U.S. patent application number 13/191614 was filed with the patent office on 2012-02-16 for handheld field maintenance tool with field device simulation capability.
Invention is credited to Christopher P. Kantzes, Adam E. Lund, Brad N. Mathiowetz, Todd M. Toepke, Kun Yang.
Application Number | 20120041744 13/191614 |
Document ID | / |
Family ID | 44629535 |
Filed Date | 2012-02-16 |
United States Patent
Application |
20120041744 |
Kind Code |
A1 |
Kantzes; Christopher P. ; et
al. |
February 16, 2012 |
HANDHELD FIELD MAINTENANCE TOOL WITH FIELD DEVICE SIMULATION
CAPABILITY
Abstract
A handheld field maintenance tool and associated method are
provided. The handheld field maintenance tool includes a process
communication module configured to communicate in accordance with a
process industry communication standard. A controller is coupled to
the process communication module and is configured to access a
device description relative to a selected simulated field device. A
user interface is configured to receive a user input relative to a
parameter of the simulated field device. The controller generates
communication through the process communication module to simulate
the selected field device based on the user input.
Inventors: |
Kantzes; Christopher P.;
(Minneapolis, MN) ; Mathiowetz; Brad N.;
(Lakeville, MN) ; Toepke; Todd M.; (Eden Prairie,
MN) ; Yang; Kun; (Eden Prairie, MN) ; Lund;
Adam E.; (St. Louis Park, MN) |
Family ID: |
44629535 |
Appl. No.: |
13/191614 |
Filed: |
July 27, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61368477 |
Jul 28, 2010 |
|
|
|
Current U.S.
Class: |
703/13 |
Current CPC
Class: |
G05B 2219/25062
20130101; Y04S 10/50 20130101; G05B 2219/36128 20130101; G05B
19/0426 20130101; G05B 2219/24028 20130101; G05B 2219/23406
20130101; G05B 2219/33331 20130101; G05B 2219/23054 20130101; G06Q
30/0601 20130101; G05B 2219/24001 20130101; G05B 2219/23126
20130101; G05B 2219/32007 20130101; G05B 2219/23163 20130101; G05B
2219/24012 20130101; G05B 2219/35429 20130101; G05B 2219/36122
20130101; Y02P 90/02 20151101; G05B 2219/32226 20130101; G05B
2219/35422 20130101; G05B 19/409 20130101; G05B 2219/23446
20130101; G06Q 40/04 20130101; C07C 29/1518 20130101; G06Q 20/204
20130101; G05B 2219/31475 20130101; G05B 2219/50193 20130101; G05B
2219/23445 20130101; G05B 2219/25428 20130101; G06Q 10/06315
20130101; G05B 19/4068 20130101; G05B 2219/31121 20130101; G05B
19/042 20130101; G05B 2219/31197 20130101; G05B 2219/23018
20130101; G05B 2219/24056 20130101; G05B 2219/32144 20130101 |
Class at
Publication: |
703/13 |
International
Class: |
G06G 7/62 20060101
G06G007/62 |
Claims
1. A handheld field maintenance tool comprising: a process
communication module configured to communicate in accordance with a
process industry communication standard; a controller coupled to
the process communication module, the controller being configured
to access a device description relative to a selected simulated
field device; a user interface configured to receive a user input
relative to a parameter of the simulated field device; and wherein
the controller is configured to generate communication through the
process communication module to simulate the selected field device
based on the user input.
2. The handheld field maintenance tool of claim 1, wherein the
process communication module is a wired process communication
module.
3. The handheld field maintenance tool of claim 1, wherein the
process communication module is a wireless process communication
module.
4. The handheld field maintenance tool of claim 1, and further
comprising a database of device descriptions stored on computer
readable media within the handheld field maintenance tool and
coupled the controller.
5. The handheld field maintenance tool of claim 1, and further
comprising at least one secondary wireless communication protocol
module coupled to the controller, wherein the controller is
configured to access the device description using the at least one
secondary wireless communication protocol module.
6. The handheld field maintenance tool of claim 1, wherein the
communication generated through the process communication module by
the controller is indicative of simulation.
