U.S. patent application number 12/367584 was filed with the patent office on 2010-08-12 for wireless particle collection system.
Invention is credited to Daniele C. Brotto, Andrew Robbins, Andrew E. Seman, JR..
Application Number | 20100199453 12/367584 |
Document ID | / |
Family ID | 42539146 |
Filed Date | 2010-08-12 |
United States Patent
Application |
20100199453 |
Kind Code |
A1 |
Brotto; Daniele C. ; et
al. |
August 12, 2010 |
WIRELESS PARTICLE COLLECTION SYSTEM
Abstract
A wireless particle collection system includes a dust collector
and at least one power tool coupled to the dust collector. The
power tool is associated with a unique identifier contained in a
wireless signal transmitted from the power tool upon an activation
event of the tool. The unique identifier is recognized by the dust
collector, and the dust collector activates or de-activates upon
receipt of the wireless signal.
Inventors: |
Brotto; Daniele C.;
(Baltimore, MD) ; Robbins; Andrew; (Newark,
DE) ; Seman, JR.; Andrew E.; (White Marsh,
MD) |
Correspondence
Address: |
CHARTER IP, LLC
P.O. BOX 64
The Plains
VA
20198
US
|
Family ID: |
42539146 |
Appl. No.: |
12/367584 |
Filed: |
February 9, 2009 |
Current U.S.
Class: |
15/301 |
Current CPC
Class: |
A47L 9/2894 20130101;
A47L 7/0047 20130101; B08B 15/002 20130101; B23D 59/006 20130101;
B23Q 11/0046 20130101; A47L 7/0095 20130101; A47L 9/2878 20130101;
B01D 46/42 20130101; A47L 9/2889 20130101; A47L 9/2857
20130101 |
Class at
Publication: |
15/301 |
International
Class: |
A47L 5/38 20060101
A47L005/38 |
Claims
1. A wireless particle collection system, comprising: a dust
collector, and at least one power tool coupled to the dust
collector, the at least one power tool having a unique identifier
and configured to transmit a wireless signal upon sensing a tool
state change event, the wireless signal including the unique
identifier, the dust collector configured to change state upon
receipt of a wireless signal including a recognized unique
identifier.
2. The system of claim 1, further comprising a tool transmitter for
transmitting the wireless signal with the unique identifier based
on a sensed current in the power tool.
3. The system of claim 2, wherein the tool transmitter is connected
between an AC power source and the power tool.
4. The system of claim 2, wherein the tool transmitter is
integrated within microelectronics of the power tool.
5. The system of claim 2, wherein the tool transmitter is a
hand-held remote device independent of the power tool and dust
collector.
6. The system of claim 1, wherein the dust collector includes a
vacuum receiver for controlling a motor of the dust collector, the
vacuum receiver adapted to recognize the unique identifier in the
transmitted wireless signal to control the motor.
7. The system of claim 6, wherein the wireless signal is an
RF-coded signal with the unique address contained in a header
thereof, the unique address stored or firmware-coded within the
vacuum receiver.
8. The system of claim 1, further comprising a relay device
configured to receive and forward the wireless signal to the dust
collector.
9. The system of claim 1, further comprising: a vacuum conduit
coupled between the dust collector and the power tool for providing
a vacuum pressure to the power tool, a blast gate coupled to the
vacuum conduit for selectively controlling the vacuum pressure to
the power tool, and a blast gate receiver for controlling the blast
gate, the blast gate receiver adapted to actuate the blast gate
based on a wireless signal received in response to the activation
event.
10. The system of claim 9, wherein the wireless signal is an
RF-coded signal with the unique address contained in a header
thereof, and the unique address is further stored or firmware-coded
within the blast gate receiver.
11. The system of claim 9, wherein the transmitted wireless signal
includes a command to open or close the blast gate.
12. The system of claim 9, wherein the transmitted wireless signal
includes a command to the blast gate receiver to transmit a
wireless signal with the address of the unique identifier to the
dust collector.
13. The system of claim 9, wherein the wireless signal is
simultaneously received at the blast gate and dust collector.
14. The system of claim 9, further comprising a relay device
adapted to extend the range of the system and configured to receive
and forward the wireless signal to a receiver or another system
device.
15. A particle collection system, comprising: a plurality of dust
collectors, a plurality of power tools, at least one vacuum conduit
coupled between the dust collectors and the power tools for
providing a vacuum pressure to the power tools, a plurality of
blast gates coupled to the vacuum conduit for selectively
controlling the vacuum pressure to the power tools, wherein each of
the power tools is associated with a given dust collector and blast
gate, each power tool having its own unique identifier recognizable
by its corresponding dust collector and blast gate, and an address
related to the unique identifier and included in a wireless signal
transmitted in response to an activation event of a given power is
received by the tool's corresponding dust collector and blast gate
to activate or deactivate the dust collector and open or close the
blast gate.
16. The system of claim 15, further comprising: a remote control
device configured to communicate with any of the power tool, dust
collector and blast gates to initiate an activation event.
17. The system of claim 15, further comprising: a relay device
configured to communicate with any of the power tool, dust
collector and blast gates extend system range.
18. The system of claim 17, wherein the relay device is powered by
AC mains power.
19. The system of claim 17, wherein the relay device is powered by
at least one of a replaceable, rechargeable, solar-powered and
combination rechargeable and solar-powered battery.
