Note: Descriptions are shown in the official language in which they were submitted.
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MICRO-ELECTRO-MECHANICAL INTEGRAL CONTROL SYSTEMS
Related Application
This case claims priority to USSN 60/054,951 entitled Micro-Electro Mechanical
Integrated Control System, filed 7 August 1998.
Field of the Invention
The invention relates to control systems and more particularly to control
systems
capable of monitoring the operating state of a process or system.
Background of the Invention
Today, a number of companies develop and sell control systems for monitoring
and controlling complex systems, such as chemical plants, assembly lines, and
transportation networks. These control systems rely on sophisticated data
processing
devices that connect to a plurality of sensors and instruments that are
coupled into the
system being monitored at.locaxions that yield useful information about the
operating
state of the system. Accordingly, a typical control system will employ a
centralized data
processor that is in communication with a plurality of different sensors, such
as pressure
sensors, tachometers, and temperature sensors. Each sensor is positioned to
collect
information about the system or process under control that allows the data
processor to
regulate the process and achieve a desired operating condition.
Although these control systems can work well, they can be quite complex and
expensive. One source of complexity and expense is the interface between the
data
processing systems and the different sensors and instruments connected into
the system
being monitored. Commonly, each type of sensor, such as a thermometer or a
tachometer, has a proprietary or customized interface that must connect to the
data
processor. The interface can sometimes include a software device driver that
has been
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custom written for each sensor and instrument in the control system.
Accordingly, the
control system must be custom adapted to operate these different sensors.
Additionally,
each type of sensor or instrument can have a different type of hardware
interface, such as
a parallel, serial, or bus interface. This requires a customized interface
hardware for
coupling the sensors to the data processing equipment.
Consequently, there is a need for a control system in which a data processor
can
be easily and efficiently integrated with the sensors and instruments coupled
to the system
being controlled.
Moreover, control systems and closed-loop control systems have been developed
for large-scale mechanical, electromechanical or processing systems. With the
advent of
micro-mechanics and subsequently "mechatronics", the coalescence of micro-
mechanics
and micro-electronics, there is a need far control systems at the scale of
these devices.
Summary of the Invention
The systems and methods of the invention include integrated control
instntments
that can be directly coupled to the sensors, motors, valves, or other device
used in a
controlled system. These micro-electro-mechanical integrated control systems
(MEMICS) provide an architecture for open or closed loop control of systems
and
devices including micro systems for micro-electronic, micro-mechanic or micro-
chemical
processing. The devices contain components and processes that allow control
supervision by a computer or by an operator (open loop) of multiple micro-
systems and
of micro-sensors. Moreover, each integrated control unit can control or
monitor a
plurality of control devices and sensors and provide a standardized interface
for the plural
devices to the data processing system. This allows for the achievement of
e~ciencies in
the transfer of data and instructions between the data processing system and
the control
devices and sensors.
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More particularly, the invention is understood to include apparatus for
controlling
a system, comprising a data interface for communicating data packages
representative of
data and command signals across a data network, a communications manager
coupled to
the data interface for processing the data packages to exchange data and
command
signals with a data processor, wherein each data package organizes the data
and
command signals according to a predetermined format suitable for transfer
across the
data network, and a device manager adapted for processing the data and command
signals to generate control signals for selectively configuring an operating
characteristic
of a device coupled to the system being controlled. In one embodiment, the
device
includes a sensor that is coupled in communication with the device manager. In
another
embodiment, the device includes an actuator that is coupled into communication
with a
device manager. In a further embodiment the device is maintained within a
housing that
contains the sensor, the device manager, the communications manager and the
data
interface. Each of these elements can be held within the housing, such that
the actuator
and the sensors are maintained within the housing along with the device
manager and the
communications interface. In one embodiment, the device further includes a
multiplexed
interface for allowing the device manager to monitor and control a plurality
of devices
coupled to the system being controlled.
In an optional embodiment, the system includes an encryption processor for
encrypting and decrypting the data signals and command signals that are
transferred
across the data network. In yet a further embodiment, the apparatus can
include an
interface for coupling to a system monitor that allows a user to monitor and
adjust the
operation of the device, and can further include a system clock for
maintaining a measure
of time within the system.
