Applying Smart Sensor Technology

to Legacy Systems

Sensors Expo and Conference

San Jose, California
May 21, 2002

Robert N. Johnson and Ralph F. Eschenbach

Telemonitor, Inc.
www.telemonitor.com
 What is a smart sensor?
l One definition is found in IEEE 1451.2-1997:
l A Smart Transducer is “A transducer that provides
functions beyond those necessary for generating a
correct representation of a sensed or controlled
quantity. This functionality typically simplifies the
integration of the transducer into applications in a
networked environment.”
l A Smart Sensor is “A sensor version of a smart
transducer.”
l Key concept: A smart sensor adds value to the data to
enable or support distributed processing and decision
making
May 21, 2002 ©2002 Telemonitor, Inc. 2
 Desirable functions in smart sensors
l Self-identification, self-diagnosis.
l Output digital data in standard engineering units.
l “Time aware” for timestamping and correlation
l Software functions, e.g.:
– signal processing and data logging
– measurements derived from multiple channels
l Conforming to a standard data and control protocol

May 21, 2002 ©2002 Telemonitor, Inc. 3

 A general model of a smart sensor
Network
Network specific

Local user
interface

Analog-to-
Signal Application
Sensor digital Communication
conditioning algorithms
conversion

Data storage

Some points regarding “smart”:

• Moving intelligence closer to the point of measurement/control.
• Confluence of transducers, computation and communication towards common goal.
• Goal: make it cost effective to integrate/maintain distributed systems.

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 “Always in motion is the future…”

l Someday most non-trivial sensors will be

smart (to some degree)
l Standards, such as the IEEE 1451 family,
will evolve to define interoperability
l Meanwhile, we have to deal with a large
base of “legacy” systems
l We need a transition path to the future
l Existing open standards may help define
such a path
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 Legacy ≠ Obsolete

l A lot of legacy devices have some very

desirable characteristics:
– Industrial-strength I/O
– Local functions and operator interface
– Digital data (frequently RS-232 or RS-485)
– They are installed (and paid for?)
– THEY WORK!
l Why break existing applications?

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 What do we need to add?

l Any missing elements from earlier list:

– Self-identification, self-diagnosis.
– Digital data in standard engineering units.
– Timestamps
– Data logging
– Multi-channel measurements
– Standard data and control protocol
l All can be external to the sensor itself
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 Useful existing assets

l Serial ports
– RS-232/RS-485
– Modbus RTU
– Proprietary serial interfaces
– etc.
l Ethernet
– Almost certainly in the building
– May already be in the vicinity
– Becoming “industrial-grade”
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 Real-life example project

l UNC Chapel Hill Chilled Water Dept.

– Large extended multi-campus facility
– Use chilled water for cooling
– Need central monitoring of system
– Converting to billed utility
l Assets in place
– Process controllers with Modbus RTU
– Plant control software with Web interface
– Extensive Ethernet network
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 Bridging islands of automation

May 21, 2002 ©2002 Telemonitor, Inc. 10

 Feasibility Demonstration Project
• Performed in 1999 and previously
reported in Sensors Conference
• Web server with Modbus interface
connected to each process controller
• Used inter-campus Internet access
• Firewall-friendly interface (HTTP
GET returns data in HTML page)
• Demonstrated feasibility and flexibility
• Server embedded in controller for next
phase (ultimately 100 buildings)
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 Remote access of water chiller data

May 21, 2002 ©2002 Telemonitor, Inc. 12

 Important features in a Web server
• Network configuration
• Data logger
• Dynamic data (w/SSI)
• File system (w/FTP)
• Real-time clock (w/SNTP)
• Multi-level security
• Firewall-friendly open
standard interface (HTTP,
XML, etc.)
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 Network configuration support

• Find all devices on local sub-net

• View and set network setting and useful identification
• DHCP may not be appropriate for all applications
• Permits self-identification
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Data logger with time-stamped records
• Control of data to log
• Control of sampling
• Log to standard file with
FTP support
• Access to logged data
thru firewall-friendly Web
interface
• Log events (alarms,
power loss, etc.) as well as
data
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 Data logger graphical display

May 21, 2002 ©2002 Telemonitor, Inc. 16

 Summary

l We need to move toward smart sensors for

the future
l We need to preserve and use our investment
in legacy devices and working systems
l Embedded Web servers and open standards
can help with the transition:
– Many existing devices have serial ports
– Many installations already have Ethernet
– Many enterprise software packages support
Web interfaces (HTTP, XML, etc.)
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 Questions/Discussion?

May 21, 2002 ©2002 Telemonitor, Inc. 18