Field Device Energy Store Serviceability Monitoring
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Solution Overview
Problem
Field devices in process automation technology face serviceability issues due to internal aging effects and environmental influences, leading to potential functional failures and long downtimes, which can result in financial losses.
Innovation Solution
A method for monitoring the serviceability and remaining service time of field devices by measuring the capacitance and power consumption of their energy stores, allowing for predictive maintenance and identification of defective components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If field devices operate continuously for long periods, then productivity is improved, but reliability deteriorates due to internal aging effects and environmental influences
Solution Approach 1:
The system performs preliminary diagnostics by measuring capacitance and power consumption parameters before actual failure occurs. The control unit continuously monitors energy store characteristics and compares them against reference values to detect early signs of degradation, enabling preventive maintenance actions before the device becomes unserviceable.
Solution Approach 2:
The system establishes a feedback loop where measurement results from capacitance and power consumption tests are fed back to the control unit. This feedback mechanism allows continuous updating of the device's serviceability status, with automatic comparison against reference values and triggering of maintenance alerts when deviations exceed predetermined thresholds.
2Reliability
If field devices are monitored continuously, then reliability is improved through early detection of serviceability issues, but use of energy increases due to continuous measurement activities
Solution Approach 1:
Instead of continuous monitoring, the system performs measurements periodically at predetermined intervals. The control unit schedules capacitance and power consumption measurements at optimized time points, balancing the need for reliable serviceability detection with energy conservation. This periodic approach reduces overall energy consumption while maintaining effective monitoring capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables early detection of serviceability issues, predicts remaining service time, and allows for timely maintenance or replacement, thereby reducing downtime and financial losses.
Implementation Method 1
The electronic unit at least is supplied by an energy store of the field device
Implementation Method 2
The power consumption at the energy store can also be determined by measuring the voltage drop
Data Source
AI summary
Disclosed is a method for determining the serviceability of a fill-level measuring device that includes at least one electronic unit. The method can be applied to any type of field device that includes at least one electronic unit supplied by an energy store of the field device. The method includes: measuring the capacitance of the energy store and/or measuring the power withdrawal at the energy store. The field device is classified as not operationally reliable if the capacitance of the energy store is below a defined minimum capacitance and/or if the power withdrawal deviates from a predefined normal consumption. An advantage of the method according to the invention is that, in addition to the functional diagnosis, in particular also a prediction up to the expected elapsing of the remaining operating time can be created by recording the power withdrawal or the capacitance over progressive measurement cycles.