U.S. patent application number 14/981601 was filed with the patent office on 2016-06-16 for wireless in-kiln moisture sensor and system for use thereof.
The applicant listed for this patent is SCS Forest Products, Inc.. Invention is credited to Scott Schneider, Patrick Youssi.
Application Number | 20160169826 14/981601 |
Document ID | / |
Family ID | 49878031 |
Filed Date | 2016-06-16 |
United States Patent
Application |
20160169826 |
Kind Code |
A1 |
Youssi; Patrick ; et
al. |
June 16, 2016 |
WIRELESS IN-KILN MOISTURE SENSOR AND SYSTEM FOR USE THEREOF
Abstract
A wood monitoring system and method is disclosed for monitoring
lumber characteristics (e.g., lumber moisture) in environments of
extremely high and prolonged temperature and moisture, e.g., a
kiln. The monitoring system and method includes: (a) Sensors
(provided within lumber stacks), wherein such sensors are battery
powered and wirelessly communicate measurements indicative of
moisture content of the wood adjacent to and/or between metal
plates provided in an electrical circuit with the sensors and the
wood between the plates; (b) Computer implemented methods and
systems for wireless communication that conserve sensor battery
power such that the sensors can operate for, e.g., six months
within extremely adverse temperature and moisture environmental
variations; and (c) Computer implemented methods and systems for
estimating moisture content with a wood/lumber stack, and for
predicting such moisture content (e.g., as a substantially steady
state within the wood) after drying completion.
Inventors: |
Youssi; Patrick; (Denver,
CO) ; Schneider; Scott; (Highlands Ranch,
CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SCS Forest Products, Inc. |
Englewood |
CO |
US |
|
|
Family ID: |
49878031 |
Appl. No.: |
14/981601 |
Filed: |
December 28, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13934887 |
Jul 3, 2013 |
9222906 |
|
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14981601 |
|
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61667942 |
Jul 4, 2012 |
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Current U.S.
Class: |
324/664 |
Current CPC
Class: |
F26B 2210/16 20130101;
G01N 33/46 20130101; F26B 21/02 20130101; F26B 21/08 20130101; G01N
27/048 20130101; F26B 25/22 20130101; G01N 27/223 20130101 |
International
Class: |
G01N 27/22 20060101
G01N027/22; G01N 33/46 20060101 G01N033/46; G01N 27/04 20060101
G01N027/04 |
Claims
1. A method for monitoring the moisture content of a collection of
wood members drying in a kiln, the kiln operable for applying heat,
and air circulation for drying the collection to a specified
moisture content, wherein a wireless sensor in operable contact
with the wood collection for forming an electrical circuit with the
wood, wherein the circuit additionally includes two spaced apart
conductive plates positioned within the wood collection, and
wherein the sensor and the circuit are configured to establish each
of a capacitance and resistance of a water content of at least a
portion of the collection, the portion residing between the spaced
apart conductive plates; and wherein the sensor includes: (a) a
wireless transmitter for wirelessly communicating with a stationary
device, the stationary device for wirelessly receiving data from
the sensor related to the water content of the portion of the
collection, the data including measurements of the capacitance and
resistance, and (b) one or more batteries for providing electrical
power to the sensor; comprising performing the following steps by
computational machinery: activating a timer for determining when a
first time limit is exceeded; wirelessly transmitting a first
instance of the data to the device, via the wireless transmitter,
when the first time limit is exceeded; evaluating a predetermined
condition, wherein the evaluation of the predetermined condition
performs one of: (i) a comparison of an elapsed time for drying the
collection in the kiln with a predetermined elapsed time limit for
drying the collection in the kiln, (ii) a comparison of a humidity
in the kiln with a humidity threshold, or (iii) a comparison of an
impedance for the portion of the collection with an impedance
threshold; obtaining, when the predetermined condition evaluates to
a predetermined result, information for a second time limit
different from the first time limit; using the information for
activating the timer to determine when the second time limit is
exceeded; and wirelessly transmitting a second instance of the data
to the device, via the wireless transmitter, when the second time
limit is exceeded; wherein for conserving the batteries, the first
time limit is longer than the second time limit.
2. The method of claim 1, wherein the timer outputs a notification
when the first time limit is exceeded.
3. The method of claim 1, wherein the first time limit is at least
twice the duration of the second time limit.
4. The method of claim 1, wherein the using step includes replacing
the first time limit with the second time limit.
5. The method of claim 1, further including the steps of: obtaining
an instance of the data during the first time limit; determining a
value indicative of a change between the instance and a previous
instance of the data; comparing the value to a predetermined change
related condition indicative of particular changes between
instances of the data; and wirelessly transmitting the instance to
the device, via the wireless transmitter, when the comparing step
yields a first result indicative of the predetermined change
related condition occurring between the one instance and the
previous instance, and not wirelessly transmitting the instance
when the comparing step yields a second result indicative of the
predetermined change related condition not occurring between the
one instance and the previous instance.
6. The method of claim 5, wherein the predetermined change related
condition includes a threshold for determining whether a
temperature change between the one instance and the previous
instance is out of a range corresponding with the threshold, and
wireless transmitting the one instance to the device when the
temperature difference is out of the range.
7. The method of claim 5, wherein the predetermined change related
condition includes a threshold for determining whether a humidity
change between the one instance and the previous instance is out of
a range corresponding with the threshold, and wireless transmitting
the one instance to the device when the humidity difference is out
of the range.
8. The method of claim 5, wherein the predetermined change related
condition includes a threshold for determining whether a
capacitance change in the circuit between the one instance and the
previous instance is out of a range corresponding with the
threshold, and wireless transmitting the one instance to the device
when the temperature difference is out of the range.
9. The method of claim 5, wherein the predetermined change related
condition includes a threshold for determining whether a resistance
change in the circuit between the one instance and the previous
instance is out of a range corresponding with the threshold, and
wireless transmitting the one instance to the device when the
temperature difference is out of the range.
10. The method of claim 1, wherein the evaluation of the
predetermined condition comparing an elapsed time for drying the
collection in the kiln with a predetermined elapsed time limit for
drying the collection in the kiln.
11. The method of claim 1, wherein the evaluation of the
predetermined condition comparing the humidity in the kiln with a
humidity threshold.
12. The method of claim 1, wherein the evaluation of the
predetermined condition comparing the impedance for the portion of
the collection with an impedance threshold.
13. The method of claim 1, further including using the device as an
intermediate wireless device for providing communications between a
controller for controlling the drying of the collection in the
kiln, the second wireless device for wirelessly communicating with
a second sensor wirelessly.
14. The method of claim 1 further including using the device as an
intermediate wireless device for providing communications between a
controller for controlling the drying of the collection and the
sensor, wherein the controller accesses data for locating the
sensor within the collection or within the kiln.
15. The method of claim 14, wherein the controller selectively
activates or deactivates the sensor dependent upon its
location.
16. The method of claim 15, wherein the location of the sensor is
relative to one or more other wireless sensors in the collection or
in the kiln.
17. A wireless sensor for monitoring the moisture content of a
collection of wood members being dried in a kiln, the kiln operable
for applying heat, and air circulation for drying the collection to
a specified moisture content, wherein the wireless sensor is in
operable contact with the wood collection for forming an electrical
circuit with the wood, wherein the circuit additionally includes
two spaced apart conductive plates positioned within the wood
collection, and wherein the sensor and the circuit are configured
to establish capacitance and resistance of a water content of a
portion of the collection, the portion residing between the spaced
apart conductive plates; the sensor comprising: one or more
batteries for electrically powering the sensor; a wireless
transmitter for wirelessly communicating with a stationary device,
the wireless communications including transmissions by the
transmitter of data related to the water content of the portion of
the collection, the data including measurements of each of the
capacitance and resistance, measurements of the humidity in the
kiln, and measurements of a temperature in the kiln; a processor
for iteratively: (i) obtaining one of the measurements of the
capacitance, one of the measurement of the resistance, one of the
measurements of the humidity, and one of the measurements of the
temperature, and (ii) providing the one measurement of each of: the
capacitance, resistance, humidity and temperature to the wireless
transmitter for wirelessly transmitting as an instance of the data;
a timer for determining when a first time limit is exceeded;
wherein the wireless transmitter wirelessly transmits a first
instance of the data to the device when the first time limit is
exceeded; wherein the processor evaluates a predetermined
condition, the evaluation of the predetermined condition performs
one of: (i) a comparison of an elapsed time for drying the
collection in the kiln with a predetermined elapsed time limit for
drying the collection in the kiln, (ii) a comparison of a humidity
in the kiln with a humidity threshold, or (iii) a comparison of an
impedance for the portion of the collection with an impedance
threshold; wherein the processor obtains, when the predetermined
condition evaluates to a predetermined result, information for a
second time limit different from the first time limit; wherein the
processor uses the information for activating the timer to
determine when the second time limit is exceeded; wherein the
wireless transmitter wirelessly transmits a second instance of the
data to the when the second time limit is exceeded; wherein for
conserving the batteries, the first time limit is longer than the
second time limit.
