Modular input / output node

Abstract

Examples described herein provide a modular input / output (I / O) node. The modular I / O node includes an encapsulated housing mechanically coupled to a piece of industrial equipment via a single mechanical connection. The modular I / O node further includes a plurality of ports for electrically connecting the modular input / output node to another device. The modular I / O node further includes a printed circuit board electrically connected to the plurality of ports. The modular I / O node further includes an accelerometer electrically connected to the printed circuit board, the accelerometer being configured to collect movement data associated with the piece of industrial equipment, the movement data being used to determine an orientation of the modular input / output node relative to the piece of industrial equipment.

Description

MODULAR INPUT / OUTPUT NODEBACKGROUND

[0001] Embodiments described herein generally relate to energy management, and more specifically, to a modular input / output node.

[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 high-pressure 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.BRIEF SUMMARY

[0004] According to an embodiment, a modular input / output node is provided. The modular I / O node includes an encapsulated housing mechanically coupled to a piece of industrial equipment via a single mechanical connection. The modular I / O node further includes a plurality of ports for electrically connecting the modular input / output node to another device. The modular I / O node further includes a printed circuit board electrically connected to the plurality of ports. The modular I / O node further includes an accelerometer electrically connected to the printed circuit board, the accelerometer being configured to collect movement data associated with the piece of industrial equipment, the movement data being used to determine an orientation of the modular input / output node relative to the piece of industrial equipment.

[0005] According to another embodiment, a reciprocating compressor is provided. The reciprocating compressor includes a plurality of modular input / output nodes, each of the plurality of input / output nodes includes: an encapsulated housing mechanically coupled the reciprocating compressor, a plurality of ports for electrically connecting the modular input / output node to one another directly or indirectly via another device, a printed circuit board electrically connected to the plurality’ of ports, and an accelerometer electrically connected to the printed circuit board, the accelerometer being configured to collect movement data associated with the reciprocating compressor, the movement data being used to determine an orientation of the modular input / output node relative to the reciprocating compressor.

[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 SEVERAL VIEWS OF THE DRAWINGS

[0007] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0008] FIGS. 1 and 2 depict schematic diagrams of a modular input / output node according to one or more embodiments.

[0009] FIG. 3 depicts a schematic illustration of an alignment guide according to one or more embodiments.

[0010] FIGS. 4 and 5 illustrate line drawings of the modular input / output node of FIGS. 1 and 2 according to one or more embodiments.

[0011] FIG. 6 illustrates a shroud for the modular input / output node of FIGS. 1. 2. 4, and 5 according to one or more embodiments.

[0012] FIG. 7 illustrates a block diagram of a magnetic direction switch for detecting the shroud of FIG. 6 according to one or more embodiments.

[0013] FIGS. 8A and 8B depict views of a controller that includes a shroud according to one or more embodiments;

[0014] FIG. 9 illustrates a block diagram of a system architecture according to one or more embodiments; and

[0015] FIG. 10 illustrates an electrical schematic of a shroud detect circuit according to one or more embodiments.DETAILED DESCRIPTION

[0016] Before any embodiments are explained in detail, it is to be understood that such embodiments are not limited in their application to the details of construction and the arrangement of components set forth in this description or illustrated in the following drawings. Alternative embodiments can be devised without departing from the scope of the claims, and various embodiments are capable of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description should not be regarded as limiting.

[0017] Various technologies that pertain to systems and methods will now be described with reference to the drawings, where like reference numerals represent like elements throughout. The drawings 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 suitably arranged apparatus. It is to be understood that functionality that is described as being carried out by certain system elements may be performed by multiple elements. Similarly, for instance, an element may be configured to perform functionality that is described as being carried out by multiple elements. The numerous innovative teachings of the present application will be described with reference to exemplary non-limiting embodiments.

[0018] Also, it should be understood that the words or phrases used herein should be construed broadly, unless expressly limited in some examples. For example, the terms ■’including." “having,” and “comprising,” as well as derivatives thereof, mean inclusion without limitation. The singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Further, the term “and / or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. The term “or” is inclusive, meaning and / or, unless the context clearly indicates otherwise. 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. Furthermore, while multiple embodiments or constructions may be described herein, any features, methods, steps, components, etc. described with regard to one embodiment are equally applicable to other embodiments absent a specific statement to the contrary.

[0019] Also, although the terms “first,” “second,” “third,” and so forth may be used herein to refer to various elements, information, functions, or acts, these elements, information, functions, or acts should not be limited by these terms. Rather these numeral adjectives are used to distinguish different elements, information, functions or acts from each other. For example, a first element, information, function, or act may be termed a second element, information, function, or act, and, similarly, a second element, information, function, or act may be termed a first element, information, function, or act, without departing from the scope of the present disclosure.

