Source: http://www.google.com/patents/US6519546?dq=7,433,694
Timestamp: 2018-01-18 20:55:39
Document Index: 572346714

Matched Legal Cases: ['art 2', 'art 2', 'art 2', 'art 4', 'art 4', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09', 'application No. 09']

Patent US6519546 - Auto correcting temperature transmitter with resistance based sensor - Google Patents
A transmitter in a process control system includes a resistance-based sensor sensing a process variable and providing a sensor output. Self heating circuitry coupled to the sensor provides a self heating signal related to the sensor. Analog-to-digital conversion circuitry coupled to the sensor output...http://www.google.com/patents/US6519546?utm_source=gb-gplus-sharePatent US6519546 - Auto correcting temperature transmitter with resistance based sensor
Publication number US6519546 B1
Application number US 09/175,832
Also published as CA2346095A1, CN1183377C, CN1323389A, EP1131614A1, US6594603, WO2000023776A1
Publication number 09175832, 175832, US 6519546 B1, US 6519546B1, US-B1-6519546, US6519546 B1, US6519546B1
Inventors Evren Eryurek, Jogesh Warrior
Original Assignee Rosemount Inc.
Patent Citations (241), Non-Patent Citations (145), Referenced by (108), Classifications (15), Legal Events (5)
Auto correcting temperature transmitter with resistance based sensor
US 6519546 B1
A transmitter in a process control system includes a resistance-based sensor sensing a process variable and providing a sensor output. Self heating circuitry coupled to the sensor provides a self heating signal related to the sensor. Analog-to-digital conversion circuitry coupled to the sensor output provides a digitized sensor output, and transmitter output diagnostic correction circuitry provides an auto corrected output as a function of the self heating signal output or in another embodiment, the transmitter outputs a residual life estimate of the sensor as a function of the self heating index. A novel method of calculating the self heating index is also disclosed, which is applicable to various methods for providing a diagnostic transmitter output.
1. A transmitter in a process control system, comprising:
a resistance temperature sensor sensing a process variable and providing a sensor output;
self heating circuitry coupled to the sensor providing a self heating signal related to a self heating index of the sensor;
analog to digital conversion circuitry coupled to the sensor output and the sensor monitoring circuitry and providing a digitized sensor output and a digitized self heating signal;
output circuitry coupled to a process control loop for transmitting a signal related to sensor temperature; and
diagnostic circuitry coupled to the digitized self heating signal responsively providing a diagnostic output related to sensor calibration as a function of the digitized self heating signal.
2. The transmitter of claim 1 including a memory storing a set of expected results related to the self heating signal.
3. The transmitter of claim 1 wherein the diagnostic circuitry comprises a neural network.
4. The transmitter of claim 1 wherein the diagnostic circuitry comprises fuzzy logic.
5. The transmitter of claim 1 wherein the diagnostic circuitry provides a residual lifetime estimate output.
6. The transmitter of claim 5 wherein the diagnostic circuitry determines the residual lifetime estimate as a function of rate of change (ROC) of the digitized self heating signal.
7. The transmitter of claim 1 wherein the self heating circuitry includes a current source and voltage measurement circuitry.
8. The transmitter of claim 1 wherein the self heating circuitry determines the SH index as a function of a change in sensor resistance in response to a change in power applied to the sensor.
9. The transmitter of claim 8 wherein the SH index is calculated as (R1-R2)/(P1-P2).
10. The transmitter of claim 1 wherein the output circuitry calibrates the sensor temperature signal in response to the diagnostic output.
11. The transmitter of claim 1 wherein the calibration is a function of the self heating signal.
12. The transmitter of claim 1 wherein the diagnostic output is indicative of sensor life expectancy.
13. A method for diagnosing a resistance based temperature sensor in a process control transmitter, comprising:
sensing and digitizing resistance of the sensor to provide a digitized sensor output;
obtaining a self heating index (SHI) for the sensor;
providing a diagnostic output as a function of the SHI.
14. The method of claim 13 wherein obtaining the SHI comprises measuring change in sensor resistance in response to a change in power applied to the sensor.
15. The method of claim 14 wherein the self heating index is calculated as (R1-R2)/(P1-P2).
16. The method of claim 13 including estimating residual life of the sensor based upon a rate of change of the SHI.
17. The method of claim 13 wherein obtaining the SHI includes sequentially injecting at least two different current levels into the sensor and measuring the resultant voltage drop across the sensor.
