U.S. patent application number 12/802811 was filed with the patent office on 2010-10-07 for temperature sensing devices.
This patent application is currently assigned to BeadedStream, LLC. Invention is credited to Brian Rafael Shumaker, David Howard Shumaker, Nicole Yvonne Shumaker.
Application Number | 20100254429 12/802811 |
Document ID | / |
Family ID | 39091946 |
Filed Date | 2010-10-07 |
United States Patent
Application |
20100254429 |
Kind Code |
A1 |
Shumaker; Brian Rafael ; et
al. |
October 7, 2010 |
Temperature sensing devices
Abstract
A digitally based system is designed to sense temperatures at a
plurality of places and transmit temperature data along a hard-wire
cable or distributed (wireless) network to an integrated data
collection and control appliance. The system can perform single
"spot" measurements or arrange multiple readings in a database for
later use. Semiconductor-based sensors with digital output and data
transmission capabilities allow large numbers of sensors to be
placed along extended lengths of signal cable consisting of only
three or four wires. The device incorporates electrical insulating
materials, encapsulants, and mechanical strain relief designed to
protect the sensors and transmission lines from failures related to
exposure to extreme cold. Though described here for cold region
applications, the embodiment of this invention encompasses moderate
and tropical environments as well, or temperatures ranging from -40
C. to +85 C.
Inventors: |
Shumaker; Brian Rafael;
(Anchorage, AK) ; Shumaker; Nicole Yvonne;
(Atlanta, GA) ; Shumaker; David Howard;
(Hendersonville, TN) |
Correspondence
Address: |
WELLS ST. JOHN P.S.
601 W. FIRST AVENUE, SUITE 1300
SPOKANE
WA
99201
US
|
Assignee: |
BeadedStream, LLC
|
Family ID: |
39091946 |
Appl. No.: |
12/802811 |
Filed: |
June 14, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11890661 |
Aug 7, 2007 |
7736052 |
|
|
12802811 |
|
|
|
|
60837183 |
Aug 11, 2006 |
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Current U.S.
Class: |
374/208 ;
374/E1.011 |
Current CPC
Class: |
G01K 1/08 20130101; G01K
1/026 20130101 |
Class at
Publication: |
374/208 ;
374/E01.011 |
International
Class: |
G01K 1/08 20060101
G01K001/08 |
Claims
20. A temperature sensing device comprising: a housing comprising
an elongated structure having opposite ends spaced from each other
in the elongated direction; a temperature sensor in the housing;
and a cable extending from one end of the opposite ends of the
housing, the cable comprising signal communication with the
temperature sensor.
21. The device of claim 20 wherein the housing comprises a single
structure of material.
22. The device of claim 20 wherein the housing comprises a single
structure of polymeric material.
23. The device of claim 20 wherein the one end of the housing
comprises a tapered configuration extending along the elongated
direction to the cable.
24. The device of claim 20 further comprising a printed circuit
board in the housing and wherein the temperature sensor is mounted
on the printed circuit board.
25. The device of claim 20 wherein the cable comprises a conductor
dedicated solely to an unregulated input power supply, and the
conductor is coupled to the temperature sensor.
26. The device of claim 20 wherein the cable comprises at least
four discrete conductors.
27. The device of claim 20 wherein the housing comprises polymeric
material and wherein the cable comprises polymeric material, and
wherein the polymeric material of the housing and the cable are the
same polymeric material.
28. The device of claim 20 wherein the housing comprises a first
polymeric material and wherein the cable comprises a second
polymeric material different from the first polymeric material of
the housing.
29. The device of claim 20 wherein the cable comprises a first
polymeric material and a second polymeric material, the first
polymeric material being a different composition relative the
second polymeric material.
30. The device of claim 20 wherein the cable comprises at least
three discrete polymeric structures.
31. The device of claim 20 wherein the cable comprises a first
polymeric material and a second polymeric material, the first
polymeric material comprising a different composition relative the
second polymeric material.