18. The sensor of claim 17, wherein one of the instances of the
data is obtained by the processor during the first time limit;
wherein the processor obtains a value indicative of a change
between the one instance and a previous instance of the data;
wherein the processor compares the value to a predetermined change
related condition for identifying specific changes between
instances of the data, and thereby obtaining one of: a first result
indicative of the predetermined change related condition occurring
between the one instance and the previous instance, and a second
result indicative of the predetermined change related condition not
occurring between the one instance and the previous instance; and
wherein the wireless transmitter wirelessly transmits the instance
to the device when the first result is obtained, and does not
wirelessly transmit the instance when second result is
obtained.
19. The sensor of claim 17, further including a component that
persistently stores an identifier, wherein the identifier is
retrieved from the component and included in each instance of the
data for distinguishing wireless transmissions of the instances
from wireless transmissions not originating with the sensor.
Description
RELATED APPLICATION
[0001] The present application is a continuation-in-part (CIP)
application of U.S. patent application Ser. No. 13/934,887, filed
Jul. 3, 2013, which claims the benefit of U.S. Provisional Patent
Application No. 61/667,942 filed Jul. 4, 2012, each of which is
fully incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention is related to the wireless monitoring
of drying of wood in a kiln, and more particularly, wireless
sensors for monitoring the wood drying process wherein the life of
the batteries for the sensors is extended.
BACKGROUND
[0003] Today's market for kiln dried lumber demands significantly
greater attention to the lumber production process. Government and
industry regulations and customer expectations of wood quality have
increased every year. Additionally, competitive pricing of final
lumber grade has become more severe. Therefore, mills must maintain
a high level of scrutiny of each production stage to reduce or
eliminate product errors and waste. Process mistakes that do occur
result in wood products that have compromised strength properties,
may be susceptible to mold, or can lose significant value due to
shrinkage or any number of visual defects. In addition, wood
processing errors can cause lost productivity as well as higher
energy costs for a mill.
[0004] There are a number of vendors that provide in-kiln moisture
measurement systems. In fact, prior art systems have been
commercially available for two decades. Such prior art systems
(e.g., by the manufacturers Wagner, Wellons, and Accudry, SCS
Forest Products) have been described in significant detail in
various public disclosures, including the following U.S. patent
Nos.: U.S. Pat. No. 4,389,578 by Wagner; U.S. Pat. No. 4,580,233 by
Parker, et al.; U.S. Pat. No. 6,703,847 by Venter et al.; and U.S.
Pat. No. 6,989,678 by Venter et al. each of which is fully
incorporated herein by reference. Additionally, the following U.S.
patent numbers are fully incorporated herein by reference: U.S.
Pat. No. 3,807,055 by Kraxberger; U.S. Pat. No. 4,107,599 by
Preikschat; U.S. Pat. No. 6,124,584 by Blaker et al.; U.S. Pat. No.
6,281,801 by Cherry et al.; U.S. Pat. No. 6,784,671 by Steele, et
al.; U.S. Pat. No. 6,784,672 by Steele, et al.; U.S. Pat. No.
7,068,050 by Steele; and U.S. Pat. No. 7,068,051 by Anderson. U.S.
Patent Application Publication No. US 2004/0187341 by Studd, et al.
is also fully incorporated herein by reference.
[0005] All of these systems work using decades-old theory by
converting capacitance response to moisture content. This is
accomplished by placing two or more metal plates in a lumber stack,
which are vertically separated by some calculated distance. The
system then creates a capacitor by applying an electrical signal to
the plates. The main dipolar constituent between the plates is
water within the lumber stack. Therefore, the capacitance response
diminishes during a drying cycle as water is removed. The drop in
capacitance is correlated to the loss of moisture.
[0006] To-date, the prior art systems that perform the function of
measuring the change in capacitance over time, have relied upon
placing one or more fixed wall-mounted metering devices inside,
outside or near the kiln for drying the lumber therein. The
metering devices are responsible for determining the electrical
response of the circuit formed by the metal (steel) plates and the
lumber stack between the two plates. Cables connect the meters to
the plates inserted in the lumber stack. The metering devices, in
turn, are connected, via wire or cables, to a central programmable
logic controller (PLC) or other computing device (e.g., a personal
computer, PC herein). The calculation of moisture content is
performed either at the meters themselves or at a central PLC or
PC. These wired systems have been installed throughout lumber
drying kilns in North America.
[0007] These prior-art lumber drying systems have a number of
limitations. Since all of these systems are connected via cables to
a main PC or controller, the number of meters is limited by
financial constraints. In addition to the per-unit cost for each
meter, conduit runs must be installed to protect cables that
transmit electrical measurements to the PCL or PC. Depending on the
configuration of the kiln, these conduit runs can be hundreds of
feet long. Running high temperature cable inside aluminum conduit
between each meter and the PLC or PC is a considerable upfront
expense as well as an on-going maintenance expense.
[0008] Another limitation of such prior art lumber drying
monitoring systems is that once a measurement point (e.g., meter)
is fixed to the kiln wall and conduit is run to that point, the
location cannot be easily changed without incurring significant
cost. Therefore, the operator does not have flexibility to target
desired locations in the kiln drying lumber. Often times, lumber
mills will produce new lumber products that require greater in-kiln
observation in the first number of manufacturing cycles. Installing
additional moisture sensors in a timely manner is not an option.
Therefore, mills will often incur costly production loss and
greater energy usage in the early manufacturing runs until the
manufacturing process has been standardized.
[0009] Finally, the entire lumber production industry is undergoing
a significant shift as the industry moves from batch processing of
lumber to continuous processing. Instead of packages of lumber
being placed inside a kiln for a set period of time, operators are
continuously moving the stacks of lumber on rail tracks through
various heating chambers. Having measurement sensors within such
lumber stacks wherein the sensors are tethered to meters of fixed
location is not an option in this case. In particular, the lumber
stacks may travel approximately 100 feet (or greater, e.g., 200
feet) through the various drying chambers. At any one time, there
may be 10 or more distinct lumber stacks moving through the drying
process. Moving cables attached to each lumber stack would create
too many safety and logistical issues for the mills to consider
this a viable option.
[0010] Regarding wireless technology, unfortunately, commercially
available in-situ wireless moisture measurement sensors are not an
option for a number of reasons. First, there are no viable wireless
systems that can survive softwood kiln temperatures. In most cases,
kiln temperatures reach 260.degree. Fahrenheit (F) or higher, which
is far higher than conventional moisture sensor technology allows.
Second, the kiln environment has very high humidity with hot ash
and sap sticking to any available surface. Because of these
conditions, very limited electronics have heretofore been provided
inside the kiln. In particular, most commercially available
electronics have a maximum temperature of 125.degree. F. and are
not effective for marine environments (e.g., where there is
consistently high moisture content of, e.g., 90% or more). Further,
in-kiln temperatures can range from -40 to +260.degree. F., and
this wide temperature range is especially problematic in that kiln
temperatures can ramp from the low end of this range to the upper
end of this range in a matter of hours (e.g., three to four hours
or less). Furthermore, sensors (in the lumber stacks) and the
meters placed in the kiln must operate continuously for, e.g., up
to three weeks.
[0011] Moreover, if the moisture sensors within the lumber stacks
are to be untethered (e.g., wireless) in their communications, then
they must be powered by batteries. However, in general, battery
life for electronic devices is severely degraded by the elevated
kiln temperatures as recited above. In fact, studies show that
batteries operating at temperatures above 113.degree. F. will lose
50% of their useful operating life performing a task whereas at
lower temperatures (e.g., 100.degree. F.), there would only be a
20% to 30% reduction in such useful operating life. This is
particularly important for the drying and processing of softwood
lumber since such lumber may need to be monitored for lengthy time
periods, e.g., approximately six months or longer in kiln
environments with extremely high prolonged temperatures and/or
extremely high prolonged moisture content. Accordingly, perhaps the
most challenging for wireless lumber monitoring sensors is the
battery life. This is probably the primary reason that no other
manufacturer has developed a wireless sensor based capacitance
system for the monitoring the moisture content of softwood within
wood drying kilns since softwood lumber in-kiln drying requires
sensor batteries to be operationally useful at prolonged
temperatures of 260.degree. F. (or higher)--significantly higher
than the top range for standard batteries to effectively operate,
e.g., a typical wireless sensor. In particular, such high
temperatures may be required for up to twenty-one days. It is,
however, worth mentioning that there are specialty batteries that
operate at higher temperatures, but battery life would still be a
significant issue.
[0012] Because there are no wireless options for the softwood
market, meter suppliers have looked at creating physical
connections using sleds instead of cables between the meters and
the lumber stack. As the lumber stack moves past a fixed sled, the
sensors within the lumber stack come into electrical contact (e.g.,
via a protrusion from each sensor contacting sled) the meter can
make a valid measurement. There are a number of disadvantages with
such sled systems, including, but not limited to installment cost,
maintenance costs, accuracy and limited lumber moisture sampling
ability due to the sleds being attached to the kiln wall.
