keith j. abate sr. – perpetuum director of business development
DESCRIPTION
Vibration Energy Harvesting: Perpetual Power for Emerson Wireless Transmitters. Keith J. Abate Sr. – Perpetuum Director of Business Development. Session: 12-2158. Presenters. Keith Abate Dan Crainer Tim Bonnin. Introduction. Vibration Energy Harvesting for Wireless Automation - PowerPoint PPT PresentationTRANSCRIPT
Presentation Title
Speaker name and title
Keith J. Abate Sr. – Perpetuum Director of
Business Development
Vibration Energy Harvesting:
Perpetual Power for
Emerson Wireless Transmitters
Session: 12-2158
Presenters
Keith Abate
Dan Crainer
Tim Bonnin
Introduction Vibration Energy Harvesting for Wireless Automation Topics to be Covered:
– Construction, Operation, Performance, Usage – Why use an Energy Harvester– Market Segments and Applications– Maintenance Logistics and Costs of “Battery Only” Solutions– Vibration Energy Harvesters & Emerson Wireless Transmitters– Transmitter Performance With and Without Energy Harvesters– Site Walk Down & Installation– Current Field Trials
Topics presented will provide an understanding of the issues and costs associated with “battery only” powered wireless transmitters and how Vibration Energy Harvesters can eliminate or minimize these barriers.
The Evolution of Power for
Wireless Monitoring and Automation
Vibration Energy Harvesters convert vibration to electrical energy
providing perpetual power for Industrial Wireless Sensor Nodes (WSN)
Vibration Energy Harvesting
VEH Construction & Operation
Electromagnetic VEH Construction: Magnets, Coils & Springs Power management Temperature compensation
Vibration moves magnet across a fixed coil.
AC current is generated accordingto Faraday's Law.
AC current rectified to DC output.
MAGNET
COIL
SPRING
SPRING
VIBRATION
CASE
Robust and Reliable
Core Product Description
• Electromagnetic – Coils & Magnets
• Industrially robust & reliable
• Hazardous Area Certified
• Full Temp. Compensation -40C to +85C
• With or W/O internal energy storage
Vibration Energy Harvester
Detailed Product Description
• 20mW max Power output
• 4mA max current output
• ~ .3mA output with 0.025g vibration level
• Current drive independent of load voltage
• 316L stainless steel, hermetically sealed case
• ATEX, IECEx, FM, CFM certified. Class1 Div1.
• -40C to +85C Temperature Operation
•Standard IEC connector interface
Why Use a Vibration Harvester?
Battery (D Cell) Vibration Energy Harvester
Life Cycle ~4 years Indefinite
Start of Life Uncertainty 1-3 years None
Maintenance Difficult to Predict None Needed
Calculations based on:
* Single Lithium Thionyl Chloride Cell battery with 19,000 mA-hour capacity.
* 0.5mA @ 7.2V Average Transmitter Power Draw.
Market Segments & Applications
Industrial
• Oil & Gas
• Power Generation
• Chemicals
• Paper & Pulp
• Water / Waste water
• Process Monitoring
• Equipment Health
Transportation
• Rail
• Wheel bearing monitoring
• Cargo
• Security
• HazMat
Cost of Changing Batteries
Simple Case
Cost of Changing Power Moduales for Deployed WSN's: Battery
(Time): Identify & locate 30
(Time): Paperwork & Logistics 30
(Time): Pull repair stock items 15
(Time): Traveling to & locating, devices 30
(Time): Change time per Power Module 5
(Time): Number of Power Modules to change 1
(Time): Added travel time for multiple WSNs (5 mins/ea) 0
(Time): Power Module Change time - Total 5
(Time): Return & Verify operation 40
(Time): Disposal of old batteries 15
(Time): Total Time in minutes 165
(Cost): Burdened hourly labor rate $100
(Cost): Hourly Rate Cost $275.00
(Cost): Consumables / Other costs $15.00
(Cost): Replacements $150.00
(Cost): Inventory cost of spares $45.00
(Cost): Lost Labor Productivity $68.75
Total Costs $553.75
Cost of Scale
Wireless Sensors Networks can not scale using batteries alone
Battery Only
VEH Augmented Power
Staggered Battery Life Disruption
At
$500-
$1000+
Per
Battery
Change!
Battery Only Powered Transmitter
Wireless Transmitter
Measurement
Processing
Transmit Data
Control Panel
Battery Power
Costly, Disruptive
and Unnecessary
Maintenance Logistics
Ahead
VEH Assisted Transmitter
Fit & Forget
Control Panel
Harvester Enabled Power Module
Intelligent Power Management
Key features:
Same form factor and capability as current Emerson Smart
Power Module
Flexibility to add harvester benefits anytime
Harvester Power Module provides same capability as current
Emerson Smart Power Module but does not need to be changed
Interface to Wireless Transmitter
1
2
3
4
5
Battery Life – No Harvester
0
2
4
6
8
10
12
0 4 8 12 16 20 24 28 32
Batt
ery
Life
(Yea
rs)
Update Rate (Secs)
Battery Only
Battery Life Reduces Rapidly as Update Rate Increases
Impact of Using Harvesters
0
2
4
6
8
10
12
0 4 8 12 16 20 24 28 32
Batt
ery
Life
(Yea
rs)
Update Rate (Secs)
Battery Only With Harvester
No battery changes needed
for 4 sec Update Rates
Battery life increases from 1 to
3.5 years @ 2 sec Update Rates
Dramatic Improvements using Energy Harvesters
Business Case per Node (4 sec)
0
500
1000
1500
2000
2500
3000
0.00 2.00 4.00 6.00 8.00 10.00
Cost
($)
Time(Years)
4 sec Update Rate
Battery Only
With Harvester
Saving of $1870
over 10 years
(per node)
Business Case per Node (2 sec)
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
0.00 2.00 4.00 6.00 8.00 10.00
Cost
($)
Time (Years)
2 Sec Update Rate
Battery Only
With Harvester
Saving of $2870
over 10 years
(per node)
Perpetual Power for Wireless
End-User Field Trials - Oxea
End-User Field Trials – Dan Crainer & Oxea
Dan Crainer– Puffer-Sweiven account manager for Fisher Controls
products at Oxea, Bay City Location.
