Modular valve controller system

Abstract

Examples described herein provide a system that includes a controller and a plurality of nodes in communication with the controller and arranged in a node tree structure. The controller is configured to detect a miswiring condition or a node replacement based at least in part on the node tree structure and a unique identifier associated with each of the plurality of nodes. At least one of the plurality of nodes is configured to perform fault detection.

Description

MODULAR VALVE CONTROLLER SYSTEMBACKGROUND

[0001] Embodiments described herein generally relate to energy management, and more specifically, to a modular valve controller system and data acquisition system.

[0002] An industrial reciprocating compressor is a positive displacement compressor that uses a piston to compress gas. Such compressors are used in various industries, such as chemical processing, gas refineries, gas transportation, manufacturing, and / or the like, including combinations and / or multiples thereof.

[0003] Gas operated infinite step controllers are used in industrial reciprocating compressor designs that utilize a gas source to control an inlet valve system for one or more cylinder chambers of the reciprocating compressor. Gas operated infinite step controllers use gas (as opposed to electrical or mechanical means) to function. Such controllers make continuous, fine adjustments, such as to the inlet valve system for cylinder chambers, to provide precise control over the compressor’s operation.SUMMARY

[0004] According to an embodiment, a system is provided. The system includes a controller and a plurality of nodes in communication with the controller and arranged in a node tree structure. The controller is configured to detect a miswiring condition or a node replacement based at least in part on the node tree structure and a unique identifier associated with each of the plurality of nodes. At least one of the plurality of nodes is configured to perform fault detection.

[0005] According to another embodiment, a method is provided. The method includes providing a controller and a plurality of nodes in communication with the controller and arranged in a node tree structure, wherein each of the plurality of nodes is associated with one of a plurality of valve actuators. The method further includes detecting a miswiring condition or anode replacement based at least in part on the node tree structure and a unique identifier associated with each of the plurality of nodes. The method further includes performing fault detection for at least one of the plurality of valve actuators.

[0006] The above features and advantages, and other features and advantages, of the disclosure are readily apparent from the following detailed description when taken in connection with the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The specifics of the exclusive rights described herein are particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features and advantages of one or more embodiments described herein are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

[0008] FIGS. 1A-1E depict isometric and cross-sectional views, respectively, of an embodiment of a gas operated infinite step valve assembly according to one or more embodiments;

[0009] FIG. 2 depicts a portion of a reciprocating compressor cylinder assembly showing the compressor chamber with a gas operated infinite step valve assembly according to one or more embodiments;

[0010] FIG. 3A is a block diagram of an overall system architecture of a controller according to one or more embodiments;

[0011] FIG. 3B depicts a partial section of FIG. 3 A and shows one of the nodes of FIG. 3 A in more detail;

[0012] FIGS. 3C and 3D depict an example of one of the actuator / sensor nodes of FIG. 3A according to one or more embodiments;

[0013] FIGS. 3E and 3F depicts an example of the machine node of FIG. 3 A according to one or more embodiments;

[0014] FIGS. 3G and 3H depicts an example of the controller of FIG. 3A according to one or more embodiments;

[0015] FIG. 4 depicts a node tree structure according to one or more embodiments;

[0016] FIG. 5 depicts the node tree structure of FIG. 4 with a node replaced by another node according to one or more embodiments;

[0017] FIG. 6 depicts an exemplary node with a mis wire of a node of the node tree structure of FIG. 4 according to one or more embodiments;

[0018] FIG. 7 depicts graphs for coil diagnostics for a solenoid according to one or more embodiments;

[0019] FIG. 8 depicts a graph indicative of pneumatic valve diagnostics, such as measuring the movement of pintle by measuring the change of inductance of the moving valve versus the stationary valve, according to one or more embodiments;

[0020] FIG. 9 depicts a sensor and a graph for valve motion sensing according to one or more embodiments;

[0021] FIG. 10 depicts an embodiment of a sending / actuating assembly according to one or more embodiments;

[0022] FIG. 11 shows a flow diagram of a method for miswiring / replacement detection and fault detection according to one or more embodiments; and

[0023] FIG. 12 shows a processing system for miswiring / replacement detection and fault detection according to one or more embodiments.DETAILED DESCRIPTION

[0024] The figures discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitablyarranged device. The numerous innovative teachings of the present application will be described with reference to exemplary non-limiting embodiments.

[0025] One or more embodiments described herein provide for miswiring / replacement detection and fault detection.

