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Keith J. Abate Sr. – Perpetuum Director of Business Development

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

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Keith J. Abate Sr. – Perpetuum Director of Business Development

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  1. Vibration Energy Harvesting: Perpetual Power for Emerson Wireless Transmitters Keith J. Abate Sr. – Perpetuum Director of Business Development Session: 12-2158

  2. Presenters • Keith Abate • Dan Crainer • Tim Bonnin

  3. 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.

  4. Vibration Energy Harvesting The Evolution of Power for Wireless Monitoring and Automation Vibration Energy Harvesters convert vibration to electrical energyproviding perpetual power for Industrial Wireless Sensor Nodes (WSN)

  5. 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. CASE SPRING MAGNET COIL SPRING VIBRATION

  6. Robust and Reliable

  7. Core Product Description Vibration Energy Harvester • Electromagnetic – Coils & Magnets • Industrially robust & reliable • Hazardous Area Certified • Full Temp. Compensation -40C to +85C • With or W/O internal energy storage

  8. 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

  9. Why Use a Vibration Harvester? Calculations based on: * Single Lithium Thionyl Chloride Cell battery with 19,000 mA-hour capacity. * 0.5mA @ 7.2V Average Transmitter Power Draw.

  10. 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

  11. Cost of Changing Batteries Simple Case

  12. Cost of Scale Wireless Sensors Networks can not scale using batteries alone Battery Only VEH Augmented Power

  13. Staggered Battery Life Disruption At $500-$1000+Per Battery Change!

  14. Battery Only Powered Transmitter Transmit Data Control Panel Processing Wireless Transmitter Battery Power Measurement Costly, Disruptive and Unnecessary Maintenance LogisticsAhead

  15. VEH Assisted Transmitter Control Panel Fit & Forget

  16. 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

  17. Interface to Wireless Transmitter 3 5 1 4 2

  18. Battery Life – No Harvester Battery Life Reduces Rapidly as Update Rate Increases

  19. Impact of Using Harvesters 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

  20. Business Case per Node (4 sec) Saving of $1870over 10 years(per node)

  21. Business Case per Node (2 sec) Saving of $2870over 10 years(per node)

  22. Perpetual Power for Wireless

  23. End-User Field Trials - Oxea

  24. 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

  25. Pictures and Field Trial Overview

  26. 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 LawSenior Instrument & Electrical Engineer - Oxea

  27. End-User Field Trials - Firestone

  28. 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

  29. Pictures and Field Trial Overview

  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”. • “Thecost 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 JulianSenior Instrument & Electrical Engineer - Firestone Polymer

  31. 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) • Battery changes eliminated @ 4 sec Update Rate for life of equipment • Battery life increased from 1 to 3.5 years @ 2 sec Update Rate • Business Case: • Close to pay back on 1st avoided battery change (on easy assets) • Pay back on 1st avoided change on more difficult assets

  32. 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. Power Puck VEH connected to multi-meter

  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 business • Energy Harvester Payback ~ Cost of One Battery Change • How many Batteries are you planning to change?

  35. Vibration Energy Harvesting Perpetual Power Solutions forWireless Monitoring & Automation Who’s Harvesting Your Success?

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