Modular Sensor System Galvanic Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current process automation systems face issues with inaccurate measurements and communication disruptions due to lack of electrical isolation, unsuitable connections, and distance between sensors and transmitters, making maintenance and operation challenging, especially in hard-to-reach locations.
Innovation Solution
A modular process sensor system with an electronic module and detachable operating device that includes a microprocessor, digital interfaces, and a means for galvanic isolation, allowing direct digital communication with the process control system via standardized protocols like Modbus, enabling on-site monitoring and maintenance without conventional transmitters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional transmitters are used to connect sensors to the process control system, then measurement data can be transmitted, but electrical isolation problems and connection issues lead to inaccurate measurements and communication disruptions
Solution Approach 1:
The patent extracts the transmitter functionality from the sensor assembly, allowing the sensor to be directly connected to the process control system without an intermediate transmitter. This eliminates the electrical isolation problems and connection issues that occur at the transmitter interface, while the sensor itself performs signal conditioning and digital communication.
Solution Approach 2:
The patent introduces a digital communication interface as an intermediary between the sensor and the process control system, replacing the analog 4-20mA signal transmission. This digital intermediary eliminates ground loops and electrical interference problems while maintaining reliable data transmission.
2Adaptability or versatility
If sensors are placed far from the process control system for spatial reasons, then installation flexibility is improved, but maintenance and operation become challenging due to inaccessibility
Solution Approach 1:
The patent segments the measurement system into a remote sensor unit and a separate operating device. The sensor can be placed far from the control system for installation flexibility, while the operating device can be brought close during maintenance and operation. The wireless or wired communication bridge connects these segments, allowing the sensor to remain in its optimal remote position while maintaining ease of operation.
3Object-affected harmful factors
If radio communication is used to avoid data lines between transmitter and higher-level unit, then wired transmission problems are avoided, but radio connection failures can cause delays and errors in the control loop
Solution Approach 1:
The patent uses digital communication protocols (HART, Fieldbus, Modbus) as an intermediary between the sensor and the higher-level unit, replacing both traditional analog wired transmission and radio communication. This digital intermediary provides reliable, interference-free communication with error checking and correction capabilities, eliminating the problems of both wired analog transmission and wireless radio communication.
4Loss of information
If proprietary protocol transmitters are used for communication between sensor and transmitter, then digital communication is enabled, but the system is tied to specific transmitter requirements and increases device complexity
Solution Approach 1:
The patent makes the sensor universal by equipping it with multiple communication interfaces (analog 4-20mA, digital HART, Fieldbus, or Modbus). This allows the same sensor to work with different process control systems without requiring proprietary transmitters, reducing device complexity and increasing flexibility. The sensor itself performs the signal conditioning that would otherwise require a separate transmitter.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The device has an electronic module (101), a process sensor separately connected with the electronic module and a control unit separately connected with the electronic module. The electronic module has a microprocessor (113) with a storage unit, multiple digital interfaces (108,112) and a unit for transmitting analog signals of the process sensor to a process control system (105).