U.S. patent application number 10/691758 was filed with the patent office on 2005-04-28 for sensor assembly, system including rfid sensor assemblies, and method.
Invention is credited to Gosselin, Stephen R., Harris, Joe C., Skorpik, James R..
Application Number | 20050087235 10/691758 |
Document ID | / |
Family ID | 34521931 |
Filed Date | 2005-04-28 |
United States Patent
Application |
20050087235 |
Kind Code |
A1 |
Skorpik, James R. ; et
al. |
April 28, 2005 |
Sensor assembly, system including RFID sensor assemblies, and
method
Abstract
A system comprises a valve; a plurality of RFID sensor
assemblies coupled to the valve to monitor a plurality of
parameters associated with the valve; a control tag configured to
wirelessly communicate with the respective tags that are coupled to
the valve, the control tag being further configured to communicate
with an RF reader; and an RF reader configured to selectively
communicate with the control tag, the reader including an RF
receiver. Other systems and methods are also provided.
Inventors: |
Skorpik, James R.;
(Kennewick, WA) ; Gosselin, Stephen R.; (Richland,
WA) ; Harris, Joe C.; (Kennewick, WA) |
Correspondence
Address: |
WELLS ST. JOHN P.S.
601 W. FIRST AVENUE, SUITE 1300
SPOKANE
WA
99201
US
|
Family ID: |
34521931 |
Appl. No.: |
10/691758 |
Filed: |
October 22, 2003 |
Current U.S.
Class: |
137/554 |
Current CPC
Class: |
F16K 37/00 20130101;
Y10T 137/8242 20150401 |
Class at
Publication: |
137/554 |
International
Class: |
F16K 037/00 |
Goverment Interests
[0001] This invention was made with government support under
contract number DE-AC0676RL01830 awarded by the U.S. Department of
Energy. The Government has certain rights in the invention.
Claims
1. A system comprising: a valve; a plurality of RFID sensor
assemblies coupled to the valve to monitor a plurality of
parameters associated with the valve; a control tag configured to
wirelessly communicate with the respective tags that are coupled to
the valve, the control tag being further configured to communicate
with an RF reader; and an RF reader configured to selectively
communicate with the control tag, the reader including an RF
receiver:
2. A system in accordance with claim 1 wherein the valve is a
fluid-operated valve.
3. A system in accordance with claim 2 wherein the valve includes a
valve positioner, an electrical conductor, and an I/P transducer
coupled to the valve positioner by the electrical conductor, and
wherein at least one of the plurality of RFID sensor assemblies is
coupled to the electrical conductor.
4. A system in accordance with claim 2 wherein the valve includes a
pneumatic actuator, a valve stem coupled to the pneumatic actuator,
and an actuator-valve stem coupler, and wherein at least one of the
plurality of RFID sensor assemblies is coupled to the
actuator-valve stem coupler.
5. A system in accordance with claim 2 wherein the valve includes a
pneumatic actuator, a valve positioner, and a fluid conduit in
fluid communication between the pneumatic actuator and the valve
positioner, and wherein at least one of the plurality of RFID
sensor assemblies is coupled to the fluid conduit between the
pneumatic actuator and the valve positioner.
6. A system in accordance with claim 2 wherein the valve includes a
pneumatic actuator, a valve positioner, a booster, a first fluid
conduit in fluid communication between the pneumatic actuator and
the booster, a second fluid conduit in fluid communication between
the booster and the valve positioner, and wherein at least one of
the plurality of RFID sensor assemblies is coupled to the first
fluid conduit and at least another one of the plurality of RFID
sensor assemblies is coupled to the second fluild conduit.
7. A system in accordance with claim 6 and further comprising a
fluid supply line in fluid communication with the booster, and
wherein at least one of the plurality of RFID sensor assemblies is
coupled to the fluid supply line.
8. A system in accordance with claim 7 and further comprising a
regulator valve in fluid communication between the fluid supply
line and the valve positioner, a conduit between the regulator
valve and the valve positioner, and wherein at least one of the
plurality of RFID sensor assemblies is coupled to the conduit
between the regulator valve and the valve positioner.
9. A system in accordance with claim 1 and further comprising a
conduit upstream of the valve and a conduit downstream of the
valve, wherein at least one of the plurality of RFID sensor
assemblies is coupled to the conduit upstream of the valve and at
least another one of the plurality of the RFID assemblies is
coupled to the conduit downstream of the valve.
10. A system in accordance with claim 1 wherein the valve includes
a seat and wherein the RFID sensor assemblies are used to determine
valve seating force.
