WO2024018202A1 - Wireless field device and a network thereof - Google Patents
Wireless field device and a network thereof Download PDFInfo
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- WO2024018202A1 WO2024018202A1 PCT/GB2023/051894 GB2023051894W WO2024018202A1 WO 2024018202 A1 WO2024018202 A1 WO 2024018202A1 GB 2023051894 W GB2023051894 W GB 2023051894W WO 2024018202 A1 WO2024018202 A1 WO 2024018202A1
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- wireless field
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- field device
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/10—Plc systems
- G05B2219/15—Plc structure of the system
- G05B2219/15117—Radio link, wireless
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/25—Pc structure of the system
- G05B2219/25428—Field device
Definitions
- the invention to which this application relates is a wireless field device for monitoring and controlling industrial processes and a network thereof.
- Industrial processes are employed in the monitoring of manufacturing processes, and process variable sensors are used to monitor the operation of such industrial processes. These sensors measure variables such as flow rate, temperature, pressure, fluid level, count, etc. and transmit the information to a central location.
- field devices include process variable transmitters or a controller, the latter of which may be utilised to control/ actuate a particular element with which it is connected.
- Industrial plants are fitted with numerous field control devices with associated sensors and/or with stand-alone sensors.
- Industrial sensors are currently quite heterogeneous. Therefore, each sensor type/ sensor product group often requires the usage of specific communication technology or even or a product specific gateway. This hampers integration efforts or even makes integration impossible without the creation of bespoke modifications or acquiring a licence to use the proprietary technology/protocol.
- the field devices rely on wired communication to a process control system at a central location, which requires a significant amount of cabling to be installed.
- Example wireless communication techniques are set forth in numerous protocols including ISA100, Bluetooth Mesh, ZigBee and Wireless HART® communication, within the 2.4Ghz band in accordance with international standards.
- a wireless field device for use in an industrial process, said device including: at least one input terminal arranged to couple with a process interface element; at least one output terminal arranged to couple with a process interface element; communication means; and computing means; characterized in that said input terminal is arranged to accept analogue or digital signals, and said output terminal is arranged to generate analogue or digital signals.
- the wireless field device includes a single input terminal configurable to accept analogue or digital input from the process interface element; and includes a single output terminal configurable to generate analogue or digital output to the process interface element. That is to say, the input and output terminals are universal in the sense that they each may accept or generate analogue or digital signals depending on the process interface element with which they couple.
- the present invention therefore provides a wireless field device which may be provided to couple with process interface elements that comprise only analogue terminals, digital terminals, or a mixture of both, thereby providing universal application.
- the wireless field device is configured for in-line installation / coupling with the process interface element.
- such in-line installation may be between an industrial automation controller and a process variable sensor, or between an industrial automation controller and an actuator, in use.
- the device is configured to disconnect a signal sent between connected elements in an in-line installation and permit an alternative signal to be sent, in use, which has been received by the communication means of the device or generated by the computing means of the device.
- said process interface element may be a sensor and/or controller.
- the wireless field device is configured to interrupt input signals to the process interface element with which it is arranged to be coupled, permitting the computing means to contextualize and format the signals and allow the communication means to transmit the signals in the form of readable information.
- the wireless field device is configured to interrupt input signals which are either analogue or digital.
- the computing means is configured, via the communications means or associated connection means, to interpret input signals to the process interface element, permitting the computing means to contextualize and format the information into valid output messages to be sent through the communication means.
- the wireless field device can be configured to understand the type of sensor/actuator to which it is connected, in order to contextualise the signal, i.e., a pressure sensor signal of 5V would be 25 Pa or Nm 2 ; a connected valve would be half open at 12mA, etc.. This is then used to generate the messages that are sent to other wireless field devices and/or a gateway for consumption by external systems.
- the wireless field device is configured to interpret information received by the communication means, permitting the computing means to contextualize and format the information into valid output signals to be sent through the output terminal to the process interface element.
- the output signals may be either analogue or digital.
- said communication means are arranged to receive and transmit information, and are provided in the form of wireless communication means.
- wireless communication means are provided in accordance with any appropriate technique such as, for example, the Wireless HART® communication protocol in accordance with the IEC 62591 Standard.
- the wireless field device of the present invention thus acts, in its base configuration, as a pass-thorough element within a control circuit, acting as a data acquisition device reading, interpreting and contextualising the signal before transmitting via the communication means.
- the device can be interactively configured to interrupt the signal flow and inject an alternative signal to be sent to the process interface element.
- said computing means is provided in the form of a microprocessor.
- the wireless field device further includes memory means provided therewith. Said memory means are provided so as to enable the wireless field device to store data, instructions, information, models and the like.
- the wireless field device further includes control means provided associated therewith.
- the wireless field device may be arranged to be controlled from a remotely located control means, via signals transmitted and received through the communication means, it may also be possible to access and control functioning of the device via control means provided directly thereon.
- the wireless field device may further include user display means provided thereon.
- the device may include connection means to permit the connection of a separate user display means thereto.
- the wireless field device may include internal sensor means.
- said sensor means may be provided to measure any or any combination of the following: ambient temperature, atmospheric pressure, light levels, magnetic fields and vibration.
- ambient temperature e.g., ambient temperature
- atmospheric pressure e.g., atmospheric pressure
- light levels e.g., light levels
- magnetic fields and vibration e.g., vibrations
- Such measurements may be taken independently of a process interface element to which the device is connected. Such sensing means would then be used to augment captured data and Al algorithms.
- the wireless field device is configured to transmit information to and receive information from one or more further wireless field devices, via said communication means.
- the wireless field device is configured to transmit information to and receive information from a remotely located control means, via said communication means.
- said computing means include a machine learning (ML) and/or an artificial intelligence (Al) algorithm implemented thereon.
- said machine learning algorithm is provided in the form of a reinforcement learning algorithm.
