Field Device Radio Bridging for Brownfield Data Synchronization
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Solution Overview
Problem
Field devices in automated process installations often lack bidirectional digital communication capabilities, preventing consistent data synchronization between devices and central facilities, especially in brownfield installations where infrastructure upgrades are costly and impractical.
Innovation Solution
A method utilizing a mobile communication terminal to establish a bridge for bidirectional data exchange between field devices and central facilities via short-range and long-range radio connections, enabling data synchronization without requiring permanent digital network connections or hardware upgrades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If field devices are linked only via analog input/output maps, then device complexity is reduced and ease of manufacture is improved, but digital data cannot be accessed and passed on to the central facility
Solution Approach 1:
The mobile communication terminal serves as an intermediary device that bridges the analog field device and the central facility. It establishes a radio connection with the field device, retrieves digital data that would otherwise be inaccessible through analog maps alone, and transmits this data to the central facility via internet connection, thus resolving the information loss without requiring modification of the original field devices or input/output maps
Solution Approach 2:
The patent replaces the need for physical infrastructure upgrades (such as installing HART multiplexers, gateways, or radio-based infrastructure) with a software-based solution running on a mobile communication terminal. This substitutes complex mechanical/electrical systems with a more flexible electronic communication approach using existing radio and internet infrastructure
2Loss of information
If HART multiplexers or gateways are installed to enable digital data access, then digital data can be read and transmitted, but installation shutdown is required and costs increase
Solution Approach 1:
The mobile communication terminal acts as a portable intermediary that can be brought to the field device location temporarily. It establishes direct radio communication with the field device and transmits data to the central facility over the internet, eliminating the need for permanent installation of HART multiplexers or gateways and avoiding production stoppages entirely
Solution Approach 2:
Instead of investing in expensive permanent infrastructure (HART multiplexers, gateways, radio infrastructure), the patent uses a mobile communication terminal that leverages existing, widely available mobile phone technology. This temporary, portable solution is far less expensive and requires no installation shutdown, making it economically advantageous for brownfield installations
3Loss of information
If a radio-based infrastructure with fixed-location access points and gateways is built, then bidirectional data exchange is enabled, but device complexity increases and installation costs become prohibitive
Solution Approach 1:
The mobile communication terminal performs multiple functions: it acts as a radio transceiver, a data gateway, and an internet communication device all in one universally available platform. This eliminates the need for specialized fixed-location access points, multiple gateways, and complex radio infrastructure, significantly reducing system complexity while enabling bidirectional data exchange
Solution Approach 2:
The mobile communication terminal serves as a versatile intermediary that can move between different field device locations as needed. Unlike fixed infrastructure that requires installation at every location, this single portable device can establish temporary connections with multiple field devices sequentially, greatly simplifying the overall system architecture
4Loss of information
If conventional parameterization tools are used to read data on site, then data access is possible, but data cannot be synchronized with the central server
Solution Approach 1:
The mobile communication terminal serves as an active intermediary that not only reads data from the field device but also automatically transmits it to the central facility's database. This ensures that centrally held data is always synchronized with current device data, eliminating the data consistency problems associated with standalone parameterization tools that only read data locally
Solution Approach 2:
The system establishes a feedback loop where data from the field device is continuously transmitted to the central facility via the mobile communication terminal. This ensures that the central database always reflects the current state of field devices, enabling reliable data consistency and supporting applications like predictive maintenance that require up-to-date information
Data Source
AI summary
Method for producing a bidirectional connection between a device forming a field device and an application in a central facility, wherein a bidirectional connection is produced between the device that forms the field device and the application in a central facility, where a bridge function running on a mobile communication terminal establishes a short-range radio connection with the device, establishes a long-range radio connection with the application in the central facility and establishes a data channel for bidirectional communication between the application in the central facility via the long-range radio connection and the device via the short-range radio interface.