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FIELD OF INVENTION
The present invention relates to a controller that enables monitoring and control
of electrostatic precipitator, by sending e-mail (electronic mail) to the mail
address assigned to the controller. More particularly, the invention relates to an
enhanced controller for performing remote monitoring and control of electrostatic
precipitator. The invention further relates to an enhanced controller which is
capable to serve web pages enabling the user to monitor and control the
Electrostatic precipitator from a web-interface.
BACKGROUND OF INVENTION
Electrostatic precipitation is one of the most effective ways to control air
pollution generated by industrial emissions. This technique, which has proven
highly effective in controlling air pollution, has been used for removal of
undesirable matter from a gas stream by electrostatic precipitation. Electrostatic
precipitator (hereafter referred to as ESP) is an air pollution control device
designed to electrically charge and collect particulates generated from industrial
processes such as those occurring in power plants, cement plants, pulp and
paper mills and utilities etc. The electrically charged particles are attracted
towards electrode plates, viz., discharge electrode and collection plate. ESP is
divided into a plurality of fields depending on the dust load. During continuous
operation of an electrostatic precipitator, the dust from collector plates &
discharge electrodes must be periodically removed for further conveying of the
collected dust.

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In the ESP, the electrostatic precipitation is achieved by controlling the
transformer rectifier set by a dedicated ESP controller. An ESP installation
consists of a plurality of fields, each field being controlled by a dedicated ESP
controller. However, the existing ESP-controllers fail to provide an enhanced
control and monitoring of the ESP performance via remote monitoring and
control of the ESP through web-interface and e-mail interface. The existing ESP-
controllers also needs separate controller for rapping control, an additional user
interface for communicating with the controller, and a separate display unit.
The prior art ESP- controller for controlling the ESP (hereafter referred to as the
ESP controller) is an embedded system based on a single processor. Such prior
art ESP controllers are not based on core-module based CPU design.
Further, the ESP controller of prior art is not equipped to communicate both over
Ethernet network as well as RS-485 protocol.
Again, the ESP controller of prior art is not capable of being remotely monitored
through e-mail or through a web-interface.
In some of the prior art, the ESP controller controls the transformer-rectifier set
of the ESP, and the rapping motors of the ESP by a separate controller
(hereafter referred to as the rapping controller).

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0B3ECTS OF THE INVENTION
It is therefore an object of invention to propose an enhanced controller for
performing remote monitoring and control of electrostatic precipitators.
Another object of the invention is to propose an enhanced controller for
performing remote monitoring and control of electrostatic precipitators which is
based on a dual CPU configuration having a core module.
A further object of the invention is to propose an enhanced controller for
performing remote monitoring and control of electrostatic precipitators which is
capable of communicating over an Ethernet network.
A still another object of the invention is to propose an enhanced controller for
performing remote monitoring and control of electrostatic precipitators which is
capable of being connected to a Local Area Network (LAN.).
A still further object of the invention is to propose an enhanced controller for
performing remote monitoring and control of electrostatic precipitators which is
capable to communicate over RS-485 protocol.
Yet another object of the invention is to propose an enhanced controller for
performing remote monitoring and control of electrostatic precipitators which
monitors and controls the ESP remotely through e-mail or through a web
browser.

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Another object of the invention is to propose an enhanced controller for
performing remote monitoring and control of electrostatic precipitators which is
capable of receiving e-mails through the Ethernet network and decode the
message, control, and furnish the requested data through e-mail.
A still another object of the invention is to propose an enhanced controller for
performing remote monitoring and control of electrostatic precipitators which is
capable of presenting the ESP with operating parameters in the form of web
pages that can be viewed with the help of a web interface, and receiving
data/control signals through the web interface.
A further object of the invention is to propose an enhanced controller for
performing remote monitoring and control of electrostatic precipitators which is
capable to control the rapping motors of the ESP, thereby eliminating the need
for a rapping controller.
A still further object of the invention is to propose an enhanced controller for
performing remote monitoring and control of electrostatic precipitators which
provides communication interface with MODBUS protocol based plant level
controllers.
Yet another object of the invention is to propose an enhanced controller for
performing remote monitoring and control of electrostatic precipitators which is
equipped with an in-built display unit capable of interaction with the user
including displaying the ESP and rapping function parameters thereby eliminating
the need for a separate display unit for the users.

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SUMMARY OF THE INVENTION
Accordingly, there is provided an enhanced controller for performing remote
monitoring and control of electrostatic precipitators.
Thus, the present invention provides a system capable of remote monitoring
and control including in-built rapping control in a single embedded device. The
invention provides two types of communication in a single embedded device. The
enhanced controller has dual processor architecture, and utilizes a core module
with peripheral components for implementing the hardware. The core module is
an intelligent processor based printed circuit board having multiple
communication channels, digital inputs/ outputs and in-built memory.
The enhanced controller has two processors, one of which functions as the
master and the other one functions as the slave. The two processors have a
communication channel through which the exchange of data and signals is
performed.
The enhanced controller comprises hardware circuit for RS-485 communication
and Ethernet communication. For each type of communication individual ports
are provided, through which the enhanced ESP controller and the plant level
controllers are connected. Communication transceivers are used in the hardware
to interface the communication channels of the processor to the physical
communication bus.