In a further embodiment, the invention can be understood as an
integrated.control
device for monitoring characteristics of a system under control. The
integrated control
device can include a housing that is adapted for being removably and
replaceably
mounted to, adjacent, or proximate the system under control. The housing can
contain
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the data interface for communicating the data packages representative of the
data and
command signals, the communications manager, and the device manager that is
responsive to the data and command signals and capable of controlling and
monitoring a
sensor that monitors a characteristic of the operating state of the system
under control.
In a fixrther embodiment, the invention can be understood as a semiconductor
device for monitoring a system under control. The semiconductor device can
include a
substrate that has a plurality of circuits formed thereon. The circuits can
include a
communications manager for processing data packages having data and command
signals
wherein each data package organizes the data and command signals according to
a
predetermined format suitable for transfer across a data network. The circuits
can further
include a device manager adapted for processing the data and command signals
to
generate control signals for operating a device coupled to the system being
controlled, a
sensor capable of monitoring a characteristic of the system under control and
an actuator
capable of adjusting an operating parameter of the system under control,
whereby
command signals communicated from a data processor are processed by the device
manager for controlling the sensor and the actuator to perform selected
operations. In
one embodiment the semiconductor device can include sensors that consists of
tilt
sensors, temperature sensors, pressure sensors, an accelerometer, a gyroscope,
a light
detector, a microphone, and any combination thereof including a plurality of
similar
sensors, such as a plurality of pressure transducers. Similarly, the
semiconductor device
can include actuators of a number of different types including motors, pumps,
valves,
data ports and I/O lines, as well as any combinations thereof including
combinations that
provide plurality of similar types of actuator elements, such as the plurality
of different
motors or pumps.
In a further embodiment, to provide for sophisticated communication between
the
devices monitoring the system under control and the data processor, the
integrated circuit
can include a communications manager that can generate an ID signal or a field
for
storing an ID signal which will identify the system under control that is
associated with
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that data package. Similarly, the communications manager can include a device
»
generator that will generate a device ID signal suitable for identifying the
device that is
generating the particular data packet carrying that device ID signal. In this
way, a single
data processor can be operating a plurality of different processes each of
which is
listening for data packages associated with a particular one or set of systems
under
control. Further, the data processor as well as other elements of the system
can identify
from data packages the particular device that is generating the information
representative
of a characteristic of the operating state of the system under control. This
is particularly
helpful in those situations where each device includes an interface to a radio
frequency
transmission system for exchanging data signals through radio frequency
signals. This
can allow a transceiver in communication with the plurality of different
devices to
understand which of the devices is generating which set of information.
In a further aspect, the invention can be understood as control systems that
monitor and adjust an operating state to the system under control. The control
systems
can include a data processor of the type capable of processing information
representative
of at least one characteristic of an operating state of the system under
control, and of
generating command signals representative of instructions for configuring the
operating
of a sensor device. The systems can further include a data network coupled to
the data
processor and being of the type suitable for communicating information
signals, and a
plurality of sensor devices wherein each is coupled to the system under
control for
monitoring a characteristic of the operating state of the system and wherein
each sensor
device includes a communications manager, a device manager and a sensor
capable of
monitoring characteristics of the system under control. In these systems,
command
signals generated by the data processor and communicated across the data
network can
be received by the plurality of sensor devices for configuring each of the
sensor devices
to operate in a certain manner. In this way, a control system can be provided
wherein a
plurality of generic, or similar, sensor devices are located at different
locations on the
system being controlled and are configured according to the needs of the data
processor
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to provide information representative of characteristics of the operating
state of the
system under control.
In a further aspect, the invention can be understood as a process for
controlling a
system having an operating state having at least one characteristic
representative of the
operating state. These processes can include providing a data processor of the
type
capable of processing information representative of at least one
characteristic of the
operating state of the system under control and of generating command signals
representative with instructions for configuring the operation of a sensor
device,
providing a data network coupled to the data processor and being of the type
suitable for
communicating information signals and coupling a sensor device to the system
under
control for monitoring the characteristics of the operating system, wherein
the system has
a communications manager, a sensor capable of monitoring characteristics of
the system,
and a device manager adapted for processing data and command signals from the
data
processor for controlling the operation of the sensor. In a further step,
these processes
can transmit from the data processor command signals that will configure the
sensors to
operate in a selected manner. In a further embodiment of these processes, the
sensor
devices can further include actuator elements that are capable of adjusting or
modifying
an operating parameter of the system under control. For these systems, the
data
processor can also generate command signals that are capable of operating, or
configuring, the actuator to adjust the selected parameter of the system under
control.
