Commissioning and configuration of control electronics associated with systems

Abstract

Device for monitoring installations (14) comprising the following: Sensors (26) arranged on the systems (14) to generate sensor signals according to the characteristics of the systems (14); Control electronics connected to the sensors (26) for receiving and analyzing sensor signals and for sending information and commands; a mobile device for communicating with the control electronics and sensors (26); where the mobile device has an input and is configured and programmed to: a. Receiving location data from the input, wherein the location data corresponds to sensor identity, plant identity and sensor signals, b. Transmitting location data to the electronics (16), and c. Generating and transmitting mobile control signals to the control electronics based on user inputs made through the input of the mobile device (32); the control electronics are configured and programmed as follows: a. with plant data corresponding to the identities and locations of the sensors (26), identities of the plants (14), acceptable states of the plants (14) and abnormal states of the plants (14), b. to analyze the sensor signals and determine the condition of the systems (14) based on the system data, c. to send (1) commands and / or (2) information when a detected condition of a plant (14) is an abnormal condition, d. to receive and analyze location data and mobile control signals, e. to modify the (1) sending of commands and / or (2) analysis of sensor signals based on one or more of the location data and mobile control signals, wherein the mobile device and the control electronics are programmed to perform a linearization function by: Identifying multiple sensors (26) and storing the identities of the sensors (26) in the mobile device to generate a sensor identification for each identified sensor (26); Receiving and storing multiple sensor parameter values ​​and timestamps in the mobile device, where each sensor parameter value is associated with a sensor identification and a timestamp; Storing multiple sensor identifications in the control electronics; Receiving and storing multiple sensor signal values ​​and timestamps in the control electronics, wherein each of the sensor signal values ​​is associated with a timestamp and a sensor identification, Sending linearization data from the mobile device to the control electronics, wherein the linearization data includes the multiple sensor parameter values, an associated sensor identification for each sensor parameter value, and an associated timestamp for each sensor parameter value; Using the timestamps and sensor identifications associated with the sensor parameter values ​​and the timestamps and sensor identifications associated with the sensor signal values ​​to correlate the sensor parameter values ​​with the sensor signal values ​​by the mobile device, in order to associate a sensor signal value with a sensor parameter value in order to generate multiple value pairs for multiple sensor identifications; and Using the value pairs to interpret the sensor signal from each identified sensor (26) by the control electronics, so that the value pairs are used to linearize the correlation between sensor parameters and sensor signal values ​​for each of the identified sensors (26).

Description

AREA

[0001] The present invention relates to electronics used for monitoring and controlling industrial plants, and in particular to a mobile device used for commissioning and configuring sensors and control electronics associated with industrial plants, and typically for monitoring, protecting and controlling plants and predicting the health of plants. BACKGROUND

[0002] The term "equipment" as used herein refers to physical objects such as industrial plants, which include electric motors, pumps, tanks, pipes, and similar equipment. In many environments, it is useful to monitor and control these installations with sensors and control electronics that perform various functions, including monitoring, predicting the health of the equipment, protection, and control. The term "sensor" is used generally and refers to any device that generates a signal containing information about an installation. For example, a switch could be a sensor. The term "control electronics" is also used generally and refers to a specialized processor or computer that receives signals from sensors and performs one of the functions described above. Thus, control electronics do not necessarily perform a control function.For example, control electronics can perform a purely monitoring function. Typically, the control electronics performing such functions are located remotely from the equipment and sensors and other devices mounted on or near the equipment, and are hardwired back to the control electronics. The sensors and other devices can also communicate wirelessly with the control electronics, such as via Wi-Fi, or other communication methods, such as fiber optic cables, can be used. When using such control electronics, it is often necessary or desirable for the user to be located both in a control room and in the field at the equipment site. For example, a user might need to go to the equipment site and collect some type of data and then return to the control room to input the data into the control electronics.Data collected in the field is often entered via a keyboard in the control room, and human error is quite possible. The need to be present at the plant in the field is particularly prevalent during the initial setup or commissioning of equipment (plants) and during necessary maintenance operations. The traditional process of collecting field data and entering it into the control electronics associated with the plants was cumbersome and prone to human error.

[0003] For example, German patent DE 10 2012 101 461 A1 discloses a method for controlling the workflow of a process plant in automation technology. This method involves determining the unique identifier of the stored field device at a predetermined location using computerized location data. The field device is recognized and stored in mobile service devices as a response from service personnel. The field device's parameter and calibration data are also stored. A loop test is performed by the service personnel. A positive result authorizes the field device to be put into operation in a processing unit. The workload of the responsible service personnel is controlled based on the specific event that occurred.

[0004] DE 10 2007 060 281 A1 discloses a method and a device for the selective output of alarm messages from a technical plant operation, in particular a production and / or power plant. The method includes partially preventing and / or identifying unnecessary and / or requested alarm messages, while the alarm messages are selected and / or classified based on a combination of alarm messages from a technical system operation with the status information from a computerized maintenance management system and / or an enterprise resource planning system. The information is automatically obtained via a communication link and / or linked together and stored in a data storage device. An independent claim also relates to a device for the selective output of alarm messages about the technical system operation of a production plant and / or a power plant. SUMMARY

[0005] The present invention addresses the problems and difficulties associated with acquiring field data and inputting such field data into electronics associated with various systems in the field. The invention is defined in the independent claims. Further advantageous embodiments are defined in the dependent claims.