[0026] FIGS. 1-1E and FIG. 2, which are now described together, depict isometric assembly and component views, respectively, of an embodiment of a gas operated infinite step valve assembly 100 and compressor cylinder assembly. The gas operated infinite step valve assembly 100 includes an unloader control valve 102, a compressor inlet valve assembly 104, a compressor cylinder valve cover 105, and a control valve actuator 106 coupled to a cylinder chamber of a reciprocating compressor 108 (see FIG. 2).

[0027] According to one or more embodiments, the gas operated infinite step valve assembly 100 can be controlled, in whole or in part, by a controller and a node associated with the gas operated infinite step valve 100. For example, a controller can be in communication with a “node” (e.g., node 304 shown in FIGS. ID and IE, among others) that is associated with (e.g., mechanically coupled to) the gas operated infinite step valve 100. The controller can send signals to the node, such as via an electrical cable, the signals controlling the control valve actuator 106, for example, using a solenoid 326 (shown in FIGS. ID and IE, among others). The controller and node are further described now with respect to at least FIGS. 3A-3F.

[0028] FIG. 3A shows an overall system architecture for a system 300 of a controller 302 for the gas operated infinite step valve 100 of FIG. 1 according to one or more embodiments. In an embodiment, the overall system architecture 300 includes the controller 302 and nodes 304, 306 in communications with the controller 302. The nodes 304 represent actuator / sensor nodes (also referred to simply as “pucks,” “valve pucks,” or “cylinder pucks”) that provide sensor information, such as an actuator coil sensor, and actuation signals, such as commands to a pneumatic valve. The nodes 304 can be associated with gas operated infinite step valves, such as the gas operated infinite step valve 100 of FIG. 1. The node 306 represents a machine node that is associated with a machine other than a gas operated infinite step valve. The machine node can collect data (e.g., sensor data) from the machine and transmit the data to the controller 302. Themachine node 306 can also receive commands from the controller 302 and cause the machine to implement those commands.

[0029] The controller 302 can connect to a programmable logic controller (PLC) 310 via a machine puck 306 or ethernet port 354. The controller 302 can connect to a local human machine interface (HMI 312) directly via a port 354 and / or through a network 314 via a port 356. The controller 302 can also connect to a remote console 316 through the network 314 via the port 356. The controller can collect and store data as a data log in a data storage device 318, which connects to a port 358. The controller 302 also connects to the nodes 304, 306 via ports 360. According to one or more embodiments, the nodes 304, 306 are connected via a network called “PosLink”, which provides power, data and diagnostics over a standard cable.

[0030] According to one or more embodiments, each of the nodes 304 of FIG. 3A may include multiple separate nodes as shown in FIG. 3B. In particular, FIG. 3B is a partial section of FIG. 3A and shows one of the nodes 304 in more detail. In this example, the node 304 includes eight separate nodes 304a, 304b, 304c, 304d, 304e, 304f, 304g, 304h. The nodes 304a-304h are communicatively coupled together by cables. According to one or more embodiments, the nodes 304a-304h are configured in a node tree structure (see, e.g., FIG. 4) as follows: the node 304f is a “root node” and downlink ports of the node 304f are connected to an uplink port of the node 304e. A downlink port of the node 304e is connected to uplink ports of the nodes 304g and 304d. A downlink port of the node 304d is connected to uplink ports of the nodes 304b and 304c, and a downlink port of the node 304g is connected to uplink ports of the nodes 304h and 304a. In this way, nodes lower in the node tree structure send data back to the controller 304 through intermediate nodes in the node tree structure. For example, data from the node 304a is sent to the node 304g, which then sends the data to the node 304f, which sends the data to the controller 302.

[0031] FIGS. 3C and 3D depict an example of one of the actuator / sensor nodes (referred to as node 304) according to one or more embodiments. The node 304 (also referred to as a “valve puck”), includes an input port 322 (PosLink in), multiple output ports 324 (PosLink out), a solenoid 326, a resistance temperature detector (RTD) 328, an indicator light 330 (e.g., a light emitting diode (LED)), a power input 332, a 3-axis accelerometer 334, and a position sensor 336.

[0032] The input port 322 connects the node 304 to another node that is higher up the node tree structure (e.g., closer to a root node), and the output ports 324 connects the node 304 to other nodes that are lower down the node tree structure (e.g., farther away from the root tree node). In this way, the node 304 acts as a “splitter” to connect multiple other nodes to the node tree structure. Although two output ports 324 are shown, the node 304 can have other numbers of output ports.

