CN104618079A - 双线过程控制回路诊断 - Google Patents
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Abstract
一种用于耦合至过程控制回路(18)的诊断设备(50)，包括：数字通信电路(52)，被配置成从过程控制回路(18)接收数字通信信号。数字通信信号是过程控制回路(18)上的数字调制模拟信号，所述数字调制模拟信号被调制成代表数字值的多个离散模拟信号电平。诊断电路(54)基于数字调制模拟信号，诊断可能包括过程控制回路的现场设备在内的过程控制回路(18)的操作。
Description
分案申请说明
本申请是申请日为2007年10月3日、申请号为200780036956.5(国际申请号PCT/US2007/021242)的、题为“双线过程控制回路诊断”的发明专利申请的分案申请。
技术领域
本发明涉及工业过程控制和监控系统。更具体地，本发明涉及利用双线过程控制回路(loop)来发送信息的工业过程控制和监控系统的诊断。
背景技术
在许多应用中使用工业过程控制和监控系统来控制和/或监控工业过程的操作。例如，炼油厂、化工厂、或造纸厂可能具有大量必须受到监控和控制的过程。
在这样的工业过程中，在整个过程中，在远程位置对过程变量进行测量。示例过程变量包括温度、压力、流量等。将该信息通过双线过程控制回路发送至中央位置(例如，控制室)。类似地，可以使用置于过程中的控制器来控制过程变量。控制器从双线过程控制回路接收控制信息，并作为响应通过例如打开或关闭阀门、加热过程流体等，来控制过程变量。
已经使用各种协议在双线过程控制回路上通信。一种协议使用4-20mA的信号来在回路上承载信息。4mA的信号可以代表过程变量的零值或低值，而20mA可以代表高值或全量程值。过程变量发射机可以将电流控制在4和20mA之间，来代表过程变量的中间值。更复杂的通信技术是通信协议，其中，将数字信息叠加在4-20mA信号之上。通常，在这样的配置中，每一现场设备需要分离的双线过程控制回路。
在双线过程控制回路上所使用的更复杂的通信技术通常被称作基于现场总线的协议(例如，FoundationTM现场总线)。在现场总线协议中，所有信息以数字方式发送，并且不需要过程控制回路上的模拟电流电平来承载信息。这样的配置的一个优势在于：多个过程变量发射机或控制器可以以串联的方式耦合在单个过程控制回路上。回路上的每一设备具有一个地址，从而可以识别发往其自身的消息。类似地，由现场设备发送的消息可以包括该设备的地址，从而可以识别发送者。
发明内容
耦合至过程控制回路的诊断设备包括：被配置为从过程控制回路接收数字通信信号的数字通信电路。数字通信信号是过程控制回路上被调制成代表数字值的多个离散模拟信号电平的数字调制模拟信号。诊断电路基于所述数字调制模拟信号对过程控制回路的操作进行诊断。
附图说明
图1是包括双线过程控制回路的过程控制或监控设施的简化图。
图2是过程控制回路诊断设备的简化框图。
图3A和3B是回路电流I与时间的关系曲线图。
图4更详细地示出了图2的数字通信电路。
图5更详细地是出了过程控制回路诊断设备。
具体实施方式
本发明涉及过程控制回路中的诊断，所述诊断包括：诊断使用在双线过程控制回路本身中的接线(wiring)，以及诊断与过程控制回路连接的其他设备。具体地，本发明提供的诊断包括：检测根据基于现场总线的协议操作的双线过程控制回路中的故障或潜在故障组件，在基于现场总线的协议中，多个设备可以连接至单个双线过程控制回路。