Accordingly, the MEMICS architecture makes it possible to integrate the
electronic and mechanical parts of the control system in a single instrument.
The
integrated control instrument can provide a battery of sensors and devices
that can be
configured for a selected application to monitor (micro-) electronic, (micro-)
mechanic or
(micro-) process machines such as sensors, motors, alarm systems,
communication
systems, spectrogaphs, aerospace devices, and medical devices. These systems
provide
configurable control devices that can exists at the scale of the devices being
controlled,
including systems as the circuit and component level.
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Brief Description of the Illustrated Embodiments
The figures depict certain illustrative embodiments of the invention and are
not to
be understood as limiting in any sense.
Fig. 1 depicts a functional block diagram of one architecture of a device
according
to the invention;
Fig. 2 depicts a control system having a plurality of devices of the type
depicted in
Figure 1 coupled into a system under control;
Fig. 3 depicts in block diagram form an integrated circuit device for
controlling a
system;
Fig. 4 depicts a device having a housing capable of being mounted to a system
being controlled; and
Fig. 5 depicts a flow chart of one process according to the invention.
Detailed Description of the Illustrated Embodiments
The systems and methods described herein provide integrated control devices
that
can operate a plurality of devices, including a plurality of sensors. For
illustrative
purposes, the systems and methods described herein will be generally shown as
sensor
systems that allow for the monitoring and controlling of a work-space, or
other similar
environment. However, it will be understood by one of ordinary skill in the
art that the
systems and methods described herein are not to be so limited and that other
applications
of this technology fall within the spirit and scope of the invention.
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The systems and devices described herein provide integrated electrical
mechanical
control systems that provide a configurable sensor and actuator device. Each
configurable device can include a battery of sensors, such as thermometers,
pressure
gages, accelerometers, and other devices as including one or more actuators,
such as
pumps, valves, motors, adjustable lenses, and other devices. Each of these
devices, both
sensors and actuators can be controlled by a device manager that will
configure the
parameters under which these sensors and actuators will work. For example, the
device
manager can configure the temperature ranges over which a temperature sensor
will
operate. Similarly, the device manager can configure the operational
parameters of a
motor to define the rate at which the motor can turn. Further, the device
manager can
also enable and disable certain ones of the sensors and actuators such that in
a device
containing a pressure sensor, and a thermometer, only the thermometer is
enabled for
operation such that the sensor device is collecting solely temperature
information.
To configure the operation of the sensors and actuators, the device manager
can
receive commands through a communications manager that is interfaced either
directly,
or indirectly, to a data network that can exchange data packages with a data
processor
coupled to the network. The data processor can generate data packages that
include
command signals which will be transferred through the communications manager
of the
integrated control instrument to the device manager. The device manager will
respond to
the command signals for configuring the device, such as by enabling certain
ones of the
sensors coupled to the device,~and selecting the operating parameters for that
device. In
this way, the data processor can provide a central station that can configure
a plurality of
integrated sensor devices which are located at different locations on the
system under
control. Each of the sensors can monitor a certain parameter that is
associated with the
operating state of the system under control and can provide data packets of
information
through the data network to the data processor for allowing the data processor
to
monitor, and in some applications adjust, the operating state of the system
under control.
Accordingly, it will be understood that the integrated control systems
described herein
provide for configurable sensor and actuator systems that can be located at
different
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locations of a system under control and dynamically configured by a data
processing
system to allow the data processing system to implement a control system for
monitoring
and adjusting the operating state of the system under control.