[0020] In addition, the term “adjacent to” may mean that an element is relatively near to but not in contact with a further element or that the element is in contact with the further portion, unless the context clearly indicates otherwise. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. Terms “about” or “substantially” or like terms areintended to cover variations in a value that are within normal industry' manufacturing tolerances for that dimension. If no industry standard is available, a variation of twenty percent would fall within the meaning of these terms unless otherwise stated.

[0021] It may be desirable to monitor aspects of industrial equipment. For example, some industrial reciprocating compressor designs utilize a high-pressure gas source to control an inlet valve system for one or more cylinder chambers of the reciprocating compressor. It may be desirable to monitor aspects of such a reciprocating compressor to predict and / or detect undesirable behavior, errors, problem states, and / or the like, including combinations and / or multiples thereof. To do this, sensors may be associated with such a reciprocating compressor or other suitable system, device, or component.

[0022] It can be difficult to attach sensors to industrial equipment. For example, industrial equipment is often deployed in harsh operating conditions (e.g., high or low temperatures, dusty environments, etc.) and is subject to vibrations and other forces. It is also often difficult to attach sensors to such equipment due to the physical designs of the equipment. For example, it is difficult to mechanically attach sensors to curved or other non-planar surfaces, such as cylinder chambers of reciprocating compressors.

[0023] One or more embodiments described herein addresses these and other challenges by providing a modular input / output (I / O) node for monitoring aspects of industrial equipment, such as industrial reciprocating compressors. One or more embodiments can be easily and reliably mounted to industrial equipment using a single mounting point.

[0024] The modular I / O node is equipped with a sensor, such as an accelerometer, to collect data about the industrial equipment. For example, the accelerometer can detect vibrations associated with the industrial equipment. Such data can be used to predict and / or detect undesirable behavior, errors, problem states, and / or the like associated with the industrial equipment. One ormore embodiments provide for determining an orientation of the modular I / O node in order to determine the direction of any movement (e g., vibrations) detected by the accelerometer. For example, in some implementations, movement or vibration may be expected along one axis but not another axis; thus, it is useful to determine the orientation of the accelerometer to identify the direction of movement or vibration.

[0025] One or more embodiments also provides a shroud to cause power to be disconnected before a connector connected to the modular I / O node can be removed. This can prevent undesirable electrical events, such as short circuits, sparks, electrocution, and / or the like, including combinations and / or multiples thereof.

[0026] FIGS. 1 and 2 depict schematic diagrams of a modular I / O node 100 according to one or more embodiments and are now described together. The modular I / O node 100 is a low-cost interface to machine IO. where the machine may be any suitable industrial equipment, such as a reciprocating compressor, IO.

[0027] According to one or more embodiments, the modular I / O node 100 includes various ports for facilitating data or signal transfer between the modular I / O node 100 and one or more other devices. According to one or more embodiments, the modular I / O node 100 includes current sensor interfaces 102, resistance temperature detectors (RTD) interfaces 104, speed pickups 106 (e.g., supporting variable reluctance (VR) or Hall-A pe speed sensors), programmable logic controller (PLC) I / O digital inputs 108 and digital outputs 110, proprietary connection port 112, and / or the like, including combinations and / or multiples thereof. According to one or more embodiments, the modular I / O node 100 also includes a temperature sensor 114 for temperature sensing, an accelerometer 118 for motion sensing.

[0028] The modular I / O node 100 communicates information, for example, over the proprietary connection port 112 that carries both data and power over a single cable / connection. The modular design of the modular I / O node 100 may includeone or more interface connectors for attaching communication and / or power cables thereto. The modular design of the modular I / O node 100 may include circuit boards (PCB) interconnected with low-cost flat-flex cables, such as a PCB 120. As shown in FIG. 1, the modular I / O node 100 includes the PCB 120 board that the vertical interface connectors mount into. The vertical interface connectors are those connectors on a top portion 100a of the modular I / O node 100. According to one or more embodiments, the modular I / O node 100 includes a second PCB (not shown) and a third PCB (not shown) that right-angle horizontal connectors plug into. The right-angle horizontal connectors are those connectors on side portions 100b, 100c of the modular I / O node 100. The right-angle horizontal connectors may be arranged substantially symmetric around a central bolt hole 130 for receiving a bolt 131. This configuration enables a single PCB design (for the second PCB and third PCB) to serve both side portions 100b, 100c, thereby reducing the number of components to be designed and built.

