Wireless Module Powering via Heat Trace Energy Storage
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Solution Overview
Problem
Heat trace systems in industrial settings face challenges in powering wireless sensors and control devices due to the risk of battery failure and the expense of running separate power cables, which can lead to catastrophic failures such as frozen pipes.
Innovation Solution
A heat trace system that powers wireless modules using energy storage devices connected to heat trace elements, allowing these modules to communicate wirelessly with a main control system via a wireless communication network, eliminating the need for batteries and separate power lines by storing energy from the voltage difference across the heat trace elements and momentarily increasing power when needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If batteries are used to power wireless modules in heat trace systems, then wireless operation is enabled, but reliability deteriorates due to battery failure risk
Solution Approach 1:
The heat trace element serves dual functions: heating the pipe and powering the wireless module through its voltage output. The system uses itself (the heat trace element) to provide power to the wireless module, eliminating the need for separate battery power sources and their associated reliability issues.
2Reliability
If separate power cables are run to wireless devices, then reliable power is provided, but installation cost and complexity increase
Solution Approach 1:
The heat trace element is designed to perform multiple functions simultaneously: it heats the pipe to prevent freezing and provides electrical power to the wireless module through its inherent voltage output. This multi-functionality eliminates the need for separate power cables and reduces installation complexity.
3Duration of action of stationary object
If energy storage devices are added to store voltage from heat trace elements, then continuous operation is enabled, but device complexity increases
Solution Approach 1:
The energy storage device (capacitor) is pre-charged during periods when the heat trace element provides sufficient voltage. This preliminary energy storage allows the wireless module to operate continuously even when the heat trace element voltage drops below the required threshold, smoothing out power availability without requiring complex power management systems.
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
This solution ensures continuous operation of wireless modules in heat trace systems by using stored energy from heat trace elements, preventing failures and reducing installation costs by eliminating the need for separate power sources.
Implementation Method 1
comprises an energy storage device connected to the associated heat trace element for storing energy from the associated heat trace element
Implementation Method 2
electrical heating elements or heat traces that are in physical contact with the pipe or tank
Data Source
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AI summary
Heat trace system for heating vessels of a piping system comprises a main control system, a plurality of heat trace elements, and a plurality of wireless modules. Each heat trace element is adjacent to one of the vessels of the piping system and connected to an electrical power source of the main control system 16. Each of the wireless modules: (a) is connected to and powered by an associated heat trace element; (b) comprises an energy storage device connected to the associated heat trace element for storing energy from the associated heat trace element to power the wireless module; and (c) comprises an RF module for communicating wirelessly with the main control system via a wireless communication network. The stored energy in the energy storage device can be used to power components of the wireless module, even when no current is flowing in the heat trace element to which the wireless module is connected.