Patent ID: 12237128

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The following detailed description refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements. The following detailed description does not limit the invention.

Current loops are generally used in process control applications for carrying signals to Proportional-Integral-Derivative (PID) controllers, Supervisory Control and Data Acquisition (SCADA) systems, or programmable logic controllers (PLCs). Current loops may, for example, carry sensor information from field instrumentation (e.g., pressure, temperature, or flow sensors) or may carry control signal signals to process modulating devices (e.g., valves). A system employing a current loop may include a sensor, a current transmitter, a current loop wire(s), a power source, and a receiver. The sensor measures a process variable, and the transmitter converts the sensor's measurements into an output current based on the applied power source. The current loop wire(s) carries the transmitter's output current to the receiver, which interprets the current signal to retrieve the original sensor measurement. The receiver may include a PID controller, a SCADA system, or a PLC.

In monitoring, automation, and SCADA systems, analog inputs and digital inputs may be provided in banks, with some number of auxiliary digital and analog inputs pre-designed into the system. In such systems, the number of analog and digital inputs, including auxiliary digital and/or analog inputs, is defined in the design phase and is limited by hardware and/or space considerations. Additional inputs, such as additional digital inputs, for example, may later be needed that exceed the pre-existing number of digital inputs of the system, and adding such additional digital inputs can be costly and time-consuming. For example, a monitoring, automation, or SCADA system may need to monitor the state of numerous dry contact switches (e.g., the open/closed state of numerous relays) involved in a particular process or application and, therefore, needs numerous digital inputs to receive the inputs from each of the dry contact switches. The needed digital inputs may exceed the number of existing digital inputs pre-designed into the bank of digital inputs of the monitoring, automation, or SCADA system. Embodiments described herein provide the ability to re-purpose an existing, unused analog input of a monitoring, automation, or SCADA system as a digital input for receiving a dry contact switch input. This re-purposing requires minimal system downtime or programming to recognize an existing dry contact switch input, as compared to physically installing new digital input hardware and programming the system to recognize the hardware.

To re-purpose an existing, unused analog input of a monitoring, automation, or SCADA system to monitor a state of a dry contact switch, current loop transmitter circuitry, as described herein, may be used to translate a state of the dry contact switch (i.e., switch open or switch closed) into a current loop output current. The output current may be transmitted, via a current loop, to the monitoring, automation, or SCADA system as one of multiple different current levels that represent the state of the dry contact switch. In one implementation described herein, the current loop transmitter circuitry may generate a current loop current in a range of 4-20 milliamps (mA). A current measuring unit, that may be associated with the monitoring, automation, or SCADA system, measures the current level in the current loop, and, in some implementations, interprets those current level measurements as digital highs or lows. For example, a low current level (e.g., approximately 4 mA) in the current loop may represent a digital low and indicate that the dry contact switch is open (i.e., switch off), and a high current level (e.g., approximately 20 mA) in the current loop may represent a digital high and indicate that the dry contact switch is closed (i.e., switch on). Additionally, implementations described herein may include a “fault state” in which zero current transmitted in the current loop represents a failure or fault associated with the dry contact switch input and/or with the current loop transmitter circuitry.

FIG.1depicts current loop transmitter circuitry100, according to one example embodiment, that translates a state of an input dry contact switch to a current loop output current. As shown, current loop transmitter circuitry100includes an input105that connects to a dry contact switch110and outputs a translated current output current160, via a connector (J1)120, to a current loop130based on a current state (e.g., switch open, switch closed) of the dry contact switch110. Connector120includes an input terminal that connects to a first conductive wire of current loop130and an output terminal that connects to a second conductive wire of current loop130. A current measuring unit150may be connected in series with the current loop130such that the current of the current loop130flows through the current measuring unit140. A Direct Current (DC) power supply voltage (VPS)140may be connected in parallel with the current loop130. In one implementation, as shown inFIG.1, VPS140may be a component of current measuring unit150and is connected internally, within unit150, with current loop130. In another implementation, not shown inFIG.1, VPS140may be connected in parallel with current loop130as a component that is external to current measuring unit150.