Accordingly, the adoption of these sleds has been very slow.
[0013] Due to the drawbacks (e.g., as recited above) with the prior
art lumber drying monitoring systems for the lumber industry, the
technology in the present disclosure has been developed for
addressing such drawbacks, and in particular, providing an
apparatus (e.g., one or more computational devices/equipment) and
computer methods for monitoring lumber characteristics (e.g.,
moisture content), wherein wireless lumber measurements are taken
by sensors embedded within lumber stacks and such sensors can
remain operationally effective for extended periods of time without
maintenance such as battery replacement.
[0014] Accordingly, it would be advantageous to have a lumber
monitoring system and method that mitigates or cures the
above-identified drawbacks of the current lumber drying systems and
methods.
SUMMARY
[0015] A lumber monitoring system and method is disclosed
hereinbelow for monitoring lumber characteristics (e.g., lumber
moisture) in environments of extremely high and prolonged
temperature and moisture. The present lumber monitoring system and
method includes: [0016] (a) Sensors (provided within lumber
stacks), wherein such sensors are (1) battery powered and
wirelessly communicate measurements indicative of, e.g., the
moisture content of the wood adjacent to and/or between metal
plates provided in an electrical circuit with the sensors and the
wood between the plates, and (2) able to effectively operate in
such extreme environments that vary from, e.g., from -40 to
+260.degree. F., with ambient moisture content ranging from
extended durations near zero moisture to extended durations of 90%
to 100% moisture; [0017] (b) Computer implemented methods and
systems for wireless communication that conserve sensor battery
power such that such sensors can effectively operate for, e.g., six
months within extremely adverse temperature and moisture
environmental variations; and [0018] (c) Computer implemented
methods and systems for estimating moisture content with a
wood/lumber stack, and for predicting such moisture content (e.g.,
as a substantially steady state within the wood) after drying
completion.
[0019] In one embodiment of the presently disclosed system and
associated method, the lumber monitoring equipment (including
associated computer systems for performing various computations)
can be configured for measuring attributes or characteristics of
lumber prior to, during and after such lumber is processed within,
e.g., a lumber drying kiln facility and/or another lumber
processing facility such as a saw mill. In particular, such lumber
attributes or characteristics are monitored so that the lumber's
environment (e.g., in kiln environment) can be adjusted and/or
maintained so that the lumber attains (and retains) a desired range
of moisture content. Such lumber monitoring equipment may determine
appropriate lumber moisture content ranges, wherein such ranges may
be dependent upon, e.g., the type of wood, the current content of
moisture, expected environmental conditions to which the lumber may
be subjected, etc. Such monitoring equipment typically includes a
PLC or PC (as these terms are defined above) having various
specialized computer programmatic instructions for (a) controlling
the wood monitoring process and (b) computing, e.g., estimated
current wood moisture content and/or predicting a resulting
substantially steady state moisture content within the wood after
drying. Note that the hardware and software for performing (a) and
(b) immediately above also will be referred to hereinbelow as a
"controller".
[0020] The novel lumber monitoring system and method of the present
disclosure provides a unique solution that limits battery usage by
sensors, e.g., within lumber stacks. In particular, the following
features are provided: [0021] (a) Each such sensor only wirelessly
transmits (to a wireless device identified as a "hub" or "hub
device" herein) when capacitance within the lumber stack (within
which the sensor is embedded) has changed by a predetermined amount
(e.g. a percentage thereof), and [0022] (b) Each such sensor
wirelessly reduces the number of readings and wireless
transmissions during less critical phases and increases the read
rate and wireless transmissions when these readings are most
important. In particular, embodiments of the lumber monitoring
equipment and associated method therefor increase battery
performance such that empirical testing shows batteries can
potentially last six months or more in a typical operating
environment within a lumber drying kiln.
[0023] Another novel aspect of the present disclosure includes
computer instructions (and/or dedicated computational machine
device(s) implementing such instructions in hardware and/or
software) for estimating moisture content using both capacitance
and resistance. In particular, the present disclosure describes the
creation and use of a unique index (Measurement Index herein) for
assessing moisture content in lumber, wherein both capacitance and
resistance are provided as inputs, and such inputs may be combined
or weighted for estimating the moisture content in lumber. For
example, at one or more time intervals (e.g., during the drying of
lumber), resistance measurements are given an increased weight in
the Measurement Index in comparison to capacitance measurements. In
particular, capacitance is not as accurate as resistance at high
moisture readings. However, as lumber dries, it has been determined
that capacitance becomes far more accurate than resistance in
measuring lumber moisture content. Thus, alternating current (AC)
resistance measurements can be a good indicator of moisture content
when wood is very wet since, e.g., large changes in resistance may
be the result of small changes in moisture content while
capacitance measurements are more indicative of wood moisture
content when such moisture content is below, e.g., a range of fiber
saturation point as one skilled in the art will understand.
Therefore, the novel wood drying system and method models the wood
drying process much more consistently and accurately when both
capacitance and resistance are used.
[0024] Embodiments of the present wood drying system and method
also provide for the wireless monitoring of wood moisture content.
Further, such wireless monitoring can be performed in: [0025] (1) A
batch mode where the wood in a given batch is dried separately from
other batches, or [0026] (2) A continuous mode where wood for
various products is dried concurrently, albeit according to each
product specifications; in particular, such continuous wood drying
includes the movement of the stacks of wood between drying
chambers.
[0027] It is also an aspect of the presently disclosed monitoring
system that the wireless sensors used for such monitoring can be
easily repositioned as desired for better monitoring the moisture
content of the wood for the product intended. Moreover, it is
within the scope of the presently disclosed wood monitoring system
to allow various sensors to be wirelessly activated and deactivated
by, e.g., a hub device with which a plurality of such sensors
wirelessly communicate. Accordingly, wireless sensors may be
distributed throughout a wood stack, and one or more of the sensors
may be activated in response to, e.g., data received from a subset
of the sensors. In particular, a PLC or PC performing the
computations for converting received sensor data (obtained via one
or more hub devices, likely at fixed locations along the
wood/lumber processing or drying path) may determine whether sensor
data from additional sensors within a wood stack should be
activated.
[0028] It is a further aspect of an embodiment of the presently
disclosed monitoring system that such a PLC or PC has access to
mapping data which indicates the locations of the sensors within
the wood/lumber stack. In one embodiment, each sensor may be
wirelessly located within its wood stack and/or relative to other
sensors so that a data map of the sensors within the wood stack can
be generated and used for selectively activating and/or
deactivating various sensors (subsets thereof) depending on the
sensor's location within its stack (or more generally in the kiln),
and/or wood monitoring data received from, e.g., a particular
subset of the sensors. In one embodiment, disjoint subsets of
sensors may be activated and deactivated throughout the storage and
processing of a wood/lumber stack (i.e., while being dried in a
kiln, being stored after or before drying, being processed after
being dried) for determining the moisture within the wood. Such
disjoint subsets of sensors may provide the following advantages:
(1) the battery life of each sensor is extended since its subset is
only activated occasionally, (2) if each sensor subset is
distributed differently but still is able to provide monitoring
data for the entire wood/lumber stack, then the various sensor
views of, e.g., moisture within the wood/lumber stack from the
various sensor subsets can provide greater assurance that the
wood/lumber is being properly processed and/or maintained, and (3)
the sensor subsets provide a failsafe ability to the monitoring
process in that one or more failed sensors may be tolerated due to
the plurality of views of the wood/lumber provided by multiple
sensor subsets. Accordingly, the PLC or PC (referred as a
"controller" hereinbelow) may perform such selective activation
and/or deactivation via wireless transmissions to the sensors
activated or deactivated.
[0029] In one embodiment of the presently disclosed monitoring
system, the positions of the sensors within a wood/lumber stack are
determined relative to one another, relative to another location,
or as an absolute location (e.g., via GPS). Accordingly, the
presently disclosed monitoring system can detect an unintended
dislocation of a sensor relative to other sensors, and adjustments
may be made in the monitoring of the wood/lumber and/or an operator
may be alerted to, e.g., reposition the dislocated sensor.
[0030] Since lumber drying kiln operators can deploy as many of the
presently disclosed measurement sensors as required for the
specific wood product being produced, in some cases, mills may add,
subtract or reposition sensors within a wood stack between kilns to
provide improved sampling in a particular kiln. Note that since
various kilns may have substantially different wood drying
characteristics (e.g., heat flow patterns, heat gradients, air
circulation, and venting) such repositioning of sensors may be
dependent upon the kiln within which the wood stack is provided.
Additionally/optionally, a plurality of sensor subsets may be
provided in the wood stack so that one or more sensor sets may be
activated dependent upon the particular kiln in which the wood
stack having the sensor subsets is provided.
