Patent Publication Number: US-2022224422-A1

Title: Acoustic node for configuring remote device

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority from U.S. Provisional Patent Application No. 63/135,323, filed Jan. 8, 2021, the entire disclosure of which is incorporated herein by reference. 
    
    
     BACKGROUND 
     Remote devices, such as Accutech or Instrument Area Network (IAN) remote telemetry devices, available from Schneider Electric, often operate outdoors in environments that can involve exposure to undesirable moisture, chemicals, and the like. These products use enclosures to protect against ingress of fluids, noxious gases, etc., such as those rated NEMA4 by the National Electrical Manufacturers Association (NEMA) and/or rated IP66 by the International Electrotechnical Commission (IEC). However, an operator using a device such as an Accutech or IAN remote telemetry device may still wish to communicate with the device to gather information from it while on site, to update its configuration, or to update its programming or firmware. Such communication requires either physical or wireless access. The device, ideally, will remain sealed and in place while the operator is communicating with it to prevent the risk of damage to the equipment and disruption of its associated processes. 
     Conventional solutions to this situation include physical approaches such as buttons on the outside of the enclosure or magnetic switches, or the use of wireless interfaces with a device such as a phone or tablet using wireless network protocols (e.g., WIFI) or short-range wireless technology (e.g., Bluetooth). For instance, production and maintenance of NEMA4 or IP66 compliant external buttons present cost and quality challenges. In addition, buttons are prone to failure over time as the sealing material around the buttons ages and is exposed to sunlight. Moreover, simple button approaches, which often rely on 2, 3, or 4 buttons to encompass a configuration, cannot efficiently transmit complex information such as strings, multiple parameters, etc. 
     Some industrial control panels include WIFI routers to enable a WIFI connection for providing wireless access to remote telemetry devices and the like. But WIFI connections greatly deprecate the battery life of the device. 
     SUMMARY 
     Briefly, aspects of the present disclosure provide an improved approach to exchanging status information, configurations, files, and programming between users and programmable logic controllers (PLC), sensors, remote terminal units (RTU), variable frequency drives (VFD), motor controllers, pump off controllers (POC), and other remote devices. An acoustic interface embodying aspects of the present disclosure addresses the cost and quality challenges with the production and maintenance of a NEMA4 or IP66 compliant external button. In addition, the acoustic interface provides the user a more efficient means of transmitting complex information such as strings, multiple parameters, etc. when compared to simple button approaches. 
     In an aspect, a method of configuring an industrial process device, including a a remote telemetry device, comprises directing first acoustic energy from a remote programming device to the industrial process device. The first acoustic energy has an associated tone or tones (sequential or non-sequential) indicating a request to establish communication between the remote programming device and the industrial process device. The method also includes processing the tone or tones associated with the first acoustic energy on the industrial process device to identify the request to establish communication and, in response to the industrial process device, accepting the request to establish communication and then directing second acoustic energy from the industrial process device to the remote programming device. The second acoustic energy has an associated tone or tones indicating acceptance of the request to establish communication. After processing the tone or tones associated with the second acoustic energy on the remote programming device to identify the acceptance of the request to establish communication, the method comprises directing third acoustic energy from the remote programming device to the industrial process device. The third acoustic energy has an associated tone or tones indicating a request for information relating to a current configuration of the industrial process device. The method further comprises processing the tone or tones associated with the third acoustic energy on the industrial process device to identify the request for information relating to the current configuration of the industrial or remote telemetry device and directing fourth acoustic energy from the industrial or remote telemetry device to the remote programming device. The fourth acoustic energy has an associated tone or tones indicating the information relating to the current configuration of the industrial process device. 
     In another aspect, an acoustic node coupled to an industrial process device comprises a microphone coupled to a receiver and configured to receive one or more incoming tones from a remote programming device. The acoustic node also comprises a speaker coupled to a transmitter and configured to transmit one or more outgoing tones to the remote programming device. A memory device stores processor-executable instructions that, when executed by an audio processor, configure the audio processor for converting the received one or more incoming tones to incoming digital data, authenticating the remote programming device based on the incoming digital data, and determining a command based on the incoming digital data. The audio processor instructs the remote industrial process device to execute the command and generates outgoing digital data responsive to the executed command. The audio processor is further configured for converting the outgoing digital data to the one or more outgoing tones, wherein the speaker transmits the one or more outgoing tones to the remote programming device. 