The current loop transmitter circuitry100, as described in further detail below, effectively adjusts it internal resistance, as seen by the external current loop130, based upon the state of the dry contact switch110. Thus, when the dry contact switch110is in an open state (i.e., switch off), the current loop transmitter circuitry100effectively decreases its internal resistance such that an increased level of current (e.g., a high current level) flows from VPS140through the current loop130and through circuitry100. When the dry contact switch110is in a closed state (i.e., switch on), the current loop transmitter circuitry100effectively increases its internal resistance such that a decreased level of current (e.g., a low current level) flows from VPS140through the current loop130and through the circuitry100.

Current loop transmitter circuitry100may include a current transmitter Integrated Circuit (IC), in addition to other components on an input side of the circuitry100and on a current loop output side of the circuitry100. The current transmitter IC may be selected from one of multiple different models of existing current transmitter ICs. In one implementation, described below with respect toFIGS.3A and3B, current loop transmitter circuitry100may include a Texas Instruments (TI) XTR115 or XTR116 4-20 mA Current Loop Transmitter Integrated Circuit (IC). Other types and/or models of current loop transmitters may, however, be used in circuitry100. In some implementations, input105, current loop transmitter circuitry100and connector J1120may be components of a single device (i.e., contained within a single device housing). In a further implementation, input105, current loop transmitter circuitry100, connector J1120, VPS140, and current measuring unit150may be components of a single system. In yet another implementation, current loop transmitter circuitry100, connector J1120, and VPS140may be components of a single system, and current measuring unit150may be a component of an external device or system (e.g., current measuring unit150may be a component of monitoring, automation, or SCADA system200).

FIG.2Adepicts a monitoring, automation, or SCADA system200with which the current loop transmitter circuitry100described herein may be used for translating dry contact switch inputs to current loop current levels. System200may include any type of monitoring, automation, or SCADA system that monitors a state of at least one dry contact switch (e.g., the open/closed state of a relay), and may monitor the state of numerous dry contact switches simultaneously. As shown, system200may include a bank of analog inputs205and a set of auxiliary analog inputs210, and a bank of digital inputs215and a set of auxiliary digital inputs220. The analog inputs of the bank of analog inputs205may each receive an analog input signal from an analog source (not shown). For example, the analog inputs205may each receive an analog input signal from a respective temperature, pressure, flow rate, or humidity sensor. The digital inputs of the bank of digital inputs215may each receive a digital input signal from a digital source (not shown). For example, the digital inputs215may each receive a digital input signal from a respective flow switch, level switch, pressure switch, or proximity switch.

FIG.2Bdepicts an example of the use of current loop transmitter circuitry100to convert an analog input of monitoring, automation, or SCADA system200(e.g., an auxiliary analog input210ofFIG.2B) into a digital input for purposes of receiving a digital signal from a dry contact switch. As shown, the dry contact switch110connects to input105of current loop transmitter circuitry100, and the current loop input and output terminals of connector J1120connect to wires of the current loop130. VPS140connects in parallel with current loop130such that it is also parallel-connected across the input and output terminals of connector J1120and across the input and output terminals of analog input210of system200. The output terminal of connector J1120connects in series, via a first current loop wire, with an input terminal of analog input210of system200, and an input terminal of connector J1120connects in series, via a second current loop wire, with an output terminal of analog input210of system200. Current measuring unit150, shown as a component of system200in the example ofFIG.2B, completes the current loop with a connection across the terminals of analog input210. In other implementations, such as shown inFIG.1, current measuring unit105may be a component that is separate from, and external to, system200. VPS140is shown inFIG.2Bas a component of current measuring unit150that is connected with parallel with current loop130. In another implementation (not shown), VPS140may be connected in parallel with current loop130as a component that is external to current measuring unit150and/or external to system200.

Current loop transmitter circuitry100effectively varies its internal resistance, based on a state of the dry contact switch110connected to input105, to generate, in conjunction with the voltage applied by VPS140, the current loop output current (current loop). The current loop output current flows, in the example depicted inFIG.2B, counterclockwise from a positive (+) terminal of VPS140through a first terminal of analog input210, via a first wire of current loop130, through a first terminal of connector J1120, through current loop transmitter circuitry100, out a second terminal of connector J1120, via a second wire of current loop130, into a second terminal of analog input210, and through current measuring unit150to return to the negative (−) terminal of VPS140.

