WO2018009081A1

WO2018009081A1 - Measurement and control system for remote monitoring and regulation of physical parameters

Info

Publication number: WO2018009081A1
Application number: PCT/PL2016/000077
Authority: WO
Inventors: Paweł PENKALA
Original assignee: Vitrochem Group Production
Priority date: 2016-07-05
Filing date: 2016-07-05
Publication date: 2018-01-11
Also published as: PL127059U1

Abstract

The measurement and control system for remote monitoring and regulation of selected physical parameters, consisting of a controller, measuring modules connected to it, actuators and an Internet control panel. Data concerning the measured parameters are read off the touch screen which constitutes an integral part of the controller. The screen also allows for regulating the operation of the assisting devices. The Internet control panel enables a real-time monitoring of all data gathered by the connected sensors. Full operation history of the device may also be generated using the panel. It also allows for setting target values and remote controlling of the measurement and control system. The measurement and control system communicates with the modules by means of a data bus in compliance with EIA RS-485 standard, using a communication protocol.

Description

Measurement and control system for remote monitoring and regulation of physical para meters

1. Introduction

According to International Patent Classification the subject matter of the application may be classified as items: C02F 5/00, G05D 21/00, G05D 29/00, G01 D 9/08,

2. Background

Prior to the development of the invention it was necessary to involve human factor or use separate devices for parameters control, performing analyses of the liquid, setting target values of parameters, monitoring chemicals and salt tablets levels in water treatment installations, as well as for performing activities related to the operation of chemical water correction systems such as regulation of the applied preparations, water softening station regeneration, etc. The invention combines the benefits of several separate devices such as measurement devices, automatic desalination systems, Internet data transfer devices. It allows actions previously carried out by qualified staff on site to be performed remotely, and to some degree automatically. 3. Subject of the patent application

Construction

The system comprises two basic parts: a controller connected to measuring and controlling de- vices and an Internet control panel.

The controller is a microprocessor module equipped with suitable software and an integrated color touch display. The controller consists of: a processor, power supply system with a voltage regulator, data transmission system, ICT network data transmission systems, a display with a touch screen as well as executive components. The controller is equipped with relay modules, each of which may control a solenoid valve, a dosing pump etc.. Data transmission system is connected to a transmission bus. The controller is equipped with an input allowing for external communication module plugin.

The controller is connected to modules by means of power cables. The cables supply power to the modules, sensors etc. and are used for receiving data ihrough the controiler, as well as for controlling devices ( e.g. solenoid valves, pumps). Actuators are microprocessor modules equipped with suitable software. Modules consist of a processor, a power supply system, a data transmission system and executive components in a form of: controlling relays and opto-isolators respectively and other systems.

Measuring modules are microprocessor modules equipped with suitable software. Modules consist of a processor, a power supply system, a data transmission system, and systems of measuring amplifiers (measuring modules)

The controller communicates with the modules by means of serial communication bus in compliance with EIA RS-485 standard and a communication protocol consisting of: one byte of module address, one byte of command, one byte of register address, optional data block (consisting of up to thirteen bytes), one byte of Cyclic Redundancy Check and one byte of end of fra - me symbol. The system enables the user to address 256 modules, each module may have 256 registers for value reading, 256 cells of non-voiatile EEPROM memory in write/read mode, 256 different executive commands parameterized by the register address and the data block.

Each measuring module is usually connected to one sensor. In modules for pH and conductivity measurements a temperature sensor may be added.

A maximum of two solenoid valves or two dosing pumps may be connected to each actuator.

The control panel is a separate element of the system. The panel is an Internet application pro- viding the user with a data access by means of a browser.

The control panel displays information from the readings in a form of tables and charts, as well as data concerning the condition of valves and other devices. The panel also features functions concerning setting target values of the parameters, opening and closing of solenoid valves as well as switching the devices on and off. The aforementioned functions are activated by com- mand selection.