11. A system in accordance with claim 1 wherein the valve includes
a spring and wherein the RFID sensor assemblies are used to
determine a spring preload of the spring.
12. A system in accordance with claim 1 wherein the valve includes
a spring and wherein the RFID sensor assemblies are used to
determine a spring constant of the spring.
13. A system in accordance with claim 1 wherein the valve includes
a spring and wherein the RFID sensor assemblies are used to
determine spring compression.
14. A system in accordance with claim 1 wherein the RFID sensor
assemblies are used to determine a friction load on the valve.
15. A system in accordance with claim 1 wherein the RFID sensor
assemblies are used to determine valve position.
16. A system in accordance with claim 1 wherein the RFID sensor
assemblies are used to determine valve stroke times.
17. A sensor assembly comprising: an RFID tag; a thermocouple; and
a probe having first and second ends, the first end defining a tip,
the thermocouple being supported on the tip, and the RFID tag being
supported on the second end and electrically coupled to the
thermocouple.
18. A sensor assembly in accordance with claim 17 wherein the probe
defines an electrical conductor electrically coupling the RFID tag
to the thermocouple.
19. A sensor assembly in accordance with claim 17 wherein the RFID
tag includes memory and is configured to log measurements from the
thermocouple, at different times, in the memory.
20. A plurality of RFID sensor assemblies for sensor use in
industrial process control, the plurality comprising: sensors
configured to sense at least two of temperature, pressure, and
strain; at least one of the sensor assemblies including a band
configured to encircle a fluid conduit; and an RFID tag supported
by the band and in electrical communication with at least one of
the sensors.
21. A sensor assembly in accordance with claim 20 wherein the RFID
tag includes memory and is configured to log data in the memory
from the at least one sensor in electrical communication with the
RFID tag, at different times.
22. A sensor assembly comprising: an RFID tag; a pressure sensor;
and a band configured to encircle a fluid conduit, the RFID tag
being supported by the band and in electrical communication with
the pressure sensor.
23. A sensor assembly in accordance with claim 22 wherein the RFID
tag includes memory and is configured to log data from the pressure
sensor in the memory at different times.
24. A method of monitoring an industrial process which makes use of
a valve, the method comprising: coupling a plurality of RFID sensor
assemblies to the valve to monitor a plurality of parameters
associated with the valve; providing a control tag to wirelessly
communicate with the respective tags that are coupled to the valve,
the control tag being configured to communicate with an RF reader;
and selectively communicating with the control tag using an RF
reader, the reader including an RF receiver.
25. A method in accordance with claim 24 wherein the valve is a
fluid-operated valve, wherein the valve includes a valve
positioner, an electrical conductor, and an I/P transducer coupled
to the valve positioner by the electrical conductor, and wherein
the method comprises coupling at least one of the plurality of RFID
sensor assemblies to the electrical conductor.
26. A method in accordance with claim 24 wherein the valve is a
fluid-operated valve, wherein the valve includes a pneumatic
actuator, a valve stem coupled to the pneumatic actuator, and an
actuator-valve stem coupler, and wherein the method comprises
coupling at least one of the plurality of RFID sensor assemblies to
the actuator-valve stem coupler.
27. A method in accordance with claim 24 wherein the valve is a
fluid-operated valve, wherein the valve includes a pneumatic
actuator, a valve positioner, and a fluid conduit in fluid
communication between the pneumatic actuator and the valve
positioner, and wherein the method comprises coupling at least one
of the plurality of RFID sensor assemblies to the fluid conduit
between the pneumatic actuator and the valve positioner.
28. A method in accordance with claim 24 wherein the valve is a
fluid-operated valve, wherein the valve includes a pneumatic
actuator, a valve positioner, a booster, a first fluid conduit in
fluid communication between the pneumatic actuator and the booster,
a second fluid conduit in fluid communication between the booster
and the valve positioner, and wherein the method comprises coupling
at least one of the plurality of RFID sensor assemblies to the
first fluid conduit and coupling at least another one of the
plurality of RFID sensor assemblies to the second fluild
conduit.
29. A method in accordance with claim 28 wherein a fluid supply
line is in fluid communication with the booster, and wherein at
least one of the plurality of RFID sensor assemblies is coupled to
the fluid supply line.
30. A method in accordance with claim 29 wherein a regulator valve
is in fluid communication between the fluid supply line and the
valve positioner, a conduit is between the regulator valve and the
valve positioner, and wherein at least one of the plurality of RFID
sensor assemblies is coupled to the conduit between the regulator
valve and the valve positioner.
