Protocol Converter for SCADA Meter Totalization Accuracy
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Solution Overview
Problem
Industrial SCADA systems face challenges in accurately reading and interpreting meter totalizations from pulse-output and milliamp-output registers, which can lead to errors due to power failures, noise, and inability to differentiate between forward and backward flows, resulting in costly maintenance and synchronization issues.
Innovation Solution
A supervisory control and data acquisition protocol converter that reads encoded meter registers using proprietary protocols like Sensus and Neptune, converting the data into standard industrial protocols such as MODBUS, ADAM-4000, and EtherNet/IP, enabling precise totalization and flow rate information transmission while eliminating the need for periodic synchronization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pulse-output and milliamp-output meter registers are used in industrial SCADA systems, then the systems can interface with standard industrial protocols, but the totalization accuracy deteriorates due to power failures, noise, and synchronization errors
Solution Approach 1:
The patent introduces an encoded register as an intermediary device between the flow meter and the SCADA system. This encoded register stores totalization data in a protected, non-volatile memory that is immune to power failures and electrical noise. The register acts as a mediator that provides accurate totalization readings without requiring complex synchronization protocols, thereby resolving the contradiction between reliability and device complexity
Solution Approach 2:
The patent replaces the mechanical/electrical pulse-counting system with an electronic encoded register system. Instead of relying on pulse counters that are susceptible to noise and power interruptions, the system uses an electronic register with non-volatile memory to store and transmit totalization data. This substitution eliminates the synchronization problems inherent in mechanical pulse-based systems while maintaining compatibility with SCADA systems through standard protocols like MODBUS
2Measurement precision
If encoded meter registers with proprietary AMR protocols are used, then totalization accuracy is improved, but compatibility with industrial SCADA systems deteriorates due to protocol barriers
Solution Approach 1:
The patent makes the encoded register multi-functional by enabling it to communicate through both its native proprietary AMR protocol and standard industrial protocols like MODBUS. The register can serve multiple functions: maintaining accurate totalization data in its native format while simultaneously providing compatibility with diverse SCADA systems through standard protocols. This universality resolves the contradiction between measurement precision and adaptability
Solution Approach 2:
The patent changes the communication parameters of the encoded register to accommodate both proprietary and standard protocols. By modifying the protocol parameters (such as data format, communication mode, and command structures) while preserving the core totalization measurement function, the system achieves both high measurement precision and broad protocol compatibility. The register can dynamically adjust its communication parameters based on the connected device
3Measurement precision
If pulse-output meters are used to measure flow, then the system can detect flow rate, but the ability to differentiate between forward and backward flows is lost
Solution Approach 1:
The patent uses the concept of counterweight by implementing a differential measurement approach. The encoded register measures forward flow and backward flow separately, then computes the net flow as the difference between these two opposing flows. This counterweight approach allows the system to detect flow direction accurately while maintaining a relatively simple device structure, as the register handles the differential calculation internally
Data Source
AI summary
A supervisory control and data acquisition protocol converter having encoded meter register input ports which are able to interrogate, read, and retain data stored in viscous fluid or gas meter registers which communicate with the Automatic Meter Reading (AMR) protocols and convert that data upon request to an industrial monitoring and control system protocol such as MODBUS®, DF1, EtherNet/IP™, or ADAM 4000. The present art further provides serial RS-232C and RS-485, and Ethernet ports whereby said data may be transmitted and/or the apparatus may be setup according to user defined specifications. The present art apparatus also provides industrial standard pulse (0-5 volts) and current (4-20 milliamps) inputs. The present art further provides a user configurable display which may display any or only a portion of the aforesaid data along with other user desired data. The apparatus further serves a web page over the Ethernet port with the aforesaid data populating a table.