IP-Enabled Smart Transducer for Industrial Remote Visibility
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Solution Overview
Problem
Industrial automation systems lack remote visibility into the state, behavior, and environment of processing equipment or devices due to commercially available field devices' limited communication capabilities and inability to measure certain physical quantities, which hinders product quality improvement, waste reduction, and yield optimization.
Innovation Solution
IP-enabled smart transducers that convert field data into Internet Protocol (IP) data using a processor and communications interface, enabling direct visibility and communication over an IP bus, with support for various transport methods and compliance with open standards like OPC UA, allowing data to be transmitted to remote locations for analysis and use in diverse industrial processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional field devices with serial protocol communication are used, then device compatibility and control functionality are improved, but remote visibility and data accessibility are worsened
Solution Approach 1:
The patent introduces an intermediary device (gateway or protocol converter) that bridges traditional serial protocol field devices and IP-based networks. This intermediary translates serial communication protocols (HART, Fieldbus, CAN) into IP-compatible formats, enabling remote visibility without replacing existing field devices. The intermediary maintains backward compatibility while providing modern network accessibility.
Solution Approach 2:
The patent implements multi-functional field devices that can operate in multiple communication modes simultaneously. These devices support both traditional serial protocols and IP-based communication, allowing them to function as both legacy field devices and networked smart devices. This universal capability enables seamless integration into existing systems while providing enhanced remote visibility.
2Loss of information
If IP-enabled smart transducers are deployed, then remote visibility and data accessibility are improved, but device complexity and implementation cost are worsened
Solution Approach 1:
The patent divides the IP-enablement function into separate modular components: protocol conversion modules, data formatting modules, and communication interface modules. This segmentation allows incremental implementation where organizations can add IP capability to existing devices without redesigning the entire system. Each module can be independently configured and maintained, reducing overall implementation complexity.
Solution Approach 2:
The patent uses intermediary gateway devices that handle the complex protocol conversion and data formatting tasks, keeping the actual field devices relatively simple. The gateway acts as a mediator that absorbs the complexity of IP protocol implementation, while field devices can remain relatively straightforward sensors and actuators with added communication interfaces.
3Reliability
If proprietary communication protocols are used, then device interoperability within manufacturer ecosystems is improved, but third-party integration and open standards compliance are worsened
Solution Approach 1:
The patent implements field devices and gateways with multi-protocol support capabilities. Devices can simultaneously support proprietary manufacturer protocols and open standards like OPC UA, Modbus TCP, and other industry protocols. This universal compatibility allows seamless integration within manufacturer ecosystems while enabling third-party system integration and adherence to open standards.
Solution Approach 2:
The patent introduces protocol translation gateways that act as intermediaries between proprietary protocol devices and open standard networks. These gateways maintain reliable communication with proprietary devices while translating their data into open standard formats, enabling third-party integration without compromising the reliability of original device-to-device communication.
Data Source
AI summary
An Internet Protocol (IP)-enabled smart transducer includes a sensor for generating field data regarding a physical quantity associated with processing equipment or a device in an industrial processing facility, and a signal conditioning circuit for at least one of amplifying and filtering the field data to provide conditioned field data. A communications interface is coupled to the signal conditioning circuit including a processor having an associated memory and a field data to IP data conversion algorithm for generating the IP data from the conditioned field data, and a transmitter is for transmitting the IP data across an IP bus to at least one application connected to the IP bus.