Source: https://patents.google.com/patent/US8538560B2/en
Timestamp: 2019-04-19 17:11:48+00:00

Document:
This application is a continuation-in-part application of and claims priority to U.S. patent application Ser. No. 29/204,502, filed Apr. 29, 2004.
The present invention relates to industrial process control or monitoring systems. More specifically, the present invention relates to a system that adds wireless capability to field devices in such systems.
In some installations, wireless technologies have begun to be used to communicate with field devices. Wireless operation simplifies field device wiring and setup. Wireless installations are currently used in which the field device is manufactured to include an internal battery, potentially charged by a solar cell, or other technique to obtain power without any sort of wired connection. Problems exist in using an internal battery as the energy demands of wireless devices may vary greatly depending on numerous factors such as the device reporting rate, device elements, et cetera. A power and communication system that is external to the field device for wireless communication would be a significant improvement in this area.
A wireless power and communication unit for field devices is configured to connect to a field device and provide operating power and wired, preferably digital, communication between the unit and the field device. RF circuitry configured to provide radio frequency communication. In one embodiment, power supply circuitry in the unit includes one or more solar power cells that convert solar energy into electricity to power both the unit and the field device. The wireless power and communication unit powers the field device and interacts with the field device in accordance with a standard industry communication protocol. The unit communicates wirelessly with an external device, such as a control room, based upon the interaction with the field device.
FIG. 5 is a front elevation view of a wireless power and communication unit in accordance with another embodiment of the present invention.
FIGS. 6 and 7 are diagrammatic views of a wireless power and communication unit operating with a plurality of field devices in accordance with embodiments of the present invention.
FIG. 8 is a block diagram of a wireless power and communication unit in accordance with embodiments of the present invention.
FIG. 9 is a rear elevation view of a wireless power and communication unit in accordance with an embodiment of the present invention.
The present invention includes a wireless power and communication unit for allowing field devices that are designed for wired communication to operate wirelessly. While some devices are currently being developed which add wireless communication to wired devices, such developments do not function to untether legacy wired type field devices from their control loops since they still are wired to and receive power from their control loops.
FIGS. 1 and 2 are diagrammatic and block diagram views of an exemplary field device with which a wireless power and communication unit in accordance with the present invention is particularly useful. Process control or monitoring system 10 includes a control room or control system 12 that couples to one or more field devices 14 over a two-wire process control loop 16. Examples of process control loop 16 include analog 4-20 mA communication, hybrid protocols which include both analog and digital communication such as the Highway Addressable Remote Transducer (HART®) standard, as well as all-digital protocols such as the FOUNDATION™ Fieldbus standard. Generally process control loop protocols can both power the field device and allow communication between the field device and other devices.
In this example, field device 14 includes circuitry 18 coupled to actuator/transducer 20 and to process control loop 16 via terminal board 21 in housing 23. Field device 14 is illustrated as a process variable (PV) generator in that it couples to a process and senses an aspect, such as temperature, pressure, pH, flow, et cetera of the process and provides and indication thereof. Other examples of field devices include valves, actuators, controllers, and displays.
FIG. 3 is a block diagram of a wireless field device in accordance with the prior art. Field device 34 includes internal power supply module 38, controller 35, wireless communication module 32, and actuator/transducer 20. Power supply module 38 typically includes a battery that powers field device 34 for a period of time, until the battery needs to be replaced. Some field devices include a built-in solar cell. The power from supply 38 energizes controller 35 to interact with actuator/transducer 20 and wireless communications module 32. Wireless communications module 32, in turn, interacts with other devices as indicated by reference numeral 24 via antenna 26. One drawback with providing the wireless capability of device 34 internally, is that if a battery, solar cell, or wireless communications module should be damaged, the entire field device must be repaired or replaced. Another disadvantage of using an internal battery is that some users of wireless devices require much more energy than other users. For example, if the field device is activated once per minute, versus once per hour, the energy consumption is greatly increased. The energy usage also varies widely based on whether the device is configured with minimum system elements or is fully configured. Thus, the use of an internal power source is not scalable in the sense that varying energy demands from various users cannot be accommodated well.