– Oxea operations:
Oxea Chemicals, Bay City Site is the largest production facility in North America. The site produces wide range of Oxo intermediates and derivative products.
– Emerson Wireless at Oxea:
Oxea has installed Emerson Wireless products in one production unit and has several additional projects in different stages of execution.
– Vibration Energy Harvester – Value Proposition:
The “Vibration Energy Harvester” allows for use of wireless field instruments with lower cost power supply than standard Emerson power module.
– Benefits– Alternate power options vs. batteries only– Faster update rates while minimizing/eliminating battery changes– Reduced overall maintenance logistics & costs
Pictures and Field Trial Overview
Oxea Quotes:
“Vibration Energy Harvesting offers Oxea a cost effective way to utilize the fastest
update rates available on any wireless instrument we choose without the costs
and maintenance logistics of frequent battery replacements. This is an obvious
aid in process optimization and we see it as the next step towards wireless control”.
“Low maintenance costs are critical to the operations of a small facility with limited resources.
Vibration Energy Harvesting is seen as a means to reduce maintenance costs due to fewer battery
replacements, reduction in stock and lower battery disposal costs. These benefits will also
increase as we consider new uses for wireless devices in more remote plant locations”.
Sherri Law
Senior Instrument & Electrical Engineer - Oxea
End-User Field Trials - Firestone
End-User Field Trials – Tim Bonnin & Firestone Polymer
Tim Bonnin– Senior Instrument Representative; Beaumont, TX
Firestone Polymer operations:
Firestone Polymers supplies synthetic rubber, thermoplastic elastomers and impact modifiers to rubber, plastics, adhesive and asphalt markets around the world
Emerson Wireless at Firestone Polymer
Firestone was an early adapter of Wireless HART. They have employed WiHart devices throughout the plant and continue to look to wireless instruments as reliable and inexpensive monitoring solutions
Vibration Energy Harvester – Value Proposition
The Vibration Energy Harvesters have performed exactly as advertised. The Harvesters has been a welcomed addition to the wireless network that is established at Firestone and gives greater confidence that signal loss due to power interruption will not be a problem. Faster update rates while minimizing/eliminating battery changes is a huge positive for Firestone. The use of the Vibration Energy Harvester should result in reduced overall maintenance logistics and costs
Pictures and Field Trial Overview
Firestone Polymer Quotes: “Firestone Polymers has benefited from being one of the facilities chosen to
host the beta testing of Perpetuum Vibration Energy Harvesters”.
“We have learned that the concept is useful in more ways than one”.
– “The cost savings that are realized by eliminating the continued
purchase and replacement of batteries for wireless instruments”.
– “Harvesting technology can lead to an even greater reduction in cost for the prioritized wireless instruments in our facility. These instruments require the fastest update rates”.
– “Fast update rates drastically reduce battery life, it would be prudent to target these wireless instruments as a first justification toward putting this technology to work for our benefit”.
Christopher Julian
Senior Instrument & Electrical Engineer - Firestone Polymer
Key Points
Maintenance:
Overloaded and diminishing available skilled resources
Batteries present disruptive & unnecessary maintenance logistics
VEH can minimize or eliminate disruptive logistics
Impact on Battery Life:
Emerson 3051S: (Wireless Transmitter with Greatest Power Profile)
oBattery changes eliminated @ 4 sec Update Rate for life of equipment
oBattery life increased from 1 to 3.5 years @ 2 sec Update Rate
Business Case:
Close to pay back on 1
st avoided battery change (on easy assets)
Pay back on 1
st avoided change on more difficult assets
Installation
Simple Site Walk Down Logistics
Use Power Puck to determine optimal VEH Frequency Unit.
Measure the current with a multi-meter to verify the
exact current that will be supplied to transmitter when
connected to VEH.
VEH connected to multi-meter Power Puck
Installation Overview Find suitable asset to harvest from. (Power Puck)
Attach VEH to Transmitter Power Module.
Install wireless transmitter.
Power transmitter - connect to gateway & network.
Collect & Transmit PV’s / QV’s at up to maximum data rates.
Eliminate/Minimize battery change maintenance logistics >10 yrs.
Summary
Unplanned maintenance is disruptive and costly
Unnecessary maintenance is just bad business
Energy Harvester Payback ~ Cost of One Battery Change
How many Batteries are you planning to change?
Perpetual Power Solutions for
Wireless Monitoring & Automation
Who’s Harvesting Your Success?
Vibration Energy Harvesting