     In yet another aspect, a remotely configurable industrial system includes a remote programming device, an industrial process device, and the acoustic node coupled to the industrial process device. 
     Other features will be in part apparent and in part pointed out hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a block diagram of a system including an acoustic node interfacing with one or more remote programming devices according to an embodiment. 
         FIG. 2  is a block diagram of the acoustic node of  FIG. 1 . 
         FIGS. 3-6  are flow diagrams illustrating example processes for operating the acoustic node of  FIG. 1 . 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the drawings. 
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a system  100  including an acoustic node  102  interfacing with one or more remote programming devices  104 . Aspects of the present disclosure provide an improved approach to exchanging one or more of status information, configurations, files, and programming between users (via the remote programming device  104 ) and a remote industrial process device  106 . The remote device  106  may be a remote telemetry device or industrial control device, including a programmable logic controller (PLC), sensor, remote terminal unit (RTU), variable frequency drive (VFD), motor controller, pump off controller (POC), or the like. 
     The acoustic node  102 , which includes a speaker  110  and a microphone  112 , is coupled to remote device  106 . In an embodiment, the remote device  106  comprises a remote low power (e.g., battery or solar powered) sensor device such as an Accutech or IAN remote telemetry device. An audio processor  114  of acoustic node  102  is configured execute computer-executable code stored in a memory device  116  to interpret one or more tones, including a sequence of tones, received via the microphone  112  and derive digital information, such as data requests, instructions, configuration parameters, a logic application, and firmware, from the received tones. The tone or tones may be sequential or non-sequential. In addition, the communicated tones may be within or outside the audible range of human hearing and may or may not be encrypted. 
     In one embodiment, acoustic node  102  and remote device  106  are separate devices housed together within a sealed enclosure. In another embodiment, the speaker  110 , microphone  112 , and processor of acoustic node  102  are integrated with remote device  106  as a single device housed within a sealed enclosure. 
     In another embodiment, speaker  110  and microphone  112  are coupled to or integrated with remote device  106 , namely, an industrial control device or remote telemetry device (e.g., VFD, PLC, or RTU) to form acoustic node  102 . When integrated with the acoustic components, a computing device associated with remote device  106  is configured to interpret received tones and to derive digital information, such as data requests, instructions, configuration parameters, a logic application (including an IEC 61131-3 program), and/or firmware, from the received tones. 
       FIG. 2  is a block diagram of the acoustic node  102  of  FIG. 1  and illustrates additional components. In an embodiment, acoustic node  102  includes speaker  110 , microphone  112 , processor  114 , and memory device  116 . 
     In the embodiment of  FIG. 2 , memory device  106  stores one or more of firmware  202 , logic or applications  204 , files  206 , configuration information  208 , and status/historical information  210 . The processor  114  of includes a central processing unit (CPU)  214  configured to execute processor-executable instructions (e.g., firmware  202  and/or logic or applications  204 ) stored in the memory device  116 . The processor-executable instructions, when executed, configure the CPU  214  to receive digital signals from microphone  112  and process the signals to derive information, such as data requests, instructions, configuration parameters, logic applications (including an IEC 61131-3 program), and/or firmware. The processor-executable instructions, when executed, further configure the CPU  214  to generate digital signals for transmitting information via speaker  110 . In addition, processor  114  includes an audio processing device  216  for performing various functions to prepare the digital signals to and from the acoustic components. These functions include one or more of buffering, encryption/decryption, data compression, and error correction. 
