3 Introduction Vibration Energy Harvesting for Wireless Automation Topics to be Covered:Construction, Operation, Performance, UsageWhy use an Energy HarvesterMarket Segments and ApplicationsMaintenance Logistics and Costs of “Battery Only” SolutionsVibration Energy Harvesters & Emerson Wireless TransmittersTransmitter Performance With and Without Energy HarvestersSite Walk Down & InstallationCurrent Field TrialsTopics 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.
4 The Evolution of Power for Wireless Monitoring and Automation Vibration Energy HarvestingThe Evolution of Power for Wireless Monitoring and AutomationVibration Energy Harvesters convert vibration to electrical energy providing perpetual power for Industrial Wireless Sensor Nodes (WSN)
5 VEH Construction & Operation Electromagnetic VEH Construction:Magnets, Coils & SpringsPower managementTemperature compensationVibration moves magnet across a fixed coil.AC current is generated according to Faraday's Law.AC current rectified to DC output.MAGNETCOILSPRINGVIBRATIONCASE
7 Core Product Description Vibration Energy HarvesterElectromagnetic – Coils & MagnetsIndustrially robust & reliableHazardous Area CertifiedFull Temp. Compensation -40C to +85CWith or W/O internal energy storage
8 Detailed Product Description 20mW max Power output4mA max current output~ .3mA output with 0.025g vibration levelCurrent drive independent of load voltage316L stainless steel, hermetically sealed caseATEX, IECEx, FM, CFM certified. Class1 Div1.-40C to +85C Temperature OperationStandard IEC connector interface
9 Why Use a Vibration Harvester? Battery (D Cell)Vibration Energy HarvesterLife Cycle~4 yearsIndefiniteStart of Life Uncertainty1-3 yearsNoneMaintenanceDifficult to PredictNone NeededCalculations based on:* Single Lithium Thionyl Chloride Cell battery with 19,000 mA-hour capacity.* 7.2V Average Transmitter Power Draw.
11 Cost of Changing Batteries Cost of Changing Power Moduales for Deployed WSN's:Battery(Time): Identify & locate30(Time): Paperwork & Logistics(Time): Pull repair stock items15(Time): Traveling to & locating, devices(Time): Change time per Power Module5(Time): Number of Power Modules to change1(Time): Added travel time for multiple WSNs (5 mins/ea)(Time): Power Module Change time - Total(Time): Return & Verify operation40(Time): Disposal of old batteries(Time): Total Time in minutes165(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$68.75Total Costs$553.75Simple Case
12 Wireless Sensors Networks can not scale using batteries alone Cost of ScaleWireless Sensors Networks can not scale using batteries aloneBattery OnlyVEH Augmented Power
13 Staggered Battery Life Disruption At $500- $1000+ Per Battery Change!
14 Battery Only Powered Transmitter Transmit DataControl PanelProcessingCostly, Disruptive and UnnecessaryMaintenance Logistics AheadWireless TransmitterBattery PowerMeasurement
15 VEH Assisted Transmitter Control PanelFit & Forget
16 Harvester Enabled Power Module Intelligent Power ManagementKey features:Same form factor and capability as current Emerson Smart Power ModuleFlexibility to add harvester benefits anytimeHarvester Power Module provides same capability as current Emerson Smart Power Module but does not need to be changed
24 End-User Field Trials – Dan Crainer & Oxea 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.BenefitsAlternate power options vs. batteries onlyFaster update rates while minimizing/eliminating battery changesReduced overall maintenance logistics & costs
26 Sherri Law Senior Instrument & Electrical Engineer - Oxea 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
28 End-User Field Trials – Tim Bonnin & Firestone Polymer Senior Instrument Representative; Beaumont, TXFirestone Polymer operations:Firestone Polymers supplies synthetic rubber, thermoplastic elastomers and impact modifiers to rubber, plastics, adhesive and asphalt markets around the worldEmerson Wireless at Firestone PolymerFirestone 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 solutionsVibration Energy Harvester – Value PropositionThe 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
30 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
31 Key Points Business Case: Maintenance: Impact on Battery Life: Overloaded and diminishing available skilled resourcesBatteries present disruptive & unnecessary maintenance logisticsVEH can minimize or eliminate disruptive logisticsImpact on Battery Life:Emerson 3051S: (Wireless Transmitter with Greatest Power Profile)Battery changes 4 sec Update Rate for life of equipmentBattery life increased from 1 to sec Update RateBusiness Case:Close to pay back on 1st avoided battery change (on easy assets)Pay back on 1st avoided change on more difficult assets
32 VEH connected to multi-meter InstallationSimple Site Walk Down LogisticsUse 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-meterPower Puck
33 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.
34 Summary Unplanned maintenance is disruptive and costly Unnecessary maintenance is just bad businessEnergy Harvester Payback ~ Cost of One Battery ChangeHow many Batteries are you planning to change?
35 Perpetual Power Solutions for Wireless Monitoring & Automation Vibration Energy HarvestingPerpetual Power Solutions for Wireless Monitoring & AutomationWho’s Harvesting Your Success?