FIG. 4 is a front elevation view of a wireless power and communication unit 100 attached to a field device 14, shown in phantom. Unit 100 preferably attaches to device 14 via a standard field device conduit 102. Examples of suitable conduit connections include 1/2-14 NPT, M20x1.5, G1/2, and 3/8-18 NPT. Unit 100 may include a joint allowing rotation 104 about axis 106 and rotation 108 about axis 110. Further, attachment region 112 of unit 100 is preferably hollow in order to allow conductors therein to couple unit 100 to device 14. In embodiments where positional adjustment of the housing is not desired, attachment region 112 could simply be a piece of conduit.
FIG. 4 also illustrates one or more photovoltaic cells 116 mounted proximate a top surface 118 of housing 114. In one embodiment, the photovoltaic cells(s) 116 form part of a sealed lid for the housing 114. In such embodiments, a clear cover preferably extends over cell(s) 116 to protect them from exposure. Cells 116 are preferably inclined at an angle of about 30 degrees and transform light falling thereon into electrical energy in order to power unit 100 and device 14. Since unit 100 is external to device 14, multiple variations of unit 100 can be provided with varying photovoltaic cell configurations and/or sizes depending upon the specific power requirements of the field device to which the unit will be attached. Unit 100 also preferably includes wireless communication circuitry (not shown in FIG. 4) which is coupled to antenna 120. Providing external antenna 120 facilitates wireless communication in comparison to internal antennas since many field-hardened enclosures are metal and would likely attenuate the wireless signal. However, embodiments with an internal antenna proximate a radio-transparent portion of housing 114, or cell(s) 116 can be practiced as well. External antenna embodiments, however, are particularly advantageous where unit 100 is field hardened in order to withstand environments similar to those for which field devices are designed.
In accordance with one aspect of the invention, unit 100 includes a local user interface. Accordingly unit 100 may include a display, such as an LCD display 122 that may be mounted proximate one of cells 116. In order to receive local user input, unit 100 can include one or more local inputs such as button 124. A local user interface is important because when the combined unit/field device system is operating totally wirelessly, it is more convenient for a technician to interact with the local user interface rather than wirelessly trying to access the device via a handheld computing device or the like. The local interface can be used to access the unit, the field device, or both. As defined herein “local user interface” means having either local user input(s) (such as a button), local user output(s) (such as an LCD), or a combination of the two. As illustrated in FIG. 4, the LCD can be co-located with cell(s) 116.
FIG. 5 is a front elevation view of a wireless power and communication unit in accordance with another embodiment of the present invention. Wireless power and communication unit 200 bears many similarities to wireless power and communication unit 100 and like components are numbered similarly. The primary difference between wireless power and communication unit 200 and wireless power and communication unit 100 is the configuration of the local user interface display. Specifically, unit 200 does not include a display proximate or co-located within the photovoltaic cell(s) 116. Instead, display 202 is integrated into attachment region 112. Preferably, display 202 is independently rotatable about axis 106 by approximately 270°.
Providing a user interface display proximate attachment region 112 increases the modularity of unit 200. Specifically, housings 114 and all components therein can be manufactured similarly to achieve economies of scale. In installations where a local user display is desirable, it can simply be added as a module between housing 114 and joint 204 of attachment region 112. Such modularity is also useful in embodiments where one unit 200 is used to operate and communicate with multiple field devices as will be described in greater detail with respect to FIGS. 6 and 7. Thus, as installation site needs dictate, the power system, which includes the solar cell and antenna can be remotely mounted by utilizing an adapter fitted with a cable gland that connects to the top 206 of LCD display 202. An adapter base is then used for mounting the housing 114 and bringing the interconnecting cable via a cable gland. This allows positioning housing 114 in an optimal performance location while keeping a local user interface proximate each field device.
FIG. 6 is a diagrammatic view of a wireless power and communication unit 300 in accordance with an embodiment of the present invention. Wireless power and communication unit 300 is adapted for mounting remote from one or more field devices 14. Unit 300 includes suitable power generation and storage capabilities to power field devices 14 simultaneously, sequentially, or asynchronously. As illustrated in FIG. 6, each field device 14 is coupled individually to unit 300 by an attachment region 112 illustrated diagrammatically in FIG. 6. As stated above with respect to FIG. 5, attachment region 112 preferably includes a local user interface, such as button 124 and/or display 202. Since each field device 14 is individually coupled to unit 300, analog or digital communication with individual field devices 14 can be effected. While it is preferred that user interfaces are included in attachment regions 112 in the embodiment illustrated in FIG. 6, some embodiments may provide an additional, or alternative user interface embodied within unit 300.
