Ethernet-APL Gateway Using PROFINET IO Mediation for Field Device Scaling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automation devices struggle to efficiently manage a large number of field devices using Ethernet-APL due to high communication and computational overhead, limiting their capacity and complicating integration and configuration in larger systems.
Innovation Solution
A device configured to act as a PROFINET IO device for higher-level automation systems and a PROFINET IO controller for field devices, while also functioning as an Ethernet-APL gateway, reducing data traffic and processing load by managing connections and preprocessing data, with aggregator and controller optimization functionalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If field devices are connected directly to the automation device using Ethernet-APL, then communication performance is improved, but the communication and computational overhead increases significantly
Solution Approach 1:
The patent introduces an APL switch as an intermediary device between the automation device and field devices. The APL switch handles Ethernet-APL communication with field devices while presenting a simplified PROFINET interface to the automation device, thereby mediating the communication protocols and reducing the computational burden on the automation device.
Solution Approach 2:
The system is segmented into distinct functional layers: the APL switch handles the complex Ethernet-APL protocol layer and field device management, while the automation device focuses on higher-level control tasks. This segmentation allows each device to specialize in specific functions, reducing overall system overhead.
2Adaptability or versatility
If a large number of field devices are connected to the automation device, then system functionality is improved, but the automation device cannot efficiently manage them due to overhead
Solution Approach 1:
The APL switch acts as a mediator that manages multiple field device connections and presents a consolidated interface to the automation device. This allows the system to scale to numerous field devices without proportionally increasing the management complexity of the automation device.
Solution Approach 2:
The APL switch creates virtual representations or proxies of field device connections for the automation device, allowing the automation device to interact with simplified copies of the actual complex field device interfaces rather than managing each device individually.
3Productivity
If Ethernet-APL is used for field device connections, then communication efficiency is improved, but integration and configuration in larger systems becomes more complex
Solution Approach 1:
The APL switch is designed with multi-functionality, supporting both Ethernet-APL protocols for field device communication and PROFINET protocols for automation device integration. This universal compatibility simplifies integration into existing systems while maintaining the communication efficiency benefits of Ethernet-APL.
Solution Approach 2:
The APL switch serves as an intermediary that handles the complexity of Ethernet-APL configuration and protocol translation, shielding the automation device and system integrators from the complexities of direct Ethernet-APL configuration while preserving communication efficiency.
Data Source
Figure 1
Figure 2
AI summary
A device (3) is proposed which has a plurality of interfaces (5a, 5b, 5c) for connection (6a, 6b, 6c) with field devices (4a, 4b, 4c) of a technical plant, in particular a process or manufacturing plant, based on Ethernet-APL and PROFINET, and which has an interface (7) for connection (8) with a higher-level automation device (2) of the technical plant based on PROFINET, wherein the device (3) is designed to act as a communication switch between the higher-level automation device (2) and the field devices (4a, 4b, 4c).The device (3) is characterized in that it is designed to act as a PROFINET IO device within the context of the connection (8) with the higher-level automation device (2), and to act as a PROFINET IO controller within the context of the connection (6a, 6b, 6c) with the field devices (4a, 4b, 4c), in order to act as an Ethernet-APL gateway within the context of the connections (6a, 6b, 6c) with the field devices (4a, 4b, 4c) and the higher-level automation device (2).