31. A method in accordance with claim 24 wherein a conduit is
upstream of the valve and a conduit is downstream of the valve,
wherein at least one of the plurality of RFID sensor assemblies is
coupled to the conduit upstream of the valve and at least another
one of the plurality of the RFID assemblies is coupled to the
conduit downstream of the valve.
32. A method in accordance with claim 24 wherein the valve includes
a seat and wherein the method comprises using the RFID sensor
assemblies to determine valve seating force.
33. A method in accordance with claim 24 wherein the valve includes
a spring and wherein the method comprises using the RFID sensor
assemblies to determine a spring preload of the spring.
34. A method in accordance with claim 24 wherein the valve includes
a spring and wherein the method comprises using the RFID sensor
assemblies to determine a spring constant of the spring.
35. A method in accordance with claim 24 wherein the valve includes
a spring and wherein the method comprises using the RFID sensor
assemblies to determine spring compression.
36. A method in accordance with claim 24 and comprising using the
RFID sensor assemblies to determine a friction load on the
valve.
37. A method in accordance with claim 24 and comprising using the
RFID sensor assemblies to determine valve position.
38. A method in accordance with claim 24 and comprising using the
RFID sensor assemblies to determine valve stroke times.
39. A method of manufacturing a sensor assembly, the method
comprising: providing an RFID tag; providing a thermocouple;
providing a probe having first and second ends, the first end
defining a tip; supporting the thermocouple on the tip, and
supporting the RFID tag on the second end and electrically coupling
the RFID tag to the thermocouple.
40. A method in accordance with claim 39 and comprising using the
probe to define an electrical conductor electrically coupling the
RFID tag to the thermocouple.
41. A method in accordance with claim 39 wherein the RFID tag
includes memory, the method comprising logging measurements from
the thermocouple, at different times, in the memory.
42. A method of using a plurality of RFID sensor assemblies for
sensor use in industrial process control, the method comprising:
providing a plurality of sensors configured to sense at least two
of temperature, pressure, and strain; providing a mechanical
package to support at least one of the sensors and define a sensor
assembly, the package including a band configured to encircle a
fluid conduit; and supporting an RFID tag by the band, in
electrical communication with at least one of the sensors.
43. A method in accordance with claim 42 wherein the RFID tag
includes memory, the method comprising configuring the RFID tag
supported by the band to log data, at different times, in the
memory from the at least one sensor supported by the band.
44. A sensor method comprising: providing an RFID tag; providing a
pressure sensor; providing a band configured to encircle a fluid
conduit; supporting the RFID tag by the band and placing the RFID
tag in electrical communication with the pressure sensor.
45. A method in accordance with claim 44 wherein the RFID tag
includes memory and is configured to log data from the pressure
sensor in the memory at different times.
Description
TECHNICAL FIELD
[0002] The invention relates to sensors. The invention also relates
to valves and process control.
BACKGROUND OF THE INVENTION
[0003] Industrial process control environments typically require
physical sensing of parameters such as temperature, pressure, flow
rate, strain, displacement, humidity, vibration, etc. Adapting a
sensor network and its cabling infrastructure to existing plant
environments is usually cost prohibitive.
[0004] Various sensors that incorporate transmitters are known in
the art. For example, U.S. Pat. No. 5,774,048 (incorporated herein
by reference) relates to a valve that generates a wireless
transmittable signal if pressure drops within vehicle tires. U.S.
Pat. No. 6,005,480 to Banzhof et al. relates to similar subject
matter.
[0005] U.S. Pat. No. 6,199,575 to Widner (incorporated herein by
reference) discloses a valve system that includes a MEMS pressure
sensor that senses pressure and functions as a mechanical actuator
for a valve. A transmitter is integrated with the valve and a
receiver is located at a remote location. A transmitter may be
formed on the MEMS along with a pressure transducer and its
associated circuitry. An alternative embodiment is disclosed in
which a digital modulator is included in a transducer valve.
[0006] U.S. Pat. No. 6,445,969 to Kenney et al. (incorporated
herein by reference) discloses a system and method of monitoring
process parameters associated with a manufacturing or testing
process. This reference discloses that radio frequency
identification tags may be used to transmit an event signal. If an
event trigger is detected, a command is sent to a particular sensor
to measure a specified process parameter.
[0007] U.S. Pat. No. 6,484,080 to Breed discloses an acceleration
sensor including an RFID unit. U.S. Pat. No. 6,563,417 to Shaw
discloses an RFID tag including a temperature sensor.