20. The system of claim 15, further comprising: a tool transmitter
for transmitting the wireless signal with unique identifier based
on a sensed current in the power tool. a vacuum receiver for
controlling a motor of the dust collector, the vacuum receiver
adapted to recognize the unique identifier to control the motor,
and a blast gate receiver for controlling the blast gate, the blast
gate receiver adapted to recognize the unique identifier to control
the blast gate.
21. The system of claim 20, wherein the wireless signal is an
RF-coded signal with the unique address contained in a header
thereof, and the unique address is further stored or firmware-coded
within the vacuum receiver and blast gate receiver.
Description
BACKGROUND
[0001] 1. Field of the Invention
[0002] Example embodiments of the present invention generally
relate to a wireless particle collection system, and to a tool
transceiver, vacuum transceiver and blast gate transceiver of the
system.
[0003] 2. Description of Related Art
[0004] Power tools that can create dust during operation are often
coupled to motorized air handling devices to help remove the dust.
The vacuuming process is referred to as dust extraction and the
vacuum device is known as a dust collector. Historically, the dust
collector was manually switched on before the tool operation and
again manually switched off after the tool operation was completed.
This operation was often tedious for the user since there was
always a manual activation/deactivation involved with a distant
dust collector. Alternately, the tool user may leave the dust
extraction unit on continuously creating adverse noise, premature
failure due to wear, and inefficient use of electricity.
[0005] To address these problems, an automated dust collection
system has been developed. This is a wired system electrically
connecting "blast gates" and a vacuum motor to a main controller.
The blast gates serve to selectively isolate or connect ducting
between power tools and a vacuum source.
[0006] In the wired system, each blast gate is associated with a
piezo element sensor that senses the vibration of a given power
tool that is associated with tool turn-on. A signal from the piezo
element that represents "ON" is sent to the main controller. The
main controller in turn sends a power signal over the wiring to
energize a gate motor to open the blast gate in the ducting
connected to the energized power tool, and an electric signal to
power the vacuum motor.
[0007] However, a wired dust collection system has limitations as
to distance and location of the power tools, and has limited
flexibility. For example, additional wiring will be necessary when
adding additional power tools to the wired system.
SUMMARY
[0008] An example embodiment of the present invention is directed
to a wireless particle collection system. The system includes a
dust collector and at least one power tool coupled to the dust
collector. The power tool is associated with a unique identifier
contained in a wireless signal transmitted from the power tool upon
an activation event of the tool. The unique identifier is
recognized by the dust collector, and the dust collector activates
or de-activates upon receipt of the wireless signal.
[0009] Another example embodiment is directed to a particle
collection system. The system includes a plurality of dust
collectors, a plurality of power tools, a vacuum conduit system
coupled between the dust collectors and the power tools for
providing a vacuum pressure to the power tools, and the vacuum
conduit system including a plurality of blast gates for selectively
controlling the vacuum pressure to the power tools. Each of the
power tools is associated with a given dust collector and blast
gate, with each power tool having its own unique identifier
recognizable by its corresponding dust collector and blast gate. An
address related to the unique identifier and included in a wireless
signal is transmitted in response to an activation event of a given
power tool. The signal with the address is received by the tool's
corresponding dust collector and blast gate to activate or
deactivate the dust collector and open or close the blast gate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Example embodiments of the present invention will become
more fully understood from the detailed description given herein
below and the accompanying drawings, wherein like elements are
represented by like reference numerals, which are given by way of
illustration only and thus do not limit the example
embodiments.
[0011] FIG. 1 is a block diagram of a particle collection system
with wireless controls in accordance with an example
embodiment.
[0012] FIG. 2 is a block diagram of the system to illustrate
sensing of tool activation/deactivation and wireless signal
transmission in more detail.
[0013] FIG. 3 is a block diagram of a particle collection system
with wireless controls in accordance with another example
embodiment.
[0014] FIG. 4 is a block diagram of the system of FIG. 3 to
illustrate an alternative wireless transmission path.
[0015] FIG. 5 is a block diagram of a particle collection system
with wireless controls in accordance with another example
embodiment.
[0016] FIG. 6 is a block diagram of a tool transceiver in
accordance with the example embodiments.
[0017] FIG. 7 is a block diagram of a vacuum transceiver in
accordance with the example embodiments.
[0018] FIG. 8 is a block diagram of a blast gate transceiver in
accordance with the example embodiments.
[0019] FIG. 9 is a block diagram of a battery-powered blast gate
transceiver in accordance with the example embodiments.
[0020] FIG. 10 is a block diagram of a remote control device in
accordance with the example embodiments.
[0021] FIG. 11 is a block diagram of a relay device in accordance
with the example embodiments.
[0022] FIG. 12 is a block diagram of a battery-powered relay device
in accordance with the example embodiments.
DETAILED DESCRIPTION
[0023] The example wireless particle collection system described in
more detail hereafter senses power tool operation and remotely
activates and/or deactivates a dust collector at optimum times.
Activation of the dust collector may alternatively be accomplished
manually via a key fob that is independent of tool operation.
[0024] The example system can be understood as a network of
wireless, independent devices that can communicate with other
devices in the network. The devices include a plurality of
transceivers, with a given transceiver acting as a primary
transmitter and other transceivers acting as receivers ("listening
devices"). The primary transmitter, upon a tool activation event,
broadcasts a signal that is understood by certain ones of the
listening devices. The broadcast signal includes a unique
identifier associated with a particular tool and recognized by a
group of the receivers so as to associate the primary transmitter
with the receivers.
[0025] The transceivers of the system include at least one
transceiver operatively connected to a power tool, and a
transceiver operatively connected to a dust collector (sometimes
referred to as a vacuum). In another example, the system can
include a transceiver operatively connected to a blast gate. The
system or network of independent devices may include multiple dust
collectors, multiple power tools and/or blast gates.
