阅读说明：本技术 用于检测液位控制器上的杠杆锁定位置的系统和方法 (System and method for detecting lever locking position on a liquid level controller ) 是由 L·张 于 2016-04-21 设计创作，主要内容包括：在运输或其它处理事件期间,通过手动地接合杠杆锁定机构以固定液位控制器的杠杆组件来保护液位控制器不受损害是有必要的。在校准或将液位控制器投入运行之前,必须手动地分离杠杆锁定机构。为了更好地有助于操作者监控杠杆锁定机构的状态,将传感器耦合到杠杆锁定机构,以检测杠杆锁定机构是处于锁定位置还是解锁位置。随后经由用户接口将该信息提供给操作者。与当前的视觉检查相比,使用传感器更加稳健和可靠,并且提供了一种用于确定杠杆锁定机构的状态的简单的非接触方法。(During shipping or other handling events, it is necessary to protect the level controller from damage by manually engaging the lever lock mechanism to secure the lever assembly of the level controller. The lever locking mechanism must be manually disengaged before the level controller is calibrated or put into operation. To better assist the operator in monitoring the status of the lever locking mechanism, a sensor is coupled to the lever locking mechanism to detect whether the lever locking mechanism is in the locked or unlocked position. This information is then provided to the operator via the user interface. The use of sensors is more robust and reliable than current visual inspection and provides a simple non-contact method for determining the state of the lever locking mechanism.)

1. A computer-implemented method for detecting a lever locking position on a liquid level controller, the method comprising:

detecting, by one or more processors, a magnetic field generated by a feedback element of a sensor, the magnetic field detected using a sensing element of the sensor, and the sensor coupled to a lever locking mechanism of the liquid level controller, wherein the sensing element comprises a normally open contact;

closing the normally open contact in response to detecting the magnetic field;

in response to the normally open contact being closed, determining that the lever locking mechanism is in a locked position and opening or closing an electrical circuit to indicate that the lever locking mechanism is in the locked position;

detecting that the magnetic field is no longer detected;

opening the normally open contact in response to detecting that the magnetic field is no longer detected;

in response to the normally open contact opening, determining that the lever locking mechanism is in an unlocked position and opening or closing the circuit to indicate that the lever locking mechanism is in the unlocked position; and

providing, by one or more processors, the determined locked or unlocked position of the lever locking mechanism to a user.

2. The computer-implemented method of claim 1, wherein the sensing element is selected from the group consisting of: reed switches with normally open contacts, hall effect sensors, magnetic field sensing devices, fluxgates, and giant magnetoresistive bridges.

3. The computer-implemented method of claim 1, the sensing element being a reed switch having a normally open contact and the feedback element being a magnet.

4. The computer-implemented method of claim 1, wherein providing the determined locked or unlocked position of the lever locking mechanism to the user comprises: generating, via a user interface, a visual representation of the locked position or the unlocked position.

5. The computer-implemented method of claim 1, wherein providing the determined locked or unlocked position of the lever locking mechanism to the user comprises: generating, via a user interface, an audio representation of the locked position or the unlocked position.

6. A non-transitory computer-readable storage medium comprising computer-readable instructions executing on one or more processors of a system for detecting a lever lock position on a liquid level controller, the instructions when executed cause the one or more processors to:

closing the normally open contact in response to detecting the magnetic field;

in response to the normally open contact being closed, determining that the lever locking mechanism is in a locked position and opening or closing an electrical circuit to indicate that the lever locking mechanism is in the locked position;

detecting that the magnetic field is no longer detected;

opening the normally open contact in response to detecting that the magnetic field is no longer detected;

in response to the normally open contact opening, determining that the lever locking mechanism is in an unlocked position and opening or closing the circuit to indicate that the lever locking mechanism is in the unlocked position; and

providing, by one or more processors, the determined locked or unlocked position of the lever locking mechanism to a user.

7. The non-transitory computer readable storage medium of claim 6, wherein the sensing element is a reed switch and the feedback element is a magnet.

8. The non-transitory computer-readable storage medium of claim 6, wherein the instructions for providing the determined locked or unlocked position of the lever locking mechanism to the user comprise: instructions that when executed generate a visual representation of the determined locked or unlocked position via a user interface.

