CN1188759C - 在工艺系统中检测事件的装置和方法 - Google Patents
在工艺系统中检测事件的装置和方法 Download PDFInfo
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0221—Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B13/00—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion
- G05B13/02—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric
- G05B13/0265—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric the criterion being a learning criterion
- G05B13/0275—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric the criterion being a learning criterion using fuzzy logic only
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B21/00—Systems involving sampling of the variable controlled
- G05B21/02—Systems involving sampling of the variable controlled electric
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0259—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the response to fault detection
- G05B23/0275—Fault isolation and identification, e.g. classify fault; estimate cause or root of failure
- G05B23/0278—Qualitative, e.g. if-then rules; Fuzzy logic; Lookup tables; Symptomatic search; FMEA
Abstract
一种与工艺控制环路(6)耦合的工艺装置(40)。工艺装置(40)接收工艺信号。工艺装置中的一存贮器(48)容纳一额定参数值(78)和一规则(80)。计算电路(46)计算工艺信号的统计参数并根据所存规则(80)对统计参数和所存额定值(78)进行运算而且根据运算作出响应提供一事件输出。输出电路(42)对事件输出作出响应提供一输出。
Description
技术领域
本发明涉及与工业用途类型的工艺控制环路耦合的装置和方法。更具体地说,本发明涉及通过监控工艺信号检测工艺控制系统中的事件。
背景技术
工艺控制环路在诸如炼油厂之类的工业中被用于控制工艺操作。发送器是环路的特有部分并设置于现场,用以测量并向例如控制室的设备发送诸如压力、流量或温度之类的工艺变量。如阀门控制器之类的控制器也是工艺控制环路的部分,它根据从控制环路上接收到的或是内部产生的控制信号控制阀门的位置。其它还有例如控制电动机或电磁线圈的控制器。控制室设备也是工艺控制环路的部分,它使控制室中的操纵人员或是计算机能够根据从现场的发送器接收到的工艺变量监测工艺,并通过向相应的控制装置发送控制信号作出控制工艺的响应。另一个可以是控制环路部分的工艺装置就是便携式的通话装置,它能在工艺控制环路上监测和发送工艺信号。一般说来,这些就是用于构造形成环路的装置。
最好是检测到在工艺控制系统中出现的事件。一般说来,现有技术已限于简单的检测技术。例如,监测到压力之类的工艺变量,且当工艺变量超过预定的限度时,发出警报声或是启动保险断路。然而,为了鉴别触发报警的事件,就必需使用复杂的模型,而它在为进行大量计算所需的能量与资源受到限制的工艺环境中是难以实现的。
发明内容