The systems described herein can couple to or incorporate a wide range of
disparate sensor types, each of which can operate differently. To facilitate
the use of
these disparate devices, a device manager is provided which can couple to an
inputloutput interface device. Each of the sensors coupled to the system, can
be
connected to the interface, such as, for example, by being coupled in
electrical circuit to
the interface. The device manager can operate the input/output device to
initialize,
disable, monitor and control the sensors. The device manager can then
encapsulate the
information collected by the sensors into common format, and the encapsulated
data can
be sent to a central processing facility that reads the data and effects
control changes as
appropriate.
Fig. 1 depicts one example of an integrated electronic and mechanical sensor
control device. To that end, the depicted system 10 includes a command and
control
computer 12 that couples to a transceiver 14, which in turn communicates with
the
MEMIC device 16. The MEMIC device 16 can work as a stand-alone device or in a
many-to-many configuration, wherein a plurality of MEMICS can interact with
many
command and control units. This allows back-up and enhanced availability. Fig.
1
further depicts, a plurality of devices 40, a system monitor 44, an open loop
feedback
device 42, and open loop interrupt device 46, a system clock 50, a power
manager 52,
and a power supply 54. The MEMICS 16 of Fig. 1 is shown in functional block
diagram
form and includes a transceiver 20, a communication manager 22, an
encoder/decoder 26,
an encryptor/decryptor 28, a device manager 24, a device monitor 30, DAC/ADC
devices
32 and a device I/O manager 34.
The command and control computer 12 depicted in Fig. 1 is a data processing
system of the type commonly employed for running a computer program that
implements
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a monitor and control process, and for example can be a stand alone controller
system,
such as the type sold by the Foxboro Company of Foxboro, Massachusetts, or can
be a
conventional computer work station, such as an IBM PC compatible work station
that is
running a computer program to configure it to operate as a data processor
control
system.
The command and control computer 12 can run under the control of a computer
program that is capable of directing the command and control computer 12 to
generate
command signals that are representative of signals for initializing, enabling
and
configuring the devices 40 depicted in Fig. 1. The command signals can include
instructions for enabling or disabling an interface to a device 40. The
command signals
can further include instructions for setting the operating ranges, such as
temperature
ranges, pressure ranges, and other parameters that are employed for setting up
the
devices 40. The computer program running on the command and control computer
12
can be a conventional computer program such as a C language program or a JAVA
language program that can download aplets from the command and control
computer 12
to the integrated control unit 16 for providing client side control of the
initialization and
operaxion of devices 40.
The Fig. 1 further depicts a transceiver 14 that couples to the command and
control computer 12. The transceiver 14 can be a network interface card that
takes
command signals and data signals generated by the command and control computer
12
and formats them in a format suitable for delivery over the physical layer of
a computer
network, such as an ethernet network, or any IP network. Alternatively, the
transceiver
14 can be a network interface card that is connected through a data network to
the
command and control computer 12 for receiving data packets, such as IP data
packets
carried on a computer data network which provides a bidirectional data path
between the
transceiver 14 and the command and control computer 12. The transceiver 14 can
receive the data packets from the computer network and translate these data
packages
into signals that can be broadcast to the integrated control unit 16. For
example, the
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transceiver 14 can include a network interface card that couples to the data
network in
communication with the command and control computer I2. The network interface
card
of transceiver 14 can couple to a radio frequency transceiver that will
broadcast data and
command signals to the transceiver 20 of the integrated control unit 16. In
this way, the
integrated control unit 16 can be physically separated from the computer
network
without requiring a connection to the network cable. Although the above
transceiver 14
has been described with reference to a radio frequency link, it will be
understood by one
of ordinary skill in the art that infra red links, twisted pair links, or any
other suitable
communication link between the transceiver 14 and the integrated control unit
16.
The depicted transceiver 14 is attached to the I/O bus of the command and
control computer 12, through communication, parallel or PC-Card ports. The
transceiver
unit receives power from the computer. An operator can take control away from
the
main program and interrupt the device control system. The operator can
interact with a
system monitor that can include a keypad, switch, video display or other
suitable 1/O
device or devices.
The integraxed control unit 16 includes a transceiver 20 for exchanging data
and
command signals with the transceiver 14. The transceiver 20 can be any
conventional
transceiver element, including a radio frequency, ar infra red transceiver
unit and will be
selected to be compatible with the transceiver I4 that is in communication
with the
command and control unit 12. Accordingly, each device 16 can have a
transceiver
through which it communicates with the transceiver of the command and control
system.
