Wireless Adapter Wire Harness Encapsulation for Hazardous Locations
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Solution Overview
Problem
Industrial process plants face challenges in utilizing advanced data from field devices due to high costs and the need for wireless communication adapters that maintain hazardous location approval ratings, particularly explosion-proof and intrinsically safe certifications, while minimizing form factor and circuit board size.
Innovation Solution
A wireless process communication adapter with a housing, field device coupling, and adapter circuitry, using wire stripping and tinning with encapsulation to prevent gas entry, and a wire retainer for mechanical strength and spacing, ensuring explosion-proof and intrinsically safe certifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If wireless communication adapter is added to field device, then wireless data transmission capability is improved, but device complexity and form factor increase
Solution Approach 1:
The patent combines the wireless communication adapter with the existing field device housing, integrating the adapter circuitry, wire retainer, and encapsulation materials into a unified structure that attaches to the field device without requiring separate external components
Solution Approach 2:
The adapter is designed to be universally compatible with multiple types of field devices featuring process control loops, using a standardized coupling mechanism that can interface with various device configurations while providing wireless communication functionality
2Reliability
If explosion-proof enclosure is used to contain potential explosions, then safety is improved, but device size and complexity increase
Solution Approach 1:
The patent uses a thin-walled enclosure design with integrated sealing mechanisms that provide explosion-proof protection without requiring thick protective walls, allowing the adapter to maintain a compact form factor while containing potential explosions
Solution Approach 2:
The enclosure provides explosion protection specifically at critical areas such as the process control loop connections and adapter circuitry housing, rather than requiring uniform thick protection throughout the entire device structure
3Reliability
If wire harness is stripped and tinned for gas sealing, then explosion-proof rating is maintained, but manufacturing complexity increases
Solution Approach 1:
The wire retainer is designed to pre-position and secure the stripped and tinned wire ends before final encapsulation, ensuring proper gas sealing geometry is achieved without requiring complex manual wire manipulation during assembly
Solution Approach 2:
The wire retainer acts as an intermediary component that simplifies the wire preparation process by providing a structured interface for inserting and securing the stripped/tinned wires, eliminating the need for complex wire management procedures
4Reliability
If intrinsically safe spacing is maintained between electronic components, then safety is improved, but circuit board size increases
Solution Approach 1:
The patent uses encapsulation material to create an inert environment around the adapter circuitry, allowing electronic components to be positioned closer together than traditional intrinsically safe spacing requirements would permit, thereby reducing circuit board size while maintaining safety
Solution Approach 2:
The encapsulation material acts as a protective barrier that enables reduced spacing between components by providing the necessary isolation and protection, allowing the circuit board to be miniaturized while still meeting intrinsically safe requirements
Data Source
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AI summary
A wireless process communication adapter (14, 30) includes a housing (120) having a first end and a second end. A field device coupling (122) is attached to one of the first and second ends. Adapter circuitry (154) is disposed within the housing (120) and the adapter circuitry (154) is coupled to a plurality of wires that pass through the field device coupling (122). A wire retainer (160) is engaged upon the plurality of wires to maintain the wires in a fixed position. An encapsulation material (136) encapsulates the adapter circuitry (154), the wire retainer (160), and the plurality of wires.