根据本发明的一个方面,其提供一种与工艺控制环路耦合的工艺装置,其特征在于,它包括:一工艺信号输入装置,用于提供与一种工艺有关的一工艺信号;存储器,容纳一表示观测的工艺信号的统计函数的序列值和一规则;计算电路,计算表示工艺信号的统计函数的当前参数,并根据所述规则对所述当前参数和所述序列值进行运算,从而在与故障事件相关的工艺信号中识别一模式,并且响应于根据所述运算检测的工艺中的事件响应地输出一故障事件;以及输出电路,输出故障事件输出。在一项实施例中,统计参数是从包括标准偏离、平均值、取样偏差、范围、均方根及变化率在内的参数组中选出的。在一项实施例中,选择规则以从包括信号尖峰、信号漂移、信号偏置、信号噪声、信号保留、信号过猛,循环信号、杂散信号和非线性信号在内的信号组中检测出事件。
本发明的装置包括诸如发送器、控制器、电动机、传感器、阀门、通话机或控制室设备之类的任何工艺装置。
一种在工艺控制系统中由工艺装置进行检测工艺事件的方法,包括步骤:取得一与工艺有关的工艺信号;从存储器中取出一规则;从存贮器中取出表示观察到的工艺变量的统计函数的一序列值;计算表示工艺信号的统计函数的一当前参数;按照规则所确定的关系将当前参数与序列值进行比较,从而在与故障事件相关的工艺信号中识别出一种模式;以及根据比较步骤作出响应提供一工艺故障事件输出。
附图说明
图1为包括发送器、控制器、手持通话机和控制室在内的工艺控制环路的简化示图。
图2为本发明工艺装置的方框图。
图3为运用规则计算统计参数和灵敏度参数给出工艺事件输出的示图。
图4为表示各种类型事件工艺信号输出随时间变化的曲线图。
图5示出按照本发明工艺事件运行的推理机的方框图。
图6为用于本发明的推理机的简化方框图。
具体实施方式
工艺变量一般是在工艺过程中要受到控制的主要变量。作为这里所用到的工艺变量是指描述诸如压力、流量、温度、产品等级、pH值、混浊度、振动、位置、电机电流、任何其它工艺特性等等的工艺条件。控制信号是指(除工艺变量之外的)用于控制工艺的任何信号。例如,控制信号是指诸如温度、压力、流量、产品等级、pH值或混浊度等所要求的工艺变量值(即设置值),它由一控制器进行调节或是用于控制工艺。此外,控制信号是指校对值、报警、报警条件、输送给控制元件的信号诸如输往阀门调节器的阀门位置信号以及输往加热元件的能量等能、电磁线圈开/关信号等、或是与工艺控制有关的任何其它信号。这里所用的诊断信号包括与工艺控制环路中的装置和元件有关的运行信息,但不包括工艺变量或控制信号。例如,诊断信号包括阀门杆位置、施加的力矩或力、调节器压力、用于调节阀门的压缩气体的压力、电压、电流、功率、电阻、电容、电感、装置温度、静磨擦、磨擦力、全开和全关位置、移动、频率、幅度、频谱和频谱成分、刚性、电场或磁场强度、周期、密度、运动、电动机的反电动势、电动机电流、与环路有关的参数(如控制环路电阻、电压或电流)、或在系统中可以检测或测量到的其它任何参数。还有就是,工艺信号是指与工艺过程中的工艺或元件有关的任何信号,例如一项工艺变量、一个控制信号或是一个诊断信号。工艺装置包括形成工艺控制环路的部分或与工艺控制环路耦合并在工艺控制或监视中使用的任何装置。
图1是一工艺控制系统2的例子示图,它包括运送工艺流体的工艺管道4和带环路电流I的双线工艺控制环路6。一个发送器8,与诸如一个调节器、阀门、一个泵、电机或电磁线圈之类的环路中的最终控制元件耦合的控制器10,通话器12以及控制室14,它们是组成工艺控制环路6的全部。要明白环路6是用一种结构表示的,而任何适合的工艺控制环路都是可以使用的,诸如4-20毫安的环路、2、3或4线的环路、多压差环路以及按哈尔特(HART)菲尔德奔斯(Fieldbus)或其它数字或模拟通信规约运行的环路。在运行中,发送器8用传感器16测出流量之类的工艺变量并在环路6上传送测得的工艺变量。此工艺变量可以由控制器/阀门调节器10、通话机12和/或控制室设备14所接收。控制器10被绘示成与阀门18耦合并能通过调节阀门18控制工艺,用以改变管道4中的流体。控制器10在环路6上接收一来自譬如控制室14、发送器8或通话机12的控制输入并作出调节阀门18的响应。在另一实施例中,控制器10根据在环路6上接收到的工艺信号开始产生控制信号。通话器12可以是图1中所示的便携式通话器,也可以是永久装设的监视工艺并进行计算的工艺部件。工艺装置包括譬如图1中所示的发送器8(如可从罗斯蒙特公司买到的3095型发送器)、控制器10、通话机12和控制室14。另一类工艺装置则为一台个人计算机(PC)、可编程的逻辑部件(PLC)或是其它采用合适的输入/输出电路与环路耦合的计算机使得能在环路上进行监视、管理和/或传送。
