Source: https://patents.google.com/patent/US9921120B2/en
Timestamp: 2019-04-25 18:32:46+00:00

Document:
The present application is a Divisional of and claims priority of U.S. patent application Ser. No. 12/107,225, filed Apr. 22, 2008, the content of which is hereby incorporated by reference in its entirety.
Some field devices include a process variable sensor. Typically, the transducer transforms an input into an output having a different form. Types of transducers include various analytical equipment, pressure sensors, thermistors, thermocouples, strain gauges, flow transmitters, positioners, actuators, solenoids, indicator lights, and others. Other field devices include a control element and are used to control the industrial process. Examples of such process devices include valve controllers, valve position controllers, heater controllers, pump controllers, etc.
FIG. 4 is a bottom plan view of a sensor module including an isolation diaphragm for use with a piezoelectric transducer.
Process device 16 is shown coupled to process piping 12 which is configured to carry a process fluid 14. A process interface element 18 is configured to couple to the process and is used for input or output to the process device 16. For example, if the process device is configured as a process control transmitter, interface element 18 can comprise some type of a process variable sensor such as a pressure sensor, flow sensor, temperature sensor, etc configured to sense a process variable. On the other hand, if process device 16 is configured as a process control device, interface element 18 can be, for example, a valve, a heater, a motor, a pump, etc., which is used to control the process. Process device 16 couples to remotely located circuitry such as control room 20 over a process control loop 22. Process control loop 22 is illustrated as a two wire process control loop and can comprise, for example, a process control loop configured to operate in accordance with industrial standards. Example industrial standards include 4-20 mA protocols, the HART® protocol, FieldBus protocols, and others. In some embodiments, device 16 communicates using a wireless process control loop and may or may not also couple to wired loop 22. FIG. 1 also shows a pressure pulse 72 carried in the process fluid.
In general, power from the process cannot be harvested using this technique unless there is kinetic energy. For example, a pressurized vessel may contain a significant amount of potential energy. However, if the pressure remains constant, the energy cannot be harvested. One solution is to harvest energy created by process pressure noise such as due to a water “hammer” effect, pump pulsations, etc. With the present invention, such energy can be harvested using a piezoelectric effect. Typical piezoelectric elements have a relatively low current output. However, given a sufficient input force, enough power may be generated to be useful in process control devices. In various configurations, the piezoelectric transducer can be used to harvest power from pressure pulsations in the process fluid. The piezoelectric transducer can be integrated into a pressure sensor module or process connection to thereby eliminate external wiring. A battery capacitor or other power storage device, such as power storage 82 shown in FIG. 3, can be included in the configuration. The battery can wholly or partially supplement power provided by the piezoelectric transducer. Further, the piezoelectric transducer can be used, to charge the battery when there is sufficient excess energy. This can also extend the life of the battery by reducing discharge. In another example configuration, a control signal can be applied to the piezoelectric transducer 68 from microcontroller 60 to thereby cause movement of the transducer 68 and provide pressure pulsations. In such a configuration, the induced pressure signal can be sensed by a pressure sensor of the process device to diagnose or verify transmitter operation. The magnitude of the signal can also be used to provide an indication of line pressure. Although a single piezoelectric transducer 68 is illustrated, multiple circuits can be used.
Although other configurations may be used, in one embodiment, the circuitry may include a super capacitor to store electrical charge from the piezoelectric transducer. When the energy being scavenged is sufficient to power the device, the scavenged energy can be used rather than energy from a battery. Further, when scavenged energy is still greater, excess charge can be stored in, for example, a super capacitor. However, if the energy generated by the transducer 68 is not sufficient to power the device, energy from a battery may be used. Thus, in such a configuration, the energy scavenging does not replace the battery in the device, but rather extends battery life.
wherein the electrical circuitry is configured to diagnose operation of the industrial process based upon the electrical output from the piezoelectric sensor by comparing the electrical output from the piezoelectric sensor with nominal signal values stored in the memory and responsively providing an output indicative of a life expectancy of the component in the industrial process.
2. The apparatus of claim 1 wherein the process device is powered with the electrical output.
3. The apparatus of claim 1 including an analog to digital converter having a digital output related to the electrical output.
4. The apparatus of claim 1 including a microcontroller configured to perform diagnostics based upon the electrical output from the piezoelectric sensor.
5. The apparatus of claim 1 wherein the nominal signal values stored in the memory comprise amplitude values.
6. The apparatus of claim 1 wherein the nominal signal values stored in the memory comprise frequency values.
7. The apparatus of claim 1 wherein the nominal signal values stored in the memory comprise a signature.
8. The apparatus of claim 1 wherein the piezoelectric sensor is configured to receive a control signal which causes movement of the piezoelectric sensor.
9. The apparatus of claim 8 wherein movement of the piezoelectric sensor induces pressure pulsations in the process fluid which are sensed by the process variable sensor, the electrical circuitry further configured to diagnose process device operation based upon the sensed pressure pulsations.
10. The apparatus of claim 1 wherein the electrical circuitry includes power storage circuitry configured to store power from the piezoelectric sensor.
13. The apparatus of claim 1 wherein the piezoelectric sensor is mounted in the housing of the process device.
14. The apparatus of claim 1 wherein the piezoelectric sensor is mounted in a sensor module of the process device.
15. The apparatus of claim 1 wherein the piezoelectric sensor is carried on a mounting flange used to couple the process device to the industrial process.
16. The apparatus of claim 1 wherein the piezoelectric sensor is positioned at a location which is spaced apart from the device housing.
17. The apparatus of claim 1 wherein the piezoelectric sensor couples to the process fluid through a resonant pipe.
18. The apparatus of claim 1 wherein the piezoelectric sensor couples to process fluid through a diaphragm.
diagnosing operation of the industrial process based upon the electrical output by comparing the electrical output from the piezoelectric sensor with nominal signal values stored in the memory and responsively providing an output indicative of a life expectancy of the component in the industrial process.
20. The method of claim 19 including powering the electrical circuitry with the electrical output.
22. The method of claim 19 wherein the nominal signal values stored in the memory comprise amplitude values.
23. The method of claim 19 wherein the nominal signal values stored in the memory comprise frequency values.
24. The method of claim 19 wherein the nominal signal values stored in the memory comprise a signature.
25. The method of claim 19 including providing a control signal to the piezoelectric sensor which causes movement of the piezoelectric sensor.
26. The method of claim 25 wherein the movement of the piezoelectric sensor induces pressure pulsations in the process fluid and sensing the pressure pulsations with the process variable sensor, the method further including diagnosing process device operation based upon the sensed pressure pulsations.
27. The method of claim 19 wherein the piezoelectric sensor is mounted in the housing of the process device.
28. The method of claim 19 wherein the piezoelectric sensor is mounted in a sensor module of the process device.
29. The method of claim 19 wherein the piezoelectric sensor is carried on a mounting flange used to couple the process device to the industrial process.
30. The method of claim 19 wherein the piezoelectric sensor is positioned at a location which is spaced apart from the device housing.
31. The method of claim 19 wherein the piezoelectric sensor couples to process fluid through a resonant pipe.
32. The method of claim 19 wherein the piezoelectric sensor couples to process fluid through a diaphragm.
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