     The speaker  110  of  FIG. 2  includes a digital to analog (D/A) converter  220 , an encoder  222 , and a transmitter  224 . The D/A converter  220  receives the digital signal from CPU  214  via audio processing device  216  and converts it to a corresponding analog signal. The encoder  222  then encodes (e.g., converts or translates) the analog signal output from D/A converter  220  into a selected audio format for transmission. The transmitter  224  outputs a modulated signal to a speaker cone  226 , which in turn outputs the corresponding acoustic signal to remote programming device  104 . Conversely, microphone  112  includes a transducer  230  for receiving an acoustic signal from remote programming device  104 . The microphone  112  in the illustrated embodiment also includes a receiver  232 , a decoder  234 , and an analog to digital (A/D) converter  236 . The receiver  232  demodulates the acoustic signal captured by the transducer  230  and the decoder  234  then decodes the analog signal from the demodulated signal. In this instance, the A/D converter  236  receives the analog signal and outputs a corresponding digital signal to audio processing device  216 . 
     While acoustic node  102  advantageously eliminates the need for a NEMA4 or IP66 compliant external button, it is to be understood that a physical interface  240  could be provided for manually activating or initiating the transmitting and/or receiving of acoustic signals. 
     According to a further aspect of the present disclosure, speaker  110  acts as an energy source to activate the circuitry for performing the acoustic communication for the devices described herein. 
     The remote programming device  104  also includes an integrated speaker and microphone according to embodiments of the present disclosure. Examples of remote programming devices  104  suitable for use in the system  100  of  FIG. 1  include a personal computer, smartphone, or tablet. 
     As described above, the computing device in remote device  106  (e.g., remote telemetry device or industrial control device) is capable of interpreting received tones and from the received tones deriving digital information such as status messages, configuration parameters, and file transfer including logic application (including an IEC 61131-3 program) and firmware. 
     The computing device in remote device  106  (e.g., remote telemetry device or industrial control device) is also capable of publishing one or more tones, including a sequence of tones, through the microphone  112 . The tones so published are derived from digital information such as data requests, instructions, configuration parameters, a logic application, and/or firmware. 
     In an embodiment, remote programming device  104  executes an application to convert the published tones to digital data. Likewise, remote programming device  104  executes an application to convert digital data such as a data request, instruction on command, logic application, or file to a series of tones that can be transmitted to an acoustic node  102  at the command of a local or remote user. 
     The exchange of security credentials acoustically between the programming device  104  and the acoustic node  102  limits or prevents full or partial access to the acoustic node  102  by the programming device  104 . The combination of an acoustic credential exchange with a second credential such as an entered password or other secret improves security. 
       FIGS. 3-6  are flow diagrams illustrating example processes for operating the acoustic node of  FIG. 1 . In general, processor  114  executes processor-executable instructions stored in memory  116  to implement the processes of  FIGS. 3-6 . 
       FIG. 3  illustrates an example process for applying a command from remote programming device  104  to remote device  106  via acoustic node  102 . Beginning at  302 , a user activates the audio function of acoustic node  102  using, for example, the interface  240 . The processor  114  establishes a connection between acoustic node  102  and remote programming device  104  at  304 , authenticates user access at  306 , and receives a user command applied to acoustic node  102  at  308 . If the operation has timed out, as determined at  312 , node  102  deactivates the audio function at  314  and proceeds to end at  316 . On the other hand, if the operation timeout has not been met, processor  114  decides at  320  if it can apply the command at  320 . If not, processor  114  again determines if the operation timeout has been met at  312 . If the command is applied at  320 , operations proceed to  322 ,  324 ,  326 , and  328 . The processes at these steps include, respectively, the node  102  reporting status and reporting its configuration and the remote programming device  104  configuring the parameters and loading a new configuration into node  102 . The operation is considered complete at  330 . If the user deactivates the audio function on node  102  at  334 , the process ends at  316 . If the audio function has not been deactivated, the process returns to  320 . 
     In  FIG. 4 , an example process is shown for mutually authenticating acoustic node  102  and remote programming device  104  to establish a connection for communication. The connection is established at  402 . Proceeding to  404 , acoustic node  102  transmits its identification information and, at  406 , it listens for an acknowledgement from remote programming device  104 . If the response from device  104  is not valid, as determined at  408 , processor  114  proceeds to  412  for determining if the operation timeout has been met. If not, operations loop back to  404 . Similar to  FIG. 3 , if the operation has timed out, the acoustic node  102  deactivates the audio function at  414 . If processor  114  determines at  408  that the response is valid and it is before timeout, the process continues at  418  where remote programming device  104  acknowledges the identification information. At  420 , node  102  requests credentials and, at  422 , listens for the requested credentials from remote programming device  104 . If the response from device  104  is not valid, as determined at  424 , processor  114  proceeds to  428  for determining if the operation timeout has been met. If not, operations loop back to  420 . If the operation has timed out, the acoustic node  102  deactivates the audio function at  414 . If processor  114  determines at  424  that the response is valid and it is before timeout, the process continues at  432  where node  102  acknowledges the credentials. At  434 , node  102  transmits that it is ready to receive a command. 