FIG.3Aillustrates an exemplary implementation of the current loop transmitter circuitry100ofFIG.1in which circuitry100includes a XTR115 4-20 mA Current Loop Transmitter IC (shown as “U1”). The circuitry100, in the exemplary implementation ofFIG.3A, includes an input resistive network300, U1310, and current loop current carrying components320. Input resistive network300includes a network of resistors R1-R4that connect to various pins of IC U1and establish the input current to U1310that changes depending upon the state of the dry contact switch110(e.g., switch open, or switch closed). Current loop current carrying components320include a transistor Q1, diodes D1-D4, a capacitor C1, and connector J1120that carry the output current which flows through the current loop (not shown) that connects to J1120. The dry contact switch110connects, in parallel, across resistor R4in the input resistive network300. The resistive value to which variable resistor R1is currently tuned to set the highvalue current for the current loop current when the dry contact switch in the open, or OFF, state. Therefore, when variable resistor R1is tuned to its highest resistance, and the dry contact switch110is in an OFF state, the current loop current that flows through the current loop current carrying components320will be at a lowest “high” current loop current level. When the variable resistor R1is tuned to its lowest resistance, and the dry contact switch110is in an OFF state, the current loop current that flows through the current loop current carrying components320will be at a highest “high” current loop current level.

As shown inFIG.3A, U1includes 4 pins that connect to components in the input resistive network300of circuitry100: pin1(VREF), pin2(IIN), pin3(IRET), and pin8(VREG). A top of variable resistor R1connects to pin8(VREG) of U1and the bottom of R1connects to a top of R4and to one side of R3. The other side of R3connects to one side of resistor R2, and the other side of R2connects to pin1(VREF) of U1. Pin3(IRET) of U1, and a bottom of R4, both connect to ground.

As further shown inFIG.3A, U1includes another 4 pins that connect to components in the current loop current carrying components320of circuitry100: pin4(IO), pin5(E(emitter)), pin6(B(base)), and pin7(V+). The collector of Q1connects to pin7of U1310and to the cathodes of D1and D2. The base of Q1connects to pin6(base), and the emitter of Q1connects to pin5(emitter) of U1310. Pin4of U1310connects to the anodes of D3and D4. The anode of D1connects to the cathode of D3, and to a first side of capacitor C1. The anode of D2connects to the cathode of D4and to a second side of capacitor C2. One terminal of connector J1120connects to an anode of D1, a cathode of D3, and to the first side of capacitor C1, and the other terminal of connector J1120connects to an anode of D2, a cathode of D4, and to the second side of capacitor C1.

FIG.3Bdepicts, at a high-level, the operation of the current loop transmitter circuitry100ofFIG.3A, including the involvement of the internal components of U1310in transmitting the current loop current via current loop130. The internal components of U1310are shown to illustrate the operation of the XTR115 4-20 mA Current Loop Transmitter U1310within circuitry100. One skilled in the art will recognize, however, that substitution of U1310with a different model or type of current loop transmitter may change the configuration of the internal components of U1, and may also cause a modification in the components, and arrangement of the components, of input resistive network300, and the current loop current carrying components320of circuitry100.

When dry contact switch110is placed in an open state (alternatively referred to herein as an OFF state), as shown inFIG.3B, an increased current (and a corresponding increased voltage) is applied, via resistor R3and pin2(TIN), to the positive (+) input of the operation amplifier (op amp) A1. An increased voltage at the positive (+) input of A1, in turn, causes an increased voltage to be output from A1, thereby increasing the bias voltage to the base of Q1and the base of Q2. Increasing the bias voltage to the base of Q1and Q2turns on Q1and Q2, effectively decreasing the internal resistance of circuitry100, as seen from the external current loop130, such that an increased level of current flows through Q1(shown as icurrent_loop1) and Q2(shown as icurrent_loop2). Since the overall current loop current icurrent_loopis approximately equal to icurrent_loop1plus icurrent_loop2(i.e., icurrent_loop≈icurrent_loop1+icurrent_loop2), then increasing the bias voltage to the base of Q1and Q2increases the current loop current icurrent_loopflowing out of connector J1120and into the current loop130(not shown inFIG.3B).