[0026] In an example, the transceivers of the dust collectors and
blast gates act as listening devices for the signal broadcast from
the tool transceiver. The system or network may allow the addition
or removal of devices, such as blast gates for example, with simple
programming to add or remove the unique identifier that may be
stored in memory for association with a common unique identifier
contained in the signal broadcast by the tool transceiver upon a
tool activation event. The association can be understood as a
process to make designated vacuum and/or blast gate receivers
respond to the signal transmitted by the tool transmitter. Thus, a
power tool may be associated with one or more blast gates and one
or more dust collectors. Conversely, a given blast gate or dust
collector may be associated with one or more power tools.
[0027] FIG. 1 is a block diagram of a particle collection system 10
with wireless controls in accordance with an example embodiment.
The system 10 may include a tool transceiver device 100, referred
to hereafter as a "tool transmitter 100" unless otherwise
indicated. In FIG. 1, the tool transmitter 100 is in electrical
connection with a machine such as a power tool 500. An activation
or deactivation event of the power tool 500 causes the tool
transmitter 100 to generate a wireless signal 700, such as an RF
signal, that is broadcast within the system 10. The wireless signal
700 can be an activation or deactivation signal, as required by the
situation. The wireless signal 700 is detected by a vacuum
transceiver device 200, referred to hereafter as a "VAC receiver
200" unless otherwise indicated. VAC receiver 200 is in electrical
connection with a vacuum source, hereafter "dust collector 400".
The VAC receiver 200 may be arranged between a plug 60 and an AC
mains line 65 that powers both the VAC receiver 200 and dust
collector 400, for example. Alternatively, the VAC receiver 200
could be integrated within the microelectronics of the dust
collector 400.
[0028] In an example, the wireless signal 700 may be based on the
ZigBee standard and contains coded keys to differentiate one tool
transmitter 100.sub.1 from another tool transmitter 100.sub.n,
n=1-N, allowing a work site to utilize multiple power tool/vacuum
devices concurrently. As an example, the wireless signal 700
includes a unique identifier (such as a serial number/code or
association number, for example) for the power tool 500. The power
tool 500 may in turn be associated with one or more the dust
collectors 400. The unique identifier could be a unique address
contained within the wireless signal transmitted by the tool
transmitter 100 and recognized by the VAC receiver 200. The VAC
receiver 200 includes a memory element (not shown). The memory
element includes a set of tool unique identifiers with which the
VAC receiver (and in turn, the dust collector) is associated.
[0029] In another embodiment and as to be described in more detail
hereafter, system 10 may optionally include one or more blast gates
350 (a single blast gate 350 shown in dotted line fashion). A blast
gate 350, if present, is provided in a given vacuum conduit 550
between the power tool 500 and a given dust collector 400. Each
blast gate 350 has a blast gate receiver 300 configured to control
the blast gate 350 and adapted to recognize the unique identifier
in the wireless signal 700 transmitted by tool transceiver 100. The
blast gate receiver 300 includes a memory element (not shown). The
memory element includes a set of tool unique identifiers with which
the blast gate is associated.
[0030] In a further embodiment and as to be described in more
detail hereafter, system 10 may optionally include one or more
relay devices 800 (a single relay device 800 is shown in dotted
line fashion). The relay device 800 functions as a range extender
to extend the system area and/or network range. The relay device
800 is configured to re-transmit or repeat any signal it receives,
and is thus adapted to recognize the unique address in the wireless
signal 700 transmitted by tool transceiver 100 and to retransmit
the signal to distant devices outside the signal range, such as to
a distant VAC receiver 200 and/or blast gate receiver 300.
[0031] In another example, a wireless signal 705 may be generated
by a transceiver of a remote control device such as a key fob 600
or other remote device that is recognized by the VAC receiver 200,
for example. The wireless signal 700, 705 generated by the tool
transmitter 100 or key fob 600 is received by the VAC receiver 200
(and optionally one or both of the blast gate receiver 300 and
relay device 800) and activates the dust collector 400 and/or
optionally the blast gate 350 (and/or optionally a distant dust
collector 400/blast gate 350 outside the range of wireless signal
700 via relay device 800 repeating the signal). Once the power tool
500 operation terminates, another wireless signal (not shown) may
be generated by the tool transmitter 100/key fob 600 to deactivate
the dust collector 400 (and optionally close blast gate 350 and/or
a remote device outside the signal range via relay device 800). The
transmission of a `deactivation signal` may be immediate, or may be
delayed for a period after the power tool 500 turns off in order to
clear the remaining dust out of the vacuum conduit 550. The delay
may be incorporated in a circuit within the tool transmitter 100,
or it may be incorporated in the VAC receiver 200 circuitry. In an
example, the delay duration may be part of a coded wireless signal
700 transmitted by the tool transmitter 100 to the VAC receiver
200.
[0032] While the tool transmitter 100 and key fob 600 are described
herein as primarily transmit devices and the VAC receiver 200 is
described primarily as a receiver devices, each of the devices in
this embodiment can be transceivers to enable two-way communication
between the power tool 500/key fob 600 and the dust collector 400.
In an example, receiver side circuitry in the VAC transceiver 200
confirms reception of the activation or deactivation signal, and
then transmits such confirmation to be received by receiver-side
circuitry in the tool transceiver 100.
