Kai König, Ulf Ahrend, IDTechEx, 2016-04-27
Current and future wireless and
energy autonomous sensing in
industrial applications
Agenda
Wireless Instrumentation and Energy Harvesting in
the Process Industry
Energy Harvesting for Wireless Condition
Monitoring
The Dilemma of Energy Harvesting:
Competing against Primary Batteries
© ABB Group
April 30, 2016 | Slide 3
Agenda
Wireless Instrumentation and Energy Harvesting in
the Process Industry
Energy Harvesting for Wireless Condition
Monitoring
The Dilemma of Energy Harvesting:
Competing against Primary Batteries
© ABB Group
April 30, 2016 | Slide 4
More than just the instruments…
Wireless changes many parts of a control system offering
Wireless I/O and IP networks
Wireless Field Instrumentation
Condition
monitoring
Battery powered
wireless transmitters
Energy harvesting
wireless transmitters
Industrial wireless IP
networks
AC 800M
controller
Gateway
Seamless integration
into
ABB Control systems
Long range wireless
RTU‘s
Extended
operator
workplace
System
800xA
workplace
Project execution and system integration expertise
© ABB Group
April 30, 2016 | Slide 5
www.abb.com/wirelessmeasurement
ABB Wireless I/O and IP Networks
ABB Total Flow: Long range I/Os
ABB‘s WellTel wireless I/O system allows users to connect remote
sensors where cabling prohibitive due to distance and transmit data
back to the RTU over up to 1.5 miles (line of sight)
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© ABB Group
April 30, 2016 | Slide 6
Remote Device I/O points include:
• 4 Digital Input or Outputs
• 4 Analog Inputs
• 1 Analog Outputs
• 2 RTD Inputs
Up to 32 Remote I/O Devices per RTU
Remote I/O visible in RTU as locally connected points
Remote Battery Status Available for alarming
Remote Communications port allows for
communication of data across remote line (such as
connecting ABB XMV)
Remote I/O updates as fast as 1 second
Ability to expand I/O on secondary I/O bus on remote
end
Build on 900MHz frequency
Powering Wireless Process Instruments
Energy Harvesting Wireless Temperature Transmitter
ΔT≈ ± 35°C
conventional wired
temperature
transmitter
© ABB Group
April 30, 2016 | Slide 7
energy harvesting powered
wireless temperature transmitter
and other ABB wireless solutions
proven in chemical plants, food
and beverage factories,
on ships and oil rigs
Powering Wireless Devices
Power Sources for Process Instruments
Challenges
Recent Key Enablers

Mid-power instruments (> 10 mW)

Progress in DC-DC converters

Processes near ambient temp.

Progress in battery research

Supplier & technology risk

Development cost
Consequent Opportunities

Standardization

Photovoltaics with rechargeable
batteries in new applications

Conventional TEGs

New TEG concepts
© ABB Group
April 30, 2016 | Slide 8
Agenda
Wireless Instrumentation and Energy Harvesting in
the Process Industry
Energy Harvesting for Wireless Condition
Monitoring
The Dilemma of Energy Harvesting:
Competing against Primary Batteries
© ABB Group
April 30, 2016 | Slide 9
ABB Wireless Field Instruments
ABB WiMon100: Wireless Vibration Monitor
• Predictive maintenance reduces costs and improves productivity
• Vibration monitoring allows early detection of faults allowing for better
planned maintenance
ABB
WiMon100
© ABB Group
April 30, 2016 | Slide 10
Wireless Devices for Condition Monitoring
Requirements in Condition Monitoring
Failing machines in industry can cause very high costs
BUT
products for industrial use normally are extremely reliable.

False alarms must be far less frequent than real problems

Monitoring system must not be less reliable than monitored system

Service or inspection interval for monitoring system must not be shorter than
that of the machinery being monitored

Monitoring system must be low cost
Justify costs by: preventing downtime / reducing maintenance effort / both

High-cost: small market, only critical equipment

Low-cost: large market, most equipment
© ABB Group
April 30, 2016 | Slide 11
Possible Energy Harvesting Applications
Motor Condition Monitoring
Thermal Gradient
Vibration, Rotation
Photovoltaic
Acoustic/Noise
EM Harvesting
Near Field
Induction
© ABB
April 30, 2016
| Slide 13
Dedicated RF
Transmitter
Environmental
Radiation
Requirements

Avg. Power > 200 µW

Update rate: 1/d to 1/s

Support of multiple sensing
functions

Amb. temp. -40 … 85°C

Retrofit application possible

Ex: at least ATEX zone 2

Ultra low cost
(ideally < 10 € per unit)
Possible Energy Harvesting Applications
Buildings
Building Automation
Dedicated
RF radiation
Natural (window)
+ artificial light

Generally low cost

Potential for high volume

Average precision

Good reliability, long lifetime,
rather low maintenance

Average robustnesses

Update rates depend on
application

Power depends on application
Heat gradient
Magnetic field
from power lines
Kinetic /
Mechanical Energy
© ABB
April 30, 2016
| Slide 15
Powering Wireless Devices
Requirements Comparison
Process Sensors
Industrial Condition
Monitoring
Building Automation
Cost sensitivity
Low
High
Medium - High
Volume
Low
High
High
Precise
Indicate trend
Average
≈ 1/s
≈ 1/h to 1/d
application dependent
> 10 years
maximum reliability
> 5 - 10 years
high reliability
> 5 - 10 years
high reliability
ATEX, SIL, …
usually ATEX
less important
Mech. robustness
Extreme
High
Average
Safety & security
Critical
Important
application dependent
High
Low
application dependent
Accuracy
Update rates
Lifetime, reliability
Certifications
Average power need
© ABB Group
April 30, 2016 | Slide 16
Agenda
Wireless Instrumentation and Energy Harvesting in
the Process Industry
Energy Harvesting for Wireless Condition
Monitoring
The Dilemma of Energy Harvesting:
Competing against Primary Batteries
© ABB Group
April 30, 2016 | Slide 17
Powering Wireless Devices
The Dilemma of Energy Harvesting
Harvesting solution must be better than primary batteries
Where are the niches for harvesting?

© ABB Group
April 30, 2016 | Slide 18
High-power devices: Primary battery is too bulky
•
Harvester must be more endurant at smaller size or lower cost
•
Example: WellTel (w. PV panel & ‘car battery‘), radiothermal generators
Powering Wireless Devices
The Dilemma of Energy Harvesting
Harvesting solution must be better than primary batteries
Where are the niches for harvesting?

© ABB Group
April 30, 2016 | Slide 19
Ultra-low power devices: Battery will last “forever“
•
Harvester must be more compact or cheaper
•
Harvesting system must be as reliable and at least as long-lived as battery
•
Example: Wireless light switches, RFID (sensor) tag
Powering Wireless Devices
The Dilemma of Energy Harvesting
Harvesting solution must be better than primary batteries
Where are the niches for harvesting?

Mid-power devices: Consider total cost of ownership
•
Detailed analysis of application needed
•
High development cost of harvesting system must be offset by significant benefits
•
Example: Wireless Temperature Transmitter
ΔT≈ ± 35°C
© ABB Group
April 30, 2016 | Slide 20
www.abb.com/wirelessmeasurement