System and method for monitoring devices and components

[0002] The present invention relates generally to systems and methods for monitoring devices and components. In particular, the invention is directed to the system and method in which devices and/or components are maintained or replaced.

[0003] Conventional monitoring systems may include a plurality of field devices, e.g., smart field devices, positioned at various locations on a network. The smart field devices may include a processor, and can be temperature sensors, pressure sensors, flow rate sensors, valves, switches, etc., or combinations thereof. The smart field devices may be communicatively coupled to each other using an open smart communications protocol. Such open smart communications protocols may include HART®, PROFIBUS®, FOUNDATION® Fieldbus, etc. These open smart communications protocol enable smart field devices that are manufactured by different manufactures to be used together in the same process. The conventional systems also may include a controller communicatively coupled to each of the smart field devices using the open smart communications protocol. Moreover the controller may include a processor, and can receive data from each of the smart field devices.

[0004] In operation, each smart field device may perform a particular function. For example, a temperature sensor may measure a temperature of a liquid, a pressure sensor may measure pressure within a container, a flow rate sensor may measure a flow rate of the liquid, etc. Similarly, valves and switches may open to allow or increase the flow of the liquid, or may close to stop the flow of the liquid or to decrease the flow rate of the liquid. After the smart field devices obtain measurements of various process parameters, or the valves or switches are opened/closed, the smart field devices may communicate with the controller. For example, the smart field devices may forward the data to the controller, and the controller can implement a control procedure based on the received data.

[0005] Moreover, the smart field devices, the controller, or both, may be adapted to detect existing problems associated with the smart field devices. For example, the smart field device can measure instantaneous temperatures and/or instantaneous flow rates of a fluid, and may store the temperatures and flow rates in a database. The smart field devices can also continuously calculate an average fluid temperature or an average fluid flow rate, and compare the most recently measured temperature or flow rate to the average fluid temperature or flow rate, respectively. When the efficiency of the smart field device decreases, the most recently measured temperature or flow rate may be substantially less than or greater than the average temperature or flow rate, respectively. When the smart field device detects this deviation, it forwards the data to the controller, and the controller reports the existence of the problem to a computer system. Subsequently, the smart field device may be replaced and/or maintenance can be performed on the smart field device.

[0006] Nevertheless, such systems only depend on the data associated with the performance of the smart field device to determine whether to replace or perform maintenance on the smart field device. Consequently, problems with the smart field device arise before the maintenance is performed on the smart field device, or before the smart field device is replaced, or both.

[0007] Therefore, a need has arisen to provide a system and method for monitoring devices and components which overcome the above-described and other shortcomings of the conventional systems and methods. One of the advantages of the present invention is that data associated with the performance of the field device and/or data collected independent of the performance of the field device can be used to determine whether to replace or perform maintenance on the field device. For example, when the amount of time (that the field device has been in operation) is greater than a predetermined value, this data can be forwarded to a computer system. Consequently, such computer system may instruct the field device to be replaced, or can require maintenance to be performed on the field device before problems arise associated with the field device.

[0008] According to an exemplary embodiment of the present invention, a system and method for monitoring a device or component are provided. In particular, a controller is communicatively coupled to at least one field device, and a computer system is communicatively coupled to the controller. For example, the at least one field device may be a smart field device, and the controller may communicate with the smart field device using an open smart communications protocol, e.g., Foundation Fieldbus protocol, PROFIBUS protocol, etc. Moreover, the controller and/or the field device may be adapted to transmit monitoring data associated with the field device to the computer system when an amount of time that the field device has been in operation is greater than a predetermined value. Alternatively, a server may be communicatively coupled to the computer system, such that the server is adapted to access the monitoring data, and transmit a request for a replacement field device and/or a recommendation that maintenance be performed on the field device independent of a performance of the field device.

[0009] In another exemplary embodiment of the present invention, the field device may be a temperature sensor, a pressure sensor, a flow rate sensor, a valve, a switch, etc. Also, the monitoring data may include values associated with temperature, pressure, flow rate, the amount of time that the field device has been in operation, a position of the valve, a position of the switch, etc. Moreover, the controller and/or the field device may be adapted to compare an instantaneous temperature, pressure or flow rate with an average temperature, pressure or flow rate, respectively. The controller also may be adapted to transmit the monitoring data to the computer system when the difference between the instantaneous temperature, pressure or flow rate and the average temperature, pressure or flow rate, respectively, is greater than a predetermined value.

[0010] For a more complete understanding of the present invention, the needs satisfied thereby, and the objects, features, and advantages thereof, reference now is made to the following descriptions taken in connection with the accompanying drawings.

[0011] FIG. 1ais a schematic of an exemplary embodiment of a system according to the present invention.

[0012] FIG. 1bis a flowchart of another exemplary embodiment of a system according to the present invention for monitoring a device or component.

