Portable Setup Commissioning for Distributed Control Nodes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The commissioning of devices like distributed control nodes (DCNs) in process automation systems is cumbersome due to the need for manual configuration and potential errors, especially when they lack necessary parameters to join and communicate over the process automation network, often requiring a separate sub-network setup and extensive manual intervention.
Innovation Solution
The use of a portable setup device (PSD) with an out-of-band communication channel, such as Wi-Fi direct, NFC, or Bluetooth, to establish communication with DCNs, allowing for the exchange of configuration data without burdening the process automation network, using a passive data store for static information like QR codes or RFID tags to facilitate automatic configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual configuration is used to commission DCNs, then flexibility and control are improved, but time consumption and error rates increase
Solution Approach 1:
The system performs preliminary actions by pre-configuring DCNs with static network configuration parameters before they are deployed to the process automation network. This allows the DCNs to be pre-prepared with necessary configuration data, reducing the time required for on-site manual configuration and commissioning.
Solution Approach 2:
A separate sub-network is introduced as an intermediary between the DCN configuration process and the process automation network. This sub-network allows configuration data to be exchanged without burdening or exposing the production process automation network, enabling automated configuration while maintaining network security and stability.
2Extent of automation
If pre-configuration with static network parameters is used, then automation is improved, but device complexity increases due to separate sub-network requirements
Solution Approach 1:
The network infrastructure is segmented into a separate sub-network for configuration purposes and the production process automation network. This segmentation allows automated configuration activities to occur in isolation without affecting the production network, reducing the risk of disruptions while enabling higher automation levels.
Solution Approach 2:
The separate sub-network acts as an intermediary layer that facilitates automated configuration exchanges. This intermediary structure enables DCNs to be configured with static parameters and then seamlessly integrated into the production network without requiring complex direct integration between the configuration process and the production network.
3Productivity
If the process automation network is used for device commissioning, then resource utilization is improved, but network security and stability are compromised
Solution Approach 1:
The network is segmented into distinct functional zones: a separate sub-network for commissioning and configuration activities, and the production process automation network for operational activities. This segmentation ensures that commissioning traffic does not burden or expose the production network, maintaining security and stability while still allowing efficient resource utilization within each zone.
Solution Approach 2:
The separate sub-network serves as an intermediary buffer between external configuration activities and the production process automation network. This intermediary structure allows configuration data to be exchanged securely without directly exposing the production network to potential security risks or performance burdens from commissioning activities.
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, decreases the time and expertise required for onboarding or replacing DCNs, enhances security, and automates the configuration process, minimizing human intervention while ensuring only authorized devices are commissioned.
Implementation Method 1
a passive electronic tag that conveys the static information using radio waves, such as a radio frequency identification (RFID) or near-field communication (NFC) transmitter
Implementation Method 2
a PSD may include one or more sensors (e.g., vision sensors, RFID sensors, etc.) that are configured to detect the static information conveyed by the passive data store
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.