The depicted transceivers allow the device to operate in wireless mode,
whether in radio
frequency, infra red or otherwise. To that end they are equipped with the
necessary
electronics and logic for telecommunication including antennas or electro-
optical or
ultrasound or any other means. The transceiver contains means to perform error
detection/error correction and all necessary facilities to ensure proper data
transfer.
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The transceivers and may be replaced with electrical or optical wire, on
condition
that the communication signal is properly managed. The communication manager
is
responsible for preparation and acceptance of the messages for transmission.
It has two
main modules: an encoder/decoder unit that organizes the data in the message,
and an
encryptor/decryptor unit that ensures that messages are only exchanged with
authorized
command/control computers or are exchanged in a format that can only be
understood or
processed by authorized or selected processors.
As further shown by Fig. 1, the transceiver 20 is in bidirectional
communication
with the communications manager 22. The communications manager 22 includes an
encoder/decoder element 26 and an encrypter/decrypter unit 28. As further
shown by
Fig. 1, both the encoder unit 26 and encrypter unit 28 are coupled in
bidirectional
communication. As further shown by Fig. 1, the communication manager 22 is
coupled
between the transceiver 20 and the device manager 24. The communications
manager
can be an electronic circuit, or a software program running on a general
purpose
microprocessor. The communication manager 22 employs the encoder/decoder unit
26
to organize the data in the data packet for transmission through transceiver
20 to
transceiver 14. The data is organized by encoder 26 into a format that will be
understood
by the computer program operating on the command and control computer 12.
Similarly,
~ the encoder/decoder 26 can receive data packets generated by the command and
control
computer 12 and select from these data packets the command and data signals
that are to
be sent to the device manager 24 for initializing and configuring the
operation of sensors
40. Data transferred from the encoder 26 through transceiver 22 and to
transceiver 14
can, in one embodiment, be formatted by a network interface card that is part
of
transceiver 14 into a format that is suitable for transmission across the data
network that
carries data between the transceiver 14 and the command and control computer
12.
Fig. 1 further depicts an optional element, the encrypter/decrypter 28. The
encrypter/decrypter 28 can be an electrical circuit or alternatively, can be a
software
routine running on a conventional microprocessor. The encrypter/decrypter can
operate
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to encrypt and decrypt signals to provide a layer of security for the
communications
between the integrated control unit 16 and the command and control computer
12. This
reduces the likelihood of tampering that could interfere with the proper
monitoring of the
system under control.
S
Fig. 1 further depicts a device manager 24 that includes a device monitor 30
that
couples through the digital analog converter 32 and to the device
I/Omultiplexer 34. The
device manager 30 transfers data between the devices 40 and the communications
manager 22. Additionally, the device manager 24, which can be an electrical
circuit, or a
software routine running on a microprocessor, processes and responds to the
command
and data signals provided from the command and control computer for
configuring,
enabling, and operating the devices 40. Specifically, the device manager 30
can include a
state machine that responds to the command signals to selectively enable, and
disable the
devices 40. For example, in one embodiment, the command and control computer
12 can
transfer a command signal to the device manager 24 that directs the device
manager 24 to
enable one of the devices 40, wherein that enabled device 40 consists of a
pressure
sensor. Additionally, the control computer 12 can set command and data signals
that
direct the device manager 30 to set the operating parameters of the enabled
pressure
sensor 40. For example, certain pressure sensors can be operated within
selected ranges
by selecting a reference voltage that is applied to the pressure sensor.
In this embodiment, the device manager 30 will respond to commands from
command and control computer 12 to select the proper reference voltage to
achieve the
desired pressure sensing range. It will be understood by one of ordinary skill
in the art,
that the device manager 30 can set any of the parameters necessary for the
devices 40 and
that the design and development of such device managers is well known to those
of
ordinary skill in the art of electrical engineering. The device monitor 30 can
also receive
data from the sensors, such as pressures measured by the sensors 40. A device
manager
can pass these signals through to the communications manager 22 for
encapsulation
30 and delivery to the transceiver 14. The digital to analog converter and
analog to digital
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converter 32 depicted in Fig. 1 can be any suitable circuit system for
performing these
functions and can be separate integrated circuit components or integrated
circuit
components provided as part of a single integrated circuit. However, it will
be
understood that modifications can be made to the signal conditioning circuitry
employed
by the devices described herein as necessary, and such modifications are
deemed to be
within the skill of one of ordinary skill in the art of electrical
engineering.