18. The method of claim 13 including determining sensor life expectancy as a function of the diagnostic output.
19. The method of claim 13 including determining temperature of the sensor as a function of the sensor output and the SHI.
20. A temperature transmitter for use in a process control system, comprising:
a resistance based temperature sensor;
a current source coupled to the sensor to inject a current into the sensor;
voltage measurement circuitry coupled to the sensor providing an output related to voltage drop across the sensor; and
diagnostic circuitry providing a self heating (SH) index output as a function of injected current and the voltage drop across the sensor.
21. The transmitter of claim 20 wherein the diagnostic circuitry provides a life expectancy output as a function of the SH index.
22. The transmitter of claim 20 including temperature measurement circuitry providing an output related to sensor temperature as a function of sensor resistance and the SH index.
23. The transmitter of claim 20 wherein the SH index is determined as a function of a change in sensor resistance in response to a change in power applied to the sensor.
24. The transmitter of claim 21 wherein the SH index is calculated as (R1-R2)/(P1-P2).
25. A temperature transmitter for use in a process control system, comprising:
measurement circuitry calculating a measurement temperature of the temperature sensor as a function of the digitized sensor output and the digitized self heating signal; and
output circuitry coupled to the process control loop for transmitting the measured temperature on the loop.
26. The temperature transmitter of claim 25 wherein a constant R0 of the temperature sensor changes as a function of change in the self heating signal.
27. The temperature transmitter of claim 25 wherein a constant alpha (α) of the temperature sensor changes as a function of change in the self heating signal.
28. The temperature transmitter of claim 25 wherein the measured temperature is a function of the sensor signal times a constant K.
29. The temperature transmitter of claim 28 wherein the measured temperature is linearly related to K, where K is a function of the self heating index.
30. The temperature transmitter of claim 28 including a lookup table stored in a memory, the lookup table providing K as a function of the self heating signal.
31. The temperature transmitter of claim 25 including diagnostic circuitry coupled to the digitized self heating signal responsively providing a diagnostic output related to sensor calibration as a function of the digitized self heating signal.
32. The temperature transmitter of claim 25 including:
33. A transmitter in a process control system, comprising:
self heating circuitry coupled to the sensor providing a self heating signal related to a self heating index of the sensor, the self heating index defined as a change in sensor resistance for a given change in power input to the sensor;
34. A method for diagnosing a resistance based temperature sensor in a process control transmitter, comprising:
sensing and digitizing resistance of the sensor to provide a digitized resistance sensor output;
obtaining a self heating index (SHI) for the sensor, the self heating index defined as a change in sensor resistance for a given change in power input to the sensor;
35. A temperature transmitter for use in a process control system, comprising:
diagnostic circuitry providing a self heating (SH) index output as a function of injected current and the voltage drop across the sensor, the self heating index defined as a change in sensor resistance for a given change in power input to the sensor.
36. A temperature transmitter for use in a process control system; comprising:
This is a Continuation-In-Part application of application Ser. No. 09/016,216, filed Jan. 30, 1998 abandoned which is a Continuation-In-Part of application U.S Ser. No. 08/744,980, filed on Nov. 7, 1996 now U.S. Pat. No. 5,828,567.
The present invention relates to transmitters of the type used in the process control industry. More specifically, the invention relates to diagnostics for process control transmitters which include a resistance based temperature sensor.
Process control transmitters are used to monitor process variables in industrial processes. For example, a transmitter might monitor temperature and transmit such information back to a control room. Furthermore, some transmitters are capable of performing the control function directly. In order to monitor a process variable, the transmitter must include a sensor, for example, an RTD which is a resistance based temperature sensor.
As the RTD sensor ages or is subjected to harsh environmental conditions, the accuracy of the sensor tends to degrade. It is possible to compensate for this degradation by periodically recalibrating the transmitter. Typically, this requires an operator to enter the field and perform a calibration process on-site on the transmitter. This is both inconvenient and time consuming for the operator. Further, it is difficult to determine the condition of a sensor, prior to its ultimate failure.
It is also necessary for the sensors to be periodically replaced as they age. However, it is difficult to determine precisely when a replacement is necessary. Therefore, sensors are typically replaced well before their failure or, in some cases, they may fail unexpectedly.