Operation

After the start-up, the controller connects to the network, which constitutes a requirement for the operation of the device. Each controller is identified by a unique serial number, when the controller connects to the network, the serial number is verified in a database. Following a positive verification, the device is activated. In case when the connection is disrupted, the controller resumes the connection automatically. Operation of the measuring modules is based mostly on continuous measurement of the parameters. Modules measuring the following values may be used in the system: pH, conductivity, temperature, liquid level , salt tablets level as well as modules measuring the condition of the following devices: a dosing pump, head servomechanisms, liquid flow through the head, the head power supply. Eight measuring modules of each measuring type may be used in the system. The invention allows for any configuration of the aforementioned modules. Data detected by the sensors can be read off a display of the controller. The controller features functions such as an executive function, an acquisition function, a presentation function and a data transmission function, it collects data from measuring modules, presents data on an integrated display, records data in an outside database and enables relay control of the connected devices. From the level of the controller it is also possible to set the parameters target values, open and close the solenoid valves, switch the devices on and off. The controller features an automatic response function activated when the set limit value of the measured parameters is exceeded. This situation results in a signal being sent to an appropriate module which initiates necessary actions such as valve opening or pump activation aiming at maintaining the parameter value within the expected range.

Another function featured by the controller is a standard format data transfer to the server where MySQL database is located. Data transfer takes place at one-minute intervals, Data are processed and presented in a graphic form on a website. The aforementioned website features the fol- lowing functions:

● regarding parameters such as conductivity, pH, hardness, temperature, iron content: current value as well as access to measurements records with a date and time range selection option, graphs, target values range selection option; if a measured value exceeds the target range it is displayed in red,

● chemical agent level, salt tablets level: visualization of the level and access to levels records with a date and time range selection option,

● current water flow through the water softening station, graphs presenting the flow as well as the access to the archives of levels with a date and time range selection option,

● water softening station valve: position, condition, archive access,

● status of the devices, that is: the water softening station, dosing pump, valves, measuring modules- on or off,

● amounts of dosed preparations as well as levels of preparations in the container.

Data received by the server are displayed in the Internet panel allowing for remote control of the cooperating devices, real-time moniioring of all data provided by the connected sensors, as well as access to full history of the device operation and managing the settings of the device controller. The panel allows for monitoring of the current regeneration process of the water softening station, currently operating column of the water treatment station as well as the amount of the dosed preparations.

The control panel displays the status of the device {on/off, etc.) and of the sensors, together with all service warnings.

The control panel is accessible from any location by means of an Internet connection and an ac- cordingly configured web browser.

From the level of the control panel it is possible to remotely manage target values ( value ranges) of the measured parameters, manage the settings of the dosing pump, remotely manage the operation of the water treatment station, manage solenoid valves compatible with pH sen- sors, conductivity sensors and temperature sensors.

Detailed specifications concerning modifications introduced through the control panel:

• modifications of the measured indicator are introduced by modifying limit values. After exceeding the limi value, the system sends an impulse, which opens the solenoid valve releasing the liquid with exceeded parameter, at the same time the liquid is supplied from a connected outside automatic supply system- up to the level where target parameter values are reached, this process is followed by the solenoid valve being closed,

• activation and management of the water treatment station regeneration process,

• thanks to the connection with the controller of the membrane dosing pump modification of the set dosing values may be introduced,

• thanks to the connection between the controller and the individual devices the operation mode of the devices may be modified from on to off, and from off to on.

All modification introduced remotely by means of the control panel are initiated by a command coming from the control panel through the server using the Internet connection to the main controller, which receives the command and depending on the modification, sends it to the appropriate relay module which in turn implements the modification by controlling the end device (valve, pump) 4. Exemplary execution of the system

Figure no.2 presents the construction of the controller and exemplary connections with the modules The following diagram illustrates selected technical specifications of the controller:

The following were used in the exemplary controller (Fig.1 ): Atmega 2560 processor (6), data transmission system in accordance with EIA RS-485 norm (1 ), WiFi (5) and GSM (4)wireless network transmission system- socket with a SIM card- as well as Ethernet wired network sys- tem(3), additionally two opto-isolators (8), and four relay outputs: two mechanical ones (9) and two electronic ones(10) The controller is equipped with a USB input (2) used for connecting external GPRS communication module and a power supply socket (7). In addition, the controller has a display with a 5" TFT touch screen.

