Inter-Plant Communication via Gateway Distribution Units
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Solution Overview
Problem
Existing methods for interplant communication in industrial compounds are slow, costly, and inflexible, often requiring extensive hardwiring that is impractical due to scarce space and scalability issues.
Innovation Solution
A method and distribution unit for interplant communication using a network-based system that allows for indirect connection between industrial plants, leveraging existing operational layers to transmit plant-related data and broadcast data via a distribution unit, enabling efficient and scalable communication without direct physical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hard wiring is used to directly connect each plant to every other plant, then communication reliability and availability are improved, but installation cost and device complexity increase significantly
Solution Approach 1:
The fully interconnected mesh network is segmented into a hierarchical structure with gateway devices at plant boundaries and central communication infrastructure. This segmentation reduces the number of direct connections required while maintaining communication reliability through the distributed gateway architecture.
Solution Approach 2:
Gateway devices act as intermediaries between individual plant control systems and the broader communication network. These gateways consolidate multiple connection points, reducing overall system complexity while maintaining reliable communication paths between all plants through the intermediary gateway layer.
2Reliability
If hard wiring is installed between all plants, then dedicated communication channels are ensured, but scalability and adaptability deteriorate when new plants are added
Solution Approach 1:
The network is segmented into modular units with gateway devices that can be independently added or removed. This modular segmentation allows new plants to be integrated by adding their gateway device to the existing network without requiring reconfiguration of all existing connections, thereby maintaining dedicated channel reliability while enabling easy scalability.
Solution Approach 2:
The gateway devices provide universal communication interfaces that can handle multiple communication protocols and connection types. This universality allows the system to accommodate different plant types and communication requirements while maintaining a consistent network architecture that supports both reliability and scalability.
3Speed
If extensive hardwiring infrastructure is deployed, then communication speed and reliability improve, but cost and ease of manufacture worsen due to scarce space and installation requirements
Solution Approach 1:
The physical hardwired mechanical connection system is replaced with wireless communication technology for the inter-plant links. This substitution eliminates the need for extensive physical cable installation between plants, reducing installation complexity and cost while maintaining communication speed through wireless protocols. Local hardwiring within plants is retained for control functions.
Solution Approach 2:
Gateway devices serve as intermediaries that consolidate communication infrastructure requirements. By concentrating communication interfaces at gateway locations rather than requiring direct plant-to-plant wiring, the system reduces the overall infrastructure burden while maintaining fast communication through the intermediary gateway nodes.
4Reliability
If direct physical connections are established between all plants, then information exchange reliability improves, but loss of time in setup and maintenance increases
Solution Approach 1:
The communication system is segmented into modular gateway components that can be independently configured, installed, and maintained. This segmentation reduces setup time by allowing parallel installation of multiple plant gateways without coordinating complex inter-plant wiring, while maintaining reliable information exchange through the standardized gateway interface.
Solution Approach 2:
Gateway devices act as maintainable intermediaries that centralize communication functions. Instead of maintaining numerous direct physical connections between all plant pairs, the system maintains connections only to gateway nodes, significantly reducing maintenance time and complexity while preserving information exchange reliability through the intermediary gateway layer.
Data Source
AI summary
A method for interplant communication between a plurality of industrial plants is disclosed. The method comprises:i. receiving, at at least one distribution unit, plant related data from at least one industrial plant of the plurality of industrial plants; andii. transmitting, via the at least one distribution unit, broadcast data to the plurality of industrial plants specifically to each industrial plant of the plurality of industrial plants, wherein the broadcast data comprises at least a part of the plant related data;wherein the reception of the plant related data and the transmission of the broadcast data are done via at least one network. Further, a distribution unit for interplant communication between a plurality of industrial plants, a plant communication system for enabling interplant communication between a plurality of industrial plants, a computer program, a computer program product and a computer-readable storage medium is disclosed.