Multi-protocol field device in process control systems
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Solution Overview
Problem
Existing field devices in process control systems are limited by their ability to communicate using only one industrial communication protocol, requiring multiple versions and complicating integration across different plant automation systems, leading to increased inventory and development costs, as well as reduced flexibility in deployment across various systems.
Innovation Solution
A multi-protocol field device that incorporates multiple communication units capable of using different protocols, such as Ethernet/IP and HART/IP, allowing it to communicate with various systems using different protocols simultaneously, enabling real-time process control and device management communications over a single network link.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a field device uses only one communication protocol, then it can be designed and implemented with a single protocol architecture, but it requires multiple versions of the same field device to participate in different automation systems, leading to increased inventory and development costs
Solution Approach 1:
The field device incorporates multiple communication protocol stacks (first protocol stack and second protocol stack) within a single device, enabling it to communicate with different automation systems using different protocols. This multi-functionality allows one field device version to replace multiple protocol-specific versions, reducing inventory complexity while maintaining ease of manufacture through standardized hardware platforms.
Solution Approach 2:
The communication architecture is segmented into separate protocol stacks (first communication protocol stack and second communication protocol stack) that operate independently within the field device. Each stack handles a specific protocol, allowing the device to selectively engage appropriate protocols for different communication needs without interfering with each other, thus achieving versatility while maintaining manageable complexity.
2Device complexity
If a field device uses only one communication protocol, then the device design is simpler, but the same field device cannot be easily transported or used within different plants or different plant automation systems
Solution Approach 1:
By integrating multiple communication protocol stacks into a single field device, the invention creates a universal device that can operate across different plants and automation systems regardless of which protocol they use. This eliminates the need for protocol-specific device versions, thereby improving portability and adaptability while keeping device complexity manageable through modular protocol stack architecture.
Solution Approach 2:
The field device dynamically selects and switches between different communication protocol stacks based on the requirements of the connected automation system. This dynamic adaptability allows the same physical device to be deployed in different plants with different protocol requirements without requiring hardware changes, thus enhancing portability while maintaining relatively simple device design.
3Reliability
If multiple versions of a field device are created for different protocols, then each version can be optimized for its specific protocol, but it requires different drawings, user manuals, parts, and inventory for essentially the same field device
Solution Approach 1:
The invention consolidates multiple protocol capabilities into a single field device version that contains both first and second communication protocol stacks. This universal device can be configured to use either protocol as needed, eliminating the need to maintain separate device versions for different protocols. Consequently, a single set of drawings, user manuals, parts, and inventory can serve all protocol requirements, reducing administrative complexity while maintaining protocol-specific optimization through software configuration.
4Device complexity
If a field device uses a single protocol, then the communication architecture is simpler, but real-time process control and asset management cannot be performed simultaneously using different protocols
Solution Approach 1:
The field device implements segmented communication architecture with separate first and second communication protocol stacks, where each stack can independently handle different communication tasks. This segmentation enables simultaneous execution of real-time process control using one protocol and asset management using another protocol, thereby improving productivity without significantly increasing overall communication architecture complexity through modular design.
Solution Approach 2:
The field device acts as an intermediary that translates and forwards communications between different protocols. It can receive real-time control commands via one protocol stack, process them internally, and communicate with the control system using another protocol stack simultaneously. This intermediary capability enables parallel control and management operations across different protocol domains while maintaining relatively simple internal architecture.
Data Source
AI summary
A field device includes components to communicate with a control and/or asset management system of a process control system or with other field devices using any of several different communication protocols such as several different internet protocol (IP) protocols. This architecture allows for a single version of a field device to be provided in automation or plant control systems that use any of these communication protocols, thus saving on inventory and product development costs. Moreover, the multi-protocol field device or a system using the multi-protocol field device can manage the asset (read and write parameterized data from and to the asset) using one protocol while at the same time communicating real-time process/factory automation information using a second and different protocol. Moreover, the field device may be able to communicate to other devices including other field devices and host devices using both of these protocols or other protocols for different purposes.