图1中所示的任何工艺装置8、10、12或14可以包含本发明的事件监视电路。图2为形成部分环路6的工艺装置40的方框图。装置40表示成一般形式,并可以包含诸如发送器8、控制器10、通话机12或控制室设备14之类的任何工艺装置。控制室设备14可以包括譬如一个用一PLC实现的数据控制系统(DCS),而控制器也可以包括一个“灵活的”电机和泵。工艺装置40包括与环路6在端部44耦合的输出/输出(I/O)电路42。I/O电路具有按已有技术预选的适合于与装置40往来通信的输入与输出阻抗。装置40包括与I/O电路42耦合的微处理器46、与微处理器46耦合的存贮器48以及与微处理器46耦合的时钟50。微处理器46接收一工艺信号输入52。方框输入是用来表示任意工艺信号的输入,并且如前面说明的,工艺信号输入可以是一项工艺变量,或是一项控制信号,并且可以是从使用I/O电路42的环路6接收到的或者可以是由现场装置40的内部产生的。现场装置40是用一个传感器输入通道54和一个控制通道56表示的。一般说来,如发送器8之类的发送器将仅仅包括传感器输入通道54,而像控制器10之类的控制器则仅仅包括一条控制通道56。环路6上的其它装置如通话机12和控制室设备14可以不包含通道54和56。要明白装置40可以包含多条通道监视多项工艺变量并且/或者控制多个相应的控制元件。
传感器输入通道54包括传感器16,它测出工艺变量并向放大器58提供传感器输出,放大器58有经模-数传换器60进行数字化的输出。通道54通常在像发送器8之类的发送器中使用。补偿电路62补偿数字化的信号并向微处理器46提供一数字的工艺变量信号。在一项实施例中,通道54包括一条接收一诊断信号的诊断通道。
当工艺装置40像控制器8那样的控制器工作时,装置40包括带有例如阀门之类控制元件18的控制通道56。控制元件18通过数-模转换器64、放大器66和调节器68与微处理器46耦合。数-模转换器64使一来自微处理器46输出指令数字化,经放大器66放大。调节器68根据来自放大器66的输出控制控制元件18。在一项实施例中,调节器68直接与环路6耦合并对流过环路6的电流I作出响应控制一个压缩气体源(未示出)对控制元件18定位。在一项实施例中,控制器10包括用以控制一控制元件的控制通道56并且还包括传感器输入通道54,传感器输入通道54提供诸如阀门件位置、力、力矩、调节器压力、压缩空气源的压力等等的一类诊断信号。
在一项实施例中,I/O电路42提供用于全部启动工艺装置40中的其它电路的功率输出,而工艺装置40是用来自环路6的电源。一般情况下,如发送器8或控制器10之类的现场装置是脱离环路6供电的,而通话机12或控制室14则有单独的电源。如前所述,工艺信号输入52向微处理器46提供一工艺信号。工艺信号可以是来自传感器16的一项工艺变量、向控制元件18提供的控制输出、由传感器16发送的一项诊断信号、或是在环路6上接收到的一项控制信号、工艺变量或诊断信号、或是通过如其它I/O通道之类的某些其它途径接收或产生的一项工艺信号。
还有一个与微处理器46相连的用户I/O电路76,并在装置40和一用户之间提供通信。在一般情况下,用户I/O电路76包括一输出的显示和音响以及一输入的键盘。在一般情况下,通话机12和控制室14包括能使用户监视和输入工艺信号的I/O电路76,这些工艺信号有如工艺变量、控制信号(设置值、校准值、报警、报警条件等等)以及如在以后所述的规则、灵敏度参数和序列值。用户还可以使用通话机12或控制室14中的电路76在环路6上与发送器8和控制器10相互发送和接收这样一些工艺信号。此外,这样的电路能在发送器8、控制器10或是任何其它工艺装置40中直接实现。
微处理器46按照存在存贮器48中的程序进行工作。存贮器48也包含本发明的序列值78、规则80和灵敏度参数82。灵敏度参数82和序列值78的组合提供了额定值79。图3示出逻辑实现装置40的方框图83。逻辑方框84接收工艺信号并为工艺信号计算统计参数。这些统计参数包括例如,标准偏离、平均、取样偏差、均方根(RMS)、范围(ΔR)以及工艺信号的改变率(ROC)。这些由以下公式给出:
ΔR=XMAX-XMIN 式5
