Control Signal Migration Assembly for Low-Downtime Swing-Over
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Solution Overview
Problem
Existing industrial control system migration processes often require significant downtime and are limited by the need for specific devices to handle different signal types, making simultaneous and minimal disruption swing-overs challenging, especially when dealing with a variety of field devices that operate within specific voltage ranges.
Innovation Solution
A migration tool comprising analog and discrete sub-assemblies, selectors, and voltage range selectors, along with signal buffering and tapping cables, allows for the replication and switching of signals between old and new control systems with minimal disruption, enabling instantaneous or reversible swing-overs without interfering with existing wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional system replacement procedures are used, then complete system replacement can be achieved, but production downtime increases significantly
Solution Approach 1:
The patent introduces a migration tool as an intermediary device between the old control system and new control system. This migration tool includes signal replicating devices that can replicate signals from the old system and route them to the new system, allowing gradual migration without complete system shutdown. The intermediary enables seamless transition by maintaining signal flow throughout the migration process.
Solution Approach 2:
The migration tool is installed and configured in advance before the actual system replacement. The tool is pre-configured with the ability to replicate various signal types (analog, discrete, voltage, current) and is positioned to intercept and redirect signals before the new system is fully operational. This preliminary setup allows the migration to proceed without production interruption.
2Manufacturing precision
If specific devices are used for different signal types, then signal handling precision is improved, but device complexity and migration difficulty increase
Solution Approach 1:
The migration tool combines multiple signal replicating devices into a single integrated unit. Instead of using separate devices for analog signals, discrete signals, voltage signals, and current signals, the patent merges these functions into one migration tool that can handle all signal types simultaneously. This reduces the number of components and simplifies the migration process while maintaining precision for each signal type.
Solution Approach 2:
The migration tool is designed as a universal device that can replicate and handle multiple types of signals (analog, discrete, voltage, current) through a single platform. The tool includes configurable replicating devices that can adapt to different signal types, eliminating the need for multiple specialized devices and reducing overall system complexity.
3Manufacturing precision
If multiple specialized devices are used for different signal types, then signal replication accuracy is maintained, but simultaneous swing-over capability deteriorates
Solution Approach 1:
By merging multiple signal replicating devices into a single integrated migration tool, the patent enables simultaneous operation across all signal types. The unified device can perform swing-overs for analog, discrete, voltage, and current signals at the same time, whereas separate devices would require sequential operation and coordination.
Solution Approach 2:
The universal migration tool provides consistent swing-over capability across all signal types through a single controlled interface. The tool can replicate and switch signals simultaneously for different types (analog, discrete, voltage, current) without requiring separate coordination of multiple devices, greatly simplifying the migration operation.
4Reliability
If migration preparation is done in advance, then migration completeness is ensured, but migration time increases
Solution Approach 1:
The migration tool is installed and pre-configured before migration begins, with all signal replicating devices positioned and configured to handle the specific signal types in the system. This preliminary setup ensures that when migration is executed, the tool is ready to immediately replicate and switch signals without delays for configuration or setup during the actual migration process.
Data Source
AI summary
A migration tool, and the use thereof, for replicating and/or migrating at least one signal, associated with at least one field device, from a pre-existing control system to an external system or new control system, comprising: at least one analog sub-assembly, capable of relaying said at least one signal wherein said at least one signal is an analog signal; at least one discrete sub-assembly capable of relaying said at least one signal wherein said at least one signal is a discrete signal; a first selector for switching said at least one signal between (i) an analog mode where said at least one signal is directed to said at least one analog sub-assembly, and (ii) a discrete mode where said at least one signal is directed to said at least one discrete sub-assembly.