7. The handheld field maintenance tool of claim 6, wherein the
communication generated through the process communication module
includes an additional communication packet to allow a host to
display an indicator relative to the simulated field device.
8. A method of simulating a field device over a process
communication loop, the method comprising: coupling a handheld
field maintenance tool to the loop; selecting a field device to
simulate with the handheld field maintenance tool; accessing a
device description for the selected field device; receiving user
input relative to at least one parameter indicated by the device
description to be a variable of the simulated field device; and
generating process communication on the loop with the handheld
field maintenance tool based on the device description and the user
input.
9. The method of claim 8, wherein the handheld field maintenance
tool simulates a plurality of field devices.
10. The method of claim 8, wherein the process communication
includes data indicating that the process communication is from a
simulated field device.
11. The method of claim 8, wherein accessing the device description
includes wirelessly communicating with a remote database to obtain
the device description.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is based on and claims the benefit
of U.S. provisional patent application Ser. No. 61/368,477, filed
Jul. 28, 2010, the content of which is hereby incorporated by
reference in its entirety.
BACKGROUND
[0002] Handheld field maintenance tools are known. Such tools are
highly useful in the process control and measurement industry to
allow operators to conveniently communicate with and/or interrogate
field devices in a given process installation. Examples of such
process installations include petroleum, pharmaceutical, chemical,
pulp, and other fluid processing installations. In such
installations, the process control and measurement network may
include tens or even hundreds of various field devices which
periodically require maintenance to ensure that such devices are
functioning properly and/or calibrated. Moreover, when one or more
errors in the process control and measurement installation are
detected, the use of a handheld field maintenance tool allows a
technician to quickly diagnose such errors in the field. Handheld
field maintenance tools are generally used to configure, calibrate,
and diagnose problems relative to intelligent field devices using
digital process communication protocols.
[0003] Since at least some process installations may involve highly
volatile, or even explosive, environments, it is often beneficial,
or even required, for field devices and the handheld field
maintenance tools used with such field devices to comply with
intrinsic safety requirements. These requirements help ensure that
compliant electrical devices will not generate a source of ignition
even under fault conditions. One example of Intrinsic Safety
requirements is set forth in: APPROVAL STANDARD INTRINSICALLY SAFE
APPARATUS AND ASSOCIATED APPARATUS FOR USE IN CLASS I, II and III,
DIVISION NUMBER 1 HAZARDOUS (CLASSIFIED) LOCATIONS, CLASS NUMBER
3610, promulgated by Factory Mutual Research October, 1998. An
example of a handheld field maintenance tool that complies with
intrinsic safety requirements includes that sold under trade
designation Model 475 Field Communicator, available from Emerson
Process Management of Austin, Tex.
SUMMARY
[0004] A handheld field maintenance tool and associated method are
provided. The handheld field maintenance tool includes a process
communication module configured to communicate in accordance with a
process industry communication standard. A controller is coupled to
the process communication module and is configured to access a
device description relative to a selected simulated field device. A
user interface is configured to receive a user input relative to a
parameter of the simulated field device. The controller generates
communication through the process communication module to simulate
the selected field device based on the user input.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIGS. 1A and 1B are diagrammatic views of a handheld field
maintenance tool with which embodiments of the invention are
particularly useful.
[0006] FIG. 2 is a diagrammatic view of a handheld field
maintenance tool with which embodiments of the present invention
are particularly useful.
[0007] FIG. 3 is a block diagram of a handheld field maintenance
tool in accordance with an embodiment of the present invention.
[0008] FIG. 4 is a flow diagram of a method of simulating a field
device in accordance with an embodiment of the present
invention.
DETAILED DESCRIPTION
[0009] FIGS. 1A and 1B are diagrammatic views of a handheld field
maintenance tool 22 coupled to field devices 20, 23. As shown in
FIG. 1A, handheld field maintenance tool 22 includes a pair of
terminals 25, 27 that couple to test leads 30, 32, respectively,
which are then coupled to terminals 24 of field device 20.
Terminals 24 may be dedicated terminals to allow such a handheld
field maintenance tool to couple to device 20 and interact with
device 20. The utilization of terminals 25, 27 to couple to field
device illustrates an example of a wired connection between
handheld field maintenance tool 22 and field device 20.
