Processing device and physical quantity detection device

Abstract

To enable easy retrofitting of a physical quantity detection function, exchange of a physical quantity detection function, or replacement of a battery employed for the physical quantity detection function.SOLUTION: A processing device 10 comprises an acquisition circuit provided in an actuator that pneumatically operates a valve V, the acquisition circuit configured to acquire a physical quantity of air detected by a sensor 11 disposed at an atmosphere vent port (second port 21B) through which air passes at the time of operating the valve V, and a processing execution circuit that executes processing based on the physical quantity acquired by the acquisition circuit. The processing device 10 performs valve diagnosis as the processing. The processing device 10 may further comprise the sensor 11 and a fixing structure 14 fixing the sensor 11 to the atmosphere vent port.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a processing device and a physical quantity detection device. [Background technology]

[0002] When diagnosing or controlling field devices such as valves used in petrochemical plants, some physical quantity occurring in the field devices is detected and processed. Patent Document 1 discloses a system that detects the angle change of a valve stem, which is such a physical quantity, and compares transition vectors based on the detected angle change to monitor whether or not the field devices are malfunctioning. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Special Publication No. 2015-528085 Summary of the Invention [Problem to be solved by the invention]

[0004] Field devices are generally used for a long period of time. For this reason, older field devices may not have a function for detecting physical quantities. In such cases, there is a demand for retrofitting existing field devices with a detection function. In addition, for field devices that have been used for a long period of time, it may be necessary to replace the entire device that realizes the function for detecting physical quantities or the battery of that device.

[0005] An object of the present invention is to facilitate retrofitting of a physical quantity detection function, replacement of the physical quantity detection function, or replacement of a battery used for the physical quantity detection function. [Means for solving the problem]

[0006] In order to solve the above problems, the processing device according to the present invention includes an acquisition circuit that is provided in an operating device that pneumatically operates a field device and acquires a physical quantity of the air detected by a sensor placed in an air vent through which air passes when the field device is operated, and a processing execution circuit that executes processing based on the physical quantity acquired by the acquisition circuit.

[0007] The physical quantity detection device according to the present invention is provided in an operating device that pneumatically operates a field device, and includes a sensor that is disposed in an air-opening port through which air passes when the field device is operated, and that detects a physical quantity of the air, and a fixing structure that fixes the sensor to the air-opening port. [Effects of the Invention]

[0008] According to the present invention, it is easy to retrofit a function for detecting a physical quantity, to replace the function for detecting a physical quantity, or to replace the battery used for the function for detecting a physical quantity. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a configuration diagram of a processing device according to an embodiment of the present invention and a pneumatic circuit in which the processing device is used. [Figure 2] FIG. 2 is a configuration diagram of a processing device according to an embodiment of the present invention and a pneumatic circuit in which the processing device is used. [Figure 3] FIG. 3 is a configuration diagram of the processing device. [Figure 4] FIG. 4 is a configuration diagram of an arithmetic unit included in the processing device. [Figure 5] FIG. 5 is a flowchart of the diagnostic process. [Figure 6] FIG. 6 is a configuration diagram of a processing device according to a modified example. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, this embodiment will be described with reference to the drawings.

[0011] As shown in Figures 1 and 2, a processing device 10 according to this embodiment is used while being fixed to an actuator 20 that drives a valve V to open and close a fluid flow path F. The valve V is driven by a pneumatic circuit 100 that includes the actuator 20, a solenoid valve 30, an air supply source 40, and air pipes L1 and L2. Figure 1 shows a state in which the flow path F is open, and Figure 2 shows a state in which the flow path F is closed. The flow path F is normally open. Below, each element of the pneumatic circuit 100 will be described, followed by a description of the processing device 10.

[0012] The operating device 20 includes a cylinder 21, a piston 22, an elastic body 23, and a valve stem 24.

[0013] The space within the cylinder 21 is divided into a first chamber R1 and a second chamber R2 by the piston 22. The cylinder 21 has a first port 21A formed as a through-hole that connects the first chamber R1 to the outside, and a second port 21B formed as a through-hole that connects the second chamber R2 to the outside. The first port 21A is connected to an air pipe L1. The second port 21B is not connected to an air pipe or the like and is open to the atmosphere. In other words, the second port 21B is an air-opening port that is open to the atmosphere.