[0029] The central bolt hole 130 is a central through hole that extends from the top portion 100a through the modular I / O node 100 and out through a bottom portion (not shown). As such, the central bolt hole 130 enables the modular I / O node 100 to be attached to industrial equipment. To do this, a fastener (e.g., the bolt 131) is passed through the central bolt hole 130 to attach the modular I / O node 100 to the industrial equipment (e.g., reciprocating compressor).

[0030] According to one or more embodiments, the modular I / O node 100 maybe mounted to the industrial equipment using a single connection. This approach enables the modular I / O node 100 to be connected using a single bolt (e.g., the bolt 131), which makes it easier to mount the modular I / O node 100 to non-planar (e.g., curved) surfaces of the industrial equipment. For example, the modular I / O node 100 can be mounted to a cylinder chamber of a reciprocating compressor as follows.

[0031] First, a hole is drilled at a desired location on a non-planar surface of the reciprocating compressor. Next, an area around the drilled hole is surfaced to create a planar portion on the non-planar surface. According to one or moreembodiments, the planar portion of the non-planar surface is smaller in surface area than a surface area of a planar surface of the modular I / O node 100 that is being mounted to the reciprocating compressor. The drilled hole can then be tapped to create threads. At this point, the bolt 131 can be inserted through the central bolt hole 130 of the modular I / O node 100 and into the threaded hole in the reciprocating compressor.

[0032] According to one or more embodiments, a physical alignment aid 132 (see FIG. 1) can be used to align the modular I / O node 100 in a desired orientation relative to the reciprocating compressor. For example, using an alignment guide, an alignment hole is drilled in proximity to the threaded hole in the reciprocating compressor, the alignment hole being configured to receive the physical alignment aid 132. FIG. 3 depicts a schematic illustration of an alignment guide 300 according to one or more embodiments. The alignment guide 300 shown in FIG. 1 includes a steel collar 302 with a center hole 304 that receives an attachment bolt 306, which may be the bolt 131 or another suitable bolt. The attachment bolt 306 passes through the center hole 304 and into the threaded hole in the reciprocating compressor or other piece of industrial equipment to temporarily mechanically couple the alignment guide 300 to the reciprocating compressor or other piece of industrial equipment. The alignment guide 300 further includes a drill guide hole 308 for drilling an alignment hole in the reciprocating compressor or other piece of industrial equipment in proximity to the threaded hole. In this way, the alignment guide 300 provides spacing the drill guide hole 308 from the threaded hole a desired distance and provides for vertically drilling a hole to receive the physical alignment aid 132. The single bolt configuration shown in FIGS. 1 and 2, among others, eases installation of the modular I / O node 100 in the field where precisely aligning multiple holes may be difficult and that difficulty is increased because many times the surface of the reciprocating compressor or other piece of industrial equipment to receive the modular I / O node 100 is a cast curved or other non-planar surface.

[0033] The single bolt hole as described above increases the sensitivity of the on-board accelerometer (e.g.. the accelerometer 118). Because the accelerometer118 records down to 0 Hz (e.g., no motion and can sense orientation), the accelerometer 118 may be used, when the reciprocating compressor or other piece of industrial equipment is stopped, to detect the orientation of the modular I / O node 100. In the case where the alignment hole is not used, the orientation of the modular I / O node 100 may not be consistent. In such cases, the modular I / O node 100 may measure the orientation of itself from vertical and either make a software-based correction within circuitry or software of the modular I / O node 100 or tag the correction inside the data files for use and / or correction in postcollection processing. During reinstallation of the modular I / O node 100, such as after maintenance, the orientation of the modular I / O node 100 can be checked to ensure that the orientation has not changed, and that the modular I / O node 100 has not been swapped with another node on the reciprocating compressor or other piece of industrial equipment.

[0034] According to one or more embodiments, the modular I / O node 100 is "potted ' or “encapsulated,” such as in an epoxy matrix. In this way. the modular I / O node 100 includes an encapsulated housing, which includes the top portion 100a, side portions 100b, 100c, among others. According to one or more embodiments, the accelerometer 118 is isolated from the encapsulated housing. For example, the accelerometer 118 may exist in a vacuum enclosure within the modular I / O node 100. The epoxy that forms the encapsulated enclosure can deform the vacuum of the accelerometer 118, which may cause the accelerometer 118 to be inaccurate or inoperable. According to one or more embodiments, the accelerometer 118 is surrounded with foam before pouring the epoxy used to form the encapsulated housing.