[0008] Pneumatic or fluid controlled valves are known in the art
and used in a variety of applications, such as to control water and
other fluids in nuclear reactors. Such valves are discussed in U.S.
Pat. No. 5,197,328 to Fitzgerald; U.S. Pat. No. 6,026,352 to Burns
et al.; U.S. Pat. No. 5,329,956 to Marriott et al.; and U.S. Pat.
No. 5,774,048 to Achterholt, all of which are incorporated by
reference. In a typical pneumatic operated valve, a current to
pressure (I/P) transducer is coupled to a valve positioner which
supplies an operating pneumatic pressure to a valve diaphragm
actuator. The diaphragm actuator in turn is coupled to a sliding
valve stem and plug. Feedback is provided by a mechanical linkage,
such as by a valve positioner arm having one end connected to the
actuator/valve stem and the other end coupled to the positioner so
as to track movement of the valve stem. Alternatively, electrical
signal feedback is provided from installed valve positioner
instrumentation.
[0009] The value of sensor for providing both diagnostics and
prognostics is readily accepted; however, innovative technical
developments are needed to facilitate the implementation.
SUMMARY OF THE INVENTION
[0010] Some aspects of the invention provide a system comprising a
valve; a plurality of RFID sensor assemblies coupled to the valve
to monitor a plurality of parameters associated with the valve; a
control tag configured to wirelessly communicate with the
respective tags that are coupled to the valve, the control tag
being further configured to communicate with an RF reader; and an
RF reader configured to selectively communicate with the control
tag, the reader including an RF receiver:
[0011] Other aspects of the invention provide a suite of RFID
sensor assemblies for use in industrial process control. The suite
can include, for example, sensors configured to sense one or more
of temperature, pressure, strain, or other process control
parameters. In some aspects of the invention, a tailored mechanical
package is provided to allow the RFID tag to be readily adapted to
a particular process component or parameter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Preferred embodiments of the invention are described below
with reference to the following accompanying drawings.
[0013] FIG. 1 is a block diagram of a system including a
pneumatically operated valve and a plurality of RFID sensor
assemblies embodying various aspects of the invention.
[0014] FIG. 2A is a circuit schematic of a RFID sensor
assembly.
[0015] FIG. 2B is a reader embodying various aspects of the
invention.
[0016] FIG. 3 is a perspective view of an RFID sensor assembly in
accordance with some embodiments.
[0017] FIG. 4 is a perspective view of an RFID sensor assembly in
accordance with other embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] FIG. 1 shows a system embodying various aspects of the
invention. The system 9 includes a fluid control or pneumatically
operated valve 10. The air operated valve 10 includes a control
valve 11, a pneumatic diaphragm actuator 12, a stem coupler 13, a
valve positioner 14, a pressure or volume booster 15, a controller
and I/P or E/P converter 16, a sensor 17, an air regulator 18, and
a pneumatic fluid supply line 19. The valve 11 controls fluid flow
through a main fluid line 20. The main fluid line 20 transfers
fluid in connection with an industrial process. For example, the
main fluid line could transfer fluid used in a power plant (e.g.,
water or other fluids used in a nuclear power plant). The fluid
line 20 may be any other sort of fluid line in an industrial
process facility.
[0019] In the illustrated embodiment, a condition of the fluid line
20 is sensed (e.g., temperature, pressure, flow) and this
information is sent to the valve positioner 14. For example, in the
illustrated embodiment, the sensor 17 is a pressure transducer that
senses pressure upstream of the valve 11. In alternative
embodiments, different parameters can be sensed either upstream or
downstream of the valve 11. In the illustrated embodiment, an
electro-pneumatic type valve positioner 47 is shown, including
pneumatic positioner 14 and I/P converter 16. The sensor 17
provides an output, which is an electrical output in the
illustrated embodiment. More particularly, in the illustrated
embodiment, the sensor 17 provides a current output. The converter
16 is coupled to the sensor (transducer) 17 and converts an
electrical signal (current in the illustrated embodiment) from the
sensor 17 to pressure. Other I/P or E/P converters could be
employed. In some embodiments, the sensor 17 provides a signal that
can be directly used by the valve positioner 14 and the converter
16 is omitted. In alternative embodiments, converter 16 can receive
electrical signals from the valve position controller 39, from the
sensor 17, or from both the valve position controller 39 and the
process sensor 17. The valve position controller 39 is a remote
controller, in some embodiments. The valve position controller 39
is a manually operable controller in some embodiments.
