Power generation for process devices

• US 8,145,180 B2
• Filed: 09/27/2005
• Issued: 03/27/2012
• Est. Priority Date: 05/21/2004
• Status: Active Grant

• Current Assignee: Rosemount Incorporated (Emerson Electric Company)
• Original Assignee: Rosemount Incorporated (Emerson Electric Company)
• Inventors: Brown, Gregory C., Klosinski, Andrew J., Trimble, Steven R., Fandrey, Mark
• Primary Examiner(s): Decady, Albert
• Assistant Examiner(s): DUNN, DARRIN D
• Application Number:
  US11/236,317
• Publication Number:
  US 20060116102A1
• Time in Patent Office: 2,373 Days
• Field of Search: 320/101, 700/17, 290/44, 713/300, 455/343.1
• US Class Current: 455/343.1
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/31121 Fielddevice, field controller, interface connected to fieldbus
• CPC Class Codes: G05B 2219/33192 Radio link, wireless
• CPC Class Codes: Y02P 80/10 Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A process device includes a controller and a wireless communications module. The wireless communications module is coupled to the controller. A power generation module is provided to generate electricity for the process device. The power generator module can be disposed within the process device or it can be a separate unit coupled to the process device.

Claims

1. A system comprising:

a field device coupled to a conduit having a hydrocarbon-based process fluid therein wherein the field device senses an aspect of the hydrocarbon-based process fluid, the unit comprising; and

a wireless power communication for providing wireless operation to the field device, the unit comprising;

a housing;

an attachment region coupled to the housing and being coupled to the field device;

a power generation module including a hydrocarbon-based fuel cell operably coupled to the conduit to receive the hydrocarbon-based process fluid to provide electricity to the field device;

a loop communicator connected to the field device via the attachment region and configured to communicate digitally with the field device;

a controller coupled to the power source and loop communicator, the controller being configured to interact with the field device using the loop communicator; and

a wireless communication module coupled to the controller and being configured for wireless communication.

2. The system of claim 1, wherein the fuel cell is a methanol fuel cell.

3. The system of claim 1, and further comprising a storage tank coupled to the fuel cell to provide a stored source of fuel to the fuel cell.

4. The system of claim 3, wherein the fuel cell, the storage tank, and the controller are disposed within the housing, and wherein the housing includes a thermal barrier that thermally isolates the fuel cell from the storage tank and the controller.

5. The system of claim 1, wherein the wireless power and communication unit includes a controller disposed within the housing, the controller being configured to actively manage power for itself and the field device.

6. The system of claim 5, wherein actively managing power includes causing at least one of the controller and the field device to enter a sleep mode.

7. The system of claim 6, wherein the sleep mode results from commanding the field device to set its operating current at its lowest allowable current rail.

8. The system of claim 6, wherein the controller generates a sleep mode command based upon the occurrence of an event.

9. The system of claim 8, wherein the event includes an event selected from the group consisting of the expiration of an activity period, and input from a local user input, communication from an attached field device, and wireless communication.