Industrial Signal Routing Using Unique IDs for Faster Commissioning
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Solution Overview
Problem
Manual cable-based communication channel setup in industrial communication networks is laborious, time-consuming, prone to faulty cables, and incorrect terminations, leading to unscheduled downtimes.
Innovation Solution
A system with a connector device, field signal marshal device, and junction box device that uses unique device IDs superimposed on field signals for intelligent routing, automated cable engineering, and fault detection and rectification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual cable-based communication channels are implemented between field devices and controllers, then communication connectivity is established, but the process becomes laborious and time-consuming
Solution Approach 1:
The system enables self-identification and self-routing of field devices through automated signal processing. The signal mixer automatically superimposes unique IDs on field signals, and the field signal marshal device automatically routes signals based on these IDs, eliminating the need for manual cable engineering and commissioning.
Solution Approach 2:
The patent replaces manual mechanical cable routing and termination with an automated electronic system. The field signal marshal device uses electronic signal processing and automated routing logic to substitute for manual cable management, significantly reducing commissioning time and labor.
2Reliability
If manual loop testing is performed on each cable to identify faulty cables, then faulty cables can be detected, but the process becomes laborious and time-consuming
Solution Approach 1:
The system performs self-diagnosis by automatically monitoring communication signals. The field signal marshal device detects faults in communication channels through automated signal analysis, eliminating the need for manual loop testing while maintaining high reliability in fault detection.
3Reliability
If faulty cables are identified and replaced, then communication reliability is improved, but extensive downtime is required
Solution Approach 1:
The system performs preliminary fault detection and diagnosis continuously during operation. By identifying faulty cables or communication channels before they cause system failures, the system enables proactive maintenance that minimizes downtime. The automated monitoring system prepares replacement routing paths in advance.
Solution Approach 2:
The system dynamically reroutes communication signals around faulty cables in real-time. The field signal marshal device automatically adjusts signal paths based on detected faults, maintaining communication reliability without requiring system shutdown or extensive downtime for repairs.
4Ease of manufacture
If incorrect cable termination is performed, then communication errors occur, but manual termination is difficult and prone to errors
Solution Approach 1:
The system performs self-configuration and self-verification of cable connections. The field signal marshal device automatically detects connection status and verifies signal integrity, compensating for potential termination errors and ensuring correct communication paths without requiring high precision manual termination.
Data Source
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AI summary
The present invention provides a system, apparatus, and method for intelligent signal routing in an industrial communication network. The system comprises a connector device comprising a signal mixer configured to superimpose a at least one unique ID on at least one field signal to generate a mixed signal. The system further comprises a field signal marshal device comprising a first input-output channel configured to transmit to a junction box device, a first request for a specific field signal associated with a specific unique ID. The junction box device comprises a first processing unit configured to determine whether the specific unique ID matches with the at least one unique ID in the mixed signal. The first processing unit is further configured to route the mixed signal to the first input-output channel based on a determination that the specific unique ID matches with the at least one unique ID.