U.S. patent application number 15/946461 was filed with the patent office on 2018-08-09 for programmable logic controller-based system and user interface for air.
The applicant listed for this patent is Veltek Associates, Inc.. Invention is credited to Nathan G. KOCHER.
Application Number | 20180224413 15/946461 |
Document ID | / |
Family ID | 55400385 |
Filed Date | 2018-08-09 |
United States Patent
Application |
20180224413 |
Kind Code |
A1 |
KOCHER; Nathan G. |
August 9, 2018 |
PROGRAMMABLE LOGIC CONTROLLER-BASED SYSTEM AND USER INTERFACE FOR
AIR
Abstract
A system and method for sampling air at multiple locations in a
controlled environment. The system and method includes automatic
adjustment of mass flow rates and duration of vacuum connections
(either via time elapsed or indirectly by volume) based on rates
set by an operator. Additionally, the system and method enables
users to monitor and control aspects of the system via
network-connected devices. Additionally, the system enable a vacuum
pump to be disconnected from power in response to a physical
emergency button, a software-based emergency stop button available
on network connected devices, and an automatic power disconnection
in response to an abnormal mass flow reading that could potentially
impact the vacuum pump.
Inventors: |
KOCHER; Nathan G.; (West
Chester, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Veltek Associates, Inc. |
Malvern |
PA |
US |
|
|
Family ID: |
55400385 |
Appl. No.: |
15/946461 |
Filed: |
April 5, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14471848 |
Aug 28, 2014 |
9939416 |
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15946461 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01N 1/2273 20130101;
G01N 1/26 20130101; G01N 33/0073 20130101; F24F 11/50 20180101;
G01N 33/0011 20130101; F24F 11/74 20180101; F24F 2011/0005
20130101; G01N 1/24 20130101 |
International
Class: |
G01N 33/00 20060101
G01N033/00 |
Claims
1-30. (canceled)
31. A system for sampling air at multiple locations in a controlled
environment comprising: a plurality of air sampling devices, each
configured to monitor and test a volume of air within a controlled
environment; a plurality of vacuum connections, each configured to
receive the volare of air from one of the plurality of air sampling
devices; a vacuum pump configured to draw the volume of air from
the plurality of air sampling devices through the plurality of
vacuum connections; a contactor configured to deliver and control
power to the vacuum pump; and a flow center including a
programmable logic controller (PLC) configured to monitor and
control mass flow rates of air received by the plurality of vacuum
connections, wherein the system is configured to disconnect power
to the vacuum pump in response to a determination that the mass
flow rate of the volume of air received by one of the vacuum
connections in flow communication to the vacuum pump is below a
predetermined threshold.
32. The system of claim 31, wherein the contactor comprises an
emergency stop button configured to disconnect the power to the
vacuum pump.
33. The system of claim 31, further comprising: a graphical user
interface (GUI) for receiving one or more setpoints indicative of a
desired. mass flow rate at one of the air sampling devices;
34. The system of claim 33, wherein the graphical user interface
comprises an emergency stop button configured to disconnect power
to the vacuum pump.
35. The system of claim 33, wherein the graphical user interface is
output by an operator interface terminal co-located with the flow
center.
36. The system of claim 33, wherein the graphical user interface is
output by an operator interface terminal co-located with one of the
plurality of air sampling devices.
37. The system of claim 33, wherein the graphical user interface is
output by a server to a network connected device.
38. The system of claim 33, wherein the graphical user interface is
output by a web server to a web browser of an internet-connected
device.
39. The system of claim 33, further comprising: a plurality of flow
control valves, each configured to control a mass flow rate of the
volume of air received by one of the vacuum connections; a
plurality of actuators, each configured to open and close one of
the flow control valves; and a plurality of flow sensors, each
configured to sense the mass flow rate of the volume of air
received by one of the vacuum connections, wherein the flow center
controls the mass flow rate of air received by the plurality of
vacuum connections by: determining errors indicative of the
differences between the measured flow rates and the setpoints; and
outputting control signals to the plurality of actuators to reduce
the differences between the measured flow rates and the
setpoints.
40. The system of claim 39, wherein: the plurality of air sampling
devices comprises a first air sampling device and a second air
sampling device; the plurality of vacuum connections comprises a
first vacuum connection configured to receive the volume of air
from the first air sampling device and a second vacuum connection
configured to receive the volume of air from the second air
sampling device, the first and second vacuum connections in flow
communication with the vacuum pump via a manifold; and the PLC is
configured to reduce the difference between the measured flow rate
of the volume of air received by the first vacuum connection and
the setpoint indicative of the desired mass flow rate at the first
air sampling device caused by a change in the volume of air through
the second vacuum connection.
41. The system of claim 39, wherein the each of the flow control
valves are configured to adjust such that a change in position of
the flow control valve is proportional to the size of the
difference between the set point and the measured flow rate of the
vacuum connection corresponding to the respective flow control
valve.
42. The system of claim 39, wherein the each of the flow control
valves are configured to adjust such that a rate of change in
position of the flow control valve is proportional to a rate of
change of the difference between the set point and the measured
flow rate of the vacuum connection corresponding to the respective
flow control valve.
43. The system of claim 31, wherein the system is configured to
output data indicative of the mass flow rates of the volumes of air
received by the plurality of vacuum connections to an external
device via a network connection.
44. The system of claim 43, wherein the external device is a
supervisory control and data acquisition system or data collection
system.
45. The system of claim 43, wherein the network connection includes
communication via the internet and the external device receives the
data via a web browser or remote desktop application.
46. A method for sampling air at multiple locations in a controlled
environment, the method comprising: monitoring and testing, by a
plurality of air sampling devices, volumes of air within a
controlled environment; receiving, by a plurality of vacuum
connections, the volumes of air from each of the plurality of air
sampling devices; drawing, by a vacuum pump, the volumes of air
from the plurality of air sampling devices through the plurality of
vacuum connections; delivering and controlling power to the vacuum
pump by a contactor; monitoring and controlling, by a flow center
including a programmable logic controller (PLC), mass flow rates of
air received by the plurality of vacuum connections; and
disconnecting power to the vacuum pump in response to a
determination that the mass flow rate of the volume of air received
by one of the vacuum connections in flow communication to the
vacuum pump is below a predetermined threshold.