[0006] According to one embodiment, sensors are positioned on or near equipment in the field to generate sensor signals corresponding to the equipment's characteristics. Control electronics are connected to the sensors to receive and analyze these signals and to send commands or information based on them. The control electronics may include machine state control electronics, which receive and analyze sensor signals and send commands and information about the machine's condition. The control electronics may also control the equipment based on the sensor signals and the commands and data provided by the machine state electronics. A mobile device is provided to communicate with the control electronics, and this device is configured and programmed to receive location data in the field through one or more electronic inputs.The location data can correspond to sensor identity, plant identity, and sensor signals. The mobile devices are also configured to transmit the location data collected in the field to the machine status electronics, either wirelessly or via other communication channels. The mobile device generates and transmits mobile control signals and mobile data to the control electronics based on user input via a user interface on the mobile device and based on location data collected through electronic input to the mobile device.

[0007] The control electronics are configured and programmed with plant data corresponding to the identities and locations of the sensors and equipment, and are also programmed with data or other information about acceptable and abnormal plant states. The control electronics can analyze sensor signals and determine the plant state based on the plant data. When an abnormal state is detected, the control electronics can send control commands (such as a shutdown command) or machine state data (such as a warning or alarm). The control electronics also receive and analyze location data and mobile control signals provided by the user via the mobile device. Based on one or more of the location data and mobile control signals, the control electronics can modify the output of control commands and machine state commands or data.For example, in a maintenance mode, the control electronics can prevent equipment shutdowns based on commands from the mobile device, even if the sensor signals indicate abnormal conditions.

[0008] The mobile device may also have an electronic input capable of reading characters, and characters are provided at the location of each sensor and at the location of each piece of equipment to identify the sensors and equipment, respectively. The characters may be a barcode or another type of machine-readable code, such as an electronic chip programmed to store and transmit an electronic code. The mobile device may be configured to assist in setting up the control electronics with respect to a specific piece of equipment by identifying the specific piece of equipment and one or more associated sensors. The mobile device then sends information to the control electronics, specifying the identities of the piece of equipment and the associated sensors.The mobile device can also be used to configure the control electronics, or an external computer can be used to configure the control electronics after the mobile device has specified the identities of the systems and associated sensors.

[0009] The machine state control electronics can include several microprocessor-based units programmed to monitor signals from the sensor. In such a case, the mobile device can be programmed to select a specific unit to monitor a particular sensor associated with a specific piece of equipment. For example, the mobile device might display a graphical representation of the control electronics, identifying its multiple units. To associate a specific sensor with a particular unit, the user identifies the sensor either manually via a user interface or electronically using an electronic code reader. Then, a specific control electronics unit is selected by tapping the unit's representation displayed on the mobile device.

[0010] The mobile device can also be programmed to select an operation for monitoring and analyzing sensor signals for a specific sensor. To do this, the user selects an operation and a sensor and sends the identity of the selected operation and the identity of the specific sensor to the electronics. The control electronics are pre-programmed with operations for monitoring and analyzing sensor signals. In response to the identity of the selected operation provided by the mobile device, the control electronics configure themselves to analyze signals from the selected sensor based on the operation identity and the identity of the specific sensor as sent by the mobile device.

[0011] The mobile device is also programmed to execute a sensor linearization function. The sensor is exposed to a known environmental condition, such as a known displacement for a distance sensor, and the sensor signal is measured under this condition. By exposing the sensor to a series of different known conditions, such as different displacements, and measuring the sensor signal for each different condition, multiple pairs of values ​​can be generated, such as a pair consisting of a displacement value and a sensor signal value. These pairs of values ​​can be used by the control electronics to execute a linearization function, allowing the control electronics to accurately determine the sensor's displacement based on the sensor signal.For example, the value pairs could be stored as a lookup table, and when a sensor signal is received, the lookup table could be used to look up the positional displacement value corresponding to the sensor signal. If the exact value of the sensor signal is not in the table, a positional displacement value corresponding to the exact value of the sensor signal could be determined by interpolation. Alternatively, the lookup table can be used to correct the sensor signal values ​​to establish a linear relationship between the sensor signal values ​​and the positional displacement values.

[0012] The linearization function can be performed in several different but similar ways. For example, linearization can be performed by storing a code that identifies a specific sensor in the mobile device and by receiving and storing multiple position displacement values ​​corresponding to several position displacements of that specific sensor. A timestamp is then recorded in association with each sensor position displacement value, corresponding to the time at which the position displacement value was generated. The mobile device also receives and stores multiple sensor signal values ​​and timestamps corresponding to the magnitudes of the sensor signal from the specific sensor at multiple points in time. The timestamps are used to associate the sensor position displacement values ​​with the sensor signal values ​​to generate multiple pairs of values, each pair containing one position displacement value and one sensor signal value.The value pairs are stored in the mobile device and then sent to the machine state control electronics, which are programmed to use the value pairs to linearize the sensor signal from the specific sensor. Alternatively, the value pairs in the mobile device can be used to generate linearization information, and this linearization information can be sent to the control electronics for use in linearizing sensor signals. The linearization information can be a function (formula) applied to a sensor signal to linearize it. Alternatively, the linearization information can be a function (formula) applied to a sensor signal value to convert it into a sensor position displacement value.