In the depicted embodiment, a plurality of devices 40 coupled by a
bidirectional
path to the device manager 24. To this end the device manager 24 includes a
device
I/Omultiplexer 34. The device I/Omultiplexer can be an electrical circuit or a
software
routine running on a conventional microprocessor. The operation of such
multiplexers
for switching between individual ones of the devices 40 for transferring data
between the
selected device and the device manager 24 are well known in the art and any
suitable
multiplexer can be employed with the present invention.
The integrated control device 16 depicted in Fig. I includes a bidirectional
interface to a system monitor 44. The system monitor 44 can be a visual
display such as
a computer terminal with a keyboard that allows an operator to interface with
the
integrated control instrument, for example, changing parameters of the sensor
devices 40,
as well as for monitoring data generated by the sensor devices 40. A system
monitor 44
couples to an open loop feedback device 42. These open loop feedback devices
42 can
be, for example, alarms, such as sirens or flashing lights, that are activated
by the
integrated control unit 16 when certain data from one of the devices 40
indicates an alarm
condition. The depicted system monitor 44 also connects to an interrupt device
46. The
interrupt devices 46 allow an operator to override the command signals being
implemented by the device manager 24. Accordingly, the interrupt devices allow
for
disabling selected devices 40, or enabling other devices 40, or for allowing a
user to send
information through the integrated control instrument 16 to the command and
control
computer 12. In other applications for the interrupt devices 46 can be
employed with the
systems described herein without departing from the scope of the invention.
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Fig. 1 further shows that the integated control unit 16 can couple to a system
clock 50 and a power management and power supply unit 52 and 54. The system
clock
can be a conventional electronic clock element that provides a clock signal to
the device
manager 30. Such clock signals can be employed for timing the rate of changes
of certain
parameters such as pressures and temperatures as well as for monitoring and
maintaining
information about the status of the integrated control unit 16, such as how
long the
control unit 16 has been operating and on what day and time data was collected
to be
transferred back to the command and control computer 12. The system clock
allows the
synchronization of all the signals processed in the control unit 16. An
optional power
management unit is responsible for energy conservation and allocation over the
various
devices in fixnction of the needs indicated by the system monitor. The power
management and power supply units 52 and 54 can be conventional battery or AJC
power
supplies. Although the system clock 50 and power management and power supply
systems 52 and 54 are depicted by Fig. 1 as being separate components of the
system 10,
it will be understood by one of ordinary skill in the art that these
components can be
incorporated into the integated control device 16.
The main progam of a closed-loop system runs in the computer 12 or array of
computers. The program has a user interface for interaction with an operator
and
performs the principal data analysis and command and control functions. The
progam
can optionally include an encryption progam. The program can provide for real-
time
operation by providing command signals with priority values that will be
understood by
the device managers 30 for determining the order of which operations occur.
This allows
the computer to determine which sensor data is reported back first, and which
actuator is
activated first, or in any other order.
As discussed, the device manager transfers the messages from/to the devices
that
are being controlled. It contains a device monitor responsible for the digital
processing of
the signals, equipped with the necessary logical and arithmetic fiznctions,
and with the
necessary memory to assure throughput. The depicted device manager contains a
digital-
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to-analog converter and an analog-to-digital converter. It also contains a
device
input/output channel multiplexor, that allows the device monitor to switch its
attention
from one device to another.
Although Fig. 1 depicts a single control unit 16, multiple (micro) electro-
mechanical devices can be interfaced to the integrated control instrument of
the
MEMICS. They can be sensors, motors, process devices. The integrated control
device
is supervised by a system monitor. The system monitor is responsible for the
general
functioning of the ICI. It exchanges status information with the command and
control
computer or with the operator via open loop feedback devices such as light
emitting
diodes. It reacts on the command signals received from the command and control
unit or
from the operator via interrupt devices such as switches or buttons. In this
way, an
operator can override the command system, shutdown the sensor or device, run
separate
tests off line, or other similar function.