[0010] FIG. 1B shows an alternate arrangement where handheld field
maintenance tool 22 couples directly to the process control loop 34
to which field device 23 is coupled. In either case, the wired
connection between the handheld field maintenance tool and the
field device allows the handheld field maintenance tool to interact
with the desired field device 20, 23.
[0011] FIG. 2 is a diagrammatic view of handheld field maintenance
tool 102 interacting with wireless field device 104. System 100
includes handheld field maintenance tool 102 communicating with
field device 104. Handheld field maintenance tool 102 is
communicatively coupled to field device 104 via communication link
114. Communication link 114 can take any suitable form including
wired connections as shown in FIGS. 1A and 1B, as well as wireless
communication techniques that are currently being used or being
developed. Handheld field maintenance tool 102 allows a technician
to interact with field device 104 to configure, calibrate, and/or
diagnose problems with respect to field device 104 using a digital
process communication protocol such as FOUNDATION.TM. Fieldbus
and/or the HART.RTM. protocol. Handheld field maintenance tools,
such as tool 102 can be used to save configuration data from field
devices, such as field device 104.
[0012] Field device 104 may be any device that senses a variable in
the process and transmits information related to the variable over
a process communication loop; such as a pressure or temperature.
Field device 104 may also be a device that receives information
from a process communication loop and sets a physical parameter,
such as a valve closure, based on the information. Field device 104
is depicted as an industrial process fluid pressure transmitter
having a pressure manifold 106 coupled thereto, and an electronics
enclosure 108. Field device 104 is provided for illustrative
purposes only. In reality, field device 104 may be any industrial
device, such as a process fluid temperature transmitter, process
fluid level transmitter, process fluid flow transmitter, valve
controller, or any other device that is useful in the measurement
and/or control of industrial processes.
[0013] Handheld field maintenance tool 102 generally includes a
user interface that comprises a display 120 as well as a number of
user input buttons 122. Display 120 may be any suitable display
such as an active-matrix liquid crystal display, or any other
suitable display that is able to provide useful information.
Buttons 122 may comprise any suitable arrangement of buttons
relative to any number of functions to which the handheld field
maintenance tool may be directed. Buttons 122 may comprise a
numeric keypad, an alphanumeric keypad, any suitable number of
custom functions and/or navigation buttons, or any combination
thereof.
[0014] FIG. 3 is a diagrammatic system block diagram of a handheld
field maintenance tool in accordance with the embodiment of the
present invention. It is preferred that tool 52 comply with at
least one intrinsic safety specification, such as that listed
above, in order to help ensure safety in potentially explosive
environments. Handheld field maintenance tool 52 includes at least
one wireless process communication module 121. Suitable examples
for wireless process communication module 121 include a module that
generates and/or receives proper signals in accordance with a known
wireless communication protocol, such as the known WirelessHART
protocol (IEC 62591). Another wireless process communication
protocol is set forth in ISA100.11a. While FIG. 3 shows a single
wireless process communication module 121, it is expressly
contemplated that any suitable number of wireless process
communication modules can be used to communicate in accordance with
various wireless process communication protocols now in existence
or later developed.
[0015] Handheld field maintenance tool 52 also includes at least
one secondary wireless communication protocol module 123. Wireless
communication protocol module 123 can communicate in accordance
with one or more of the options shown in phantom in FIG. 3.
Specifically, wireless communication protocol module 123 may
communicate in accordance with a Bluetooth specification 124 (such
as Bluetooth Specification 2.1 rated at Power Class 2; a Wi-Fi
specification 126 (such as IEEE 802.11.a/b/g/n); a known RFID
specification 128; cellular communication techniques 130 (such as
GSM/CDMA); and/or satellite communication 132. These communication
techniques and methodologies allow handheld field maintenance tool
52 to communicate directly with a wireless gateway or other
suitable device either via direct wireless communication, or using
the Internet. While one wireless communication protocol module 123
is shown in FIG. 3, any suitable number may be used. Each of the
wireless process communication protocol module 121 and wireless
communication protocol module 123 is coupled to controller 130
which is also coupled to the wired process communication module
138. Controller 130 is preferably a microprocessor that executes a
sequence of instructions stored therein, or in memory coupled to
controller 130, to perform handheld field maintenance tasks. Wired
process communication module 138 allows handheld field maintenance
tool 52 to be physically coupled via a wired connection at
terminals 142, 144 to a field device. Examples of suitable wired
process communication include the Highway Addressable Remote
Transducer (HART.RTM.) protocol, the FOUNDATION.TM. Fieldbus
protocol, Profibus and others.
