Field Signal Wireless Interface for Long-Range Plant Data Links
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Solution Overview
Problem
Conventional industrial wireless communication technologies face limitations in long-distance communication and require numerous access points, making them costly and inefficient for large-scale plant facilities, and they often cannot utilize existing field devices without wireless communication functions.
Innovation Solution
A communication device comprising a signal acquirer, a controller, and a wireless communicator, which enables field devices without wireless communication functions to perform long-distance wireless communication by converting signals into digital formats suitable for transmission using LPWA or narrowband LTE standards, allowing flexible network construction and low-cost deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If conventional industrial wireless communication (ISA 100.11a, HART) is used, then field devices can be connected wirelessly, but the arrival distance is limited and numerous access points are required
Solution Approach 1:
The patent changes the fundamental communication parameter from 2.4 GHz spread spectrum to sub-1 GHz narrowband modulation. This parameter change enables signals to propagate much farther with lower attenuation, achieving several kilometers of arrival distance without requiring multiple access points or relay devices.
2Productivity
If conventional wireless communication is deployed in large-scale plants, then data collection is enabled, but the cost of constructing multiple access points and relay devices increases
Solution Approach 1:
The patent extracts the wireless communication function from complex infrastructure requirements (multiple access points, relay devices) and implements it through simple terminal devices with narrowband modems. This extraction eliminates the need for expensive infrastructure deployment while maintaining data collection productivity.
3Adaptability or versatility
If existing field devices are to be used, then device compatibility is improved, but devices without wireless communication functions cannot be utilized
Solution Approach 1:
The patent creates a universal terminal device that can interface with various existing field devices through different communication protocols while providing integrated narrowband wireless communication. This multi-functional terminal device enables existing field devices without wireless capabilities to participate in LPWA networks.
4Reliability
If 2.4 GHz spread spectrum is used for wireless communication, then industrial communication standards are met, but power consumption increases and arrival distance is limited
Solution Approach 1:
The patent changes the frequency parameter to sub-1 GHz and adopts narrowband modulation instead of spread spectrum. This parameter change reduces power consumption by approximately one order of magnitude compared to 2.4 GHz spread spectrum while maintaining reliable industrial communication.
Data Source
AI summary
A communication device includes a signal acquirer, a controller, and a wireless communicator. The signal acquirer has terminals for a plurality of types of interfaces for acquiring signals from an external field device. The controller acquires the signals output from the signal acquirer and performs control for externally transmitting digital data based on the signals using wireless communication. The wireless communicator externally transmits the digital data in accordance with a wireless communication scheme based on the control performed by the controller.