[0033] The solenoid 326 controls the control valve actuator 106. The RTD 328 measures temperature data. The indicator light 330 indicates a status of the node 304 (e.g., powered on, error state, nominal operation, and / or the like, including combinations and / or multiples thereof). The 3-axis accelerometer 334 and the position sensor 336 monitor data associated with movement of the node 304, which is used to determine a geographic position and orientation (referred to as “pose”) of the node 304.

[0034] FIGS. 3E and 3F depict an example of the machine node (referred to as node 306) according to one or more embodiments. Similar to the node 304, the node 306 includes an input port (PosLink in) and multiple output ports (PosLink out). Although not shown, the node 306 can have other components or aspects, such as an accelerometer, a position sensor, an indicator light, digital I / O, other connectors, and / or the like, including combinations and / or multiples thereof.

[0035] FIGS. 3G and 3H depict an example of the controller 302 of FIG. 3A according to one or more embodiments. The controller 302 may have any number of (PosLink) ports, ethernet ports, and / or the like, including combinations and / or multiples thereof.

[0036] A node (e.g., one of the nodes 304) may be configured as an assembly that may be attached to the gas operated infinite step valve 100 and / or directly to the control valve actuator 106. The system 300 may include devices and algorithms to predict faults and minimize down time in valve controller maintenance, for example to differentiate types and immediacy of failures to minimize the number of parts needing replacement in the system. In an aspect, the systems and algorithms minimize wiring confusion and identify new modules when replaced, including for example, node replacement and simple-miswiring of replacement assembly and part identification and location for reinstallation during overhaul. One or more embodiments described herein advantageously include an integrated valve actuation and detection device thatcan correlate valve movement and vibration profile to filter high-g impact out from vibration data to find uneven or leaky valve seating in vibration data and provide dual temperature sensing, one inside the module the other inside the actuator body indicates net heat flow out of the valve body and possible valve leakage.

[0037] Features and functionality of the nodes 304, 306, and / or the controller 302, are now described in more detail, including miswiring / replacement detection and fault detection.

[0038] FIG. 4 depicts a node tree structure 400 according to one or more embodiments. The node tree structure 400 includes the controller 302 connected, directly or indirectly, to multiple nodes 401a, 401b, 401c, 402a, 402b, 402c, 402d, 402e, 402f, 403a, 403b, 403c, 403d (collectively referred to as “nodes 401-403”) configured and arranged as shown to form the node tree structure 400. The nodes 401-403 can be actuator / sensor nodes (e.g., the node 304) and / or machine nodes (e.g., the node 306). The nodes 401a, 401b, 401c form a first level and are referred to as “root nodes,” the nodes 402a, 402b, 402c, 402d, 402e, 402f form a second level and are referred to as “intermediate nodes,” and the nodes 403a, 403b, 403c, 403d form a third level and are referred to as “terminal nodes.” Three levels of nodes are shown but more are possible. A balanced network is shown but not required.

[0039] Each of the nodes 401-403 of the node tree structure 400 may have one upstream port (represented by a filled circle) and two (or more) downstream ports represented by an empty circle). Once the node tree structure 400 is implemented, the controller 302 maps the node tree structure 400 and stores the resulting node tree structure 400. In normal operation, setpoints are generated on the controller 302 and passed from node to node (e.g., from node 403a to node 402c, to node 401b). Data is collected from the nodes and passed to the various nodes higher up the node tree structure 400. According to one or more embodiments, nodes keep locally configured parameters (e.g., sensor gains) and learned parameters (e.g., proportional-integral- derivative (PID) feed-forward parameters).

[0040] Each of the nodes 401-403 has a universally unique identifier (referred to as the “node ID”), which may be a medium access control (MAC) address, a universally unique chip serial number, or a device serial number, or other numeric or alpha-numeric string. In an aspect, the controller 302 performs miswiring / replacement detection of the nodes 401-403 using thenode ID for nodes 401-403. According to one or more embodiments, the controller 302 provides checks to identify and correct wiring confusion. According to one or more embodiments, the controller 302 provides for identifying a new node when one of the nodes 401-403 is replaced and to identify parts and location for reinstallation during overhaul / maintenance. For example, if a node is replaced, the controller 302 uses the node ID to identify that the old node is missing / removed and that a new node is present. The controller 302 stores the node ID for each of the nodes 401-403. The controller 302 may periodically or aperiodically (e.g., responsive to a trigger event) compare the node IDs for the nodes 401-403 in the node tree structure 400 to determine whether those node IDs match the node IDs that are stored. According to one or more embodiments, the controller 302 can either auto-replace or ask for user confirmation of the replacement of a node. This can be extended to multiple nodes as long as the tree shape remains intact.

