Field Device Compatibility Assessment Tool

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Solution Overview

Problem

In industrial process control systems, determining the compatibility of replacement field devices is challenging due to differences in manufacturer, model, device description revision, or firmware version, leading to difficulties in finding suitable replacements, increased downtime, and potential re-engineering of control system configurations.

Innovation Solution

An apparatus and method that compare device description files of field devices to identify differences and determine compatibility, using a tool that provides a compatibility report to facilitate the selection of suitable replacements and minimize system reconfiguration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If field devices from multiple manufacturers are used in an industrial process control system, then the system has greater flexibility and adaptability, but determining replacement compatibility becomes more complex and time-consuming

Engineering Contradiction:

Improveflexibility in field device selectionVSAvoidtime to determine replacement compatibility

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system performs preliminary compatibility assessment by comparing device description files and characteristics before actual replacement occurs. The compatibility determination is done in advance using automated comparison of device parameters, communication protocols, and control system requirements, allowing operators to prepare replacement strategies before field devices fail.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A compatibility assessment tool acts as an intermediary between the diverse field devices and the control system. This tool standardizes the compatibility evaluation process by interpreting device description files from multiple manufacturers and translating them into a unified compatibility determination framework, eliminating the need for manual comparison of multiple device specifications.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If manual comparison of device characteristics is performed, then compatibility can be determined, but the process is time-consuming and prone to errors

Engineering Contradiction:

Improveaccuracy of compatibility determinationVSAvoidtime for compatibility assessment

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The manual mechanical process of comparing device characteristics is replaced with an automated computer-based system. The compatibility assessment tool automatically retrieves device description files, extracts relevant characteristics, compares parameters using predefined compatibility criteria, and generates compatibility determinations without human intervention, eliminating both time consumption and human error.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Instead of manually examining original device documentation and specifications, the system creates and compares digital copies of device description files. These standardized digital representations contain all necessary device characteristics in a structured format that can be automatically processed and compared, ensuring consistent and accurate compatibility assessment.

Inventive Principle:

Principle #26Copying

3Stability of the object's composition

If identical field devices are required for replacement, then system compatibility is maintained, but availability of replacement devices is reduced

Engineering Contradiction:

Improveconsistency of field device specificationsVSAvoidavailability of replacement devices

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The system evaluates compatibility based on critical parameters rather than requiring exact identity of all device specifications. By identifying which device characteristics are essential for control system compatibility and which can vary, the system allows replacement with devices that have different non-critical parameters while maintaining system stability. This expands the pool of acceptable replacement devices.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The compatibility assessment framework serves multiple functions: it evaluates replacement compatibility, identifies required modifications, and provides guidance for seamless integration. This multi-functional approach allows the same tool to support both strict compatibility requirements and more flexible replacement scenarios, accommodating diverse replacement needs within a unified system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9557725B2Apparatus and method for determining replacement compatibility of field devices in industrial process control systems

Publication Date: 2017.01.31 HONEYWELL INTERNATIONAL INC

AI summary

A method includes identifying device description files corresponding to first and second field devices associated with an industrial process control system. The method also includes comparing multiple field device characteristics of the first and second field devices using the device description files. The method further includes identifying any differences between the device characteristics of the first field device and the device characteristics of the second field device. In addition, the method includes determining a compatibility of the first and second field devices based on any identified differences. The field device characteristics can relate to field device attributes, field device function blocks, and function block parameters of the first and second field devices.