47. The method of claim 46, wherein the contactor comprises an
emergency stop button configured to disconnect the power to the
vacuum pump.
48. The method of claim 46, further comprising: a graphical user
interface (GUI) for receiving one or more setpoints indicative of a
desired mass flow rate at one of the air sampling devices:
49. The method of claim 48, wherein the graphical user interface
comprises an emergency stop button configured to disconnect power
to the vacuum pump.
50. The method of claim 48, wherein the graphical user interface is
output by an operator interface terminal co-located with the flow
center.
51. The method of claim 48, wherein the graphical user interface is
output by an operator interface terminal co-located with one of the
plurality of air sampling devices.
52. The method of claim 48, wherein the graphical user interface is
output by a server to a network connected device.
53. The method of claim 48, wherein the graphical user interface is
output by a web server to a web browser of an internet-connected
device.
54. The method of claim 48, further controlling, by a plurality of
flow control valves, mass flow rates of the volumes of air received
by each of the vacuum connections; sensing, by a plurality of flow
sensors, the mass flow rates of the volumes of air received by each
of the vacuum connections; determining the differences between the
measured flow rates and the setpoints; and outputting control
signals to a plurality of actuators to adjust the flow control
valves and reduce the differences between the sensed mass flow
rates and the setpoints.
55. The method of claim 54, wherein: the plurality of air sampling
devices comprises a first air sampling device and a second air
sampling device; the plurality of vacuum connections comprises a
first vacuum connection configured to receive the volume of air
from the first air sampling device and a second vacuum connection
configured to receive the volume of air from the second air
sampling device, the first and second vacuum connections in flow
communication with the vacuum pump via a manifold; the PLC reduces
the difference between the measured flow rate of the volume of air
received by the first vacuum connection and the setpoint indicative
of the desired mass flow rate at the first air sampling device
caused by a change in the volume of air through the second vacuum
connection.
56. The method of claim 54, wherein the actuators adjust the flow
control valves such that a change in position of the flow control
valve is proportional to the size of the difference between the set
point and the measured flow rate of the vacuum connection
corresponding to the respective flow control valve.
57. The method of claim 54, wherein the actuators adjust the flow
control valves such that a rate of change in position of the flow
control valve is proportional to a rate of change of the difference
between the set point and the measured flow rate of the vacuum
connection corresponding to the respective flow control valve.
58. The method of claim 56, further comprising: outputting data
indicative of the mass flow rates of the volumes of air received by
the plurality of vacuum connections to an external device via a
network connection.
59. The method of claim 58, wherein the external device is a
supervisory control and data acquisition system or data collection
system.
60. The method of claim 58, wherein the network connection includes
communication via the Internet and the external device receives the
data via a web browser or remote desktop application.
Description
FIELD OF INVENTION
[0001] The present invention relates to devices and methods for
monitoring airborne contaminants. In particular, the present
invention relates to a programmable logic controller-based system
and one or more corresponding operator interface terminals for
controlling air sampling in controlled environments.
BACKGROUND OF THE INVENTION
[0002] Clean rooms found in manufacturing, research, and other
facilities are typically classified into two broad categories based
on the static air pressure inside the rooms relative to atmospheric
pressure and/or based on the air pressure in spaces adjacent the
clean rooms. A positive air pressure room is maintained at an
absolute air pressure greater than atmospheric pressure, greater
than the air pressure in spaces adjacent the clean room, or both.
The positive air pressure in such rooms is provided by pumping
filtered and/or conditioned air into the rooms and controlling the
flow of air out of the rooms. The adjacent spaces, which may be
manufacturing facilities or offices, are typically maintained at or
close to atmospheric pressure by heating, ventilation, and air
conditioning (HVAC) systems, or by providing an opening to the
environment that allows the adjacent spaces to equilibrate with
atmospheric pressure. Thus, air flowing from the positive pressure
clean room will flow toward the lower pressure in adjacent rooms or
to the atmosphere.
[0003] When a positive air pressure clean room is breached, air
flowing to adjacent spaces or the atmosphere is generally not a
problem as long as airborne contaminants present in the clean room
do not pose a potential adverse health effect to people in the
adjacent spaces. Typically, the air inside clean rooms in which
electronics, aerospace hardware, optical systems, military
equipment, and defense-related research are manufactured or
conducted may not contain airborne gases, vapors, and particulate
matter at concentrations that present a safety or health concern to
human health or the environment. However, that is not always the
case, as other operations within those industries may generate
contaminants that are above acceptable levels and, therefore, must
be prevented from escaping the clean room without treatment.
[0004] A negative air pressure room is maintained at an absolute
air pressure that is either less than atmospheric pressure, less
than the air pressure in spaces adjacent the clean room, or both.
The negative pressure is maintained by pumping air out of the room
at a rate faster than that at which filtered and/or conditioned air
is pumped into the room. Negative pressure rooms are often used
when there is a concern that contaminants in the air in the room
may pose a potential health threat to human health in adjacent
spaces or the environment.
[0005] Notwithstanding the human health and environmental
implications, certain types of manufacturing and research
operations must be conducted within a positive air pressure clean
room to satisfy regulatory requirements and industry-adopted good
manufacturing and laboratory quality control standards. For
example, state and federal regulations, including those promulgated
by the National Institute for Occupational Safety and Health
(NIOSH), may necessitate the use of positive or negative pressure
clean rooms.
[0006] In particular, the U.S. Food & Drug Administration (FDA)
requires that pharmaceutical production be performed within the
confines of clean rooms that provide for the validation and
certification that manufactured batches of pharmaceutical products
are being produced in a sanitary environment. Various FDA
regulations and standards also specify requirements for air
sampling and/or air monitoring equipment to be used inside clean
rooms to verify or validate the cleanliness of the facility during
certain drug manufacturing activities. The regulations also provide
for electronic data recording, accuracy, precision, and
record-keeping relating to monitoring the air quality within clean
rooms. Similar requirements are imposed on other industries, such
as the biotechnology industry.
[0007] Current systems for testing and monitoring the air quality
in controlled environments include a plurality of sterilizable
microbial atriums (SMA) that are connected to a distributed digital
control (DDC) controller. An example of an SMA-DDC system includes
the SMA-DDC-10 and integrated One Touch Control System produced by
Veltek Associates Inc. of Malvern, Pa. Other systems are shown in
U.S. Pat. Nos. 8,169,330; 7,973,668; 7,940,188; 8,188,874;
8,701,980; and U.S. Patent Publication Number 2014-0132415 A1, the
disclosures of which are hereby incorporated by reference. Such
systems typically include a hardware-based interface that allows
users to interface with the air sampling equipment.