32. The device of claim 20 wherein the cable comprises at least
three discrete polymeric structures, one of the three polymeric
structures comprises a composition different from a composition of
an other of the three polymeric structures.
33. The device of claim 20 wherein the cable comprises at least
three discrete polymeric structures, the three polymeric structures
comprising three different polymeric compositions.
34. A temperature sensing device comprising: a housing comprising
an elongated structure extending in an elongated direction; a
temperature sensor in the housing; and a cable extending from the
housing and comprising an elongated structure that extends in the
elongated direction with the housing, the cable comprising signal
communication with the temperature sensor.
35. The device of claim 34 wherein the housing comprises an outer
surface configuration having only three surfaces.
36. The device of claim 35 wherein the three surfaces comprise a
central cylindrical surface between two opposite end surfaces, the
two end surfaces comprising conical surfaces.
37. The device of claim 34 wherein: the housing comprises a first
cylindrical configuration between two opposite ends; the cable
comprises a second cylindrical configuration having diametric
dimensions less than diametric dimensions of the first cylindrical
configuration of the housing; and the two opposite ends of the
housing comprise conical configurations extending between the first
and second cylindrical configurations.
38. A temperature sensing device comprising: a temperature sensor;
a voltage regulator coupled to the temperature sensor; and a
housing encapsulating the temperature sensor and the voltage
regulator.
39. The device of claim 38 further comprising a printed circuit
board encapsulated in the housing, wherein the temperature sensor
and the voltage regulator are both mounted on the printed circuit
board.
Description
CROSS REFERENCE TO A RELATED APPLICATION
[0001] This patent resulted from a continuation application of U.S.
patent application Ser. No. 11/890,661, filed Aug. 7, 2007, U.S.
Pat. No. 7,736,052, Issue Date Jun. 15, 2010, which was based on
U.S. Provisional Patent Application No. 60/837,183, filed Aug. 11,
2006, entitled "Multipoint Digital Temperature Acquisition System",
and the teachings of all the applications are incorporated herein
by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention pertains generally to ambient air, soil, and
water temperature sensing and reporting instrumentation. More
specifically, the invention discloses an assembly of temperature
sensor modules specially adapted for repeated and prolonged use in
harsh outdoor, underground and underwater conditions, especially at
low ambient temperatures (i.e. to at least -40 degrees C./F.), and
designed to resist damage from mechanical stresses arising from
actions on the assembly such as flexure, twisting, kinking, and
tension. The invention can be provided with a standard format
electrical connector for electrical association with a separate
external device via a signal cable. Alternatively the invention can
utilize available wireless digital communication technology to
operate without hard wire connections. The temperature sensors can
be placed at any position along the signal cable.
[0003] The preferred embodiment of the invention features
encapsulated sensor modules with integral strain relief and robust
environmental protection. The materials and methods of construction
offer superior extreme low temperature performance (i.e. to at
least -40 degrees C./F.) and enable the sensor elements to tolerate
more coil and uncoil cycles than the prior art.
BACKGROUND
[0004] The short cool summers and long cold winters that typify the
climatic conditions found at high latitudes are conducive to the
formation of permafrost or perennially frozen ground. Climatic
conditions at very high latitudes also result in seasonal and
multiyear ice formations on many lakes and offshore (marine)
environments. Permafrost soils present unique design and
construction challenges in cold regions around the world for a
broad range of projects including community housing, schools,
utilities, roads and bridges, airports, resource development, and
defense. The occurrence of freshwater ice on inland water bodies
and sea ice in the offshore realm also has ongoing relevance to
commercial and academic interests focused on resource development
and transportation.
[0005] Continuous records of accurate ground temperature data
highly resolved with depth are required for engineering,
construction, and scientific purposes on a regional, local and site
specific basis. The invention addresses a need to improve the
reliability and performance over previous art while achieving user
cost reductions.
