Wireless Diagnostic Concentrator for HART Protocol Translation
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Solution Overview
Problem
Existing process control systems face challenges in fully utilizing new field devices with advanced communication protocols due to the need for costly upgrades and shutdowns, as they often require modifications to both process controllers and field termination assemblies, which are resource-intensive and difficult to justify.
Innovation Solution
The implementation of a wireless diagnostic system that includes a diagnostic concentrator capable of receiving signals from field devices, extracting and transmitting diagnostic information, and communicating this data wirelessly to a diagnostic monitor, allowing for the collection and processing of diagnostic data without the need for immediate upgrades to the process controller or associated circuitry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a process controller is upgraded to support a new communication protocol, then the full functionality of new field devices can be utilized, but the system requires shutting down operation and incurs high upgrade costs
Solution Approach 1:
A protocol converter is introduced as an intermediary device between the old process controller and new field devices. The converter translates communication protocols, allowing the legacy controller to communicate with modern field devices without requiring controller upgrades or plant shutdowns. This mediator enables full functionality utilization while maintaining operational continuity.
2Adaptability or versatility
If a process controller is upgraded to support a new communication protocol, then the full functionality of new field devices can be utilized, but the upgrade cost becomes too expensive
Solution Approach 1:
The system is segmented into three independent components: the legacy process controller, the protocol converter, and the new field devices. This segmentation allows the expensive controller upgrade to be avoided by placing the protocol translation functionality in a separate, more affordable converter device. The converter handles protocol translation independently, enabling full field device functionality at lower cost.
3Adaptability or versatility
If a process controller is upgraded to support a new communication protocol, then the full functionality of new field devices can be utilized, but the upgrade process is complex and resource-intensive
Solution Approach 1:
The protocol converter serves as a mediator that handles all protocol translation complexity internally. The legacy controller and new field devices each maintain their original communication interfaces, while the converter manages the protocol conversion. This approach avoids complex system modifications and reduces implementation complexity.
Solution Approach 2:
The protocol converter creates a virtual copy of the communication interface, translating between different protocols without requiring physical modifications to the controller or field devices. This copying approach simplifies integration by maintaining original device interfaces while enabling new protocol support.
Data Source
AI summary
A diagnostic concentrator includes a first interface that is capable of receiving a signal sent from a field device to a process controller. The signal includes a primary process variable and additional information. The diagnostic concentrator also includes a controller that is capable of generating a message corresponding to the received additional information and a second interface that is capable of transmitting the generated message. The first interface may be a HART interface. The second interface may be a wireless interface or a network interface. The message may be transmitted to a diagnostic monitor or a process controller. The first interface may receive a plurality of signals sent from a plurality of field devices to the process controller. The controller may generate a plurality of messages corresponding to the plurality of additional information in the signals and transmit the messages via the second interface.