[0008] As described below, conventional systems require manual
control of flow switches to control the mass flow rates of vacuum
connections. Additionally, conventional systems require users to
monitor and control aspects of the system from limited locations.
Additionally, the vacuum pumps of conventional systems may be
physically damaged or cause injury if a vacuum connection or air
sampling device is obstructed.
SUMMARY OF THE INVENTION
[0009] In order to overcome these and other drawbacks of
conventional air sampling systems, aspects of exemplary embodiments
of the present invention enable automatic regulation of the mass
flow rates of each of the vacuum connections based on rates set by
an operator. Additionally, aspects of exemplary embodiments of the
present invention enable users to monitor and control aspects of
the system via network-connected devices. Additionally, aspects of
exemplary embodiments of the present invention enable a vacuum pump
to be disconnected from power in response to a physical emergency
button, a software-based emergency stop button available on network
connected devices, and an automatic power disconnection in response
to an abnormal mass flow reading that could potentially impact the
vacuum pump.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For the purpose of illustration, there are shown in the
drawings certain embodiments of the present invention. In the
drawings, like numerals indicate like elements throughout. It
should be understood that the invention is not limited to the
precise arrangements, dimensions, and instruments shown. In the
drawings:
[0011] FIG. 1 is a schematic diagram of an exemplary facility
having a clean room therein, in accordance with an exemplary
embodiment of the present invention;
[0012] FIG. 2 is a schematic diagram of a tracking/logging and air
sampling/monitoring system for use in the clean room of FIG. 1 that
includes a PLC-based controller and one or more associated touch
panel displays, in accordance with an exemplary embodiment of the
present invention;
[0013] FIG. 3 is a schematic diagram of a flow center according to
an exemplary embodiment of the present invention;
[0014] FIG. 4 illustrates a system overview screen of a graphical
user interface (GUI) according to an exemplary embodiment of the
present invention;
[0015] FIG. 5 illustrates a floor plan screen of the GUI according
to an exemplary embodiment of the present invention;
[0016] FIG. 6 illustrates a port overview screen of the GUI
according to an exemplary embodiment of the present invention;
[0017] FIG. 7 illustrates a labeling screen of the GUI according to
an exemplary embodiment of the present invention;
[0018] FIG. 8 illustrates a group control screen of the GUI
according to an exemplary embodiment of the present invention;
[0019] FIG. 9 illustrates an event log screen of the GUI according
to an exemplary embodiment of the present invention;
[0020] FIG. 10 illustrates a security screen of the GUI according
to an exemplary embodiment of the present invention;
[0021] FIG. 11 illustrates a time and date screen of the GUI
according to an exemplary embodiment of the present invention;
and
[0022] FIG. 12 illustrates a pump overview screen of the GUI
according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present invention will be explained in terms of
exemplary embodiments. This specification discloses one or more
embodiments that incorporate the features of this invention. The
disclosure herein will provide examples of embodiments, including
examples of data analysis from which those skilled in the art will
appreciate various novel approaches and features developed by the
inventors. These various novel approaches and features, as they may
appear herein, may be used individually, or in combination with
each other as desired.
[0024] Turning first to FIG. 1, shown therein is a schematic of an
exemplary facility 100 having one or more clean rooms 102 therein,
in accordance with an exemplary embodiment of the present
invention. The clean room 102 is surrounded by an adjacent space
104 and the outdoor atmosphere 106. The adjacent space 104 may be
one or more rooms within the same facility 100 in which the clean
room 102 is located and that adjoin the clean room 102, such as,
for example, a separate manufacturing room, another clean room, a
finish and fill room, a research laboratory, offices, etc. The
clean room 102 and adjacent space 104 are separated by a divider,
such as a wall 105.
[0025] The clean room 102 in the exemplary facility 100 is capable
of being maintained at an air pressure P.sub.1 that is less than or
greater than the air pressure P.sub.2 of the adjacent space 104 and
atmospheric air pressure P.sub.ATM of the outdoor atmosphere 106.
That is accomplished by an HVAC system (not shown) that causes
conditioned and filtered air to be pumped into the clean room 102
at a controlled flow rate Q.sub.IN as depicted in FIG. 1. Air
inside the clean room 102 that is pumped out of or otherwise flows
out of the clean room 102 is represented by Q.sub.OUT. When the
difference between Q.sub.IN and Q.sub.OUT (i.e.,
Q.sub.IN-Q.sub.OUT) is greater than zero, a positive pressure will
be maintained in the clean room 102. And, when the difference
between Q.sub.IN and Q.sub.OUT is less than zero, a negative
pressure will be maintained in the clean room 102.
[0026] Turning now to FIG. 2, shown therein is a schematic diagram
of an air sampling/monitoring system 200, in accordance with an
exemplary embodiment of the present invention. The system 200
generally includes a controller 210, flow centers 240, air sampling
devices 260, operator interface terminals 270, a vacuum pump 340
and a contactor 350. The controller 210, the flow centers 240, and
the operator interface terminals 270 may include, processors,
displays, wireless devices, and memory to operate in accordance
with the invention. As described below, the controller 210, flow
centers 240, air sampling devices 260, operator interface terminals
270 may each be associated with its own sensor 291 or a shared
sensor 291.
[0027] The system 200 is configured for use in tracking and logging
data obtained from the process of air sampling through the air
sampling devices 260. During air sampling, air from the clean room
102 is drawn through the air sampling devices 260 of the system 200
to collect contaminants present in the air of the clean room 102.
The data acquired about the air sampling devices 260 is used to
monitor and gather airborne particle count and other parameter
levels in the clean room 102 in order to maintain the integrity of
experiments or production processes therein.
[0028] One or more flow centers 240 are provided to monitor and
control the flow of air through one or more vacuum connections 232.
