Sensor assembly for hygenic material processing systems

Abstract

A sensor assembly includes a replaceable sensor module and an assembly housing. The assembly housing contains an assembly housing processor and an electrical connector connected to the processor. The replaceable sensor module has an enclosure adapted to be mounted in a position to sense a process variable, a process variable transducer positioned in said enclosure so as to be exposed to the process variable, and a non-volatile memory having stored therein specific profiling data for the sensor module. The assembly housing processor has data representing a desired sensor assembly output characteristic, and is responsive to receipt of specific profiling data and to the data representing the desired sensor assembly output characteristic to calibrate the sensor assembly to provide the desired sensor assembly output characteristic when connected to the sensor module having the specified profiling data. Radial and axial seals are provided for the openings in the assembly housing. Measurement of loop current (I L ) in a two-wire loop current communication system for the sensor assembly and detection of sensor aging are also included.

1 . A sensor assembly having a replaceable sensor module, with the sensor assembly being adapted to be positioned in a flow stream of material flowing in a hygienic material processing system for sensing parameters of the material and generating signals for use by an automated process controller for controlling the operation of the hygienic material processing system, the sensor assembly comprising:
 a first module constituting a replaceable sensor module;   a second module constituting a data processing module, with the first and second modules being detachably secured to each other via a mechanical interconnection and being in electrical communication with each other via an electrical interconnection, wherein the replaceable sensor module comprises:   a generally cylindrical enclosure adapted to be mounted in a position in a flow stream of a material;   a transducer positioned in the enclosure toward a first end of the second sensor module for sensing parameters of the material;   at least one electronic circuit connected to said transducer for generating sensor data indicative of parameters of the material; and   wherein the mechanical interconnection comprises a first O-ring and a second O-ring of generally annular configuration for blocking leakage of material in the flow stream past the mechanical interconnection from entering the data processing module, wherein the first O-ring and the second O-ring are positioned at a second end of the sensor module enclosure generally coaxially therewith, wherein the first O-ring seal is subjected to compression in an axial direction of the sensor module enclosure when the sensor module is secured to the data processing module, and wherein the second O-ring seal is subjected to compression in a radial direction of the sensor module enclosure when the sensor module is secured to the data processing module.   
     
     
         2 . The sensor assembly as set forth in  claim 1  wherein the mechanical interconnection further comprises a first mating surface on the replaceable sensor module and a second and corresponding mating surface on the data processing module adapted to mate with the first mating surface for detachably securing the replaceable sensor module to the data processing module to form a unitary sensor assembly structure. 
     
     
         3 . The sensor assembly as set forth in  claim 2  wherein the mating surfaces are threaded. 
     
     
         4 . The sensor assembly as set forth in  claim 1  wherein the electrical interconnection provides electrical communication between the first and second modules when the mechanical interconnection secures the first and second modules together. 
     
     
         5 . The sensor assembly as set forth in  claim 1  wherein the electrical interconnection comprises an electrical connector at the second end of the sensor module and an electrical connector on the data processing module that are engaged when the first and second modules are assembled together. 
     
     
         6 . The sensor assembly as set forth in  claim 1  wherein the mechanical interconnection is adapted to be manually engaged to make and break the mechanical connection between the first and second modules without the need of tools. 
     
     
         7 . The sensor assembly as set forth in  claim 1  wherein the parameter of the material is selected from the group consisting of a parameter indicative of pressure of the material, a parameter indicative of temperature of the material, a parameter indicative of volume of the material, and a parameter indicative of flow rate of the material. 
     
     
         8 . The sensor assembly as set forth in  claim 1  wherein the identification data for the transducer stored in the non-volatile memory includes pressure-temperature characteristics for the transducer in the replaceable sensor module. 
     
     
         9 . The sensor assembly as set forth in  claim 1  wherein the microprocessor in the data processing module uses calibration information to generate a calibration curve for the sensor assembly. 
     
     
         10 . The sensor assembly as set forth in  claim 1  wherein the replaceable sensor module includes a temperature measurement transducer in addition to the process variable transducer. 
     
     
         11 . The sensor assembly as set forth in  claim 1  further comprising a cover formed at least in part of a transparent material and detachably secured to the data processing module, with the cover closing a corresponding opening in the data processing module when secured to the data processing module. 
     