[0013] The term "linearization," as used here, is a general term referring to the function of establishing a relationship between the magnitude of a parameter detected by a sensor (e.g., distance) and the value of the sensor signal. Ideally, the functional relationship between the detected quantity and the sensor signal is linear. In reality, however, the relationship is almost never linear. Therefore, to linearize a sensor signal, a number of value pairs are established for each sensor, where each value pair contains the actual magnitude of the detected parameter and the value of the sensor signal at that measured quantity. These value pairs are used to interpret the sensor signal values ​​and to accurately determine the actual quantity detected at a given sensor signal value.For example, the value pairs can be used to correct the sensor signal and generate a corrected sensor signal that actually has a linear relationship to the detected quantity. The corrected sensor signal is then used to determine the detected quantity using a linear conversion function. Alternatively, the value pairs can be used to generate a function or a lookup table that is used to convert a given sensor signal value into a specific parameter quantity. In this alternative technique, the sensor signal value is never corrected to generate a linear relationship between the sensor signal and the parameter quantity; rather, this technique or function is also considered "linearization" as used in the present application.

[0014] In the example discussed above, the mobile device receives a sensor signal or sensor signal values ​​and uses the timestamps to correlate the sensor's displacement values ​​with the sensor signal values. However, the mobile device can also be used to execute the linearization function without actually collecting the sensor signal values. In such a case, the sensor is displaced by a known amount, and the mobile device is used to store the displacement value plus a timestamp indicating the time the sensor was displaced by that net amount. Simultaneously, the control electronics record the sensor signal and generate multiple timestamped sensor signal values.Once the mobile device has collected a desired number of displacement values ​​and the corresponding timestamp for a specific sensor, these displacement values ​​and timestamps are sent to the electronics, and the control electronics are programmed to correlate the sensor signal values ​​and the displacement values ​​with the timestamps. In this way, the control electronics generate several pairs of values, each containing a sensor displacement value and a sensor signal value.

[0015] This technique is applied to any sensor type that measures any parameter type, and the displacement parameter is used only as an example. For instance, a temperature sensor could be linearized in the same way. The sensor would be exposed to several different temperatures, and in this case, the parameter would be temperature. The user would input the several different temperature values ​​(parameter values), and the mobile device or control electronics would capture the temperature sensor signal value according to each temperature value. This generates multiple pairs of values, with each pair containing a temperature and a corresponding sensor signal value.

[0016] According to the above descriptions, methods for linearizing or calibrating sensors can be summarized as follows: 1. Workflow without a connection from the mobile device to the control electronics during data acquisition in the field: a. according to a given list of relocation values ​​or by manually entering them on the mobile device; b. physically relocate the sensor by the given distance each time; c. each time, press a button on the mobile device to obtain the current timestamp associated with this location change; d. create a pair of values ​​(distance timestamps) each time; e. go to the control room and connect and send these pairs directly to the corresponding card of the control electronics (not possible in our current setup, but possibly possible) or to the PC with Machine Studio configuration software installed (in our current setup, one of two possible sensors connected to the card must also be selected); f. Either the card or the Machine Studio software must provide historical sensor signal values ​​with time information (not possible in our current setup for the card, but possibly possible); g. either the card (not possible in our current setup, but possibly possible) or the Machine Studio software must create the required pairs of values ​​(distance-sensor signal value) based on the timestamps; h. either the card configures itself (not possible in our current setup, but possibly possible) with the new linearization function or the Machine Studio software sends the new configuration to the card. (The PC / control electronics must be synchronized with the mobile device). 2. Workflow with connection (wired, wireless or otherwise) from the mobile device to the control electronics during data acquisition in the field: a. direct connection to the corresponding control electronics in the field (enter IP address or scan possibly readable code on machine); b. select the appropriate map and sensor (one of two in our current hardware) that is connected to the map (possibly graphically or by scanning from a list or readable code at the sensor location); c. according to a given list of relocation values ​​or by manually entering them on the mobile device; d. physically relocate the sensor by the given distance each time; e. Press a button on the mobile device each time to directly generate a pair of values ​​(position displacement sensor signal value). The sensor signal value is available at all times through the connection to the electronics; f. send these pairs directly to the corresponding card of the control electronics (not possible in our current setup, but possibly possible) or to the PC with Machine Studio configuration software installed; g. either the card configures itself (not possible in our current setup, but possibly possible) with the new linearization function or the Machine Studio software sends the new configuration to the card.

[0017] The mobile device can also be programmed to support maintenance operations on equipment. For example, if maintenance is to be performed on a particular piece of equipment while it is operating, the maintenance might create an operating condition that would be detected as abnormal. Normally, the control electronics would analyze the sensor signals and determine that the equipment is operating abnormally. The electronics would then act according to their programming in response to the abnormal operating condition. One response might be to shut down the equipment to stop its operation. A shutdown command would disrupt the maintenance work being carried out on the equipment. To quickly overcome this problem, the mobile device is programmed to generate a maintenance command associated with at least one piece of equipment. An electronic button is provided on the mobile device to activate the maintenance command, which is then sent to the electronics.In response to the maintenance command, the control electronics modify its operations and programming to prevent the output of certain commands or information. For example, the control electronics might be programmed to send an alarm indicating that a particular piece of equipment is operating abnormally and simultaneously send a command to shut down that equipment. However, the control electronics might also be programmed to issue a cautionary warning upon receiving the maintenance command, indicating that a particular piece of equipment is undergoing maintenance and that this maintenance is causing the equipment to appear abnormal. In such a case, the control electronics would not send a shutdown command.The mobile device is also programmed to generate a reactivation command when another electronic button is pressed, and the reactivation command is sent to the electronics, which changes its programming back to normal, and the control electronics send warnings and shutdown commands according to its original programming. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Further advantages of the invention become apparent upon reference to the detailed description when considered in conjunction with the figures, which are not to scale in order to show the details more clearly, with the same reference numerals indicating the same elements in the various views. This shows: Fig. 1. A somewhat schematic circuit diagram showing a mobile device and control electronics connected to a system that includes an electric motor, a pump, and a sensor; and Fig. 2 A somewhat schematic representation of a mobile device for communicating with electronics. DETAILED DESCRIPTION