[0035] FIGS. 4 and 5 show line drawings of the modular I / O node 100 according to one or more embodiments.

[0036] According to one or more embodiments, one or more the ports of the modular I / O node 100 are made intrinsically safe and protected by a hard fuse and / or e-fuse (not shown). The e-fuse keeps the current limited to safe levels. If the e-fuse fails, then the hard fuse provides backup protection to protect the userfrom explosion by disabling the module, which may be permanent. This configuration may be selected to minimize cost and board space while still providing intrinsic safety and short circuit protection.

[0037] In case of the interface cables connected to the ports shown in FIGS. 1, 2. 4, and 5. additional safety protections can be provided. For example, as shown in FIG. 6, a shroud 602 may be installed over the interface cables 604 that connect to ports of the modular I / O node 100. In order to remove the interface cables 604, the shroud 602 must be removed first. The shroud 602 may include magnets embedded in it that can be detected by a contactless sensor within the modular I / O node 100. More particularly, as shown in FIG. 7, the modular I / O node 100 includes a should detect circuit 700 that may be configured to include a corresponding proximity probe 702 (e.g., an eddy current sensor) that detects if the pin 703 of the shroud 602 is present and in the right location. For example, the shroud 602 can include a pin 703 that is glued or molded into the shroud. When the pin 703 is detected to be within proximity of the proximity probe 702 (e.g., within a predefined distance), it is determined that the shroud 602 is in place; otherwise, the shroud 602 is considered not to be in place and power is therefore disconnected to the port(s) associated with the shroud 602. That is, if the magnet of the shroud 602 is not detected where it should be, then port(s) of the modular I / O node 100 are disable. According to one or more embodiments, in such cases, the modular I / O node 100 can also be disabled. An upstream device can then automatically disable power to affected module because it does not see a valid device. Then the interface cables 604 can be disconnected safely.

[0038] According to one or more embodiments, the shroud 602 enables the modular I / O node 100 to trickle “intrinsically safe” power (e.g., power at 3.3V) to power the proximity probe 702 (e.g.. eddy current sensor). The proximity probe 702 is built onto a PCB 701, which is included in the modular I / O node 100. The proximity probe 702 detects the presence of a pin 703. A fastener 704 (e.g., a bolt or quick release fastener) holds down the shroud 602. A hardware circuit (shown in FIG. 10) disables downstream power and releases an upstream “OK” signal that causes upstream node to disconnect. That is, when the pin 703 is notdetected, the proximity probe 702 causes a signal, which may be implemented with a Zener diode, to disable “unsafe"’ power at the port(s) of the modular I / O node 100.

[0039] FIGS. 8 A and 8B depict views of a controller 800 that includes a shroud 802 according to one or more embodiments. According to one or more embodiments, the shroud 802 is installed over interface cables that connect to ports of controller 800. The shroud 802 is operatively similar to the shroud 602; however, the configuration, arrangement, and dimensions of the shroud 802 may differ from those of the shroud 602 due to differences between the controller 800 and the modular I / O node 100.

[0040] FIG. 9 depicts a safety system 900 with last make first break connector and shroud system according to one or more embodiments. The safety system 900 provides a safety strategy for hazardous area acceptance / approval of the modular I / O node 100. The safety system 900 includes the controller 800 communicatively connected to a plurality of modular I / O nodes 100, which implement the shroud detect circuit 700. The controller 800 is also electrically connected to a protected power supply 904. The shroud detect circuit 700 provides safe disconnect functionality for the I / O modules 100 that are equipped with the shroud detect circuit 700.

[0041] The protected power supply 904 includes a power source 905, a crowbar 906, and a relay 907 configured and arranged as shown. In such an embodiment, the protected power supply 904 provides last make first break (LMFB) functionality by using LMFB connector short pins 910 of an LMFB connector 908 that open the relay 907 before long pins 911 of the LMFB connector 908 are disconnected. That is, as the LMFB connector 908 begins to be removed, the LMFB connector short pins 910 first open, which cause the relay 907 to open, before the long pins 911 of the LMFB connector 908 are disconnected.

[0042] FIG. 10 depicts the shroud detect circuit 700 in more detail according to one or more embodiments. The shroud detect circuit 700 includes variouscomponents configured and arranged as shown, distributed among the controller, a downstream module 1000, and an upstream module 1001. The downstream module 1000 and the upstream module 1001 are examples of the modular I / O node 100.