When dry contact switch110is placed into a closed state (alternatively referred to herein as an ON state)(not shown inFIG.3B), a decreased current (and a corresponding decreased voltage) is applied, via resistor R3and pin2(IIN), to the positive (+) input of the operational amplifier (op amp) A1. A decreased voltage at the positive (+) input of A1, in turn, causes a decreased voltage to be output from A1, thereby decreasing the bias voltage to the base of Q1and the base of Q2. Decreasing the bias voltage to the base of Q1and Q2turns off Q1and Q2, effectively increasing the internal resistance of circuitry100, as seen from the external current loop130, such that a decreased level of current flows through Q1(shown as icurrent_loop1) and Q2(shown as icurrent_loop2). Since icurrent_loop≈icurrent_loop1+icurrent_loop2, then decreasing the bias voltage to the bases of Q1and Q2decreases the current loop current icurrent_loopflowing out of connector J1120and into the current loop130(not shown).

FIG.3Bfurther depicts the flow of the current loop current icurrent_loopthrough the current loop current carrying components320of circuitry100. As shown, due to the applied voltage of power supply VPS140(not shown inFIG.3B), the current loop current flows from the current loop130(not shown) in through a first terminal of connector J1120and through forward-biased diode D1. The current loop current then flows through, and is divided among, a first circuit branch that includes transistor Q1and a second circuit branch that includes transistor Q2. A small portion of the current loop current is also supplied to the +5 V regulator of U1. The current loop current recombines, after flowing through the first circuit branch that includes Q1and through the second circuit branch that includes Q2, to flow through resistors R9and R6. After flowing through resistors R9and R6, the current loop current icurrent_loopflows through forward-biased diode D4and out a second terminal of connector J1120into the current loop130(not shown). Multiple different levels of the current loop current icurrent_loopmay flow through current loop current carrying components320based on the state of dry contact switch110. For example, the current loop current icurrent_loopmay flow at a low level (e.g., 4 mA) when dry contact switch110is in a closed state (i.e., switch=ON). As another example, the current loop current icurrent_loopmay flow at a high level (e.g., 20 mA) when dry contact switch110is in an open state (i.e., switch=OFF), where the high current level is set by adjustment of variable resistor R1in the input resistive network300of circuitry100.

FIG.4is a diagram that depicts exemplary components of a controller device400(referred to herein as “controller400”). In some implementations, controller device400may be a component of monitoring, automation, or SCADA system200. In other implementations, controller device400may be a stand-alone device that includes current measuring unit150. In further implementations, current measuring unit150may be a stand-alone device, or a device within a larger system, that may include the components of controller device400shown inFIG.4.

Controller400may include a bus410, a processing unit420, a memory430, an input device440, an output device450, a communication interface460, and current measuring unit150. Bus410may include a path that permits communication among the components of controller400. Processing unit420may include one or more processors or microprocessors which may interpret and execute instructions, or processing logic. Memory430may include one or more memory devices for storing data and instructions. Memory430may include a random access memory (RAM) or another type of dynamic storage device that may store information and instructions for execution by processing unit420, a Read Only Memory (ROM) device or another type of static storage device that may store static information and instructions for use by processing unit420, and/or a magnetic, optical, or flash memory recording and storage medium. The memory devices of memory430may each be referred to herein as a “tangible non-transitory computer-readable medium,” “non-transitory computer-readable medium,” or “non-transitory storage medium.” In some implementations, the processes/methods set forth herein can be implemented as instructions that are stored in memory430for execution by processing unit420.

Input device440may include one or more mechanisms that permit an operator to input information into controller400, such as, for example, a keypad or a keyboard, a display with a touch sensitive panel, voice recognition and/or biometric mechanisms, etc. Output device450may include one or more mechanisms that output information to the operator, including a display, a speaker, etc. Input device440and output device450may, in some implementations, be implemented as a user interface (UI) that displays UI information and which receives user input via the UI. Communication interface460may include a transceiver(s) that enables controller400to communicate with other devices and/or systems. For example, communication interface460may include one or more wired and/or wireless transceivers.