- said machine learning algorithm and/or artificial intelligence is provided to monitor and assess parameters and/ or functionality, including external data and/ or signals, of the process interface element with which the wireless field device is coupled, and consequently determine, in real time, if said parameters and/ or functionality need to be altered, paused or otherwise optimised, and subsequently transmit a command to carry out the required action.
- an ML and/or Al algorithm with the computing means of the wireless field device ensures that as the various parameters and functionality of the process interface element with which it is coupled are analysed and assessed, the device can, in real time, react to any changes or other variables — environmental or within the element itself — and transmit commands in order to optimise the functionality of the process interface element. This is as opposed to employing such software on a remote central controller or merely receiving commands from a remote, centralized location.
- the computing means may have a machine learning (ML) and/or an artificial intelligence (Al) algorithm implemented thereon.
- ML algorithms tend to be more compute intensive and consume more energy, as they are built to effectively “learn on the job”, understanding what optimum parameters and functionality of the particular process elements are, and maintaining and/or improving this.
- Al algorithms are preprogrammed algorithms wherein a set of accepted parameters are already included in the algorithm, and consequently no learning is required. Consequently, they require less power than ML algorithms and as such may be preferred in some embodiments. Further, such Al algorithms provided may also be publicly available “off the shelf”, and the specific Al algorithm may thus also be tailored to the specific function or use of the process interface element with which the device is coupled.
- the wireless field device is arranged to communicate any alteration, pausing or otherwise optimising of the parameters and/ or functionality of the process interface element with which it is coupled, or other relevant information or alerts, to one or more further wireless field devices and/ or a remotely located central control means, via said communication means.
- said ML and/or Al algorithm and/or other software associated with the computing means may be updated via communication with a remotely located control means.
- the wireless field device is configured to draw a supply of power from the process interface element with which it couples, through the input and/ or output terminals.
- the device may further include power supply means provided therewith.
- said power supply means may be provided in the form of at least one battery cell.
- said battery cell is rechargeable.
- said battery cell may be recharged by drawing a supply of power from the process interface element with which the device couples, through the input and/ or output terminals.
- the wireless field device is arranged to connect with and draw power from an external supply of power.
- said external supply of power may be a mains supply of power, and/or may be a portable supply of power, for example, a battery pack.
- a network of at least two wireless field devices as described above, said devices in communication with each other via said communication means; said devices arranged to couple with distinct process interface elements; said communication means permitting communication between each of said devices and arranged to transmit and receive information about the respective process interface elements with which they couple; characterized in that computing means on a first of said devices are configured to send commands, alerts or other such notifications, via the communication means, to the process interface element with which it is coupled and/ or one or more of the other devices in the network and thus associated process interface elements, to begin, cease, alter or otherwise optimize the functioning thereof.
- the network further includes one or more control means.
- said control means act as gateways and are arranged to receive information from each of the wireless field devices and transmit information and/or send commands to said devices.
- said control means is arranged to transmit information to third-party locations or devices.
- each of said wireless field devices in the network include a single input terminal configurable to accept analogue or digital input from a process interface element; and include a single output terminal configurable to generate analogue or digital output to a process interface element.
- each of the wireless field devices further include control means provided associated therewith.
- the wireless field devices may further include user display means provided thereon.
- the devices may include connection means to permit the connection of a separate user display means thereto.
- the computing means of each of said devices include a machine learning and/or artificial intelligence algorithm implemented thereon.
- said machine learning algorithm is provided in the form of a reinforcement learning algorithm.
- said ML and/ or Al algorithm is provided to monitor and assess parameters and/or functionality of the process interface elements with which each of the wireless field devices are coupled, and consequently determine, in real time, if said parameters and/ or functionality need to be altered, paused or otherwise optimised, and subsequently transmit a command to carry out the required action or actions.
- each of said devices are arranged to transmit and receive signals and information to and from one another. Consequently, each of said devices are configurable to communicate with one another the status, functioning etc. of the process interface elements with which they are coupled, and the computing means of each of the devices are arranged to transmit commands to carry out an action or actions to alter, pause or otherwise optimise the parameters and/or functionality of one or more of the process interface elements in response to a detected change in the parameters and/or functionality of another one or more of the process interface elements.
- the network of devices is configured to transmit, via the communication means, information relating to parameters and/or functionality of the process interface elements, and/or commands issued, to one or more remotely located control means.
- said one or more remotely located control means act as gateways and are arranged to communicate outside of the network.
- Figure 1 illustrates a wireless field device in accordance with an embodiment of the present invention
- Figure 2 illustrates a network of wireless field devices in accordance with an embodiment of the present invention.
- the process interface element 3 may be a controller or sensor device of an industrial machine, with which the device 1 of the present invention is provided to be coupled to read, monitor and assess signals input therefrom and, where required, transmit signals and/or commands thereto.
- the element 3 may comprise two or more components, for example, a controller and a sensor device, or a controller and an actuator etc.
- the device 1 includes at least one input terminal 5 and at least one output terminal 7, each arranged to couple with the process interface element 3.
- Both the input and output terminals are configured to accept and generate either analogue or digital signals, depending on the age, make and type of element 3 to which the device 1 is to be coupled.
- the device 1 further includes computing means in the form of a microprocessor 9 to enable the device 1 to contextualize, format and otherwise read signals received, and process and issue commands; and communication means in the form of wireless communication circuitry 11 enabling the device 1 to send and receive signals to and from a remote location — be it a remotely located control unit or one or more further similar such devices 1.
- the device 1 may also include memory means (not shown) provided therewith, enabling the device 1 to store data, instructions, information, models and the like.
- the device 1 includes a single input terminal 5 and a single output terminal 7, each of which are configurable to accept analogue or digital input from the process interface element 3, and generate analogue or digital output to the process interface element 3, respectively. That is to say, the input and output terminals 5, 7 are universal in the sense that they each may accept or generate analogue or digital signals depending on the process interface element with which they couple, and thus the device 1 can couple with process interface elements 3 that comprise only analogue terminals, digital terminals, or a mixture of both.
