CN-122001950-A - Edge module and communication method

Abstract

The present disclosure relates to an edge module and a communication method. A method includes receiving, by an edge module connected to a device, a Modbus packet from a management system. The packet includes a block write command to a command buffer and a block read command to a response buffer, wherein the buffers are associated with a contiguous set of registers of the edge module. The edge module interprets the request based on the command buffer data, determines an associated register of the device to perform the action. The edge module generates and transmits a second Modbus packet that includes commands to the determined registers for the devices to perform actions. The edge module writes data to the response buffer for reading by the management system based on the device capabilities.

Inventors

• D. T. Southwell

Assignees

• 恩文特服务有限责任公司

Dates

Publication Date

20260508

Application Date

20251105

Priority Date

20241105

Claims (20)

1. 1. A communication method for a device within a control system, the control system comprising a plurality of devices in communication with a management system, the method comprising: Receiving, by an edge module connected to the device, a first Modbus packet from the management system over a communication line, the first Modbus packet comprising: A block write command to a first contiguous register array of the edge module, the first contiguous register array of the edge module collectively designated as a command buffer, wherein the block write command corresponds to a request for the device to perform an action, and A block read command to a second consecutive register array of the edge module, the second consecutive register array of the edge module collectively designated as a response buffer; the edge module interprets the request based on data within a command buffer, including determining a register of the device associated with the request; The edge module generates and transmits a second Modbus packet including a command to the determined register of the connected device for the device to perform the action, and The edge module writes data in a response buffer for reading by the management system based on the device performing the action.
2. 2. The method of claim 1, further comprising the edge module storing operational data from the device in a local memory for data logging.
3. 3. The method of claim 1, wherein the edge module operates in a transition mode in which the device retains autonomous operation control, and the edge module translates commands from the management system into configuration changes for the device to perform the actions.
4. 4. The method of claim 1, wherein the edge module operates in an overlay mode in which the edge module converts commands from a management system into direct control commands to a resource of a device for the device to perform the action.
5. 5. The method of claim 1, wherein the communication line is a wireless communication line.
6. 6. The method of claim 1, further comprising the edge module directly reading sensor inputs and controlling relay outputs associated with the device.
7. 7. The method of claim 1, wherein the edge module is a first edge module, and further comprising the first edge module communicating with a second edge module connected to the device in a configuration redundant to the first edge module, wherein one of the first edge module and the second edge module operates as an active edge module to generate and transmit the second Modbus packet and the other operates as a passive edge module.
8. 8. The method of claim 7, further comprising the passive edge module monitoring the active edge module by monitoring traffic between the active edge module and the management system.
9. 9. The method of claim 8, further comprising, when it is determined during the monitoring that an old active edge module fails, the passive edge module becomes a new active edge module and the active edge module becomes an old active edge module.
10. 10. The method of claim 9, further comprising the new active edge module disabling the old active edge module when it is determined during the monitoring that an old active edge module is malfunctioning.
11. 11. An edge module configured to be connected between a management system and a device of an industrial system, the edge module comprising: an upstream serial port; A downstream serial port; A microcontroller comprising a memory storing program instructions and a processor executing the program instructions to: Receiving a first Modbus packet sent from the management system to the upstream serial port across a communication link, the first Modbus packet including a multi-register write command to a first continuous Modbus register array, the first continuous Modbus register array being designated as a command buffer, Converting the multi-register write command by mapping Modbus registers of the device associated with the multi-register write command, and A second Modbus packet is generated and sent via the downstream serial port, the second Modbus packet including commands to the Modbus registers of the mapped device.
12. 12. The edge module of claim 11, further comprising a flash memory in communication with the microcontroller, wherein the flash memory is configured to store operational data from the device for data logging operations.
13. 13. The edge module of claim 11, further comprising at least one wireless communication module selected from a field area network module and a bluetooth/Wi-Fi module, wherein the wireless communication module enables wireless communication with the management system, the device, other edge modules, a remote device, or a combination thereof.
14. 14. The edge module of claim 11, further comprising a housing configured to be mounted to an outer surface of the housing, the housing comprising: a base configured to be mounted against an outer surface, and A threaded neck extending from the base is configured to pass through an opening in the housing.
15. 15. The edge module of claim 14, further comprising a top case coupled to the base, and a wireless antenna structure coupled to a bottom side of the top case.
16. 16. The edge module of claim 15, further comprising an indicator LED located within the housing, the indicator LED configured to emit light to indicate an operational status of the edge module or the device.
17. 17. The edge module of claim 16, wherein the indicator LED is located below a lens coupled with the top case.
18. 18. The edge module of claim 11, further comprising a housing sized to fit on a DIN rail.
19. 19. A method for an edge module to overlay a host device in an industrial control system, the method comprising: Identifying, by the edge module, a type of the host device by detecting the host device via a downstream port of the edge module to determine device information; Mapping, by the edge module, resources of the host device, wherein the mapping includes determining a register address for each resource; Regulating, by the edge module, the host device to be in a passive state by disabling an automatic control mode, and In response to action commands from the management system, execution control of the host device is overridden by the edge module by directly accessing and manipulating the resources of the host device.
20. 20. The method of claim 19 wherein one of the resources comprises a relay and overriding comprises implementing on/off control of the relay.