[0031] Moreover, in one embodiment of the presently disclosed
monitoring system, the number, location and/or activation of
sensors within a wood stack also can be dependent upon the type of
wood. Some wood/lumber products can be more variable in their
moisture content within a wood drying kiln. In particular,
additional moisture content sensor data samples may be needed to
fine tune the wood drying process. In other wood/lumber products
being dried, the wood/lumber moisture content may be more evenly
distributed; thus fewer sensors (or activations thereof) may be
required to make (1) an accurate prediction of the current moisture
content of a wood stack, and/or (2) make a prediction of what the
moisture content of the wood stack will be after drying (assuming,
e.g., the wood stack is stored or processed in a manner that is
amenable to such prediction).
[0032] It is a further aspect of the wood sensors disclosed herein
that they have a reduced susceptibility to corrosion from the
drying of wood. In particular, such sensors are subjected to
potentially corrosive substances in wood ash and sap. Note, it is
well known that wood is corrosive by nature and can be made more
corrosive by various treatments. In particular, wood includes
acetic acid which is volatile, and in an ill-vented space (such as
in a kiln), wood can cause metal corrosion; further, wood ash
includes from 0.2 to 4% of mineral ash, which consists largely of
calcium, potassium and magnesium as carbonate, phosphate, silicate,
and chloride; aluminum, iron and sodium are also present. Sulphate
contributes 1 to 10% of wood ash by weight, and chloride 0.1 to 5%,
and these two radicals augment the corrosive action of the acetic
acid.
[0033] Accordingly, embodiments of the wood monitoring system and
method herein may provide the following benefits: [0034] 1. Since
the hub(s) need not be tethered to the sensors, such hub(s) can be
flexibly located inside or outside the kiln from which the hub(s)
receive wireless sensor transmissions. In particular, such hub(s)
need only be able to wirelessly communicate with the sensors and
also transmit data (e.g., via a cable) to the controller (as this
term is described above). Thus, such hub(s) need only be placed in
wireless range for communicating with the sensors in the kiln
associated with hub(s). Thus, such hubs may be positioned in a mill
yard, sawmill, planer mill, etc. That is, the hub devices are no
longer limited to being located in the kilns. Also, since such hub
devices can be positioned virtually anywhere along a wood
processing path (e.g., within a saw mill), real-time monitoring of
wood moisture content can be determined where heretofore such has
not been possible. [0035] 2. When a sensor's battery potential
reduces below, e.g., a predetermined threshold, the frequency of
data transmissions may be reduced to conserve the battery. [0036]
3. In one embodiment, the controller is provided with data
indicative of critical wood drying intervals for a wood stack.
Accordingly, the controller may instruct the sensors within the
wood stack to reduce their moisture sampling rates outside of such
critical intervals to thereby extend the sensors' effective battery
life. Note that such critical intervals may be based on historical
wood/lumber drying for the type of wood/lumber being currently kiln
dried, and/or the particular kiln being used for the drying, and/or
the kiln settings (e.g., timing of heat applied, venting,
circulating fans activated, etc.). [0037] 4. More accurate and
reliable moisture content estimation is achieved by using both
capacitance and resistance to estimate wood/lumber moisture content
as discussed hereinabove. [0038] 5. The sensors have a reduced
susceptibility to wood product corrosion.
[0039] In one embodiment, the present disclosure is directed to a
method for monitoring the moisture content of a collection of wood
members (e.g., lumber) drying in a kiln, the kiln operable for
applying heat, and air circulation for drying the collection to a
specified moisture content, wherein: [0040] There is a wireless
sensor in operable contact with the wood collection for forming an
electrical circuit with the wood, wherein the circuit additionally
includes two spaced apart conductive plates positioned within the
wood collection, and wherein the sensor and the circuit are
configured to establish each of a capacitance and resistance of a
water content of at least a portion of the collection, the portion
residing between the spaced apart conductive plates; and [0041]
wherein the sensor includes: (a) a wireless transmitter for
wirelessly communicating with a stationary device, the stationary
device for wirelessly receiving data from the sensor related to the
water content of the portion of the collection, the data including
measurements of the capacitance and resistance, and (b) one or more
batteries for providing electrical power to the sensor;
[0042] wherein the method performs the following steps by
computational machinery: [0043] (a) activating a timer for
determining when a first time limit is exceeded; [0044] (b)
obtaining an instance of the data during the first time limit;
[0045] (c) determining a value indicative of a change between the
instance and a previous instance of the data; [0046] (d) comparing
the value to a predetermined change related condition indicative of
particular changes between instances of the data; [0047] wirelessly
transmitting the instance to the device, via the wireless
transmitter, when the comparing step yields a first result
indicative of the predetermined change related condition occurring
between the one instance and the previous instance, and not
wirelessly transmitting the instance when the comparing step yields
a second result indicative of the predetermined change related
condition not occurring between the one instance and the previous
instance; [0048] wirelessly transmitting a further instance of the
data to the device, via the wireless transmitter, when the first
time limit is exceeded; [0049] (e) evaluating a predetermined
condition, wherein the evaluation of the predetermined condition
performs one of: (i) a comparison of an elapsed time for drying the
collection in the kiln with a predetermined elapsed time limit for
drying the collection in the kiln, (ii) a comparison of a humidity
in the kiln with a humidity threshold, or (iii) a comparison of an
impedance for the portion of the collection with an impedance
threshold; [0050] (f) obtaining, when the predetermined condition
evaluates to a predetermined result, information for a second time
limit different from the first time limit; [0051] (g) using the
information for activating the timer to determine when the second
time limit is exceeded; and [0052] (h) wirelessly transmitting a
second instance of the data to the device, via the wireless
transmitter, when the second time limit is exceeded; [0053] wherein
for conserving the batteries, the first time limit is longer than
the second time limit.
[0054] In a related embodiment, the present disclosure is directed
to a wireless sensor for monitoring the moisture content of a
collection of wood members (e.g., lumber) being dried in a kiln,
the kiln operable for applying heat, and air circulation for drying
the collection to a specified moisture content, wherein the
wireless sensor is in operable contact with the wood collection for
forming an electrical circuit with the wood, wherein the circuit
additionally includes two spaced apart conductive plates positioned
within the wood collection, and wherein the sensor and the circuit
are configured to establish capacitance and resistance of a water
content of a portion of the collection, the portion residing
between the spaced apart conductive plates; the sensor including:
[0055] (a) one or more batteries for electrically powering the
sensor; [0056] (b) a wireless transmitter for wirelessly
communicating with a stationary device, the wireless communications
including transmissions by the transmitter of data related to the
water content of the portion of the collection, the data including
measurements of each of the capacitance and resistance,
measurements of the humidity in the kiln, and measurements of a
temperature in the kiln; [0057] (c) a processor for iteratively:
(i) obtaining one of the measurements of the capacitance, one of
the measurements of the resistance, one of the measurements of the
humidity, and one of the measurements of the temperature, and (ii)
providing the one measurement of each of: the capacitance,
resistance, humidity and temperature to the wireless transmitter
for wirelessly transmitting as an instance of the data; [0058] (d)
a timer for determining when a first time limit is exceeded; [0059]
wherein one of the instances of the data is obtained by the
processor during the first time limit; [0060] wherein the processor
obtains a value indicative of a change between the one instance and
a previous instance of the data; [0061] wherein the processor
compares the value to a predetermined change related condition for
identifying specific changes between instances of the data, and
thereby obtaining one of: a first result indicative of the
predetermined change related condition occurring between the one
instance and the previous instance, and a second result indicative
of the predetermined change related condition not occurring between
the one instance and the previous instance; [0062] wherein the
wireless transmitter wirelessly transmits the instance to the
device when the first result is obtained, and does not wirelessly
transmit the instance when second result is obtained; [0063]
wherein the wireless transmitter wirelessly transmits a further
instance of the data to the device when the first time limit is
exceeded; [0064] wherein the processor evaluates a predetermined
condition, the evaluation of the predetermined condition performs
one of: (i) a comparison of an elapsed time for drying the
collection in the kiln with a predetermined elapsed time limit for
drying the collection in the kiln, (ii) a comparison of a humidity
in the kiln with a humidity threshold, or (iii) a comparison of an
impedance for the portion of the collection with an impedance
threshold; [0065] wherein the processor obtains, when the
predetermined condition evaluates to a predetermined result,
information for a second time limit different from the first time
limit; [0066] wherein the processor uses the information for
activating the timer to determine when the second time limit is
exceeded; [0067] wherein the wireless transmitter wirelessly
transmits a second instance of the data to the when the second time
limit is exceeded; [0068] wherein for conserving the batteries, the
first time limit is longer than the second time limit.
[0069] This Summary section is neither intended to be, nor should
be, construed as being representative of the full extent and scope
of the present disclosure. Additional benefits, features and
embodiments of the present disclosure are set forth in the attached
figures and in the description hereinbelow, and as described by the
claims. Accordingly, it should be understood that this Summary
section may not contain all of the aspects and embodiments claimed
herein.