- the microprocessor 9 is configured, via the communications circuitry 11 or associated connection elements, to interpret input signals to the process interface element 3, permitting the microprocessor 9 to contextualize and format the information into valid output messages to be sent through the communication circuitry 11.
- the device 1 can be configured to understand the type of sensor/ actuator to which it is connected, in order to contextualise the signal, i.e., a pressure sensor signal of 5V would be 25 Pa or Nm 2 ; a connected valve would be half open at 12mA, etc.. This is then used to generate the messages that are sent to other wireless field devices and/ or a gateway for consumption by external systems.
- the device 1 is provided to be coupled or installed in-line with the process interface element 3, for example, such coupling may be between an industrial automation controller and a process variable sensor, or between an industrial automation controller and an actuator. Consequently, the device 1 may disconnect signals sent through and/ or between the connect elements and allow an alternative signal to be sent.
- Such alternative signal may have been received by the wireless communication circuitry 11 from a remote location, or be generated by the microprocessor 9 of the device 1.
- the device 1 once coupled with the process interface element 3, interrogates input signals — analogue or digital — and allows the microprocessor 9 to contextualize and format those signals and allow the communication circuitry 11 to subsequently transmit the signals as readable information.
- the device 1 of the present invention acts as a pass-thorough element within a control circuit, acting as a data acquisition device reading, interpreting and contextualising the signal before transmitting via the communication circuitry 11.
- the device can be interactively configured to interrupt the signal flow and inject an alternative signal to be sent to the process interface element.
- the device 1 in some embodiments of the present invention may include control means associated therewith, enabling the device 1 and its functionality to be directly accessed and controlled by a user if desired. This may be in addition to controlling the device 1 remotely by transmitting signals to it via the wireless communication circuitry 11. If so required, the device 1 may further include user display means 13 allowing a person to access visual representations of relevant/required information. Alternatively, the device 1 may simply include a further connection means to which a user display interface may be connected.
- the communication circuitry 11 allows the device 1 to send and receive signals to and from a remotely located control means and/or one or more further wireless field devices 1 forming a mesh network of devices, discussed in further detail later and with reference to Figure 2.
- the device 1 may also include internal sensors (not shown) .
- sensors would be provided to measure any or any combination of the following: ambient temperature, pressure, light levels, magnetic fields and vibration, and such measurements are taken independently of the process interface element 3 to which the device 1 is connected. The data acquired from the sensors would then be used to augment captured data and Al algorithms.
- the microprocessor 9 of the device 1 is provided to include a machine learning and/or artificial intelligence algorithm implemented thereon.
- the machine learning (ML) and/or artificial intelligence (Al) algorithm is provided to be able to monitor and assess parameters and/or functionality of the process interface element 3 with which the device 1 is coupled, and consequently determine, in real time, if said parameters and/ or functionality need to be altered, paused or otherwise optimised, and subsequently transmit a command to carry out the required action.
- an ML and/or Al algorithm with the microprocessor 9 ensures that as the various parameters and functionality of the process interface element 3 with which it is coupled are analysed and assessed, the device 1 can, in real time, react to any changes or other variables — environmental or within the element itself — and transmit commands in order to optimise the functionality of the process interface element. This is as opposed to employing such software on a remote central controller/gateway and merely receiving commands from a remote, centralized location.
- the computing means may have a machine learning (ML) and/or an artificial intelligence (Al) algorithm implemented thereon — such a decision may be made depending on the power requirements/availability and the specific role the device 1 is to perform when connected to the process interface element 3. If the device 1 is required to learn and evolve the algorithm over time to the workings/ functioning of the process interface element 3, and the power availability permits, then it may be more appropriate to provide an ML algorithm to be implemented on the microprocessor 9 of the device 1. Alternatively, if power availability is an issue and/or no learning is required, i.e., if an appropriate tailored algorithm is already available off the shelf, then the provision of an Al algorithm would be more appropriate.
- ML machine learning
- Al artificial intelligence
- the device 1 is thus able to communicate any alteration, pausing or otherwise optimising of the parameters and/ or functionality of the process interface element 3 with which it is coupled, or other relevant information, alerts or messages, to one or more further devices 1 formed as part of a network, and/ or a remotely located control means.
- the ML and/or Al algorithm itself, and any other software implemented on the microprocessor 9 can be updated remotely via the wireless communication circuitry.
- the microprocessor 9, with the ML and/or Al algorithm implemented thereon, is able to run various models which provide configurable outputs.
- These outputs could be, amongst other examples, in the form of an alert message sent to a centralized controller or visualization element/ display means, or a message sent to a corresponding field controller via the communication means to perform specific actions.
- the present invention therefore not only provides a wireless field device 1 which can be utilized universally, that is to say, on most all industrial machinery irrespective of age, type and make, but which also applies artificial intelligence or machine learning while monitoring the functionality of the process interface element 3 with which it is coupled, enabling it to send commands to optimize the element, transmit relevant information to other such devices on a network where needed, or send information and/or alerts or requests to a remotely located control means, allowing personnel to implement required actions in real-time.
- the device 1 is configured to draw a supply of power from the process interface element 3 with which it couples, through the input and/or output terminals 5, 7.
- the device 1 may further include at least one battery cell 15 to provide its own independent power source.
- the battery cell 15 is provided to be rechargeable and can be recharged by drawing a supply of power from the coupled process interface element 3 through the input and/or output terminals 5, 7.
- the device 1 may instead be configured to connect with an external supply of power, such as a mains supply of power or a battery pack, from which it may draw additional power and/or charge the battery cell 15 provided thereon.
- each of the devices 1 is coupled with a distinct process interface element 3 —that is to say, there may be provided two or more devices 1 coupled to different sections of the same piece of industrial machinery, and/ or device may be provided to be coupled with differing machines entirely, but which may form part of the overall industrial process.
- the communication circuitry 11 in each device 1 enables signals/information to be sent and received between devices, essentially allowing the devices to “talk” to one another.