Figure 2 depicts a system 10 according that includes a plurality of
transceiver
elements 16a-16f coupled to a network bus 15 that is connected to a command
and
control computer 12. As discusses above the command and control computer 12
performs the processing for the control system and responds to operator input.
Figure 2
further depicts a room 30 that includes the transceiver 16d and four
integrated control
units 18a-18d of the type described above with reference to Fig. 1. The room
30 can
contain an assembly line, chemical plant, a working environment or any system
or space
that is to monitored or controlled. The integrated control units 18a-18d each
couple to a
sensor or device. For example, the unit 18a couples to a valve 20 that has a
motorized
shutoff assembly. Similarly, the units 18a and 18b couple to thermostats 22
and 24
respectively. The unit 18d couples to a generic sensor/device element
representative of
any element suitable for use in a control system.
As described above, the units 18a-18d can receive commands and provide data to
the transceiver 16d via a data link such as an lR or radio link. Optionally, a
hardwired
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link can be employed. The transceiver 16d, in the depicted embodiment,
exchanges data
and instructions with the command computer 12 via the network 15.
Each unit 18a-18d can receive command data signals from the command
computer 12. This data can instruct the device manager 24 on how to drive, or
interface
with the sensor, actuator or other device coupled to that unit. The device
manager 24
can use this information to collect information from the sensor actuator and
devices and
can translate this information into a standard data format that can be sent to
the
transceiver 16d. The transceiver 16d can format the data into a standard
format suitable
I O for delivery over the network 14. Accordingly, the system 10 provides a
control system
with a standard interface to its devices, actuators and sensors.
Figure 3 depicts an alternative embodiment in the invention wherein the
integrated
control device is foamed as an integrated circuit such that on a substrate the
circuits and
15 sensors of a device according to the invention are formed. Specifically,
Figure 3 depicts
an integrated circuit 60 that includes a microprocessor core 62, a static RAM
64, and
electrically programmable memory 66 and a read-only memory 68. The device 60
fixrther
includes a gyroscope 70, a temperature sensor 72, a gyroscope 74, and an
accelerometer
76. The microprocessor core 62 can be a conventional microprocessor core that
operates
20 in response to a computer program stored in the ROM 68 and the EEPROM 66.
The
microprocessor core 62 can also act in response to input signals received from
an IO
interface (not shown) of the type commonly employed with microcontroller
circuits.
Figure 3 depicts that the integrated control device can be formed on a
substrate
25 wherein a programmable microprocessor core 62 operaxes under the control of
a program
to implement the communications manager, and device manager functions of the
integrated control device. In one embodiment, the microprocessor core 62 is
similar to
the 68HC05 core developed by the Motorola Company, which can be programmed in
a
high-level language, such as C, to generate a set of instruction signals that
can implement
30 the communications manager and device manager functions. The development of
such
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programs follows from principals well-known in the art of electrical
engineering and
computer science and any suitable computer program can be employed with the
present
invention without departing from the scope thereof. The integrated system 60
depicted in
Figure 3 also includes four sensor elements which can be individually
configured by the
microprocessor circuit to operate to collect selected information about the
system under
control. For example, in one embodiment the microintegrated control device 60
can be
attached to a box moving on a conveyor belt. In this embodiment, the
microprocessor
can employ the accelerometer 76 and gyroscope 74 to receive directional and
movement
information for use by the control program running on the command and control
computer 12. In an alternate portion of the control system, the device 60 can
be placed
at a location on the system under control where measures of temperature are
relevant to
maintaining an optimal operating state, and this application the command and
control
program can send a program to the microcontrol unit 60 that executes from the
EEPROM 66 to direct the microprocessor core to activate the temperature sensor
72 and
to report back temperature data gathered from that sensor. To report back
data, the
element 60 can be coupled to an infrared transceiver element (not shown) that
acts to
exchange data between the transceiver 14 that couples to the computer data
network
which will transmit information between the transceiver 14 and the command and
control
computer 12.
