This invention relates to actuators, systems, and methods that use a Bluetooth Low Energy beacon to allow the status of actuators to be monitored.

Background

In many industrial systems, devices such as valves are operated using powered actuators. Large installations, particularly industrial installations handling liquids or gases, can have many actuators distributed over a wide area or can have actuators in remote of difficult to access locations. Monitoring such actuators can be a difficult job. While some actuators can be networked, many are not, requiring visual inspection to determine if there are any faults or any remedial action is needed.

Many actuators have on-board control systems that provide status signals and fault detection. While such devices can be configured remotely using a Bluetooth Setting Tool or a wireless PC application, it is still necessary for an operator to go to each actuator in turn, connect to that actuator, and configure or interrogate the actuator. Even where the actuators are networked, it is often necessary to inspect each one to fully understand any issues.

This invention seeks to provide a convenient way to obtain status updates in relation to actuators that does not require an operator to devote significant time to each actuator just to understand its status.

Summary of the Invention

One aspect of the invention comprises an actuator, comprising: an actuator housing enclosing a motor for operating a device to be actuated, a control system, and a series of sensors for monitoring the condition of the actuator and the device to be actuated; wherein the housing further comprises a Bluetooth Low Energy beacon device that is connected to the control system and is configured to receive signals from the series of sensors, and to output a signal indicative of the condition of the actuator.

By using the BLE beacon, an operator can get updates of actuator status when in the vicinity of the actuator and can then follow up, if necessary, after reviewing a display of the received signals.

The signal indicative of the condition of the actuator can indicate that a remedial action is required by the actuator.

The control system can be configured to generate alarm signals in response to sensor signals indicative of problems with the actuator.

The actuator can further comprise a power supply for operating the motor and the Bluetooth Low Energy beacon is connected to the power supply. The beacon can also include its own battery. Access to the actuator power supply (including any batteries used to power the actuator) can provide a longer beacon life that just its own internal battery, avoiding the need to replace the beacon battery so frequently.

The Bluetooth Low Energy beacon can be configured to include data uniquely identifying the actuator in the output signal.

Another aspect of the invention comprises a system comprising a number of actuators which are spaced apart from each other, and a portable device configured to receive the output signals from each actuator and display the condition and identity of each actuators when the portable device is moved within a predetermined range of each actuator.

The portable device can be configured to display when an actuator is in need of remedial action based on the received signals.

A further aspect of the invention comprises a method of monitoring the status of a series of actuators, the method comprising: moving a portable device configured to receive the output signals from the actuators near to the actuators; receiving the output signals from individual actuators when the portable device comes within a predetermined distance of the individual actuators; and generating a display indicting the condition of the actuators based on the output signals.

Further aspects of the invention will be apparent from the detailed description.

Description of Drawings

Figure 1 shows a schematic representation of a system according to the invention.

Detailed Description

This invention provides apparatus, systems and methods that allow the status of actuators to be monitored remotely. Fig. 1 illustrates a schematic installation comprising a number of actuators distributed over a relatively large area. One example of an installation is in an oil installation in which there are numerous valves, each with its own actuator. Not only are the actuators distributed over a large area, they can also be relatively inaccessible within the installation. In another installation, the actuators may be far apart and in remote areas.

Figure 1 shows a schematic representation of an actuator installation. The installation comprises a number of actuators A1 - An. Each actuator A has a housing H which enclose the various parts of the actuator, and which is connected to a valve V as the device being actuated. The housing H encloses an eletric motor M, a power supply PS, a control system CS, and a series of sensors S. The motor M is connected to the valve V by a drive shaft (not shown). The control system CS is configured to operate the actuator and valve according to certain predetermined conditions. For example, in the IQ3 range of actuators, a Bluetooth Setting Tool (not shown) can be used to configure the control system CS to operate the actuator. The Bluetooth Setting Tool must be paired with each control system CS and the configuration uploaded and stored for that actuator. Once configured, the control system will ensure that the actuator A operated according to the desired conditions.

The sensors S allow the control system CS to monitor operation of the actuator A and valve V to ensure that they operate correctly and to allow the status of the valve V and actuator A to be understood by an operator. The sensors S will also detect if any faults have occurred, and the control system CS can generate alarm signals in response to any faults detected by the sensors S.

While some installations have the actuators A networked together so that their status can be monitored continuously online, in many cases, there is either no network or insufficient capacity to allow continuous monitoring. In such cases, the only option is to visually inspect each actuator to determine status by either examination of a display or by connecting a remote monitoring tool to each actuator and interrogating the control system CS. For a large and dispersed installation, this is time consuming and expensive.

The actuators according to the invention have a Bluetooth Low Energy (BLE) beacon BLEb installed within the housing H and connected to the control system CS. The beacon BLEb will receive the status signals from the control system CS, including any fault signals and will broadcast its own signal, including a unique identifier of the actuator. The repetition of the broadcast signal can be set within the normal BLE environment. The beacon BLEb can be powered from the actuator power supply PS and an on-board battery can be provided for backup in case of power failure.

The second part of the system comprises a Bluetooth enabled mobile device MOB such as a mobile phone, tablet, or other computing device that can be configured to receive BLE signals. The mobile device has an app BLEr that interprets any received BLE signals and provides a display indicating the status of the actuator from which they originated. When ever the device MOB comes within range of a beacon BLEb, it will receive the BLE signals and generate a record that can be displayed on the device. In its simplest form, the display might be a simple identification of the particular actuator A and an indication that there is or is not a fault.

The app BLEr does not require the user of the mobile device MOB to specifically connect to each actuator A. Instead, it is active all of the time and will receive signals from each beacon BLEb when it is in range. The operator simply needs to be within range of the actuators to receive the signal and does not have to inspect each one to determine its status. Therefore, it is possible for the operator to monitor some or all of the actuators in an installation while performing other activities. Once an actuator with a fault has been detected, the operator can then go to that specific actuator and determine what remedial action must be taken.

The faults that can be reported can include the standard faults available from the control system of an IQ3 range actuator and can include, for example, issues relating to operation of the motor, the position of the valve, or problems with the power supply or control system.

Various changes can be made within the scope of the invention.