[0043] In this example, pull up with 3.3V with a series term and inductor on the positive terminal is performed. The 3.3V is a barrier clamped at 12V. A FET pulls a 2.5 V Zener diode 1010 to ground, the cathode of the Zener diode 1010 ties, via an inductor, to the positive terminal. This puts the difference between the positive terminal and the negative terminal between IV and 0.5V apart. A window' comparator on the PSE side measures the T1 differential voltage and, if it is within the IV and 0.5V window as determined by a comparator 1011, power is enabled at power supply enable 1012.

[0044] Although an exemplary embodiment of the present disclosure has been described in detail, those skilled in the art wall understand that various changes, substitutions, variations, and improvements disclosed herein may be made without departing from the spirit and scope of the disclosure in its broadest form.

[0045] None of the description in the present application should be read as implying that any particular element, step, act, 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 a means plus function claim construction unless the exact words "means for" are follow ed by a participle.

Claims

CLAIMSWhat is claimed is:

1. A modular input / output node comprising: an encapsulated housing mechanically coupled to a piece of industrial equipment via a single mechanical connection; a plurality of ports for electrically connecting the modular input / output node to another device; a printed circuit board electrically connected to the plurality of ports; and an accelerometer electrically connected to the printed circuit board, the accelerometer being configured to collect movement data associated with the piece of industrial equipment, the movement data being used to determine an orientation of the modular input / output node relative to the piece of industrial equipment.

2. The modular input / output node of claim 1, wherein the piece of industrial equipment is a reciprocating compressor.

3. The modular input / output node of claim 1, wherein the accelerometer is isolated from the encapsulated housing.

4. The modular input / output node of claim 1. wherein the accelerometer is isolated from the encapsulated housing by surrounding the accelerometer with foam before pouring epoxy used to form the encapsulated housing.

5. The modular input / output node of claim 1, wherein the encapsulated housing comprises a central bolt hole extending from and through a top portion of the modular input / output node, through the modular input / output node, and to and through a bottom portion of the modular input / output node.

6. The modular input / output node of claim 5, wherein the single mechanical connection comprises a bolt passing through the central bolt hole and into a threaded hole of the piece of industrial equipment.

7. The modular input / output node of claim 6, wherein a physical alignment aid is used to align the modular input / output node in a desired orientation relative to the piece of industrial equipment.

8. The modular input / output node of claim 1, wherein the encapsulated housing is mechanically coupled to a substantially non-planar surface of the piece of industrial equipment via the single mechanical connection.

9. The modular input / output node of claim 8, wherein the substantially non-planar surface of the piece of industrial equipment has a non- planar portion and a planar portion, the planar portion of the substantially non- planar surface being smaller in surface area than a surface area of a planar surface of the modular input / output node that is mechanically coupled to the piece of industrial equipment.

10. A reciprocating compressor comprising: a plurality of modular input / output nodes, each of the plurality of input / output nodes comprising: an encapsulated housing mechanically coupled the reciprocating compressor; a plurality of ports for electrically connecting the modular input / output node to one another directly or indirectly via another device; a printed circuit board electrically connected to the plurality of ports; and an accelerometer electrically connected to the printed circuit board, the accelerometer being configured to collect movement data associated with the reciprocating compressor, the movement data being used to determine anorientation of the modular input / output node relative to the reciprocating compressor.

11. The reciprocating compressor of claim 10, wherein the accelerometer is isolated from the encapsulated housing.

12. The reciprocating compressor of claim 10. wherein the accelerometer is isolated from the encapsulated housing by surrounding the accelerometer with foam before pouring epoxy used to form the encapsulated housing.

13. The reciprocating compressor of claim 10, wherein the encapsulated housing comprises a central bolt hole extending from and through a top portion of the modular input / output node, through the modular input / output node, and to and through a bottom portion of the modular input / output node.

14. The reciprocating compressor of claim 13, wherein at least one of the plurality of modular input / output nodes is connected to the reciprocating compressor via a single mechanical connection, the single mechanical connection comprising a bolt passing through the central bolt hole and into a threaded hole of the reciprocating compressor.

15. The reciprocating compressor of claim 14, wherein a physical alignment aid is used to align the modular input / output node in a desired orientation relative to the reciprocating compressor.

16. The reciprocating compressor of claim 10, wherein the encapsulated housing is mechanically coupled to a substantially non-planar surface of the modular input / output node via a single mechanical connection.

17. The reciprocating compressor of claim 16, wherein the substantially non-planar surface of the reciprocating compressor has a non-planar portion and a planar portion, the planar portion of the substantially non-planar surface being smaller in surface area than a surface area of a planar surface of themodular input / output node that is mechanically coupled to the reciprocating compressor.

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