[0070] Additionally, the disclosure herein is not meant to be
limiting or restrictive in any manner. Moreover, the present
disclosure is intended to provide an understanding to those of
ordinary skill in the art of one or more representative
embodiments. Thus, it is important that the embodiments herein be
regarded as having a scope including constructions of various
features of the present disclosure insofar as they do not depart
from the scope of the methods and apparatuses consistent with the
present disclosure. Moreover, the present disclosure is intended to
encompass and include obvious improvements and modifications of the
present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0071] FIG. 1 is an illustration of a vertical cross section
through a prior art lumber kiln moisture system, wherein a kiln for
drying lumber is shown having a lumber stack therein, and the stack
has spaced apart metal plates inserted therein. Each of the metal
plates is tethered to a kiln wall mounted meter for obtaining,
e.g., capacitance and resistance measurements indicative of the
moisture content of the lumber between the metal plates.
Accordingly, such prior art meters perform the processing provided
herein by the novel sensors 20 (FIG. 2). However, since the
wood/lumber stack is tethered to the wall of the kiln, the stack
cannot be moved without disconnecting the cables from the meter.
Moreover, the moisture in the wood/lumber stack can only be
monitored where such a meter is in close proximity for connecting
the cables thereto.
[0072] FIG. 2 shows a vertical cross section through an embodiment
of a novel wireless in kiln lumber monitoring system according to
the present disclosure.
[0073] FIG. 3: is a block diagram showing the major system
components.
[0074] FIG. 4: is a block diagram showing the components of the
wireless moisture sensor.
[0075] FIG. 5: is a block diagram showing the components of the
wireless hub.
[0076] FIG. 6: is a flow chart describing the logic used to
conserve battery in a wireless sensor 20. In this case,
transmissions are reduced by only transmitting when certain
conditions have been met.
[0077] FIG. 7: is a flow chart describing the logic used to
conserve battery power in a wireless sensor 20. In this case, the
moisture readings are reduced.
[0078] FIG. 8: is a circuit diagram.
DETAILED DESCRIPTION OF THE INVENTION
[0079] FIGS. 2 and 3 illustrate embodiments of the lumber
monitoring system and method as configured in a typical lumber
mill. The main components are the wireless sensors 20, the wireless
hubs 24 (also referred to as "hub devices" hereinabove and below)
and a controller 28. Although only three sensors 20 are illustrated
in FIG. 3 as residing in each of the stacks 32, this is only for
illustrative purposes. In general, a substantially larger number of
sensors 20 may be distributed within a corresponding wood/lumber
stack 32 for collecting, e.g., wood/lumber capacitance and
resistance data related to the moisture content of the stack 32.
Each of the sensors 20 wirelessly communicates with a corresponding
hub 24 for transmitting, e.g., the following data to the
corresponding hub 24:
[0080] (1) a sensor 20 identifier (for identifying each sensor 20
uniquely),
[0081] (2) capacitance and resistance data indicative of the
moisture content in the stack 32,
[0082] (3) measurements indicative of remaining battery power.
Other data values transmitted to its corresponding hub 24 (and
subsequently transmitted to the controller 28) are disclosed in
Appendix A hereinbelow).
[0083] Note that the sensors 20 are preferably distributed within
or about the stack 32 according to a known configuration that may
be based on: (a) the wood type in the stack 32, (b) an
indication/estimation of wood moisture, and/or (c) characteristics
of the kiln itself (as discussed in the Summary section
hereinabove). More particularly, as shown in FIG. 2, each sensor 20
may be attached, via cables 34, to a unique pair of metal plates 36
(in some embodiments, a single cable 34 is connected to just one of
the metal plates 36 with the other metal plate 36 being grounded),
this pair being referred to herein as being "associated" with its
sensor 20. The metal plates 36 are spaced apart within the
wood/lumber stack 32, generally in a vertical direction; however
they may be spaced apart horizontally as well. The associated pair
of metal plates 36 is used to provide its sensor 20 with electrical
properties related to the wood/lumber residing between these metal
plates, and more particularly, information indicative a capacitance
and resistance of the wood/lumber between these metal plates. A
description of the use of such capacitance and resistance for
determining the moisture content of the wood/lumber by the sensor
20 is provided in Appendix A hereinbelow. Related discussions of
the use and computation of wood moisture content is provided in,
e.g., various U.S. patents such as some of those recited above, and
more particularly, U.S. Pat. No. 7,676,953 (the '953 patent herein)
assigned to Signature Control Systems, Inc. which is also fully
incorporated by reference herein.
[0084] The sensors 20 offer substantially more flexibility in
monitoring wood moisture over prior art systems having a "meter"
attached to the kiln wall as shown in FIG. 1. Since the sensors 20
are each wireless, each such sensor can be transported with the
wood/lumber stack 32 without connecting and disconnecting cables.
Thus, such sensors 20 and their associated cables 34 and metal
plates 36 can be attached to their wood/lumber stacks 32 prior to
the stack entering the kiln, and can remain with the stack after
the kiln drying process is complete to thereby continue to monitor
the moisture in the stack if desired.
[0085] Various configurations of the sensors 20 (and their
associated metal plate 36 pairs) may be provided within a
wood/lumber stack 32. In one embodiment, a first row of the sensors
20 may be distributed, evenly spaced, in (or about) the stack 32
substantially around a horizontal perimeter of the stack at a first
height relative to the stack (e.g., at or near the top of the stack
as illustrated in FIG. 2), wherein for each of the sensors 20, its
associated metal plate 34 pair is approximately adjacent to its
sensor 20, and such that this sensor is operably attached to (or
contacting) the stack 32 in a manner that allows this sensor to,
e.g., determine a local humidity of the air adjacent to this
sensor, and determine a local temperature adjacent to this sensor
which is indicative of at least one of: the wood/lumber at the
sensor 20 or the air temperature thereabout. Since the spacing of
the metal plates 36 within the stack 32 is likely to be no more
than six to eight feet (and possibly substantially less), depending
on, e.g., the height of the stack 32, a copy of the first row of
sensors 20 (and their associated metal plate 34 pairs) may be
provided as a second row of sensors 20 wherein this second row is
provided at a different height relative to the stack. In
particular, the first row of sensors 20 may be near or at the top
of the stack 32, and the second row may be positioned below the
first row an effective distance so that the sensors can reliably
collect capacitance and resistance data for the wood between
corresponding vertically aligned metal plate 36 pairs associated
with each of the sensors 20 (e.g., without electrical interference
from another sensor and its associated metal plate 36 pair. Since
the wood/lumber stack 32 may be as much as 12 feet high, a
plurality of instances of the first and second sensor rows may be
provided in the stack at spaced apart vertical intervals. Note that
the sensors 20 and the wireless hubs 24 for wirelessly
communicating therewith (such sensors 20 and their hub 24 referred
to herein as "corresponding" herein) may wirelessly communicate
according to any one of the conventional wireless communication
protocols such as WIFI, Bluetooth and any other protocol of a
wireless frequency as allowed by law as one of ordinary skill in
the art will understand.
[0086] The controller 28 may be connected to each of the wireless
hubs 24 via a cable or wire (illustrated as a double headed arrow
in FIG. 3 and identified as a cable in FIG. 2). Although two hubs
24 are shown in FIG. 3 as communicating with the controller 28,
such a controller can be in signal communication with only one hub
24 or a relatively large plurality of hubs 24 (e.g., 15 to 30
meters or more). In one embodiment, the controller 28 may be
collocated with one of the hubs 24. The communication between a
controller 28 and a hub 24 is two-way to thereby enable, e.g., (1)
sensor data (obtained by the hub 24 from corresponding wireless
sensor 20 transmissions) to flow from the hub to the controller,
and (2) controller 28 commands to be transmitted to the hub 24 and
its corresponding sensors 20 (with which the hub wirelessly
communicates) for controlling both the hub and such sensors 20. In
one embodiment, the wired or cable connection between a hub 24 and
the controller 28 is via an Ethernet cable run in conduit as one
skilled in the art will understand.
[0087] FIG. 3 also illustrates an embodiment where there is an
exchange of information between the hubs 24 themselves (e.g., via
wireless communications such as WIFI or Bluetooth, or an Ethernet
cable connection) as illustrated by the double headed arrow between
the two illustrated hubs 24. Such communication between hubs 24
allows these hubs to be daisy-chained so that data can be sent from
hub to hub (e.g., for a potentially large number of hubs such as
twenty hubs). Accordingly, when the hubs 24 are daisy-chained, the
direct connection between, e.g., the hub in kiln #2 and the
controller 28 can be dispensed with if the hub 24 in kiln #1 is
configured to transfer designated communications between the hub 24
of kiln #2 and the controller 28. Assuming such a daisy-chain
configuration includes wireless communications between the hubs 24,
such a configuration may limit the cost of the present wood
monitoring system by reducing the amount of conduit that must be
run for providing communications between the controller 28 and the
plurality of hubs 24 operably controlled by this controller.