[0014] The elastic body 23 is made of a spring or the like, is housed in the second chamber R2, and urges the piston 22 to be positioned at the first position in Fig. 1. The valve shaft 24 passes through the cylinder 21 and has one end connected to the piston 22 and the other end (not shown) directly or indirectly connected to the valve body (not shown) of the valve V.

[0015] The solenoid valve 30 includes a cylinder 31, a valve element 32, an iron core 33, an elastic body 34, and an electromagnet 35. The cylinder 31 has first to third ports 31A to 31C, each of which is a through hole. An air pipe L1 is connected to the first port 31A. That is, the first port 31A is connected to the first port 21A of the actuator 20 via the air pipe L1. The second port 31B is connected to the air supply source 40 via the air pipe L2. The third port 31C is open to the atmosphere.

[0016] When the valve element 32 is in the position shown in Fig. 1, it connects the first port 31A and the third port 31C, and when it is in the position shown in Fig. 2, it connects the first port 31A and the second port 31B. The elastic body 34 biases the valve element 32 to the position shown in Fig. 1. The electromagnet 35 functions as a magnet when a current is supplied from the controller C. The electromagnet 35 as a magnet attracts the iron core 33, thereby moving the valve element 32.

[0017] When the controller C receives a command from the host device 90 to close the flow path F, it applies current to the electromagnet 35 of the solenoid valve 30. This causes the electromagnet 35 to function as a magnet and attract the iron core 33. As a result, the valve element 32 moves to the position shown in FIG. 2 against the biasing force of the elastic body 34. This movement connects the second port 31B and the first port 31A, and air (here, compressed air) from the air supply source 40 is supplied to the second chamber R2 via the second port 31B, the space within the cylinder 31, the first port 31A, and the air piping L1 (see arrow A1). This air supply pushes the piston 22 of the actuator 20 toward the second chamber R2, moving the piston 22 to the position shown in FIG. 2 against the biasing force of the elastic body 23. The movement of the piston 22 moves the valve element of the valve V via the valve stem 24, closing the flow path F. Furthermore, the movement of the piston 22 pushes the air in the second chamber R2 out through the second port 21B to the atmosphere (see arrow A2), thereby discharging the air in the second chamber R2.

[0018] When the controller C receives a command from the host device 90 to open the flow path F, it stops supplying air to the electromagnet 35 of the solenoid valve 30. In this case, the magnetic force of the electromagnet 35 disappears, causing the elastic body 34 to move the valve element 32 to the position shown in FIG. 1. This movement connects the first port 31A and the third port 31C. The elastic body 23 of the actuator 20 moves the piston 22 to the position shown in FIG. 1, forcing air from the first chamber R1 out of the first port 21A. The forced air passes through the air pipe L1, the first port 31A, the space within the cylinder 31, and the third port 31C, and is exhausted to the atmosphere (see arrow A3 in FIG. 1). As the piston 22 moves to the position shown in FIG. 1, atmospheric air is drawn into the second chamber R2 from the second port 21B (see arrow A4 in FIG. 1).

[0019] 3, the processing device 10 includes a sensor 11 that detects the physical quantity of air flowing in and out of the second port 21B of the controller 20, i.e., the air-opening port, a calculation device 12 that processes the output of the sensor 11, and a battery 13 that supplies driving power to the sensor 11 and the calculation device 12. The supply of driving power from the battery 13 to the sensor 11 includes supply via the calculation device 12.

[0020] The sensor 11 detects the flow velocity of the air flowing in and out of the second port 21B, i.e., the air open port, as the physical quantity of the air, and outputs the detected value to the calculation device 12. For example, the sensor 11 detects the physical quantity of the air by converting the physical quantity of the air into an electric signal, and outputs the converted electric signal to the calculation device 12. The air flow velocity is expressed as a positive value in the direction of arrow A2 in FIG. 1 (exhaust direction), and as a negative value in the direction of arrow A4 in FIG. 2.