[0033] FIG. 2 is a block diagram of the system 10 to illustrate
sensing of tool activation/deactivation and wireless signal
transmission in more detail. In an example method, the dust
collector 400 is wirelessly activated when a particle-generating
power tool 500, such as a saw is activated. In this example, the
tool transmitter 100 is arranged between a wall plug 50 and the
power tool 500 in the AC mains line 55 which provides power to both
tool transmitter 100 and power tool 500.
[0034] The tool transmitter 100 monitors tool (saw) activation by
sensing current in the AC mains line 55 to the power tool 500. Upon
sensing the current, the tool transmitter 100 transmits the
wireless signal 700. The VAC receiver 200 receives the signal and
"recognizes" the unique identifier of the tool 500 from the signal.
Upon receipt of the signal 700, the VAC receiver 200 acts as a
switch to permit power to activate the dust collector 400,
permitting dust or wood shavings to be suctioned by dust collector
400 via the vacuum conduit 550.
[0035] Alternately, other devices such as a switch integral to the
power tool 500 may trigger the transmission of a wireless signal.
Accordingly the functions of the tool transmitter 100 can be
integrated within the microelectronics of the power tool 500. In
further embodiments, the transmission may be an IR signal, an
ultrasonic signal or may be a carrier line (mains) signal. FIG. 2
thus represents an entry-level wireless system 10 in which there is
a one-to-one correspondence between dust collector 400 and power
tool 500.
[0036] FIG. 3 is a block diagram of a particle collection system
10' with wireless controls in accordance with another example
embodiment. In addition to the entry-level system 10 as shown in
FIGS. 1 and 2, where a dust collector 400 is dedicated to a
specific power tool 500, many machine or woodworking shops connect
a plurality of tools 500.sub.n (n=1 to N) to a single dust
collector 400. To isolate the dust collector 400 from a tool
500.sub.n that may not be activated (not generating dust so not
needing suction) a blast gate 350.sub.n is employed. The blast gate
350.sub.n blocks airflow between the dust collector 400 and an
"off" tool, while allowing airflow between the dust collector 400
and an "on" tool. Blast gates typically are manually actuated or
electrically actuated using a solenoid that controls a motor for
opening and closing the gate.
[0037] In FIG. 3, there are shown a plurality of power tools
500.sub.1-500.sub.N connected to a common dust collector 400 via a
corresponding blast gate 350.sub.1-300.sub.N to a vacuum conduit
system 550. Each blast gate 350.sub.n has a corresponding blast
gate transceiver operatively connected thereto, hereafter referred
to as a "blast gate receiver n" for purposes of clarity. Upon a
given tool transmitter 100.sub.n, sensing a current indicating tool
turn on, a signal 700 is received by the VAC receiver 200 and also
by all blast gate receivers 300 including the associated blast gate
receivers 300.sub.n. As to be described in further detail
hereafter, not all of the receivers in the system will act upon
receiving the wireless signal 700. Only those receivers having an
association with a given transmitter 100.sub.n (or a key fob 600 or
other transmitter), will act on the signal 700.
[0038] Similar to the example described in FIG. 2, in the example
of FIG. 3 the signal 700 transmitted by a given tool transmitter
100.sub.n includes a unique identifier such as a coded unique
address that is recognized by the VAC receiver 200 and the
corresponding blast gate receiver 300.sub.n. The identifier is
stored in memory of the VAC receiver 200 and in memory of the
respective blast gate receiver 300.sub.n, for example, to associate
the given power tool 500.sub.n to its blast gate receiver 300.sub.n
and to the dust collector 400.
[0039] Thus, in one example, upon sensing current to power tool
500.sub.n, tool transmitter 100.sub.n sends an activation signal
700 to both the VAC receiver 200 and blast gate receiver 300.sub.n.
The blast gate 350.sub.n opens upon a control power signal sent
from the blast gate receiver 300.sub.n to a motor of the blast gate
350.sub.n, and the dust collector 400 is concurrently activated as
the VAC receiver 200 switches the AC mains 65 to its motor, so
clear dust from the operation of power tool 500.sub.n. When power
tool 500.sub.n is deactivated for longer than a given or preset
period of time, tool transmitter 100.sub.n sends a deactivation
signal to close blast gate 350.sub.n and deactivate the dust
collector 400.
[0040] Concurrently, other tools 500.sub.n may be activated,
causing their respective blast gates 350.sub.n to operate and
activating the dust collector 400 if it is not already active.
After a period of power tool inactivity, which in an example could
be in a range between about 4-10 seconds, or fixed at a particular
time such as 7 seconds, a respective deactivation signal to close
the respective blast gates 350.sub.n and turn off the dust
collector 400 is transmitted. In one example, this time delay may
timed and the deactivation signal emitted by the tool transmitter
100.sub.n. Alternatively, the tool transmitter 100.sub.n may send
an immediate signal indicating tool deactivation, with the delay
being timed by the blast gate receiver 300.sub.n or VAC receiver
200. In a further alternative, the time period may be user
selectable, such as by key pressure on a button on the power tool
or remote device, via DIP switches or by a control signal issued by
the tool transmitter 100.sub.n or by a remote device such as key
fob 600, for example.
[0041] Each of the devices in this embodiment can be transceivers
to enable two-way communication between power tool 500.sub.N and
blast gate 350.sub.n and/or dust collector 400. For example,
receiver side circuitry in the blast gate transceiver 300.sub.n
confirms reception of an activation or deactivation signal 700 from
its tool transceiver 100.sub.n, and then transmits such
confirmation to be received by receiver-side circuitry in the tool
transceiver 100.sub.n.