A transmitter in a process control system includes a resistance-based sensor sensing a process variable and providing a sensor output. Self heating circuitry coupled to the sensor provides a self heating signal related to the sensor. Analog-to-digital conversion circuitry coupled to the sensor output provides a digitized sensor output, and transmitter output diagnostic correction circuitry provides an auto corrected output as a function of the self heating signal output or in another embodiment, the transmitter outputs a residual life estimate of the sensor as a function of the self heating index. A novel method of calculating the self heating index is also disclosed, for use in the present invention.
FIG. 3 is a simplified block diagram of a transmitter in accordance with one embodiment of the invention.
FIG. 4 is a simplified block diagram in accordance with an embodiment of the present invention.
FIG. 1 is a diagram of process control system 2 including field mounted temperature transmitter 40 and a valve controller 12 coupled electrically to control room 4 over a two wire process control loops 6 and 14, respectively. Transmitter 40, mounted on a manifold and connected to the pipe via a manifold, monitors the temperature of process fluid in process piping 18. However, the present invention applies to any resistance based process variable measurement such as a resistance based pressure measurement or a resistance based pH measurement. Transmitter 40 transmits temperature information to control room 4 over loop 6 by controlling the current flowing through loop 6. For example, the current flowing through loop 6 may be controlled between 4 and 20 mA and properly calibrated to indicate temperature. Additionally or in the alternative, transmitter 40 may transmit digital information related to temperature over loop 6 to control room 4 such as in a HART® or an all digital protocol such as Fieldbus. Transmitter 40 includes circuitry described herein in more detail which provides advanced diagnostics related to temperature sensor operation.
One aspect of the present invention includes a recognition of a close correlation, in some cases linear relationship, of the SH index to the “alpha” and/or R0 of the sensor. As is known, alpha and/or R0 of a sensor is related to sensor calibration and therefore to sensor lifetime. Accordingly, if the SH index is measured, the lifetime of the sensor can be estimated. Furthermore, the sensor output can be corrected in real-time as a function of the amount of degradation (e.g., the difference between a preselected value of the SH index and the true current value of the SH index) . This provides an autocorrection to the transmitter output.
One aspect of the invention includes a new technique for determining the self heating (SH) index of an RTD sensor. Typically, prior art self heating index measurement was performed by monitoring temperature change in the RTD due to an applied current. However, in a transmitter it is impractical to perform such a measurement due to power limitations and the necessity of a separate temperature measurement. The present invention includes defining the self heating index as the change in sensor resistance for a given change in the power input to the RTD sensor. This technique is preferable for a temperature transmitter because it does not require the RTD to be calibrated. Furthermore, the technique does not require the RTD to be removed from the process such that real-time data can be collected without the trouble and cost of interrupting the process. The self heating index can be calculated in a transmitter by applying two different input currents, for example, 5 mA and 15 mA. The resulting voltages across the RTD are measured and the resistance of the sensor is calculated at the two different currents using the equation R =V/I. The power applied to the RTD is determined at the two different currents as P =I·V. The self heating index is calculated in accordance with equation 1: SHI = R 1 - R 2 P 1 - P 2 Eq .  1
The invention can be practiced in any of a number of places in a process system control system. In particular, the present invention as realized in software and a microprocessor, can reside in a central controller or even a final control element 12 such as a valve, motor or switch as shown in FIG. 1. Furthermore, modern digital protocols such as Fieldbus, Profibus and others allow for the software which practices the present invention to be communicated between elements in a process control system, and also provide for process variables to be sensed in one transmitter and then sent to the software.
FIG. 2 is a simplified block diagram of a temperature transmitter 40 connected to RTD temperature sensor 10 in accordance with the present invention. Transmitter 40 includes terminal block 44, current source 45, multiplexer 46, differential amplifier 48, high accuracy A/D converter 50, microprocessor 52, clock circuit 54, memory 56 and input-output circuit 58.
Terminal block 44 includes terminals 1 through 5 for coupling to, for example, RTD temperature sensor 10. Sensor 10 can be either internal or external to transmitter 40. Sensor 10 includes RTD sensor element 61 having a resistance R1 which varies with changes in the ambient temperature. Leads 16 include four element leads 62, 64, 66 and 68. Lead 62 is connected between sensor element 61 and terminal 4, lead 64 is connected between sensor element 61 and terminal 3, lead 66 is connected between sensor element 61 and terminal 2, and lead 68 is connected between sensor element 61 and terminal 1.