[0088] Hubs 24 may be located on the outside of a kiln having
sensors 20 corresponding to the hub. The number of hubs 24 per kiln
may be determined by the size and/or design of the kiln. For
typical batch kilns, (e.g., kilns that dry all the wood in the kiln
according to a single drying method where all the wood is moved
into the kiln prior to kiln operation for drying the wood, and all
wood in the kiln is moved out of the kiln only after all the wood
is dried), one hub 24 may be placed in a location amenable for
effective wireless communications with all the sensors 20 in the
kiln. However, depending on the wireless environment, e.g., within
the kiln, additional hubs 24 may be distributed about the kiln.
[0089] The wireless sensors 20 attached to a wood stack 32 can be
grouped. The highest grouping typically will include all the
sensors 20 residing in a single stack 32, or if the kiln is a batch
kiln, all the sensors 20 residing in the kiln. Subgroupings or
subsets (as discussed hereinabove) may be provided. Each sensor 20
in a group (or subset) wirelessly transmits data to a single
predetermined corresponding hub 24. Each group of sensors 20 may
monitor a single kiln or a chamber within a kiln; however, a single
stack 32 also may be monitored. When a hub 24 receives data from
its corresponding sensors 20, the hub will, in turn, put the data
in a buffer and subsequently relay the data to the controller 28.
Once the data is received by the controller 28, the controller
stores the data in a database (not shown). Note, although not shown
in FIG. 3, the sensor data may be displayed to an operator
accessing the controller 28 so that the operator can monitor the
wood drying process in substantially real-time.
[0090] In an embodiment, the case of the kiln may be molded (e.g.,
using plastic injection molding) to allow the movement of the
antennas (e.g., the hub antenna 72) to move inside the box (e.g.,
for improved reception with the sensor antenna). The case of the
kiln may also be made of other materials (e.g., metal such as
aluminum).
[0091] FIG. 4 shows a high level embodiment of a sensor 20. The
sensor 20 includes a micro-processor 40 having firmware installed
therein for performing at least the following tasks: (i)
transmitting stack 32 moisture related data, e.g., when such data
has changed in some meaningful way, and (ii) changing the moisture
data sampling rate, e.g., the sample rate may be reduced during
"non-critical" wood drying stages). Both of these aspects are
described in more detail below.
[0092] The sensor 20 further includes the following components
(each such component may be an integrated circuit more commonly
known as a chip): [0093] (a) An ID component 44 which may be a
programmable EPROM or other silicon based component for storing
identification data. The ID component 44 outputs, when requested by
the micro-processor 40, identification data that uniquely
identifies the sensor 20 from all other sensors 20. [0094] (b) An
analog measurements component(s) 48 which may be impedance chip
AD5934 by Analog Devices, Inc., One Technology Way, Norwood, Mass.
02062-9106 (USA). The analog measurements component(s) 48 receives
input from: (i) a temperature measurement component 48a (e.g., the
AD5934 chip above also has an embedded temperature sensor).
Further, the analog device component 48 determines capacitance and
resistance electrical measurements corresponding to a moisture in
the drying wood between the associated metal plates 36 for this
sensor 20. [0095] Regarding capacitance and resistance
measurements, the analog measurements component(s) 48 determines
capacitance measurements according to the disclosure in Appendix A
provided hereinbelow. [0096] (c) A humidity component 52 which may
be a relative humidity sensor such as model number HTS2030SMD by
Measurement Specialties, Inc., 1000 Lucas Way Hampton, Va. 23666
(USA). The humidity component 52 outputs, on request from the
micro-processor 40, a measurement of the ambient humidity at the
sensor 20. [0097] (d) One or more batteries 54 for providing
electrical power to the components of the sensor 20. [0098] (e) An
analog-digital converter component 56 which may be a
micro-processor from the SAM4L family of microcontrollers by Atmel
Inc., 1600 Technology Drive, San Jose, Calif. 95110 (USA). The
analog-digital converter component 56 receives analog electrical
signal input from the battery 54 indicative of the useful
additional life in the battery for powering the sensor 20. In one
embodiment, the output from the battery 54 may be a current
measurement or a voltage. Upon request from the micro-processor 40,
the analog-digital converter 56 outputs digital data corresponding
to the input received from the battery as one skilled in the art
will understand. [0099] (f) A wireless transceiver component 64
which may be a radio transceiver or transmitter by Micrel, Inc.,
2180 Fortune Drive, San Jose, Calif. 95131 (USA), model number: P/N
MICRF405YML operating at 900 MHz. Upon receiving an output data
packet from the micro-processor 40, the wireless transceiver
component 64 wirelessly transmits the data packet to the hub 24 to
which the sensor 20 corresponds. A wireless transceiver 68 and
antenna 72 (FIG. 2) in the hub 24 receives the wireless data
packet.
[0100] At certain designated times (or time intervals) while
wood/lumber in-kiln drying is proceeding, the micro-processor 40
requests and receives data from each of the following components:
the ID component 44, the analog measurements component(s) 48, the
humidity component 52, and the AD (analog to digital) component 56.
Once the data has been received from each of these components, the
information is assembled into a data packet and provided to the
wireless transceiver component 64 for wireless transmission to the
hub 24 corresponding with the sensor 20.
[0101] For generating a data packet, the micro-processor 40
requests information from the components 44 through 56.
Subsequently, the micro-processor 40 receives from the ID component
44, hexadecimal sensor identification data that uniquely identifies
the sensor 20. The identification data is transmitted to the hub 24
with every data packet generated by the micro-processor 40 for
identifying the source sensor of the data. For each data packet
generated, preferably, the micro-processor 40 also obtains output
from the analog measurements component(s) 48. As described above,
the analog measurements component(s) 48 measures capacitance,
resistance and temperature, and at least for the capacitance and
resistance value, calibration values provided by the
micro-processor 40 are used, wherein such calibration values are
well known in the art for calibrating capacitance and resistance of
the wood between the metal plate 36 pairs connected to the sensor
20. The calibration values are used by the analog measurements
component(s) 48 to reduce or substantially entirely factor out
extraneous capacitance and resistance values not indicative of the
wood/lumber between the metal plate 36 pair associated with the
sensor 20. In particular, for the electrical circuit 70 (FIG. 2) of
the sensor 20, the attached cable(s) 34, the associate metal plate
36 pair, and the wood/lumber between these metal plates 36, the
calibration values are used to remove, or substantially reduce,
from the capacitance and resistance measurements, factors such as
the capacitance and resistance of the cables 34 so that the
capacitance and resistance values output by the analog measurements
component(s) 48 to the micro-processor 40 substantially are only
indicative of the moisture in the wood/lumber between the metal
plates 36 associated with the sensor 20.
[0102] Additionally, the micro-processor 40 obtains from the
humidity component 52 the relative humidity of the ambient air
surrounding the sensor 20 for also providing in each generated data
packet. Finally, an analog to digital component 56 is utilized to
calculate a digital value of the voltage level of the batteries 54
and such calculated voltages are provided to the micro-processor 40
for inclusion in each data packet.
[0103] For a given collection of data from the components 44, 48,
52, and 56 (the data obtained for a same time), the micro-processor
40 generates a corresponding data packet that includes the content
of the collected data. Note, that the micro-processor 40 includes a
timing component (e.g. firmware), well-known in the art, for
programmatically determining when to request and collect the data
from the components 44, 48, 52, and 56. The timing component can be
modified by commands from the controller 28, wherein such
modifications may be: [0104] (1) for setting a time interval
between data collections from the components 44, 48, 52, and 56
(and substantially immediate transmissions of the corresponding
resulting data packet to the controller 28, via wireless
transmission to the hub 24), [0105] (2) for setting a range for at
least one value from the collected data, wherein if the at least
one value is outside of the range, then subsequent data collections
are performed at a different frequency (e.g., a greater or lesser
frequency as may be determined by communications from the
controller 28, [0106] (3) setting different frequencies for
collecting data from the components 44, 48, 52, and 56; for
example, if the sensor's battery is low and it is not expedient to
replace the battery or provide another proximate sensor 20 in the
near term (e.g., due to the sensor 20 being not easily accessible),
then unless a wood drying anomaly is detected, the sensor may
conserve battery power by the micro-processor 40 only obtaining
data input from a subset of the components 44 through 56 for at
least some instances of the data packets generated and
transmitted.
[0107] Note that in one embodiment, some of the components 44, 48,
52, and 56 may not be included in the sensor 20. In particular, in
one embodiment, the humidity component may not be provided.
Instead, humidity data may be obtained separately from the sensors
20, and communicated to the controller 28. Moreover, in one
embodiment, the sensor 20 may also include an acoustic component
for capturing particular sounds associated with the drying of wood
such as wood cracking, shifting, and/or warping, etc. Accordingly,
data from such an acoustic component can be also collected and
provided in the micro-processor generated data packet for
transmission to the controller 28.