[0041] FIG. 5 depicts the node tree structure 400 with node 402d replaced by node 402d’ (highlighted) according to one or more embodiments. Periodically or upon the occurrence of a trigger event (e.g., user initiated, maintenance mode entered, etc.), the controller 302 validates that the nodes 401-403 are the same nodes as previously configured based on the stored node ID and location of the node in the node tree structure 400. When a node (e.g., node 402d) is replaced in the network with a new node (e.g., node 402d’), the controller 302 identifies the node ID associated with the replaced node (e.g., node 402d) in the list of stored node IDs and updates it with the node ID for the new node (e.g., the node 402d’). The controller 302 can also configure the new node (e.g., the node 402d’) using information collected by the old node (e.g., the node 402d), such as parameters learned over time. This provides the new node to benefit from historical information based on the old node.

[0042] A port swap detect function may also be implemented. If nodes on the downstream ports of a node are swapped, the controller 302 can detect a mirrored setup in the node tree structure 400. In such cases, the controller 302 may refuse to run or run in a limited capacity until the node wiring is restored or a re-configuration process is run to re-configure the node tree structure 400 to account for the miswiring. According to one or more embodiments, the controller 302 can prompt an operator to query whether this port swap was intentional. If so, the controller 302 can reconfigure the node tree structure 400 to account for the swap and accept itas a new node tree structure. If the swap was unintentional, the operator can restore the physical layout by correcting the port swap.

[0043] According to one or more embodiments, if the same set of node IDs are identified, but in a different order, the controller 302 can alert an operator of a miswiring. A miswiring is when a node is not wired in an expected way. For example, as described herein, a node may be connected to two other nodes via downlink ports. If, during reconfiguration or replacement those connections become swapped, as shown in FIG. 6, a miswiring is present. Particularly, FIG. 6 depicts an exemplary node with a miswire of the node (highlighted) according to one or more embodiments. The output ports of the nodes 401-403 may be physically identical according to one or more embodiments, which provides for common connection cables for all nodes. However, in some cases, cables can be swapped, resulting in a miswiring. If a miswire occurs, the controller 302 identifies the miswire by comparing known connections (e.g., it is known that the connection between the node 402d and the node 403 c should use a first port of the node 402d and a connection between the node 402d and the node 403 d uses a second port of the node 402d). The controller 302 can then alert an operator of the miswire, and the operator can correct the mistake. According to one or more embodiments, the controller 302 can accept the new wiring configuration and update the node tree structure 400 to reflect the change. If the nodes remain at the same depth of the node tree structure 400 and with the same parent node, the miswire may be accepted and the node tree structure 400 corrected / updated to reflect the miswire.

[0044] In another aspect, the angle and orientation of an installed node can be recorded to differentiate it from other installed nodes on the network. The controller 302 may log the 3-axis accelerometer data and store position data to assist with reinstallation. For example, when a node is removed and added back, accelerometer data and position data can be compared to known / expected accelerometer data / position data to determine whether the node is installed at the correct position / orientation. According to one or more embodiments, each component of a system (e.g., each node, each valve, each machine, etc.) can include an electronic identifier, such as a radio frequency identifier (RFID) or a near field communication (NFC) identifier, to identify and assist with reinstallation of the components back into the same system in the sameconfiguration. Because the components, for example, may need to be individually shimmed, the controller 302 logs which locations need which shims according to one or more embodiments.

[0045] One or more embodiments provide for determining a minimum subset of parts to replace in case of a faulty actuator. For example, 3-levels of fault determine minimum replacement parts and wear level based on, for example, coil diagnostics and pneumatic valve diagnostics. For example, an efficient part replacement strategy suggested by the system may include: if coil diagnostics fail, replace valve assembly; if pilot valve operation fails, replace pilot valve; if main valve motion fails, check air supply; if air supply good, replace main valve; and / or the like, including combinations and / or multiples thereof.

[0046] According to one or more embodiments, the controller 302 and / or the nodes (e.g., the nodes 304; the nodes 401-403) provide fault detection functionality to detect faults at the nodes. One type of failure is coil failure of a solenoid, which can be detected using coil diagnostics (e.g., FIG. 7). Another type of failure is a pneumatic valve failure, which can be detected using pneumatic valve diagnostics (e.g., FIG. 8). Yet another type of failure is a valve motion failure, which can be detected using valve motion sensing (e.g., FIG. 9). These fault detection approaches are not described in more detail with reference to FIGS. 7-9.