[0013] FIG. 2ais a flowchart of a first exemplary embodiment of the method according to the present invention for monitoring the devices and/or component.

[0014] FIG. 2bis a flowchart depicting examples of monitoring data which may be transmitted to a controller by at least one field device using the exemplary method of FIG. 2a.

[0015] FIG. 2cis a flowchart of a second exemplary embodiment of the method according to the present invention.

[0016] FIG. 2dis a flowchart of a third exemplary embodiment of the method according to the present invention.

[0017] FIG. 3ais a flowchart of a fourth exemplary embodiment of the method of the present invention.

[0018] FIG. 3bis a flowchart depicting examples of monitoring data which may be transmitted to a controller by the field device using the exemplary method of FIG. 3a.

[0019] Exemplary embodiments of the present invention and their advantages may be understood by referring to FIGS. 1a-3b,like numerals being used for like corresponding parts in the various drawings.

[0020] In particular, as shown in FIG. 1a, an exemplary embodiment of a system 100 for maintaining devices and components according to the present invention is provided. The system 100 may include at least one field device 10 (e.g., at least one smart field device) positioned on a network, and each field device 10 may include a processor (not shown). Referring to FIG. 1b,which shows another exemplary embodiment of the system 100, each of the smart field devices 10 may be a sensor, a control element, etc. The sensor may be a temperature sensor, a pressure sensor, a flow rate sensor, etc., and the control elements can be a valve, a switch, etc. In operation, each of the field devices 10 may perform a function within the system 100. For example, a field device 10awhich is a temperature sensor may measure a temperature of a liquid, a field device 10bwhich is a pressure sensor may measure pressure within a container, a field device 10cwhich is a flow rate sensor may measure a flow rate of the liquid, etc. Similarly, field devices 10dand 10ewhich are a valve and a switch, respectively, may open to allow for or increase the flow rate of the liquid, or may close to stop the flow of the liquid or to decrease the flow rate of the liquid. In an exemplary embodiment of the system 100 according to the present invention, each field device 10 may be communicatively coupled to at least one other field device 10 using an open smart communications protocol 30. Such open smart communications protocols may be HART®, PROFIBUS®, FOUNDATION® Fieldbus, etc.

[0021] Referring again to FIG. 1a,the system 100 also may include a controller 20. The controller 20 may have a processor (not shown), and also can be communicatively coupled to each field device 10 using the open smart communications protocol 30. The system 100 further may include a computer system 40 communicatively coupled to the controller 20. In an exemplary embodiment of the present invention, the computer system 40 may be communicatively coupled to the controller 20 using an Ethernet connection. In operation, each of the smart field devices 10 may collect monitoring data associated with a function block of that particular field device 10. For example, in a case when the field device 10 is a sensor, the monitoring data may include values associated with instantaneous temperatures, pressures, flow rates, etc. detected by the field device 10 at various times. When the field device 10 is a control element, the monitoring rate may include values associated with a position of the field device 10 at various times. Moreover, when the field device 10 is a sensor or a control element, the monitoring rate further may include values associated with historical data, e.g., the amount of time that the field device 10 has been in operation.

[0022] Further, the controller 20 and/or the field device 10 may be adapted to continuously calculate the average temperature, pressure, flow rate, etc., and to compare the most recently obtained instantaneous temperature, pressure, flow rate, etc. with the average temperature, pressure, flow rate, etc. respectively. The field device 20 and/or the controller 20 further may transmit the monitoring data to the computer system 40 when a difference between the instantaneous temperature, pressure, flow rate, etc. and the average temperature, pressure, flow rate, etc. is greater than a predetermined temperature, pressure, flow rate, etc. differential, respectively. Similarly, when the amount of time that the field device 10 has been in operation exceeds a predetermined amount of time, the field device 10 and/or the controller 20 may transmit the monitoring data to the computer system 40. The predetermined amount of time may be selected such that the field device 10 will not experience a substantial decrease in the efficiency prior to the expiration of the predetermined amount of time. As such, the monitoring data may be transmitted to the computer system 40 before the field device 10 experiences a decrease in efficiency. Such data transmission can be performed independently from, or in combination with, the performance of the field device 10.