[0020] In the illustrated embodiment, the converter 16 is coupled
to the valve positioner 14 which supplies an operating pneumatic
pressure to the actuator 12. The diaphragm actuator 12 includes a
diaphragm 21, and a spring 23 operating on the diaphragm. The
diaphragm actuator 12 can be of a type that is opened by pneumatic
fluid and closed by the spring, or can be of a type that is closed
by a pneumatic fluid and opened by the spring. The actuator 12 is
coupled to a sliding valve stem 24 and to the control valve 11. The
spring 23 is biased between the valve stem 24 and the diaphragm 21.
Feedback is provided by the actuator-valve stem coupler 13 which
has one end connected to the valve stem 24 and another end coupled
to the positioner 14 so as to track movement of the valve stem 24.
As the valve 11 approaches the closed position, feedback is used to
seat the valve 11 without slamming. The regulator valve 18 merely
reduces pressure from pneumatic supply line 19 and booster 15
merely increases pressure to a level required to operate the
pneumatic actuator 12.
[0021] Alternative arrangements are possible. For example, while
the pneumatic actuator 12 shown in FIG. 1 is a direct-acting
pneumatically operated diaphragm actuation, in which increasing
pneumatic pressure pushes down on the diaphragm 21 extending the
actuator stem 24, alternative actuator types could be employed. For
example, in one alternative embodiment (not shown), a
reverse-acting pneumatically operated diaphragm actuator type is
employed in which increasing pneumatic pressure pushes up on the
diaphragm and retracts the actuator stem. In another alternative
embodiment (not shown), a reversible type pneumatic actuator is
employed that can be assembled and installed as either a
direct-acting or reverse-acting type pneumatic actuator.
[0022] Similarly, while an electro-pneumatic type valve positioner
47 is shown in FIG. 1, including pneumatic positioner 14 and I/P
converter 16, alternative embodiments are possible. For example,
while an analog type electro-pneumatic positioner 14 is shown in
FIG. 1, a digital electro-pneumatic positioner is used in
alternative embodiments. Further, in some applications a pneumatic
type positioner will be used. In these embodiments, the pneumatic
positioner 14 receives a pressure input signal directly from the
process sensor 17 or valve position controller 166.
[0023] In some embodiments, a plurality of RFID sensor assemblies
is provided to establish on-line self-diagnostic, prognostic, and
calibration capabilities for the pneumatically operated valve. To
instrument a component such as the pneumatically operated valve 10,
individual RFID sensor assemblies are attached to monitor various
parameters. Various RFID sensor assemblies may have unique sensor
interfaces. More particularly, the RFID sensor assemblies include
mounting structure such that the mounting and sensing is
noninvasive to normal valve operation. Some such mounting
structures are described below in connection with FIGS. 3 and
4.
[0024] The RFID sensor assemblies are used, in the embodiment of
FIG. 1, to provide on-line or in-use self-diagnostic, prognostic,
and calibration capabilities for pneumatically operated process
control valves and control system components. For example, RFID
sensor assemblies can be coupled to or proximate (e.g., upstream or
downstream of) components such as, for example, the I/P or E/P
converter 16, the valve positioner 14, the pressure or volume
booster 15, the actuator spring 23, the packing of the control
valve 11, and the fluid supply regulator valve 18. In FIG. 1, an
RFID sensor assembly 31 is coupled to an electrical conductor 41
between the converter 16 and the valve positioner 14, an RFID
sensor assembly 32 is coupled to the actuator-valve stem coupler
13, an RFID sensor assembly 33 is coupled to a conduit 22 between
the booster 15 and the pneumatic actuator 21, an RFID sensor
assembly 34 is coupled to a conduit 43 between the valve positioner
14 and the booster 15, an RFID sensor assembly 35 is coupled to a
conduit 45 between the valve positioner 14 and regulator valve 18,
an RFID sensor assembly 36 is coupled to pneumatic supply line 19
between feeds to the regulator valve 18 and to the booster 15, and
RFID sensor assemblies 37 are coupled to the process line or
conduit 20 on either side of the control valve 11.
[0025] The use of RFID sensor assemblies 31-37 allows for condition
monitoring (e.g., periodic monitoring and data logging) of
important valve performance parameters such as valve seating force,
spring 23 preload and spring constant, bench set, spring packing
drag or bearing friction loads, linearity of the spring 23,
condition of the diaphragm 21, and valve 11 position, stroke times,
and calibration. Bench set comprises compression on the spring.
