Virtual Field Device Platform for High-Speed Sensor Analytics
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Solution Overview
Problem
Field devices in hazardous environments face challenges in upgrading or updating complex functionalities due to design constraints and physical limitations, with legacy communication protocols limiting power and data bandwidth, making it difficult to incorporate advanced features and diagnostics.
Innovation Solution
A system utilizing high-speed communication protocols like Ethernet APL to transmit unfiltered measurement data to a virtual analytics platform in the cloud, enabling advanced diagnostics, analytics, and functionality updates without physical access to the field devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex measurement and communication routines are incorporated into field devices, then functionality and diagnostic capabilities are improved, but device complexity and power consumption increase
Solution Approach 1:
The patent introduces a gateway device as an intermediary between field devices and the control network. The gateway performs complex measurement routines, data processing, and communication protocols externally, allowing field devices to maintain simple intrinsically safe designs while still providing advanced functionality through the gateway's processing capabilities.
Solution Approach 2:
Complex functionality including measurement routines, communication protocols, and diagnostic capabilities is extracted from the field device and relocated to the gateway device. This extraction reduces the computational burden and power requirements of field devices while preserving advanced features through the gateway's processing.
2Reliability
If advanced diagnostic functions are added to field devices, then measurement reliability is improved, but power consumption and processing requirements increase
Solution Approach 1:
The gateway acts as an intermediary that performs advanced diagnostic processing externally. Field devices can implement basic diagnostics with minimal power consumption, while the gateway provides enhanced diagnostic capabilities including detailed analysis, trend monitoring, and predictive maintenance functions without increasing field device power requirements.
3Productivity
If high-speed communication protocols are implemented, then data bandwidth and processing capability are improved, but compatibility with legacy systems and power requirements increase
Solution Approach 1:
The communication architecture is segmented into two parts: field devices use low-power legacy protocols (HART, Fieldbus) for basic communication, while the gateway implements high-speed Ethernet protocols for advanced data transmission. This segmentation allows high-bandwidth communication for analytics and diagnostics without requiring field devices to consume excessive power.
4Measurement precision
If unfiltered measurement data is transmitted to enable advanced analytics, then measurement precision and analytics capability are improved, but data bandwidth requirements and processing load increase
Solution Approach 1:
The gateway serves as an intermediary that receives, stores, and processes unfiltered measurement data from field devices. It provides high-fidelity data access to analytics platforms while managing data volume through selective transmission, compression, and intelligent filtering based on analytics requirements, reducing unnecessary data bandwidth consumption.
Data Source
AI summary
A system for creating a virtual field device is provided. The system includes a processor having memory that when executed causes the processor to provide a sensor selection user interface element configured to receive user selection of at least one process sensor providing high-speed, unfiltered measurement data. The processor also provides a processing selection user interface element configured to receive user selection of at least one processing action to perform on the high-speed, unfiltered measurement data to generate a process output. The processor also provides an output selection user interface element configured to receive user selection of at least one remote device to which the process output is communicated. A computer-implemented method of creating a virtual field device is also provided.