FIG. 7 is a diagrammatic view of unit 350 in accordance with another embodiment of the present invention. Unit 350 is illustrated with a single connection 352 to a plurality of field devices 14. Those skilled in the art will appreciate that the configuration illustrated in FIG. 7 has the ability to drastically reduce interconnection wiring and efforts for coupling field devices 14 to unit 350. In order to be able to communicate with individual field devices 14, unit 350 preferably employs digital communication utilizing either a hybrid-type protocol or an all-digital industry standard protocol. Further, such a protocol is used to power all of field devices 14, simultaneously, sequentially, or asynchronously as desired. FIG. 7 also illustrates each of field devices 14 coupling to the network utilizing an attachment region 112 illustrated diagrammatically. Thus, each of field devices 14 may still have a local user interface comprising a local user input and/or a local user output such as an LCD display.
FIG. 8 is a block diagram of a wireless power and communication unit in accordance with embodiments of the present invention. Unit 360 includes controller 362, power storage device 364 (illustrated as a battery), energy converter 365, loop communicator 368, and wireless communication interface module 366.
Controller 362 preferably includes a low-power microprocessor and appropriate charging circuitry to convey suitable amounts of energy from cell(s) 116 and/or storage device 364 to power unit 360 and any field devices coupled to attachment region 112. Additionally, controller 362 also directs excess energy from cell(s) 116 to storage device 364. Controller 362 can also be coupled to optional temperature measurement circuitry such that controller 362 can reduce charging current to storage device 364 if device 364 begins to overheat. For example, the temperature measuring circuit may contain a suitable temperature-sensing element, such as a thermocouple coupled to storage device 364. An analog-to-digital converter could convert the signal from the thermocouple to a digital representation thereof, and provide the digital signal to controller 362.
Energy converter 365 can be any device that is able to convert potential energy in the environment proximate unit 360 into electrical energy. In the preferred embodiments, converter 365 is simply one or more photo-voltaic cells 116. However, converter 365 can be any device, known or later developed, that can translate potential energy near unit 360 into electricity. Thus converter 365 can include a generator coupled to a movable member such that environmental motion, such as waves or wind generate electricity. Further, converter 365 can employ thermopile devices to generate electricity from disparate temperatures using the Peltier Effect. Further still, the process may provide a source of energy in the form of compressed gas or the like, that could be transformed into electricity. Finally, in embodiments where the power storage device has a relatively large capacity in comparison to the energy needs of the application, converter 365 may be omitted.
Memory 370 is illustrated in FIG. 8 as being separate from controller 362, but may, in fact, be part of controller 362. Memory 370 can be any suitable type of memory including volatile memory (such as Random Access Memory), non-volatile memory (such as flash memory, EEPROM memory, etc.) and any combination thereof. Memory 370 may contain program instructions for controller 362 as well as any suitable administrative overhead data for unit 360. Memory 370 may contain a unique identifier for unit 360, such that unit 360 can distinguish wireless communications meant for it among other wireless communications. Examples of such an identifier could include, a Media Access Controller (MAC) address, Electronic Serial Number, global phone number, Internet Protocol (IP), or any other suitable identifier. Moreover, memory 370 may include information about attached field devices, such as their unique identifiers, configurations, and abilities. Finally, controller 362, using memory 370 can cause the output of unit 360 to be provided in any suitable form. For example, configuration and interaction with unit 360 and/or one or more associated field devices could be provided as HyperText Markup Language (HTML) web pages.
FIG. 8 also illustrates optional operator button block 374 and LCD display block 376 in phantom being coupled to controller 362. This illustration is intended to show that all local inputs, be they on individual field devices, wireless power and communication unit 360, or both are coupled to controller 362. Additionally, local user displays, on each field device, wireless power and communication unit 360, or both are also coupled to controller 362. This allows controller 362 to interact with each local display individually based upon inputs from the field device, the configurable button associated with the field device, one or more buttons or inputs disposed proximate unit 360, or from wireless communication.
FIG. 9 is a rear elevation view of a wireless power and communication unit in accordance with an embodiment of the present invention. Wireless unit 400 is coupled to field device 14 as in previous embodiments. However, wireless communication module 366 and/or antenna 120 can be located within field device 14 instead of within housing 114 of unit 400. Wireless communication module 366 and/or antenna 120 can be added to field device 14 as a feature board. Further, wireless communication module 366 could be an integral part of field device 14. Thus, in some embodiments, module 366 may be coupled to a controller within unit 400 via attachment region 112. In other embodiments, module 366 may be integral with the field device, and in such embodiments, unit 400 could simply provide operating power.
