Pluggable APL Switch Module for Hazardous Area Field Networks
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Solution Overview
Problem
Existing field network stations in industrial settings, particularly in hazardous areas, face challenges in providing reliable and fail-safe Ethernet communication and power supply to field devices, as they often require multiple wires and are not designed for explosive environments, limiting their usability and redundancy.
Innovation Solution
The introduction of a station with exchangeable modules, including switch modules with APL or SPE Ethernet ports, and redundant power supply modules, allowing for safe operation in hazardous areas by using single-pair Ethernet standards like Ethernet-APL or SPE, which enable reliable data communication and power delivery over a single 2-wire cable, and allowing for module exchange without interrupting operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional Ethernet communication is used in hazardous areas, then data communication can be established, but the system requires multiple wires and is not fail-safe for explosive environments
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional multi-wire Ethernet to single-pair Ethernet (SPE) and Ethernet Advanced Physical Layer (Ethernet-APL) standards. This changes the physical layer parameters including cable type (from multiple wires to single twisted pair), voltage levels, and signaling methods to enable safe operation in hazardous areas while maintaining Ethernet communication functionality
Solution Approach 2:
The patent implements universality by designing a module carrier system that can accommodate multiple types of modules (switch modules, power supply modules, I/O modules) within a single platform. This allows the same physical infrastructure to support various communication standards (traditional Ethernet, SPE, Ethernet-APL) and functions (data switching, power supply, I/O control) through interchangeable modules
2Ease of repair
If fixed configuration stations are used, then initial setup is simple, but maintenance and redundancy require system shutdown
Solution Approach 1:
The patent applies segmentation by dividing the station into independent, interchangeable modules (switch modules, power supply modules, I/O modules) that can be individually replaced. Each module is functionally independent and can be exchanged without affecting other modules, enabling hot-swapping capability where maintenance can be performed without shutting down the entire system
Solution Approach 2:
The patent implements preliminary action by designing modules with pre-configured connection interfaces (connectors, terminals) that are prepared in advance for quick exchange. The module carrier is pre-designed with standardized slots and connection points, allowing modules to be rapidly swapped without complex installation procedures, thus maintaining system operation during maintenance
3Device complexity
If single-pair Ethernet standards (Ethernet-APL or SPE) are adopted, then cable complexity is reduced, but power supply and communication over single cable must be reliably achieved
Solution Approach 1:
The patent applies merging by combining power supply and data communication functions into a single cable infrastructure. The single twisted-pair cable simultaneously carries both power delivery (Power over Data Line - PoDL) and Ethernet data signals, eliminating the need for separate power and data cables. This is achieved through integrated modules that can receive both power and data through the same physical medium
Solution Approach 2:
The patent uses intermediary components including PoDL power supply modules that mediate between the single-pair Ethernet cable and the power requirements of connected devices. These intermediary modules manage power delivery, signal conditioning, and protocol conversion to ensure reliable operation over the single cable connection in hazardous area environments
Data Source
AI summary
A station for use in a field network between at least one field device and a central unit, includes a module carrier and exchangeable pluggable modules thereon, wherein at least one of the exchangeable pluggable modules is designed as a switch module to which the at least one field device is connectable, and wherein optionally, in addition, at least one of the exchangeable pluggable modules is designed as a power supply module, the at least one switch module comprises at least one APL Ethernet port and/or at least one SPE Ethernet port for connecting the at least one field device. Further, a switch module is exchangeably pluggable in a module carrier to which one or more field devices is connectable.