Parallel Communication Module for Wireless Field Device Diagnostics
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Solution Overview
Problem
Existing industrial installations with older field devices face challenges in retrieving diagnosis data due to the complexity and cost of retrofitting for digital communication, particularly in limited spaces and hazardous conditions, where 4-20 mA technology restricts data retrieval and requires additional power supply.
Innovation Solution
A communications module that connects in parallel with field devices, utilizing an energy storage unit powered by a transducer unit to capture electrical or physical variables, allowing for wireless transmission of diagnosis data without disrupting the current loop, using HART protocol for communication and low-power wireless protocols like Bluetooth LE for efficient data transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If additional components are installed to enable digital communication with field devices, then diagnosis data can be read out, but installation complexity and costs increase due to limited space and need to open communications loops
Solution Approach 1:
The communications module is integrated within an existing device housing (e.g., transmitter or controller), nesting multiple functions (digital communication, power supply, data processing) within a single compact unit. This eliminates the need for separate additional components and simplifies installation by utilizing existing mounting spaces and power supplies.
Solution Approach 2:
The communications module serves multiple functions simultaneously: it enables digital communication for diagnosis data retrieval, provides power supply to the field device through the communications loop, and interfaces with both the field device and superior control units. This multi-functionality reduces the number of separate components needed.
2Loss of information
If additional components are installed to enable digital communication, then diagnosis data can be transmitted, but acquisition and installation costs increase
Solution Approach 1:
The communications module combines the digital communication interface, power supply circuitry, and data processing functions into a single integrated unit that can be installed in existing device housings. This merging of functions into one component reduces the total cost of acquisition and installation compared to deploying multiple separate components.
Solution Approach 2:
The communications module utilizes the existing communications loop and power supply infrastructure to operate, rather than requiring dedicated additional power supplies or communication channels. The module harvests power from the existing loop and uses it to enable digital communication functions.
3Adaptability or versatility
If the communications loop is opened for electrical installation of additional components, then digital communication can be implemented, but system processes must be stopped
Solution Approach 1:
The communications module is designed to be installed within existing device housings without requiring opening of the communications loop. The module taps into existing connection points and integrates into the existing electrical architecture, allowing installation while the system remains operational.
4Use of energy by stationary object
If battery supply is used for additional components, then power can be provided, but batteries must be changed frequently and replacement is difficult in hazardous conditions
Solution Approach 1:
The communications module harvests power from the existing communications loop that is already present in the system. By utilizing the existing power infrastructure, the module eliminates the need for separate battery supplies or external power connections, and the power is continuously available without requiring manual intervention for replacement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables simple and efficient retrieval of diagnosis data from field devices without affecting measurement accuracy, reducing installation complexity and costs, and allowing for centralized data collection and visualization in the control station.
Implementation Method 1
continual storage of electric power in an energy storage unit of the communications module by means of a transducer unit connected upstream of the energy storage unit up to a predetermined limit value, wherein the transducer unit captures an electrical and/or physical variable and converts it into electric power
Data Source
AI summary
The present disclosure comprises a method, a communication module, and a system for transmitting diagnosis data of a field device that is connected to a superordinate unit via a communication loop. The communication module is connected to the communication loop in parallel with the field device. The method includes the continual storage of electrical energy in the communication module by a transducer unit within the communication module that captures an electrical and/or physical variable and converts it into electrical energy. The method includes polling the diagnosis data of the field device by the communication module and wireless transmission of the polled diagnosis data to a reception unit by the communication module.