     
         12 . The sensor assembly as set forth in  claim 12  further comprising a third O-ring and a fourth O-ring of generally annular configuration positioned adjacent the cover and generally coaxially therewith, with the third O-ring being subjected to compression in a axial direction of the cover and the fourth O-ring being subjected to compression in the radial direction of the cover when the cover is detachably secured to the data processing module. 
     
     
         13 . The sensor assembly as set forth in  claim 1  further comprising a visual indicator to provide notification if one of either the first O-ring or the second O-ring is not properly seated after the first module has been assembled to the second module. 
     
     
         14 . The sensor assembly as set forth in  claim 1  further comprising a tactile indicator to provide notification if one of either the first O-ring or the second O-ring is not properly seated after the first module has been assembled to the second module. 
     
     
         15 . A sensor assembly having a replaceable sensor module, with the sensor assembly being adapted to be positioned in a flow stream of material flowing in a hygienic material processing system for sensing parameters of the material and generating signals for use by an automated process controller for controlling the operation of the hygienic material processing system, the sensor assembly comprising:
 a first module constituting a replaceable sensor module;   a second module constituting a data processing module, with the first and second modules being detachably secured to each other via a mechanical interconnection and being in electrical communication with each other via an electrical interconnection, wherein the replaceable sensor module comprises:   an enclosure adapted to be mounted in a position in a flow stream of a material;   a transducer positioned in the enclosure toward a first end of the second sensor module for sensing parameters of the material;   at least one electronic circuit connected to said transducer for generating sensor data indicative of parameters of the material; and   wherein the mechanical interconnection comprises one or more O-rings, including a first O-ring and a second O-ring of generally annular configuration for blocking leakage of material in the flow stream past the mechanical interconnection from entering the data processing module, wherein the first O-ring and the second O-ring are positioned at a second end of the sensor module enclosure generally coaxially therewith, wherein the first O-ring seal is subjected to compression in an axial direction of the sensor module enclosure when the sensor module is secured to the data processing module, and wherein the second O-ring seal is subjected to compression in a radial direction of the sensor module enclosure when the sensor module is secured to the data processing module.   
     
     
         16 . The sensor assembly as set forth in  claim 16  further comprising a cover and detachably secured to the data processing module, with the cover closing a corresponding opening in the data processing module when secured to the data processing module. 
     
     
         17 . The sensor assembly as set forth in  claim 17  further comprising a third O-ring and a fourth O-ring of generally annular configuration positioned adjacent the cover and generally coaxially therewith, with the third O-ring being subjected to compression in a axial direction of the cover and the fourth O-ring being subjected to compression in the radial direction of the cover when the cover is detachably secured to the data processing module. 
     
     
         18 . The sensor assembly as set forth in  claim 1  further comprising a tactile indicator to provide notification if one of either the first O-ring or the second O-ring is not properly seated after the first module has been assembled to the second module. 
     
     
         19 . A sensor assembly having a replaceable sensor module, with the sensor assembly being adapted to be positioned in a flow stream of material flowing in a hygienic material processing system for sensing parameters of the material and generating signals for use by an automated process controller for controlling the operation of the hygienic material processing system, the sensor assembly comprising:
 a first module constituting a replaceable sensor module;   a second module constituting a data processing module, with the first and second modules being detachably secured to each other via a mechanical interconnection and being in electrical communication with each other via an electrical interconnection, wherein the replaceable sensor module comprises:   an enclosure adapted to be mounted in a position in a flow stream of a material;   a transducer positioned in the enclosure toward a first end of the second sensor module for sensing parameters of the material;   at least one electronic circuit connected to said transducer for generating sensor data indicative of parameters of the material; and   wherein the mechanical interconnection includes a first O-ring and a second O-ring of generally annular configuration for blocking leakage of material in the flow stream past the mechanical interconnection from entering the data processing module, wherein the first O-ring and the second O-ring are positioned at a second end of the sensor module enclosure generally coaxially therewith, wherein the first O-ring seal is subjected to compression in an axial direction, and wherein the second O-ring seal is subjected to compression in a radial direction.