[0042] In an example, associations may be made via DIP switches
which the end-user selects to appropriately match the various
devices within the system 10''. While effective, setting DIP
switches may be cumbersome and could incur the cost of the
switches, which may be substantial.
[0043] Another approach is to use a unique serial number and/or
association number encoded in the firmware at place of manufacture
for each of the devices. Each of the devices may include a string
of an enterprise (TOOL, GATE, and VAC) that are powered when an
association event is initiated. This event may be initiated, for
example, by a switch closure by the user on one of the devices
(tool transmitter 100.sub.n, VAC receiver 200, and blast gate
receiver 300.sub.n). Alternately an association event may be
initiated by a switch closure sequence on the key fob 600.
[0044] During an association event, a coded wireless signal with
unique identifier data is transmitted, and all devices within a
string exchange serial and/or association number information via
wireless communication. For example, taking the system 10' depicted
in FIG. 3 prior to association, the following devices are to be
associated.
TABLE-US-00001 VAC Receiver 200: Serial #123, Association: none
Blast gate receiver 300.sub.1: Serial #321, Association: none Tool
transmitter 100.sub.1: Serial #876, Association: none
Each device also may store serial numbers or "association numbers"
which identify the devices to which it respond. In an example, once
the devices are powered and an association event is initiated
(i.e., an activation or deactivation event triggering transmission
of the wireless signal), the associations are:
TABLE-US-00002 VAC Receiver 200: Serial #123, Association: #876
Blast gate receiver 300.sub.1: Serial #321, Association: #876 Tool
transmitter 100.sub.1: Serial #876, Association: #123, #321.
[0045] When power tool 500.sub.1 is activated, tool transmitter
100.sub.1 transmits an activation signal with associations #123 and
#321, which may serve as unique addresses transmitted in the header
of the signals 700 broadcast to devices in the system 10. VAC
Receiver 200 (having its own serial number 123 and the serial or
association number of the transmitter 100.sub.1 tool transmitter
100.sub.1 stored or firmware-coded therein) and blast gate receiver
300.sub.1 (having its own serial number 321 and the serial or
association number of the transmitter 100.sub.1 stored or
firmware-coded therein) recognize the unique association number
addresses contained in the header of the signal 700 sent by the
tool transmitter 100.sub.1 and thus activate. Both may optionally
transmit status to its tool transmitter 100.sub.1, as the as tool
transmitter 100 (having its own serial number address 876 and the
serial or association numbers of the receivers 200, 300.sub.1
stored therein) would recognize the association number address
received in the confirmation wireless signal.
[0046] Additional associations may be conducted such that multiple
gate/tool combinations may be associated to a particular dust
collector 400. For example, the full complement of devices in FIG.
3 could be associated as follows.
TABLE-US-00003 Tool transmitter 100.sub.1: Serial #876,
Association: #321, #123 Blast gate receiver 300.sub.1: Serial #321,
Association: #876 Tool transmitter 100.sub.2: Serial #765,
Association: #543, #123 Blast gate receiver 300.sub.2: Serial #543,
Association: #765 Tool transmitter 100.sub.N: Serial #987,
Association: #778, #123 Blast gate receiver 300.sub.N: Serial #778,
Association: #987 VAC Receiver 200: Serial #123, Association: #876,
#765, #987
[0047] Thus, the associations above can be considered freeform as
each of the transceivers can operate in an ad-hoc mode, whereby
multiple receivers (VAC, blast gate) may have multiple associations
with multiple tool transmitters. Conversely, a given tool
transmitter may have associations with multiple VAC receivers and
blast gate receivers.
[0048] The example embodiments provide for associations to be
erased or reset by a user. In an example this may be performed via
a reset button provided on the tool transmitter 100.sub.n, by some
key closure sequence, or an override command transmitted by the
tool transmitter 100.sub.n, so as to clear associations in the
primary receivers (VAC receiver 200, blast gate receiver
300.sub.n).
[0049] FIG. 4 is a block diagram of the system 10' of FIG. 3 to
illustrate an alternative wireless signal transmission path. FIG. 4
depicts a similar operation except that the signal to activate the
dust collector 400 emanates from the blast gate receiver 300.sub.n
(which is a transceiver) instead of the tool transmitter 100.sub.N.
In either case as depicted in FIGS. 3 or 4 within the system 10', a
particular tool transmitter 100.sub.n is associated to a particular
blast gate receiver 300.sub.n. This association may be via an
embedded code with a unique identifier or address signal as
described above, such that the signal transmitted by the tool
transmitter 100.sub.N is unique to its associated blast gate
350.sub.n. Each blast gate 350.sub.n responds only to the tool
transmitter 100.sub.n associated with it; i.e., tool transmitter
100.sub.2 emits a coded signal with unique address signal that only
the associated gate 350.sub.2 (via its blast gate receiver
300.sub.2) is responsive to.
[0050] Thus, a wireless signal transmitted by any of the tool
transmitters 100.sub.n can activate the dust collector 400, as
shown in FIG. 3. In this example, any of blast gate receivers
300.sub.n could transmit dust collector 400 activation signals 720,
once activated by a wireless signal 700 received from its
corresponding tool transmitter 100.sub.n. Accordingly, a given
blast gate receiver 300.sub.n may exhibit independent control to
activate or deactivate a given dust collector 400. In an example, a
given blast gate 350.sub.n could include an override button to
activate the gate and enable the blast gate transceiver 300.sub.n
to send an activation signal to a VAC receiver 200 to turn on the
dust collector 400. This envisions a scenario in which the signal
700 issued from a tool transmitter 100.sub.n has not been received
by either of the blast gate and VAC receivers 300.sub.n, 200,
perhaps due to interference, for example.
