Abstract:
An industrial process field device with improved power generation is provided. The process device can be a process variable transmitter, process actuator, or any other suitable field device. The field device includes a wireless transceiver that transceives information related to the process via a wireless medium. A power supply within the field device is couplable to a source of pressurized gas and generates motion within the power supply that is translated into electrical energy. This electrical energy is then used to operate the field device.

Description:
FIELD OF INVENTION  
       [0001]     The present invention is related to process control and measurement field devices such as transmitters and actuators. More specifically, the present invention is related to relatively low-power field devices.  
       BACKGROUND OF THE INVENTION  
       [0002]     Field devices, also referred to herein as process devices, are used by the process control and measurement industry for a variety of purposes. Usually such devices have a field-hardened enclosure so that they can be installed outdoors in relatively rugged environments and are able to withstand climatalogical extremes of temperature, humidity, vibration, mechanical shock, etc. These devices also can typically operate on relatively low power. For example, field devices are currently available that receive all of their operating power from a known 4-20 mA loop. These devices are able to not only operate upon the loop but communicate over the loop both with analog signals (actually modulating the 4-20 mA signal) and digitally.  
         [0003]     One example of a field device is known as a process variable transmitter. Transmitters sense a process parameter such as pressure, temperature, flow, pH, conductivity, turbidity, etc. and provide a signal over the process communication loop (such as a 4-20 mA loop) that is indicative of the sensed process variable. Process actuators are similar to process variable transmitters in that they generally have a relatively field-hardened enclosure and communicate upon a process control and measurement loop. Process actuators, however, actually affect the process based upon signals received from the loop. Other field devices can include process control modules, process alarm modules, process diagnostic modules, et cetera.  
         [0004]     In some process control plants, or in remote measurement stations, it is often useful to provide a transmission of the process variable data by means other than over a copper-wire process communication loop. Usually, a wireless communication is used for such applications. Temporary or add-on process variable monitoring would also benefit from a wireless installation.  
         [0005]     For a wireless installation, data is usually transmitted in bursts. During these transmission bursts, relatively significant operating power is required (in excess of 100 milliwatts). During the dwell time between the transmission bursts, the device generally goes into a low-power measurement mode consuming less than 10 milliwatts. In some applications, the unit goes into a sleep mode between measurements. This sleep mode can have an operating power on the order of the microwatts. When process variable measurement is required, or information is required to be transmitted, the unit will then wake up and perform the requisite action.  
         [0006]     One pervasive problem for remote, wireless measurement and control applications is providing a reliable, self-contained power source capable of providing adequate power for measurement and transmission. Presently, batteries, or combinations of batteries and solar panels are used by these devices. These approaches have drawbacks because the batteries need changing, or the solar panel sometimes does not receive enough light to adequately charge the back-up batteries. Eventually under these low-light conditions, the measurement and transmission schedule is interrupted due to low batteries. For example, in some geographical locations, low-light conditions can exist, during some seasons, for substantially the entire day.  
         [0007]     Providing a power source for wireless remote process installations that does not require either sunlight, or periodically changing batteries would significantly benefit the art.  
       SUMMARY OF THE INVENTION  
       [0008]     An industrial process field device with improved power generation is provided. The process device can be a process variable transmitter, process actuator, or any other suitable field device. The field device includes a wireless transceiver that transceives information related to the process via a wireless medium. A power supply within the field device is couplable to a source of pressurized gas and generates motion within the power supply that is translated into electrical energy. This electrical energy is then used to operate the field device. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]      FIG. 1  is a diagrammatic view of an industrial process environment in which embodiments of the present invention are particularly useful.  
         [0010]      FIGS. 2 and 3  are diagrammatic view of field devices in which embodiments of the present invention are particularly useful.  
         [0011]      FIG. 4  is a block diagram of a process variable transmitter for which embodiments of the present invention are particularly useful.  
         [0012]      FIGS. 5 and 6  are diagrammatic views of a power supply module converting pressurized gas into electricity in accordance with embodiments of the present invention.  
         [0013]      FIG. 7  is a diagrammatic view of a field in accordance with an embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0014]      FIG. 1  is a diagrammatic view of a process industry installation employing a field device shown in this example as a process variable transmitter  12  physically coupled to the process and providing a wireless signal  14  indicative of at least one process variable.  
         [0015]      FIGS. 2 and 3  are diagrammatic views of exemplary process variable transmitters with which embodiments of the present invention are particularly useful.  FIG. 2  illustrates temperature transmitter  12  coupled to process container (pipe)  18  such that transmitter  12  can measure the temperature of process fluid therein.  
         [0016]      FIG. 3  is a diagrammatic view of process fluid flow transmitter  22  coupled to process container  20 , which transmitter  22  measures a differential pressure across a flow obstruction interposed within container  20  and calculates process fluid flow based upon the measured differential pressure. Process variable transmitters  12  and  22  are specific examples of types of field devices that can advantageously employ embodiments of the present invention. Those skilled in the art will recognize that embodiments of the present invention can be practiced with any field device including process variable transmitters, process actuators, and other suitable devices, that couples to a process.  
         [0017]     Embodiments of the present invention generally employ or utilize a source of pressurized gas and convert that pressurized gas to electrical energy for use by the field device. In some embodiments, for example, the embodiment illustrated in  FIG. 3 , it may be possible for the source of pressurized gas to be the process fluid itself. In other embodiments, a separate source of pressurized gas (in the form of an external tank of pressurized gas) can be coupled to the field device.  