[0047] FIG. 7 depicts graphs 700, 701 for coil diagnostics for the solenoid (e.g., the solenoid 326) according to one or more embodiments. The graph 700 plots current over time, and the graph 701 plots voltage over time. Failure can be total failure of the coil, such as when either the coil opens and no current is sensed or the coil shorted and the pulses are a minimum time.According to one or more embodiments, one of the failure modes is incipient failure, such as the coil itself shorting out. The coil of the solenoid has a thin magnet wire and cycles many times. As the coil fails, it becomes evident that, for the same current, the inductance goes down, so the coil fires more times, which is indicated by measuring the current (e.g., graph 700). A change in time counter (At) is a higher pulse count when the coil is failing than when the coil is new, which indicates a potential failure.

[0048] According to one or more embodiments, coil diagnostics can be performed by active coil inductance measurement. This can include counting switch pulses per unit time, adjusting for peak / hold current profile and drive voltage, and dividing by time. If the count increases (e.g.,X% above a base / threshold), there is an insulation breakdown in the coil indicative of impending coil’s fault. In such cases, the controller 302 can notify an operator to replace the solenoid (e.g., at a next service interval). According to one or more embodiments, if a short is detected (e.g., by measuring if switch event is faster than X), the solenoid is faulty and needs to be immediately replaced. This is useful, especially in the context of multilevel, such as 3-level, diagnostics.

[0049] An expected failure mode in the node (e.g., the node 304, the nodes 401-403) may include a breakdown in the insulation on the coil wires. This will result in lower inductance and less force on the armature. Initially, the system will still work, and the closed loop control will deal with this minor failure. The purpose of this diagnostic is to identify this failure while the system is still running and classify which part needs to be replaced.

[0050] The coil may run a fixed and measured switch current. By counting the pulses of the PWM current controller and correcting for voltage and temperature, the inductance in the coil can be measured. A change in this inductance in the field indicates a short within the coil and that the module needs to be changed.

[0051] Turning now to FIG. 8, pneumatic valve diagnostics to detect pneumatic valve failure is described. Valve motion failure occurs when a valve is stuck. In particular, FIG. 8 depicts graphs 800, 801 indicative of pneumatic valve diagnostics, such as measuring the movement of pintle by measuring the change of inductance of the moving valve versus the stationary valve, according to one or more embodiments. The inductance of a solenoid with the pintle moving is less than the inductance of the solenoid with nothing moving. The change in inductance can be observed by a change in the slope, shown at the inflection 802. If the inflection 802 is not observed or the inflection 802 is later than expected, it can be determined that the valve is not moving (e.g., the valve is stuck) even if the solenoid is applying the proper field. According to one or more embodiments, the inductance may be lower during the ballistic phase, so the rate of current rise will be faster. This can be measured by analog measurement of the current profile (e.g., the graph 800) or the time analysis of the current control pulsetrain. In another embodiment, this can be measured by determining the time between the start of solenoid actuation and the end of pintle movement, and it can be determined whether the valve is getting sticky and that the valve assembly needs to be replaced soon. It can also be detected whether the valve is stuck by the lackof an inflection in the wave (graph 800), which indicates a need for immediate replacement. Other diagnostics may include: multi-level valve diagnostics, sense stroke of actuator, autocalibrates to largest extent of stroke, indication of a potential leak if stroke decreases, stuck valve if the stroke stops, cross-check across machine for differences, and / or the like, including combinations and / or multiples thereof.

[0052] Turning now to FIG. 9, valve motion sensing for detecting valve motion failure is now described. In particular, FIG. 9 depicts a sensor 900 and a graph 901 for valve motion sensing according to one or more embodiments. For example, measuring the resting angles 0i and O2 of the sensor 900, the extents of travel of a washer of the main valve can be determined as the a washer of the main valve travel between a first position 911 and a second position 912. Because of manufacturing tolerances in the valve assembly, the resting angles are unique for each valve. Changes in either 0i or 02 indicates a blockage. 03 is the midpoint of the sweep between the first position 911 and the second position 912 and is used for position feedback. Measuring the time between turn on and 02 (Ati) as well as turn off and 0i (At2) provides a travel time. In-field calibration of each valve assembly can then be performed based on results of the valve motion sensing (e.g., the travel time, that is the time between turn on and 02 ( Ati) as well as turn off and 01 (At2)).

