Wireless Adapter Loop Current Bypass for Two-Wire Process Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial process control systems often face challenges in maintaining communication and power supply to field devices due to failures in wireless communication circuitry, leading to disruptions in data transmission and device operation when connected via two-wire process control loops.
Innovation Solution
A wireless adapter with loop current bypass circuitry is introduced, which provides a current path in case of an open circuit in the wireless communication circuitry, ensuring continuous operation and communication by coupling in series with the two-wire process control loop, thereby maintaining power and data flow to field devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wireless communication circuitry is integrated into the process control loop, then wireless communication capability is provided, but system reliability deteriorates due to potential open circuit failures
Solution Approach 1:
The patent implements a bypass circuit that is pre-configured and remains dormant during normal operation. When the wireless communication circuitry fails, this bypass circuit automatically activates to maintain current flow. This prior cushioning approach ensures that failure protection is already in place before any malfunction occurs, eliminating the need for complex real-time detection and switching mechanisms while guaranteeing continuous operation.
2Adaptability or versatility
If wireless adapter is connected in series with the process control loop, then wireless data transmission is enabled, but device complexity increases due to additional circuitry
Solution Approach 1:
The patent combines the wireless communication adapter functionality with the existing process control loop connection by integrating the bypass circuit directly into the adapter's series connection. This merging approach allows the adapter to provide wireless capability while using the same physical connection path for both wireless adaptation and failure bypass functions, thereby avoiding additional separate components and reducing overall system complexity.
3Reliability
If loop current bypass circuitry is added, then reliability is improved by providing redundant current path, but device complexity increases
Solution Approach 1:
The bypass circuit is designed as a simple, passive, fail-safe mechanism that requires no active components, intelligence, or maintenance. It uses basic electrical components (resistors, diodes, or transistors) configured to automatically conduct when the main wireless circuit fails. This approach prioritizes simplicity and reliability over sophistication, accepting minimal added complexity in exchange for robust failure protection that never requires intervention.
Data Source
AI summary
A wireless adapter for use with a two-wire process control loop (22) is configured to couple to a process field device (12) in an industrial process control system. The wireless adapter (30) is coupled to the two-wire process control loop (22) and provides wireless communication to the process field device (12). The adapter (30) includes first and second loop terminals configured to couple in series with the two-wire process control loop (22). Wireless communication circuitry (155) is coupled to the first and second loop terminals and is adapted to provide wireless communication to the process field device (12). Loop current bypass circuitry (164) is electrically connected between the first and second loop terminals and is configured to provide a loop current path therebetween in response to an open circuit in wireless communication circuitry (155).