Current measuring unit150may include any type of circuitry that can measure a current level flowing in current loop130. Current measuring unit150may include, for example, DC ammeter circuitry that connects in series with current loop130and measures the current flowing within current loop130.

The configuration of components of controller400illustrated inFIG.4is for illustrative purposes. Other configurations may be implemented. Therefore, controller400may include additional, fewer, and/or different components, that may be arranged in a different configuration, than depicted inFIG.4.

FIG.5is a flow diagram of an example process for determining a state of a dry contact switch based on a measurement of current loop current transmitted by current loop transmitter circuitry100. The exemplary process ofFIG.5may be implemented by current measuring unit150and/or controller400, in conjunction with current loop transmitter circuitry100and VPS140, such as is shown inFIGS.1,2B,3A, and/or3B (and described above).

The example process includes current measuring unit150measuring the current loop current output (icurrent_loop) from the current loop transmitter circuitry100(block500). Referring toFIG.1, orFIG.2B, current measuring unit150may receive the current (icurrent_loop), flowing through the current loop130, that is transmitted by circuitry100based on the voltage applied by VPS140.

The current measuring unit150, and/or controller400, determines a dry contact switch state based on the measured current loop transmitter circuitry output current icurrent_loop(block510). Current measuring unit150, and/or controller400, compares the current measurement obtained in block500with current threshold levels to determine the state of the dry contact switch110. For example, if the measurement of icurrent_loopsatisfies the condition: low_current1≤icurrent_loop≤low_currrent2, then the dry contact switch110may be determined to be in a closed (or ON) state. In one specific example, this condition may be the following: 4 mA≤icurrent_loop≤5 mA. As another example, if the measurement of current loop satisfies the condition: high_current1≤icurrent_loop≤high_current2, then the dry contact switch110may be determined to be in an open (or OFF) state. In one specific example, this condition may be the following: 19 mA≤icurrent_loop≤20 mA. As yet a further example, if the measurement of icurrent_loopsatisfies the condition: icurrent_loop=0 mA, then the dry contact switch110, circuitry100, and/or system200, may be determined to be in a fault state.

The current measuring unit150, and/or controller400, stores the determined dry contact switch state, and a time indicator, in memory (block520). Current measuring unit150, and/or controller400, obtains a time indicator, such as a clock time maintained by processing unit420, and stores the dry contact switch state (e.g., open, closed, or fault) and the time indicator in, for example, memory430. The memory may, for example, store a data structure that maintains a log, over time, of dry contact switch states (e.g., for system200).

The foregoing description of implementations provides illustration and description, but is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. For example, while a series of blocks has been described with respect toFIG.5, the order of the blocks may be varied in other implementations. Moreover, non-dependent blocks may be performed in parallel.

Certain features described above may be implemented as “logic” or a “unit” that performs one or more functions. This logic or unit may include hardware, such as one or more processors, microprocessors, application specific integrated circuits, or field programmable gate arrays, software, or a combination of hardware and software.

Embodiments described herein may be implemented as a non-transitory computer-readable storage medium that stores data and/or information, such as instructions, program code, a data structure, a program module, an application, a script, or other known or conventional form suitable for use in a computing environment. The program code, instructions, application, etc., is readable and executable by a processor (e.g., processing unit420) of a device. A non-transitory storage medium includes one or more of the storage mediums described in relation to memory430. The non-transitory computer-readable storage medium may be implemented in a centralized, distributed, or logical division that may include a single physical memory device or multiple physical memory devices spread across one or multiple network devices.

No element, act, or instruction used in the description of the present application should be construed as critical or essential to the invention unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise.

All structural and functional equivalents to the elements of the various aspects set forth in this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims.

Use of ordinal terms such as “first,” “second,” “third,” etc., in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another, the temporal order in which acts of a method are performed, the temporal order in which instructions executed by a device are performed, etc., but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements.

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 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.