Removable Power Module for Reliable Wireless Transmitter Battery Swaps
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Solution Overview
Problem
The challenge in industrial settings is the labor-intensive installation of wired field devices and the need for frequent battery replacement in wireless field devices, which can lead to incorrect installation and potential damage if the new battery is not properly connected, causing operational issues and safety concerns.
Innovation Solution
A removable industrial power module with integrated battery test circuitry that provides visual indicators for correct battery polarity and functionality, allowing operators to easily replace batteries and ensure proper installation, preventing damage and ensuring safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wireless field devices with internal batteries are used, then installation labor is reduced and wireless communication is enabled, but battery replacement becomes necessary and carries risk of incorrect installation
Solution Approach 1:
The power module is pre-configured with battery compartments and electrical connections before field installation. The module includes built-in test circuitry that automatically checks battery installation correctness, preventing incorrect installation risks during field battery replacement operations.
Solution Approach 2:
A removable power module serves as an intermediary between the battery and the wireless field device. This module contains the battery, test circuitry, and connection interfaces, allowing battery replacement to occur at the module level rather than directly inside the field device, thus reducing installation risks.
2Duration of action of moving object
If batteries are replaced in the field, then operational continuity is maintained, but incorrect installation may cause damage and safety issues
Solution Approach 1:
The power module includes test circuitry that provides immediate feedback on battery installation correctness through visual indicators (LEDs). The system tests battery polarity and connectivity automatically, alerting operators to incorrect installation before the module is installed in the field device, thus preventing potential damage.
Solution Approach 2:
Battery installation verification is performed in advance at the power module level before the module is installed in the field device. This preliminary testing prevents incorrectly installed batteries from being deployed, eliminating the risk of damage during field operations.
3Reliability
If visual indicators are added to the power module, then battery installation correctness is verified, but device complexity increases
Solution Approach 1:
The test circuitry and visual indicators are localized within the removable power module rather than being distributed throughout the entire field device. This concentrates the added complexity in a small, replaceable unit, making the overall system easier to maintain and reducing the complexity burden on the main device.
Data Source
AI summary
A wireless process variable transmitter for use in an industrial process includes a process variable sensor configured to sense a process variable of the industrial process. Measurement circuitry connected to the process variable sensor provides an output related to the sensed process variable. Wireless communication circuitry connected to the measurement circuitry wirelessly transmits information related to the sensed process variable to a remote location. A removable industrial power module is configured to hold a replaceable battery and provide power to the process variable sensor, the measurement circuitry and the wireless communication circuitry. Battery test circuitry in the removable industrial power module connects to the replaceable battery and provides a visual output related to a condition of the replaceable battery.