APL Adapter for Bridging Legacy Field Devices to Ethernet
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Solution Overview
Problem
Legacy field devices in industrial process control systems are not compatible with Ethernet-APL systems, leading to communication barriers and delays in adopting newer, APL-connected devices that match the functionality of existing legacy devices.
Innovation Solution
An Advanced Physical Layer (APL) adapter is introduced, which includes a 2-wire APL spur connection, physical layer (PHY) circuitry, and connectivity circuitry. The adapter enables communication between legacy field devices and Ethernet-APL systems by converting legacy communication protocols to Ethernet protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If legacy field devices use traditional 4-20mA communication protocols, then they can maintain wide compatibility and established functionality, but communication speed is significantly slower (300 times slower than Ethernet-APL) and they cannot interface with modern Ethernet-APL systems
Solution Approach 1:
The patent introduces an adapter as an intermediary device that connects legacy field devices to Ethernet-APL systems. The adapter includes a legacy communication interface that interfaces with the legacy field device using traditional protocols (4-20mA, HART, Modbus, PROFIBUS, Foundation Fieldbus, or IO-Link) and an Ethernet-APL interface that communicates with the Ethernet-APL system. This intermediary translates and bridges the communication between the two incompatible systems, enabling legacy devices to access high-speed Ethernet-APL networking without requiring replacement.
2Adaptability or versatility
If new field devices with APL connectivity are developed to match legacy device functionality, then compatibility with Ethernet-APL systems is achieved, but there is a development delay and legacy devices cannot be immediately upgraded
Solution Approach 1:
The adapter serves as a temporary intermediary solution that allows immediate adoption of Ethernet-APL systems while waiting for native APL-capable field devices to be developed. Organizations can upgrade their networking infrastructure to Ethernet-APL and connect legacy field devices through the adapter, achieving high-speed communications now rather than waiting for new device development cycles. This eliminates the time loss by providing an immediate bridge solution.
3Speed
If legacy field devices are replaced with new APL-compatible devices, then communication speed and Ethernet-APL compatibility are improved, but device replacement costs and system reconfiguration time increase
Solution Approach 1:
The adapter eliminates the need for expensive device replacements and complex system reconfiguration. By inserting the adapter between the legacy field device and the Ethernet-APL system, organizations can maintain their existing field devices and continue using familiar communication protocols while gaining access to high-speed Ethernet-APL networking. This approach avoids the complexity of replacing devices and reconfiguring systems, as the adapter handles all protocol translations and interface adaptations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adapter facilitates the functional interconnection of legacy field devices with Ethernet-APL systems, allowing existing devices to benefit from high-speed data communications and power delivery while meeting intrinsic safety requirements, thereby bridging the compatibility gap.
Implementation Method 1
The PHY circuitry is capacitively coupled to the first pair of terminals
Data Source
AI summary
An Advanced Physical Layer (APL) adapter for enabling functional interconnection of a 2-wire APL spur to at least one industrial process legacy field device includes a first pair of terminals, APL physical layer (PHY) circuitry, a second pair of terminals and connectivity circuitry. The first pair of terminals is configured for connection to the 2-wire APL spur. The APL PHY circuitry is capacitively coupled to the first pair of terminals. The connectivity circuitry is configured to communicate with a legacy field device connected to the second pair of terminals in accordance with a legacy communication protocol and control the APL PHY circuitry to communicate through the first pair of terminals in accordance with an Ethernet protocol.