Wireless Single Hop Device for Multi-Loop Current Monitoring
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Solution Overview
Problem
In industrial process control facilities, existing technologies face challenges in efficiently monitoring and controlling multiple process parameters due to limitations in current loop communication, such as the need to break loops for measurement, restricted data availability, and high costs associated with wireless infrastructure, leading to inefficient data transmission and diagnosis.
Innovation Solution
The implementation of a multi-current loop junction box with an analog front end and a wireless single hop device that enables direct monitoring and transmission of analog current signals to a wireless transmitter, allowing remote monitoring without disrupting current loops and using loop power, thereby simplifying data access and reducing infrastructure costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If current measuring instruments are connected in series with the current loop to sense current signals, then measurement capability is improved, but the loop must be broken causing communication disruption and increased complexity
Solution Approach 1:
The patent introduces an intermediary current sensing device that couples to the current loop without breaking it. This device senses the current signal through electromagnetic coupling or other non-intrusive means, acting as a mediator between the current loop and the measurement system, thereby enabling current measurement while maintaining continuous loop operation and communication.
2Loss of information
If wireless adapters are used to transmit process variable data wirelessly, then data availability is improved, but infrastructure cost and device complexity increase significantly
Solution Approach 1:
The patent makes the existing junction box universal by equipping it with both wired and wireless communication capabilities. The junction box continues to perform its traditional wired function while also incorporating a wireless transceiver to transmit process variable data wirelessly. This multi-functionality allows the same device to serve multiple purposes without requiring separate dedicated wireless infrastructure at each process variable level.
Solution Approach 2:
The junction box serves itself by generating and transmitting wireless data using its own embedded transceiver and the power already available in the current loop. It utilizes existing resources (loop power, processed data) to provide wireless communication capability without requiring external wireless infrastructure or additional power sources, thereby reducing overall system cost and complexity.
3Reliability
If multiple data hops are used to transmit sensor data from level 0 to level 4 network, then data transmission capability is maintained, but transmission efficiency and time are worsened
Solution Approach 1:
The patent segments the data transmission path by enabling direct wireless transmission from the junction box (level 0 or 1) to remote wireless devices, bypassing the traditional sequential hops through level 1, level 2, level 3 to level 4 network. This segmentation creates an alternative parallel transmission path that reduces the number of hops and associated delays while maintaining data reliability through appropriate communication protocols.
Data Source
AI summary
A process interface device for a process facility running a physical process includes a multi-loop current junction box including an analog front end (AFE) having a signal path including an input node, an output node, and an internal current sensor for each current loop. Respective input nodes receive analog current sensing signals (sensing signals) originating from each field devices within the process facility. An analog to digital converter (ADC) has inputs coupled across an output of the internal current sensor device. A wireless single hop device (WSH device) includes a processor and a wireless transmitter, wherein an input of the WSH device is coupled by a communications bus to receive respective outputs generated by the ADC being digitized versions of sensed ones of the sensing signals (sensed sensing signals). The WSH device is for wirelessly multiplex transmitting the sensed sensing signals for remote monitoring of the current loops.