[0019] Now, with reference to Fig. Figure 1 shows a plant system 10, which includes a computer system 12 and a plant 14, which in this case has a pump 28 and an electric motor 30. The computer system 12 includes control electronics 16, which is connected via a computer communication path 18 to an external computer 20 and a wireless transceiver 34, such as a WiFi router, via a communication path 24. Typically, several sensors 26 are connected to the electronics 16 via sensor communication paths 22. The control electronics 16 are in Fig. 1 is represented as a single card rack, but it can also represent numerous card racks and can represent cards in numerous locations. The control electronics 16 can include machine condition electronics, which includes monitoring electronics, predictive maintenance electronics, and protection electronics, and the control electronics 16 can, of course, provide control functions for the systems 14. Thus, the control electronics 16 can control the operation of systems, monitor the current operating status of systems, predict the future condition or maintenance requirements of the systems, and intervene to protect the systems when abnormal operating conditions are detected. The single sensor 26 in Fig. 1 represents one or more sensors that can be connected to the control electronics 16. In this example, sensor 26 is mounted next to a bearing of a pump 28 and monitors the bearing's displacement, specifically vibration-induced displacement. A mobile device 32 is also connected to the control electronics 16 via the wireless transceiver 34. Communication paths 24, 22, and 18 are preferably wired communication paths, but they can also be other types of communication paths, including wireless communication and fiber optics. While the communication path between the mobile device 32 and the control electronics 16 is preferably wireless, it can also be connected via wires, fiber optics, or other communication paths.

[0020] A machine-readable code 26a, such as a barcode or an electronic chip, is mounted on sensor 26. This code contains a number to identify sensor 26. Similarly, a machine-readable code 28a is placed next to the sensor to identify a measurement point on pump 28. This measurement point identifies where on the pump a measurement is taken, as well as the characteristics of the measurement, such as the front bearing of pump 28 or a vertical vibration-induced displacement measurement. Machine codes 30a and 28b are also provided to identify motor 30 and pump 28, respectively.

[0021] The control electronics 16 typically includes several microprocessor-based units (e.g., cards or specialized computers) used to monitor sensors and communicate with various other devices. An acceptable device for use as the control electronics 16 would be a CSI 6500 ATG Rack manufactured by Emerson Process Management. The mobile device 32 can communicate with the control electronics 16 either wirelessly or via a wired connection. Additionally, the device 32 can communicate wirelessly with the sensor 26 through the control electronics 16 or communicate directly with the sensor 26 via a wired connection 35. In wireless communication, a sensor signal generated by the sensor 26 is transmitted to the control electronics 16 and then routed back to the mobile device 32, and the mobile device 32 can send commands or information to the sensor 26 by communicating through the control electronics 16.

[0022] The mobile device 32 is in Fig. 2 is described in more detail and can be a relatively standard device, such as an industrial tablet, to which software and hardware features are added to provide functionality. The mobile device 32 includes a speaker 36 for transmitting sound to the user, and a transceiver 38 enables wireless communication such as WiFi communication. A machine code reader 46 is a hardware device, such as a mobile camera or a light transmitter and reader, that can be used to read a barcode. The reader 46 can also include other types of electronic readers that can read electronic codes. A touchscreen 42 is provided for displaying information and receiving user input commands, and a button 44 is provided for controlling the touchscreen 42 and providing additional user input.Signals can be applied to the mobile device 32 via port 48, and signals can be transmitted to and from a sensor via port 48, for example. Intelligent commissioning

[0023] Again with reference to Fig.1. The mobile device 32 offers convenient setup and control of sensors 26, which are typically located far from the control electronics 16. For example, during the initial installation and commissioning of the sensors 26, the mobile device 32 includes programming applications (apps) that support the commissioning of the sensors 26. Once the sensors are installed and electronic codes are placed on or near the sensor to identify it, and electronic codes are also placed on or near the equipment being monitored, in this example, the sensor 26 may have an electronic code that, when read, returns the number "01", and the pump 28 may have an electronic code that, when read, returns the number "02".The control electronics 16 can be programmed to know that sensor 26 is identified with code 01 and that pump 28 is identified with code 02. It can also be programmed with the location and other operating and identification parameters of pump 28. The mobile device 32 can be used to associate a specific sensor with a specific system and to provide this information to the control electronics 16. For example, in this case, the mobile device 32 is used to read the codes from both sensor 26 and pump 28 and send these two codes to the control electronics 16, so that the two codes are associated and the control electronics 16 now associates sensor 26 with pump 28. It is possible that the control electronics 16 was previously programmed manually to associate sensor 26 with pump 28. For example, a person may have manually read and recorded the code from sensor 26 and the code from pump 28.The person then returned to computer 20 and programmed a specific card in the control electronics 16 to associate sensor 26 with pump 28 and to associate the specific card of the control electronics 16 with sensor 26 and pump 28. However, this manual process is prone to human error. Therefore, the process of electronically reading the sensor and pump codes and electronically transferring the information to the control electronics 16 provides a useful check and verification of the manual process.