其中N为取样周期内的数据点总数,Xi和Xi-1为工艺信号的两相邻值,两T则为两值之间的时间间隙。此外,XMAX和XMIN分别是在整个取样或序列时间周期内工艺信号的最大和最小值。这些统计参数是单独地或以任意组合进行计算的。大家将会了解到,除在以后要明显设置可用于分析工艺信号的那些统计参数之外,本发明包括任何统计参数。所计算的统计参数由规则计算方框86接收,此规则方框86按存贮器48中所存的规则80运算。规则方框86还从存贮器48接收序列值78。序列值是工艺信号的额定(即标准的)或统计参数值并包含与逻辑方框84所用相同的统计参数(标准偏离、平均、取样偏差、均方根(RMS)、范围和改变率等等)。在另一项实施例中,序列值由生产者提供并在制造时存在发送器40的存贮器48中。在另一项实施例中,序列值由环路6上的寻址装置周期地更新。在又是另一项实施例中,输入电路76可以产生或接收序列值或是用于向环路6上的另一工艺装置发送序列值。在又一项实施例中,由统计参数逻辑方框84产生序列值,在正常时工艺运行期间,逻辑方框84产生或得到额定或正常的统计参数。这些统计参数用于产生存贮器48中产生序列值78供将来使用。这就使得能为每个特定的环路和运行条件进行序列值78的动态调节。在此实施例中,根据工艺动态响应时间为用户提供可选的时间周期对统计参数84进行监控。
规则方框86从存贮器48接收灵敏度参数82。规则逻辑方框86提供不同规则数的例子,每一灵敏度参数值82提供一可接收的范围或是由所计算的统计参数84和相应序列值78之间的相应规则所确定的关系。灵敏度参数值82可以由生产者设置,在环路6上接收到或是用输入电路76输入。灵敏度参数要为特定的应用进行调节。例如,在工艺控制的应用中要求有高精度,灵敏度参数就要设置成使工艺信号相对于序列值只能有小量偏差。使用灵敏度参数使得诊断和事件检测作出的决定能够根据特定的工艺和用户的要求作出控制。
图4为一例工艺信号随时间的变化,它示出利用本发明检测的各种工艺事件(如正常、偏置、漂移、噪声、尖蜂和滞留)。图4中所示工艺信号以正常状态起始而后移向偏置条件。接着,工艺信号经一漂移条件,继之以噪声信号条件。最后,在工艺信号中出现一系列尖峰事件,继之以滞留条件。下面讲述检测这些事件所用的规则。
漂移
当一工艺信号在此期间自其确切(即额定)值改变时就出现漂移。本发明的一项实施例包括一种运用统计参数平均值(μ)、序列参数平均值(μ′)和调谐参数α检测漂移的规则。
漂移灵敏度由信号灵敏度参数α控制。α代表在正常平均信号电平以上或以下的百分比,在漂移或检测到事件之前它是可以容许的。通过规则计算方框86进行的下列规则检测一项漂移事件:
若μ<μ′(1-α) 则为负漂移事件
若μ>μ′(1+α) 则为正漂移事件
其中μ为来自84的工艺信号电流平均值,μ′为来自78的序列平均值,而α则为限定对平均值的可接受变动的来自82的灵敏度参数。此外,在整个期间监测着平均值。漂移事件只是在一系列连续取样期间平均值离开了序列值时才能检测到。序列平均值(μ′)可以在工艺正常运行期间由序列装置40得到。
偏置
偏置是一时漂移到所预期的信号电平以上或以下一个“平稳的”确定电平的结果。一旦停止漂移,所形成的信号就被偏置,有时称为对确切/额定值的偏移。偏置是利用在检测漂移中所用的同一规则进行检测的。此外,在整个期间监测着平均值。若是平均值未连续偏离序列平均值(μ′),这时就将事件定为偏置,而非漂移。
噪声
一种不同的组合规则、调谐参数和序列值检测工艺信号中的噪声。噪声检测的灵敏度是通过调节灵敏度参数β进行调节的。β是在一项噪声检测之前能够超出序列标准偏离(σ′)的电流标准偏离(σ)总量。例如,当工艺信号为序列值的两倍噪声时,只要用户想检测噪声事件,就要将β发送至2.0。还通过规则利用范围(ΔR)将噪声与正常的信号变动区分开。用于噪声检测的一例规则是:
若σ>βσ′并且
ΔR>ΔR′则检测到噪声。
其中σ和σ′分别是电流和序列的标准偏离,ΔR和ΔR′分别为电流和序列的范围,而β则为噪声灵敏度参数。
滞留
又是另一项组合规则、统计值、调谐参数和序列值检测工艺信号中的滞留条件。“滞留”工艺信号是以工艺信号不随时间改变为其条件。滞留灵敏度是通过调节灵敏度参数82的γ得到控制的。γ的数值表示成序列标准偏离(σ′)的百分比,并代表引发一次滞留事件检测要与序列值有多么小的标准偏离改变。例如,当工艺信号的噪声级为序列值的一半时,若是用户希望检测一次滞留条件,就要将γ设置成等于百分之50(0.5)。此外,还能利用信号范围(ΔR)消除随着小信号出现的误差。一例规则为:
若是(σ+ΔR)≤γ(σ′+ΔR′)
则检测到一次滞留事件。
尖峰
利用一种不同的组合规则、一个统计数值、序列值和灵敏度参数检测一次尖峰事件。当信号在瞬间达到一个极值时出现了尖峰事件。对工艺信号中的尖峰的灵敏度是通过调节来自82中所存δ的灵敏度参数进行控制的。δ是在两相邻数据点之间可接受序列的最大改变率(ΔPmax)。例如,若是用户希望检测到任何尖峰具有来自方框84的相对于序列值的改变率(ROC)超过来自方框78的Δγmax的30%,来自82的δ就要设置达1.30。一例规则为:
若是ROC>δ·Δγmax
则检测到一次尖峰事件。
其它规则包括检测工艺信号中的循环振荡的循环规则和检测工艺信号中的不稳定状况的不稳定规则。应该了解到,其它规则也可以实现以观察工艺信号中的其它事件,并可使用不同的公式或计算方法以检测事件。一项规则可以对一个以上的统计参数或是对一个以上的工艺信号进行运算。例如,若是流速之类的工艺变量超过了预定的极限,而另一工艺温度之类的工艺变量形成峰值,一项规则就能确定工艺过热并可存在紧急关断的条件。此外,另一类规则是以模糊逻辑实现的,其中的统计参数是由一灵敏度参数对其运算的,灵敏度参数是用来表示序列值成员资格函数。
这里所讨论的所有规则按照规则的运用提供工艺事件的输出。应该了解到,根据规则的运用,工艺事件输出可以有多个分离的或连续的数值。要注意灵敏度参数和序列值的组合提供了一个额定参数值,而规则对额定参数值和统计参数进行运算。可以采用加权平均或是合适的模糊逻辑将各式各样的工艺信号、参数和序列值组合起来。成员函数包括譬如,梯形的和三角形的函数。例如,可以在所选的成员函数上标绘统计参数。然后在编序中用这些产生序列值,并产生供规则使用的统计参数。
在一项实施例中,通过判定工艺稳定求得序列值,并产生一段可选定期间的统计参数。这些就作为序列值贮存起来。可选定期应与取样期或与为产生统计参数所用方框的运行期大致相同。这一处理可以由使用者启动或是自动进行。
输出的规则可以在环路6上传送,在用户的I/O电路76上输出,贮存起来供今后使用,用作向另一规则或控制函数之类的另一计算输入,或是以任何适合的方式使用。在另一项实施例中,本发明监测有关的工艺信号并进行比较,而且在这些信号之间进行相关。例如,在图2中诸如A/D转换器60的输出之类的信号、补偿电路62和通过环路6的电流I可以按照图3进行分析。例如,多种工艺信号都要在以后经过灵敏度参数、规则和序列值的适合组合设置成所要求的相互容许的范围内。
图5是一幅示出推理机102的方框图100。推理机102归属于工艺装置40,是环路6的部分,并接收工艺变量104、控制信号106和工艺事件108。工艺事件是按照本发明检测到的。推理机102包括计算电路110和工艺数据112。工艺数据112可以包括,譬如,录入的工艺变量之类的历史信息、控制信号、工艺事件或其它工艺信号,并且可以包含进一步确定所监测的工艺的专用信息。根据出现的工艺事件,推理机102判定在各种工艺装置中哪一个部件失效。计算电路110分析工艺变量104、控制信号106、工艺事件108和其它工艺信号以判定产生工艺事件的原因。计算电路按照诸如在一种专家系统的已有技术中使用过的一系列规则进行运算。计算电路110对包括工艺数据112在内的所有输入进行运算并提供一警告信号之类的失效元件输出。例如,若是检测到漂移事件,推理机102就运行以判定漂移的原因。例如,漂移可能是由于改变控制的设置点造成的,在此情况下计算电路110就判定控制环路为正常运行。然而,若是设置点并未改变,推理机还要进一步分析各种输入,并如,通过相应的诊断检查装置的完善状况作出诸如阀门电机、泵、振动设备等等工艺事件的报告。例如,若对阀门表示出阀门运行正常,则此时推理机要进行发送器的诊断以判定发送器及其有关的传感器是否运行正常。这些诊断可以是观察从角度检查特定元件得到的信息,也可以是观察从上流程或下流程传感器等等之类的控制环路上的其它来源接收到的信息。计算电路110使用诸如一系列规则、模糊逻辑或神经网络之类的任何合适的计算技术。在一项最佳实施例中,推理机是用微处理器和存贮器实施的,并可设置在某些遥控位置或其自身现场的控制室中。推理机102可以用图1中所示任何工艺装置8、10、12或14实施。能向工作人员提供失效元件输出,或者通过增加在环路上作进一步诊断的计算电路能够使其得到利用。