The flow centers 240 may be free standing or wall mounted within
the clean room 102, outside the clean room 102, or in multiple
clean rooms 102. (As illustrated in FIG. 2, for example, flow
center 240a is inside the clean room 102 and the flow center 240b
is outside the clean room 102.) The flow centers 240 may include
modular ports, such as the modular ports described and illustrated
in the '330 patent, where each of such ports may be connected to a
vacuum connection 232. Using these ports, the flow centers 240 can
be configured to draw in air from the air sampling devices 260 and
to provide for the air sampling performed by the air sampling
devices 260. The vacuum connections 232 may be connected across the
wall 105 via a wall-mounted quick disconnect outlets 114, where the
outlets and are located on the wall 105 in between the clean room
102 and the adjacent space 104.
[0029] A plurality of air sampling devices 260 may be co-located
together in the clean room 102 or in multiple clean rooms. The air
sampling devices 260 may be any known air sampling device for
collecting a volume of air. An example of an air sampling device
suitable for use as the air sampling devices 260 is described in
the '330 patent and/or U.S. Pat. No. 8,474,335, the contents of
which are incorporated herein by reference.
[0030] The subjects 265 are located at various sites within the
clean room 102. The subjects 265 may be equipment, personnel, etc.
The air sampling devices 260 may be positioned, for instance,
adjacent to one or more of the subjects 265 to collect the air
surrounding respective subjects 265, i.e., to draw air over the
subjects 265 during air sampling, so that contaminants in the air
of the clean room 102 at sites of interest are collected by the air
sampling devices 260. The sensors 291 may device configured to
identify the subjects 265. For example, the sensors may include
cameras, radio frequency identification (RFID) readers, barcode
scanners, etc
[0031] The controller 210 communicates data and commands for
monitoring and controlling the system 200 in real time (or near
real time) and logging the data and commands in a database 290
maintained by the controller 210. The controller 210 may be any
suitable computing device, such as a server. The controller 210 may
be freestanding or wall mounted in a rack-style chassis. The
database 290 may be any computer-readable storage medium and may be
co-located with the controller 210 or remotely located. (The
controller 210 may include the same or similar features as
"controllers" or "control centers" described in documents
incorporated in this description by reference.)
[0032] The operator interface terminals 270 communicate data and
commands for monitoring and controlling the system 200. Each of the
operator interface terminals 270 may be any suitable computing
device, such as a desktop computer, notebook computer, touch screen
computer, an identifying device (such as a camera, a barcode
scanner, an RFID reader, a fingerprint reader, etc.), etc. Each
operator interface terminal 270 may include a monitor, a speaker, a
touch screen and/or a keyboard. The operator interface terminals
270 may be wall-mounted, desktop, portable, or a combination.
Operator interface terminals 270 may be located throughout the
system 200. For example, operator interface terminals 270 may be
co-located with the controller 210, the flow centers 240, the air
sampling devices 260, etc. An operator interface terminal 270 that
is co-located with another hardware component (such as the
controller 210, the flow centers 240) may communicate with the
hardware component directly or via a network connection. As
described below, each operator interface terminal 270 includes a
graphical user interface (GUI) that can be readily accessed by the
users to monitor and control the system 200.
[0033] The exemplary embodiment of the system 200 illustrated in
FIG. 2 illustrates one clean room 102, two flow centers 240a-b and
four vacuum connections 232a-232d, each of which corresponds to a
respective one of four air sampling devices 260a-260d. It is to be
understood that the number of clean rooms 102, flow centers 240,
vacuum connections 232, air sampling devices 260, and sensors 291
is not limited thereto. That is, the system 200 is linearly
scalable to substantially any number, n, of clean rooms 102a-102n,
flow centers 240a-240n, vacuum connections 232a-232n, air sampling
devices 260a-260n, subjects 265a-265n, and operator interface
terminals 270a-270n.
[0034] The controller 210, the flow centers 240, and the operator
interface terminals 270 communicate with one another in any
suitable manner. For example, the operator interface terminals 270
and the flow centers 240 may have network addresses, and the
controller 210 may communicate with the flow centers 240 and the
operator interface terminals 270 by use of those network addresses
via a common connection (e.g. an Ethernet network or wireless local
area network (LAN)). In the exemplary embodiment illustrated in
FIG. 2, the flow centers 240a and 240b and the operator interface
terminals 270c and 270b communicate with the controller 210 via
wired networking connections 275 while the operator interface
terminals 270a and 270b communicate with the control panel 210 via
wireless signals 285. The wired networking connections 275 may pass
from the adjacent space 104 into the clean room 102, for example,
via channels 112. The controller 210, the flow centers 240, and the
operator interface terminals 270 may communicate via networking
communication and/or raw electronic signals.
[0035] In one exemplary scenario, a first operator interface
terminal such as first operator interface terminal 270a may be
located near a first air sampling device such as air sampling
device 260a and away from a second air sampling device such as air
sampling device 260b. By interacting with the graphical user
interface presented by the first operator interface terminal 270a,
the user may cause a signal to be sent to the controller 210 and/or
the flow center 240a for thereby controlling or monitoring the
second air sampling device 260b. Thus, any air sampling device
260a-d may be controlled or monitored using any operator interface
terminal 270a-d irrespective of where they are located.
[0036] In another exemplary scenario, an alarm may be generated by
a first operator interface terminal 260a and a notification of the
alarm may be presented to one or more of the operator interface
terminal 270a-d irrespective of their locations. For example, in
the exemplary configuration shown in FIG. 2, an alarm generated by
the operator interface terminal 260a may be detected by the
controller 210 and then information associated with the alarm may
be relayed to one or more of the remotely-located operator
interface terminal 270b-d, instead of or in addition to the
adjacent operator interface terminal 270a. In this way, important
alarm information may be automatically presented to the location(s)
where users are located when the alarm is detected rather than
being presented only at the location of the alarm, where users may
or may not be located. It will be recognized, however, that the
operator interface terminal 270 can directly communicate with one
another, such as to de-activate an alarm signal.
