Distributed Sensor Network for Hazardous Environment Control
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Solution Overview
Problem
Existing measurement and control systems in hazardous environments are limited by single high-function devices that require careful intrinsic safety design, leading to restricted power capacity, limited expansion, and cumbersome device integration, with power consumption challenges and manual configuration processes.
Innovation Solution
A distributed network of microprocessor-controlled, tiered devices optimized for specific functions, using an intrinsically safe bus for power and communication, enabling auto-detection and auto-configuration, and sharing battery power to maintain operation during power interruptions, with devices communicating via industry-standard protocols like Modbus over RS-485.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If single high-function devices are used in hazardous environments, then measurement and control capabilities are improved, but intrinsic safety requirements become more restrictive and power capacity is limited
Solution Approach 1:
The system divides a single high-function device into multiple distributed sensor/control devices, each with specialized functions. These devices operate independently on the hazardous area side of the ISB, collectively providing the measurement and control capabilities previously requiring a single complex device, thereby reducing individual power consumption while maintaining overall system capability.
Solution Approach 2:
The patent introduces a hierarchical dimension to the system architecture, with devices organized in tiers (Tier 1: basic sensors, Tier 2: intermediate processing, Tier 3: advanced control). This dimensional organization allows power-intensive functions to be distributed across multiple levels, with only essential functions running locally in hazardous areas, reducing the power capacity requirements of individual devices.
2Adaptability or versatility
If single high-function devices are used, then system functionality is improved, but device complexity and expansion capability are limited
Solution Approach 1:
The system segments functionality across multiple devices organized in a hierarchical structure. Each device is relatively simple in design, but the collective network provides advanced functionality. New devices can be added to any tier without redesigning existing devices, enabling easy expansion while maintaining simple individual device complexity.
Solution Approach 2:
The patent creates universal device modules that can function at multiple tiers depending on configuration. A single device type can operate as a basic sensor (Tier 1), intermediate processor (Tier 2), or integrated controller (Tier 3), providing multi-functionality without increasing individual device complexity. This universality enables flexible system expansion.
3Loss of information
If networked devices are used behind ISB, then data sharing capability is improved, but power consumption control becomes difficult
Solution Approach 1:
The patent implements local quality by enabling devices to operate autonomously with local data storage and processing capabilities. Each device maintains its own data cache and can perform local computations, reducing the need for continuous communication with the master control panel. This localized operation reduces power consumption while maintaining data sharing capabilities through selective upstream transmission upon request.
4Manufacturing precision
If manual configuration is required for device integration, then system control precision is improved, but installation time and complexity increase
Solution Approach 1:
The patent implements preliminary action through automatic device detection and configuration protocols. When a new device is added to the network, it automatically announces its presence, and the master control panel or neighboring devices automatically detect and configure the device parameters. This preliminary automated configuration eliminates manual setup time while maintaining configuration accuracy through standardized protocols.
Solution Approach 2:
The system enables self-service through automatic device identification and configuration. New devices automatically determine their own address, communication parameters, and integration settings without human intervention. The devices self-configure into the appropriate tier level based on their capabilities, reducing installation time while maintaining precise configuration through automated validation protocols.
Data Source
AI summary
The invention is a networked system of devices positioned in a hazardous environment to monitor/control process conditions. The devices include sensors and controls such as valves. The sensors detect process conditions/control device settings and are monitored by a slave devices having, generally microprocessor controlled and having associated memory to receive and record the sensor/control device data. The network includes master devices, each master device may be associated with one or more slaved devices and associated sensors, where the master device communicates to is associated slave devices through a digital communication bus. The master device can automatically detect its associated slave devices and detect the communication and data characteristics of the slave devices. The master may also set parameters for detected slave devices, such as needed for computations performed by the master (using its own microprocessor) using data received form the slave device(s). The master device receives slave device data by requesting or polling the data from the slave device over a digital communication bus.