[0051] FIG. 5 is a block diagram of a particle collection system
10'' with wireless controls in accordance with another example
embodiment. FIG. 5 further expands the shop area by depicting a
system 10'' with a plurality of dust collectors 400.sub.x (x=1 to
N) generally the same shop location. In this example, a first group
of the blast gate receivers 300.sub.x has a unique association with
its corresponding tool transmitter 100.sub.x of power tools
500.sub.x. The VAC receivers 200.sub.x may have associations with
multiple blast gate receivers 300.sub.xy and/or multiple tool
transmitters 100.sub.x.
[0052] Although all devices (i.e., tool transmitters 100.sub.n, VAC
receivers 200.sub.n, and blast gate receivers 300.sub.n) may be
configured as transceivers, in the example of FIG. 5 the tool
transmitters 100.sub.n are primarily transmitters, and the VAC
receivers 200.sub.n and blast gate receivers 350.sub.n are
primarily receivers. In all instances, the devices may act as
transceivers, whereby primary receives may transmit status to
primary transmitters to confirm that transmitted commands were
acknowledged.
[0053] In a variation of FIG. 5, the signal to activate the dust
collector 400 in system 10'' can emanate from the blast gate
receiver 300.sub.n (which is a transceiver) instead of the tool
transmitter 100.sub.n, as described in FIG. 4. Each blast gate
350.sub.n responds only to the tool transmitter 100.sub.x
associated with it; i.e., each tool transmitter 100.sub.n transmits
a coded signal with address signal that only the associated gate
350.sub.x (via its blast gate receiver 300.sub.x) is responsive
to.
[0054] While not depicted, the key fob 600 may be incorporated into
the system 10'' to initiate blast gate 350.sub.n and/or dust
collector 400.sub.n sequences. Events initiated by a given blast
gate 350.sub.n may override initiation events issued by a given
power tool 500.sub.ny, such that only the key fob 600 may alter
events initiated thereby.
[0055] As previously described with regard to FIG. 3, each of the
devices may include a string of an enterprise (TOOL, GATE, and VAC)
powered upon initiation of an association event, such as by a
switch closure by the user on one of the devices (tool transmitter
100.sub.n, VAC receiver 200.sub.n, blast gate receiver 300.sub.n ),
or a switch closure sequence on the key fob 600. During the
association event, all devices within a string exchange serial
number information via wireless communication, as previously
described above.
[0056] FIG. 6 is a block diagram of a tool transceiver in
accordance with the example embodiments. The tool transceiver 100
may be integrated inside a portable or stationary power tool 500 or
it may be separate device connectable between the AC mains 55 and
the power tool 500. The transceiver 100 may include a mains input
55, a power supply 105, a current shunt 110 and an amplifier 120.
The transceiver 100 may further include a microcontroller and
wireless receiver 130, for example a radio circuit; an externally
visible LED 140, a resettable over-current circuit breaker 150, and
mains plug 102 for the power tool.
[0057] The internal power supply 105 provides DC power for the
microcontroller and radio circuit 130. In an example, voltage
provided to the microcontroller and radio circuit 130 can be
between about 5V to 12VDC under all conditions of acceptable mains
input voltage and frequency. In an example, the power supply 105
may be a universal supply (90VAC to 240 VAC) or a different design
based on a US (120 VAC nominal) or European (230VAC nominal)
version.
[0058] In an example, the microcontroller and radio circuit 130 may
comprise a circuit board containing a Freescale 2.4 GHz radio and
microcontroller on a chip and associated circuitry. Circuit 130 may
include a 3.3V regulator on-board. The regulator is used to
generate regulated voltage for the microcontroller and radio
circuit 130 as well as for the LED 140.
[0059] The microcontroller of circuit 130 senses the power tool 500
actuation. In FIG. 6, this sensing is performed by monitoring
current flowing to the power tool 500 via the current shunt 110 and
amplifier 120. When the tool 500 is actuated, current flowing
through the shunt 110 is converted to a voltage. The voltage is
amplified at amplifier 120 and presented to the microcontroller in
circuit 130. In an example, the current shunt 110 may have a small
resistance value (such as 0.01 ohms) to prevent overheating. This
results in a small voltage across the shunt 110 when tool currents
are flowing.
[0060] The shunt voltage is amplified at amplifier 120 to a level
acceptable to the microcontroller of circuit 130. When the
amplified shunt voltage exceeds a threshold, the tool 500 is
considered "ON". Thus, the microcontroller acts as a sensor to
detect tool 500 activation by sensing current flow to the tool 500.
In an example, other means of sensing tool activation such as
vibration may be utilized.
[0061] Upon sensing activation of tool 500, the microcontroller of
circuit 130 activates the radio to send a coded signal with the
aforementioned unique address code indicating tool actuation. The
VAC receiver 200, blast gate receiver 300, and other listening
devices which can recognize the unique address code may respond to
the tool's actuation codes.
[0062] When the microcontroller detects that the tool 500 operation
has been suspended, the microcontroller may activate the radio of
circuit 130 to send a coded signal with a unique address code
indicating tool suspension. The VAC receiver 200, blast gate
receiver 300, and other listening devices which can recognize the
unique address code may respond to the tool's actuation codes.
[0063] As part of the confirmation, given receiver devices may also
transmit wireless confirmation signals that are read by the tool
transceiver 100. In one example, if the tool transceiver 100 does
not receive a confirmation signal, or receives erroneous
confirmation signals, the tool transceiver 100 may retransmit
activation or suspension codes within its wireless signal.