[0037] The programmable logic controller (PLC) may be a digital
computer used for automation of electromechanical processes,
including control of machinery, such as the sterilizable microbial
atriums (SMAs) described herein. Unlike general-purpose computers,
the PLC may be designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical
noise, and resistance to vibration and impact. The PLC may be
programmed using application software executed on separate general
purpose computers. Such a computer may be connected to the PLC
through Ethernet, RS-232, RS-485, RS-422, or other suitable
communications cabling. Generally, the programming software
provides functions for debugging and troubleshooting the PLC
software, for example, by highlighting portions of the logic to
show current status during operation or via simulation. The
software can upload and download the PLC program for backup and
restoration purposes. In some PLC embodiments, the program is
transferred from a personal computer to the PLC through a
programming board which writes the program into a removable memory
chip such as an SD card, an EEPROM, an EPROM, etc. PLCs may be used
to interact with users for the purpose of configuration, alarm
reporting or everyday control. A human-machine interface (HMI) is
employed for this purpose. HMIs are also referred to as a
human-computer interface (HCI), a man-machine interface (MMI) and a
graphical user interface (GUI) displayed on a human-machine
interface. A simple system may use buttons and lights to interact
with the user. Text displays are available as well as graphical
touch screens.
[0038] The system 200 may also be configured to interface with a
customer's existing hardware. For example, the controller 210 may
send and receive data to and from a customer's existing industrial
control systems, such supervisory control and data acquisition
(SCADA) systems and/or data collection systems (DCS). A typical
SCADA system is a desktop or server-based computer running a SCADA
application. The controller 210 may also contain power supplies for
remote systems such as the flow centers 240, the distributed PLCs
310 (discussed below), and the operator interface terminals
270.
[0039] FIG. 3 is an overview of a flow center 240 according to an
exemplary embodiment of the present invention. The flow center 240
includes a distributed PLC 310, an operator interface terminal 270,
and one or more mass flow controllers 320. Each of the mass flow
controllers 320 includes a flow control valve 322, an actuator 324,
and a flow sensor 326. Each of the vacuum connections 232 may be in
flow communication with a manifold 330 and a vacuum pump 340. The
vacuum pump 340 and/or the manifold 330 may be located in
interstitial space outside the clean room 102.
[0040] The flow center 240 includes one or more vacuum connections
232, each of which are in flow communication with one of the air
sampling devices 260. The flow center 240 is configured to draw air
from each of the air sampling devices 260 through the vacuum
connections 232. The air drawn from through the vacuum connections
232 is combined by the manifold 330 and exhausted to the vacuum
pump 340. The vacuum pump 340 may be in flow communication with
either the flow center 240 or the controller 210. (As illustrated
in FIG. 2, for example, the vacuum line of the vacuum pump 340 is
split by the controller 210 and regulated by the flow centers
240.
[0041] The flow center 240 is configured to independently monitor
and adjust the flow rate of each of the vacuum connections 232
while sending and receiving signals from the distributed PLC 310 to
each of the mass flow controllers 320. Each of the mass flow
controllers 320 includes a flow control valve 322 configured to
control the flow rate through the vacuum connection 232 by
positioning the valve. Each of the mass flow controllers 320 also
includes an actuator 324 configured to outputs electrical signals
to open or close the flow control valve 322 based on electrical
signal received from the distributed PLC 310. Each of the mass flow
controllers 320 also includes a flow sensor 326 configured to
output an electrical signal to the distributed PLC 310 based on the
rate of flow through the vacuum connection.
[0042] The flow sensor 326 may be any suitable device configured to
output an electrical signal proportional to the mass flow rate of
air passing through the vacuum connection 232. For example, the
flow sensor 326 may be a capillary configured to draw in a small
volume of air, sense an increase in temperature proportional to the
flow rate, translate a change in resistance (due to the increase in
temperature) into an electrical voltage, and output an electrical
current to the distributed PLC 310. The distributed PLC 310
includes software configured to scale the electrical signal to the
appropriate engineering units.
[0043] The distributed PLC 310 may communicate with the controller
210 via any suitable method. For example, the distributed PLC 310
may communicate with the controller 210 using common industrial
protocol (or other protocols) over a wireless or wired network
connection. The distributed PLC 310 is configured to monitor the
flow rate of each of the vacuum connections 232 in the flow center
240 based on the flow rate measurements received from each flow
sensor 326 of each mass flow controller 320 and output the flow
rate measurements to the controller 210 or other networked
devices.
[0044] The distributed PLC 310 is also configured to control the
flow rate of each of the vacuum connections 232 in the flow center
240 by outputting electrical signals to actuator 324 of the mass
flow controller 320. For example, the flow center 240 may be
configured such that the distributed PLC 310 compares a desired
flow rate (or "setpoint") set by the user with the actual measured
flow rate received from the flow sensor 326 and determines the
difference ("error") between the setpoint and the measured flow
rate. Depending on whether the error is positive (i.e., the
measured flow rate is greater than the setpoint) or negative (i.e.,
the setpoint is greater than the measured flow rate), the
distributed PLC 310 outputs electrical signals to the actuator 324
to either open or close the flow control valve 322. The electrical
signals output to the actuator 324 may be proportional to the size
of the error. For example, if the error is small, the distributed
PLC 310 will output an electrical signal to the actuator 324 to
open or close the valve 324 by a small amount. If the error is
large, the distributed PLC 310 will output an electrical signal to
the actuator 324 to open or close the valve 324 by a larger amount.
Accordingly, the change in position (i.e. magnitude) of the flow
control valve 322 may be proportional to the size of the error.
Additionally, the rate at which the flow control valve 322 changes
may be proportional to how fast the mass flow rate measurement
changes. This is known as proportional-integral-derivative control
or PID control.
[0045] Using conventional systems, the mass flow rates of each of
the vacuum connections 232 must be manually controlled by manually
adjusting a flow switch on each line to change the position of each
valve. Because some or all of the vacuum connections 232 are in
flow communication (for example, via a manifold 330), adjusting one
flow switch for one vacuum connection 232 may inadvertently affect
the mass flow rates of other vacuum connections 232. Accordingly,
conventional systems required multiple flow switches to be adjusted
to adjust the mass flow rate of one vacuum connection 232 and
maintain a constant mass flow rate of other vacuum connections 232.
Additionally, multiple flow switches of a conventional system must
be adjusted if an additional vacuum connection 232 is active or if
an air sampling device 260 is disturbed. The system 200 overcomes
this drawback of conventional systems by automatically adjusting
the mass flow rates of each of the vacuum connections 232 to the
individual rates set by an operator.
[0046] Each of the flow centers 240 may include an operator
interface terminal 270, including a graphical user interface (GUI)
that can be readily accessed by the users to monitor and control
the mass flow rates of each of the vacuum connections 232.