DESCRIPTION OF PRIOR ART
[0006] The prior art has been known and widely used for at least
three decades. The prior art accomplishes temperature measurement
using a plurality of analog sensors mounted on dedicated circuits
within a multiconductor signal cable. The analog sensors typically
consist of thermistors, temperature sensitive resistors, which
exhibit a temperature dependent resistance. A separate conductor
within a cable must be allocated to each sensor although multiple
sensors of this type can share a common ground. DC resistance is
the measured parameter for this type of sensor. Measurements are
typically, accomplished in the field by connecting the leads from a
conventional test meter to one dedicated circuit at a time and
manually recording resistance values. Often a manual switching
device is used between the test meter and multiconductor cable to
improve the quality of the connections and speed of the procedure.
Generic automated analog polling and data logging devices have also
been used in cases where relatively few sensors are installed on a
long-term basis such as under buildings or remote land-based or
sea-based monitoring stations. The measured resistance is later
converted to a temperature using the Hart-Steinhardt Equation with
appropriate input parameters for the specific thermistor
employed.
[0007] The use of thermistors for several decades has led to
general acceptance of the methodology for obtaining multipoint
temperature data as well as incremental improvements to the art.
However, inherent limitations to the prior art persist. The signal
cable must possess a separate conductor for each analog sensor plus
one additional conductor to be used for ground. For applications
that require many sensors, specialty signal cable with an unusually
large number of conductors or more than one smaller multiconductor
cable must be used to provide the required dedicated circuits. The
use of cables with high numbers of conductors also increases
manufacturing costs, and the cost of maintenance and repair. Large
cables also tend to be heavy and inflexible for the end user who
must carry, deploy, and recover the cables multiple times. The
installation of analog sensors within a cable is typically
completed using heat sensitive shrink materials which frequently
form an unreliable seal with the outer jacket material and
introduce areas of concentrated bending stress on either side of
the splice area. Cold temperature failures of the outer cable
jacket are common.
[0008] The invention possesses numerous benefits and advantages
over known multipoint temperature sensing cables for cold regions.
In particular, the invention utilizes an established digital
communication protocol to reduce the number of required conductors
within a cable, thereby affording lower weight and increased
flexibility to the user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The appended claims particularly point out and distinctly
claim the subject matter of this invention. The various objects,
advantages and novel features of this invention will be more fully
apparent from a reading of the following detailed description in
conjunction with the accompanying drawings in which like reference
numerals refer to like parts, and in which:
[0010] FIG. 1 depicts various hard-wired network topologies within
arbitrary landscapes in which this invention could be used;
[0011] FIG. 2 depicts an alternate hard-wired network topology and
a distributed wireless network topology within an arbitrary
landscape in which this invention could be used;
[0012] FIG. 3 is a diagrammatic view of a computer system upon
which an embodiment according to the present invention can be
implemented;
[0013] FIG. 4 depicts the signal cable in detailed
cross-section;
[0014] FIG. 5 is a partial cutaway view depicting embedded
conductors, the sensor module, and segments of signal cable potted
according to the preferred embodiment.
[0015] FIG. 6 depicts the printed circuit board as viewed from the
top and bottom, including electronic components and integrated
circuits according to the preferred embodiment;
[0016] FIG. 7 is a system electrical schematic of one embodiment of
the invention;
[0017] FIG. 8 is a diagrammatic flow chart of steps of an exemplary
processing method in accordance with the present invention;
[0018] FIG. 9 is a diagram of the relationship between major layers
of a software algorithm in one embodiment of the present
invention.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0019] The preferred embodiment of the invention uses the
capability for the digital communications protocol to adapt to
various network topologies shown in FIGS. 1 and 2 within arbitrary
landscapes. The same embodiment may be used interchangeably in each
topology without modification. A star topology 10 describes a
plurality of sensor modules 12 arranged on multiple legs 14 of
varying length extending from a control appliance 16. A linear
topology 18 describes a single leg 20 starting at a control
appliance 16 and extending to the farthest sensor module 22. A
plurality of sensor modules 12 are attached to the leg along its
length.
[0020] The preferred embodiment may also be used in a mixed
topology 26 having aspects of both star 10 and linear 18 topologies
including multiple legs 14 extending from a control appliance 16
and a plurality of sensor modules 12 mounted along their length.