图1是示出了过程控制或监控系统10的简化图，过程控制或监控系统10包括耦合至过程管道16的现场设备12和14。设备12和14耦合至单个双线过程控制回路18，单个双线过程控制回路18继而耦合至控制室20。图1还示出了耦合至回路18的双线过程控制回路诊断设备22。回路18承载电流I，电流I可以用来向回路18上的所有现场设备供电，并且能够在控制室20处产生。通过将数字信号调制在回路电流I上，在回路18上以数字方式发送信息。例如，设备12和14可以包括唯一地址，从而能够唯一地识别其发送的消息，并且识别发往它们的接收消息。设备12和14可以包括任何类型的现场设备，所述现场设备包括过程变量发射机和控制器。过程控制回路18在段终止器24处终止。术语“段(segment)”是指双线过程控制回路18的全部或一部分。
图2是类似于图1所示的设备22的、根据本发明的双线过程控制回路诊断设备50的简化框图。诊断设备50耦合至双线过程控制回路18，并包括数字通信电路52和诊断电路54。在一些配置中，可以以现场设备12、现场设备14、独立的诊断设备22和/或控制室20实现双线过程控制回路诊断设备50。
操作过程中，数字通信电路52从双线过程控制回路18接收数字通信信号。该数字通信信号包括已经过数字调制的模拟信号。这样的调制基于现有技术。例如，可以使回路电流I周期性改变，使得特定阈值之上的变化代表二进制1，特定阈值之下的变化代表二进制0。在图3A中示出了这样的配置，图3A是回路电流I与时间的关系曲线图。在图3A中，已将曲线图的时间轴划分成五个时间段：t0、t1、t2、t3和t4。在时间段t0期间，电流电平I是不确定的，并代表a 0或a 1。在时间段t1和t4期间，电流电平I代表二进制0。类似地，在时间段t2和t3期间，回路电流电平I代表二进制1。如图3B所示，另一数据编码技术能够将每一比特周期分成两个相等的部分。二进制1由在比特时间的前半部分大于阈值而在后半部分小于阈值的电流电平来表示。二进制0由在比特时间前半部分大于阈值而在后半部分小于阈值的电流电平表示。
图2中所示的诊断电路54基于数字调制模拟信号I执行诊断。更具体地，诊断电路54基于数字调制模拟信号的模拟特性来执行诊断，数字调制模拟信号的模拟特性包括：信号幅度、波形、电流、误比特率(BERT)、段阻抗、或通过监控回路18上的电流获得的其他参数。此外，通过监控哪个设备发送了特定的信号，诊断电路54可以识别回路18上已发生故障或未来将发生故障的具体设备。
图4是诊断设备50的更详细的图，并且更详细地示出了数字通信电路52的一种配置。数字通信电路52包括：以串联方式与输入/输出(I/O)电路62耦合的感测电阻60和双线过程控制回路18上的其他设备。信号感测电路64跨接在感测电阻60两端，并向诊断电路54提供输出。诊断电路54可选地连接至I/O电路62。I/O电路62被配置成通过过程控制回路18进行数字通信，并在一些配置中被配置成向诊断设备电路供电，所述电能是通过回路18从回路电路I中产生。信号感测电路64接收与回路电流I相关的、跨感测电阻60产生的电压信号。信号感测电路可以可选地对该信号进行放大，将该信号进行数字化，并在向诊断电路54提供电压信号的数字表示之前，可选地执行附加预处理。信号感测电路64可以包括例如数字信号处理(dsp)集成电路及相关硬件。
图5是被配置成过程变量发射机或过程控制器的诊断设备的简化图。在图5中，以数字控制器70和存储器72来实现所示的珍断电路54。例如，控制器70可以包括根据存储器72中的程序指令进行操作的微处理器等。过程接口76可以包括用于感测过程变量的过程变量传感器，或可以包括用于例如通过定位阀门来控制过程的控制元件。当被配置为过程变量传感器时，元件74包括向控制器70提供数字信号表示的模拟到数字转换器及相关电路。控制器70被配置成通过回路18发送与所感测的过程变量相关的信息。类似地，如果过程接口76被配置为控制元件时，元件74包括数字到模拟转换器及相关电路，将来自控制器70的数字信号转换成用于控制过程的模拟值。