图6示出一幅如象机器102那样按照一种规则基准运行的简化推理样机的方框图200。根据出现的工艺事件,在框202处推理机102检查工艺事件以鉴别所检测到的特定事件。若事件为漂移事件,则使控制移至框204。若事件为尖峰、噪声或偏置之类的某种其它事件,则使控制移至按照检测到特定事件所组成的规则基准上。在框204处,推理机检查观察工艺设置点是否有新的改变。若是重新改变了设置点,则提供一输出表示工艺在它的正常范围内运行,而所检测到的漂移是因改变设置点造成的。然而,若是设置点未经改变,推理机就移至框206进行进一步的诊断。在框206处,推理机指示工艺装置40在诊断电路板上测试以进一步判定漂移的原因。在208处,若是用装置40进行的诊断鉴别出漂移的原因,推理机就提供一鉴别失效部件的输出。然而,若是诊断表示为装置40正常运行,推理机就指示有关装置在框210进行诊断。例如,有关装置可以是上流程或下流程、控制器或发送器。在框212处,推理机判定有关的工艺装置之一是否为失效装置。若是引起漂移的是有关装置之一的失效,推理机就提供一鉴别装置和失效部件的输出。若是有关装置无一有差错,推理机就在框214处观察其它工艺信号企图在框216处鉴别已知的工艺条件。若漂移是由于一已知的工艺条件引起的,例如,因向一储备箱充入工艺流体而引起流体压力下降。若知道了工艺条件,就鉴别了特定条件。若工艺条件未知,工作人员就得到通知告诉未能鉴别已检测到的漂移事件产生的原因。根据任何的各种规则,推理机可在流程卡200中的任一点起动关断程序关断工艺。如前面所讨论的,真正的推理机将包含非常多的复杂的规则基准以及/或者专门对各种工艺控制应用采取更加复杂的诸如模糊逻辑和神经网络之类的逻辑形式。
尽管本发明已参照最佳实施例进行了描述,专业人员将会承认那些在形式和细节上所能作出的改变仍不脱离本发明的精神和范围。例如,这里描述的所有各种各样的功能和电路能够用包括软件、专用集成电路(ASIC)、模糊逻辑技术、或者甚至模拟工具在内的任何合适的电路进行实施。此外,工艺装置可以包含任意输入和控制通道的数量和组合,并可对任何数量的、单独的或是组合的工艺信号进行运算,而且规则也可依此运算。
Claims (38)
1.一种与工艺控制环路耦合的工艺装置,其特征在于,它包括:
一工艺信号输入装置,用于提供与一种工艺有关的一工艺信号;
存储器,容纳一表示观测的工艺信号的统计函数的序列值和一规则;
计算电路,计算表示工艺信号的统计函数的当前参数,并根据所述规则对所述当前参数和所述序列值进行运算,从而在与故障事件相关的工艺信号中识别一模式,并且响应于根据所述运算检测的工艺中的事件响应地输出一故障事件;以及
输出电路,输出故障事件输出。
2.按照权利要求1所述的装置,其特征在于,所述存储器进一步包括灵敏度参数,而且所述故障事件输出由或根据所述灵敏度参数形成。
3.按照权利要求1所述的装置,其特征在于,其中的工艺控制环路是从由双线工艺控制环路、三线工艺控制环路和四线工艺控制环路组成的一组中选出的。
4.按照权利要求1所述的装置,其特征在于,其中的装置完全是由从工艺控制环路接收的电源驱动的。
5.按照权利要求1所述的装置,其特征在于,其中的统计函数是从由标准偏离、平均值、取样偏差、均方根、范围和变化率组成的一组中选出的。
6.按照权利要求1所述的装置,其特征在于,其中的计算电路根据多个统计函数提供故障事件输出。
7.按照权利要求1所述的装置,其特征在于,其中的规则是从由尖峰、漂移、偏置、噪声和滞留组成的一组中选出的。
8.按照权利要求1所述的装置,其特征在于,其中的计算电路包含模糊逻辑,而规则则采用一成员函数。
9.按照权利要求8所述的装置,其特征在于,在存储器中所存的包含模糊成员函数在内,并且其中的计算电路在规则运算前将成员函数用于所述序列值。
10.按照权利要求1所述的装置,其特征在于,其中的工艺信号输入装置包括一传感器输入通道并且工艺信号包括一工艺变量。
11.按照权利要求10所述的装置,其特征在于,其中的传感器输入通道包括:
一传感器,提供一与工艺有关的传感器输出;以及
一模拟—数字转换器,将传感器输出转换成数字化的工艺变量。
12.按照权利要求11所述的装置,其特征在于,其中的传感器是从由压力、温度、酸碱度、流量、混浊度、水平传感器、位置、电导率、电机电流、电机反电动势和振动组成的一组中选出的。
