Network-Based Sensor System Using TCP/IP for Process Automation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The integration of field bus technology in process automation is hindered by complexity and the lack of training for operating personnel, leading to difficulties in mapping functionality to control and regulation systems, and the need for separate IT and OT infrastructures, which increases maintenance efforts.
Innovation Solution
A network-based measuring system utilizing TCP/IP protocol for bidirectional data exchange between sensors and an intermediate unit, eliminating the need for 'classic' transmitters and allowing sensors to communicate directly, forming a flexible network that can be expanded with new subscribers, with options for Ethernet, SPE, and wireless protocols, and including explosion-proof configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If field bus technology is used for process automation, then information transmission and remote control capabilities are improved, but device complexity and difficulty of operation increase
Solution Approach 1:
The patent introduces a transmitter as an intermediary device between the sensor and the control system. The sensor connects to the transmitter via a simple cable, and the transmitter handles the complex field bus communication protocols and data processing. This mediator approach allows sensors to benefit from advanced communication capabilities without directly facing the complexity of field bus technology.
Solution Approach 2:
The system is divided into separate functional components: sensors for measurement, transmitters for signal processing and communication, and control systems for regulation. This segmentation allows each component to be optimized independently, with transmitters bearing the complexity burden while sensors remain simple measurement devices.
2Ease of manufacture
If field bus technology is implemented, then wiring effort is reduced and signal quality is improved, but mapping functionality to control systems becomes difficult
Solution Approach 1:
The transmitter is equipped with automatic device recognition and configuration capabilities. When a sensor is connected, the transmitter automatically detects the sensor type, configures appropriate parameters, and establishes communication without requiring manual intervention for functionality mapping. This self-service approach simplifies operation while maintaining advanced communication benefits.
3Reliability
If separate IT and OT infrastructures are maintained, then system availability is improved, but maintenance effort and training requirements increase
Solution Approach 1:
The patent combines IT and OT infrastructures by having sensors and transmitters participate in both process control (OT) functions and network communication (IT) functions simultaneously. The same physical connection and communication protocol serve dual purposes, eliminating the need for separate infrastructures while maintaining system availability through redundant communication paths.
Data Source
AI summary
The present disclosure discloses a network-based measuring system, including a first sensor, at least one second sensor, and at least one intermediate unit, wherein the first and/or second sensor are electrically connected to the intermediate unit via a connection. The first and second sensors are supplied with power via the connection and data is exchanged bidirectionally. The connection comprises a network-based protocol, wherein the intermediate unit is connected to a higher-level unit, wherein the first and second sensors exchange data with one another without knowledge of the higher-level unit.