Finally, a distributed wireless network topology 28 may be used
having a plurality of sensor modules 12 attached to an interface
device 30 associated with a bi-directional wireless communication
unit 32. A distributed network 28 may utilize wireless mesh-type
intelligence to independently form associations enabling
communication between individual communication units 32 which
independently would have physical separation distances exceeding
their range.
[0021] The preferred embodiment includes a complete temperature
acquisition system 34 illustrated diagrammatically in FIG. 3.
Additional functionality is achieved by a combination of integrated
hardware and software resident in the control appliance 36. The
control appliance 36 serves as a platform for a serial
communications bus 38, data storage 40, random access memory 42,
and external connectivity 44 via RS-232, USB or serial radio
communication with a host device, Ethernet-type computer network,
the internet or any other type of network. Low-level communication
with the sensor modules 12 is accomplished by an interface device
46 as would be understood by those skilled in the art. According to
the preferred embodiment, the interface device 30 communicates with
the control appliance 36 via a serial communications bus 38. The
serial communications bus 38 may be associated with the interface
device 46 either by direct electrical connections (wired) 48 or by
a suitable radio technology (wireless) 50. The communication
protocol applied in the preferred embodiment is exemplary and other
communication protocols can be used.
[0022] The control appliance CPU 52 supports an embedded operating
system capable of running a software load that controls the
embodiment of the invention, issues various commands to acquire
temperature data, organizes the returned data into a database file
and attempts to transmit the data externally at user defined time
intervals or in response to user requests.
[0023] The preferred embodiment of the invention advantageously
uses the specialized signal cable 54 illustrated in FIG. 4
developed specifically to maximize mechanical reliability in
extreme low temperatures (i.e. to at least -40 degrees C./F.) for
prolonged periods. An outer cable jacket 56 of suitable polymeric
material, typically polyurethane, provides overall mechanical
protection from actions on the embodiment such as flexure,
twisting, kinking, and abrasion to temperatures as low as -40 C.
The cable jacket also protects the internal components from
environmental contaminants and fluids such as oil and water. Four
tinned copper stranded wire conductors provide bi-directional data
transmission 58, data ground or reference 60, unregulated input
power supply 62, and regulated power supply 64 connections to the
sensors. Each conductor is insulated 66 using a suitable polymeric
material, typically polypropylene. The data transmission and ground
reference conductors are twisted to minimize electromagnetic
interference during operation. The unregulated power supply and
regulated power supply conductors are also twisted to facilitate
cable manufacture. A binding wrap 68, typically Mylar, may be
employed to further facilitate manufacture and improve
concentricity of the conductor group and outer jacket 56.
[0024] Given the cable outer diameter as a physical constraint, the
use of fewer conductors than required in the prior art permits
additional annular space to be allocated to other functions such as
insulation, shielding, and mechanical protection improving the
performance and service life of the cable. Moreover, fewer
conductors diminishes manufacturing labor requirements and its
associated costs.
[0025] The signal cable 54 provides a reliable path for power
supply and communication between the control appliance 36 and
individual sensor modules 12. FIG. 5 shows how each sensor module
12 is housed in an assembly designed to provide robust
mechanical'protection and a continuous environmental seal or
barrier against external particles and fluids. A printed circuit
board 70 mounted with the sensor element IC 72 and other components
more fully described below, signal cable conductors 74, and a short
length of outer jacket at each end of the assembly 76 are potted in
a suitable polymeric material 78, typically polyurethane given form
by casting within a mold. The formed polymeric material 78 provides
a continuous structural connection between lengths of signal cable
44 by forming a permanent chemical bond with the signal cable outer
jacket 76 exposed to the polymeric material 78 inside a mold. The
mold form incorporates a smooth taper 80 between the signal cable
outer jacket and the outer diameter of the form for integral strain
relief and to minimize the tendency for the cable to catch on sharp
edges during use.