Additionally, each distributed PLC 310 is network connected to the
controller 210 and other industrial and enterprise devices via
proprietary and open-source communications protocols. Because the
distributed PLCs 310 are network connected, the mass flow rates of
each of the vacuum connections 232 may also be monitored and/or
controlled from the controller 210, other operator interface
terminals 270 (i.e., terminals that are not co-located with the
flow center), and/or an office computer, industrial workstation,
mobile device, or any other internet-enabled computing device via a
web browser. The industrial control systems may include supervisory
control and data acquisition (SCADA) systems, data collection
systems (DCS), human machine interfaces (HMI), manufacturing
execution systems (MES), plant-monitoring systems (PMS), and
similar systems. The controller 210, the distributed PLCs 310, the
operator interface terminal 270, and the industrial control systems
may be connected via a network as described above. Each of the
network-connected systems may be remotely accessed via the
internet.
[0047] If one or more of the air sampling devices 260 or vacuum
connections 232 becomes obstructed, the corresponding vacuum pump
340 may overheat or suffer physical damage. A damaged vacuum pump
340 has the potential to threaten the safety of personnel by
causing a fire or projecting broken pieces. In order to minimize
this potential safety risk, each of the vacuum pumps 340 includes a
contactor 350 to deliver and control electrical power to the
respective vacuum pump 340. The system 200 may be configured such
that the contactor 350 automatically disconnects power from the
vacuum pump 340 if a flow rate is not detected by one or more of
the flow sensors 326. Additionally, each of the contactors 350 may
include an emergency stop button 352 that, when actuated,
interrupts all electrical power connections to the vacuum pump 350
and outputs an alarm signal to the distributed PLC 310, the
controller 210, and/or other network-connected devices. In addition
to the emergency stop button 352, each of the contactors 350 may be
controlled by a software-based emergency stop button included in
the graphical user interface (GUI) of the operator interface
terminal 270 or other network connected devices. The GUI may also
output an indication if an emergency is detected by any
network-connected device or if one of the emergency stop buttons
352 or software-based stop buttons is selected on another
network-connected device.
[0048] The system 200 is also configured to automatically
disconnect the power supplied to a vacuum pump 350 in response to a
determination that any one of the vacuum connections 232 in flow
communication with the vacuum pump 350 is experiencing an
abnormally low mass flow rate (e.g., 0). Whereas conventional
systems would shut down a vacuum pump only if all sample points
were manually aborted, the system 200 provides additional
protection against a vacuum pump 350 being damaged by an obstructed
air sampling device 260 or vacuum connection 232.
[0049] In addition to the normal operation described above, the
system 200 may also be configured enter an auxiliary mode (or
Isolator Mode) wherein the system 200 is configured to purge the
vacuum connections 232 and the air sampling devices 260. An
exemplary purging process is described in U.S. Pat. No. 8,169,330
(which is incorporated herein by reference). The system may include
one or more purge pumps (not shown) in flow communication with the
vacuum connections 232. Each of the vacuum connections 232 may
include isolator equipment (not shown) configured such that air
from the air sampling devices 260 bypasses the flow centers 240 and
instead flows to the purge pumps. The isolator equipment may be
co-located with or external to the flow centers 240. The isolator
equipment and the purge pump may be connected via a network as
described above.
[0050] As described above, the system 200 may be configured such
that a graphical user interface (GUI) is available on any of the
operator interface terminals 270 or other network-connected
devices. The GUI displays information regarding each of the ports
(e.g., air sampling devices 260) and vacuum pumps 340 received from
the controller 210, flow centers 240, or other network connected
devices. The system 200 may be configured such that a user may
control any of the ports (e.g., air sampling devices 260) or vacuum
pumps 340 throughout the system via the GUI. Referring to FIGS. 2
and 3, for example, a user may adjust the air sampling rate of the
air sampling device 260b from the operator interface terminal 270a
(which may be located next to the air sampling device 260a) by
inputting a setpoint for the air sampling device 260b via the GUI.
In response to the user input, the system 200 may send a signal
from the operator interface terminal 270a to the distributed PLC
310 associated with the vacuum connection 232b in flow
communication with the air sampling device 260b (for example, via a
wireless signal 285 to the controller 210 and via a wired or
wireless signal to the distributed PLC 310 of the flow center
240a). The distributed PLC 310 of the flow center 240a sends a
signal to actuator 324b to adjust the flow control valve 322b and
receives a signal from the flow sensor 324b regarding the mass flow
rate of the vacuum connection 322b. The distributed PLC 310 adjusts
the flow control valve 322b in response to signals from the flow
sensor 324b as described above until the mass flow rate of the
vacuum connection 232b corresponds to (e.g., is within a
predetermined margin of error of) the user input. Because the
vacuum connection 232b is also in flow communication with the
vacuum connection 232a via the manifold 330, adjusting the flow
rate of the vacuum connection 232b as described above may
indirectly affect the flow rate of the vacuum connection 232a.
Accordingly, the distributed PLC 310 may receive updated
measurements of the mass flow rate of the vacuum connection 232a
from the flow sensor 326a and send signals to the actuator 324a to
compensate for the indirect change in the mass flow rate of the
vacuum connection 232a until the mass flow rate of the vacuum
connection 232a corresponds to the previously determined setpoint
for the air sampling device 260a.
[0051] FIG. 4 illustrates an overview screen 400 of the GUI
according to an exemplary embodiment of the present invention. The
overview screen 400 may include a top toolbar 410, including the
software-based emergency stop button 412 to issue a system halt
request as described above. Users can use navigation buttons on the
top toolbar 410 to navigate to screens to log in or log out of
their account, access system settings, monitor sample points (for
example, each of the flow sensors 326), monitor the vacuum pumps
340, view a log of system activity, and navigate back to the
overview screen 400. The overview screen 400 includes an overview
area 450, including operational parameters regarding one or more
ports. For example, the overview area 450 may include the name 452,
location 454, status 456, current flow rate 458, sample duration
460, and the volume sampled 462. During sampling, the overview area
450 may include the volume remaining and/or the time remaining. The
overview area 450 may also include the inactive time 464 (i.e., how
long sampling has been inactive) when the port is inactive, the
time remaining during Isolator mode, the volume or time remaining
when sampling, and/or the alarm duration if the sample is alarming.