[0026] In the illustrated embodiment, the system 9 further includes
an RFID control tag 38, and each of the RFID sensor assemblies
31-37 communicates to the control tag 38. This is, in some
embodiments, a bi-directional link so that the control tag 38 can
request data from the RFID sensor assemblies 31-37 and also
communicate with a reader. The system 9 further includes a reader
40 defined by, for example, a portable computer 42 such as a laptop
or personal digital assistant plus an RF receiver or module 44
coupled to the laptop or personal digital assistant for
communication with the laptop or personal digital assistant.
Communication can be via an RS-232 link, PCMCIA connection, serial
port, or other communication link. In the illustrated embodiment,
the computer 42 includes software that allows for data transfer
from the control tag 38 and/or the RFID sensor assemblies 31-37.
The software (or separate software) permits setting up the
tags.
[0027] In other embodiments, the RFID sensor assemblies 31-37
communicate directly with the reader, instead of through the
control tag 38.
[0028] In the illustrated embodiment, the RF link between the
reader 40 and the control tag 38 (and/or the sensor assemblies
31-37) is a low power link. For example, low power is used for
transmissions. This allows the read/write range to be restricted to
a predetermined range. The restricted read/write range allows for
multiple networks to be placed in zones or grids, much like cell
phone grids, without crossover RF interference.
[0029] The tags have individual IDs, only tags with requested IDs
will respond. In the illustrated embodiment, the tags and reader
operate in a frequency band that does not require government
licensing such as the ISM (industrial scientific measurement) band
in the U.S. or frequency bands that similarly do not require
government licensing in other countries.
[0030] The RFID sensor assemblies 31-37 could be or include, in
some embodiments, RFID tags that are the same as or substantially
similar to the RFID tags described in the following patent
applications, which are incorporated herein by reference: U.S.
patent application Attorney Ser. No. 10/263,826, filed Oct. 2,
2002, entitled "Radio Frequency Identification Device
Communications Systems, Wireless Communication Devices, Wireless
Communication Systems, Backscatter Communication Methods, Radio
Frequency Identification Device Communication Methods and a Radio
Frequency Identification Device" by inventors Michael A. Hughes and
Richard M. Pratt; U.S. patent application Ser. No. 10/263,809,
filed Oct. 2, 2002, entitled "Method of Simultaneously Reading
Multiple Radio Frequency Tags, RF Tag, and RF Reader", by inventors
Emre Ertin, Richard M. Pratt, Michael A. Hughes, Kevin L. Priddy,
and Wayne M. Lechelt; U.S. patent application Ser. No. 10/263,873,
filed Oct. 2, 2002, entitled "RFID System and Method Including Tag
ID Compression", by inventors Michael A. Hughes and Richard M.
Pratt; U.S. patent application Ser. No. 10/264,078, filed Oct. 2,
2002, entitled "System and Method to Identify Multiple RFID Tags",
by inventors Michael A. Hughes and Richard M. Pratt; U.S. patent
application Ser. No. 10/263,940, filed Oct. 2, 2002, entitled
"Radio Frequency Identification Devices, Backscatter Communication
Device Wake-Up Methods, Communication Device Wake-Up Methods and A
Radio Frequency Identification Device Wake-Up Method", by inventors
Richard Pratt and Michael Hughes; U.S. patent application Ser. No.
10/263,997, filed Oct. 2, 2002, entitled "Wireless Communication
Systems, Radio Frequency Identification Devices, Methods of
Enhancing a Communications Range of a Radio Frequency
Identification Device, and Wireless Communication Methods", by
inventors Richard Pratt and Steven B. Thompson; U.S. patent
application Ser. No. 10/263,670, filed Oct. 2, 2002, entitled
"Wireless Communications Devices, Methods of Processing a Wireless
Communication Signal, Wireless Communication Synchronization
Methods and a Radio Frequency Identification Device Communication
Method", by inventors Richard M. Pratt and Steven B. Thompson; U.S.
patent application Ser. No. 10/263,656, filed Oct. 2, 2002,
entitled "Wireless Communications Systems, Radio Frequency
Identification Devices, Wireless Communications Methods, and Radio
Frequency Identification Device Communications Methods", by
inventors Richard Pratt and Steven B. Thompson; U.S. patent
application Ser. No. 10/263,635, filed Oct. 4, 2002, entitled "A
Challenged-Based Tag Authentication Model", by inventors Michael A.
Hughes and Richard M. Pratt; U.S. patent application Ser. No.
09/589,001, filed Jun. 6, 2000, entitled "Remote Communication
System and Method", by inventors R. W. Gilbert, G. A. Anderson, K.