         [0018]      FIG. 4  is a diagrammatic view of a process variable transmitter, such as transmitter  12 , illustrating the basic elements of the transmitter. Transmitter  12  is generally coupled to a process variable sensor  24  that generates a signal indicative of a process variable, such as process fluid temperature, process fluid pressure, etc. Sensor  24  is coupled to analog-to-digital converter  26  which converts the analog signal from sensor  24  to a digital value and passes the digital value through bus  28  to microprocessor  30 . Microprocessor  30  executes a program, preferably stored in memory  32  and generates a process variable output signal based upon the digital value provided to microprocessor  30  through bus  28 . This process variable output is provided to wireless transceiver  34 , which is coupled to antenna  36 . Antenna  36  and wireless transceiver  34  cooperate to provide wireless interaction with one or more suitable devices. Illustratively, wireless transceiver  24  is a transceiver that can employ either radio-frequency or optical techniques for wireless communication. In order to conserve power, transmitter  12  will preferably transmit data in bursts. During these transmission bursts, relatively significant operating power is required (potentially in excess of 100 milliwatts). This is to ensure that sufficient energy is put into the wireless transmission to provide quality communication and range.  
         [0019]     In order to provide power to the components within process variable transmitter  12 , power supply module  40  is provided. Power supply module  40  is coupled to all electrical components within process variable transmitter  12  as indicated by line  42  labeled PWR. As will be described in greater detail below, power supply module  40  is fluidically coupled to a source of pressurized gas  44  via line  46 . The source of pressurized gas  44  and line  46  can, in some embodiments, be a part of the process variable transmitter installation such as when gas  44  is the process fluid itself. However, in other embodiments, gas source  44  is an external tank of pressurized gas. For example, remote process applications often use pneumatically actuated valves to control flow. Typically, either a compressed air source or natural gas source drives these actuators. This pressurized gas source could be utilized as gas source  44  for the field device.  
         [0020]      FIG. 5  is a top plan view of power supply module  40  in accordance with an embodiment to the present invention. Power supply module  40  includes a base  48  that is fluidically coupled (not shown) to a source of pressurized gas. Base  48  is formed of a material that facilitates MEMS construction, such as silicon. Pressurized gas fills chamber  50  and flows in the direction of arrow  52  through nozzle  53  and ultimately flows over bluff body  54  and causing cantilever member  56  to oscillate in an up and down motion (into and out of the plane of the drawing). Nozzle  53  increases the efficiency of energy conversion since it causes an localized increase in gas velocity, thereby increasing the kinetic energy of the gas. Examples of pressurized gas include air, natural gas and process gas. Cantilever member  56  may include electrical traces or conductors  58  disposed thereon and arranged to be proximate a pole  60  of a permanent magnet  62 . When cantilever member  56  oscillates in the proximity of permanent magnet  62 , conductors  58  moving within the magnetic field  64  generate an electric current along conductor  58 . This electric current can be provided directly to power regulation circuitry for ultimate provision to components within transmitter  12 , or can be coupled to an optional battery  66  (indicated in phantom in  FIG. 5 ). Illustratively, bluff body  54  has a triangularly shaped cross-section, as indicated in  FIG. 6 , but can include any suitable shape including, without limitation, a cylinder, an air-foil shape, an ellipse shape, and a spherical shape.  
         [0021]      FIG. 6  is a front elevation view of power supply module  40  in accordance with an embodiment of the present invention.  FIG. 6  illustrates line  46  coupling to chamber  50  which is bound on its top surface by cover layer  68  which is preferably formed of Pyrex and diffusion bonded to base  48 . The pressurized gas passes along passageway  52 , preferably through a nozzle, and flows over bluff body  54 . The oscillation of cantilever member  56  is illustrated by double-headed vertical arrow  72 . While embodiments of the present invention preferably use a permanent magnet and conductor moving upon cantilever member  56 , embodiments of the present invention can also be practiced using a piezoelectric material disposed within or along cantilever member  56 . In any event, embodiments of the present invention transform oscillation of cantilever member  56  into electricity. This electricity is then provided to components of the field device, either directly or indirectly.  
         [0022]      FIG. 7  is a diagrammatic view of a field device in accordance with another embodiment of the present invention. Field device  90  includes power supply module  80 , which is similar to power supply module  40 , illustrated in  FIG. 6 , and like components are numbered similarly. One of the main differences between module  80  and module  40  is that module  80  is hermetically sealed such that the pressurized gas flowing past bluff body  54 , which generates the oscillation of cantilever member  56 , is ultimately recaptured and passed through port  74  which is preferably coupled to the process.  FIG. 7  illustrates module  80  being coupled to a pair of process pressure points on piping  92 . As process fluid flows within piping  92 , a differential pressure will exist between points  94  and  96 . This differential pressure can be increased, if desired, by placing a suitable flow obstruction within piping  92  between points  94  and  96  As long as a differential pressure exists points  94  and  96 , module  80  will operate. Accordingly, module  80  can be employed in a completely sealed system to generate electricity in response to process gas flowing in response to differential pressure. Additionally, since the amount of electricity generated will be related to the differential pressure observed between process pressure points  94  and  96 , the amount of electricity generated in module  80  can be used as an indication of that differential pressure. The differential pressure is also related to the flow in piping  92 . Thus, the electricity generated by module  80  can be used as an indication of the fluid flow rate in piping  92 . Finally, since embodiments of the present invention allow field devices to be powered by pressurized gas, and provide indications of process fluid flow, embodiments of the present invention can be used to provide process powered flow sensors.  
         [0023]     All of the structures indicated on  FIGS. 5 and 6  are preferably constructed from materials that facilitate MEMS fabrication. Examples of such material include silicon, Pyrex, and any other suitable materials. MEMS fabrication techniques and methodologies are well known.  
         [0024]     Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.