[0024] The mobile device 32 can also be used to configure a specific map in the control electronics 16 to monitor the sensor 26 in a specific way, depending on the situation. The control electronics 16 includes numerous computer applications for monitoring many different sensor types, and each application may require specific input types to run the monitoring application. To configure the control electronics 16 to monitor a specific system, the correct computer application must be selected, and to monitor a specific sensor, the correct parameters must be provided to the application. The mobile device 32 does not include the numerous monitoring applications themselves, but it does include the application identities and has the capability to transmit the parameters required by each of the computer applications used by the control electronics 16.For example, suppose sensor 26 monitors vibrations of a pump bearing, and it is known that the bearing failure may have been preceded by vibrations in a specific frequency band. It is also known that the bearing operates in a very noisy environment with many sporadic vibration signals that sensor 26 may detect. Therefore, sensor 26 should be monitored by applying an electronic filter so that the control electronics 16 only monitor vibrations in a specific frequency band from X to Y Hertz and send an alarm when vibrations in this frequency band exceed a limit of A units.

[0025] When the mobile unit 32 sends the codes from sensor 26 and pump 28, it can also use a lookup table to select a specific application for monitoring sensor 26. For example, the mobile unit can provide a menu list of application types, and the user can select "Vibration" as the desired application type. A menu of different vibration application subtypes will then be displayed. In this case, the user selects an application subtype called Vibration Band Filter, which allows the input signal to be band-filtered. After selecting the application subtype, the mobile unit prompts the user to enter the upper and lower frequencies of the band filter (X and Y) and the maximum permissible amplitude (A) of the vibration signal within that frequency band before sending a warning.The user then manually enters the parameters (X, Y, and A) and sends these parameters to the control electronics along with the electronic code identifying the sensor. The control electronics 16 then uses this information to configure itself for proper monitoring of the sensor 26. Using the mobile device 32 to fully configure the control electronics 16 for monitoring the sensor 26 is optional. The computer 20 can also be used to select a computer application for monitoring a specific sensor.

[0026] It will be understood that there are numerous ways to use the mobile device 32 to transmit information to the control electronics 16. For example, the device 32 can be used to read the electronic codes for multiple sensors and to associate these sensors with several different codes for equipment. This information can be stored locally in the device 32 without sending the code information to the control electronics 16. After reading a desired number of sensors and associated equipment, the mobile device 32 can be connected wirelessly or via a wired connection to the control electronics 16, and all code pairs can be downloaded to the control electronics 16 to identify numerous sensor codes and to identify the equipment code for each sensor code.

[0027] In summary, to initialize a monitoring card for the control electronics 16, the intelligent commissioning application is opened on the mobile device, and the user selects the initialization application. The user then scans the machine-readable code for the sensor and the plant and selects a monitoring card to configure in order to perform the monitoring function for a specific sensor. Preferably, a graphical representation of the available cards appears on the mobile device, allowing the user to simply tap a specific card to receive the commands to execute the desired monitoring function. The machine-readable codes are then read at the plant location. The codes may include a sensor identification code and a plant identification code, and possibly other codes such as a measurement point identification code. Sending the codes is the essential part of the initialization, which is performed by the mobile device 32.However, if desired, the mobile device 32 can be used to select the measurement or monitoring application and to send the identity of the application plus the parameters required for the application to the control electronics 16. Sensor linearization

[0028] The mobile device 32 is also programmed to facilitate the linearization (calibration) of each installed sensor. For example, a typical distance sensor does not provide sensor signal outputs, so there is a linear relationship between the magnitude of the positional displacement and the magnitude of the sensor signal. Thus, the control electronics 16 must be programmed with multiple pairs of values ​​that allow for an accurate interpretation of the signal from the sensor 26. Each pair of values ​​includes a physical positional displacement of the sensor 26 and the magnitude of the sensor signal. To generate these multiple pairs of values, the user must be physically present at the sensor 26 so that the sensor can be physically moved to generate multiple positional displacements and a corresponding plurality of sensor signals.One technique for generating these value pairs involves physically connecting the mobile device 32 to the sensor 26 via an input line 35 connected to port 48 on the mobile device 32. The sensor 26 is then relocated by a known initial amount, which the user manually inputs via the inputs on the mobile device 32, such as the touch display 42. During this relocation, the mobile device 32 reads and records a first sensor signal value to generate a first value pair. The sensor 26 is then relocated by a known second amount, also entered by the user, and the device 32 reads and stores a second sensor signal value to generate a second value pair, which is stored locally on the mobile device 32. This process continues until a desired number of value pairs have been generated and stored on the mobile device 32.Then the desired number of value pairs is sent from the mobile device to the control electronics 16 and the control electronics 16 is programmed to use the value pairs to linearize (interpret) the sensor signal and thereby accurately calibrate or linearize each sensor 26 = 26.