[0053] The graph 901 plots a commanding signal 921 and an expected or desired signal 922. The node (or controller) identifies a crossing time 923. It is desirable for the crossing time to be at the desired compressor rotation. The time delays Ati and At2 are learned delays between driving signal and realization and can change based on environmental conditions (e.g., humidity in air, density of air, and / or the like, including combinations and / or multiples thereof), system age, compressor operating conditions, and / or the like, including combinations and / or multiples thereof. According to one or more embodiments, if a total failure or incipient failure is detected, one or more of the following actions can be implemented: shut down the machine, shut down the GIS system and keep the machine running, shut down the individual cylinder GIS functions, shut down the individual valve function and keep running, and / or the like, including combinations and / or multiples thereof. In incipient failure detection, the operator can be alerted to order parts, schedule service, etc., and can be prompted to selected one of the actions to be performed basedon the failure. That is, the operator can choose from the above actions to choose what action is desired to be performed automatically when incipient failure turns to total failure.

[0054] In FIG. 9, Delta T2 is not constant throughout the control range. Delta T1 depends on the air supply pressure to the solenoid 326 and the geometry of the control valve actuator 106. Delta T2 is a function of the overall pulse width 921. A feed-forward modifier to the PID controller for Delta T2 as a function of the pulse width of 921 provides a broader and more stable operating range of 922. Alternate model-based control strategies could be implemented to achieve the same results. This allows for adaptively controlling supply pressure to the machine or portions of the machine to reduce valve wear, etc.

[0055] FIG. 10 depicts an embodiment of a sending / actuating assembly 1000 configured to fit an existing control valve of a reciprocating compressor for remotely monitoring and controlling a status and action of the control valve according to one or more embodiments. For example, the assembly 1000 may include: a valve 1002, an integrated valve control assembly 1004 with data acquisition, and a single unit providing valve actuation 1006 and controlled by the integrated valve control assembly 1004. The integrated valve control assembly 104 provides networking and sensing functionality as described herein. According to one or more embodiments, the integrated valve control assembly 104 features a shallow V-shaped design, which allows keeping sensor on center-line and sliding housing on pneumatic actuator in one stroke. According to one or more embodiments, the integrated valve control assembly 104 has a “shark fin” shaped sensor housing, which allows sensor to be snugly fit in to assembly to reduce vibration and fill voids. According to one or more embodiments, the angle of the integrated valve control assembly 104 provides for sensing directly in line with a magnet and a slot inline with valve for easy assembly.

[0056] Advantages of the disclosed invention include: device and algorithms to predict faults and minimize down time in valve controller maintenance; ability to differentiate types and immediacy of failures to minimize the number of parts needing replacement; simpler installation with standard cabling to cylinders to allow “Plug and Play” implementation; elimination of current junction boxes and wiring; modular design; pre-manufacture of assemblies before installation; retains existing code base; per-valve actuation and balancing; integrated accelerometers; lower cost (~ 60% of standard panel for 4 throw compressor); customerinstallation cost is greatly reduced; and / or the like, including combinations and / or multiples thereof.

[0057] FIG. 11 shows a flow diagram of a method 1100 for miswiring / replacement detection and fault detection according to one or more embodiments. The method can be performed by any suitable device or system. For example, the method 1100 can be implemented using the controller 302 of FIG. 3A, one or more of the nodes 304, 306 of FIG. 3A, and / or the processing system 1200 of FIG. 12.

[0058] At block 1102, the method 1100 includes providing a controller (e.g., the controller 302) and a plurality of nodes (e.g., the nodes 304, 306, 401-403) in communication with the controller and arranged in a node tree structure (e.g., the node tree structure 400). Each of the plurality of nodes is associated with one of a plurality of valve actuators (e.g., the control valve actuator 106). At block 1104, the method 1100 includes detecting a miswiring condition or a node replacement based at least in part on the node tree structure and a unique identifier associated with each of the plurality of nodes. At block 1106, the method 1100 includes performing fault detection for at least one of the plurality of valve actuators.

[0059] Additional processes also may be included, and it should be understood that the processes depicted in FIG. 12 represent an illustration, and that other processes may be added or existing processes may be removed, modified, or rearranged without departing from the scope of the present disclosure. It should also be understood that the processes depicted in FIG. 12 may be implemented as programmatic instructions stored on a non-transitory computer-readable storage medium that, when executed by a processor of a computing system cause the processor to perform the processes described herein.

