Wireless power and communication unit for process field devices

• US 8,538,560 B2
• Filed: 05/21/2004
• Issued: 09/17/2013
• Est. Priority Date: 04/29/2004
• Status: Active Grant

• Current Assignee: Rosemount Incorporated (Emerson Electric Company)
• Original Assignee: Rosemount Incorporated (Emerson Electric Company)
• Inventors: Brown, Gregory, Hausler, George, Ostby, Philip, Karschnia, Robert, Nelson, Richard, Fandrey, Mark
• Primary Examiner(s): Padmanabhan, Kavita
• Assistant Examiner(s): DUNN, DARRIN D
• Application Number:
  US10/850,828
• Publication Number:
  US 20050245291A1
• Time in Patent Office: 3,406 Days
• Field of Search: 700/19, 700/17, 700/83, 700/20, 700/22, 713/320, 713/330, 455/76.11, 455/343.1, 455/574, 455/67.11
• US Class Current: 700/22
• CPC Class Codes: G05B 19/4185 characterised by the network communication
• CPC Class Codes: G05B 2219/23316 Standby, inactive, sleep or active, operation mode
• CPC Class Codes: G05B 2219/25289 Energy saving, brown out, standby, sleep, powerdown modus for microcomputer
• CPC Class Codes: G05B 2219/33192 Radio link, wireless
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A wireless power and communication unit for field devices is configured to connect to a field device and provide operating power and wired digital communication between the unit and the field device. RF circuitry in the unit is configured for radio frequency communication. In one embodiment, power supply circuitry in the unit includes one or more solar power cells that convert solar energy into electricity to power both the unit and the field device. The unit interacts with the field device in accordance with a standard industry communication protocol. The unit communicates wirelessly with an external device, such as a control room, based upon the interaction with the field device.

Claims

1. A process communication system comprising:

a process variable generator coupleable to the process, the process variable generator being operably coupled to a transducer and having communication circuitry for communication over a process control loop and receiving electrical power from the process control loop to power the process variable generator;

a wireless power and communication unit for providing wireless operation to the process variable generator, the unit including;

a housing;

an attachment region coupling the housing to the process variable generator through a standard field device conduit;

a power storage device disposed within the housing and configured to power the process variable generator;

a loop communicator connected to the process variable generator via the attachment region and configured to interact with the process variable generator via the communication circuitry;

a controller coupled to the power storage device and loop communicator, the controller being configured to interact with the process variable generator using the loop communicator and configured to actively manage power for the wireless power and communication unit and the process variable generator;

a wireless communication module coupled to the controller and being configured for wireless communication based upon interaction with the process variable generator; and

a local user interface;

wherein the power management includes causing the process variable generator to enter a sleep mode; and

wherein the power management includes causing at least a portion of the wireless power and communication unit to enter a sleep mode.

2. The system of claim 1, wherein the power storage device is a battery.

3. The system of claim 1, and further comprising a energy converter coupled to the controller and being adapted to convert a source of environmental potential energy into electricity.

4. The system of claim 3, wherein the energy converter includes at least one photo-voltaic cell.

5. The system of claim 4, wherein the at least one photo-voltaic cell seals a portion of the housing.

6. The system of claim 3, wherein the controller is adapted to recharge the power storage device with electricity from the energy converter.

7. The system of claim 3, and further comprising a temperature sensor operably coupled to the controller and disposed to sense a temperature of the energy storage device, and wherein the controller selectively charges the energy storage device based at least in part upon a signal from the temperature sensor.

8. The system of claim 7, wherein the temperature sensor is operably coupled to the controller through an analog-to-digital converter.

9. The system of claim 1, wherein the conduit has a size selected from the group consisting of a 3/8-18 NPT, a 1/2-14 NPT, a M20x1.5, and a G1/2.

10. The system of claim 1, wherein the attachment region includes at least one degree of freedom.

11. The system of claim 1, wherein the attachment region allows the housing to be rotatable about a first axis.

12. The system of claim 11, wherein the attachment region allows the housing to the rotatable about a second axis that is substantially orthogonal to the first axis.

13. The system claim 1, and further comprising a photo-voltaic cell disposed near a top surface of the housing at an angle of approximately 30 degrees with respect a bottom surface of the housing.

14. The system of claim 1, wherein the local user interface includes a button.

15. The system of claim 14, wherein the button is user configurable.

16. The system of claim 14, wherein the button is disposed proximate the attachment region.

17. The system of claim 1, wherein the user interface includes a display.

18. The system of claim 17, wherein the display is an LCD display.

19. The system of claim 17, wherein the display is located proximate a top surface of the housing.

20. The system of claim 19, wherein the display is located proximate a photo-voltaic cell.

21. The system of claim 17, wherein the display is mounted proximate the attachment region.

22. The system of claim 21, wherein the display is rotatable about the attachment region.

23. The system of claim 1, wherein the housing is field-hardened.

24. The system of claim 1, and further comprising an additional attachment region, the additional attachment region being configured to couple the wireless power and communication unit to an additional process variable generator and power and communicate with both process variable generators.

25. The system of claim 24, wherein the loop communicator is adapted to communicate digitally with both process variable generators.

26. The system of claim 1, wherein the controller includes a microprocessor.

27. The system of claim 1, wherein the loop communicator is configured to sense a current ranging between 4 and 20 milliamps.

28. The system of claim 1, wherein the loop communicator provides a two-wire connection to the process variable generator, which two wire connection provides power and communication with the process variable generator.

29. The system of claim 1, wherein the power management includes causing the process variable generator to enter a sleep mode.

30. The system claim 1, wherein the controller causes the portion of the wireless power and communication unit to enter a sleep mode based upon user input.

31. The system of claim 1, wherein the power storage device is selected based upon a scale of power required by the process variable generator.