可以以图1中所示的任一示例设备来实现诊断设备，所述任一示例设备包括：过程变量发射机或控制器、独立诊断设备22、或控制室电路20。在一种配置中，提供可以用来向操作者显示诊断信息的可选显示器78。该显示器可以提供诊断帮助状态，并且本地显示器是回路段上的所有设备的指示。在本质安全(intrinsically safe)的配置中，诊断可以位于本质安全防护栏(intrinsic safety barrier)的本质安全侧，从而提供更详细和精确的诊断，包括对本质安全栏本身的诊断。
可以通过具备表征段的能力，使由诊断电路54执行的诊断适于每一独立双线过程控制回路段。当最初将诊断设备安装在新的或现有段上时，由于每一现场设备执行正常的过程通信，设备可以分析来自每一现场设备的通信。例如，可以将该信息保存在存储器72中，单独地用作每一设备的未来参考状态。该保存数据可以用来识别正常操作，并提供用于后续诊断的基准。采用这种方式的每一设备的特征可以实现更精确的诊断。此外，可以将每一设备与符合诸如现场总线协议等特定通信协议的标准进行比较，以确保设备符合适当的标准。
由诊断电路54执行的一个示例测量基于来自单独现场设备的数字调制模拟信号的幅度。在这样的配置中，可以将幅度与所存储的阈值(或幅度签名(amplitude signature))进行比较，如果幅度超出那些阈值，则可以提供故障指示。如果单个设备未通过测试，故障指示可以是发送信号的设备可能发生故障的指示。另一方面，如果多个设备未通过这样的测试，则故障指示可以指示除特定设备以外的问题。例如，回路18的特定段内的接线，或控制室20内的电源故障等。这种诊断的优点包括，在实际故障之前，检测特定双线回路段中即将出现的故障。这允许以最小停机时间维修双线回路段。附加诊断可以包括检测限幅波形，限幅波形可能指示现场设备的静态电流的可能的增加，从而引起非平衡调制。限幅信号另一潜在原因是现场设备处的不充足端电压。这可能由于电源电压造成的，或者在固有安全配置下由故障本质安全防护栏导致的。
在另一示例配置中，信号感测电路64将数字调制模拟信号进行数字化，从而诊断电路54可以使用完整的信号波形。在这样的配置中，诊断电路54可以对完整波形进行诊断，从而可以测量例如信号中过渡部分的上升和下降时间。此外，在特定设置处，可以随时间表征通信信号，并且将通信信号用作参考，以连续地与现场实时信号进行比较，并检测随时间的幅度变化。通过将来自每一设备的信号与初始参考进行比较，可以检测现场设备的组件故障或损坏的指示。上升和下降时间的变化还可以指示双线过程控制回路18的变化。与段上所有现场设备的变化相比，使用单独现场设备的幅度和上升/下降时间的组合，可以实现详细的设备和总线分析。在正常操作段上，如果单个设备提供幅度变化，则可以将该设备标记为潜在地即将发生故障。如果对段上的其他设备进行了比较，并且所述其他设备全部指示类似的幅度变化，则可以指示机械/接线故障、电源或本质安全防护栏故障。
在另一示例配置中，诊断电路54使用例如感测电阻60和模拟到数字转换器来监控环路18中产生的电流I，所述模拟到数字转换器测量感测电阻60两端的压降。通过监控电流I的DC值，诊断电路54可以检测DC电流的异常变化。例如，DC电流的变化能够指示，连接至回路的设备的分路电流(shunt set current)增加，这可能表明特定现场设备的介质存取单元(MAU)电路中的未确定的故障。还可能表明双线回路接线中的短路。类似地，段电流的减小还可以指示即将发生的故障。