[0023] In another embodiment of the present invention, the system 100 may further include at least one server 50. The server 50 can be communicatively coupled to the computer system 40. The server 50 may be adapted to access the monitoring data stored in the computer system 40, and to transmit a recommendation that maintenance be performed on the field device 10 or that the field device 10 should be replaced. Similarly, the server 50 can transmit a request to the manufacturer of the field device 10 requiring the delivery or installation of a replacement field device 10. For example, when the amount of time that the field device 10 has been in operation exceeds a predetermined amount value of time, the field device 10 and/or the controller 20 can transmit the monitoring data to the computer system 40. Thereafter, a user (not shown) of the server 50 can access the monitoring data stored in the computer system 40. The user of the server 50 also can transmit a recommendation for the maintenance to be performed on the field device 10, transmit a recommendation for the field device 10 to be replaced, request the delivery or the installation of a replacement field device 10, or combinations thereof. Similarly, when a difference between the instantaneous temperature, pressure, flow rate, etc. and the average temperature, pressure, flow rate, etc. is greater than the predetermined temperature, pressure, flow rate, etc., respectively, the field device 10 and/or the controller 20, can transmit the monitoring data to the computer system 40. Thereafter, the user of the server 50 can access the monitoring data stored in the computer system 40. As described above, the predetermined amount of time may be selected such that the field device 10 will not experience a substantial decrease in efficiency prior to the expiration of the predetermined amount of time.

[0024] Referring to FIG. 2a,an exemplary embodiment of a method 200 according to the present invention is depicted which can be utilized by the system 100 of FIG. 1a.In step 210, the controller 20 may receive monitoring data 210 associated with at least one field device 10. Referring to FIG. 2b,in a second exemplary embodiment of the method, the monitoring data can include any combination of the monitoring data 210a-210f.For example, the monitoring data can include any combination of the amount of time that the field device 10 has been in operation (block 210′a), values associated with a temperature of a fluid measured by the field device 10 (block 210′b), values associated with a pressure within a container measured by the field device 10 (block 210′c), values associated with a flow rate of a fluid measured by the field device 10 (block 210′d), a position of a valve at various times during the operation of the field device 10 (block 210′e), and a position of a switch at various times during the operation of the field device 10 (block 210′f). In step 220, the controller 20 and/or the field device 10 may determine the amount of time that the field device 10 has been in operation, and the controller 20 and/or the field device 10 may transmit the monitoring data 210 to the computer system 40 when the amount of time that the field device 10 has been in operation exceeds the predetermined amount of time (step 225). In addition, the controller and/or the field device may transmit another indication that the threshold has not been reached in step 227, if such determination was made in step 220. In another exemplary embodiment, referring to FIG. 2c,steps 220-227 may be replaced by steps 220-227′. In step 220′, the controller 20 may determine if a difference between the instantaneous temperature, pressure, flow rate, etc. and the average temperature, pressure, flow rate, etc. is greater than the predetermined temperature, pressure, flow rate, etc. differential, respectively. The indication of the determination is formulated by the field device and/or the controller (i.e. steps 225′, 227′). Moreover, referring to FIG. 2d,in yet another exemplary embodiment, the method 200 may include steps 220-227 of FIG. 2a.and steps 220′-227′of FIG. 2c.In step 230, the server 50 may access the monitoring data from the computer system 40. Moreover, in step 240, the server 50 may transmit a recommendation for maintenance to be performed on the field device 10, the field device 10 is to be replaced, a request for the delivery and/or the installation of a replacement field device 10 to be made, etc. As such, maintenance may be performed on the field device 10 or the field device 10 may be replaced.

[0025] Referring to FIG. 3a,another exemplary embodiment of the method 300 according to the present invention which can be used by the system 100 of FIG. 1ais depicted. In step 310, the controller 20 may receive the monitoring data associated with the field device 10. Referring to FIG. 3b,in another embodiment of the method of the present invention, the monitoring data can include any combination of monitoring data 310a-310f.Specifically, the monitoring data can include any combination of the amount of time that at least one field device 10 has been in operation (block 310′a), values associated with a temperature of a fluid measured by the field device 10 (block 310′b), values associated with a pressure within a container measured by the field device 10 (block 310′c), values associated with a flow rate of a fluid measured by the field device 10 (block 310′d), a position of a valve at various times during the operation of the field device 10 (block 310′e), and a position of a switch at various times during the operation of the field device 10 (bock 310′f). In step 320, the controller 20 may transmit the monitoring data to the computer system 40. In step 330, the server 50 may access the monitoring data 310 from the computer system 40. Moreover, in step 340, the server 50 may transmit a recommendation for the maintenance to be performed on the field device 10, for the field device 10 to be replaced, a request for the delivery or the installation of a replacement field device 10, or combinations thereof. For example, the server 50 may transmit such recommendations and/or requests when the amount of time that the field device 10 has been in operation exceeds the predetermined amount of time. As such, maintenance may be performed on the field device 10, or the field device 10 may be replaced, independent from, or in combination with, the performance of the field device 10.

[0026] While the invention has been described in connection with preferred embodiments, it will be understood by those of ordinary skill in the art that other variations and modifications of the preferred embodiments described above may be made without departing from the scope of the invention. Other embodiments will be apparent to those of ordinary skill in the art from a consideration of the specification or practice of the invention disclosed herein. It is intended that the specification and the described examples are considered as exemplary only, with the true scope and spirit of the invention indicated by the following claims.