Industrial process power scavenging device and method of deriving process device power from an industrial process

• US 7,977,924 B2
• Filed: 11/03/2008
• Issued: 07/12/2011
• Est. Priority Date: 11/03/2008
• Status: Active Grant

• Current Assignee: Rosemount Incorporated (Emerson Electric Company)
• Original Assignee: Rosemount Incorporated (Emerson Electric Company)
• Inventors: Lu, Liang-Ju, Hedtke, Robert C., Broden, David A.
• Primary Examiner(s): Patel; Harshad
• Application Number:
  US12/263,625
• Publication Number:
  US 20100109331A1
• Time in Patent Office: 981 Days
• Field of Search: None
• US Class Current: 322/3
• CPC Class Codes: G01F 1/3218 bluff body design
• CPC Class Codes: G01F 1/3266 by sensing mechanical vibrations
• CPC Class Codes: G05B 23/0256 injecting test signals and analyzing monitored process response, e.g. injecting the test signal while interrupting the normal operation of the monitored system; superimposing the test signal onto a control signal during normal operation of the monitored system

Abstract

In a particular embodiment, a process device includes a fluid disruption generation element to generate a fluid disruption within process fluid flowing through a pipe associated with an industrial process and a process variable sensor coupled to the disruption generation element to measure a process parameter. The process device further includes a power generation element adapted to generate an electrical output signal in response to the fluid disruption and a power storage component coupled to the power generation element. The power storage component is adapted to accumulate a charge based on the electrical output signal.

Claims

1. A process device comprising:

a fluid disruption generation element to generate a fluid disruption within process fluid flowing through a pipe associated with an industrial process;

a process variable sensor coupled to the fluid disruption generation element to measure a process parameter;

a power generation element generating an electrical output signal in response to the fluid disruption; and

a power storage component coupled to the power generation element, the power storage component accumulating a charge from the electrical output signal, the power storage element used to power circuitry of the process device with power from the fluid disruption.

2. The process device of claim 1, further comprising a display interface coupled to the power storage component, the display interface using the accumulated charge from the power storage component for operation.

3. The process device of claim 1, wherein the power generation element comprises a piezoelectric element configured to flex in response to the fluid disruption to generate the electrical output signal.

4. The process device of claim 1, wherein the power generation element comprises a turbine turning in response to the fluid disruption to generate the electrical output signal.

5. The process device of claim 1, wherein the power generation element comprises an electrically conductive coil and a magnet, wherein the magnet and the electrically conductive coil are moving relative to one another in response to the fluid disruption to generate the electrical output signal within the electrically conductive coil.

6. The process device of claim 5, wherein the power generation element is coupled to the fluid disruption generation element via an attachment arm.

7. The process device of claim 1, wherein the power generation element comprises:

an isolating diaphragm deforming in response to the fluid disruption;

a fixed conductive coil proximate to the isolating diaphragm; and

a magnet coupled to the isolating diaphragm and moving relative to the fixed conductive coil in response to deformation of the isolating diaphragm to induce the electrical output signal in the fixed conductive coil.

8. A process device for use in a control or monitoring system associated with an industrial process, the process device comprising:

a transmitter housing coupled to a pipe carrying a process fluid that is associated with an industrial process;

a process variable sensor measuring a process variable associated with the process fluid;

a transducer coupled to the process fluid, the transducer generating an electrical output from the process fluid flowing within the pipe;

a power storage component coupled to the transducer and storing a charge from the electrical output, and thereby store power generated from the process fluid; and

circuitry coupled to the power storage component and to the process variable sensor, the circuitry adapted to receive a power supply from the power storage component and to provide an output signal related to the process variable.

9. The process device of claim 8, further comprising a fluid disruption generating element causing fluid disruption within the process fluid.

10. The process device of claim 9, wherein the disruption generating element comprises one of a Venturi tube, an annubar, a fluid vortex shedding bar, and an orifice plate.

11. The process device of claim 9, wherein the transducer comprises a piezoelectric transducer producing the electrical output in response to the fluid disruption.

12. The process device of claim 9, wherein the transducer is attached to the disruption generating element.

13. The process device of claim 9, wherein the disruption generating element includes an opening to receive the process fluid, and wherein the transducer is disposed within the disruption-generating element and is receiving the process fluid via the opening.

14. The process device of claim 8, further comprising a differential pressure generating element, wherein the transducer is positioned downstream from the differential pressure generating element within the pipe.

15. The process device of claim 8, wherein the transducer comprises a fluid turbine extending into the pipe, the fluid turbine turning in response to the process fluid to produce the electrical output.

16. The process device of claim 8, further comprising a transceiver transmitting data related to the output signal to a control center via a wireless communication path, the transceiver adapted to receive operating power from the power storage element.

17. The process device of claim 8, wherein the transducer comprises an electrically conductive coil and a magnet, wherein the magnet and the electrically conductive coil are moving relative to one another in response to the fluid disruption to generate the electrical output signal within the electrically conductive coil.

18. The process device of claim 8, wherein the transducer comprises:

an isolating diaphragm deforming in response to the fluid disruption;

a fixed conductive coil; and

a magnet coupled to the isolating diaphragm and moving relative to the fixed conductive coil in response to deformation of the isolating diaphragm, wherein relative movement of the magnet induces the electrical output in the fixed conductive coil.

19. A method of deriving process device power for a process variable transmitter from an industrial process, the method comprising:

receiving vibrations related to fluid flow at a transducer of a field device that is coupled to a process fluid within a pipe associated with an industrial process;

sensing a process variable based upon the received vibrations;

transforming the vibrations into an electrical current via the transducer;

accumulating a charge at a power storage element based on the electrical current;

sensing a process variable at a process variable sensor associated with the field device; and

transmitting data related to the process variable to a control system using a transceiver circuit;

powering circuitry of the process device with power generated from the received vibrations accumulated in the power storage element.

20. The method of claim 19, further comprising generating a fluid disruption within the process fluid using a fluid disruption element positioned upstream from the transducer.

21. The method of claim 19, further comprising providing power from the power storage element to a display interface of the field device to display data related to the sensed process variable.

22. The method of claim 19, wherein the process variable sensor and the transceiver circuit are powered from the power storage element.

23. The method of claim 19, wherein the transducer comprises a piezoelectric component flexing in response to the fluid pressure to produce the electrical current.

24. The method of claim 19, wherein the transducer comprises a turbine rotating in response to the fluid pressure, the turbine to generate the electrical current.

25. The method of claim 24, wherein the field device comprises a vortex flow meter including an opening, and wherein the turbine is positioned within the vortex flow meter and receiving the process fluid via the opening.

26. The method of claim 19, wherein the transducer comprises:

a fixed conductive coil; and

a movable magnet moving relative to the fixed conductive coil in response to the fluid pressure to induce the electrical current to flow through the fixed conductive coil.

27. The method of claim 26, wherein the transducer further comprises:

an isolating diaphragm coupled to the process fluid, the isolating diaphragm moving in response to the fluid pressure to alter a location of the movable magnet; and

an adjustable spring coupled to the movable magnet and causing the movable magnet to reciprocate along an axis of the fixed conductive coil.