Portable Setup Commissioning for Process Automation Nodes
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Solution Overview
Problem
Existing process automation systems face challenges in commissioning devices like DCNs due to the need for manual configuration and potential errors, resource overuse, and exposure of the network during device setup, especially when devices lack necessary parameters for joining and data transmission.
Innovation Solution
Utilizing a portable setup device (PSD) with an out-of-band communication channel, such as Wi-Fi direct, NFC, or Bluetooth, to establish connections with DCNs through passive data stores like QR codes or RFID tags, enabling configuration data exchange without burdening the process automation network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual configuration is used for device commissioning, then configuration can be performed with existing tools, but errors and mistakes increase and productivity decreases
Solution Approach 1:
The device performs self-configuration by automatically detecting network parameters and generating configuration data without manual intervention. The commissioning device extracts network information from the process automation network and uses it to automatically configure the new device, eliminating manual configuration steps and reducing both errors and commissioning time.
2Ease of operation
If pre-configuration with static network settings is used, then device can join network initially, but requires separate sub-network setup and increases device complexity
Solution Approach 1:
The device is pre-equipped with a passive data store containing static information and communication interfaces, but the actual network configuration is performed automatically at commissioning time. This preliminary preparation enables the device to receive automatic configuration without requiring pre-setup of separate sub-networks or manual static configuration.
Solution Approach 2:
A commissioning device acts as an intermediary between the process automation network and the new device. It extracts network configuration data from the existing network and relays it to the new device, simplifying the commissioning process and reducing device complexity by handling network adaptation externally.
3Device complexity
If commissioning data is exchanged over the process automation network, then network infrastructure is utilized, but network security is compromised and network performance is degraded
Solution Approach 1:
The commissioning communication channel is extracted from the process automation network, creating a separate communication path. The commissioning device establishes direct communication with the new device outside the main network, removing commissioning traffic from the production network and eliminating security risks and performance degradation.
4Reliability
If knowledgeable system integrator performs manual setup, then proper configuration is achieved, but time and expertise requirements increase
Solution Approach 1:
The commissioning process is automated so that the device configures itself without requiring a knowledgeable system integrator. The commissioning device automatically extracts network parameters, generates configuration data, and programs the new device, maintaining configuration correctness while eliminating the need for expert manual intervention and significantly reducing commissioning time.
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
This method reduces errors, time, and expertise required for device commissioning, enhances security, and minimizes network exposure during setup, allowing for efficient and secure integration of DCNs into the automation system.
Implementation Method 1
two-way near-field communication (NFC)
Implementation Method 2
radio frequency identification (RFID)
Implementation Method 3
peer-to-peer (P2P) communication technology such as Wi-Fi direct
Implementation Method 4
Bluetooth
Data Source
AI summary
Implementations are described herein for commissioning a device such as a distributed control node (DCN) for operation with a process automation system (PAS) using a portable setup device (PSD) and an “out-of-band” communication channel. In various implementations, static information conveyed by a passive data store of the DCN may be used to establish an out-of-band communication channel between the DCN and PSD. The out-of-band communication channel may be distinct from a process automation network through which the DCN is to be communicatively coupled with other process automation nodes of the PAS. The DCN may be commissioned to the process automation system by exchanging operational technology (OT) data between the DCN and the PSD via the out-of-band communication channel to enable the DCN to cooperate with one or more of the other process automation nodes on the process automation network to implement an at least partially automated process.