Wireless Gateway Protocol Translation for Field Devices
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Solution Overview
Problem
Process control systems face challenges in integrating wireless networks with wired field devices due to protocol compatibility issues, as not all field devices support the same communication protocols, leading to increased costs and limitations in installation and operation, especially in environments where wired devices are impractical.
Innovation Solution
A system and method that utilize a gateway to convert between different wired field device protocols, allowing wireless communication and enabling access to wired field devices by components that do not support the initial protocol, effectively acting as a multiplexer or linking device, and using mapping information to convert data between protocols such as HART, Foundation Fieldbus, and Profibus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wireless technology is used to reduce instrumentation costs and span obstacles, then installation costs and flexibility are improved, but protocol compatibility and integration with existing wired field devices deteriorate
Solution Approach 1:
The patent introduces a gateway device as an intermediary between wireless field devices and the wired process control system. The gateway translates messages between wireless protocols (such as WirelessHART) and wired protocols (such as HART, Fieldbus, or Profibus), enabling protocol compatibility without requiring changes to existing wired infrastructure or wireless devices. This mediator approach resolves the contradiction by maintaining installation flexibility while ensuring protocol interoperability.
Solution Approach 2:
The gateway is designed to support multiple wired field device protocols simultaneously, making it a universal interface that can adapt to different protocol requirements. This multi-functionality allows the system to integrate various types of wired field devices (HART, Fieldbus, Profibus) through a single wireless gateway, thereby improving protocol compatibility while maintaining the cost benefits of wireless technology.
2Adaptability or versatility
If multiple wired protocols are intermixed in the process control system, then device availability and flexibility are improved, but system complexity and integration difficulty worsen
Solution Approach 1:
The gateway acts as a protocol translation intermediary that handles multiple wired protocols on one side and a single wireless protocol on the other. This approach allows the system to maintain support for multiple wired protocols (improving device availability) while the gateway manages the complexity of protocol conversion, thereby reducing the apparent system complexity for end users and simplifying integration.
Solution Approach 2:
The patent segments the protocol conversion function into a separate gateway component, isolating the complexity of multiple protocol interactions from the main process control system. This segmentation allows each protocol handler to be independently managed and configured, reducing overall system complexity while maintaining support for diverse wired field devices.
3Reliability
If wired field devices are used for critical measurements, then measurement reliability is improved, but installation cost and flexibility worsen
Solution Approach 1:
The patent applies local quality by using wireless technology specifically for non-critical or less critical process measurements where the cost of wired installation is not justified, while maintaining wired connections for critical measurements. This localized application of wireless versus wired technology optimizes both reliability and cost-effectiveness by matching the communication method to the criticality of the measurement.
Solution Approach 2:
The wireless gateway provides a universal communication interface that can support both critical and non-critical measurements through a single wireless field device platform. This multi-functionality allows the system to use wireless technology across different measurement criticalities, reducing installation costs while maintaining the option to use wired connections where absolutely necessary for critical applications.
Data Source
AI summary
A system for integrating a wireless network with wired field devices includes a field unit that communicates with the wired field devices using a first wired field device protocol. A gateway wirelessly communicates with the field unit and communicates over a network using one or more second wired field device protocols. The gateway also converts between the first wired field device protocol and the one or more second wired field device protocols. The gateway could further permit access to the wired field devices by a component of the process control system (such as a process controller, asset management tool, or configuration tool) that does not support the first wired field device protocol. At least one of the field unit and the gateway could appear as a multiplexer or linking device to the component of the process control system, such as a HART multiplexer or a Foundation Fieldbus or Profibus linking device.