9. The non-transitory computer-readable storage medium of claim 6, wherein the instructions for providing the determined locked or unlocked position of the lever locking mechanism to the user comprise: instructions that when executed generate an audio representation of the determined locked or unlocked position via a user interface.

10. A system for detecting a lever locking position on a liquid level controller, the system comprising:

a sensor coupled to a lever locking mechanism of the liquid level controller, the sensor comprising a sensing element and a feedback element, wherein the sensing element comprises a normally open contact; and

a device coupled to the sensor, the device comprising a memory having instructions for execution on one or more processors, which when executed by the one or more processors, cause the device to:

detecting a magnetic field generated by the feedback element using the sensing element;

closing the normally open contact in response to detecting the magnetic field;

in response to the normally open contact being closed, determining that the lever locking mechanism is in a locked position and opening or closing an electrical circuit to indicate that the lever locking mechanism is in the locked position;

detecting that the magnetic field is no longer detected by the sensing element;

opening the normally open contact in response to detecting that the magnetic field is no longer detected;

in response to the normally open contact opening, determining that the lever locking mechanism is in an unlocked position and opening or closing the circuit to indicate that the lever locking mechanism is in the unlocked position; and

providing the determined locked or unlocked position of the lever locking mechanism to a user.

11. The system of claim 10, wherein the sensing element is a reed switch and the feedback element is a magnet.

12. The system of claim 10, wherein the sensing element is selected from the group consisting of: reed switches with normally open contacts, hall effect sensors, magnetic field sensing devices, fluxgates, and giant magnetoresistive bridges.

13. The system of claim 10, wherein the instructions of the device that when executed by the one or more processors provide the determined locked or unlocked position of the lever locking mechanism to the user further comprise: generating, via a user interface, an instruction of a visual representation of the locked or unlocked position.

14. The system of claim 10, wherein the instructions of the device that when executed by the one or more processors provide the determined locked or unlocked position of the lever locking mechanism to the user further comprise: generating, via a user interface, an instruction for an audio representation of the locked or unlocked position.

Technical Field

The present disclosure relates generally to meter diagnostics and, more particularly, to a system and method for detecting a lever locking position on a level controller used in a process control system.

Background

Process control systems typically employ various field devices to monitor and control the flow of fluids. These field devices operate to detect, evaluate, and/or modify various fluid parameters (e.g., pressure, temperature, level, etc.) within a process plant or system in order to ensure accurate process control.

One common field device is a level controller, which is typically mounted to a process vessel that contains a fluid or liquid. The level controller includes a rotatable lever assembly coupled to a displacer (displacer) disposed inside the vessel. The balance float moves in response to changes in fluid or liquid level and transmits these changes to the controller via changes in the rotational position of the lever assembly.

To protect the level controller from damage during transport or other handling, the operator needs to prevent the lever assembly from rotating by manually engaging the locking mechanism. Before the level controller is put into operation, the locking mechanism must be disengaged. However, if the operator forgets or ignores to disengage the locking mechanism, the lever assembly can malfunction, which in turn can render the controller inoperable.

Disclosure of Invention

According to a first exemplary aspect of the invention, a computer-implemented method for detecting a lever locking position on a liquid level controller comprises: the presence of a magnetic field generated by a feedback element of the sensor is detected. The presence of the magnetic field is detected using a sensing element of a sensor, and the sensor is coupled to a lever locking mechanism of the liquid level controller. If the presence of the magnetic field is detected, the method then determines that the lever locking mechanism is in the locked position. The method also determines that the lever locking mechanism is in the unlocked position if the presence of the magnetic field is not detected. Finally, the method provides the determined locked or unlocked position of the lever locking mechanism to the user.

According to a second exemplary aspect of the invention, a non-transitory computer-readable storage medium includes computer-readable instructions that are executed on one or more processors of a system for detecting a lever lock position on a liquid level controller. When executed, the instructions cause the one or more processors to detect the presence of a magnetic field generated by a feedback element of the sensor. The presence of the magnetic field is detected using a sensing element of a sensor, and the sensor is coupled to a lever locking mechanism of the liquid level controller. The instructions then, when executed, cause the one or more processors to: if the presence of the magnetic field is detected, it is determined that the lever locking mechanism is in the locked position. The instructions, when executed, further cause the one or more processors to: if the presence of the magnetic field is not detected, it is determined that the lever locking mechanism is in the unlocked position. Finally, when the instructions are executed, the instructions cause the one or more processors to provide the determined locked or unlocked position of the lever locking mechanism to the user.