13.按照权利要求1所述的装置,其特征在于,其中的工艺信号输入装置包括一控制通道并且工艺信号包括一控制信号。
14.按照权利要求13所述的装置,其特征在于,其中的控制通道包括:
一控制元件,用于控制工艺;以及
一调节器,用于调节控制元件。
15.按照权利要求1所述的装置,其特征在于,其中的工艺信号输入装置包括与控制环路耦合以从工艺控制环路接收工艺信号的输入电路。
16.按照权利要求1所述的装置,其特征在于,其中的输出电路与工艺控制环路耦合并在工艺控制环路上传送故障事件输出。
17.按照权利要求1所述的装置,其特征在于,其中的输出电路包括用于向用户输出故障事件输出的用户输出电路。
18.按照权利要求1所述的装置,其特征在于,其中的工艺信号输入装置包括一诊断通道并且工艺信号包括一与用于控制工艺的与控制元件有关的诊断信号。
19.按照权利要求18所述的装置,其特征在于,其中的诊断信号是从由阀门杆位置、力和压力组成的一组中选出的。
20.按照权利要求14所述的装置,其特征在于,其中的调节器包括一电动机并且控制元件包括一由电动机操纵的泵。
21.按照权利要求1所述的装置,其特征在于,包括一与故障事件输出耦合用于在工艺控制环路上进行诊断的推理机。
22.按照权利要求2所述的装置,其特征在于,其中的计算电路在工艺控制环路正常运行期间监测当前参数,从而产生序列值。
23.一种在工艺控制环路中的发送器,其特征在于,它包括:
一传感器,它测量一种工艺变量;
一模拟一数字转换器,它与传感器耦合并有一数字化的工艺变量输出;
一存储器,它容纳代表观测的工艺变量的统计函数的序列值和一规则;
计算电路,它与存储器和模—数转换器耦合,计算电路计算代表一数字化工艺变量的统计参数的当前参数,根据规则和序列值运算当前参数,从而在与故障事件相关的工艺信号中识别出一种模式,并响应地提供一工艺故障事件输出;以及
输出电路,它与工艺控制环路耦合并在环路上输出工艺故障事件输出。
24.按照权利要求23所述的发送器,其特征在于,其中的存储器还包括灵敏度参数值,而且故障事件输出还取决于该灵敏度参数。
25.按照权利要求23所述的发送器,其特征在于,其中的装置完全是由从工艺控制环路接收的电源驱动的。
26.按照权利要求23所述的发送器,其特征在于,其中的规则是从由信号尖峰、信号漂移、信号偏置、信号噪声和信号滞留组成的一组中选出的。
27.按照权利要求23所述的发送器,其特征在于,其中的传感器是从由压力、酸碱度、流量、混浊度和水平传感器组成的一组中选出的。
28.按照权利要求23所述的发送器,其特征在于,它包括用于补偿数字化工艺变量并与模—数转换器耦合的补偿电路。
29.按照权利要求24所述的发送器,其特征在于,其中的计算电路在工艺控制环路正常运行期间监测当前参数,从而产生序列值。
30.一种为在工艺控制系统中由工艺装置进行检测工艺事件的方法,其特征在于,它包括步骤:
取得一与工艺有关的工艺信号;
从存储器中取出一规则;
从存储器中取出表示观测到的工艺变量的统计函数的一序列值;
计算表示工艺信号的统计函数的一当前参数;
按照规则所确定的关系将当前参数与序列值进行比较,从而在与故障事件相关的工艺信号中识别出一种模式;以及
根据比较步骤作出响应提供一工艺故障事件输出。
31.按照权利要求30所述的方法,其特征在于,其中包括提取一灵敏度参数,而且比较的步骤还基于该灵敏度参数。
32.按照权利要求30所述的方法,其特征在于工艺信号包括一工艺变量。
33.按照权利要求30所述的方法,其特征在于,其中的工艺信号包括一控制信号。
34.按照权利要求30所述的方法,其特征在于,其中的工艺信号包括一诊断信号。
35.按照权利要求31所述的方法,其特征在于,它包括在正常运行期间计算工艺变量的当前参数以及将当前参数作为序列值存入存储器中的步骤。
36.按照权利要求30所述的方法,其特征在于,其中的规则是从由尖峰、漂移、偏置、噪声和滞留组成的一组中选出的。
37.按照权利要求30所述的方法,其特征在于,其中的统计参数是从由标准偏离、平均值、取样偏差、均方根、范围和改变率组成的一组中选出的。
38.按照权利要求30所述的方法,其特征在于,其中的比较步骤包括进行一模糊逻辑运算的步骤。
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US08/623,569 US6017143A (en) | 1996-03-28 | 1996-03-28 | Device in a process system for detecting events |