[0029] The mobile device can be used to complete the linearization process using slightly different methods. For example, the mobile device can be programmed so that the user manually enters a displacement value associated with a specific sensor 26 and immediately sends this information to the control electronics 16. When the control electronics 16 receives the displacement value, it monitors the sensor signal until it detects a stable value for that specific displacement value. It then generates and stores a value pair containing a displacement value and a sensor signal value. Once the value pair is detected and stored, the control electronics 16 sends a signal to the mobile device indicating that it is ready for the next displacement value.The user then physically moves the distance sensor to a second known displacement value, manually enters this second known displacement value, and sends it to the electronics 16. The control electronics 16 then detects and stores a pair of values, and the process repeats until a certain number of value pairs have been stored by the control electronics 16.

[0030] A variation of the process described above can be achieved locally by using the mobile device 32 to communicate wirelessly with the control electronics 16 and to receive sensor signal values ​​from the control electronics 16. Thus, when the user manually enters a displacement value into the mobile device 32, the mobile device simultaneously receives a sensor signal value from the control electronics 16 for that specific sensor and records a pair of values, namely the displacement value and the sensor signal value. The mobile device can then be used to repeat this process until a desired number of value pairs are stored in the mobile device 32. The process can also be repeated for multiple sensors, and all value pairs for all sensors can be stored in the mobile device 32.Finally, the user uploads all value pairs and sensor identities to the control electronics 16, and the control electronics 16 uses the value pairs and sensor identities to calibrate or interpret the sensor signals from each sensor.

[0031] In another variation of the technique described above, the mobile device is used to collect a number of different displacement values ​​and timestamps. For example, a user goes to a sensor 26 and physically moves the sensor by an initial known amount. The user also manually enters the first displacement value, which is associated with both the specific electronic sensor code and a timestamp. The user then physically moves the sensor by a second known amount, enters the second known displacement value into the mobile device 32, and associates this second known displacement value with the electronic sensor code and a current timestamp. This process is repeated until a desired number of displacement values ​​and timestamps have been collected for a given sensor. The process can then be repeated for each sensor for which linearization is desired.Finally, the user connects the mobile device 32 to the control electronics 16 via a wired or wireless connection and uploads the sensor codes, displacement values ​​and timestamps.

[0032] Simultaneously with collecting the displacement values ​​and timestamps as described above, the control electronics 16 constantly monitors the sensor signals from all sensors and correlates the sensor signals with time to generate multiple timestamped sensor signal values. The control electronics 16 thus creates a database of sensor signal values ​​and timestamps for each sensor. When the data from the mobile device 32 is uploaded to the control electronics 16, the control electronics 16 correlates the displacement values ​​from the mobile device 32 with the sensor signal values ​​detected by the control electronics 16 using the timestamps. In other words, for each sensor, the control electronics 16 records a specific displacement value for that specific sensor and determines the time at which this displacement value was entered.It then uses its own database to identify the specific sensor and determines the value of the sensor signal at the time the displacement value was entered. A pair of values ​​for that specific sensor is then generated and stored. This process is repeated for each displacement value sent by mobile device 32, generating multiple pairs of values ​​for use in calibrating or linearizing that specific sensor. The process is performed for each of the sensor codes sent by mobile device 32, thus calibrating several different sensors.

[0033] While the process of using timestamps may initially seem more complicated, it will become clear that it is probably the most practical process for field use. The user simply needs to relocate a specific sensor by a known amount and then enter the sensor's identity and the known relocation amount. This simple process is repeated several times for each sensor, and a database of relocation values ​​and timestamps is quickly generated without the need to connect the mobile device 32 to the sensor or communicate with the control electronics 16.

[0034] In summary, to linearize a sensor, a user opens the intelligent commissioning application on the mobile device 32 and selects the linearization sub-application. The user also connects the mobile device 32 to the user control electronics 16, and the mobile device is used to scan the machine-readable code or to enter a code and send it to the control electronics 16, which selects a monitoring map based on the sensor code. Alternatively, the user can select a map in the control electronics 16 using a graphical representation of the map. The user then manually adjusts the sensor to a specific displacement and enters this displacement value into the mobile device application. The mobile device application then retrieves the resulting voltage directly or indirectly from the sensor 26 via the control electronics 16. A pair of values ​​is then stored in the mobile device 32, in the electronics 16, or in both.The above steps are repeated until a desired or necessary number of pairs have been entered, and when all value pairs have been sent to the control electronics 16, the user can instruct the control electronics 16 to configure its application to linearize the sensor based on the value pairs. This communication can be achieved from the mobile device 32 or the computer 20. The sensor is then identified in the control electronics 16 as a linearized sensor in an operating state. Switching mode operation

[0035] The intelligent commissioning mobile application is also programmed to include a switching mode sub-application, which allows a user to set one, a group of, or all of the monitoring cards of the control electronics 16 to a specific predefined mode, such as a power-up / power-down mode. Switching mode operation can be performed with a single keystroke after defining the mode. To initially set up the application, the intelligent commissioning application is opened and a maintenance sub-application is selected. During the setup process, one or more cards from one or more card racks in the control electronics 16 are selected for switching mode operation. Next, the maintenance mode is defined by selecting an application that prevents the machine from being powered down after the switching mode button is pressed.