[0021] The arithmetic device 12 is a computer such as a microcomputer. The arithmetic device 12 includes a processor 12A such as a CPU (Central Processing Unit), a storage device 12B that stores programs and data executed or used by the processor 12A, a main memory 12C that provides a working area for the processor 12A, and a communication module 12D that is used for communication between the processor 12A and the outside of the arithmetic device 12.

[0022] The processor 12A executes the programs stored in the storage device 12B, thereby functioning as an acquisition circuit 12P and a processing execution circuit 12Q shown in FIG.

[0023] The acquisition circuit 12P acquires the physical quantity of the air output by the sensor 11 and detected by the sensor 11. For example, the acquisition circuit 12P acquires the physical quantity of the air by taking in the electrical signal into which the physical quantity of the air is converted by the sensor 11 and deriving the value of the physical quantity of the air based on the electrical signal. The acquisition circuit 12P may include an analog-to-digital conversion circuit, which is built into or external to the processor 12A, and converts the analog electrical signal from the sensor 11 into a digital electrical signal. The acquisition of the physical quantity is performed periodically.

[0024] The processing execution circuit 12Q performs a predetermined process based on the physical quantities acquired by the acquisition circuit 12P. For example, the processing execution circuit 12Q performs a process of diagnosing the state of the valve V based on the pattern of time-varying changes in the physical quantities sequentially acquired by the acquisition circuit 12P (details will be described later). The processing execution circuit 12Q outputs the diagnosis result to the higher-level device 90 via the communication module 12D wirelessly or via a wired connection.

[0025] The processing device 10 has a fixing structure 14 that supports the sensor 11, the computing device 12, and the battery 13 and fixes them to the second port 21B of the controller 20, which is an open-air port. The fixing structure 14 is made of a generally cylindrical member. The fixing structure 14 includes a first cylindrical portion 14A that fits into the second port 21B and fits into the inner wall of the second port 21B, and a second cylindrical portion 14B that is thicker than the first cylindrical portion 14A and connected to the first cylindrical portion 14A so as not to enter the second port 21B. The outer shape of the first cylindrical portion 14A is shaped to match the shape of the second port 21B. For example, if the second port 21B is circular, the outer circumferential surface of the first cylindrical portion 14A will be cylindrical. The outer shape of the second cylindrical portion 14B is arbitrary.

[0026] The second cylindrical portion 14B accommodates the sensor 11, the computing device 12, and the battery 13. The sensing portion of the sensor 11 is provided so as to be exposed from the inner wall of the second cylindrical portion 14B to the internal space 14C (the space that communicates with the second chamber R2 and the outside air). This allows the sensor 11 to detect the physical quantity of the air passing through the second port 21B (see arrows A2 and A4) when transitioning from the state shown in FIG. 1 to the state shown in FIG. 2 or vice versa.

[0027] Here, the details of the processing execution circuit 12Q will be described. The processing execution circuit 12Q stores, in the storage device 12B or the main memory 12C, physical quantities for a predetermined period going back from the present, among the physical quantities periodically acquired by the acquisition circuit 12P. When a new physical quantity is acquired, the processing execution circuit 12Q stores the new physical quantity and discards the oldest physical quantity among the physical quantities being stored. In this way, the storage device 12B or the main memory 12C stores the most recent change in the physical quantity over time. The processing execution circuit 12Q stores these physical quantities and also executes the diagnostic processing shown in FIG. 5.

[0028] In the diagnostic process shown in FIG. 5, the process execution circuit 12Q determines whether the absolute value of the rate of change over time of a physical quantity (here, flow velocity) stored in the storage device 12B or the main memory 12C (for example, the absolute value of the average slope, or the value obtained by subtracting the minimum value from the maximum value of the physical quantity) exceeds a predetermined threshold value (step S11).

[0029] If the degree of change exceeds a predetermined threshold (step S11; Yes), the processing execution circuit 12Q determines whether the pattern of the time change of the physical quantity is an increase in the positive direction (step S12).