[0060] It is understood that one or more embodiments described herein is capable of being implemented in conjunction with any other type of computing environment now known or later developed. In examples, processing system 1200 has one or more central processing units (referred to also as “processors” or “processing resources” or “processing devices”) 1221a, 1221b, 1221c, etc. (collectively or generically referred to as processor(s) 1221 and / or as processing device(s)). In aspects of the present disclosure, each processor 1221 can include a reduced instruction set computer (RISC) microprocessor. Processors 1221 are coupled to asystem memory 1222 and / or various other components via a system bus 1233. The system memory 1222 can include one or more temporary and / or persistent memory devices, such as a random access memory (RAM) 1223, a read-only memory (ROM) 1224, and / or the like, including combinations and / or multiples thereof. The system bus 1233 may include a basic input / output system (BIOS), which controls certain basic functions of processing system 1200.

[0061] Further depicted are an input / output (I / O) adapter 1227 and a network adapter 1226 coupled to system bus 1233. I / O adapter 1227 may be a small computer system interface (SCSI) adapter that communicates with a hard disk 1235 and / or a storage device 1236 or any other similar component. I / O adapter 1227, hard disk 1235, and storage device 1236 are collectively referred to herein as mass storage 1234. Operating system 4120 for execution on processing system 1200 may be stored in mass storage 1234. The network adapter 1226 interconnects system bus 1233 with an outside network 1238 enabling processing system 1200 to communicate with other such systems.

[0062] A display (e.g., a display monitor) 1239 is connected to system bus 1233 by display adapter 1232, which may include a graphics adapter to improve the performance of graphics intensive applications and a video controller. In one aspect of the present disclosure, adapters 1226, 1227, and / or 1232 may be connected to one or more I / O buses that are connected to system bus 1233 via an intermediate bus bridge (not shown). Suitable I / O buses for connecting peripheral devices such as hard disk controllers, network adapters, and graphics adapters typically include common protocols, such as the Peripheral Component Interconnect (PCI). Additional input / output devices are shown as connected to system bus 1233 via user interface adapter 1228 and display adapter 1232. A keyboard 1229, mouse 1230, and speaker 1231 may be interconnected to system bus 1233 via user interface adapter 1228, which may include, for example, a Super VO chip integrating multiple device adapters into a single integrated circuit.

[0063] In some aspects of the present disclosure, processing system 1200 includes a graphics processing unit (GPU) 1237. Graphics processing unit 1237 is a specialized electronic circuit designed to manipulate and alter memory to accelerate the creation of images in a frame buffer intended for output to a display. In general, graphics processing unit 1237 is very efficient at manipulating computer graphics and image processing, and has a highly parallel structure thatmakes it more effective than general -purpose CPUs for algorithms where processing of large blocks of data is done in parallel.

[0064] Thus, as configured herein, processing system 1200 includes processing capability in the form of processors 1221, storage capability including the system memory 1222 and mass storage 1234, input means such as keyboard 1229 and mouse 1230, and output capability including speaker 1231 and display 1239. In some aspects of the present disclosure, a portion of system memory 1222 and mass storage 1234 collectively store the operating system 1240 to coordinate the functions of the various components shown in processing system 1200.

[0065] Those skilled in the art will recognize that, for simplicity and clarity, the full structure and operation of all systems suitable for use with the present disclosure is not being depicted or described herein. Instead, only so much of the physical systems as is unique to the present disclosure or necessary for an understanding of the present disclosure is depicted and described. The remainder of the construction and operation of the systems disclosed herein may conform to any of the various current implementations and practices known in the art.

[0066] It is important to note that while the disclosure includes a description in the context of a fully functional system, those skilled in the art will appreciate that at least portions of the mechanism of the present disclosure are capable of being distributed in the form of a instructions contained within a machine-usable, computer-usable, or computer-readable medium in any of a variety of forms, and that the present disclosure applies equally regardless of the particular type of instruction or signal bearing medium or storage medium utilized to actually carry out the distribution. Examples of machine usable / readable or computer usable / readable mediums include: nonvolatile, hard-coded type mediums such as read only memories (ROMs) or erasable, electrically programmable read only memories (EEPROMs), and user-recordable type mediums such as floppy disks, hard disk drives and compact disk read only memories (CD- ROMs) or digital versatile disks (DVDs). In particular, computer readable mediums can include transitory and non- transitory mediums, unless otherwise limited in the claims appended hereto.

[0067] Although an exemplary embodiment of the present disclosure has been described in detail, those skilled in the art will understand that various changes, substitutions, variations, and improvements disclosed herein may be made without departing from the spirit and scope ofthe disclosure in its broadest form. In particular, the features and operations of various examples described herein and in the incorporated applications can be combined in any number of implementations.

