Terminal Module Data Capture for Two-Wire Fieldbus Loops
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Solution Overview
Problem
Existing industrial systems face challenges in connecting non-Ethernet capable field devices to a central database, particularly due to the use of 4-20 MA technology or hard technology, which requires extensive cabling and significant space in control cabinets.
Innovation Solution
A system comprising a head module and terminal modules, where the terminal modules are equipped with an electronics module that listens to data traffic on two-wire communication loops, converts data into a proprietary protocol, and transmits it via contacts, allowing data from non-Ethernet capable field devices to be collected and forwarded to a central location, such as a cloud-capable database, over an Ethernet-based network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If field devices are connected to a central database using 4-20 mA technology or HART technology, then data from non-Ethernet capable field devices can be transmitted, but extensive cabling and significant space in control cabinets are required
Solution Approach 1:
The patent introduces an intermediary device (gateway or protocol converter) that acts as a mediator between the 4-20 mA/HART field devices and the Ethernet-based central database. This intermediary converts data from traditional industrial protocols to Ethernet protocols, enabling data transmission without requiring extensive cabling to the database while maintaining compatibility with legacy field devices
Solution Approach 2:
The patent replaces the mechanical/electrical cabling system (4-20 mA wires) with an electronic/digital communication system (Ethernet-based wireless or wired network). By substituting the physical cable infrastructure with a digital network infrastructure, the system achieves data transmission with significantly reduced cabling requirements while maintaining reliable communication with non-Ethernet capable field devices through protocol conversion
2Reliability
If field devices are connected using 4-20 mA technology or HART technology, then data from non-Ethernet capable field devices can be transmitted, but significant space in control cabinets is required
Solution Approach 1:
The patent merges multiple functions into integrated components. The gateway device combines protocol conversion, data processing, and network communication capabilities in a single unit, eliminating the need for separate terminal blocks, communication modules, and database interfaces that would otherwise occupy significant control cabinet space. This consolidation reduces the physical footprint while maintaining data transmission capability
Solution Approach 2:
The patent substitutes the traditional wired control cabinet infrastructure with a network-based system. By replacing physical cable connections and associated terminal equipment with Ethernet-based communication (potentially wireless), the system dramatically reduces the space required in control cabinets while maintaining reliable data transmission from field devices to the central database
3Ease of operation
If data from field devices is made available in a central location via Ethernet, then data accessibility is improved, but connectivity between non-Ethernet field devices and the database is lacking
Solution Approach 1:
The patent employs an intermediary device (gateway or protocol converter) that bridges the compatibility gap between non-Ethernet field devices and the Ethernet-based central database. This intermediary translates data from 4-20 mA or HART protocols into Ethernet-compatible formats, enabling seamless data exchange and making data from legacy field devices accessible through the Ethernet network infrastructure
Solution Approach 2:
The patent changes the communication protocol parameters between field devices and the central database. By converting data transmission from analog 4-20 mA signals or HART protocol to digital Ethernet protocols (such as Modbus TCP, OPC UA, or proprietary protocols), the system maintains protocol compatibility across different device types while enabling high-speed, reliable data accessibility through the Ethernet network
Data Source
Figure 1~2
AI summary
The invention relates to a terminal module (KL), a head module (KM), and a system for collecting data from a system which comprises a field device (FG) and which exchanges telegrams with a superordinate unit by means of a communication loop (KS) using a first protocol, comprising: - a top hat rail (HS); - at least one terminal module (KL), said terminal module (KL) being pushed onto the top hat rail (HS) and being designed to monitor telegrams transmitted from the field device (FG) to the superordinate unit via the communication loop (KS), convert the monitored telegrams into the second protocol, and output the converted telegrams; and - a head module (KM), wherein the head module (KM) is pushed onto the top hat rail (HS), and the terminal module (KL) is connected to the contacts of the head module (KM) by means of contacts (KO). The electronic unit of the head module (KM) is designed to convert the telegrams output by the terminal module (KL) into a third protocol and output same via a network interface (NS1).