Intrinsically Safe Measuring Device Segmentation
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Solution Overview
Problem
Existing non-intrinsically safe powered measuring devices face challenges in operating safely in explosive environments due to ignition hazards from electrical sparks and hot surfaces, requiring expensive and restrictive flameproof encapsulations that limit design freedom and increase costs.
Innovation Solution
Designing the electronic device with 'casting encapsulation' type of protection, using intrinsically safe display devices, and connecting sensors and output circuits with 'increased safety' type of protection, eliminating the need for costly cable bushings and flameproof enclosures, while allowing for flexible design and standard power connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flameproof encapsulation is used for electronic devices in explosive atmospheres, then ignition protection is improved, but device complexity and cost increase
Solution Approach 1:
The device is divided into intrinsically safe modules (sensors, display, output circuits) and a separate electronic device with casting encapsulation. This segmentation allows each part to have optimized protection measures, reducing overall complexity while maintaining safety.
Solution Approach 2:
Connections with increased safety type of protection serve as intermediaries between the intrinsically safe components and the electronic device. These intermediary connections manage energy transfer and isolation, simplifying the overall protection architecture.
2Reliability
If flameproof encapsulation is used for electronic devices, then ignition protection is improved, but manufacturing cost increases
Solution Approach 1:
The casting encapsulation uses cost-effective materials and standard manufacturing processes compared to traditional flameproof encapsulation. The intrinsically safe components are designed to be inherently safe without requiring expensive specialized enclosures.
Solution Approach 2:
The protection approach changes from passive flameproof encapsulation to active intrinsic safety through energy limiting. This parameter change (from structural protection to energy management) reduces manufacturing costs while maintaining safety.
3Reliability
If flameproof encapsulation is used, then ignition protection is improved, but design freedom is reduced
Solution Approach 1:
By separating the electronic device from intrinsically safe components, the electronic device can have any shape or form factor without being constrained by flameproof encapsulation requirements. The intrinsically safe components maintain their own protection while allowing design flexibility.
Solution Approach 2:
The protection philosophy shifts from form-factor constrained flameproof enclosures to energy-based intrinsic safety. This allows the electronic device to adopt any shape, size, or design while safety is ensured through energy limiting rather than physical constraints.
4Reliability
If intrinsically safe connections are used throughout, then ignition protection is improved, but power transmission capability is reduced
Solution Approach 1:
The system segments power transmission and signal transmission paths. High-power connections use increased safety type protection, while intrinsically safe connections handle only low-power signal transmission. This segmentation allows optimal power transmission where needed while maintaining intrinsic safety where required.
Solution Approach 2:
The electronic device acts as an intermediary that converts non-intrinsically safe signals to intrinsically safe signals for transmission to field devices. This intermediary function allows high-power operations in the control area while maintaining intrinsic safety in the hazardous area.
Data Source
Figure 1~2
AI summary
The invention relates to an intrinsically safe powered measuring device (1), comprising a connection device (3) designed with "Increased Safety" protection for connecting the measuring device (1) to a power supply connection (2) to supply the measuring device (1) with electrical energy, an electronic device (4) containing electronic components of the measuring device (1), a display device (8), a sensor (7) designed with "Increased Safety" or "Intrinsic Safety" protection, and an output circuit (9) that is at least not designed with "Intrinsic Safety" protection. According to the invention, the electronic device (4) is designed with "Encapsulation" protection, the display device (8) is designed with "Intrinsic Safety" protection, and the display device (8), the sensor (7), and the output circuit (9) are connected to the electronic device (4) via connections designed with "Increased Safety" protection.