In the realm of industrial control, the evolution has been significant—from localized and centralized control systems to modern distributed control systems (DCS). Over the past two decades, the process industry has heavily invested in DCS and related instrumentation, with the application of these systems being widely accepted by users. The 4-20 mA signal remains a key feature that enables communication between DCS systems and field devices, marking a major step forward in control system development.
However, the current trend is shifting toward digitalization and networking. Traditional analog signals are now seen as insufficient for today’s needs, as they only provide basic measurement and control data. Smart transmitters, while capable of adding some information over 4-20 mA signals, face limitations due to their low communication speed. This has led to a growing recognition that the future of process control lies in digitalization and networked systems.
Enter the fieldbus—a fully digital, bidirectional, multi-node communication link between intelligent field devices and automation systems. Fieldbus technology has revolutionized the way field devices communicate, enabling more powerful and flexible field control. It also introduces openness into the process control system, transforming it into a comprehensive control network that supports measurement, control, execution, and diagnostics.
Fieldbus brings several key advantages over traditional DCS systems. It replaces 4-20 mA analog signals with digital ones, allows for distributed control functions at the site, adds non-control information like self-diagnosis and configuration, unifies site management and control, and ensures system openness and interoperability. These features make fieldbus-based control systems (FCS) superior in terms of structure, cost, performance, reliability, and integration flexibility.
Despite its benefits, many users are hesitant to completely replace existing DCS systems. Instead, a hybrid approach—integrating fieldbus with DCS—is becoming increasingly popular. One common method is integrating fieldbus on the DCS I/O bus through a fieldbus interface card. This allows data from fieldbus devices to be mapped onto the DCS I/O bus, making them appear as traditional DCS modules. This solution is ideal for small-scale applications or when upgrading an existing DCS system.
For example, Fisher-Rosemount’s DeltaV system uses this approach, incorporating fieldbus H1 communication modules directly into its I/O cards. This enables seamless integration of fieldbus instruments, reducing installation and maintenance costs while allowing compatibility between H1 and traditional I/O modules. A dedicated driver ensures smooth data mapping between the fieldbus and DCS systems.
Another integration approach involves connecting the fieldbus to the higher-level DCS network layer. This allows fieldbus control and measurement data to be accessed and modified from the DCS operator station, decentralizing some control functions and reducing the load on the DCS host computer. This method is particularly useful when minimal changes to the existing system are required.
For environments where both DCS and fieldbus systems coexist, a gateway can be used to connect them. This setup allows information to be transferred between the two systems, enhancing data visibility and control. It also enables the integration of Intranet and Internet through a web server, offering greater flexibility and scalability.
In conclusion, while fieldbus is set to become a dominant force in process control, DCS systems will continue to play a crucial role in real-time applications. The coexistence of both technologies offers users more choices, leading to more efficient and adaptable control solutions. As industries move toward smarter, more connected systems, the integration of fieldbus with DCS will remain a key strategy for achieving optimal performance.
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