R1 = resistance of RTD sensor element 61;
VR1 = voltage drop across the RTD sensor element 61;
VRREF = voltage drop across resistance RREF; and
RREFNOM = nominal resistance of the reference resistance
RREF in Ohms, and/or stored in memory 56.
R0=Resistance at temperature 0, in Ohms.
However, both stored lookup tables or the equation 2 must be properly calibrated for a particular RTD temperature sensor. Further, such calibration tends to change over time as the alpha (α) for the sensor drifts. Calibrating an RTD requires an accurate thermometer reference to obtain a number of correct temperature values in order to accurately determine the constants α and δ. Equation 3 and transmitter calibration are discussed in PRT Handbook Bulletin 1042, dated February 1985, published by Rosemount and incorporated by reference into this application.
The SH index is calculated when microprocessor 52 actuates switch 138 to couple current source 140 to sensor 61. Pand R1 of equation 1 are calculated with current ISH from source 140 flowing through sensor 61. Microprocessor 52 determines P2 and R2 due to current Is from source 45. The SH index is calculated using equation 1. If transmitter 40 is completely powered from loop 6, the currents ISH and Is are limited to the current I in loop 6, less any current required to operate circuitry in transmitter 40.
Another aspect of the present invention includes the use of the self heating index to correct the temperature measurement to reduce errors due to drift in alpha (α) and/or R0. As the RTD sensor ages, the constant(s) alpha (α) and/or R0 (given in equation 3) for the sensor, changes thereby causing inaccuracies in the temperature measurements. It has been discovered that there is a substantially linear relationship between the SH index and error in the temperature measurement caused by drift in alpha (α) and/or R0. The temperature can be corrected using the equation:
Tcorrected=TmeasuredK(ΔSHI) Eq. 4
K is a constant of proportionality which is a function of the change in the self heating index; and
The relationship between K and the change in SHI may be determined experimentally. Determination of K may be through an equation or, in one preferred embodiment, with a lookup table stored in memory 56 as a function of change in SHI. Similarly, SHI, or change in SHI, can be correlated to alpha (α) and R0, or changes in these constants. Further, it is within the scope of the present invention to correlate SHI or ΔSHI to other constraints in Equation 3.
FIG. 3 is a block diagram 150 illustrating the present invention as it relates to autocorrection of the temperature output as a function of the SH index. Diagram 150 shows operations which would typically be performed by microprocessor 52 in FIG. 2. At block 152, the previous value of the self heating index (SHI1) is obtained, for example, from memory 56. This value may have been stored in memory during manufacture, previously generated by microprocessor 52 or determined and stored when the transmitter was commissioned or even at a preselected time during operation of transmitter 40. At block 154 the current value of the SH index (SHI2) is determined by microprocessor 52. If the rate of change, m is greater than or equal to a maximum allowable rate of change (mMAX), decision block 158 provides an alarm output. In general, a value representative of the difference between SHI2 and SHI1 is assessed at block 156. A preferred method for this differencing function is to calculate the slope over time of the two SHI values. However, other methods of assessing the amount of difference, some as simple as comparing SH2 to a threshold value, can be implemented without block 156. The output may be transmitted, for example, over loop 6 to indicate that the sensor has degradated to such an extent that failure is imminent and replacement is necessary. Other types of diagnostics may also be performed such as those set forth in the parent application U.S. Ser. No. 08/744,980, filed Nov. 7, 1996. The value of mMAX is stored in memory 56 and may be user configurable based upon the accuracy desired for a particular process. The alarming function at block 158 is optional, but preferred to the present invention.
The various functions set forth in FIG. 3 may be performed remotely, in a process control device, in the control room, in a computer located off-site or in a combination of these locations. Generally, the invention can be practiced in any of a number of places in a process system control system. In particular, the present invention as realized in software and a microprocessor, can reside in a central controller or even a final control element such as a valve, motor or switch as shown in FIG. 1. Furthermore, modern digital protocols such as Fieldbus, Profibus and others allow for the software which practices the present invention to be communicated between elements in a process control system, and also provide for process variables to be sensed in one transmitter and then sent to the software.
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U.S. Classification 702/130, 374/172, 374/1, 374/E15.001, 702/99
International Classification G08C19/02, G05B23/02, G07C3/00, G01K15/00
Cooperative Classification G01K15/00, G07C3/00, G08C19/02
European Classification G01K15/00, G07C3/00, G08C19/02
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