Wireless Field Device Control System for Process Automation
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Solution Overview
Problem
Existing process control systems face challenges in remotely monitoring and controlling field devices due to the cost and complexity of wiring, as well as increased response times, which can lead to inaccurate and repetitive mechanical failures in pneumatic controllers, especially in harsh or remote environments.
Innovation Solution
A process control system that utilizes wireless communication between a remote controller, a wireless output device, and field devices, allowing for the remote monitoring and control of field devices without the need for extensive wiring, using a controller connected to a memory and processor with a wireless communication module, enabling flexible control strategies and complementary control between local and remote systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If field devices are wired to remote control system, then remote monitoring and control is enabled, but wiring cost and system complexity increase
Solution Approach 1:
The patent replaces the mechanical wiring system with a wireless communication system. Field devices equipped with wireless transceivers communicate directly with remote monitoring systems through wireless signals, eliminating the need for physical wire connections while maintaining remote monitoring and control capabilities.
Solution Approach 2:
The patent introduces wireless communication modules as intermediaries between field devices and remote control systems. These modules enable data transmission without direct physical connections, serving as a mediator that replaces traditional wired interfaces while preserving system functionality.
2Ease of operation
If field devices are wired to remote control system, then remote control is enabled, but response time increases
Solution Approach 1:
The patent segments the control system into distributed intelligent field devices that can operate autonomously or semi-autonomously. Each field device contains local processing capabilities that enable immediate local response to critical events, while simultaneously maintaining wireless communication for remote monitoring. This segmentation reduces the time delay associated with centralized remote control by allowing local decision-making.
3Extent of automation
If pneumatic controllers are used, then simple repetitive tasks are automated, but mechanical fatigue leads to failure
Solution Approach 1:
The patent replaces mechanical pneumatic controllers with electronic control systems featuring microprocessors and solid-state components. This substitution eliminates mechanical moving parts that are subject to fatigue and wear, thereby significantly improving reliability while maintaining automation capabilities. The electronic controllers use semiconductor devices and integrated circuits that have no mechanical wear mechanisms.
Solution Approach 2:
The patent transitions from pneumatic control parameters (air pressure, flow) to electronic control parameters (voltage, current, digital signals). This parameter change enables the use of electronic components with superior reliability characteristics, including longer operational life and resistance to environmental factors such as temperature variations and humidity.
Data Source
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AI summary
Example methods and apparatus to a controller of a local control loop having a field device and a sensor configured in a closed-loop control system are disclosed. The controller is wirelessly coupled to a control system wherein the controller and the control system execute complementary control over the field device.