Auxiliary Power Module for Wireless Valve Positioner Battery Replacement
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Solution Overview
Problem
The process control industry faces challenges in maintaining continuous operation of wireless process control devices due to the need for battery replacement, which can cause interruptions, even when done before the battery is completely drained, as the replacement process itself disrupts the device's operation.
Innovation Solution
A method and apparatus that utilize an auxiliary power module to temporarily power process control devices, allowing for the replacement of primary power sources without interrupting the device's operation, by coupling the auxiliary power module to a terminal of the process control device, providing sufficient power to maintain operation during the replacement of the primary power source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery replacement is performed in wireless process control devices, then the device can continue to operate with sufficient power, but the replacement process causes interruption in device operation
Solution Approach 1:
The auxiliary power module is connected to the process control device before the primary battery is removed, establishing a backup power supply in advance. This preliminary action ensures that power is already available when the primary power source is disconnected, preventing any operational interruption during the battery replacement process.
Solution Approach 2:
The auxiliary power module acts as an intermediary power source between the old and new primary batteries. It temporarily bridges the power supply gap that would otherwise occur during battery replacement, allowing the device to maintain continuous operation while the primary power source is being exchanged.
2Duration of action of stationary object
If battery lifetime is extended through improved battery technology, then the frequency of replacement decreases, but the battery still needs to be replaced eventually causing operational disruption
Solution Approach 1:
The auxiliary power module provides a cushioning backup power supply that is ready in advance before the primary battery is removed. This beforehand cushioning ensures that even when battery replacement becomes necessary due to eventual depletion, the device maintains continuous operation without disruption, compensating for the inherent limitation that all batteries must eventually be replaced.
3Adaptability or versatility
If wireless process control devices are deployed in hard-to-reach places, then installation flexibility is improved, but maintenance and power source replacement become more difficult
Solution Approach 1:
The power supply system is segmented into separate functional modules: the primary battery compartment and the auxiliary power module. This segmentation allows the auxiliary power module to be independently accessed and connected without requiring access to the entire device, facilitating easier maintenance in hard-to-reach locations while preserving installation flexibility.
Data Source
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AI summary
A process control device includes an interface configured to communicate with other devices in a process control system. The process control device also includes a primary power source, the primary power source configured to provide power to at least one component of the process control device, which component, if not powered, would result in disruption to the control of the process. The process control device still further includes a terminal configured to electrically couple the process control device to an auxiliary power source such that the auxiliary power source provides sufficient power to the at least one component when the auxiliary power source is connected to the terminal such that the process control device remains operable to control the process in the absence of the primary power source.