Figure 4 depicts in functional block diagam form a further alternative
embodiment of the invention. Specifically, Figure 4 depicts a system 90 that
includes a
housing 90 tube which can be mounted to a portion of the system being
controlled. The
system 90 can include a microcontroller 90 for, a transceiver 98, and sensors
102, 104
and 106. In the depicted embodiment the sensors 102, 104 and 106 are a
pressure
sensor, temperature sensor and accelerometer respectively. These three sensors
can
operate under the control of the microcontroller 94 for measuring certain
parameters of
the system under control. In an alternate embodiment, the system 90 can
include an IO
port for forming an electrical connection to a sensor, or actuator that is
physically
separated from the housing 90. In this way the integrated control device 90
can also
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communicate with devices that are separate from the unit, but coupled to the
system
being controlled.
The transceiver 98 depicted in Figure 4 can be employed far transmitting
signals
to a transceiver that is in communication with the data network and carries
data to the
central computer system. In one embodiment, a plurality of devices, such as
the device
90 could communicate to a single transceiver 14. In this embodiment, the
communications manager can generate a device ID representative of a unique one
of the
devices 90 that is communicating with the transceiver 14. This allows the
transceiver 14
to determine which device is speaking to the transceiver 14, and accordingly
provides the
transceiver 14 with information to use for transfernng data over the computer
data
network.
Figure 5 depicts one process according to the invention for controlling and
monitoring a system. Specifically, Figure 5 depicts a process 120 that
includes the steps
of generating initialization and data commands 122 broadcasting data and
commands
124, verifying the initialization of integrated control units 126, monitoring
data 128,
determining if the monitoring system needs reconfiguration 130 and generating
the
necessary reconfiguration command and data signals 132.
Specifically, the process 120 depicted in Figure 5 can be employed by the
command and control computer 12 to initialize and reconfigure the sensor units
employed
for monitoring the system under control. In the first step 122 the command and
control
computer can initialize the configuration of the system under control. In this
step, the
command and control computer 12 generates a set of configuration information
that is
employed for configuring the various unconfigured sensor devices. Accordingly,
the
command and control unit can determine which sensor devices will measure
temperature,
which will measure pressure, which will actuate valves and take air samples,
or any other
of the fiznctions offered by the various sensor devices. Once the
configuration data and
commands are generated, the process 120 proceeds to step 124 wherein these
data and
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command signals are broadcast over the data network. In this step the data and
commands are sent through the network to the transceivers, such as the
transceivers 14
depicted an Figure 1 for broadcasting information to the various transceiver
units 20 of
the different integrated control devices 16.
After step 124 the process 120 proceeds to step 126 which is an optional step
during which the command and control computer can ask for verification of the
configuration. In this step, the command and control unit can determine that
each of the
integrated control devices received the command data sent to that device and
properly
configured and has operational the sensors and actuators that have been chosen
by the
command and control computer 12. If the initialization test fails, the command
and
control unit can optionally abort the initialization procedure and require
user intervention,
or take any other suitable steps.
In step 128 the command and control unit monitors data being collected by the
various devices and transmitted back through the data network to the command
and
control computer 12. The command and control computer 12 can use this
information
for general process control and monitoring.
In the embodiment depicted in Figure 5, the process 120 has the optional step
of
proceeding to step 130 wherein the data returned from the sensor devices and
actuators is
monitored by the step 120 to determine if the process needs to be reconfigured
for
monitoring other characteristics of the system under control. If the system is
to be
reconfigured, the process 120 proceeds from step 130 to step 132 and generates
and
broadcasts new command and data signals that will reconfigure the sensor
devices and
actuator devices being employed by the command and control unit 12.
Alternatively, if
no configuration is necessary, the step 130 can proceed back to step 128 and
begin to
monitor data.
*rB
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It will be understood that the embodiments of the invention which have been
described are illustrative of some of the applications and principles of the
present
invention. Various modifications may be made by those skilled in the art
without
departing from the spirit and scope of the invention. Moreover, it will be
understood that
the systems and devices described herein can be employed in a variety of
applications
including monitoring product moving along an assembly tine, monitoring the
activities of
a vessel and any other suitable application.
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