Hybrid Power Module for Wireless Field Devices
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Solution Overview
Problem
Industrial wireless field devices face challenges in maintaining power supply reliability and longevity due to limited capacity of local power sources, such as batteries, and unpredictable energy harvesting from sources like solar panels and vibrational scavengers, which can lead to fluctuating power levels and reduced battery life when higher power demands are needed for faster update rates.
Innovation Solution
A hybrid power module that combines an energy storage device, such as a battery or supercapacitor, with power conditioning circuitry for external energy harvesting sources, allowing for simultaneous processing of voltage readings from both sources and providing diagnostic reports to ensure continuous power supply and extend battery life by supplementing power from energy storage with external sources when available.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wireless field devices transmit at faster update rates to improve monitoring responsiveness, then productivity is improved, but power consumption increases significantly reducing battery life
Solution Approach 1:
The patent combines multiple power sources (battery and energy harvesting device) into a hybrid power module that works together to supply power to the wireless field device. This merging allows the system to maintain fast update rates while extending operational life by drawing from both power sources simultaneously or alternately based on availability and demand.
Solution Approach 2:
The system dynamically changes power supply parameters by switching between different power sources and adjusting transmission power levels based on battery charge state. When battery charge is high, the system can operate at higher power consumption levels for faster updates; when charge is low, it transitions to energy harvesting supplementation or reduces power consumption to preserve battery life.
2Ease of manufacture
If local power sources have limited capacity to reduce device complexity and cost, then ease of manufacture is improved, but reliability of continuous power supply deteriorates
Solution Approach 1:
The hybrid power module is designed to accept and process multiple types of power inputs (battery and energy harvesting) through a universal interface. The power management circuitry can handle different power sources with different characteristics, providing multi-functionality that improves reliability without requiring separate dedicated circuits for each power source type.
Solution Approach 2:
The system incorporates a battery as a buffer or cushion between the intermittent energy harvesting source and the continuous power demand of the wireless device. The battery stores energy in advance during periods when energy harvesting is sufficient, cushioning against future power shortages when environmental conditions prevent harvesting, thereby ensuring continuous reliable operation.
3Duration of action of moving object
If energy harvesting systems are used to supplement power and extend battery life, then duration of action is improved, but power levels become unpredictable causing fluctuations in power supply
Solution Approach 1:
The battery acts as an intermediary buffer between the unpredictable energy harvesting source and the power consumption requirements of the wireless device. It smooths out fluctuations by releasing stored energy when harvesting is insufficient and absorbing excess energy when harvesting is abundant, providing stable power levels to the device while still extending overall operational life.
Solution Approach 2:
The system implements feedback control by monitoring battery charge state and energy harvesting availability to dynamically adjust power management strategies. Based on feedback about current power reserves and harvesting conditions, the system optimizes the balance between drawing from the battery and utilizing energy harvesting, maintaining stable operation while maximizing battery life extension.
Data Source
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AI summary
A wireless field device assembly (12) comprises a process sensor (16), a housing (100), a transmitter (102), and a power module (120). The process sensor is configured to monitor a process variable and produce a sensor signal. The housing encloses an interior space of the wireless field device. The transmitter is enclosed within the interior space, and is configured to process the sensor signal. The power module is configured to be housed in the interior space, and comprises an energy storage device (122), a connection to a local power source (22), and a processor (132) configured to provide the transmitter with a diagnostic report of the energy storage device and the local power source.