Wireless Protocol Conversion for Remote Field Device Access
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Solution Overview
Problem
Existing process control systems in process plants face challenges in efficiently collecting and processing data from field devices, particularly due to limitations in data transmission bandwidth, protocol compatibility, and the need for physical access to field devices for maintenance and diagnostics.
Innovation Solution
A computer-implemented method and system for data collection and protocol conversion, which involves receiving data sets from field devices encoded in process control protocols, extracting and storing payloads, and transmitting them in general-purpose computing communication protocols via wireless networks, thereby enabling efficient data access and control of field devices without physical intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If data is transmitted via wired networks in traditional process control systems, then protocol compatibility is maintained, but data transmission bandwidth and speed are limited
Solution Approach 1:
The patent introduces a protocol converter as an intermediary device that receives data from field devices using process control protocols (HART, Fieldbus, Profibus), converts it to standard TCP/IP protocols, and transmits it via wireless networks. This mediator resolves the contradiction by maintaining protocol compatibility on the receiving end while enabling high-speed wireless transmission on the transmitting end.
Solution Approach 2:
The protocol converter changes the parameter of communication protocol from proprietary process control protocols to universal TCP/IP protocols, enabling compatibility with general-purpose computing devices and wireless networks while maintaining the ability to interface with various field devices through multiple supported protocols.
2Productivity
If physical access to field devices is required for maintenance and diagnostics, then direct control is achieved, but operational efficiency and safety are reduced
Solution Approach 1:
The patent replaces the mechanical requirement of physical access to field devices with an electronic/digital communication system. Data from field devices is transmitted wirelessly to remote devices, allowing maintenance personnel to perform diagnostics and monitoring from safe, remote locations without physically entering hazardous process areas.
Solution Approach 2:
The wireless communication system acts as an intermediary that bridges the gap between field devices and control personnel, eliminating the need for direct physical contact while maintaining full operational capability for monitoring and diagnostics.
3Loss of time
If centralized hardware devices are used for data collection, then data security is maintained, but real-time data access is delayed
Solution Approach 1:
The patent segments the centralized data collection architecture into distributed wireless data transmission nodes. Multiple field devices transmit data independently via wireless networks to various receiving devices, eliminating the single-point bottleneck of centralized wired collection and enabling parallel data access across multiple devices simultaneously.
Data Source
AI summary
Techniques for accessing and controlling field devices to collect data and convert protocols include receiving data encoded in a process control protocol, extracting a payload, storing some of the payload, and transmitting some of the payload in a general-purpose computing communication protocol via a wireless network. A method of accessing a field device includes receiving a command of a user from a user communicator, identifying a target field device, generating a command, encoding a protocol-encoded data set, and transmitting the protocol-encoded data set to the target field device. A field communicator device includes instructions for retrieving and interpreting field device data, storing the data, and transmitting the data. A computing system includes a field communicator, wireless user communicator, and a wireless computer network for accessing and controlling field devices in a process plant.