Sensor Connecting Element Dual Protocol Communication
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Solution Overview
Problem
Conventional sensors in process automation cannot communicate with connecting elements or parent units using different communication protocols, leading to compatibility issues and interference, especially when new cable classes are introduced, limiting the ability to exchange data and power efficiently.
Innovation Solution
A method that enables communication between sensors and connecting elements using a secondary protocol independent of the primary protocol, allowing different cable and sensor classes to interconnect, with a logical unit in the connecting element or parent unit managing this communication, and switching between basic and extended functionality modes as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a new cable class with improved characteristics is introduced to provide more power to sensors, then power transmission capability is improved, but compatibility with older cable and sensor classes is lost
Solution Approach 1:
The communication protocol is segmented into two independent layers: a first protocol for parent unit to sensor communication, and a second protocol for cable to sensor communication. This segmentation allows different cable classes to use the same second protocol for compatibility while supporting different power characteristics, resolving the contradiction between improved power capability and compatibility.
Solution Approach 2:
The cable is designed with dual communication capability: it can communicate with the parent unit using the first protocol and with the sensor using the second protocol. This multi-functionality allows the cable to serve multiple purposes - maintaining compatibility with existing systems while enabling new sensor classes with higher power requirements.
2Loss of information
If unused bits in the transmitted communication protocol are used for cable-sensor communication, then data exchange between cable and sensor is enabled, but the bits are no longer unused and future use is interfered with
Solution Approach 1:
Instead of using unused bits within the existing first protocol (one-dimensional solution), the invention introduces a completely separate second protocol for cable-sensor communication (adding another dimension). This approach enables full data exchange between cable and sensor without consuming bits from the first protocol, preserving future flexibility while achieving comprehensive communication capability.
3Reliability
If the cable and sensor communicate using a known communication protocol, then communication is established, but the technique fails or bits are misinterpreted with other communication protocols
Solution Approach 1:
The system changes the protocol parameter by introducing a second communication protocol specifically designed for cable-sensor communication. This protocol can be independently optimized and configured, allowing reliable communication between cable and sensor while maintaining compatibility with the first protocol for parent unit communication. The independent protocol design prevents misinterpretation issues that arise when trying to use a single protocol for multiple purposes.
4Reliability
If the parent unit queries the sensor for cable-sensor communication to occur, then communication is possible, but the system requires constant parent unit involvement and cannot operate autonomously
Solution Approach 1:
The cable and sensor are equipped with intelligent units that enable them to autonomously initiate and manage communication using the second protocol. This self-service capability allows the cable-sensor pair to communicate independently without requiring the parent unit to initiate each interaction, reducing system complexity and enabling autonomous operation while maintaining reliable communication.
Data Source
AI summary
The disclosure relates to a method for communication in process automation between a sensor and a connecting element connectable to the sensor, wherein the sensor is configured for acquisition of a measured variable of the process automation and for transmission of a value that is dependent upon the measured variable value to the connecting element, wherein the connecting element for transmission of the value dependent upon the measured variable to a parent unit is configured via a first protocol. The method is characterized in that communication between the sensor and the connecting element takes place without the knowledge of the parent unit using a second protocol, the second protocol being independent of the first protocol.