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The enhanced controller is provided with associated software to transmit and
receive message/data both in MODBUS protocol and TCP/IP protocol. The
software module enables sending and receiving the message/data through the
communication protocols by using the TCP/IP protocol. The enhanced controller
has inbuilt means to receive e-mails and decode the e-mail message. Based on
the type of message, the enhanced controller either transmits data over TCP/IP
as e-mail or performs a control action. The system of the invention is capable of
hosting web pages that can be viewed with the help of a web interface. The
enhanced controller has the capability to present the ESP operating data in the
form of web pages and the data can be viewed using a web interface. Similarly,
the system is enabled to receive data/control signals inputted through the web
interface. The data transfer between the user and the controller using the web
interface takes place over TCP/IP protocol.
The system communicates with the field level controllers over a RS-485 network
using the MODBUS protocol. The system has inbuilt hardware for exchange of
messages with the field level controllers over the MODBUS protocol. The system
has corresponding means for coding and decoding of the communication
protocol.
The invented system has inbuilt hardware for controlling the rapping motors of
the ESP, including means for determining the sequence and timing of the
rapping motors. Thus, the system eliminates the need for separate rapping
controllers as envisaged in prior art.

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The enhanced controller also provides an in-built display unit which is capable of
displaying the ESP parameters including rapping function parameters. The in-
built display unit can further be used for user interaction thus eliminating the
need for a separate user's display unit.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig. 1 is a hardware block diagram of the enhanced controller according to the
invention.
Fig. 2 is a software logic diagram of the enhanced controller according to the
invention.
Fig. 3 is an Interface diagram of the enhanced controller with MODBUS protocol
based field level controllers including the plant level controller of electrostatic
precipitators, and the TCP/IP based systems at Plant level.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE
INVENTION
The hardware block diagram of the invented enhanced controller (10) for
performing remote monitoring and control of electrostatic precipitator is shown in
Fig.1

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As shown in figure 1, the enhanced controller is provided with a core module
based processor (01), which acts as the slave controller, and a main processor
(08), which acts as the master controller.
A first block (02) is provided to accommodate the hardware for TCP/IP based
communication. The enhanced controller communicates with the plant level
controller through a Ethernet port (05).
A second block (03) is provided which contains the hardware for the RS-485
protocol based communication. The controller interacts with other plant level
controllers and the plant level centralized monitoring system through a first port
circuit (06).
A third block (04) comprises the hardware for the rapping motor control. The
enhanced controller sends control signals and receives feedback signals from the
rapping motors of the ESP through a second port circuit (07).
The main processor (08) is interfaced with a display unit (09), which serves as
the user-interface. The display unit (09) is controlled directly by the main
processor (08) which further serves as an output interface for the user.
Fig.2 shows the software logic diagram of the present invention.

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The Software logic is shown in block (19) which comprises a main block (11), a
pair of communication driver blocks (13), (15), and a pair of high-level
communication handling blocks (12), (14).
The main block (11) initiates default values and various tasks to be performed
during the operation.
The first communication driver block (13) receives and transmits TCP/IP protocol
based message/data frames and the second communication driver block (15)
receives and transmits MODBUS protocol based data frames.
The first communication protocol conversion block (12) undertakes the task of
coding and decoding of the TCP/IP protocol based messages, and the second
communication protocol conversion block (14) comprises means for coding and
decoding of MODBUS protocol based messages.
The rapping motor control block (16) is enabled to control the various rapping
motors. The rapping motor control block comprises means for implementing the
timing and duration of the rapping motors. The block (16) also comprises means
for implementing rapping algorithms based on the feedback received from
various rapping motors of the ESP.
A memory control block (17) is provided having means for storing and retrieving
data to and from the memory, and enabled for implementing the standard
memory access protocols.