[0016] Handheld field maintenance tool 52 includes a user interface
module 156 for generating a user interface using display 120 and
keys 122. Module 156 can include suitable display driver circuitry
158 and/or memory to interact with display 120. Module 156 also
includes input circuitry 160 which is configured to interact with
buttons 122 to receive user input. Additionally, in embodiments
where display 120 includes a touchscreen, module 160 can include
circuitry to generate user input data to controller 130 based upon
a user's touch and/or gestures received by the touchscreen.
[0017] Handheld field maintenance tool 52 can include a number of
additional items that facilitate additional functionality.
Specifically, tool 52 can include a position detection module, such
as GPS module 150. GPS module 150 can be configured to additionally
use the Wide Area Augmentation System (WAAS) for improved accuracy
and/or can be configured to operate using differential GPS
techniques as appropriate. Module 150 is coupled to controller 130
to provide controller 130 with an indication of the geographic
position of tool 52. While position detection module 150 is
preferably an internal component of tool 52, it may be external and
communicatively coupled thereto using a suitable wireless or wired
communication protocol, such as Bluetooth 124, RFID 128, et cetera.
Further still, while position detection module 150 is generally
described as GPS module 150, other techniques for triangulating the
position of the handheld field maintenance tool based upon relative
strength of wireless communication with wireless transceivers
having known fixed positions can be employed. Examples of such
wireless triangulation techniques include triangulation of the
position of handheld field maintenance tool 52 based upon
communication with three or more fixed-position WiFi communication
points, or access points. Further still, as set forth above,
embodiments of the present invention may include the ability to
employ one or more wireless process communication protocol modules,
such as module 121. Such triangulation techniques can also be
employed if a suitable number of wireless interactions with
fixed-position wireless field devices can be achieved. Finally,
while the various methods provided for obtaining the position of
handheld field maintenance tool 52 are described above, they can
also be used in conjunction with one another to provide additional
accuracy and/or redundancy. Additionally, tool 52 also preferably
comprises compass module 152 coupled to controller 130 such that
tool 52 can indicate the compass direction in which it is pointing.
Finally, tool 52 can also include tilt module 154 coupled to
controller 130 to provide an indication to controller 130 relative
to an angle of inclination of tool 52 relative to gravity. However,
additional axes of sensing are also contemplated.
[0018] The positional location module 150, compass module 152 and
tilt module 154 are particularly useful where a handheld field
maintenance tool helps a technician or engineer find the physical
location of a wireless field device in the field. An oil refinery
is often a very large process installation with many field devices
positioned at various locations, some of which may not be readily
visible
[0019] Setting up a process control system often requires that the
control strategy be verified by forcing various field devices to
simulate a response signal in order to observe the control system
response and determine if it is correct. This currently requires
that the actual field device instrument be installed and powered.
Once those criteria are established, the field device(s) must then
be manipulated so that the field device(s) provides or otherwise
outputs the desired digital signal. This can be done by placing the
field device in a simulate mode and using a configuration device,
such as a handheld field maintenance tool, to set the desired
output. Alternatively, the desired output can be obtained by
actually applying an external source to the sensor(s) of the field
device(s). For example, for a process fluid pressure transmitter, a
specific pressure can be applied. The simulation capability is not
always available in all field devices. Moreover, even if a
simulation capability is provided, it can sometimes be difficult or
cumbersome to use. Further still, the external source solution, on
the other hand, can be very time consuming and cumbersome to
implement.