[0030] If the pattern of time-varying changes in the physical quantity is an increase in a positive direction (step S12; Yes), it means that air is being exhausted from the second port 21B as indicated by arrow A2 in FIG. 2. In such a case, the process execution circuit 12Q diagnoses whether the pattern of time-varying changes in the physical quantity is normal using a first diagnostic model for which necessary data is prepared in the storage device 12B (step S13). If the pattern of time-varying changes in the physical quantity is an increase in a negative direction (step S12; No), it means that air is being taken in from the second port 21B as indicated by arrow A4 in FIG. 1. In such a case, the process execution circuit 12Q diagnoses whether the pattern of time-varying changes in the physical quantity is normal using a second diagnostic model for which necessary data is prepared in the storage device 12B (step S14).

[0031] The first and second diagnostic models may include, for example, predetermined functions, thresholds, etc. The first and second diagnostic models may include one or more functions that calculate the degree of similarity between the change in the pattern of time-varying physical quantities and the change in the normal state, and derive a diagnostic result for the valve V based on the degree of similarity. Such first and second diagnostic models may be constructed by machine learning using, for example, data on the change in time of the physical quantities (flow velocity) of air passing through the second port 21B when the valve V normally closes or opens the flow path F as correct learning data. The first and second diagnostic models may include, for example, one or more functions that calculate statistics of the pattern of time-varying physical quantities, compare the statistics with a predetermined threshold, and derive a diagnostic result based on the comparison result.

[0032] The first and second diagnostic models output "normal" or "abnormal" as the diagnostic result. The first and second diagnostic models may output any of "normal," "warning," and "abnormal" as the diagnostic result. A warning indicates a state that is close to abnormal but requires attention, although it cannot be said to be abnormal. In this case, if thresholds are used, two thresholds are prepared, one for abnormality and one for warning. The diagnostic result may be a combination of multiple states, such as "normal" and "abnormal," and the likelihood (probability) of each state.

[0033] The processing execution circuit 12Q outputs the diagnostic result to the higher-level device 90 via the communication module 12D (step S15). The higher-level device 90 stores the diagnostic result from the processing execution circuit 12Q in a predetermined storage device, and displays the diagnostic result on a display unit or the like to notify an operator of the plant including the valve V. After step S15, step S11 is executed again.

[0034] If the process execution circuit 12Q determines in step S11 that the absolute value of the degree of change does not exceed the predetermined threshold value (step S11; No), it executes step S11 again, thereby excluding the pattern of time change of the physical quantity due to noise such as outside wind from the diagnosis target.

[0035] As described above, in this embodiment, the processing device 10 including the sensor 11, the arithmetic device 12 (the acquisition circuit 12P and the processing execution circuit 12Q), and the battery 13 is disposed by the fixing structure 14 at the second port 21B, which is the air-opening port of the operator 20 of the valve V. Because the air-opening port faces the atmosphere, it is easily accessible for an operator. This makes it easy to retrofit or replace the processing device 10 (especially the physical quantity detection function realized by the sensor 11), and also makes it easy to replace the battery 13.

[0036] While valve position sensors that measure the position of the valve stem can be used in the above-described valve diagnosis, they require a certain size and precise installation, making retrofitting to existing valves difficult. Another approach is to monitor supply air pressure and use changes in supply air pressure, which correlate with changes in valve position, as an indirect valve position sensor. However, even in the case of supply air pressure, measurements are taken inside the air piping. In practice, this requires temporarily suspending the plant, removing the valve, disconnecting the air piping, installing a pressure sensor, and then reinstalling the valve. This makes retrofitting a pressure sensor difficult. In this embodiment, sensors 11 and the like are installed at the air-opening port. Opening to the atmosphere means that the sensor is not inside a sealed air piping, so a pressure sensor can be retrofitted without disconnecting the air piping. This facilitates retrofitting. Furthermore, measuring supply air pressure in diagnostics may potentially enable observation of the behavior and abnormalities of the air supply source in addition to the behavior and abnormalities of the valve. However, if the focus is on diagnosing the valve, observing the air supply source is not essential, and the behavior or abnormalities of the air supply source can be a confusing noise element. In contrast, when sensor 11 is attached to the air vent as in this embodiment, it is possible to eliminate noise elements caused by the air supply source.

[0037] Furthermore, by having the processing execution circuit 12Q perform the diagnostic processing, it becomes easy to retrofit or replace a diagnostic function, or to replace the battery 13. Furthermore, the processing execution circuit 12Q determines whether a change in physical quantity is caused by an operation of a field device (for example, step S11), and does not perform the diagnostic processing if the change is not caused by the operation (for example, step S11; No), thereby suppressing the execution of unnecessary diagnoses caused by noise such as wind.