[0108] In one embodiment, the hub 24 and each of its corresponding
sensors 20 (plus possibly other sensors 20 whose wireless
transmissions the hub can detect) may communicate asynchronously
(or substantially so) on different wireless frequencies.
Accordingly, there is little likelihood of collisions of data
packets at the hub 24. However, since there may be a large
plurality of sensors 20 (e.g., 20 or more) corresponding with the
hub 24 for asynchronous wireless communication therewith, the
additional hub and sensor electronics (and corresponding cost
thereof) for allowing wireless communications between the hub 24
and each of its corresponding sensors 20 to occur on distinct
wireless frequencies may be cost prohibitive in at least some
embodiments. Thus, in an alternative embodiment, a predetermined
small number of wireless frequencies may be utilized for
communication between the hub 24 and its corresponding sensors 20.
In this alternative embodiment, when a sensor's wireless
transceiver component 64 receives a data packet from the sensor's
micro-processor 40, the component 64 wirelessly transmits the data
packet repeatedly; e.g., the data packet may be transmitted at
three randomly determined times. Sending each data packet randomly
three (or more) times is believed to substantially assure each data
packet from the sensor 20 is accurately received by the associated
hub 24 such that wireless transmissions by other sensors 20 do not
interfere with wireless reception by the hub 24 of transmissions by
the present sensor. Note that since each data packet has a unique
timestamp, any duplicate copies of a data packet received by a hub
24 can be deleted.
[0109] FIG. 5 illustrates the high level componentry of the hub 24.
In addition to the antenna 72 and the transceiver 68, each hub 24
also includes: [0110] (a) An ID component 76 which may be a
programmable EPROM or other silicon based component for storing
identification data uniquely identifying the hub 24 from all other
hubs. The ID component 76 outputs, when requested by the
micro-processor 88 (described below), the identification data to
the micro-processor 88. [0111] (b) A temperature measurement
component 80 for outputting temperature values as requested by the
micro-processor 88. Note that since this portion of the hub 24 is
outside of the kiln, this temperature measurement component 80
measures the temperature outside the kiln, and such measurements
can be useful for the controller 28 to control the wood/lumber
drying process within the kiln, and in particular, control the
activation of one or more of the heaters in the kiln, kiln intake
and exhaust fans, and fans for circulating air within the kiln as
one skilled in the art will understand. [0112] (c) A data storage
84 (which may be persistent for storing data). This data storage 84
is used to store data packets (or data therefrom) received from the
sensors 20. [0113] (d) A micro-processor 88 for storing and
accessing data packets received from sensors 20, and for
generating, on request from the controller 28, aggregated data for
sending to the controller 28. In particular, the micro-processor
aggregates the following for sending to the controller 28: (1) one
or more data packets from one or more sensors 20, (2) the unique
hub identifier from the ID component 76 for uniquely identifying
the hub, and (3) one or more temperature measurements from the
temperature measurement component 80 (with corresponding time
stamps). [0114] (e) Various components used for digitally
transmitting the aggregated data to the controller 28, such
component may include one or more of: an RS-232 port 92, and an
RS-422 port 96 together with a converter 100 for the RS-422 port as
one skilled in the art will understand.
[0115] As mentioned previously, each hub 24 may be mounted outside
its kiln in a location effective for communicating wirelessly with
the hub's corresponding sensors 20 (e.g., within the kiln). Each
hub 24 has an antenna 72 and a hub transceiver 68 that may be in
the interior of the kiln so that the hub can better receive
wireless transmissions from the corresponding sensors inside the
kiln. Thus, as shown in FIG. 2, part of the hub 24 can be interior
to the kiln (to which the hub is attached) and part of the hub can
be external to the kiln. The antenna 72 and wireless transceiver 68
captures the wireless transmission of the data packets from the
wireless sensors 20 and provides the captured data packets to the
hub's micro-processor 88. The micro-processor 88 stores the data
packets in RAM 80 until the micro-processor 88 receives a request
from the controller 28 to send the stored data packets to the
controller. Once such a request is received by the hub 24, the
micro-processor 88 retrieves the data packet(s) from the RAM 80,
asks the ID component on board for the unique tag, obtains a
reading from the local temperature component and then sends the
aggregated data stream to the controller 28 via an RS422 or RS232
port.
[0116] In an embodiment, the board may be coated (e.g., using
silicone, vapor deposition, and/or other coatings) for better
protection from the environment and other reasons.
[0117] FIG. 6 shows two high level flowcharts for limiting the
number of wireless transmissions from each sensor 20 to its
corresponding hub 24 and thereby conserving the batteries 54. The
kiln environment is exceptionally harsh with temperatures regularly
exceeding 200.degree. F. for periods ranging from 16 to 48 hours or
more. At these temperatures, the batteries 54 will experience a
substantial reduction in life in comparison to a more typical
battery environment as discussed above. For this reason, battery
consumption must be conserved as much as possible.
[0118] Since the transceiver component 64 of each sensor 20
consumes the most sensor 20 battery power, a method for reducing
the number of wireless transmissions without sacrificing critical
data transfers to the corresponding hub 24 is provided in FIG. 6.
In particular, the flowcharts of FIG. 6 provides the steps
performed by the software executed by the micro-processor 40 or the
controller 28 for comparing current sensor 20 readings to past
readings (for the same sensor 20) in order to determine if a change
in the moisture content data transmitted from this sensor warrants
a more frequent or less frequent sensor wireless data transmission
rate. Since what is deemed to be critical or/and not critical,
changes per kiln operator, one or more setpoints for changing such
transmission rates can be specified by, e.g., an operator (or
automatically via computer instructions). Note that such setpoints
may be dependent upon various wood/lumber drying characteristics,
e.g., in-kiln temperature, sensor reading of resistance or
capacitance, etc. Once such a setpoint is established, the
sensor(s) 20 affected will only send updates to its corresponding
hub 24 when the maximum or minimum corresponding conditions for the
established setpoint(s) has been reached. As a fail-safe, there is
a maximum time limit between transmissions that is allowed, so even
if a sensor's generated output data has not changed, the sensor
will still transmit wood/lumber drying related data packets to its
corresponding hub 24.
[0119] Assuming the micro-processor 40 in the sensor 20, performs
the steps of the flowcharts of FIG. 6, is the micro-processor 40
has a built-in timer (not shown) that counts the seconds (or
fractional increments thereof) until the micro-processor 40
initiates a next collection of measurements/readings from the
sensor components 44 through 56 (FIG. 4). The timer may have a
default time interval of, e.g., 5 minutes between sending
notifications so that the micro-processor 40 requests (in response
to each notification) output data from the components 44 through
56. However, this time interval may be changed depending on the
battery 56 remaining life, the wood/lumber drying measurements (or
a change thereof), kiln operator input, and/or controller 28
computations of a new time interval. Accordingly, referring to the
rightmost flowchart of FIG. 6, in step 604, once this timer has
entirely counted down its time interval (or alternatively, if the
timer is counting up to its time interval's end, then when the
timer exceeds the time interval's end, as one skilled in the art
will understand), the micro-processor 40 receives a "time interval
expired" notification from the timer, and in response, the
micro-processor 40 (step 608) sends a request to each of the
components 44 through 56 (FIG. 4) to output their corresponding
measurements/readings to the micro-processor 40. Upon receiving the
measurements/readings, the micro-processor 40 (step 612) determines
if it has exceeded the maximum time limit between wireless
transmissions of data packets to its hub 24, wherein this maximum
time limit is, in one embodiment, a time limit corresponding with
one of the "fast mode" or the "slow mode" discussed hereinbelow
with reference to FIG. 7. Note that the time interval used for
determining the expiration in step 608 may be different from the
maximum time limit. In particular, the time interval is
substantially fixed and short enough so that the highest expected
frequency of data packet generation and wireless transmission from
the sensor 20 (equivalently, the smallest maximum time limit value)
can be maintained. In particular, the time interval used in step
604 may be identical to the maximum time limit of the "fast mode"
described hereinbelow.
[0120] Accordingly, if the maximum time limit of step 612 is
exceeded, then the micro-processor 40 generates a new data packet
from the newly received data obtained from components 44 through 56
(step 616). Subsequently, in step 620, this newly generated data
packet is stored to a buffer (not shown) in the transceiver
component 64 for transmission (step 624) to the corresponding hub's
antenna 72 and wireless transceiver 68. Subsequently, in step 628,
the timer is reset and the process starts over.