D. Steele, and C. L. Carrender; U.S. patent application Ser. No.
09/802,408; filed Mar. 9, 2001, entitled "Multi-Level RF
Identification System"; by inventors R. W. Gilbert, G. A. Anderson,
and K. D. Steele; U.S. patent application Ser. No. 09/833,465,
filed Apr. 11, 2001, entitled "System and Method for Controlling
Remote Device", by inventors C. L. Carrender, R. W. Gilbert, J. W.
Scott, and D. Clark; U.S. patent application Ser. No. 09/588,997,
filed Jun. 6, 2000, entitled "Phase Modulation in RF Tag", by
inventors R. W. Gilbert and C. L. Carrender; U.S. patent
application Ser. No. 09/589,000, filed Jun. 6, 2000; entitled
"Multi-Frequency Communication System and Method", by inventors R.
W. Gilbert and C. L. Carrender; U.S. patent application Ser. No.
09/588,998; filed Jun. 6, 2000, entitled "Distance/Ranging by
Determination of RF Phase Delta", by inventor C. L. Carrender; U.S.
patent application Ser. No. 09/797,539, filed Feb. 28, 2001,
entitled "Antenna Matching Circuit", by inventor C. L. Carrender;
U.S. patent application Ser. No. 09/833,391, filed Apr. 11, 2001,
entitled "Frequency Hopping RFID Reader", by inventor C. L.
Carrender.
[0031] The RF tags offer significant features at the sensors. The
tags include microprocessors. In the illustrated embodiments, the
microprocessors allow for calibration, compensation, preprocessing,
and onboard diagnostics and prognostics. Each tag includes a large
amount of nonvolatile memory. In some embodiments, the RFID tags
are used as data loggers. The tags use the memory to periodically
or at various times store data that is measured by the sensors. The
nonvolatile memory is also used to store setup information that is
particular to the type of sensor and the tag application
requirements. For example, the time period for acquiring data is
user settable (e.g., times when data is to be taken and frequency
of data logging within specified time ranges). Each control tag and
RFID tag included in the assemblies 31-37 has its own unique
identification code or ID which is a main element in the RF
protocol for communications. In some embodiments, the RF link
between the reader 40 and the control tag or RFID assembly 31-37 is
two way (RF reader 40 request tag to transmit). In other
embodiments, the RF link between the reader 40 and the control tag
or RFID assembly 31-37 is one way (tag periodically transmits to an
RF reader). In some embodiments, the reader 40 is coupled to (or
selectively coupled to) the Internet and defines a web server so
that process reporting is performed via web pages and so that users
can monitor process parameters using web browsers. Alternatively,
data from the reader 40 is transferred at times to a web server 46
separate from the reader.
[0032] The system of FIG. 1 can be adapted for use with either
sliding stem or rotary stem control valves and actuator assemblies
with either pneumatic or electromagnetic controllers.
[0033] Another RFID sensor assembly design is shown in FIG. 2A. The
RFID sensor assemblies are relatively small. The RFID sensor
assembly 50 that is shown in FIG. 2A is configured to sense
temperature and impact (acceleration). Other parameters are sensed
in alternative embodiments. The RFID sensor assembly 50 includes a
processor 54 that can accommodate both analog and digital sensors.
In the illustrated embodiment, the processor 54 is a Texas
Instruments 430.times.325 integrated circuit microprocessor. Other
embodiments are possible. A thermocouple 53 and a temperature
sensor 55 are coupled to the microprocessor. In the illustrated
embodiment, the thermocouple 53 is a high temperature thermocouple.
Other temperature sensors are possible. The system 50 further
includes an impact sensor or accelerometer 57 coupled to the
processor 50; e.g., via a buffer op-amp.
[0034] The assembly 50 further includes an RF transceiver 56
coupled to the processor 54 and to an antenna 58. The assembly 50
further includes a low power RF detector 60 configured to provide a
wakeup signal to the processor 54.
[0035] The assembly 50 further includes a battery 62 coupled to the
integrated circuit 54 to supply power to various components of the
assembly 50 that require electrical power. In the illustrated
embodiment, the assembly 50 includes a power supervisor 64 coupled
to a reset input of the integrated circuit 54 and a power on/off
switch 66 coupled between the power supervisor 64 and the battery
62. The assembly 50 further includes a battery monitor 68 coupled
to the integrated circuit 54 and configured to monitor the
condition of the battery. In the illustrated embodiment, the
assembly 50 further includes a super capacitor or ultracapacitor 70
and an LDO regulator 72 having an input coupled to a positive
terminal of the ultracapacitor 70. The input of the LDO regulator
72 and the positive terminal of the super capacitor 70 are also
coupled to the on/off switch 66. The LDO regulator 72 has an output
that provides a regulated voltage to the various electronic
components of the assembly 50. The ultracapacitor 70 provides
supplemental power for RF communications and allows continued
operation when the battery 62 is replaced. The components of the
assembly 50 other than the battery 62 and thermocouple 53 are
enclosed in a common housing 74 and the battery 62 is enclosed in a
housing 76 that is removable from the housing 74. The components
enclosed in the housing 74 and in the housing 76, and the housings
74 and 76 together can be referred to as an RFID tag 51.