According to a third exemplary aspect of the invention, a system for detecting a lever lock position on a liquid level controller comprises: a sensor coupled to a lever locking mechanism of the liquid level controller, the sensor comprising a sensing element and a feedback element; and a device coupled to the sensor, the device comprising a memory having instructions for execution on the one or more processors. The instructions, when executed by the one or more processors, cause the device to detect a presence of a magnetic field generated by the feedback using the sensing element. The instructions, when executed by the one or more processors, cause the apparatus to: if the presence of the magnetic field is detected, it is determined that the lever locking mechanism is in the locked position. The instructions, when executed by the one or more processors, further cause the apparatus to: if the presence of the magnetic field is not detected, it is determined that the lever locking mechanism is in the unlocked position. Finally, the instructions, when executed by the one or more processors, cause the device to provide the determined locked or unlocked position of the lever locking mechanism to the user.

Further in accordance with any one or more of the preceding first, second or third exemplary aspects, the invention may include any one or more of the following further preferred forms.

In one preferred form, the sensing element is a reed switch having normally open contacts and the feedback element is a magnet.

In another preferred form, determining that the lever locking mechanism is in the locked position further comprises: if the presence of a magnetic field is detected, the normally open contact is caused to close and a signal is generated to close the circuit.

In another preferred form, determining that the lever locking mechanism is in the unlocked position further comprises: if the presence of a magnetic field is not detected, the normally open contact is caused to remain open and another signal for opening the circuit is generated.

In another preferred form, the sensing element is a reed switch having a normally closed contact and the feedback element is a magnet.

In another preferred form, determining that the lever locking mechanism is in the locked position further comprises: if the presence of a magnetic field is detected, the normally closed contacts are caused to open and a signal for opening the circuit is generated.

In another preferred form, determining that the lever locking mechanism is in the unlocked position further comprises: if the presence of a magnetic field is not detected, the normally closed contacts are caused to remain closed and another signal is generated for closing the circuit.

In another preferred form, providing the determined locked or unlocked position of the lever locking mechanism to the user includes: a visual representation of the locked or unlocked position is generated via a user interface.

In another preferred form, providing the determined locked or unlocked position of the lever locking mechanism to the user includes: an audio representation of the locked or unlocked position is generated via a user interface.

Drawings

FIG. 1 is a perspective view of an exemplary level controller mounted to a process vessel.

FIG. 2A is a bottom side view of the example liquid level controller of FIG. 1 showing the lever locking mechanism in a locked position.

FIG. 2B is a bottom side view of the example liquid level controller of FIG. 1 showing the lever locking mechanism in an unlocked position.

FIG. 3 is a flow chart representing an exemplary method for detecting a lever locking position on the exemplary level controller of FIG. 1.

Detailed Description

FIG. 1 shows a perspective view of an example level controller 102 mounted to a process vessel 104 used in a process plant or system. For example, the process vessel 104 can be a tank, a reboiler, a distillation column, and the like. The process vessel 104 includes one or more ports 106, which ports 106 allow the process vessel 104 to be filled with a fluid or liquid. The level controller 102 operates to measure the level of liquid in the process vessel 104. Alternatively or additionally, the level controller 102 may be used to measure the level of an interface between two liquids, or the density of a liquid in the process vessel 104.

Generally, the level controller 102 includes a lever assembly (not shown) coupled to a torque tube 108, which torque tube 108 in turn attaches to a balance float 110 submerged in the liquid inside the process vessel 104. The change in the level of the liquid exerts a buoyancy force on the balance float 110. This change causes a change in the position (e.g., vertical movement) of the balance float 110, which rotates the torque tube 108. The rotational motion of the torque tube 108 is then transmitted to the lever assembly. More specifically, the rotational motion moves a magnet attached to the lever assembly and, thus, changes the magnetic field sensed by the magnetic sensor (e.g., hall effect sensor). The magnetic sensor converts the changing magnetic field into a changing signal that corresponds to a change in the level of the liquid inside the process vessel 104.