- a microprocessor 9 on a first of the devices is configurable to send commands, alerts or other such notifications, via the communication circuitry, to its host device 1 and/or one or more of the other devices in the network and thus associated process interface elements 3, to begin, cease, alter or otherwise optimize the functioning thereof.
- the network of devices may also include a controller 23 in wireless communication therewith and which is arranged to receive signals in the form of information, alerts, messages, updates etc. from the devices, and likewise transmit signals to each device in the form of information and/or commands to implement an action or actions.
- the controller 23 may be one of several such controllers, as required by the network, and acts as a gateway which may further communicate/transmit information to third- party locations or devices as may be required. Such information may be alerts/ status updates etc., or may further include requests based on readings detected by the devices 1 in the network 21.
- each device is able to monitor and assess parameters and/ or functionality of the process interface elements 3 with which they are coupled, and consequently determine, in real time, if those parameters and/ or functionality need to be altered, paused or otherwise optimised, subsequently issuing a command to carry out the required action or actions.
- the devices are all in communication with one another, they can each communicate with one another the status, functioning etc.
- any such changes in the parameters or functionality of the elements 3 which are detected and/or addressed may further be communicated via the wireless communication circuitry to the controller 23 enabling a complete log of events to be provided and if any further action, manual or otherwise is required to be carried out, this may easily be determined by the relevant personnel.
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Abstract
The present invention provides a wireless field device (1) for use in an industrial process. The device includes at least one input terminal (5) arranged to couple with a process interface element (3), at least one output terminal (7) arranged to couple with a process interface element, communication means (11) and computing means (9). The input terminal is arranged to accept analogue or digital signals, and the output terminal is arranged to generate analogue or digital signals. Also provided is a network of two or more wireless field devices in communication with each other via the communication means.
Description
Wireless Field Device and a network thereof
The invention to which this application relates is a wireless field device for monitoring and controlling industrial processes and a network thereof.
Industrial processes are employed in the monitoring of manufacturing processes, and process variable sensors are used to monitor the operation of such industrial processes. These sensors measure variables such as flow rate, temperature, pressure, fluid level, count, etc. and transmit the information to a central location. Examples of field devices include process variable transmitters or a controller, the latter of which may be utilised to control/ actuate a particular element with which it is connected.
Industrial plants are fitted with numerous field control devices with associated sensors and/or with stand-alone sensors. Industrial sensors are currently quite heterogeneous. Therefore, each sensor type/ sensor product group often requires the usage of specific communication technology or even or a product specific gateway. This hampers integration efforts or even makes integration impossible without the creation of bespoke modifications or acquiring a licence to use the proprietary technology/protocol. Typically, the field devices rely on wired communication to a process control system at a central location, which requires a significant amount of cabling to be installed. However, more recently wireless communication techniques have been employed with field devices. Example wireless communication techniques are set forth in numerous protocols including ISA100, Bluetooth Mesh, ZigBee and Wireless HART® communication, within the 2.4Ghz band in accordance with international standards.
Although a multitude of solutions to this industry-wide problem do exist, these come at significant expense for additional software, servers, cabling and specialist integration engineers. Many solutions are tied to the original equipment manufacturer (OEM) partners due the vendor-locked control-systems that drive the machinery, thus restricting choice and/or access to information, and this includes the data formatting standard which requires licencing. Similar data capture or control devices that exist within the market work by converting either analogue or digital signals to and/or from a proprietary format, e.g. IO- Link, OPC-UA and HART. Often manufacturers rather than pay these ‘prohibitive’ costs appoint additional staff to record this information or take no action at all.
Further, given that the machinery and industrial processes to which a person may wish to connect or integrate a field device may be years or decades old, the connectivity may thus vary between machinery and there is currently no “universal” field device which may be appropriately used regardless of the age or type of machinery or process to which it is to be connected. Additional issues exist in certain processes where an industrial process employs numerous industrial machines, distinct from one another and potentially from differing OEMs, and which do not communicate with one another, thereby relying on workers to be specifically employed to monitor or oversee the transition of a process from one industrial machine to the next; if a problem arises in one then the process needs to be manually altered, paused or stopped in the other. Such processes are cumbersome costly, and prone to human error.
It is therefore an aim of the present invention to provide an improved wireless field device which overcomes the aforementioned problems associated with the prior art.
It is a further aim of the present invention to provide a network of two or more wireless field devices in communication with one another which overcomes the afore mentioned problems associated with the prior art.
According to a first aspect of the invention there is provided a wireless field device for use in an industrial process, said device including: at least one input terminal arranged to couple with a process interface element; at least one output terminal arranged to couple with a process interface element; communication means; and computing means; characterized in that said input terminal is arranged to accept analogue or digital signals, and said output terminal is arranged to generate analogue or digital signals.
In some embodiments, the wireless field device includes a single input terminal configurable to accept analogue or digital input from the process interface element; and includes a single output terminal configurable to generate analogue or digital output to the process interface element. That is to say, the input and output terminals are universal in the sense that they each may accept or generate analogue or digital signals depending on the process interface element with which they couple.
The present invention therefore provides a wireless field device which may be provided to couple with process interface elements that comprise only analogue terminals, digital terminals, or a mixture of both, thereby providing universal application.
Preferably, the wireless field device is configured for in-line installation / coupling with the process interface element. For example, such in-line installation may be between an industrial automation controller and a process variable sensor, or between an industrial automation controller and an actuator, in use.
In some embodiments, the device is configured to disconnect a signal sent between connected elements in an in-line installation and permit an alternative signal to be sent, in use, which has been received by the communication means of the device or generated by the computing means of the device.
Typically, said process interface element may be a sensor and/or controller.
Preferably, the wireless field device is configured to interrupt input signals to the process interface element with which it is arranged to be coupled, permitting the computing means to contextualize and format the signals and allow the communication means to transmit the signals in the form of readable information. Typically, the wireless field device is configured to interrupt input signals which are either analogue or digital.