[0064] The LED 140 may be included to provide visible feedback to
the user as to successful transmission of the radio signal. The LED
140 may be under software control as configured by the designer.
Other methods of user feedback may be employed such as audible,
LCD, or graphic displays.
[0065] FIG. 7 is a block diagram of a vacuum transceiver in
accordance with the example embodiments. Referring to FIG. 7, the
VAC transceiver 200 is powered from the AC mains 65 and provides AC
mains power to the dust collector via a switched mains output
receptacle 202. The transceiver 200 includes an on/off switch 205
to control the main power for the VAC transceiver 200, as full
motor current flows through switch 205. An internal power supply
210 provides DC power for a relay driver 215 and a microcontroller
and radio circuit 220. In an example, voltage provided to the
microcontroller and radio circuit 220 can be between about 5V to
12VDC under all conditions of acceptable mains input voltage and
frequency. In an example, the power supply 210 may a universal
supply (90VAC to 240 VAC) or different design based on a US (120
VAC nominal) or European (230VAC nominal) version.
[0066] The microcontroller and radio circuit 220 may include a 3.3V
regulator on-board. The regulator is used to generate regulated
voltage for the microcontroller and radio circuit 220, as well as
for switch 230 and LED 240.
[0067] In an example, the microcontroller and radio circuit 220 may
comprise a circuit board containing a Freescale 2.4 GHz radio and
microcontroller on a chip and associated circuitry. The relay
driver 215 receives a logic level signal from the microcontroller
and radio circuit 220 to close or open the power relay 225. The
relay driver 215 translates this signal to drive the power relay
225.
[0068] The VAC transceiver 200 includes a switch 230, an LED 240
and a resettable circuit breaker 250. Switch 230 may be configured
as a signal level SPST membrane switch with tactile feedback that
is externally activated by the user. Switch 230 closures may be
used by the microcontroller and radio circuit 220 to place the VAC
transceiver 200 into different operational modes. The LED 240 may
provide information to the user. The resettable circuit breaker 250
opens the current path if the current rating is exceeded, and may
be resettable via a pushbutton actuation, for example.
[0069] In operation, when the on/off switch 205 is activated, the
microcontroller of circuit 220 controls activation or deactivation
of the relay 225. When the appropriate coded signal (i.e., the
wireless signal transmitted by the tool transceiver 100 or the
blast gate receiver 300 containing the unique addresses) is
received by the microcontroller of circuit 220, the relay 225 is
activated, closing the AC mains 65 onto the switched mains output
receptacle 202 and an external device (motor of the dust collector
400) is turned on.
[0070] Conversely when the appropriate coded signal is received by
the microcontroller of circuit 220, the power relay 225 is
deactivated, opening the mains 65 from the switched mains output
receptacle 202 and the external device (motor) is turned off. The
switch 230 is monitored by the microcontroller of circuit 220.
Operation due to switch 230 activation may be under software
control, as configured by the designer. Similarly, as the LED 240
provides user feedback, the LED 240 may be under software control
as configured by the designer.
[0071] FIG. 8 is a block diagram of a blast gate transceiver 300 in
accordance with the example embodiments. The blast gate transceiver
300 primarily receives wireless signals from a transmitter (such as
tool transceiver 100) and opens or closes a blast gate 350 in
response to the signal to allow or block vacuum suction to remove
material from a cutting or grinding operation.
[0072] A power supply 305 similar to as described in FIGS. 6 and 7
provides power for a microcontroller and radio circuit 310 and also
provides power for the mechanical blast gate 350 (in FIG. 8, power
to gate 350 is represented by a 24V DC motor 315). A motor driver
and direction mixer 320 is controlled by the microcontroller of
circuit 310 to direct the motor 315 to move forward and reverse.
The motor driver and direction mixer 320 simply reverses the
voltage polarity across the DC motor 315. This permits opening and
closing of the blast gate 350, thereby allowing or blocking a
vacuum.
[0073] Sensors may be built into the blast gate 350 such the
microcontroller of circuit 310 detects a fully open or fully closed
blast gate 350. Operation due to sensor switch activation is under
software control. Such controls may include gate opening and
closing overrides. For example, the microcontroller may direct the
motor 315 to suspend operation once the blast gate 350 is
completely open or closed.
[0074] A current shunt 325 may be employed to detect blockages in
the blast gate passage (not shown). In an example, the current
shunt 325 may have a small resistance value (such as 0.01 ohms) to
prevent overheating. This results in a small voltage across the
shunt 325 when currents are flowing. The shunt voltage is amplified
at amplifier 312 to a level acceptable to the microcontroller of
circuit 310.
[0075] If debris builds in the gate passage impeding opening or
closing of the blast gate 350, the motor current will rise, but the
applicable "Open" gate sensor switch 330 or "Closed" gate sensor
switch 335 will not have activated. The microcontroller of circuit
310 can measure this excessive current and suspend motor operation.
Additionally, a warning of this condition may be issued via the LED
340, for example.
[0076] To clear blockages, the microcontroller of circuit 310 can
cycle the blast gate 350. Known as "jiggling", the blast gate 350
is repeatedly open and closed in an effort to jog the blockage or
debris so as to clear the vacuum conduit at the blast gate 350.
[0077] An external switch 345 may be included to provide over-ride
capability to open or close the blast gate 350. The external switch
345 may also be used to place the microcontroller 310 into various
states, such as associations with wireless transmit devices. The
external switch 345 is monitored by the microcontroller 310.