The liquid level controller 102 also includes a processor 112, a memory 114, and one or more interfaces 116. The memory 114 stores instructions that may be executed by the processor 112 to operate the level controller 102. One or more interfaces 116 enable interaction between the level controller 102 and a user or another device. For example, the one or more interfaces 116 may include a user interface that allows a user to configure or view information on the level controller 102. As another example, one or more of the interfaces 116 may include a communication interface that allows communication between the level controller 102 and other peripheral devices.

It is necessary to protect the level controller 102 from damage during transportation or other handling events. To this end, the liquid level controller 102 includes a lever lock mechanism 118, the lever lock mechanism 118 being manually engaged by an operator to prevent rotation of the lever assembly. Before the level controller 102 is calibrated or the level controller 102 is put into operation, the lever locking mechanism 118 must be manually disengaged by an operator. However, if the operator forgets or ignores to disengage the lever lock mechanism 118, the lever assembly may malfunction, which in turn may prevent proper operation of the level controller 102.

Typically, the lever locking mechanism 118 is located on the bottom or underside of the level controller 102. Thus, the lever locking mechanism 118 is not readily visible to the operator. However, to determine whether the lever lock mechanism 118 is engaged, a visual check is required. For example, current designs rely on visual cues (e.g., using "lock" or "unlock" symbols) to indicate the state of the lever locking mechanism 118.

To better assist an operator in detecting and/or monitoring the status of the lever locking mechanism 118, a sensor may be coupled to the level locking mechanism 118. The sensor operates to determine a locked or unlocked position of the lever lock mechanism 118, which may then be displayed to an operator via a user interface. In this manner, the sensor provides a simple, non-contact method for determining the state of the lever lock mechanism 118.

Fig. 2A and 2B show bottom side views of the liquid level controller 102 with the lever locking mechanism 118 of fig. 1. An operator may slide the latch 120 along the latch handle 122 to manually engage or disengage the lever locking mechanism 118.

To determine the locked or unlocked position of the lever lock mechanism 118, a sensor 126 is coupled to the lever lock mechanism 118. Generally, the sensor 126 includes a sensing element 128 and a feedback element 130. When the lock 120 is engaged, the sensing element 128 will detect the presence of the feedback element 130. Thus, the lever locking mechanism 118 is considered to be in the locked position (see fig. 2A). On the other hand, if the lock 120 is disengaged, the sensing element 128 will not detect the presence of the feedback element 130. Thus, the lever locking mechanism 118 is considered to be in the unlocked position (see fig. 2B).

In the embodiment of fig. 2A and 2B, sensing element 128 is a reed switch and feedback element 130 is a magnet. Reed switch 128 is an electrical switch that includes a pair of contacts on a ferrous metal reed. The contacts may be normally open. Thus, when a magnetic field (e.g., generated by magnet 130) approaches the contacts, the contacts will close. This indicates that the lever locking mechanism 118 is engaged in the locked position. Once the magnetic field is removed (e.g., magnet 130 is pulled a certain distance away), the contacts will return to their normally open position, indicating that lever lock mechanism 118 is now separated in the unlocked position. Alternatively, the contacts may be normally closed. Thus, the presence of a magnetic field from magnet 130 will cause the contacts to open. In this scenario, the open of the contacts indicates the locked position, while the closed contacts indicates the unlocked position.

In an exemplary embodiment, the opening and closing of the contacts will generate a signal for closing or opening the circuit. For example, if the contacts are normally open, the presence of a magnetic field will cause the contacts to close. The closing of the contacts will generate a signal for closing the circuit, which in turn indicates that the lever locking mechanism 118 is in the locked position. Removal of the magnetic field will cause the contacts to open again. The reopening of the contacts will generate another signal that opens or breaks the circuit, which in turn indicates that the lever locking mechanism 118 is in the unlocked position.

By using the sensor 126 in the lever lock mechanism 118, it is possible to notify the operator of the state of the lever lock mechanism 118 before putting the level controller 102 into operation. For example, the operator may be notified or determine whether the lever locking mechanism 118 is in the locked or unlocked position via information displayed in a user interface (e.g., one of the interfaces 116 in fig. 1).