[0026] As shown in FIG. 6, the preferred embodiment of the sensor
module 12 incorporates a PCB (printed circuit board) 70 of suitable
substrate material such as a woven fiberglass mat impregnated with
epoxy resin to mechanically support and electrically connect the
electronic components comprising the sensor module 12. The PCB 70
features through-hole contact pads 82 for permanent (soldered)
electrical association with the conductors of the signal cable
54.
[0027] The components of the preferred embodiment are readily
available and consist of a surface mount resistor 84, polarized
capacitor 86, non-polarized capacitor 88, two electrostatic
discharge protection ICs 90, a diode half-wave rectifier on chip
92. The preferred embodiment of the sensor element 72 employs a
digital temperature sensor IC capable of deriving power for
operation from the data transmission conductor 58 by including a
capacitor on chip and advantageously utilizing a communication
protocol which maintains a logic level one (voltage high) state
most of the time. Alternately, the digital temperature sensor IC 72
can recognize when external power is output from a diode half-wave
rectifier on chip 92 and made available to the appropriate pin on
the digital temperature sensor IC 72. The digital temperature
sensor IC 72 can then advantageously utilize the power for improved
reliability in extreme cold temperature conditions and/or where a
plurality of sensors cumulatively exert to too great a current draw
for regular data transmission to continue to occur reliably.
[0028] The preferred embodiment depicted as an assembled printed
circuit board 70 in FIG. 6 and as a schematic circuit diagram 94 in
FIG. 7 incorporates a novel design which permits crafting very long
signal cables that are immune to communications failures normally
associated with bus voltage levels falling below minimums for
conventional CMOS/TTL logic level one (2.2V or 2.8V). The design
reserves a single conductor from the signal cable 54 for
unregulated input power supply 62 which is separate from the data
transmission conductor 58 that is clamped for example by the
interface device 46 or control appliance 36 with an applied voltage
such as +6V or +9V well in excess of the target supply voltage to
the digital temperature IC 72 of +5V. The unregulated input power
supply line feeds a diode half-wave rectifier on chip 92 which
functions as a voltage regulator that outputs constant 5V to the
appropriate pin on the digital temperature sensor IC 72.
[0029] Although not depicted in the preferred embodiment of the
sensor module 12 shown in FIG. 5 or printed circuit board 70 shown
in FIG. 6, an alternate embodiment of the invention reserves a
single conductor from the signal cable 54 for a regulated voltage
power supply 64 to be carried from the output of only one voltage
regulator such as the diode half-wave rectifier on chip 92 featured
in FIG. 7 to a plurality of sensor elements 72 located at a
distance. The ability for a plurality of sensor elements 72 to
share the output from a single voltage regulator is a function of
the input current available to the diode half-wave rectifier on
chip 92 input pin, the output capacity of same, the demand
exhibited by each individual sensor element 72 and losses
associated with transmission through the conductors.
[0030] The preferred embodiment also reserves a single conductor
each for bi-directional data transmission 58 and data ground or
reference 60.
[0031] The stability of the supplied voltage to the digital
temperature sensor IC 72 is further ensured through the use of a
non-polarized capacitor 88 between the regulator input 62 and drain
96. An additional polarized capacitor 86 installed between the
regulator output 98 and an electrostatic discharge prevention
device 90 also serves as a redundant current stabilizer in the
event of momentary power loss. An additional ESD prevention device
90 functions to isolate the digital temperature sensor IC 72 from
ESD events along the data transmission 58 and reference or ground
lines 60.
[0032] PCBs 70 are rugged, inexpensive, and can be highly reliable.
They require much more layout effort and higher initial cost than
either wire-wrapped or point-to-point constructed circuits, but are
much cheaper, faster, and consistent in high volume production.
Also a printed circuit board can be employed as a platform for
mounting the integrated circuit-based sensor 72 and allows
additional mechanical isolation from stresses arising from flexure
of the signal cable 54.
[0033] The control appliance 36 supports access to the data stored
in memory 40 over a public data network, such as the global
Internet via a network interface card 44.
