Ethernet-APL Power Regulation for Reduced Field Device Energy Waste
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Solution Overview
Problem
Ethernet-APL systems in industrial process control face inefficiencies due to excessive power consumption, with significant power being wasted through Ethernet-APL field devices despite receiving significantly higher power than required for operation.
Innovation Solution
A power management system for Ethernet-APL field devices that includes a power regulator, main and excess power sensors, and a voltage shunt regulator to adjust DC power based on sensed signals, diverting only necessary power to circuit common and minimizing excess power waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If DC power is supplied to Ethernet-APL field devices, then the field devices can operate and communicate data, but significant power is wasted through the devices despite receiving significantly higher power than required for operation
Solution Approach 1:
The patent implements a feedback mechanism where a sensor detects the actual power consumption of the field device and feeds this information back to a power regulator. The regulator continuously adjusts the DC power supply based on the detected consumption, ensuring that the device receives exactly the power it needs for operation and data communication, thereby eliminating excessive power waste while maintaining full functionality.
2Reliability
If a fixed DC power supply is used to power Ethernet-APL field devices, then the devices can operate reliably, but excess power is diverted to circuit common creating energy inefficiency
Solution Approach 1:
The patent transitions from a static fixed DC power supply to a dynamic power supply system. The power regulator dynamically adjusts the DC power level in real-time based on feedback from the sensor that monitors actual device consumption. This dynamic adjustment ensures reliable device operation by providing sufficient power when needed while minimizing energy waste by reducing power when the device consumes less, thereby resolving the contradiction between reliability and energy efficiency.
Data Source
AI summary
A field device for an industrial process includes field device circuitry, an APL communication circuit, and a power circuit. The power circuit includes a power regulator configured to regulate DC power that powers the field device circuitry and the APL communication circuit, a main power sensor configured to generate a main power signal that corresponds to the DC power, a voltage shunt regulator configured to divert excess power to a circuit common, and an excess power sensor configured to generate an excess power signal that corresponds to a magnitude of the excess power. The power regulator adjusts the DC power based on the main power signal and the excess power signal.