In some embodiments, the sensing element 128 may be another type of magnetic field sensing device, such as a Hall effect sensor, a magneto resistor, a giant magnetoresistive bridge, a fluxgate, and so forth. Further, in certain embodiments, the sensor 126 including the sensing element 128 and the feedback element 130 may be a separate unit incorporated into the lever locking mechanism 118, while in other embodiments, the sensor 126 may be an integrated part of the lever locking mechanism 118.

FIG. 3 illustrates a flow chart of an example method 200 for detecting a lever locking position on a liquid level controller. The method 200 may include one or more blocks, routines, or functions in the form of computer-executable instructions stored in a non-transitory computer-readable medium (e.g., 114 in fig. 1) and executed using a processor (e.g., 112 in fig. 1). The level controller may include a lever locking mechanism (e.g., 118 in FIG. 1) having a sensor (e.g., 126 in FIG. 2) that is manually engaged or disengaged. Thus, the method 200 may be performed to determine whether the lever locking mechanism is locked or unlocked using a sensor.

The method 200 begins by monitoring for the presence of a magnetic field using a sensor (block 202). To this end, the method 200 may utilize a sensing element of the sensor, which may be, for example, a reed switch. The magnetic field may be generated by a feedback element (e.g., a magnet), where the feedback element is also part of the sensor. The reed switch may include a pair of contacts that are normally open or normally closed. Thus, when a magnet generating a magnetic field is brought into proximity with a reed switch, the contacts will close or open accordingly.

For example, for normally open contacts, the method 200 may detect the presence of a magnetic field by determining whether the contacts are closed. If the contacts are determined to be closed, a magnetic field is present. However, if the contacts are determined to be open, no magnetic field is present or proximate.

Based on the presence of the magnetic field, the method 200 proceeds to determine a state of the lever locking mechanism (block 206). Continuing with the example above, if the contacts are closed, the method 200 may generate a signal to indicate that the lever locking mechanism is engaged in the locked position. On the other hand, if the contacts are open (e.g., no magnetic field present or removed), the method 200 may generate another signal to indicate that the lever locking mechanism is disengaged in the unlocked position. In an exemplary embodiment, the method 200 may generate a signal for closing or opening an electrical circuit to indicate whether the lever locking mechanism is engaged or disengaged.

Next, the method 200 provides information to the user regarding the status of the lever locking mechanism (block 208). For example, the method 200 may generate a visual representation (e.g., a symbol, icon, text, etc.) via a user interface to indicate a locked or unlocked position of the lever locking mechanism. As another example, the method 200 may generate an audio representation (e.g., a beep) via a user interface to inform a user whether the lever locking mechanism is in the locked or unlocked position.

After displaying the status of the lever locking mechanism, the method 200 may return to the beginning of block 202 to continue monitoring and providing information regarding the status of the lever locking mechanism.

The following additional considerations apply to the foregoing discussion. Throughout this specification, multiple instances may implement the function, routine, or operational structure described as a single instance. While individual functions and instructions of one or more methods are illustrated and described as separate operations, one or more of the individual operations may be performed concurrently and nothing requires that the operations be performed in the order illustrated. Structures and functionality presented as discrete components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as discrete components. These and other variations, modifications, additions, and improvements may fall within the scope of the subject matter herein.

In addition, certain embodiments are described herein as including a logical unit or multiple functions, components, modules, blocks, or mechanisms. The functions may constitute software modules (e.g., non-transitory code stored on a tangible machine-readable storage medium) or hardware modules. A hardware module is a tangible unit that is capable of performing certain operations and may be configured or arranged in a certain manner. In an example embodiment, one or more computer systems (e.g., a standalone client or server computer system) or one or more hardware modules (e.g., processors or groups of processors) of a computer system may be configured by software (e.g., an application or application portion) as a hardware module that operates to perform certain operations as described herein.

