Applying wireless sensor networks in industrial plant energy management systems. Part II. Design of sensor devices

Energy evaluation and planning are important in industry for overall energy savings. Traditionally these functions are realized only for large size motors (over 500 hp) in wired systems formed by communication cables and various types of sensors. However, the installation and maintenance of these cables and sensors are usually much more expensive than the cost of the sensors themselves. Unique sensor-rich and low-cost characteristics make wireless sensor networks (WSN) the ideal structure for the low cost energy management systems. As an extension of the authors' previous work wherein a WSN is applied as the architecture of an industrial plant energy management system, this paper presents an in-depth discussion on the design and implementation of the wireless sensor devices in such applications. Various practical design considerations in both hardware and software aspects are addressed. The challenges and advantages of the proposed system are analyzed, and future real-time implementation approach is suggested. Finally, the prototype wireless sensor devices are demonstrated and experimental results are given.