[0036] In some embodiments, sensors such as strain gauges and/or
LVDTs are used. In such embodiments, interface circuitry is
provided between the sensor and the microprocessor 54.
[0037] The reader 52 (FIG. 2B) includes a transceiver 78 configured
to communicate with the transceiver 56 (FIG. 2A). The reader 52
further includes a processor 80 coupled to the transceiver 78. In
the illustrated embodiment, the processor 80 is a Texas Instruments
430.times.325 integrated circuit microprocessor. The reader 52
further includes a battery 82. The reader 52 further includes an
LDO regulator 84 configured to provide a regulated voltage to
electrical components of the reader 52. The reader 52 further
includes an on/off switch 86 coupled between the battery 82 and the
LDO regulator 84. The reader 52 also includes an interrogate switch
88 which, when actuated, causes the reader 52 to interrogate the
tag assembly 50 (FIG. 2A). The reader 52 further includes
input/output interfaces such a display 90.
[0038] In the illustrated embodiment, the reader 52 further
includes a low battery indicator, a power on indicator 92, and a
speaker 96. Other embodiments are possible.
[0039] In the illustrated embodiment, the reader 52 is configured
to be coupled to a PDA or portable computer. In alternative
embodiments, the reader 52 is coupled to or incorporated in a PDA
or portable computer and uses the display and/or speaker, and/or
keyboard or input interface of the PDA or computer.
[0040] Some aspects of the invention provide a suite of RFID sensor
assemblies for sensor use in industrial process control. The suite
can include, for example, sensors configured to sense one or more
of temperature, pressure, strain, or other process control
parameters. In some aspects of the invention, a tailored mechanical
package or mounting structure is provided to allow the RFID tag to
be readily adapted to a particular process component or
parameter.
[0041] For example, FIG. 3 is a perspective view of a sensor
assembly 150, which can be substantially similar to the RF tag
assembly 50 shown in FIG. 2A. The sensor assembly 50 includes an
RFID tag 151, which can be identical to or substantially identical
to the RFID tag 51 shown in FIG. 2A. The assembly 151 is configured
to be used to measure temperature and may be placed in a high
temperature environment. The assembly 151 includes a probe or
waveguide 152 having first and second ends 153 and 154. The first
end 153 defines a tip, and a thermocouple 155 is supported on the
tip. The RFID tag 151 is supported on the second end 154.
[0042] An RFID sensor assembly for use with a fluid conduit such as
one used in a nuclear reactor includes a band that encircles the
fluid conduit 156, and an RFID tag supported by the band. The
sensor assembly can be for sensing temperature, such as the sensor
assembly 150 shown in FIG. 3. The RFID sensor assembly 150 is for
use with a fluid conduit 156 and includes a band 157 that encircles
the fluid conduit 156, and an RFID tag 151 supported by the band
157.
[0043] An RFID sensor assembly 200 for use in sensing pressure is
shown in FIG. 4 and includes a gas inlet port 202 configured to be
coupled to a port on a conduit 206. For example, the gas inlet
port, in some embodiments, is configured to be coupled
(mechanically mated) to an ancillary port or threaded stub on a
flow pipe.
[0044] A variety of additional RFID sensor assembly designs is
contemplated, the above specific designs being provided by way of
example. Each RFID sensor assembly includes a mating adaptor that
allows for ease of installation and minimization of modification to
existing process control components. Some RFID sensor assemblies
just sense switch closures such as for limit switches or relay
contacts.
[0045] The ability to locally add desired sensing to an industrial
process provides tremendous flexibility for continually adding to,
modifying, or enhancing a sensor network.
[0046] In compliance with the statute, the invention has been
described in language more or less specific as to structural and
methodical features. It is to be understood, however, that the
invention is not limited to the specific features shown and
described, since the means herein disclosed comprise preferred
forms of putting the invention into effect. The invention is,
therefore, claimed in any of its forms or modifications within the
proper scope of the appended claims appropriately interpreted in
accordance with the doctrine of equivalents.
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