System and method for integrated sensing and control of industrial processes

Abstract

An integrated spectral sensing engine is based on a combination of energy sources (illumination) and detectors housed within an integrated package that includes the sample interfacing optics and acquisition and processing electronics. The focus is on a miniaturized sensor system that can be optimized for specific measurements and can be integrated into a manifold-based sample handling system. Design and fabrication components are selected to support high volume manufacturing of the sensors. Spectral selectivity is provided by either continuous variable optical filters or fabricated filter matrix components. The spectral response of the primary sensors covers the range from the visible (400 nm) to the near-infrared (1100 nm), as defined by the availability of suitable low-cost solid-state detector devices. Provision is made to extend the range into longer wavelengths, and to shorter wavelengths for filter-matrix devices. A broad selection of measurement modes is defined and these include transmittance / absorbance, turbidity (light scattering) and fluorescence. On board data processing not only provides the primary data acquisition, as well as data massaging and the display and output of computed results. The targeted application of the spectral sensing devices are for water, pulp and paper, chemical and petroleum based industries. Alternative packaging regimes and the production of lower cost sensing devices can lead to the use of the spectral sensing devices in the medical, clinical, forensic and consumer based areas of application.

Description

CROSS REFERENCE TO RELATED APPLICATIONS [0001] The present application is a continuation of and claims the priority benefit of U.S. nonprovisional patent application Ser. No. 10 / 913,819 filed Aug. 6, 2004, entitled “SYSTEM AND METHOD FOR INTEGRATED SENSING AND CONTROL OF INDUSTRIAL PROCESSES” of the same named inventors and assigned to a common assignee, which in turn claims the priority benefit of U.S. provisional patent application Ser. No. 60 / 494,977, filed Aug. 14, 2003, entitled “SYSTEM AND METHOD FOR INTEGRATED SENSING AND CONTROL OF INDUSTRIAL PROCESSES” of the same named inventors and assigned to a common assignee; both of said applications being incorporated herein by reference.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to integrated systems and methods for sensing parameters associated with industrial processes and controlling such processes based on the sensed information. More particularly, the present invention rela...

AI Technical Summary

Benefits of technology

[0010] It is an object of the present invention to provide an integrated spectral sensor and an optional control system for controlling industrial processes. The system includes a sampling component, a spectral engine including a sensing component and a signal conditioner, a signal exchange system, and a controller. The sampling component can include, where required a multiport manifold on a miniaturized sample handling platform (such as NeSSI) for gathering one or more fluid samples (including reagents) related to the industrial process to be controlled. The sampling component interfaces with the spectral engine that includes an optical sensing system for nonintrusive detection of features of the sampled fluid. The spectral engine further includes a light or energy source, spectral sensing component for measuring the characteristic chemical features of the fluid, a sample cell or chamber that is dimensionally optimized for the light source and sensing component, and a microprocessor for conditioning the signals output from the spectral sensor. The signal exchange system may be a wired or a wireless signal transfer device coupled locally or remotely to the sensor. The optional controller includes the signal processor and one or more embedded computer programs to evaluate the received signal information and make decisions on any process modifications to be made. The controller is a predictive controller that maximizes the ability to adjust process conditions as quickly as possible in response to the sensed process information. The controller interfaces with one or more process modification devices, including control valves, chillers and heaters, for modifying, pressure, flow rates and volumes, and temperatures of the fluid or fluids forming part of the industrial process.

[0012] In conventional industrial process plants, process sensors and actuators are hardwired using copper wire or fiber optics networking. Because of the high costs associated with installation, maintenance, and constant reconfiguration of a process, there is a large opportunity for a major cost advantage for using a wireless communications path to interconnect the sensors and actuators. This is particularly important when a network of sensors is being employed. Also, when using an optimizing predictive adaptive control system, better communications between sensors improves the overall efficiency. For this reason, the present invention contemplates the option of employing wireless connectivity to establish data signal transfer.

[0013] The integrated sample, sensing and control system of the present invention provides a more granular and immediate picture of relevant information associated with an industrial process. That picture is coupled with effective predictive process control to yield improved productivity with corresponding reduced impact on the process's surrounding environment. These and other advantages will become more apparent upon review of the following detailed description and the accompanying drawings.

Problems solved by technology

The inability to monitor the process usually means that there is a risk of low quality product, which results in the need to make corrections after the product has been made.

This is both inefficient, and leads to a high level of wastage, which can often lead to an environmental issue.

The first option is inefficient and is not effective for control purposes.

The second option is usually expensive, and as a result, it is normal to implement a single analyzer at the end of the process.

This has limited value for good process control because it is too late in the process to make meaningful adjustments.

While this is an option, it has risks because it lacks redundancy—one instrument controlling an entire process.

Once tuned, the system is only able to control the process with which it started.

Should process behavior change after start-up, the controller cannot counteract disturbances and the closed-loop system may become unstable.

While that may not be particularly difficult, repeated tuning can be tedious and time consuming, especially if the process takes hours to respond to a tuning test.

Manual tuning may not even be possible should process behavior change too frequently, too rapidly, or too much.

It is a long and complex process that requires significant investment of time and money.

Traditionally, this collection of valves and components takes up a rather large space, and can sometimes be as expensive as the measurement device to implement.

In the miniaturization of the sensing devices, it makes little sense to use such a system, in terms of efficiency and cost.

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