信号感测电路64和诊断电路可以以单个组件或通过许多组件来实现，并可以共享单独组件。优选地，电路应当具有足够的处理带宽，以基本上实时地执行诊断。这可以利用单个微处理器或通过使用数字信号处理器(DSP)或其他类型的次级微处理器来实现。需要足够处理带宽的诊断一个示例为，监控来自例如用来连接回路18的两个端子、或回路18的连接线之一和外壳或其他电气接地之间的回路18上信号噪声。利用足够的处理速度，可以实现诸如标准偏差、均方根(RMS)、或快速傅立叶变换(FFT)等分析计算，并用分析计算来检测噪声特性的差异。例如从端子之一到地的60Hz的噪声增加，能够指示电气接地的可能的故障。
另一示例诊断可以是监控连接至双线回路18的每一设备的误比特率(BERT)。如果回路18上的单个设备显示出误比特率高于针对具体安装的基准的趋势，这可以表明设备发生故障，可能需要维护。根据误比特率增加的速率，可以向操作者提供质量下降警告指示或即将发生故障的指示。对这种即将发生的故障的预测允许在下个预定维护时间间隔对设备进行维修。
在另一示例配置中，I/O电路62被配置成向回路18施加高频脉冲。该高频脉冲可以由另一设备中的信号感测电路64来测量，并用来确定两个设备之间的回路18上电阻抗。在正常总线通信期间，可以施加高频脉冲，从而不会打断回路18上的通信。通过测量接收脉冲的幅度中的上升和下降时间，可以实现阻抗测量。可以用该测量同设施的基准测量的比较，来提供诊断。在一种配置中，可以由简单设备(例如如图1所示，包括在回路18的段的末端的终止器24中的设备)来产生高频脉冲。
由于可以放置在段18上的设备总数受限于耦合至段的所有设备的电流消耗，因此优选地，本发明的电路使用降低功耗的技术来进行操作。例如，可以在特定现场设备中的其他电路不需要额外电源期间，执行这一诊断。
尽管示出本发明的诊断的各个方面被阐释为分立组件，但各种功能可以通过单个组件来实现或在组件间共享。本发明的各个方面可以以软件程序(例如，存储在存储器72中)实现、可以以硬件实现，或可以在硬件和包括链路活动调度器(LAS)的软件之间共享。链路活动调度器(LAS)是确定性、集中式总线调度器，维护针对需要被循环发送的所有设备中的所有数据缓冲器的发送时间列表。H1现场总线链路上仅一个链路主(LM)设备可以用作该链路的LAS。
尽管参照优选实施例对本发明进行了描述，但本领域的技术人员应当认识到，可以在不背离本发明的精神和范围的前提下，在形式和细节上进行修改。如这里所使用的，除了回路接线以外，双线过程控制回路还包括耦合至回路的现场设备。
Claims (21)
1.一种用于与工业过程控制或监控系统的双线过程控制回路(18)耦合的诊断设备(22；50)，包括：
数字通信电路(52)，被配置成从所述双线过程控制回路接收数字通信信号，所述数字通信信号包括所述双线过程控制回路上的数字调制模拟信号，所述数字调制模拟信号被调制成代表数字值的多个离散模拟信号电平；以及
诊断电路(54)，被配置成基于所述数字调制模拟信号来诊断所述双线过程控制回路的操作，并且
其特征在于，所述诊断电路被配置为：通过接收所述双线过程控制回路上的高频信号，来监控所述双线过程控制回路的阻抗，
其中，所述高频信号是高频脉冲，并且所述诊断电路(54)还被配置为：接收由另一设备施加在所述双线过程控制回路上的高频脉冲，
其中，所述诊断电路(54)还被配置为：测量所接收的高频脉冲的幅度的上升时间和下降时间，以测量所述双线过程控制回路的阻抗。
2.根据权利要求1所述的设备，其中，所述诊断电路还被配置为：提供所测量的阻抗与基准测量的比较。
3.根据权利要求1所述的设备，其中，所述数字通信电路包括：感测电阻。
4.根据权利要求1所述的设备，其中，所述诊断电路监控所述数字调制模拟信号的幅度。
5.根据权利要求1所述的设备，其中，所述诊断电路监控所述数字调制模拟信号的波形。
6.根据权利要求1所述的设备，其中，所述诊断电路监控所述双线过程控制回路上的数字传输的误比特率(BERT)。
7.根据权利要求1所述的设备，其中，所述诊断电路将所述数字调制模拟信号的参数与存储值进行比较，并作为响应，提供诊断输出。