[0068] None of the description in the present application should be read as implying that any particular element, step, or function is an essential element which must be included in the claim scope: the scope of patented subject matter is defined only by the allowed claims. Moreover, none of these claims are intended to invoke 35 USC §112(f) unless the exact words “means for” are followed by a participle.

[0069] As used herein the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or” is inclusive, meaning and / or; the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like; and the term “controller” means any device, system or part thereof that controls at least one operation, whether such a device is implemented in hardware, firmware, software or some combination of at least two of the same. It should be noted that the functionality associated with any particular controller may be centralized or distributed, whether locally or remotely. Definitions for certain words and phrases are provided throughout this patent document, and those of ordinary skill in the art will understand that such definitions apply in many, if not most, instances to prior as well as future uses of such defined words and phrases. While some terms may include a wide variety of embodiments, the appended claims may expressly limit these terms to specific embodiments.

Claims

CLAIMSWhat is claimed is:

1. A system comprising: a controller; and a plurality of nodes in communication with the controller and arranged in a node tree structure, wherein the controller is configured to detect a miswiring condition or a node replacement based at least in part on the node tree structure and a unique identifier associated with each of the plurality of nodes, and wherein at least one of the plurality of nodes is configured to perform fault detection.

2. The system of claim 1, wherein at least one of the plurality of nodes is configured to control a valve actuator.

3. The system of claim 2, wherein the valve actuator is coupled to a reciprocating compressor.

4. The system of claim 1, wherein detecting the miswiring condition comprises comparing, by the controller, a present wiring configuration with an expected wiring configuration.

5. The system of claim 1, wherein detecting the node replacement comprises comparing the unique identifier of at least one of the plurality of nodes with expected unique identifiers for the node tree structure.

6. The system of claim 1, wherein a first node of the plurality of nodes comprises one uplink port connected to a port of the controller via a first cable.

7. The system of claim 6, wherein the first node of the plurality of nodes comprises a first downlink port and a second downlink port.

8. The system of claim 7, wherein a second node of the plurality of nodes is connected tothe first downlink port of the first node via a second cable and a third node of the plurality of nodes is connected to the second downlink port of the first node via a third cable.

9. The system of claim 1, wherein the fault detection comprises performing coil diagnostics for a solenoid associated with one of the plurality of nodes.

10. The system of claim 1, wherein the fault detection comprises performing pneumatic valve diagnostics for a valve associated with one of the plurality of nodes.

11. The system of claim 1, wherein the fault detection comprises performing valve motion sensing for a valve associated with one of the plurality of nodes, the valve motion sensing comprising performing in-field calibration of each valve assembly based on results of the valve motion sensing.

12. The system of claim 1, wherein, responsive to detecting the node replacement, transmitting, from the controller, configured parameters and learned parameters for an old node to a new node.

13. A method compri sing : providing a controller and a plurality of nodes in communication with the controller and arranged in a node tree structure, wherein each of the plurality of nodes is associated with one of a plurality of valve actuators; detecting a miswiring condition or a node replacement based at least in part on the node tree structure and a unique identifier associated with each of the plurality of nodes, and performing fault detection for at least one of the plurality of valve actuators.

14. The method of claim 13, wherein the unique identifier is one of a medium access control (MAC) address, a universally unique chip serial number, or a device serial number.

15. The method of claim 13, wherein a first node of the plurality of nodes comprises one uplink port connected to a port of the controller via a first cable.

16. The method of claim 15, wherein the first node of the plurality of nodes comprises a firstdownlink port and a second downlink port, wherein a second node of the plurality of nodes is connected to the first downlink port of the first node via a second cable and a third node of the plurality of nodes is connected to the second downlink port of the first node via a third cable.

17. The method of claim 13, wherein the fault detection comprises performing coil diagnostics for a solenoid associated with one of the plurality of nodes to detect an incipient failure or a total failure.

18. The method of claim 13, wherein the fault detection comprises performing pneumatic valve diagnostics for a valve associated with one of the plurality of nodes to detect an incipient failure or a total failure.

19. The method of claim 13, wherein the fault detection comprises performing valve motion sensing for a valve associated with one of the plurality of nodes to detect an incipient failure or a total failure, wherein the incipient failure is determined by comparing a measured time to a numerical model.

20. The method of claim 13, wherein the fault detection comprises: performing coil diagnostics for a solenoid associated with one of the plurality of nodes; performing pneumatic valve diagnostics for a valve associated with the one of the plurality of nodes; and performing valve motion sensing for a valve associated with the one of the plurality of nodes.

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