[0036] After defining the switching mode operation, it can be activated by simply selecting the maintenance sub-application and pressing the button. All previously identified cards are instructed to enter the predefined maintenance mode, and the equipment associated with these cards is prevented from shutting down during maintenance. After performing maintenance, inspection, or another operation, the user typically wants to reactivate the standard monitoring and protection mode for all monitoring cards in the control electronics 16 racks. To do this, the maintenance sub-application is selected again, and one of the displayed buttons is a protection mode button that can be pressed to reactivate the standard protection and monitoring mode for all cards in the control electronics 16.

Claims

[1] Device for monitoring installations (14) comprising the following: Sensors (26) arranged on the systems (14) to generate sensor signals according to the characteristics of the systems (14); Control electronics connected to the sensors (26) for receiving and analyzing sensor signals and for sending information and commands; a mobile device for communicating with the control electronics and sensors (26); where the mobile device has an input and is configured and programmed to: a. Receiving location data from the input, wherein the location data corresponds to sensor identity, plant identity and sensor signals, b. Transmitting location data to the electronics (16), and c. Generating and transmitting mobile control signals to the control electronics based on user inputs made through the input of the mobile device (32); the control electronics are configured and programmed as follows: a. with plant data corresponding to the identities and locations of the sensors (26), identities of the plants (14), acceptable states of the plants (14) and abnormal states of the plants (14), b. to analyze the sensor signals and determine the condition of the systems (14) based on the system data, c. to send (1) commands and / or (2) information when a detected condition of a plant (14) is an abnormal condition, d. to receive and analyze location data and mobile control signals, e. to modify the (1) sending of commands and / or (2) analysis of sensor signals based on one or more of the location data and mobile control signals, wherein the mobile device and the control electronics are programmed to perform a linearization function by: Identifying multiple sensors (26) and storing the identities of the sensors (26) in the mobile device to generate a sensor identification for each identified sensor (26); Receiving and storing multiple sensor parameter values ​​and timestamps in the mobile device, where each sensor parameter value is associated with a sensor identification and a timestamp; Storing multiple sensor identifications in the control electronics; Receiving and storing multiple sensor signal values ​​and timestamps in the control electronics, wherein each of the sensor signal values ​​is associated with a timestamp and a sensor identification, Sending linearization data from the mobile device to the control electronics, wherein the linearization data includes the multiple sensor parameter values, an associated sensor identification for each sensor parameter value, and an associated timestamp for each sensor parameter value; Using the timestamps and sensor identifications associated with the sensor parameter values ​​and the timestamps and sensor identifications associated with the sensor signal values ​​to correlate the sensor parameter values ​​with the sensor signal values ​​by the mobile device, in order to associate a sensor signal value with a sensor parameter value in order to generate multiple value pairs for multiple sensor identifications; and Using the value pairs to interpret the sensor signal from each identified sensor (26) by the control electronics, so that the value pairs are used to linearize the correlation between sensor parameters and sensor signal values ​​for each of the identified sensors (26). [2] Device according to claim 1, further comprising wireless transceivers (38) for providing wireless communications between the mobile device and the electronics (16). [3] Device according to claim 1, further comprising: Characters indicating a sensor identity, provided on or near one or more of the sensors (26); and wherein the input of the mobile device (32) includes an electronic input which can read the characters and transmit the sensor identity to the mobile device. [4] Device according to claim 3, wherein the characters are machine-readable code (26a, 28a) which may include an electronic chip. [5] Device according to claim 1, wherein the mobile device is further configured and programmed to initialize the function of the control electronics with respect to a specific system (14) by: a. Identifying the specific installation (14) and one or more associated sensors (26), and b. Sending information to the control electronics, specifying the identity of the respective system (14) and the associated sensors (26). [6] Device according to claim 1, wherein the mobile device is further configured and programmed to initialize the function of the control electronics with respect to a specific system (14) by: a. Identifying the specific installation (14) and one or more associated sensors (26), b. Sending information to the control electronics, specifying the identity of the particular system (14) and the associated sensors (26), and c. Configuring the control electronics to monitor the associated sensors (26) of the specified system (14). [7] Device according to claim 5, wherein: a. the control electronics include several microprocessor-based units programmed to monitor signals from the sensors (26); and b. the mobile device is programmed to configure a specific unit to monitor the sensor signals of a sensor (26) associated with the specific system (14), based on user input into the mobile device. [8] Device according to claim 5, wherein: a. the mobile device is programmed to select an operation for monitoring and analyzing sensor signals for a specific sensor (26) in response to user input and to send the identity of the selected operation and the identity of the specific sensor (26) to the electronics (16); and b. the control electronics is programmed with operations for monitoring and analyzing sensor signals and is programmed to select an operation and to self-configure to analyze signals from the specific sensor (26) on the basis of the operation identity and the identity of the specific sensor (26) sent by the mobile device. [9] Device according to claim 1, wherein: a. a machine-readable code is placed at each sensor location, containing a number that identifies the sensor and a code that identifies a measurement point on a system, and b. the input of the mobile device includes a code reader for reading the machine-readable code and determining the code identifying the sensor. [10] Device according to claim 1, wherein the mobile device is programmed to perform a sensor linearization function by: a. Storing a code identifying a specific sensor (26); b. Receiving and storing multiple sensor parameter values ​​according to a parameter detected by the specified sensor (26); c. Receiving and storing multiple sensor signal values ​​corresponding to the magnitudes of the sensor signal from the specified sensor (26) at multiple time points; d. Associating sensor