In various embodiments, the hardware modules may be implemented mechanically or electronically. For example, a hardware module may comprise special purpose circuits or logic elements that are permanently configured (e.g., configured as a special purpose processor, such as a Field Programmable Gate Array (FPGA) or an Application Specific Integrated Circuit (ASIC)) to perform certain functions. A hardware module may also include programmable logic units or circuitry (e.g., as contained within a general-purpose processor or other programmable processor) that is temporarily configured by software to perform certain operations. It will be appreciated that the decision to mechanically implement a hardware module in dedicated and permanently configured circuitry or temporarily configured circuitry (e.g., configured by software) may be driven by cost and time considerations.

The term hardware should therefore be understood to encompass a tangible entity, be it a physically constructed, permanently configured (e.g., hardwired), or temporarily configured (e.g., programmed) to operate in a certain manner or to perform certain operations described herein. Considering embodiments in which the hardware modules are temporarily configured (e.g., programmed), each of the hardware modules need not be configured or instantiated at any one time instance. For example, where the hardware modules include a general-purpose processor configured using software, the general-purpose processor may be configured at different times as respective different hardware modules. The software may configure the processor accordingly, e.g., to constitute a particular hardware module at one instance in time, and to constitute a different hardware module at a different instance in time.

The hardware and software modules may provide information to and receive information from other hardware and/or software modules. Thus, the described hardware modules may be considered to be communicatively coupled. Where multiple such hardware or software modules exist concurrently, communication may be achieved through signaling (e.g., over appropriate circuits and buses) connecting the hardware or software modules. In embodiments in which multiple hardware or software modules are configured or instantiated at different times, communication between the hardware or software modules may be accomplished, for example, through the storage and retrieval of information in a memory structure accessible to the multiple hardware or software modules. For example, a hardware or software module may perform an operation and store the output of the operation in a storage device communicatively coupled to the hardware or software module. Other hardware or software modules may then access the storage device at a later time to retrieve and process the stored output. The hardware and software modules may also initiate communication with an input or output device and may operate on a resource (e.g., a collection of information).

Various operations of the example functions and methods described herein may be performed, at least in part, by one or more processors that are temporarily configured (e.g., by software) or permanently configured to perform the relevant operations. Whether temporarily or permanently configured, these processors may constitute modules that are executed by a processor that operates to perform one or more operations or functions. In certain exemplary embodiments, the modules referred to herein may comprise modules that are executed by a processor.

Similarly, methods or functions described herein may be performed, at least in part, by a processor. For example, at least some of the functions of the method may be performed by one or more processors or hardware modules executed by processors. Execution of certain functions may be distributed among one or more processors, where such processors reside not only within a single machine, but are deployed across multiple machines. In some exemplary embodiments, one or more processors may be located at a single location (e.g., within a home environment, an office environment, or as a server farm), while in other embodiments, processors may be distributed across multiple locations.

The one or more processors may also be operable to support performing related operations in a "cloud computing" environment or to operate as a "software as a service" (SaaS). For example, at least some of the functions may be performed by a group of computers (as an example of a machine including a processor), which may be accessed via a network (e.g., the internet) and via one or more appropriate interfaces (e.g., Application Program Interfaces (APIs)).

Execution of certain operations may be distributed among one or more processors, where the processors not only reside within a single machine, but are deployed across multiple machines. In some example embodiments, one or more processors or processor-executed modules may be located in a single geographic location (e.g., within a home environment, an office environment, or a server farm). In other exemplary embodiments, one or more processors or processor-executed modules may be distributed across multiple geographic locations.

Unless specifically stated otherwise, discussions utilizing terms such as "processing," "computing," "calculating," "determining," "presenting," "displaying," or the like, herein may refer to the action or processes of a machine (e.g., a computer) that manipulates or transforms data represented as physical (e.g., electronic, magnetic, or optical) quantities within one or more memories (e.g., volatile memory, non-volatile memory, or a combination thereof), registers, or other machine components that receive, store, transmit, or display information.

Upon reading this disclosure, those skilled in the art will appreciate that additional alternative structural and functional designs of the system and method for detecting a lever locking position on a liquid level controller may also or alternatively be used. Thus, while particular embodiments and applications have been illustrated and described, it is to be understood that the disclosed embodiments are not limited to the precise construction and components disclosed herein. Various modifications, changes and variations which will be apparent to those skilled in the art may be made in the arrangement, operation and details of the methods and apparatus disclosed herein without departing from the spirit and scope as defined in the appended claims.