[0034] FIG. 8 illustrates exemplary processing details of a method
100 in accordance with the present invention. The method could be
implemented as an arrangement of instructions delivered to data
storage 40 within a control appliance 36 corresponding to a mobile
handheld computing device.
[0035] In an initial step 102, the method provides for organization
of future sensed temperature data into a database for storage and
later retrieval. Incorporation of metadata associated with the
time, or geographic position, local conditions, or purposes of one
or many temperature readings benefits the consumer of the data. The
initial step 102 is exemplary and other organizational schema may
be implemented.
[0036] In a second step 104, substantial additional functionality
beyond basic control and interaction with one or a plurality of
sensor modules 12 is described for the control appliance 36.
Generic computing platforms including a mobile handheld computing
device are well suited for automation of many functions. Selection
of upper and lower temperatures for comparison with sensed
temperature data adds alarm capabilities. The frequency with which
the control appliance acquires sensed temperature data and the
duration of the recording period are described.
[0037] In a third step 106, sensor element property data specific
to one or a plurality of sensor elements such as the digital
temperature sensor IC 72 described, is determined and stored in a
database and later applied to or combined with data as it is
received from individual sensor modules to the control appliance
36, processed, and stored in a database. For instance, a constant
offset value may be applied to each result received by the control
appliance 36 from a sensor module 12.
[0038] In a fourth step 108, additional functionality is attributed
to the control appliance 36 enabling configurable import and export
operations to and from the control appliance via an input/output
device 44 of various organizational data or data specific to one or
a plurality of sensor elements.
[0039] In a fifth step 110, the method describes one means of
selectively viewing previously acquired sensed temperature data
either by project or by location or by time or by a combination of
these criteria.
[0040] In a sixth step 112, the primary functionality of the
multipoint digital temperature acquisition system is described. The
control appliance initiates interaction with one or a plurality of
sensor modules electrically associated with it and acquires sensed
temperature data in accordance with the metadata determined in step
102, the frequency, duration, alarm settings, and units prescribed
in step 104, and the unique sensor element property data determined
in step 106.
[0041] Generalized layers of a computer program product 114
embodied on a computer-readable storage medium for substantially
receiving a set of instructions for execution of method 100 by a
control appliance are illustrated in FIG. 9. A computer program
product or software algorithm 114 that consists of four distinct
layers provides flexibility for future adaptation to alternate
embodiments of the control appliance or sensor modules 12. The
layers shown are the User Interface Layer 116, the Control Layer
118, the Sensor Module Communication Protocol Layer 120, and the
Database Layer 122. By using separate layers that communicate with
each other, the individual parts (i.e., layers) can be re-used or
replaced without altering code in another layer. In addition, the
layers act to modularize the computer program product 114 and allow
for easy updating of components.
[0042] In another embodiment of the invention, a sensor module 12
could be wirelessly coupled to an interface device 46. Those with
skill in the art will understand that a plurality of sensor modules
could be coupled to the interface device 46 without departing from
the spirit and scope of this application.
[0043] In yet another embodiment of the invention, data storage
modules are incorporated between sensor modules and also between a
sensor module and the proximal or distal ends of the cable
apparatus. This embodiment, sensor modules coupled with displaced
data storage modules, provides the advantage of allowing data
relevant to one or a plurality of individual sensor modules to be
housed within a data storage module that is physically associated
with a hard-wired cable apparatus. These data can then be passed to
the control appliance 36 thereby eliminating the need for the data
to be known to the control appliance a priori and reducing the need
for user interaction via the control appliance I/O 44. Examples of
this data are cable serial number, calibration data, etc.
[0044] Embodiments of the present invention provide a novel
multipoint temperature measurement cable which successfully
integrates adaptations for improved life and performance in extreme
low temperature field applications (i.e. to at least -40 degrees
C./F.). Although the invention has been described in connection
with a preferred embodiment, it should be understood that various
modifications, additions and alterations may be made to the
invention by one skilled in the art without departing from the
spirit and scope of the invention as described herein.
[0045] claims 1-19. (canceled).
* * * * *