Preferably, the computing means is configured, via the communications means or associated connection means, to interpret input signals to the process interface element, permitting the computing means to contextualize and format the information into valid output messages to be sent through the communication means. In practice, this means that the wireless field device can be configured to understand the type of sensor/actuator to which it is connected, in order to contextualise the signal, i.e., a pressure sensor signal of 5V would be 25 Pa or Nm2; a connected valve would be half open at
12mA, etc.. This is then used to generate the messages that are sent to other wireless field devices and/or a gateway for consumption by external systems.
Preferably, the wireless field device is configured to interpret information received by the communication means, permitting the computing means to contextualize and format the information into valid output signals to be sent through the output terminal to the process interface element. Typically, the output signals may be either analogue or digital.
In one embodiment, said communication means are arranged to receive and transmit information, and are provided in the form of wireless communication means. Typically, wireless communication means are provided in accordance with any appropriate technique such as, for example, the Wireless HART® communication protocol in accordance with the IEC 62591 Standard.
The wireless field device of the present invention thus acts, in its base configuration, as a pass-thorough element within a control circuit, acting as a data acquisition device reading, interpreting and contextualising the signal before transmitting via the communication means. The device can be interactively configured to interrupt the signal flow and inject an alternative signal to be sent to the process interface element.
Typically, said computing means is provided in the form of a microprocessor.
Typically, the wireless field device further includes memory means provided therewith. Said memory means are provided so as to enable the wireless field device to store data, instructions, information, models and the like.
In some embodiments, the wireless field device further includes control means provided associated therewith. Thus, in some embodiments, while the wireless field device may be arranged to be controlled from a remotely located control means, via signals transmitted and received through the communication means, it may also be possible to access and control functioning of the device via control means provided directly thereon. Typically, the wireless field device may further include user display means provided thereon. In other embodiments, the device may include connection means to permit the connection of a separate user display means thereto.
In some embodiments, the wireless field device may include internal sensor means. Typically, said sensor means may be provided to measure any or any combination of the following: ambient temperature, atmospheric pressure, light levels, magnetic fields and vibration. Preferably, such measurements may be taken independently of a process interface element to which the device is connected. Such sensing means would then be used to augment captured data and Al algorithms.
In one embodiment, the wireless field device is configured to transmit information to and receive information from one or more further wireless field devices, via said communication means. Typically, the wireless field device is configured to transmit information to and receive information from a remotely located control means, via said communication means.
In one embodiment, said computing means include a machine learning (ML) and/or an artificial intelligence (Al) algorithm implemented thereon. Typically, said machine learning algorithm is provided in the form of a reinforcement learning algorithm.
In one embodiment, said machine learning algorithm and/or artificial intelligence is provided to monitor and assess parameters and/ or functionality, including external data and/ or signals, of the process interface element with which the wireless field device is coupled, and consequently determine, in real time, if said parameters and/ or functionality need to be altered, paused or otherwise optimised, and subsequently transmit a command to carry out the required action.
The provision of an ML and/or Al algorithm with the computing means of the wireless field device ensures that as the various parameters and functionality of the process interface element with which it is coupled are analysed and assessed, the device can, in real time, react to any changes or other variables — environmental or within the element itself — and transmit commands in order to optimise the functionality of the process interface element. This is as opposed to employing such software on a remote central controller or merely receiving commands from a remote, centralized location.
Depending on the particular requirements of the wireless field device, the computing means may have a machine learning (ML) and/or an artificial intelligence (Al) algorithm implemented thereon. ML algorithms tend to be more compute intensive and consume more energy, as they are built to effectively “learn on the job”, understanding what optimum parameters and functionality of the particular process elements are, and maintaining and/or improving this. Al algorithms are preprogrammed algorithms wherein a set of accepted parameters are already included in the algorithm, and consequently no learning is required. Consequently, they require less power than ML algorithms and as such may be preferred in some embodiments. Further, such Al algorithms provided may also
be publicly available “off the shelf”, and the specific Al algorithm may thus also be tailored to the specific function or use of the process interface element with which the device is coupled.
Typically, the wireless field device is arranged to communicate any alteration, pausing or otherwise optimising of the parameters and/ or functionality of the process interface element with which it is coupled, or other relevant information or alerts, to one or more further wireless field devices and/ or a remotely located central control means, via said communication means.
Typically, said ML and/or Al algorithm and/or other software associated with the computing means, may be updated via communication with a remotely located control means.
In one embodiment, the wireless field device is configured to draw a supply of power from the process interface element with which it couples, through the input and/ or output terminals.
In some embodiments, the device may further include power supply means provided therewith. Typically, said power supply means may be provided in the form of at least one battery cell. Typically, said battery cell is rechargeable. Preferably, said battery cell may be recharged by drawing a supply of power from the process interface element with which the device couples, through the input and/ or output terminals.
In some embodiments, the wireless field device is arranged to connect with and draw power from an external supply of power. Typically, said external supply of power may be a mains supply of power, and/or may be a portable supply of power, for example, a battery pack.
According to another aspect of the present invention, there is provided a network of at least two wireless field devices as described above, said devices in communication with each other via said communication means; said devices arranged to couple with distinct process interface elements; said communication means permitting communication between each of said devices and arranged to transmit and receive information about the respective process interface elements with which they couple; characterized in that computing means on a first of said devices are configured to send commands, alerts or other such notifications, via the communication means, to the process interface element with which it is coupled and/ or one or more of the other devices in the network and thus associated process interface elements, to begin, cease, alter or otherwise optimize the functioning thereof.
In some embodiments, the network further includes one or more control means. Typically, said control means act as gateways and are arranged to receive information from each of the wireless field devices and transmit information and/or send commands to said devices. In some embodiments, said control means is arranged to transmit information to third-party locations or devices.
In some embodiments, each of said wireless field devices in the network include a single input terminal configurable to accept analogue or digital input from a process interface element; and include a single output terminal configurable to generate analogue or digital output to a process interface element.
In some embodiments, each of the wireless field devices further include control means provided associated therewith. Typically,
the wireless field devices may further include user display means provided thereon. In other embodiments, the devices may include connection means to permit the connection of a separate user display means thereto.