       FIG. 5  illustrates an example process for acoustic node  102  to report status or configuration information (including whether the firmware and/or operating system is up-to-date or needs to be updated) to remote programming device  104 . The node reports status or configuration at  502 . Proceeding to  504 , remote programming device  104  transmits a request for information and, at  506 , it listens for an acknowledgement from node  102 . If the response from device  104  is not valid, as determined at  508 , processor  114  proceeds to  512  for determining if the operation timeout has been met. If not, operations loop back to  504 . Similar to  FIGS. 3 and 4 , if the operation has timed out, remote programming device  104  deactivates the audio function at  514 . If processor  114  determines at  508  that the response is valid and it is before timeout, the process continues at  518  where node  102  acknowledges the command. At  520 , node  102  transmits the information requested by remote programming device  104  and, at  522 , remote programming device  104  listens for the requested information from node  102 . If the response from node  102  is not valid, as determined at  524 , processor  114  proceeds to  528  for determining if the operation timeout has been met. If not, operations loop back to  520 . If the operation has timed out, the remote programming device  104  deactivates the audio function at  514 . If processor  114  determines at  524  that the response is valid and before timeout, the process continues at  532  where remote programming device  104  requests more information. If more information is requested, operations return to  504 . On the other hand, if all of the information has been requested, remote programming device  104  acknowledges the information at  534  and the operation is complete at  536 . 
       FIG. 6  illustrates an example process for remote programming device  104  to configure acoustic node  102 . The remote programming device  104  configures the parameters for node  102  at  602 . Proceeding to  604 , remote programming device  104  transmits a configuration command to node  102  and, at  606 , it listens for an acknowledgement from node  102 . If the response from node  102  is not valid, as determined at  608 , processor  114  proceeds to  612  for determining if the operation timeout has been met. If not, operations loop back to  604 . Similar to  FIGS. 3-5 , if the operation has timed out, remote programming device  104  deactivates the audio function at  614 . If processor  114  determines at  608  that the response is valid and it is before timeout, the process continues at  618  where node  102  acknowledges the command. At  620 , remote programming device  104  transmits the configuration information corresponding to the command and, at  622 , remote programming device  104  listens for the information requested from node  102 . If the response from node  102  is not valid, as determined at  624 , processor  114  proceeds to  628  for determining if the operation timeout has been met. If not, operations loop back to  620 . If the operation has timed out, the remote programming device  104  deactivates the audio function at  614 . If processor  114  determines at  624  that the response is valid and before timeout, the process continues at  632  where processor  114  determines if further configuration is needed. If so, operations return to  604 . On the other hand, if configuration is complete, remote programming device  104  transmits an acknowledgement at  634  and the operations cease at  636 . 
     An acoustic interface embodying aspects of the present disclosure addresses the cost and quality challenges with the production and maintenance of a NEMA4 or IP66 compliant external button. In addition, the acoustic interface provides the user a more efficient means of transmitting complex information such as strings, multiple parameters of etc. when compared to simple button approaches. 
     A major benefit when compared to WIFI, Bluetooth, or other radio-based approaches is that a speaker and microphone of the acoustic interface require significantly less power than a conventional wireless connection. This is of critical importance to battery-powered systems such as IAN or Accutech. Another benefit, of interest to line-powered applications, is that due to increasing concerns related to cybersecurity, the use of WIFI and Bluetooth is becoming more restricted in some industrial applications. Aspects of the present disclosure provide a wire-free interface to industrial devices without the need for networked wireless networks and their associated cost, effort, and security vulnerabilities. Security can be maintained by the user exchanging a sonic key with the acoustic node prior to the acoustic node accepting instruction from the user. 