Internet network connection is provided by Ethernet and wireless Wi-Fi or GSM network.

The controller (13) is connected by a power cable to relay modules(14-22), each of which is connected with a measuring sensor, a solenoid valve or a dosing pump. Cables constitute the power supply for the modules and sensors, as well as fulfill communication functions-they receive data through the controller, they also control the devices (solenoid valves, pumps). The controller and the modules are connected in series. The connection is carried out with UTP5 cat. 5E cable (21 ) with RJ-45 plugs. The sum of lengths of all connecting cables must not exceed 50 meters. In order to increase the length of the connecting cables, an additional power supply re- generator module should be used every 50 meters. Up to 9 regenerators may be installed, which enables the system to operate at a maximum cables length of 500 meters.

Relay modules use Atmega 168 or 328 processors, data transmission system in compliance with EIA RS-485, power supply systems with a voltage stabilizer. Modules are equipped with two inputs for RJ-45 plugs, and two sockets with cable grommets or a BNC connector with measuring sensors or peripheral devices connected to them (valves, pumps). The actuator is also equipped with a socket with a cable grommet and a cable supplying 230 V voltage.

Applied sensors are prior art pH sensors (12), water conductivity sensors (13), temperature sen- sors (14), total hardness sensors (21 ), iron level sensors (20), water flow, power supply and dosing pump condition sensors (15)valve condition sensors (22), as well as ultrasonic sensors used for monitoring liquid level in the containers (17) Salt tablets level in the containers is monitored by a laser sensor(18) The system also includes a module responsible for water treatment station data reading (16)

System built in this way allows for reading data from eight measuring sensors of every kind as well as controlling four solenoid valves and two dosing pumps. In case when more valves or pumps must be connected, additional actuators should be connected, each of them managing the settings of two pumps or up to two solenoid valves.

Due to limitations resulting from EIA RS-485 standard, a maximum of 128 modules may be connected to the controller.

5. Application The controller with the measuring modules was intended for substance parameter control, primarily in water, and chemical liquid correction processes control in industrial conditions.

The main uses of the system include monitoring and maintaining proper parameters of the working fluid in industrial cooling systems, boiler systems, steam-boiler systems, of technological water and all other substances requiring the aforementioned parameters monitoring.

6. Benefits

This device allows for combining essential measurement points of a given process in one con- trailer in any configuration. Benefits of the device include:

● continuous parameter measurement,

● substituting several devices with one comprehensive control panel,

● remote data access,

● remote control options,

● applying up to eight measuring points from every kind of measurement in any configuration according to the needs,

● reports from every measuring point generated since the beginning of the device operation, elimination of the visual substance level monitoring requirement,

● data access from any location in the world.

Claims

1. A communication protocol consisting of 1 byte of module address, 1 byte of command, 1 byte of register address, optional data block consisting of up to 13 bytes, 1 byte of Cyclic Redundancy Check and 1 byte of end of frame symbol.

2. A controller used for reading and transmission of selected physical parameters values to the server. It allows for remote physical parameters correction by managing the operation of the connected modules controlling the assisting devices, wherein the communication with the server and connected devices takes place by means of communication protocol as stated in claim no.1 and characterized in that it consists of: a processor, at least one power supply system, at least one data transmission system, at least one ICT networking data transmission system, a display with a screen, an executive component in a form of at least one relay and one opto- isolator and at least one socket for external communication module plugin.

3. A measurement and control system allowing for remote reading and regulation of all or some of the following physical parameters: pH, conductivity, temperature, hardness and iron content, characterized in that it consists of a controller, as stated in claim no.2, connected in series to measuring modules carrying out up to eight independent measurement of each of the parameters simultaneously, as well as measurements of the substance level and flow in the containers, the controller is also connected to actuators controlling the operation of solenoid valves and pumps. The system is characterized by using protocol, as stated in claim no.1 , to communicate.

4. A measurement and control system, as stated in claim no.3, wherein the additional elements include a server with a MySQL database, to which data are sent by the controller and an Internet application allowing for reading current and historical data, for reading information concerning the state and operation history of the assisting devices as well as remote managing of these devices.