Logic capable power module

• US 9,291,684 B2
• Filed: 06/28/2013
• Issued: 03/22/2016
• Est. Priority Date: 06/28/2013
• Status: Active Grant

• Current Assignee: Rosemount Incorporated (Emerson Electric Company)
• Original Assignee: Rosemount Incorporated (Emerson Electric Company)
• Inventors: McGuire, Chad Michael, Orth, Kelly Michael, Schnaare, Theodore Henry
• Primary Examiner(s): Phan, Huy Q
• Assistant Examiner(s): RIOS RUSSO, RAUL J
• Application Number:
  US13/930,700
• Publication Number:
  US 20150002185A1
• Time in Patent Office: 998 Days
• Field of Search: 324378-400, 324403-450, 324/500, 324/537, 324/764.01
• US Class Current: 1/1
• CPC Class Codes: G01D 21/00 Measuring or testing not otherwise provided for
• CPC Class Codes: G01F 1/30 for fluent solid material
• CPC Class Codes: G01R 31/392 Determining battery ageing or deterioration, e.g. state of health
• CPC Class Codes: G01R 31/40 Testing power supplies testing photovoltaic devices H02S50/10
• CPC Class Codes: H02S 50/00 Monitoring or testing of PV systems, e.g. load balancing or fault identification
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

A wireless field device assembly comprises a process sensor, a housing, a transmitter, and a power module. 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, a connection to a local power source, and a processor configured to provide the transmitter with a diagnostic report of the energy storage device and the local power source.

Claims

1. A wireless field device assembly comprising:

a process sensor configured to monitor a process variable and produce a sensor signal;

a housing enclosing an interior space of the wireless field device;

a transmitter enclosed within the interior space, and configured to process the sensor signal; and

a power module configured to be housed in the interior space, removable from the interior space as a unit, the power module comprising;

first and second voltage sensors configured to sense first and second output voltages of the energy storage device and the local power source, respectively;

an energy storage device;

a connection to a local power source; and

a processor configured to provide the transmitter with a diagnostic report of the energy storage device and the local power source, wherein the diagnostic report comprises an identification of at least one of the energy storage device and the local power source based on the first and second output voltages.

2. The wireless field device assembly of claim 1, wherein the diagnostic report comprises a fault report indicating incipient or current faults in the energy storage device or the local power source, based on the first and second output voltages.

3. The wireless field device assembly of claim 2, wherein the fault report reflects an unanticipated drop in voltage from the energy storage device, the local power source, or both.

4. The wireless field device assembly of claim 1, wherein the power module further comprises a machine readable memory, and the identification of at least one of the energy storage device and the local power source comprises an identification of the energy storage device retrieved from the machine readable memory.

5. The wireless field device assembly of claim 1, wherein the diagnostic report comprises a projected remaining life of the energy storage device based on the first and second output voltages.

6. The wireless field device assembly of claim 5, wherein the local power source further comprises a temperature sensor configured to produce an ambient temperature reading, and wherein the projected remaining life of the energy storage device is further based on the ambient temperature reading.

7. The wireless field device assembly of claim 1, wherein the power module is configured to draw power preferentially from the local power source connection, and supplementally from the energy storage device when power from the local power source is unavailable or insufficient to satisfy power demand.

8. The wireless field device assembly of claim 1, wherein the power module houses the local power source.

9. The wireless field device assembly of claim 1, wherein the local power source is situated externally to the power module, and connected to the power module via an external source terminal of the power module.

10. The wireless field device assembly of claim 1, further comprising a cover defining a receptacle between the housing and the cover, and wherein the power module is configured to be housed in the receptacle.

11. The wireless field device assembly of claim 10, wherein the power module is configured to be removably housed in the receptacle.

12. The wireless field device assembly of claim 1, wherein the energy storage device is a battery or a supercapacitor.

13. The wireless field device of claim 1, wherein the local power source is an energy harvesting device.

14. The wireless field device of claim 1, wherein the power module further comprises a power conditioner that conditions power from at least one of the energy storage device and the local power source.

15. The wireless field device assembly of claim 14, wherein the power conditioner is configured to rectify or invert power from at least one of the energy storage device and the local power source.

16. The wireless field device assembly of claim 1, wherein the transmitter is configured to send the sensor signal and the diagnostic report to a control or monitoring system.

17. A power monitoring and diagnostic method for a power module for a process variable transmitter with an energy storage device and a local power source connection to a local power source, the method comprising:

sensing within the power module a first output voltage of the local power source and a second output voltage of the energy storage device;

flagging fault or changing conditions corresponding to output voltages of the local power source and the energy storage device;

estimating a remaining energy storage device life based on the first and second output voltages;

identifying at least one of the local power source and the energy storage device based on at least one of the first and second output voltages; and

transmitting a diagnostic report including the estimated remaining energy storage device life, the flagged fault conditions, and the identification of the identification of at least one of the local power source and the energy storage device.

18. The method of claim 17, wherein estimating the remaining energy storage device life comprises estimating expected depletion rate and remaining charge of the energy storage device, and determining remaining energy storage device life from the estimated expected depletion rate and remaining charge.

19. The method of claim 17, wherein identifying at least one of the local power source and the energy storage device comprises identifying the local power source based on the first output voltage.

20. The method of claim 19, wherein identifying the local power source based on the first output voltage comprises matching a voltage signature of the first output voltage with a local power source identification using a database of voltage signatures.

21. The method of claim 17, wherein identifying at least one of the local power source and the energy storage device comprises identifying the energy storage device.

22. The method of claim 21, wherein identifying the energy storage device comprises matching a voltage signature of the second output voltage with an energy storage device identification using a database of voltage signatures.

23. The method of claim 21, wherein identifying the energy storage device comprises retrieving a stored identification of the power module that includes an identification of the energy storage device.

24. The method of claim 21 wherein the expected depletion rate is further based on a sensed temperature.

25. A wireless field device assembly comprising:

a process sensor configured to monitor a process variable and produce a sensor signal;

a housing enclosing an interior space of the wireless field device;

a transmitter enclosed within the interior space, and configured to process the sensor signal; and

a power module configured to be housed in the interior space and removable from the interior space as a single unit, the power module comprising;

a connection to a local power source from which the power module draws power preferentially;

an energy storage device from which the power module draws power supplementally, when power from the local power source is unavailable or insufficient to satisfy power demand;

first and second voltage sensors configured to sense first and second output voltages of the energy storage device and the local power source, respectively; and

a processor configured to provide the transmitter with a diagnostic report comprising an identification of at least one of the energy storage device and the local power source based on the first and second output voltages.