Hybrid power module with fault detection

• US 9,518,852 B2
• Filed: 09/27/2012
• Issued: 12/13/2016
• Est. Priority Date: 09/27/2012
• 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): Breene, John
• Assistant Examiner(s): Aiello, Jeffrey
• Application Number:
  US13/628,543
• Publication Number:
  US 20140088893A1
• Time in Patent Office: 1,538 Days
• Field of Search: 340/657, 340/679, 340/870.07, 455/277.1, 702/116, 702/64, 702/58
• US Class Current: 1/1
• CPC Class Codes: G01D 21/00 Measuring or testing not otherwise provided for
• CPC Class Codes: G01R 31/2829 Testing of circuits in sensor or actuator systems testing of apparatus for measuring electric or magnetic variables G01R35/00; testing of indicating or recording apparatus G01D; in airbag systems B60R21/0173; checking gas analysers G01N33/007; monitoring or fail-safe circuits for electromagnets H01F7/1844
• CPC Class Codes: G01R 31/36 Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
• CPC Class Codes: G01R 31/40 Testing power supplies testing photovoltaic devices H02S50/10
• CPC Class Codes: H02J 50/001 Energy harvesting or scavenging
• CPC Class Codes: H02J 7/34 Parallel operation in networks using both storage and other dc sources, e.g. providing buffering H02J7/14 takes precedence
• CPC Class Codes: H02S 50/00 Monitoring or testing of PV systems, e.g. load balancing or fault identification
• CPC Class Codes: H02S 50/10 Testing of PV devices, e.g. of PV modules or single PV cells testing of semiconductor devices during manufacturing H01L22/00
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

A wireless field device assembly comprises a process sensor, a housing, a power module, and a processor. 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 power module comprises an energy storage device and a connection to a local power source, and is configured to be housed in the wireless field device. The processor is located within the interior space, and is powered by the power module. The processor produces a fault signal value used to differentiate between energy storage device faults, local power source faults, and no-fault states.

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 power module comprising an energy storage device and a connection to a local power source, and configured to be housed in the wireless field device and power the wireless field device via at least one of the energy storage device and the local power source;

a processor powered by the power module, located within the interior space, and configured to produce a fault signal value that distinguishes between energy storage device faults, local power source faults, and no-fault states.

2. 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.

3. The wireless field device assembly of claim 2, wherein the power module is configured to be removably housed in the receptacle.

4. The wireless field device assembly of claim 1, wherein the processor is configured to produce a control/monitoring signal reflecting the sensor signal and the fault signal.

5. The wireless device assembly of claim 1, wherein the fault signal value indicates voltage at the power module, a first range of values of the fault signal value indicates an energy storage device fault, a second range of values of the fault signal value indicates a local power source fault, and a third range of values of the fault signal value indicates a no-fault state.

6. The wireless field device assembly of claim 1, wherein the power module is configured to provide 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.

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

8. The wireless field device assembly of claim 1, wherein the energy storage device is removably attached to the power module.

9. The wireless field device assembly of claim 1, wherein the connection to a local power source is configured to receive energy from an energy harvesting device.

10. The wireless field device assembly of claim 9, wherein the receptacle is configured to fit the energy harvesting device.

11. The wireless field device assembly of claim 1, wherein the connection to a local power source includes a wired connection through a conduit in the housing or the cover to an external device located outside of the interior space and the receptacle.

12. The wireless field device assembly of claim 1, wherein the power module includes a power conditioner which conditions power from at least one of the energy storage device and the local power source.

13. The wireless field device assembly of claim 12, 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.

20. The method of claim 1, wherein the power module further comprises a power conditioner.

21. The method of claim 20, 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 connection.

14. A method for providing and monitoring power for a wireless field device, the method comprising:

connecting a power module so as to provide power to the wireless field device, the power module comprising an energy storage device and a local power source connection;

powering the wireless field device primarily using power from the local power source connection;

powering the wireless field device supplementally using power from the energy storage device, when power from the local power source is unavailable or insufficient to power the wireless field device;

setting a fault signal value of a process signal based on voltage supplied by the power module;

reporting a fault with the local power source if the fault signal value falls within a first range; and

reporting a fault with the energy storage device if the fault signal value falls within a second range.

15. The method of claim 14, wherein the power module is a removable module configured to fit within an enclosed receptacle of the wireless field device.

16. The method of claim 14, further comprising transmitting the fault signal value to a control or monitoring system, and wherein faults with the local power source and the energy storage device are reported by the control or monitoring system.

17. The method of claim 14, further comprising transmitting an energy storage device failure alert if the fault signal value falls within the second range.

18. The method of claim 14, further comprising transmitting a local power source failure alert if the signal value falls within the first range.

19. The method of claim 18, further comprising ascertaining whether intermittent loss of the local power source is expected, and sending a local power source failure alert if the fault signal value falls within the first range and intermittent loss of the local power source is not expected.

22. The method of claim 14, wherein setting the fault signal value comprises setting the fault signal value to a value determined by comparing voltage at the power module with a series of thresholds, such that higher fault signal value corresponds to higher voltage.

23. A wireless field device assembly comprising:

a process sensor configured to monitor a process variable;

a housing enclosing an interior space;

a cover defining a receptacle between the housing and the cover;

a power module configured to fit removably inside the receptacle and power at least a subset of the wireless device assembly;

an energy storage device inside or affixed to the power module, and located within the receptacle;

a local power source electrically connected to the power module;

a processor located within the interior space and configured to produce;

a process variable signal reflecting the process variable monitored by the industrial process sensor; and

a fault signal value that distinguishes between energy storage device faults, local power source faults, and no-fault states based on voltage at the power module.

24. The wireless field device assembly of claim 23, wherein the energy storage device is a battery.

25. The wireless field device assembly of claim 23, wherein the energy storage device is a supercapacitor.

26. The wireless field device assembly of claim 23, wherein the local power source is a utility grid connection.

27. The wireless field device assembly of claim 23, wherein the local power source is an energy harvesting device.

28. The wireless field device assembly of claim 27, wherein the energy harvesting device is configured to fit inside the receptacle with the power module.

29. The wireless field device assembly of claim 27, wherein the energy harvesting devices is a thermoelectric scavenger.

30. The wireless field device assembly of claim 27, wherein the energy harvesting devices is a vibrational scavenger.

31. The wireless field device assembly of claim 27, wherein the energy harvesting devices is a solar panel.

32. The wireless field device assembly of claim 23, wherein the local power source is electrically connected to the power module via a wired connection passing through a conduit in the housing or the cover.

33. The wireless field device assembly of claim 23, wherein the fault signal value indicates voltage at the power module, a first range of values of the fault signal value indicates an energy storage device fault, a second range of values of the fault signal value indicates a local power source fault, and a third range of values of the fault signal value indicates a no-fault state.