8.根据权利要求1所述的设备，其中，所述诊断电路将基于所述数字调制模拟信号的诊断信息与所述双线过程控制回路上发送所述数字调制模拟信号的具体设备相关联。
9.根据权利要求1所述的设备，其中，所述诊断电路对耦合至所述双线过程控制回路的设备或对所述双线过程控制回路的接线执行诊断。
10.根据权利要求1所述的设备，包括：用于对过程的过程变量进行感测或控制的过程接口。
11.根据权利要求1所述的设备，其中，使用从所述双线过程控制回路接收到的电能向所述数字通信电路和所述诊断电路供电。
12.根据权利要求1所述的设备，其中，所述诊断电路诊断所述双线过程控制回路的过程设备的操作。
13.一种用于诊断在工业过程控制或监控系统中所用类型的双线过程控制回路(18)的方法，包括：
从耦合至所述双线过程控制回路的多个设备接收数字通信信号，所述数字通信信号包括数字调制模拟信号，所述数字调制模拟信号被调制成代表数字值的多个离散模拟信号电平；
测量所述数字调制模拟信号的属性；
基于所测量的所述数字调制模拟信号的属性，来诊断所述双线过程控制回路的操作，并且
其特征在于，测量属性包括：通过接收所述双线过程控制回路上的高频信号，来监控所述双线过程控制回路的阻抗，
其中，所述高频信号是高频脉冲，并且所述方法还包括：接收由所述多个设备之一施加在所述双线过程控制回路上的高频脉冲，
其中，测量属性还包括：测量高频脉冲的幅度的上升时间和下降时间，以测量所述双线过程控制回路的阻抗。
14.根据权利要求13所述的方法，还包括：在正常总线通信期间使用所述多个设备之一将高频脉冲施加在所述双线过程控制回路上，以免打断回路上的通信。
15.根据权利要求13所述的方法，还包括：将所测量的高频脉冲幅度的上升时间或下降时间与基准测量进行比较。
16.根据权利要求14或15所述的方法，还包括：在双线过程控制回路的末端的终止器所包括的设备中产生高频脉冲。
17.根据权利要求13所述的方法，其中，测量属性包括：监控所述数字调制模拟信号的幅度。
18.根据权利要求13所述的方法，其中，测量属性包括：监控所述数字调制模拟信号的波形。
19.根据权利要求13所述的方法，其中，测量属性包括：监控所述双线过程控制回路上的数字传输的误比特率(BERT)。
20.根据权利要求13所述的方法，包括：将所述数字调制模拟信号的参数与存储值进行比较，并作为响应，提供诊断输出。
21.根据权利要求13所述的方法，包括：将基于所述数字调制模拟信号的诊断信息与所述双线过程控制回路上发送所述信号的具体设备相关联。
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Also Published As
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| JP5068822B2 (ja) | 2012-11-07 |
| EP2067088B1 (en) | 2014-07-16 |
| US7321846B1 (en) | 2008-01-22 |
| WO2008045258A2 (en) | 2008-04-17 |
| CN104618079B (zh) | 2019-10-22 |
| WO2008045258B1 (en) | 2008-07-24 |
| CN101523318A (zh) | 2009-09-02 |
| EP2067088A2 (en) | 2009-06-10 |
| JP2010506298A (ja) | 2010-02-25 |
| WO2008045258A3 (en) | 2008-05-29 |
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