In one embodiment, the computing means of each of said devices include a machine learning and/or artificial intelligence algorithm implemented thereon. Typically, said machine learning algorithm is provided in the form of a reinforcement learning algorithm.
In one embodiment, said ML and/ or Al algorithm is provided to monitor and assess parameters and/or functionality of the process interface elements with which each of the wireless field devices are coupled, and consequently determine, in real time, if said parameters and/ or functionality need to be altered, paused or otherwise optimised, and subsequently transmit a command to carry out the required action or actions.
Typically, via wireless communication means, each of said devices are arranged to transmit and receive signals and information to and from one another. Consequently, each of said devices are configurable to communicate with one another the status, functioning etc. of the process interface elements with which they are coupled, and the computing means of each of the devices are arranged to transmit commands to carry out an action or actions to alter, pause or otherwise optimise the parameters and/or functionality of one or more of the process interface elements in response to a detected change in the parameters and/or functionality of another one or more of the process interface elements.
Further typically, the network of devices is configured to transmit, via the communication means, information relating to
parameters and/or functionality of the process interface elements, and/or commands issued, to one or more remotely located control means.
Typically, said one or more remotely located control means act as gateways and are arranged to communicate outside of the network.
Embodiments of the present invention will now be described with reference to the accompanying figures, wherein:
Figure 1 illustrates a wireless field device in accordance with an embodiment of the present invention; and
Figure 2 illustrates a network of wireless field devices in accordance with an embodiment of the present invention.
Referring now to Figure 1 there is provided a wireless field device 1 which is provided for use in an industrial process, shown schematically and coupled with a process interface element 3. The process interface element 3 may be a controller or sensor device of an industrial machine, with which the device 1 of the present invention is provided to be coupled to read, monitor and assess signals input therefrom and, where required, transmit signals and/or commands thereto. In some embodiments of the invention, in practice, the skilled person will appreciate that the element 3 may comprise two or more components, for example, a controller and a sensor device, or a controller and an actuator etc. For simplicity in the figures, a single element 3 is illustrated. The device 1 includes at least one input terminal 5 and at least one output terminal 7, each arranged to couple with the process interface element 3. Both the input and output terminals are configured to accept and generate either analogue or digital signals, depending on the age,
make and type of element 3 to which the device 1 is to be coupled. The device 1 further includes computing means in the form of a microprocessor 9 to enable the device 1 to contextualize, format and otherwise read signals received, and process and issue commands; and communication means in the form of wireless communication circuitry 11 enabling the device 1 to send and receive signals to and from a remote location — be it a remotely located control unit or one or more further similar such devices 1. The device 1 may also include memory means (not shown) provided therewith, enabling the device 1 to store data, instructions, information, models and the like. In preferred embodiments, the device 1 includes a single input terminal 5 and a single output terminal 7, each of which are configurable to accept analogue or digital input from the process interface element 3, and generate analogue or digital output to the process interface element 3, respectively. That is to say, the input and output terminals 5, 7 are universal in the sense that they each may accept or generate analogue or digital signals depending on the process interface element with which they couple, and thus the device 1 can couple with process interface elements 3 that comprise only analogue terminals, digital terminals, or a mixture of both. The microprocessor 9 is configured, via the communications circuitry 11 or associated connection elements, to interpret input signals to the process interface element 3, permitting the microprocessor 9 to contextualize and format the information into valid output messages to be sent through the communication circuitry 11. In practice, this means that the device 1 can be configured to understand the type of sensor/ actuator to which it is connected, in order to contextualise the signal, i.e., a pressure sensor signal of 5V would be 25 Pa or Nm2; a connected valve would be half open at 12mA, etc.. This is then used to generate the messages that are sent to other wireless field devices and/ or a gateway for consumption by external systems.
The device 1 is provided to be coupled or installed in-line with the process interface element 3, for example, such coupling may be between an industrial automation controller and a process variable sensor, or between an industrial automation controller and an actuator. Consequently, the device 1 may disconnect signals sent through and/ or between the connect elements and allow an alternative signal to be sent. Such alternative signal may have been received by the wireless communication circuitry 11 from a remote location, or be generated by the microprocessor 9 of the device 1. The device 1, once coupled with the process interface element 3, interrogates input signals — analogue or digital — and allows the microprocessor 9 to contextualize and format those signals and allow the communication circuitry 11 to subsequently transmit the signals as readable information. Thus, in a base configuration, the device 1 of the present invention acts as a pass-thorough element within a control circuit, acting as a data acquisition device reading, interpreting and contextualising the signal before transmitting via the communication circuitry 11. The device can be interactively configured to interrupt the signal flow and inject an alternative signal to be sent to the process interface element.
The device 1 in some embodiments of the present invention may include control means associated therewith, enabling the device 1 and its functionality to be directly accessed and controlled by a user if desired. This may be in addition to controlling the device 1 remotely by transmitting signals to it via the wireless communication circuitry 11. If so required, the device 1 may further include user display means 13 allowing a person to access visual representations of relevant/required information. Alternatively, the device 1 may simply include a further connection means to which a user display interface may be connected. The communication circuitry 11 allows the device 1
to send and receive signals to and from a remotely located control means and/or one or more further wireless field devices 1 forming a mesh network of devices, discussed in further detail later and with reference to Figure 2. In some preferred embodiments of the invention, the device 1 may also include internal sensors (not shown) . Such sensors would be provided to measure any or any combination of the following: ambient temperature, pressure, light levels, magnetic fields and vibration, and such measurements are taken independently of the process interface element 3 to which the device 1 is connected. The data acquired from the sensors would then be used to augment captured data and Al algorithms.