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CN1185841A CN1185841A (zh) | 1998-06-24 |
CN1188759C true CN1188759C (zh) | 2005-02-09 |
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CNB971902526A Expired - Lifetime CN1188759C (zh) | 1996-03-28 | 1997-03-13 | 在工艺系统中检测事件的装置和方法 |
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JP (1) | JP3923529B2 (zh) |
CN (1) | CN1188759C (zh) |
BR (1) | BR9702223B1 (zh) |
DE (1) | DE69705471T2 (zh) |
WO (1) | WO1997036215A1 (zh) |
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-
1996
- 1996-03-28 US US08/623,569 patent/US6017143A/en not_active Expired - Lifetime
-
1997
- 1997-03-13 CN CNB971902526A patent/CN1188759C/zh not_active Expired - Lifetime
- 1997-03-13 WO PCT/US1997/003859 patent/WO1997036215A1/en active IP Right Grant
- 1997-03-13 BR BRPI9702223-3A patent/BR9702223B1/pt not_active IP Right Cessation
- 1997-03-13 JP JP53443297A patent/JP3923529B2/ja not_active Expired - Fee Related
- 1997-03-13 DE DE69705471T patent/DE69705471T2/de not_active Expired - Lifetime
- 1997-03-13 EP EP97915014A patent/EP0829038B1/en not_active Expired - Lifetime
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1999
- 1999-05-03 US US09/303,869 patent/US6397114B1/en not_active Expired - Lifetime
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US6119047A (en) | 2000-09-12 |
EP0829038B1 (en) | 2001-07-04 |
JP3923529B2 (ja) | 2007-06-06 |
WO1997036215A1 (en) | 1997-10-02 |
DE69705471T2 (de) | 2001-10-31 |
JP2001501754A (ja) | 2001-02-06 |
US6397114B1 (en) | 2002-05-28 |
DE69705471D1 (de) | 2001-08-09 |
CN1185841A (zh) | 1998-06-24 |
BR9702223A (pt) | 1999-02-23 |
BR9702223B1 (pt) | 2009-01-13 |
EP0829038A1 (en) | 1998-03-18 |
US6017143A (en) | 2000-01-25 |
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