Wireless Auxiliary Switch Module for Field Devices

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Solution Overview

Problem

Existing auxiliary switches in field devices often increase product design complexity and cost due to the need for physical coupling, which affects IP/NEMA rating and overall design, and there is a need for a solution that allows for wireless communication and power transfer without disassembling the device.

Innovation Solution

An external auxiliary switch mechanism with a base device and an expansion module that uses near-field communication for data and power transfer, allowing the expansion module to be wirelessly connected and powered, thereby reducing design complexity and cost by decoupling the switch from the product's physical structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an external auxiliary switch is physically coupled with the product, then the switch can be reliably controlled, but the product design complexity and cost increase, and the IP/NEMA rating is affected

Engineering Contradiction:

Improveswitch control reliabilityVSAvoidproduct design complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical/physical coupling between the auxiliary switch and the product with a wireless electromagnetic coupling system. The base device includes a transmitter that wirelessly communicates with the auxiliary switch via electromagnetic signals, eliminating the need for physical connections that would affect IP/NEMA ratings and reduce design complexity while maintaining reliable control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If an external auxiliary switch is physically coupled with the product, then the switch can be reliably controlled, but the product cost increases

Engineering Contradiction:

Improveswitch control reliabilityVSAvoidproduct cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent eliminates physical coupling components (connectors, wiring, housing modifications) by using wireless electromagnetic communication, reducing bill of materials cost and manufacturing complexity while maintaining reliable switch control through electromagnetic signal transmission

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If the auxiliary switch is integrated into the product structure, then the design is simplified, but the IP/NEMA rating is affected and design flexibility is reduced

Engineering Contradiction:

Improvedesign simplicityVSAvoidIP/NEMA rating flexibility

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent segments the auxiliary switch system into a separate wireless auxiliary switch unit and a base device with transmitter. This segmentation allows the switch to be physically separated from the product housing, maintaining the product's IP/NEMA sealing integrity while enabling design flexibility and adaptability without compromising protection ratings

Inventive Principle:

Principle #1Segmentation

4Device complexity

If wireless communication is implemented between base device and expansion module, then design complexity is reduced and IP/NEMA rating is maintained, but power transfer capability must be achieved without physical connections

Engineering Contradiction:

Improvedesign complexityVSAvoidpower transfer capability

Core Design Contradiction:

Device complexityVSUse of energy by moving object

Solution Approach 1:

The patent implements a multi-functional wireless interface where the electromagnetic communication signals serve dual purposes: data transmission for control commands and power transfer for energizing the auxiliary switch. This universal wireless interface eliminates the need for separate power connections while maintaining design simplicity and IP/NEMA integrity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables wireless communication and power transfer between the base device and expansion module, reducing product design complexity and cost while maintaining functionality without affecting the product's IP/NEMA rating, and allowing for easy integration of additional features like human interfaces and network connectivity.

Implementation Method 1

Data may be transferred wirelessly between the transceiver of the base device and the transceiver of the expansion module with, for example, near-field communication techniques

Methodology Applied

Scientific EffectNear-field communication: Electromagnetic Induction

Implementation Method 2

the expansion module may derive power from signals from the basic device

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10680679B2Expansion modules with switches and external communication

Publication Date: 2020.06.09 HONEYWELL INTERNATIONAL INC

AI summary

An external auxiliary switch mechanism having a base device and an expansion module. The base device may incorporate a transceiver and microcontroller connected to the transceiver. The expansion module may incorporate a transceiver and a microcontroller connected to the transceiver. The microcontroller of the expansion module may have a connection to one or more switches and/or a communication module connected to a network. Data may be transferred wirelessly between the transceiver of the base device and the transceiver of the expansion module with, for example, near-field communication techniques. In some versions of the present mechanism, the expansion module may derive power from signals from the basic device.