[0038] The present embodiment can be modified in various ways. The following will list configurations including at least some of the configurations of the above embodiment and modifications thereof.

[0039] A processing device comprising: an acquisition circuit that is provided in an operating device that pneumatically operates a field device and that acquires a physical quantity of air detected by a sensor located in an air-opening port through which air passes when the field device is operated; and a processing execution circuit that executes processing based on the physical quantity acquired by the acquisition circuit. With this configuration, the sensor is located in the air-opening port, making it easy to detect the physical quantity, i.e., to later install a sensor, replace the sensor, or replace a battery used in the sensor.

[0040] Although the valve V is exemplified above as the field device, the field device may be a double-acting valve, or may be an on-off valve or an adjustable valve (control valve) with an adjustable opening. The field device may also be other devices used in a plant, etc. The operating device is the actuator 20 in the above, but it may also be a solenoid valve 30, etc. Even when the operating device is the actuator 20, the open-to-atmosphere port may be the third port 31C. When the operating device is the solenoid valve 30, the open-to-atmosphere port may also be the third port 31C. When the operating device is the solenoid valve 30, the field device may be considered to be the actuator 20.

[0041] The sensor detecting the physical quantity of air acquired by the acquisition circuit may detect the flow rate and / or air pressure instead of or in addition to the flow velocity. When the pattern of time change of the physical quantity is the same for intake and exhaust, the processing execution circuit may, for example, perform both a diagnosis using the pattern of time change of the physical quantity and a first diagnostic model and a diagnosis using the pattern and a second diagnostic model, and output both the diagnostic results of the first diagnostic model and the second diagnostic model. The processing execution circuit may acquire the content of an operation instruction to the operation device (e.g., an instruction to open or close the flow path) from outside the processing device (e.g., a controller or a higher-level device) wirelessly or via a wired connection, and select the model to be used for diagnosis from the first diagnostic model and the second diagnostic model depending on the content of the operation instruction. In this way, a model may be prepared for each content of the operation instruction, and the model to be used may be selected depending on the content of the operation instruction. Furthermore, the diagnosis using the diagnostic model may include determining whether the pattern of time change of the physical quantity of air at this time is intake or exhaust. Note that the various models may be sequentially updated based on the detected pattern of time change of the physical quantity. In such cases, the correct answer data may be provided by a person.

[0042] The processing device may be configured as a device located away from the sensor 11, such as a server computer as the host device 90. In such a case, a transmission circuit is further provided to transmit the physical quantity detected by the sensor 11 disposed at the atmospheric opening to the processing device wirelessly or via a wire.

[0043] The process may include, but is not limited to, a diagnostic process for diagnosing the status of the field device. This facilitates retrofitting a sensor, replacing the sensor, or replacing the battery used in the sensor, which detects a physical quantity used in the diagnosis. The diagnostic process may also include diagnosing the status of a pneumatic circuit that supplies air to an operating device, in addition to diagnosing the status of the field device. In such a case, when at least one of multiple devices, such as a device constituting the pneumatic circuit or a field device, malfunctions or breaks down, a model for diagnosis may be prepared by machine learning using training data that combines the pattern of time changes in the physical quantity with the malfunctioning or broken device. The diagnostic results using this model also identify the device causing the abnormality or warning when it occurs. The process may also be feedback processing, in which the detected physical quantity is used as a feedback value.

[0044] The processing may include a process of outputting the physical quantities to a device external to the processing device, such as a host device 90. In such a case, the physical quantities may be stored in the host device 90, and the host device 90 may perform the same diagnostic processing as described above based on the stored physical quantities.

[0045] The processing device may further include the sensor, whereby the entire processing device is disposed in the air-opening port, making it easy to install or replace the processing device later.

[0046] The processing device may further include a fixing structure for fixing the sensor to the atmosphere opening. This also facilitates retrofitting and replacement of the processing device. The shape of the fixing structure is arbitrary. For example, the fixing structure may be fixed to a part of the inner wall of the atmosphere opening.