     Further benefits of interest apply to devices in sealed cabinets such as PLC, RTU, or VFD. Often direct access to these devices can require a user to have an electrician on-hand to power down the associated equipment and make safe the panel prior to allowing the user to interact with the device directly. An acoustic port on the outside of a panel would provide a mechanism to communicate with the PLC, RTU, VFD or other device inside in order to query its status, adjust its configuration or apply a new logic application amongst other possible actions. In addition, a local operator on site can use a phone connection with a more capable or familiar user (e.g., the supervising engineer or technical support) to exchange diagnostic information or new configurations with the acoustic node. 
     Embodiments of the present disclosure may comprise a special purpose computer including a variety of computer hardware, as described in greater detail below. 
     For purposes of illustration, programs and other executable program components may be shown as discrete blocks. It is recognized, however, that such programs and components reside at various times in different storage components of a computing device, and are executed by a data processor(s) of the device. 
     Although described in connection with an exemplary computing system environment, embodiments of the aspects of the invention are operational with other special purpose computing system environments or configurations. The computing system environment is not intended to suggest any limitation as to the scope of use or functionality of any aspect of the invention. Moreover, the computing system environment should not be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary operating environment. Examples of computing systems, environments, and/or configurations that may be suitable for use with aspects of the invention include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, mobile telephones, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like. 
     Embodiments of the aspects of the invention may be described in the general context of data and/or processor-executable instructions, such as program modules, stored one or more tangible, non-transitory storage media and executed by one or more processors or other devices. Generally, program modules include, but are not limited to, routines, programs, objects, components, and data structures that perform particular tasks or implement particular abstract data types. Aspects of the invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote storage media including memory storage devices. 
     In operation, processors, computers and/or servers may execute the processor-executable instructions (e.g., software, firmware, and/or hardware) such as those illustrated herein to implement aspects of the invention. 
     Embodiments of the aspects of the invention may be implemented with processor-executable instructions. The processor-executable instructions may be organized into one or more processor-executable components or modules on a tangible processor readable storage medium. Aspects of the invention may be implemented with any number and organization of such components or modules. For example, aspects of the invention are not limited to the specific processor-executable instructions or the specific components or modules illustrated in the figures and described herein. Other embodiments of the aspects of the invention may include different processor-executable instructions or components having more or less functionality than illustrated and described herein. 
     The order of execution or performance of the operations in embodiments of the aspects of the invention illustrated and described herein is not essential, unless otherwise specified. That is, the operations may be performed in any order, unless otherwise specified, and embodiments of the aspects of the invention may include additional or fewer operations than those disclosed herein. For example, it is contemplated that executing or performing a particular operation before, contemporaneously with, or after another operation is within the scope of aspects of the invention. 
     When introducing elements of aspects of the invention or the embodiments thereof, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. 
     Not all of the depicted components illustrated or described may be required. In addition, some implementations and embodiments may include additional components. Variations in the arrangement and type of the components may be made without departing from the spirit or scope of the claims as set forth herein. Additional, different or fewer components may be provided and components may be combined. Alternatively or in addition, a component may be implemented by several components. 
     The above description illustrates the aspects of the invention by way of example and not by way of limitation. This description enables one skilled in the art to make and use the aspects of the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the aspects of the invention, including what is presently believed to be the best mode of carrying out the aspects of the invention. Additionally, it is to be understood that the aspects of the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The aspects of the invention are capable of other embodiments and of being practiced or carried out in various ways. Also, it will be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
     Having described aspects of the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of aspects of the invention as defined in the appended claims. It is contemplated that various changes could be made in the above constructions, products, and process without departing from the scope of aspects of the invention. In the preceding specification, various preferred embodiments have been described with reference to the accompanying drawings. It will, however, be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the aspects of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense. 
     In view of the above, it will be seen that several advantages of the aspects of the invention are achieved and other advantageous results attained. 
     The Abstract and Summary are provided to help the reader quickly ascertain the nature of the technical disclosure. They are submitted with the understanding that they will not be used to interpret or limit the scope or meaning of the claims. The Summary is provided to introduce a selection of concepts in simplified form that are further described in the Detailed Description. The Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the claimed subject matter.