The microprocessor 9 of the device 1 is provided to include a machine learning and/or artificial intelligence algorithm implemented thereon. The machine learning (ML) and/or artificial intelligence (Al) algorithm is provided to be able to monitor and assess parameters and/or functionality of the process interface element 3 with which the device 1 is coupled, and consequently determine, in real time, if said parameters and/ or functionality need to be altered, paused or otherwise optimised, and subsequently transmit a command to carry out the required action. The provision of an ML and/or Al algorithm with the microprocessor 9 ensures that as the various parameters and functionality of the process interface element 3 with which it is coupled are analysed and assessed, the device 1 can, in real time, react to any changes or other variables — environmental or within the element itself — and transmit commands in order to optimise the functionality of the process interface element. This is as opposed to employing such software on a remote central controller/gateway and merely receiving commands from a remote, centralized location. As previously mentioned, depending on the particular requirements of the wireless field device, the computing means may have a
machine learning (ML) and/or an artificial intelligence (Al) algorithm implemented thereon — such a decision may be made depending on the power requirements/availability and the specific role the device 1 is to perform when connected to the process interface element 3. If the device 1 is required to learn and evolve the algorithm over time to the workings/ functioning of the process interface element 3, and the power availability permits, then it may be more appropriate to provide an ML algorithm to be implemented on the microprocessor 9 of the device 1. Alternatively, if power availability is an issue and/or no learning is required, i.e., if an appropriate tailored algorithm is already available off the shelf, then the provision of an Al algorithm would be more appropriate.
The device 1 is thus able to communicate any alteration, pausing or otherwise optimising of the parameters and/ or functionality of the process interface element 3 with which it is coupled, or other relevant information, alerts or messages, to one or more further devices 1 formed as part of a network, and/ or a remotely located control means. The ML and/or Al algorithm itself, and any other software implemented on the microprocessor 9 can be updated remotely via the wireless communication circuitry. Thus, the microprocessor 9, with the ML and/or Al algorithm implemented thereon, is able to run various models which provide configurable outputs. These outputs could be, amongst other examples, in the form of an alert message sent to a centralized controller or visualization element/ display means, or a message sent to a corresponding field controller via the communication means to perform specific actions. The present invention therefore not only provides a wireless field device 1 which can be utilized universally, that is to say, on most all industrial machinery irrespective of age, type and make, but which also applies artificial intelligence or machine learning while monitoring the functionality of the process interface
element 3 with which it is coupled, enabling it to send commands to optimize the element, transmit relevant information to other such devices on a network where needed, or send information and/or alerts or requests to a remotely located control means, allowing personnel to implement required actions in real-time.
Finally, in order to function, the device 1 is configured to draw a supply of power from the process interface element 3 with which it couples, through the input and/or output terminals 5, 7. In some embodiments, however, the device 1 may further include at least one battery cell 15 to provide its own independent power source. The battery cell 15 is provided to be rechargeable and can be recharged by drawing a supply of power from the coupled process interface element 3 through the input and/or output terminals 5, 7. In other embodiments of the invention, the device 1 may instead be configured to connect with an external supply of power, such as a mains supply of power or a battery pack, from which it may draw additional power and/or charge the battery cell 15 provided thereon.
Referring now to Figure 2, there is provided a plurality of wireless field devices 1 which together communicate wirelessly to form a mesh network 21. Each of the devices 1 is coupled with a distinct process interface element 3 — that is to say, there may be provided two or more devices 1 coupled to different sections of the same piece of industrial machinery, and/ or device may be provided to be coupled with differing machines entirely, but which may form part of the overall industrial process. The communication circuitry 11 in each device 1 enables signals/information to be sent and received between devices, essentially allowing the devices to “talk” to one another. Consequently, a microprocessor 9 on a first of the devices is configurable to send commands, alerts or other such
notifications, via the communication circuitry, to its host device 1 and/or one or more of the other devices in the network and thus associated process interface elements 3, to begin, cease, alter or otherwise optimize the functioning thereof. The network of devices may also include a controller 23 in wireless communication therewith and which is arranged to receive signals in the form of information, alerts, messages, updates etc. from the devices, and likewise transmit signals to each device in the form of information and/or commands to implement an action or actions. The controller 23 may be one of several such controllers, as required by the network, and acts as a gateway which may further communicate/transmit information to third- party locations or devices as may be required. Such information may be alerts/ status updates etc., or may further include requests based on readings detected by the devices 1 in the network 21.
With the ML and/or Al algorithm implemented on to the microprocessors of each of the devices in the network 21 , each device is able to monitor and assess parameters and/ or functionality of the process interface elements 3 with which they are coupled, and consequently determine, in real time, if those parameters and/ or functionality need to be altered, paused or otherwise optimised, subsequently issuing a command to carry out the required action or actions. Importantly, since the devices are all in communication with one another, they can each communicate with one another the status, functioning etc. of the process interface elements 3 with which they are coupled, and if a change in parameters/environment etc., or a fault is detected with one of the elements 3, this can be communicated throughout the network 21 and subsequent commands to other devices and their associated elements may be transmitted enabling them to pause or otherwise alter their functionality in response to the change detected in the first element 3. Any such
changes in the parameters or functionality of the elements 3 which are detected and/or addressed may further be communicated via the wireless communication circuitry to the controller 23 enabling a complete log of events to be provided and if any further action, manual or otherwise is required to be carried out, this may easily be determined by the relevant personnel.
Claims
1. A wireless field device for use in an industrial process, said device including: at least one input terminal arranged to couple with a process interface element; at least one output terminal arranged to couple with a process interface element; communication means; and computing means; characterized in that said input terminal is arranged to accept analogue or digital signals, and said output terminal is arranged to generate analogue or digital signals.
2. A wireless field device according to claim 1, wherein the device includes: a single input terminal configurable to accept analogue or digital input from the process interface element; and a single output terminal configurable to generate analogue or digital output to the process interface element.
3. A wireless field device according to claim 1, wherein the device is configured for in-line installation / coupling with the process interface element.
4. A wireless field device according to claim 1, wherein the device is configured to disconnect a signal sent between connected elements in an in-line installation and permit an alternative signal to be sent, in use, which has been received by the communication means of the device or generated by the computing means of the device.
