 5, wherein the sensor is a humidity sensor.

7. The smart catheter plug of claim 5, wherein the sensor is a vibration sensor.

8. The smart catheter plug of claim 1, wherein the at least one electrical component comprises a buzzer configured to provide the indication.

9. The smart catheter plug of claim 1, wherein the at least one component comprises an RF antenna.

10. The smart catheter plug of claim 1, wherein the at least one component comprises an LCD display.

11. A method of communicating a status of a field device using a smart conduit plug installed into a conduit port of the field device, wherein the smart plug includes at least one electrical component electrically coupled with the field device.