[0078] The blast gate transceiver 300 is powered from the AC mains
50. The microcontroller and radio circuit 310 control opening or
closing of the blast gate 350. When the appropriate coded signal
(unique address) is detected by the microcontroller and radio
circuit 310, the blast gate 350 is opened. Conversely, when the
appropriate coded signal is detected by the microcontroller and
radio circuit 310, the blast gate 350 is closed.
[0079] The Open gate sensor switch 330 and the Closed gate sensor
switch 335 are monitored by the microcontroller of circuit 310 to
gauge completion of the desired operation. Motor current is also
monitored; if motor current exceeds a threshold (indicating
blockage of the blast gate 350) motor operation may be
suspended.
[0080] FIG. 9 is a block diagram of a battery-powered blast gate
transceiver in accordance with the example embodiments. Blast gate
transceiver 300' is similar to that described in FIG. 8; therefore
only the differences are described in detail hereafter. At certain
work sites, blast gates may need to be located in areas where
access to an AC power cord is not feasible or where providing
corded power would be difficult and require a lengthy cord. Thus,
instead of being powered from an AC mains source, the transceiver
300' of FIG. 9 is battery powered. This provides additional
flexibility in where to place blast gates within a work area. The
battery 305' may be a replaceable battery, such as an alkaline
battery. In another alternative, the battery 305' may be a
rechargeable battery pack composed of any of lead acid, NiCd, NiMH
or lithium ion (Li-ion) battery cells. In a further alternative,
the battery 305' could be solar-powered, where solar cells can be
charged by ambient light or by a combination of a rechargeable
battery with solar cells to charge the battery. In a further
alternative, the solar cells could be adapted to charge a super
capacitor (at least about 1 F), with the super capacitor providing
power to operate the blast gate.
[0081] FIG. 10 is a block diagram of a remote control device in
accordance with the example embodiments. A remote control device
such as key fob 600 may be employed in any of the embodiments
described in FIGS. 1-5 to transmit a signal that is recognized by
the VAC receiver 200 to activate/deactivate the dust collector 400,
and recognized by a blast gate receiver 300 to open and close a
blast gate 350. The key fob 600 includes a power source, which may
be embodied as a 9V alkaline battery 605 for example. The battery
605 powers a microcontroller and radio circuit 610 and an LED 640
upon actuation of on and off switches 645 and 655. In an example,
the microcontroller and radio circuit 610 may comprise a circuit
board containing a Freescale 2.4 GHz radio and microcontroller on a
chip with associated circuitry. An on-board 3.3V regulator is used
to generate regulated voltage for the microcontroller and radio
circuit 610 and LED 640.
[0082] FIG. 11 is a block diagram of relay device in accordance
with the example embodiments; FIG. 12 is a block diagram of a
battery-powered relay device. Referring to FIGS. 11 and 12, a relay
device 800 may be used in any of the embodiments described in FIGS.
1-5. The relay device 800 can be understood as a range extender
which provides for extending the system area and/or network range.
The relay device 800 is configured to re-transmit or repeat any
signal it receives.
[0083] For example, a tool transmitter 100 in one area or room of a
work shop broadcasts a wireless signal. This signal may not reach
an associated dust collector 400 or blast gate 350 due to range
limitations of the tool transmitter 100. Accordingly, one or more
relay devices 800 could be placed within the range of the tool
transmitter 100 so as to relay the wireless signal to the
associated dust collector 400 and/or blast gate 350, to be received
by corresponding transceivers thereof.
[0084] FIG. 11 illustrates a relay device 800 in a mains-powered
configuration. Device 800 includes a power supply 805 that receives
AC mains from a corded plug and powers a microcontroller and radio
circuit 810 and an LED 840. The relay device 800 could have its
dedicated cord or could be placed in a cord connected to a given
blast gate 350 or dust collector 400. Upon receiving a wireless
signal, the microcontroller of circuit 810 activates the radio to
re-transmit or repeat a coded signal with unique address code
indicating tool actuation. The LED 840 illuminates to indicate
transmission. A given VAC receiver 200, blast gate receiver 300,
and other listening devices within the relay device 800's range,
and which can recognize the unique address code, respond to the
tool's actuation codes.
[0085] The relay device 800' of FIG. 12 is similar in structure and
operation. However, device 800' illustrates a cordless solution in
which a battery 805' provides power to its microcontroller and
radio circuit 810 and LED 840. The battery 805' may be a
replaceable battery, such as an alkaline battery. Alternatively,
the battery 805' may be a rechargeable battery pack composed of any
of lead acid, NiCd, NiMH or lithium ion (Li-ion) battery cells. In
a further alternative, the battery 805' could be solar-powered,
where solar cells can be charged by ambient light or by a
combination of a rechargeable battery with solar cells to charge
the battery. In a further alternative, the solar cells could be
adapted to charge a super capacitor (at least about 1 F), with the
super capacitor providing power to operate the relay device
800'.
[0086] The above example embodiments therefore describe a wireless
particle collection system or network having a plurality of
independent devices that may associate with one another wirelessly
upon a tool activation event. The example system provides
flexibility in adding or removing devices there from. Tools can be
associated with specific blast gates and dust collectors, and vice
versa, based on a coded signal having a unique identifier therein
that is recognized by devices of the string, so as to distinguish
the tool transmitter of the tool from other transmission
devices.
[0087] The example embodiments being thus described, it will be
obvious that the same may be varied in many ways. Such variations
are not to be regarded as a departure from the example embodiments
of the present invention.
* * * * *