In operation, wireless power and communication units in accordance with embodiments of the present invention can add significant capabilities to process monitoring and control. While the wireless output of the wireless power and communication units may be simply indications of process variable, they may also contain much more information. For example, the wireless output could also include diagnostic and/or maintenance information. Further, the wireless power and communication unit could also provide alarms wirelessly if one or more of the field devices, or even the unit itself, generates a fault. The unit may direct the wireless alarm to the same entity as it normally sends wireless information to (such as a control room), or it may send to an alternate entity, such as a technician's pager. Further, in embodiments where the unit is coupled to more than one field device, the wireless output may be indicative of a combination of process variable, or a higher level output. Further still, in embodiments where the multiple field devices include PV generators, and one or more actuators that can effect a change in the process variable, the units themselves may actually provide local closed-loop process control autonomously without control room interaction, but still subject to wireless communication.
wherein the power management includes causing at least a portion of the wireless power and communication unit to enter a sleep mode.
2. The system of claim 1, wherein the power storage device is a battery.
3. The system of claim 1, and further comprising a energy converter coupled to the controller and being adapted to convert a source of environmental potential energy into electricity.
4. The system of claim 3, wherein the energy converter includes at least one photo-voltaic cell.
5. The system of claim 4, wherein the at least one photo-voltaic cell seals a portion of the housing.
6. The system of claim 3, wherein the controller is adapted to recharge the power storage device with electricity from the energy converter.
7. The system of claim 3, and further comprising a temperature sensor operably coupled to the controller and disposed to sense a temperature of the energy storage device, and wherein the controller selectively charges the energy storage device based at least in part upon a signal from the temperature sensor.
8. The system of claim 7, wherein the temperature sensor is operably coupled to the controller through an analog-to-digital converter.
9. The system of claim 1, wherein the conduit has a size selected from the group consisting of a 3/8-18 NPT, a 1/2-14 NPT, a M20x1.5, and a G1/2.
10. The system of claim 1, wherein the attachment region includes at least one degree of freedom.
11. The system of claim 1, wherein the attachment region allows the housing to be rotatable about a first axis.
12. The system of claim 11, wherein the attachment region allows the housing to the rotatable about a second axis that is substantially orthogonal to the first axis.
13. The system claim 1, and further comprising a photo-voltaic cell disposed near a top surface of the housing at an angle of approximately 30 degrees with respect a bottom surface of the housing.
14. The system of claim 1, wherein the local user interface includes a button.
15. The system of claim 14, wherein the button is user configurable.
16. The system of claim 14, wherein the button is disposed proximate the attachment region.
17. The system of claim 1, wherein the user interface includes a display.
18. The system of claim 17, wherein the display is an LCD display.
19. The system of claim 17, wherein the display is located proximate a top surface of the housing.
20. The system of claim 19, wherein the display is located proximate a photo-voltaic cell.
21. The system of claim 17, wherein the display is mounted proximate the attachment region.
22. The system of claim 21, wherein the display is rotatable about the attachment region.
23. The system of claim 1, wherein the housing is field-hardened.
24. The system of claim 1, and further comprising an additional attachment region, the additional attachment region being configured to couple the wireless power and communication unit to an additional process variable generator and power and communicate with both process variable generators.
25. The system of claim 24, wherein the loop communicator is adapted to communicate digitally with both process variable generators.
26. The system of claim 1, wherein the controller includes a microprocessor.
27. The system of claim 1, wherein the loop communicator is configured to sense a current ranging between 4 and 20 milliamps.
28. The system of claim 1, wherein the loop communicator provides a two-wire connection to the process variable generator, which two wire connection provides power and communication with the process variable generator.
29. The system of claim 1, wherein the power management includes causing the process variable generator to enter a sleep mode.
30. The system claim 1, wherein the controller causes the portion of the wireless power and communication unit to enter a sleep mode based upon user input.
31. The system of claim 1, wherein the power storage device is selected based upon a scale of power required by the process variable generator.
MXPA06013488A MXPA06013488A (en) 2004-05-21 2005-05-05 Power and wireless communication unit for process field devices.
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References: application No. 2008
 application No. 2007
 application No. 2006145434
 application No. 2007527282
 application No. 200680035248
 Application No. 200580014212
 Application No. 05746241