Description

Edge module and communication method RELATED APPLICATIONS The present application claims priority from U.S. c. ≡119, U.S. provisional patent application No. 63/716,621 filed on 5 at 11/2024, the entire contents of which are incorporated herein by reference. Background The heat trace solution utilizes an electrical heating element (e.g., an electrothermal trace cable) to apply heat to an external surface. Such heat tracking solutions can be used to maintain operability of critical processes, protect piping and equipment from freezing, maintain flow in the transfer lines, and provide winter safe and comfortable heating in buildings and houses. Example heat tracking applications may include, but are not limited to, temperature maintenance (e.g., to ensure a dedicated hot water supply to maintain fluids and liquids at desired temperature levels and/or to protect critical safety lines), industrial tank insulation systems (e.g., to maintain stored liquids at constant temperatures), industrial, commercial, and residential surface snow melting, roof and gutter de-icing, refractory wiring (e.g., to protect critical circuitry during fire or other emergency conditions), process temperature maintenance (e.g., to ensure fluid temperature maintenance with industrial process heating equipment), pipe anti-icing, marine anti-icing and de-icing, industrial, commercial, and residential flow maintenance (e.g., to maintain the temperature of fluids in pipes to ensure continuous flow), long pipe heating, rail heating, and frost heaving (frost heave) protection. Referring to one particular example, piping is typically used to transport liquid and/or gas products (such as petroleum products) over large distances, such as from an extraction point to a processing facility. If the extraction location and/or processing facility is located in a cold weather environment, it may be desirable to provide a heat trace cable to maintain the tubing at a desired temperature to prevent freezing of the fluid product, or in temperature sensitive operation to maintain a temperature that allows for efficient flow of the fluid product. One or more of the electrothermal tracking cables and any associated components may be referred to as an Electrical Heating Tracking (EHT) circuit. In addition, each EHT circuit is monitored and controlled by a thermal tracking controller. The thermal tracking controller may have multiple functions and, in general, certain applications include multiple EHT circuits and multiple corresponding EHT controllers. These EHT controllers are typically connected to a supervisor (supervisor) or management system via an RS-485 serial line via a Modbus data communication protocol. Disclosure of Invention In some embodiments, a communication method is provided for a device within a control system that includes a plurality of devices in communication with a management system. The method includes receiving, by an edge module connected to the device, a first Modbus packet from a management system over a communication line, the first Modbus packet being sent via the communication line. The first Modbus packet includes a block write command to a first consecutive array of registers (collectively designated as a command buffer) of the edge module, where the block write command corresponds to a request for the device to perform an action, and a block read command to a second consecutive array of registers (collectively designated as a response buffer) of the edge module. The edge module interprets the request based on the data in the command buffer, including determining a register of a device associated with the request. The edge module generates and transmits a second Modbus packet that includes commands to the determined registers of the connected device for the device to perform actions. The edge module writes data to the response buffer for reading by the management system based on the device performing an action. In some embodiments, an edge module configured to connect between a management system and a device of an industrial system is provided. In this embodiment, the edge module includes an upstream serial port, a downstream serial port, and a microcontroller including a memory storing program instructions and a processor for executing the program instructions. The processor receives a first Modbus packet that includes a multi-register write command to a first continuous Modbus register array (designated as a command buffer), which is sent across a communication link from the management system to an upstream serial port. The processor translates the multi-register write command by mapping Modbus registers of the device associated with the multi-register write command. The processor generates and transmits a second Modbus packet that includes commands to the mapped registers of the device via the downstream serial port. In some embodiments, a method for an edge module to overlay a host device in an industrial control system is pr