Field Device Data Server for Multi-Protocol Control Networks

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Solution Overview

Problem

Existing process control systems face complexity in integrating advanced communication protocols like Ethernet and IP-based protocols with traditional field devices, leading to cumbersome communication setups and reduced effectiveness due to the need for multiple I/O devices and precise mapping of physical and logical connections, which hampers the integration of advanced protocols in process plants with installed bases relying on traditional devices.

Innovation Solution

A highly versatile field device capable of operating as a data server, supporting multiple applications and communication protocols, including IP-based protocols, and nested protocols, with advanced security features, enabling direct communication with various client devices and systems while performing standard process control functions, and integrated into nodal communication networks for efficient data management and security.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple I/O devices are used to support different communication protocols, then protocol compatibility is improved, but device complexity increases

Engineering Contradiction:

Improveprotocol compatibilityVSAvoidnumber of I/O devices

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The field device is designed with multi-functionality to support multiple communication protocols (HART, Fieldbus, Profibus, Ethernet/IP, Profinet, Modbus) through a single device interface. The device can dynamically adapt to different protocols without requiring separate I/O devices for each protocol, thereby reducing overall system complexity while maintaining broad protocol compatibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Multiple communication protocol support functions are merged into a single field device rather than being distributed across multiple separate I/O devices. This consolidation eliminates the need for precise mapping between physical and logical connections across multiple devices and simplifies the communication setup architecture.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If precise mapping of physical and logical connections is implemented, then communication reliability is improved, but system complexity increases

Engineering Contradiction:

Improvecommunication reliabilityVSAvoidmapping complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The field device performs self-configuration and automatic protocol detection, eliminating the need for manual precise mapping of physical and logical connections. The device automatically adapts to the connected protocol and configures its communication parameters, thereby maintaining communication reliability while significantly reducing system complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The field device includes pre-configured support for multiple communication protocols, allowing it to immediately adapt to the required protocol upon connection without requiring complex setup or mapping procedures. This preliminary preparation enables reliable communication while simplifying the installation and configuration process.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If traditional field devices are used with installed bases, then system stability is maintained, but integration capability with advanced protocols deteriorates

Engineering Contradiction:

Improvesystem stabilityVSAvoidintegration capability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The field device incorporates dynamic protocol adaptation capabilities that allow it to switch between traditional protocols (HART, Fieldbus) and advanced protocols (Ethernet/IP, Profinet, Modbus) based on the communication requirements. This dynamic flexibility enables the device to maintain stability with traditional systems while seamlessly integrating with advanced protocols and IIoT applications.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The field device employs nested protocol support where multiple communication protocols are layered within a single device architecture. This allows traditional protocols to be nested alongside advanced protocols, enabling the device to maintain compatibility with existing installed bases while simultaneously supporting modern IIoT communication standards.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS12255973B2Highly-versatile field devices and communication networks for use in control and automation systems

Publication Date: 2025.03.18 FISHER ROSEMOUNT SYST INC

AI summary

A highly versatile process control or factory automation field device is configured with an interface and communication connection structure that enables the field device to operate as a data server that communicates with and supports multiple different applications or clients, either directly or indirectly, while simultaneously performing standard process and factory automation control functions. Moreover, various different process control and factory automation network architectures and, in particular, communication architectures, support the versatile field device to enable the versatile field device to simultaneously communicate with multiple different client devices or applications (each associated with a different system) via a common communication network infrastructure, using the same or different communication protocols.