5. A wireless field device according to claim 1, wherein the device is configured to interrupt input signals to the process
interface element with which it is arranged to be coupled, permitting the computing means to contextualize and format the signals and allow the communication means to transmit the signals in the form of readable information. A wireless field device according to claim 1, wherein the computing means is configured, via the communications means or associated connection means, to interpret input signals to the process interface element, in use, permitting the computing means to contextualize and format the information into valid output messages to be sent through the communication means. A wireless field device according to claim 1, wherein the device is configured to interpret information received by the communication means, in use, permitting the computing means to contextualize and format the information into valid output signals to be sent through the output terminal to the process interface element. A wireless field device according to claim 1, wherein said communication means are arranged to receive and transmit information, and are provided in the form of wireless communication means. A wireless field device according to claim 1, wherein the device includes internal sensor means, provided to measure any or any combination of the following: ambient temperature, atmospheric pressure, light levels, magnetic fields and vibration. A wireless field device according to claim 1, wherein the device is configured to transmit information to and receive
information from one or more further wireless field devices, via said communication means. A wireless field device according to claim 1, wherein the device is configured to transmit information to and receive information from a remotely located control means, via said communication means. A wireless field device according to claim 1, wherein said computing means include a machine learning (ML) and/ or an artificial intelligence (Al) algorithm implemented thereon, provided in the form of a reinforcement learning algorithm. A wireless field device according to claim 12, wherein said machine learning algorithm and/or artificial intelligence is provided to monitor and assess parameters and/or functionality, including external data and/ or signals, of the process interface element with which the wireless field device is coupled, and consequently determine, in real time, if said parameters and/ or functionality need to be altered, paused or otherwise optimised, and subsequently transmit a command to carry out the required action. A wireless field device according to claim 1, wherein the device is arranged to communicate any alteration, pausing or otherwise optimising of the parameters and/ or functionality of the process interface element with which it is coupled, or other relevant information or alerts, to one or more further wireless field devices and/ or a remotely located central control means, via said communication means. A wireless field device according to claim 1, wherein the device is configured to draw a supply of power from the
process interface element with which it couples, through the input and/ or output terminals.
16. A wireless field device according to claim 1, wherein the device further includes power supply means provided therewith.
17. A wireless field device according to claim 1, wherein the device is arranged to connect with and draw power from an external supply of power, said external supply of power being a mains supply of power, and/ or a portable supply of power.
18. A network of at least two wireless field devices according to claim 1 , said devices in communication with each other via said communication means; said devices arranged to couple with distinct process interface elements; said communication means permitting communication between each of said devices and arranged to transmit and receive information about the respective process interface elements with which they couple; characterized in that computing means on a first of said devices are configured to send commands, alerts or other such notifications, via the communication means, to the process interface element with which it is coupled and/ or one or more of the other devices in the network and thus associated process interface elements, to begin, cease, alter or otherwise optimize the functioning thereof.
19. A network according to claim 18, wherein the network further includes one or more control means, said control means acting as gateways and arranged to receive information from each of the wireless field devices and transmit information and/ or send commands to said devices.
20. A network according to claim 18, wherein said one or more control means are arranged to transmit information to third-party locations or devices.
21. A network according to claim 18, wherein each of said wireless field devices in the network include: a single input terminal configurable to accept analogue or digital input from a process interface element; and a single output terminal configurable to generate analogue or digital output to a process interface element.
22. A network according to claim 18, wherein each of the wireless field devices further include control means provided associated therewith.
23. A network according to claim 18, wherein each of the wireless field devices further include user display means provided thereon or associated therewith.
24. A network according to claim 18, wherein via wireless communication means, each of said devices are arranged to transmit and receive signals and information to and from one another, in use.
25. A network according to claim 18, wherein the network of devices is configured to transmit, via the communication means, information relating to parameters and/ or functionality of the process interface elements, and/ or commands issued, to one or more remotely located control means.
A network according to claim 25, wherein said one or more remotely located control means act as gateways and are arranged to communicate outside of the network.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GBGB2210607.4A GB202210607D0 (en) | 2022-07-20 | 2022-07-20 | Wireless field device and a network thereof |
| GB2210607.4 | 2022-07-20 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2024018202A1 true WO2024018202A1 (en) | 2024-01-25 |
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Family Applications (1)
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|---|---|---|---|
| PCT/GB2023/051894 Ceased WO2024018202A1 (en) | 2022-07-20 | 2023-07-19 | Wireless field device and a network thereof |
Country Status (2)
| Country | Link |
|---|---|
| GB (2) | GB202210607D0 (en) |
| WO (1) | WO2024018202A1 (en) |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20080268784A1 (en) * | 2007-04-13 | 2008-10-30 | Christopher Kantzes | Wireless process communication adapter for handheld field maintenance tool |
| US20080280568A1 (en) * | 2004-06-28 | 2008-11-13 | Kielb John A | Rf adapter for field device |
| US20140088893A1 (en) * | 2012-09-27 | 2014-03-27 | Rosemount Inc. | Hybrid power module with fault detection |
-
2022
- 2022-07-20 GB GBGB2210607.4A patent/GB202210607D0/en not_active Ceased
-
2023
- 2023-07-19 GB GB2311048.9A patent/GB2622476A/en active Pending
- 2023-07-19 WO PCT/GB2023/051894 patent/WO2024018202A1/en not_active Ceased
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20080280568A1 (en) * | 2004-06-28 | 2008-11-13 | Kielb John A | Rf adapter for field device |
| US20080268784A1 (en) * | 2007-04-13 | 2008-10-30 | Christopher Kantzes | Wireless process communication adapter for handheld field maintenance tool |
| US20140088893A1 (en) * | 2012-09-27 | 2014-03-27 | Rosemount Inc. | Hybrid power module with fault detection |
Also Published As
| Publication number | Publication date |
|---|---|
| GB202210607D0 (en) | 2022-08-31 |
| GB202311048D0 (en) | 2023-08-30 |
| GB2622476A (en) | 2024-03-20 |
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