Network Gateway Module for Process and Electrical Automation Integration
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Solution Overview
Problem
Conventional systems fail to integrate process control and electrical automation effectively, leading to conflicts between process control goals and energy management objectives in manufacturing facilities, resulting in suboptimal energy management and process automation.
Innovation Solution
The integration of a process automation system with an electrical automation system using an intelligent electrical device (IED) connected through a network gateway module, which translates data into a compatible format for Ethernet/IP, enabling a process controller to execute add-on instructions and profiles to convert and scale data, and synchronize timing between networks for intelligent energy management and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If process control and electrical automation systems operate independently, then each system can maintain its own control goals and operations, but conflicts arise between process control goals and energy management objectives leading to suboptimal overall performance
Solution Approach 1:
The patent combines process control and electrical automation systems into a unified integrated system where a central controller coordinates both process control functions and energy management functions. This merging eliminates conflicts between independent system goals while maintaining overall efficiency through centralized coordination and shared communication protocols.
Solution Approach 2:
The integrated controller serves multiple functions simultaneously - it acts as both a process controller and an energy management system. The system can perform process control operations, monitor electrical parameters, execute load shedding, and manage power distribution all through a single multi-functional platform, reducing the need for separate dedicated systems.
2Loss of energy
If conventional systems are used without integration, then system simplicity is maintained, but energy management and process automation goals conflict resulting in suboptimal energy management
Solution Approach 1:
The patent introduces a network gateway module as an intermediary between the process control network and electrical automation network. This gateway translates data formats and protocols, enabling seamless communication between the two systems without requiring complete architectural redesign. The intermediary facilitates integrated energy management while keeping the underlying system structures relatively simple.
3Reliability
If data translation and synchronization are implemented between networks, then coordinated energy management and process control are achieved, but additional components and processing requirements increase system complexity
Solution Approach 1:
The network gateway module serves as a mediator that handles data translation, protocol conversion, and synchronization between the process control network and electrical automation network. This intermediary component ensures reliable coordinated control by managing communication protocols and data formats, while isolating the complexity of integration from the core control functions.
Solution Approach 2:
The integrated system implements feedback mechanisms where the controller continuously monitors both process parameters and electrical system status, then adjusts operations to achieve optimal energy management while maintaining process control reliability. The feedback loops ensure coordinated response to changing conditions across both systems.
Data Source
AI summary
Systems, methods and apparatus are disclosed for interfacing process controllers in a process automation system with one or more intelligent electrical devices of an electrical automation system to use process and electrical control space information to perform actions and make decisions regarding actions in a connected enterprise system to facilitate energy management goals as well as process control goals in view of electrical control space information and process control space information. Some embodiments include an enclosure for a Motor Control Center unit, comprising: a DC power supply; an Ethernet switch; a network gateway module; and a controller.