[0047] The fixed structure may support a battery that provides power to operate the processing device (especially the sensor), thereby facilitating battery replacement. The processing device may be powered by a mains power supply or the like.

[0048] The fixing structure may be configured to include a passage suppression unit that suppresses air from passing through the atmosphere vent when the field device is not in operation. For example, when an exhaust port of a solenoid valve or the like is used as an atmosphere vent, the atmosphere vent may be used exclusively for exhaust. In such a case, as shown in FIG. 6, the fixing structure 14 may include a passage suppression unit 14F, such as a check valve or a windproof hood, that suppresses the inflow of external wind into the internal space 14C (a windproof hood in FIG. 6), so that noise such as wind is not detected by the sensor.

[0049] The processing execution circuit may determine whether the change in the physical quantity is caused by an operation of the field device, and may not execute the processing if the change is not caused by the operation. A specific example of this is step S11, but the processing execution circuit may also make the determination based on a pattern of time-varying physical quantities and a model that identifies patterns of time-varying physical quantities caused by noise, which is prepared in advance by machine learning or the like.

[0050] The processing device does not need to have an acquisition circuit and a processing execution circuit. In such a case, the processing device is a physical quantity detection device that is provided in an operating device that pneumatically operates a field device, is arranged in an air vent through which air passes when the field device is operated, and includes a sensor that detects a physical quantity of the air, and a fixing structure that fixes the sensor to the air vent. The physical quantity detected by the sensor may be output to the outside, for example, via a wire or wirelessly.

[0051] Although the present invention has been described above with reference to the embodiments and modifications, the present invention is not limited to the above embodiments and modifications. For example, the present invention includes various modifications to the above embodiments and modifications that can be understood by a person skilled in the art within the scope of the technical concept of the present invention. The configurations listed in the above embodiments and modifications can be combined as appropriate within a range that does not contradict. Furthermore, the omission of each configuration is optional. [Explanation of symbols]

[0052] 10 Processing device, 11 Sensor, 12 Arithmetic unit, 12A Processor, 12B Storage device, 12C Main memory, 12D Communication module, 12P Acquisition circuit, 12Q Processing execution circuit, 13 Battery, 14 Fixing structure, 14A First cylindrical portion, 14B Second cylindrical portion, 14C Internal space, 14F Passage suppression portion, 20 Actuator, 21 Cylinder, 21A First port, 21B Second port, 22 Piston, 23 Elastic body, 24 Valve stem, 30 Solenoid valve, 31 Cylinder, 31A First port, 31B Second port, 31C Third port, 32 Valve body, 33 Iron core, 34 Elastic body, 35 Electromagnet, 40 Air supply source, 90 Host device, 100 Pneumatic circuit, C Controller, F Flow path, L1 Air piping, L2 Air piping, R1 First chamber, R2 Second chamber, V Valve.

Claims

1. an acquisition circuit that is provided in an operating device that pneumatically operates a field device and acquires a physical quantity of the air detected by a sensor disposed in an air vent through which air passes when the field device is operated; a processing execution circuit that executes processing based on the physical quantity acquired by the acquisition circuit; A processing device comprising:

2. the processing includes a diagnostic processing for diagnosing a state of the field device; The processing device of claim 1 .

3. the processing includes a process of outputting the physical quantity to an external device of the processing device; The processing device of claim 1 .

4. Further comprising the sensor. The processing device of claim 1 .

5. Further provided is a fixing structure for fixing the sensor to the atmosphere opening. The processing device of claim 1 .

6. the stationary structure supports a battery that provides power to operate the processing device; The processing device according to claim 5 .

7. the fixing structure includes a passage suppression portion that suppresses air from passing through the atmosphere opening when the field device is not in operation. The processing device according to claim 5 .

8. the processing execution circuit determines whether the change in the physical quantity is caused by an operation of the field device, and does not execute the processing if the change is not caused by the operation; The processing device of claim 1 .

9. a sensor provided in an operating device that pneumatically operates a field device, the sensor being disposed in an air opening through which air passes when the field device is operated, the sensor detecting a physical quantity of the air; a fixing structure for fixing the sensor to the atmosphere opening; A physical quantity detection device comprising:

Images