Radio frequency process sensing, control, and diagnostics network

Patent metadata

Field	Value
Publication number	US-10425170-B2
Application number	US-201514733486-A
Country	US
Kind code	B2
Filing date	Jun 8, 2015
Priority date	Jun 6, 2014
Publication date	Sep 24, 2019
Grant date	Sep 24, 2019

Abstract

A sensing and control system and method is disclosed, which utilizes cavity resonance and waveguide measurements to directly monitor process state variables or detect changes in the state of a system and provide direct in situ feedback control top optimize the process. The same system may be used to monitor a number of different process parameters including the composition, amount, distribution, and physical or chemical properties of a material, or to monitor the state or health of a system or sub-system. The system is broadly applicable to wide range of systems and process including ranging from engines and exhaust systems to production plants.

First claim

What is claimed is:

1. A radio frequency process control system comprising:
a plant or machine requiring at least one input and generating at least one output stream;
at least a first module, conduit, or component in the plant or machine forming a resonant cavity for containing radio frequency signals;
at least a second module, conduit, or component in the plant or machine forming a resonant cavity for containing radio frequency signals;
at least a first radio frequency probe in the resonant cavity of the at least first module, conduit, or component to transmit and/or receive the radio frequency signals;
at least a second radio frequency probe in the resonant cavity of the at least second module, conduit, or component to transmit and/or receive the radio frequency signals; and
a single radio frequency control unit, in communication with both of the at least first and second radio frequency probes, to (i) monitor at least a change in the phase of said radio frequency signals transmitted and/or received through the resonant cavity of each of the first and second modules, conduits, or components and (ii) measure more than one parameter selected from the group including amount of a material, type of the material, spatial distribution of the material, physical or chemical properties of the material, environmental conditions, position or level, cavity integrity, or rate of change of the parameter, based on at least a measurement of the change in the phase of said radio frequency signals transmitted and/or received through the resonant cavity of each of the first and second modules, conduits, or components, the radio frequency control unit containing the components for transmitting, detecting, controlling, modulating, and monitoring the radio frequency signals transmitted and/or received by the at least first and second radio frequency probes.

2. The system of claim 1 , wherein said at least first and/or second module, conduit, or component is selected from the group including catalyst, substrate, filter, cavity, or housing, or engine.

3. The system of claim 1 , wherein said radio frequency control unit determines leakage of a material through said output stream, based on measured material accumulation in said output stream and known emissions of said material from said machine.

4. The system of claim 1 , wherein said radio frequency control unit determines an amount, quality or composition of a material in said at least first and/or second module, conduit, or component.

5. The system of claim 4 , wherein said material is selected from the group consisting of fuel, oil, coolant, air, urea, and EGR gas.

6. The system of claim 1 , wherein said at least first or second module, conduit, or component comprises an engine of the plant or machine, and the at least first or second radio frequency probe is disposed in a cylinder of said engine, to monitor one or more engine parameters.

7. The system of claim 6 , wherein the one or more engine parameters are selected from the group consisting of position of piston, quality of combustion process, emissions processed by said combustion process, quantity of fuel injected, temperature and pressure.

8. A radio frequency sensing system, comprising;
a first radio frequency probe to transmit and/or receive radio frequency signals within a first cavity within a machine, the first radio frequency probe extending in the first cavity and the first cavity containing the radio frequency signals;
a second radio frequency probe to transmit and/or receive radio frequency signals within a second cavity within the machine, the second radio frequency probe extending in the second cavity and the second cavity containing the radio frequency signals;
a timing device; and
a single radio frequency control unit, in communication with both of the first and second radio frequency probes and the timing device, to monitor at least a change in the phase and amplitude of the transmitted and/or received radio frequency signals and to measure a change in said determined process parameter based on inputs from said timing device and a measurement of the change in the phase and amplitude of the transmitted and/or received radio frequency signals, and to initiate an action based on said change in said determined process parameter, the radio frequency control unit containing all of the components for transmitting, detecting, controlling, modulating, and monitoring the radio frequency signals transmitted and/or received by both of the at least first and second radio frequency probes.

9. The radio frequency sensing system of claim 8 , wherein said radio frequency control unit provides diagnostic information to an operator based on said change in said determined process parameter.

10. The radio frequency sensing system of claim 9 , wherein said diagnostic information is selected from the group consisting of an indication of a failure of a filter element, an indication of a failure of a catalyst element, an indication of a broken conduit, and an indication of a blockage or obstruction in said machine.

11. The radio frequency sensing system of claim 8 , wherein the radio frequency control unit modifies operation of said machine based on said change in said determined process parameter.

12. The radio frequency sensing system of claim 11 , wherein said radio frequency control unit modifies fueling, air flow, boost pressure, EGR rates, injection timing, urea or hydrocarbon dosing.

13. A machine, comprising:
at least one input and generating at least one output stream;
a plurality of independently controlled radio frequency probes mounted in at least first and second cavities within said machine to transmit and/or receive radio frequency signals contained in and propagated through the at least first and second cavities within said machine, each of the plurality of radio frequency probes being operable at a specified frequency or range of frequencies which may vary depending on the type, location, and measurement application of each of the plurality of radio frequency probes; and
a single radio frequency control unit, in communication with all of the plurality of radio frequency probes, to monitor a change in at least the phase of said radio frequency signals transmitted and/or received through the first and second cavities, measure more than one parameter, based on at least a measurement of the change in the phase of said radio frequency signals transmitted and/or received through the first and second cavities, and initiate an action based on said measured parameters, the radio frequency control unit containing all of the components for transmitting, detecting, controlling, modulating, and monitoring at the same time or at different times the radio frequency signals transmitted and/or received by all of the plurality of radio frequency probes.

14. The machine of claim 13 , wherein at least a first radio frequency probe monitors said input and at least a second radio frequency probe monitors said output stream.

15. The machine of claim 13 , wherein said radio frequency control unit modifies an operation of said machine based on said measured parameters.

16. The machine of claim 13 , wherein said radio frequency control unit alters an operator of a fault condition based on said measured parameters.

17. The machine of claim 13 , wherein said radio frequency control unit is in communication with a timing device, and said radio frequency control units determines a rate of change of said measured parameters.

Assignees

• Filter Sensing Tech Inc
• Cts Corp

Inventors

• Sappok Alexander
• Bromberg Leslie

Classifications

• F02D41/1444

  characterised by the characteristics of the combustion gases · CPC title

• F02D41/0235

  in relation with the state of the exhaust gas treating apparatus (control of exhaust gas treating apparatus per se F01N) · CPC title

• F01N2900/1402

  Exhaust gas composition · CPC title

• F01N2560/12

  Other sensor principles, e.g. using electro conductivity of substrate or radio frequency · CPC title

• F01N2560/021

  for measuring or detecting ammonia NH3 · CPC title