parameter values ​​with sensor signal values ​​to generate multiple pairs of values; e. Storing the multiple value pairs in the mobile device; and f. Sending linearization information to the control electronics, which includes (1) pairs of values ​​or (2) information based on the pairs of values; wherein the control electronics are programmed to use the linearization information to linearize the sensor signal from the specified sensor (26). [11] Device according to claim 1, wherein the mobile device and the control electronics are configured to perform a linearization function by: Providing communication between the mobile device and the control electronics; Identifying a sensor (26) with the mobile device and transmitting the identity of the sensor (26) from the mobile device to the control electronics; Receiving, on the mobile device, of multiple parameter values ​​for the sensor (26) and sending each parameter value from the mobile device to the control electronics; Receiving, at the control electronics, a sensor signal from the sensor (26) and storing a value of the sensor signal and a sensor parameter value; which was received from the mobile device, so that several pairs of values ​​are generated, each pair of values ​​containing a sensor parameter value and a sensor signal value; and Using the pairs of values ​​to linearize the correlation between sensor parameters and sensor signal values ​​for the sensor (26). [12] Device according to claim 1, wherein: a. the mobile device is programmed to generate a maintenance command associated with at least one plant (14) as one of the mobile control signals, and b. the control electronics are programmed to respond to the maintenance command by modifying the programming of the control electronics to prevent the sending of a specific command type. [13] Device according to claim 12, wherein: a. the mobile device is programmed to generate a reactivation command associated with at least one system (14) as one of the mobile control signals, b. the control electronics are programmed to respond to the reactivation command in order to allow the sending of the specific command type. [14] Device according to claim 12, wherein the specified command type is a shutdown command that causes the operation of a system (14) to be shut down. [15] Device according to claim 1, wherein the control electronics further comprise at least one predictive maintenance electronics, protection electronics, monitoring control electronics and control electronics. [16] Method for monitoring installations (14) comprising the following: Arranging sensors (26) on the systems (14) to generate sensor signals according to the characteristics of the systems (14); Receiving and analyzing sensor signals with control electronics and sending information and commands based on the analysis of the sensor signals; Communicate with the control electronics and sensors (26) using a mobile device; Receiving location data in the mobile device, where the data corresponds to sensor identity, plant identity and sensor signals; Transmitting location data from the mobile device to the electronics (16); Generating and transmitting mobile control signals from the mobile device to the control electronics based on user input into the mobile device; Analyzing the sensor signals using the control electronics and determining the condition of the systems (14) based on the system data; Sending (1) commands and / or (2) information when a detected condition of a plant (14) is an abnormal condition; Receiving and analyzing location data and mobile control signals with the electronics (16); and Modifying the (1) sending of commands and / or (2) analysis of the sensor signal based on one or more of the location data and mobile control signals, Identifying multiple sensors (26) and storing the identities of the sensors (26) in the mobile device to generate a sensor identification for each identified sensor (26); Receiving and storing multiple sensor parameter values ​​and timestamps in the mobile device, where each sensor parameter value is associated with a sensor identification and a timestamp; Storing multiple sensor identifications in the control electronics; Receiving and storing multiple sensor signal values ​​and timestamps in the control electronics, wherein each of the sensor signal values ​​is associated with a timestamp and a sensor identification, Sending linearization data from the mobile device to the control electronics, wherein the linearization data includes the multiple sensor parameter values, an associated sensor identification for each sensor parameter value, and an associated timestamp for each sensor parameter value; Using the timestamps and sensor identifications associated with the sensor parameter values ​​and the timestamps and sensor identifications associated with the sensor signal values ​​to correlate the sensor parameter values ​​with the sensor signal values ​​by the mobile device, in order to associate a sensor signal value with a sensor parameter value in order to generate multiple value pairs for multiple sensor identifications; and Using the value pairs to interpret the sensor signal from each identified sensor (26) by the control electronics, so that the value pairs are used to linearize the correlation between sensor parameters and sensor signal values ​​for each of the identified sensors (26): [17] The method of claim 16, further comprising: Using the mobile device (32) to further configure and program the control electronics to initialize the control electronics with reference to a specific system (14) by: a. Identifying the specific installation (14) and one or more sensors (26) associated with the specific installation (14) in order to generate the identity of the specific installation (14) and the associated sensors (26); b. Sending information from the mobile device to the control electronics, specifying the identity of the particular system (14) and the associated sensors (26); c. Configuring the control electronics to monitor the associated sensors (26) of the specified system (14) based on the information sent. [18] The method of claim 16, further comprising: Storing a code that identifies a specific sensor (26) in the mobile device; Receiving and storing multiple sensor parameter values ​​in the mobile device, wherein the sensor parameter values ​​correspond to a parameter detected by the specified sensor (26); Recording a timestamp in association with each parameter value corresponding to the time at which each parameter value was generated; Receiving and storing multiple sensor signal values ​​and timestamps according to the magnitudes of the sensor signal from the specified sensor (26) at multiple times; Using the timestamps to associate stored sensor parameter values ​​with stored sensor signal values ​​to generate multiple value pairs, where each value pair includes a sensor parameter value and a sensor signal value; and Using the value pairs to configure the programming of the control electronics to linearize the sensor signal from the specified sensor (26). [19] The method of claim 16, further comprising: Creating a maintenance technician using the mobile device and sending the maintenance command to the electronics (16); and Responding to the maintenance command by modifying the programming of the control electronics to prevent the sending of a specific command type.

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