The overview screen 400 may also include a lower toolbar 490,
including an about button 492 that navigates to a screen which
describes the system 200, port buttons 494 that navigate to screens
to monitor and control each port, the username 496, and the
time/date 498.
[0052] Each port corresponds to one of the respective air sampling
devices 260. The operational parameters of each port are set by the
user via the GUI and/or measured by the flow sensor 326 of the flow
controller 320 corresponding to the vacuum connection 232 in flow
communication with the corresponding air sampling device 260.
[0053] The system 200 samples the subjects 265 at a desired flow
rate. The system 200 may be adjustably configured to automatically
conclude after a preset time elapses and/or after a preset volume
is sampled. The GUI enables a user to adjust the preset time,
adjust the preset volume, and configure the system to automatically
conclude after the preset time, preset volume, or both. If the flow
rate deviates from the desired flow rate beyond acceptable alarm
limits, the system 200 outputs an alarm to network-connected
devices. The GUI enables users to stop sampling in response to the
alarm. The GUI also enables the user to set and/or adjust the
desired flow rate and the acceptable limits. The GUI may be
configured to display the flow rate in either cubic feet per minute
(CFM), liters per minute (LPM), or cubic meters per minute (CMM).
The GUI may be configured to display units of volume in cubic feet
(CF), liters (L), or cubic meters (CM). The system 200 may be
configured to enter Isolator Mode as described above. The system
200 may be configured to remain in Isolator Mode until manually
aborted or until a predetermined time has elapsed. The GUI enables
the user to manually abort the Isolator Mode or set or adjust the
predetermined time for Isolator Mode to automatically conclude.
[0054] The top toolbar 410 may also include a floor plan button 414
that navigates to floor plan screens 500 of the GUI. FIG. 5
illustrates one of the floor plan screens 500 according to an
exemplary embodiment of the present invention. The floor plan
screens 500 may include the top toolbar 410 and lower toolbar 490
described above. Each of the floor plan screens 500 may also
include a zone floor plan area 550 that includes an overlay of
operational parameters onto an image of an architectural drawing.
In the exemplary embodiment illustrated in FIG. 5, the zone floor
plan area 550 includes an architectural drawing 552 of a portion of
the system 200 identified as Zone #1, which includes ports 1
through 3 in room 170. The zone floor plan area 550 may include
operational parameters regarding each port, for example, the name
452, location 454, status 456, current flow rate 458, sample
duration 460, volume sampled 462, and either volume remaining or
time remaining 464
[0055] Selecting one of the port buttons 494 navigates to a port
screen 600 corresponding to the port identified by the port button
494. FIG. 6 illustrates one of the port screens 600 according to an
exemplary embodiment of the present invention. The port screens 600
may include the toolbars 410 and 490 described above. The port
screen 600 may also include a port area 650 that provides an
overview of one of the ports. In the exemplary embodiment
illustrated in FIG. 6, the port area 650 includes the process
information of port #2. The process information may include the
name 452, location 454, status 456, current flow rate 458, sample
duration 460, volume sampled 462 and either volume remaining 664 or
time remaining 464 (when applicable) of the selected port.
Additionally, the port area 650 may include a graphical
representation 652 of the flow rate of the selected port. Alarms
654 may be displayed as they occur and colors may change to
indicate abnormal conditions. The port area 650 may also include an
initiation button 656 configured to initiate the sampling process
and/or an abort button 658 configured to abort the sampling
process. Users may also navigate to the settings screen and modify
various process control settings, such as the desired flow rate and
the preset time and/or preset volume sampled before sampling is
concluded.
[0056] FIG. 7 illustrates a labeling screen 700 according to an
exemplary embodiment of the present invention. The labeling screen
700 may include the toolbars 410 and 490 described above. The
labeling screen 700 may also include a labeling area 750 wherein a
user may label each of the ports and/or the location of each of the
ports.
[0057] The system 200 is configured such that individual ports may
be controlled as a group. FIG. 8 illustrates a group control screen
800 according to an exemplary embodiment of the present invention.
The group control screen 800 includes include group areas 850 to
control groups of ports (for example, multiple or all ports in a
single room or section of a room) with a single user operation. The
group control screen 800 may also include an all ports area 860.
Each group area 850 may include a start button 852 and an abort
button 854 configured to initiate and abort the air sampling
process in each of the ports included in the group.
[0058] The system 200 is configured to record the time of each
system event and the user of that commanded each event. FIG. 9
illustrates an event log screen 900 according to an exemplary
embodiment of the present invention. The event log screen 900 may
be accessible via the event log button 416 of the top toolbar 410
illustrated in FIG. 4. The event log screen 900 includes the date
902, time 904, and description 906 of each system event. The system
200 may also be configured such that event logs may be printed,
exported, and/or viewable on external systems. The event log screen
900 may also include a reset alarms button 910 configured to reset
alarms, a clear log button 912 configured to clear the event log,
and a silence horn button 914 configured to silence an audible
alarm.
[0059] The system 200 may be calibrated in the field (for example,
using an external flow meter). Accordingly, the system 200 may
include a Maintenance Mode in which the system is configured to
override the operational flow rate setpoint. In Maintenance Mode,
the system 200 may be configured to disable alarming functions.
Additionally, the system 200 enables a user to set a reminder for
maintenance of the vacuum pump 340. The system 200 may be
configured to enable the user to set a maintenance reminder
threshold, such as a specific date, a number of days since the
vacuum pump 340 was previously maintained, and/or a number of hours
that the vacuum pump 340 has been operating since the vacuum pump
340 was previously maintained. The system 200 may be configured to
output a reminder to the user when the maintenance reminder
threshold is near or has passed.
[0060] The system 200 is configured to authenticate users based on
user accounts, each with a username and password, to prevent
unapproved interaction with the system. FIG. 10 illustrates a
security screen 1000 according to an exemplary embodiment of the
present invention. The security screen 1000 enables a user access a
user account using a username and password. Different types of user
accounts have different access to functionality. For example, a
"guest user" account is permitted to view the status of the system
but is not permitted to issue commands; an "operator" account is
permitted to start and stop the system; an "engineering" account is
permitted to configure certain settings; and an "administrator"
account is permitted to configure user account settings.