[0020] In accordance with an embodiment of the present invention, a
handheld field maintenance tool is provided with an ability to
actually mimic one or more field devices on a process control loop
or segment. In this manner, the handheld field maintenance tool
behaves as if it were an actual field device or devices. This means
that the control setup can now be verified ahead of any
instrumentation being physically installed in the field. Moreover,
embodiments of the present invention can provide a simulation
interface that is optimized for ease of use for the technician and
can allow the technician to select specific field devices to
simulate through the use of device description (DD) technology. In
addition, embodiments of the present invention can specify what the
configuration of the simulated field device should be, and what the
dynamic variable output should be.
[0021] In accordance with an embodiment of the present invention,
handheld field maintenance tool 52 includes a database of device
descriptions stored within memory of controller 130, or memory
coupled to controller 130. Additionally, or alternatively, any
suitable device description can be obtained from a remote device
via wireless communication protocol module 123.
[0022] FIG. 4 is a flow diagram of a method of simulating a field
device in accordance with an embodiment of the present invention.
Method 200 begins at block 202 where a technician or user of a
handheld field maintenance tool, such as tool 52, selects the
device simulation function. This selection can be performed either
through pressing an appropriate button 122, or via navigation of a
handheld field maintenance device menu. Once the device simulation
function has been selected, controller 130 causes the display 120
to provide one or more user interface elements that help the user
select a particular field device. For example, the user interface
may include a dropdown box that lists all known field device
manufacturers. Then, once a user selects a device manufacturer, a
second user interface element may provide the selection of a device
type. Once the device type has been selected, a third user
interface element may provide a comprehensive listing of all known
field devices manufactured by the selected manufacturer of the
selected type. Once the user selects a specific field device(s) at
block 204, a device description (DD) is accessed for the selected
field device(s), as indicated at block 206. Additionally, if the
user indicates that the field device is not provided in the list of
field devices presented to the user from the selected manufacturer
of the selected type, method 200 can include the ability of a
handheld field maintenance tool to access an online database of
field devices available from the selected manufacturer of the
selected type using wireless communication protocol module 123. At
block 206, access of the requisite device description(s) is
preferably accomplished via an internal lookup of a database of
device descriptions stored locally within a handheld field
maintenance tool. If the required device description(s) is not
stored within a local device description database, or if no
database is provided, handheld field maintenance tool 52 can access
the requisite device description(s) preferably via wireless
communication protocol module 123 over the Internet, or any
suitable network. Once the device description(s) has been acquired
at block 206, handheld field maintenance tool 52 will possess a
comprehensive description of the capabilities and behaviors of the
selected field device for which simulation is desired. At this
point, method 200 continues at block 208 where handheld field
maintenance tool 52 presents a user interface to the technician or
user that allows the configuration of specific parameters of the
simulated field device. An example may be allowing the technician
to specify a process variable, such as a process fluid pressure, or
temperature, that is measured by the simulated field device. At
block 210, handheld field maintenance tool 52 interacts with the
process controller via a process communication module. Examples of
such interaction include communication over a wired process
communication loop or segment using wired process communication
module 138. Examples of such wired process communication include
the Highway Addressable Remote Transducer HART.RTM. protocol, the
FOUNDATION.TM. Fieldbus protocol, Profibus et cetera.
Alternatively, the handheld field maintenance tool may communicate
over a wireless process communication protocol, such as
WirelessHART using wireless process communication protocol module
121. In this sense, the handheld field maintenance tool is
communicating upon a process control loop or segment to indicate
the selected variable or parameter of the simulated field device
set by the technician to the process controller. Certainly,
embodiments of the present invention also include the ability of
the handheld field maintenance tool 52 operating in device
simulation mode to receive one or more responses from a process
controller, or other suitable device, and react to such response(s)
in accordance with the simulation as directed by technician.
[0023] Since the output of the handheld field maintenance tool
represents a "false" or simulated signal, it is certainly not
intended for use during live operations of a process control
installation. Instead, the simulation mode is intended primarily
for use as a pre-startup loop or segment verification.
Additionally, because of the significant impact a false signal
could have on plant operations, embodiments of the present
invention may include a simulation flag 212 or other suitable data
structure that is provided with the simulation communication in
block 210 such that the control system is able to distinguish such
signals. One example of such communication may be an additional
communication packet to the control/host system that allows it to
display to the operator if a device is actually a simulated
device.
[0024] Although the present invention has been described with
reference to particular 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.
* * * * *