Terminal and Head Module Protocol Conversion for HART Ethernet Data Capture

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Solution Overview

Problem

Existing industrial plants face challenges in connecting non-Ethernet capable field devices to a central database due to their reliance on 4-20 mA or HART technology, which requires extensive wiring and space in electrical cabinets, especially in existing plants where modifications are difficult.

Innovation Solution

A terminal module and head module system that converts data from field devices using 4-20 mA or HART technology into Ethernet-compatible protocols, allowing data transmission to a central location while minimizing space requirements by using a hat rail-mounted electronics module to monitor and convert data traffic, and a head module that connects to an Ethernet network for cloud-based databases.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If field devices use 4-20 mA or HART technology with separate communication loops, then reliable data transmission is achieved, but wiring effort and space requirements in electrical cabinets increase significantly

Engineering Contradiction:

Improvedata transmission reliabilityVSAvoidwiring complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple communication loops into a single Ethernet cable connection. The terminal module integrates multiple field device connections (4-20 mA, HART) into one unified Ethernet interface, eliminating the need for separate communication loops for each field device and reducing wiring complexity in electrical cabinets.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The terminal module acts as an intermediary device between field devices using 4-20 mA/HART technology and the Ethernet network. It converts protocols and transmits data through a single Ethernet cable, serving as a mediator that reduces wiring while maintaining reliable data transmission from multiple field devices.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If gateway devices are installed in parallel into each communication loop, then data transmission to central location is enabled, but space requirements in electrical cabinets increase

Engineering Contradiction:

Improveprotocol conversion capabilityVSAvoidelectrical cabinet space

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

Instead of installing separate gateway devices in parallel for each communication loop, the patent merges multiple field device connections into a single terminal module. This consolidation reduces the number of devices required and minimizes the space occupied in electrical cabinets while maintaining protocol conversion capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The terminal module is designed as a universal device that can handle multiple field device protocols (4-20 mA, HART) and convert them to Ethernet. This multi-functional approach eliminates the need for multiple specialized gateway devices, reducing space requirements while providing adaptability to different field device types.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If individual communication loops are opened for gateway installation, then data transmission is enabled, but installation time and complexity increase

Engineering Contradiction:

Improvedata transmission capabilityVSAvoidinstallation time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The terminal module combines multiple field device connections into a single integration point, eliminating the need to open and reconfigure individual communication loops. This merging approach allows for simpler installation where field devices are connected to the terminal module without disrupting existing communication loops, significantly reducing installation time.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If extensive wiring is used for non-Ethernet field devices, then reliable communication is achieved, but modification of existing plants becomes difficult

Engineering Contradiction:

Improvecommunication reliabilityVSAvoidplant modification ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical wiring system (separate communication loops with physical cables) with an Ethernet-based digital communication system. The terminal module converts traditional 4-20 mA/HART signals to Ethernet protocols, allowing existing field devices to communicate reliably while using modern Ethernet infrastructure that is easier to modify and extend in existing plants.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11500355B2Terminal module, head module, and system for collecting data from an automation system

Publication Date: 2022.11.15 ENDRESS HAUSER PROCESS SOLUTIONS AG

AI summary

Disclosed is a system for collecting data from an automated plant having a field device connected for communication and for exchanging telegrams with a superordinate unit by means of a communication loop using a first protocol. The system includes a hat rail; and a terminal module mounted on the hat rail and embodied to monitor telegrams transmitted from the field device to the superordinate unit via the communication loop. The terminal module is further embodied to convert monitored telegrams into a second protocol and to output the converted telegrams. The system further includes a head module mounted on the hat rail and connected with the terminal module. The electronics unit of the head module is embodied to convert telegrams output from the terminal module into a third protocol to output them via the first network interface.