[0061] The GUI also enables a user to synchronize the date and time
across the system 200, including the time/date of the controller
210, the operator terminals 270, etc. FIG. 11 illustrates a time
and date screen 1100 according to an exemplary embodiment of the
present invention.
[0062] The GUI also enables a user to monitor each individual
vacuum pump 340. FIG. 12 illustrates a pump overview screen 1200
according to an exemplary embodiment of the present invention. The
pump over screen 1200 may include the toolbars 410 and 419, and may
be accessible to a user by selecting the pump button 418 of the top
toolbar 410. The GUI may include a pump overview screen 1200 for
each vacuum pump 340 installed in the system 200. In the exemplary
embodiment illustrated in FIG. 13, the pump overview screen 1200
includes a pump overview section 1250 illustrating the process
information of Pump #1. The process information may include the
name 1052, location 1054, status 1056 (active or inactive), current
runtime 1058 and total runtime 1058. The current run time 1058 is
the time since the vacuum pump 340 was shut off. The total runtime
1058 is the sum of all runtime and may be reset by an operator.
[0063] The system 200 may also be configured to output alarm
notices if the system 200 experiences an alarm system while
sampling or if an abnormal condition occurs. The system 200 may
output alarm notices to the operator interface terminals 270 or
other network-connected devices via the GUI. An alarm signal may be
output in response to abnormal flow conditions, loss of system
flow, or if an emergency stop button 352 or software-based
emergency stop button 412 is pressed. For example, an alarm
indication may be output to every network-connected screen in a red
color or "alarm" text. Alarm indications may be logged in the event
log. The alarm status may remain until reset. Only certain users
may be permitted to reset the alarm status.
[0064] In addition to visual alarms output by the GUI, the system
200 may include pilot lights and lights stacks to indicate alarm
conditions. For example, each of the flow centers 240 and each of
the vacuum pumps 340 may include a pilot light or light stack. In
the event of an alarm condition relating to one of the flow centers
240 or vacuum pumps 340, a visual alarm may be output by the pilot
light or light stack associated with the flow center 240 or vacuum
pump 340 experiencing the alarm condition.
[0065] In addition to visual alarms, an auditory alarm may also be
output in response to an alarm condition. The operator interface
terminals 270 may include a speaker to output the auditory
alarms.
[0066] Process parameters may be transmitted to and from each of
the network-connected hardware components of the system 200.
Additionally, the system 200 may be configured to receive commands
from authorized users via external systems (for example, via a web
browser or remote desktop client). The system 200 may be configured
to accept electrical signals as discrete commands from external
systems. External systems may send electrical commands to initiate
processes, reset alarms, and to activate alarms. The system 200
provides electrical signals as statuses as external systems. The
system 200 may be configured to provide discrete process
statuses.
[0067] Aspects of exemplary embodiments of the present invention
overcome drawbacks of conventional systems by automatically
adjusting the mass flow rates of each of the vacuum connections to
the individual rates set by an operator. Additionally, aspects of
exemplary embodiments of the present invention enable users to
monitor and control aspects of the system via network-connected
devices. Additionally, aspects of exemplary embodiments of the
present invention enable a vacuum pump to be disconnected from
power in response to a physical emergency button, a software-based
emergency stop button available on network connected devices, and
an automatic power disconnection in response to an abnormal mass
flow reading that could potentially impact the vacuum pump.
[0068] The system 200 is also configured to automatically
disconnect the power supplied to a vacuum pump 350 in response to a
determination that any one of the vacuum connections 232 in flow
communication with the vacuum pump 350 is experiencing an
abnormally low mass flow rate (e.g., 0). Whereas conventional
systems would shut down a vacuum pump only if all sample points
were manually aborted, the system 200 provides additional
protection against a vacuum pump 350 being damaged by an obstructed
air sampling device 260 or vacuum connection 232.
[0069] The embodiment(s) described, and references in the
specification to "one embodiment", "an embodiment", "an example
embodiment", etc., indicate that the embodiment(s) described may
include a particular feature, structure, or characteristic, but
every embodiment may not necessarily include the particular
feature, structure, or characteristic. Moreover, such phrases are
not necessarily referring to the same embodiment. Further, when a
particular feature, structure, or characteristic is described in
connection with an embodiment, persons skilled in the art may
affect such feature, structure, or characteristic in connection
with other embodiments whether or not explicitly described.
[0070] Embodiments of the invention (particularly the controller(s)
210, the flow center(s) 240, the operator interface terminal(s)
270, the distributed PLC(s) 310, and the mass flow controller(s)
320, etc.) may be implemented in hardware, firmware, software, or
any combination thereof, or may be implemented without automated
computing equipment. Embodiments of the invention may also be
implemented as instructions stored on a machine-readable medium,
which may be read and executed by one or more processors or
processing devices. A machine-readable medium may include any
mechanism for storing or transmitting information in a form
readable by a machine (e.g. a computing device). For example, a
machine-readable medium or database (such as the database 290) may
include read only memory (ROM); random access memory (RAM);
hardware memory in PDAs, mobile telephones, and other portable
devices; magnetic disk storage media; optical storage media; flash
memory devices; electrical, optical, acoustical, or other forms of
propagated signals (e.g. carrier waves, infrared signals, digital
signals, analog signals, etc.), and others. Further, firmware,
software, routines, instructions, may be described herein as
performing certain actions. However, it should be appreciated that
such descriptions are merely for convenience and that such actions
in fact result from computing devices, processors, controllers or
other devices executing the firmware, software, routines,
instructions, etc.
[0071] It is appreciated that one advantage of the present
invention includes simplifying the configuration of the air
sampling devices and related components necessary for monitoring
and controlling air sampling in a controlled environment by
avoiding the need for certain components, such as conventional flow
switches. The present invention also provides a high degree of
flexibility to rearrange a display to show any number of individual
parameters associated with air sampling and monitoring including,
but not limited to, the location name, sample time, or duration of
air quality tests.
[0072] These and other advantages of the present invention will be
apparent to those skilled in the art from the foregoing
specification. Accordingly, it is to be recognized by those skilled
in the art that changes or modifications may be made to the
above-described embodiments without departing from the broad
inventive concepts of the invention. It is to be understood that
this invention is not limited to the particular embodiments
described herein, but is intended to include all changes and
modifications that are within the scope and spirit of the
invention.
* * * * *