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An input interface block (18) is further provided for sensing the input data from
the user and from the field controllers.
Fig. 3 is an Interface diagram of the enhanced controller of the invention with
the Plant level controllers of the electrostatic precipitator through a MODBUS
protocol based communication, and with the Plant level controllers through
Ethernet communication.
According to the invention, a plurality of enhanced ESP controllers (21), (22),
(23), (24) are connected together in a TCP/IP based network. The enhanced ESP
controllers interact with a MODBUS protocol based plant level controller (20).
The enhanced ESP controllers (21 to 24) accept both command and data signals
from the plant level controller (20). The enhanced ESP controllers also
communicate the status to the plant level controller (20).
The plant level controllers also communicate over TCP/IP based protocol with a
TCP/IP based network (29). A plurality of TCP/IP protocol based web-interface
enabled devices (25), (26), (27) are connected to the TCP/IP based network
(29). The web-interface enabled devices (25), (26), (27) are used to monitor
and control the enhanced ESP controllers (21), (22), (23). The monitoring and
control of the enhanced ESP controllers (21,22,23) can be done remotely from
the web-interface enabled devices (25,26,27) through e-mail or through a web-
interface. The data transfer between the enhanced ESP controllers and the
web-interface enabled devices (25,26,27) takes place over the TC/IP protocol,
through the TCP/IP based network (29).

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We Claim:
1. An embedded system for performing remote monitoring and control of
electrostatic precipitor (ESP) comprising:
- a plurality of enhanced ESP controllers (21 to 24) interconnected
over a TCP/IP based network (29), capable of communicating with
a MODBUS protocol based plant controller (20), the other plant
level controllers communicating over TCP/IP based protocol; and
- a plurality of TCP/IP protocol based web-interface enabled devices
(25 to 27) interconnected via the TCP/IP- based network (29), the
web-enabled devices (25 to 27) remotely monitoring and
controlling the enhanced ESP-controllers (21 to 24) based on the
data transfer over the TCP/IP based network (29), each of said
enhanced ESP controllers (21 to 24) comprising:
- at least one core module based processor (01) acting as a slave
controller;
- at least one master processor (08) acting as a master controller,
and being interfaced with a display unit (09);
- a first hardwire block (020 capable of communicating with the plant
level controllers (20) over TCP/IP based protocol via a TCP/IP
based network (29) by means of a first communication driver block
(13), the MODBUS based data frames being communicated by
means of a second communication driver block (14), the TCP/IB
protocol based messages and the MODBUS protocol based
messages being coded and decoded respectively via a first and
second communication conversion blocks (12,14);

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- a second hardware block (03) capable of communicating with the
other plant level controllers including the plant level centralized
monitoring system over RS-485 protocol via a first port circuit (06);
- a third hardware block (04) incorporated with a rapping motor
control block (16) for communicating with the rapping motors of
the ESP via a second port circuit (07); and
- a memory means (17) and an input interface means (18) provided
respectively for storing and retrieving data to and from the
memory, and sensing the input data from the user and the field
controllers.
2. An embedded system for performing remote monitoring and control of
electrostatic precipitor (ESP) as substantially described and illustrated herein with
reference to the accompanying drawings.


Dated This 21st day of September 2007

Accordingly, there is provided an enhanced controller for performing remote
monitoring and control of electrostatic precipitators.
Thus, the present invention provides a system capable of remote monitoring
and control including in-built rapping control in a single embedded device. The
invention provides two types of communication in a single embedded device. The
enhanced controller has dual processor architecture, and utilizes a core module
with peripheral components for implementing the hardware. The core module is
an intelligent processor based printed circuit board having multiple
communication channels, digital inputs/ outputs and in-built memory.
The enhanced controller has two processors, one of which functions as the
master and the other one functions as the slave. The two processors have a
communication channel through which the exchange of data and signals is
performed.
The enhanced controller comprises hardware circuit for RS-485 communication
and Ethernet communication. For each type of communication individual ports
are provided, through which the enhanced ESP controller and the plant level
controllers are connected. Communication transceivers are used in the hardware
to interface the communication channels of the processor to the physical
communication bus.

The enhanced controller is provided with associated software to transmit and
receive message/data both in MODBUS protocol and TCP/IP protocol. The
software module enables sending and receiving the message/data through the
communication protocols by using the TCP/IP protocol. The enhanced controller
has inbuilt means to receive e-mails and decode the e-mail message. Based on
the type of message, the enhanced controller either transmits data over TCP/IP
as e-mail or performs a control action. The system of the invention is capable of
hosting web pages that can be viewed with the help of a web interface. The
enhanced controller has the capability to present the ESP operating data in the
form of web pages and the data can be viewed using a web interface. Similarly,
the system is enabled to receive data/control signals inputted through the web
interface. The data transfer between the user and the controller using the web
interface takes place over TCP/IP protocol.
The system communicates with the field level controllers over a RS-485 network
using the MODBUS protocol. The system has inbuilt hardware for exchange of
messages with the field level controllers over the MODBUS protocol. The system
has corresponding means for coding and decoding of the communication
protocol.
The invented system has inbuilt hardware for controlling the rapping motors of
the ESP, including means for determining the sequence and timing of the
rapping motors. Thus, the system eliminates the need for separate rapping
controllers as envisaged in prior art.
The enhanced controller also provides an in-built display unit which is capable of displaying the ESP parameters including rapping function parameters. The inbuilt display unit can further be used for user interaction thus eliminating the need for a separate user's display unit.