[0121] However, if in step 612, the maximum time limit between
wireless transmissions is not exceeded, then in step 632, the steps
of the leftmost flowchart of FIG. 6 are performed, wherein in step
636, the micro-processor 40 retrieves the previous measurement data
obtained from the components 48 through 56 from its memory (not
shown), and inputs the new and old measurements/readings (e.g., the
capacitance, resistance, temperature and humidity values) to a
calculation (step 640) selected by, e.g., the kiln operator (or the
controller 28) to determine whether certain conditions, e.g., of
the wood/lumber (between the metal plates 36 associated with the
sensor 20), are satisfied. For example, such conditions may be for
detecting a change in the capacitance and/or resistance of the
wood/lumber being monitored. In particular, one or more of the
three immediately following calculations may be performed by the
micro-processor 40 to determine a change in capacitance or
resistance and subsequently determine whether a certain condition,
using this change value, is satisfied (e.g., predetermined
conditions and the particular "change" calculation may be specified
by the operator and/or the controller 28): [0122] 1. Calculate a
rate of change of the capacitance and/or resistance of the
wood/lumber between the metal plates 36 associated with the sensor
20. [0123] 2. Calculate an absolute change, e.g., the positive
value difference between the new value and the old value of the
capacitance and/or resistance. of the wood/lumber between the metal
plates 36 associated with the sensor 20 [0124] 3. Calculate the
percent of change: the absolute difference between the new value
and the old value divided by the old value of the capacitance
and/or resistance of the wood/lumber between the metal plates 36
associated with the sensor 20. However, it is also within the scope
of the present disclosure that other measurements of wood/lumber
capacitance and/or resistance may be calculated in additional to or
instead of those of (1)-(3) immediately above. Moreover, selected
calculations corresponding to in-kiln temperature and/or humidity
can also be used in evaluating conditions related thereto. Thus,
for temperature, one of the following calculations may be performed
for a given temperature related condition: [0125] 4. Calculate a
rate of change of the temperature of the wood/lumber in proximity
to the sensor 20. [0126] 5. Calculate an absolute change, e.g., the
positive value difference between the new value and the old value
of the temperature of the wood/lumber in proximity to the sensor
20. [0127] 6. Calculate the percent of change: the absolute
difference between the new value and the old value divided by the
old value of the temperature. of the wood/lumber in proximity to
the sensor 20.
[0128] Similarly, selected calculations corresponding to in-kiln
humidity can also be used in evaluating conditions related thereto.
Thus, for humidity, one of the following calculations may be
performed for a given humidity related condition: [0129] 7.
Calculate a rate of change of the humidity of the wood/lumber in
proximity to the sensor 20. [0130] 8. Calculate an absolute change,
e.g., the positive value difference between the new value and the
old value of the humidity of the wood/lumber in proximity to the
sensor 20. [0131] 9. Calculate the percent of change: the absolute
difference between the new value and the old value divided by the
old value of the humidity of the wood/lumber in proximity to the
sensor 20.
[0132] Once the selected calculations of (1)-(9) have been
performed, then in step 644, the micro-processor 40 compares the
results from the calculations of step 640 with one or more
corresponding thresholds set by the operator (by the controller 28
without operator selection of such calculations) for determining if
one or more of the certain conditions associated with these
thresholds are satisfied. For example, for a threshold of 2 units
corresponding to calculation an absolute change in the stack
moisture content of step 640, if the result from the calculation is
below the threshold, then it is presumed that the wood/lumber
between the metal plates 34 associated with the sensor 20 is
relatively dry. Additional such examples are as follows: [0133] For
a threshold of 5 degrees, corresponding to an absolute change in
temperature, if the sensor 20 registers a change greater than this
threshold, then it is presumed the ambient temperature in the kiln
(e.g., at least proximate to the sensor 20) has sufficiently
changed to warrant an update to the kiln operator. [0134] For a
threshold of 100%, corresponding to the percent of change in
humidity, if the sensor 20 registers a change greater than this
threshold, then it is presumed the ambient humidity in the kiln
(e.g., at least proximate to the sensor 20) has sufficiently
changed to warrant an update to the kiln operator. Accordingly, if
the micro-processor 40 determines that no threshold is crossed by
the corresponding result (calculated in step 640) to which the
threshold is compared thereby indicating that the corresponding
condition for the threshold is not satisfied, then no data packet
is generated for wireless transmission and the method of FIG. 6
starts over. However, if one of the thresholds is crossed, then
steps 616 through 628 are performed for generating and wirelessly
transmitting a new data packet to the corresponding hub 24. Thus,
the wireless transceiver component 64 is only activated for
performing wireless transmissions when the micro-processor 40
detects a change in one or more of the values output by the
components 48 through 56 that are deemed significant to trigger the
wireless reporting of this change to the corresponding hub 24 (and
subsequently by this hub to the controller 28). Accordingly, the
batteries 56 have their life extended by the process of FIG. 6.
Description of FIG. 7.
[0135] Referring now to FIG. 7, in a typical wood/lumber in-kiln
drying cycle, the wood/lumber starts out very wet with moisture
content in the 60%+ range by weight. Accordingly, a kiln
operator(s) will typically initially ramp up the kiln temperature
relatively high (e.g., in the range of 220.degree. F. to
260.degree. F.) and also adjust air speed inside the kiln in an
effort to dry the lumber in a uniform manner. Readings from a
moisture meter are typically used at this stage to guide this
initial drying cycle as illustrated in FIG. 1. The operator(s) may
also adjust some of the macro-conditions in the kiln (e.g., kiln
vents, etc.) so that the wood/lumber finishes this initial drying
cycle at 19% or less moisture content by weight. As the wood nears
19% in moisture content, the operator(s) may focus his/her
attention on previously determined or historical correlations
between characteristics of the drying wood/lumber and in-kiln
environmental characteristics (such correlates referred to as a
"drying curve") for achieving a targeted range of moisture content
in the drying wood/lumber. For example, such correlations may
relate, e.g., (i) the type of lumber, the amount of lumber in the
kiln, and/or the stacking configuration of the lumber, with (ii)
in-kiln temperature, in-kiln air circulation speed, kiln vent
configurations, and/or the length of time at certain kiln drying
configurations. Thus, the kiln operator(s) typically closely
monitor each of the wood/lumber stack embedded sensors 20 in order
to target a predetermined average lumber moisture content of, e.g.,
19% or less. Moreover, as the moisture content to the drying
wood/lumber gets close to the targeted lumber moisture content
(e.g., 5% higher than the targeted lumber moisture content), the
time between updated moisture related sensor values becomes more
critical since one or two percent changes in wood moisture content
can dramatically affect final product quality. Thus, such sensor 20
values need not be uniformly determined and transmitted for
estimating lumber moisture content.
[0136] Thus, in order to manage and substantially lengthen the
battery life of batteries 54 in sensors 20, a unique method for
reducing the power consumed by the various components in such
sensors has been developed and is disclosed herein with reference
to FIG. 7. In particular, FIG. 7 provides a flowchart of the steps
performed for setting the read rate (i.e., a wireless transmission
rate) for each sensor 20 to either a "fast" wherein data packets
are generated and wirelessly transmitted more frequently, or a
"slow" mode wherein data packets are generated and wirelessly
transmitted less frequently. That is, each of the fast mode and the
slow mode has a corresponding time limit value which is indicative
of the maximum time between wireless transmissions of data packets
to the hub 24, wherein this maximum time is shorter for the fast
mode, and longer for the slow mode (e.g., five minutes for the fast
mode and fifteen to twenty times for the slow mode). Note, as
indicated hereinabove, the maximum time limit used in step 612 of
FIG. 6 is the maximum time limit of whichever of the fast and slow
modes is currently being used by the micro-processor 40.
[0137] During the early phases of a drying cycle, each sensor 20
defaults to the "slow" mode in which data packet wireless
transmissions are performed, e.g., every 15 minutes. When
particular conditions are satisfied at a sensor 20, the
micro-processor 40 of the sensor 20 switches to a "fast" mode
wherein the wireless transmission rate of data packets increases
to, e.g., every 5 minutes. In this way, battery 54 power consumed
by all the components of the sensor 20 can be reduced since such
components are activated less often during the initial portion of a
drying cycle since the sensor is in slow mode.
[0138] In one embodiment, there are three possible trigger values
to switch a sensor 20 from the slow mode to the fast mode. The
three trigger values are of the following types: [0139] i. Charge
timer: A kiln operator (or the controller 28 exclusive of the
operator(s)) can set a time (e.g., the number of hours) after the
start of the drying wood/lumber drying process to switch from slow
to fast mode, or possibly vice versa. [0140] ii. Humidity level:
The kiln operator can set a threshold corresponding to a particular
relative humidity level in the kiln so that when this threshold is
reached, the sensor 20 will switch from slow to fast mode. In the
early phases of a kiln drying process, the humidity inside the kiln
is very high as water is extracted from the wood/lumber and this
extracted water disperses as moisture in the kiln air. Later in the
wood/lumber drying process, there is less remaining water in the
wood/lumber, and accordingly, the humidity levels in the kiln fall.
[0141] iii. R value level (i.e., an impedance threshold of the
circuit 70 for the sensor 20): This value is a complex resistance
value that can be used to judge the relative moisture content of
the wood between the two metal plates 36 associated with the sensor
20. Low resistance indicates wet wood. Each of these triggers may
set remotely from the sensor 20 and transmitted wirelessly (via the
sensor's corresponding hub 24) to the sensor for use by the
sensor's micro-processor 40 in performing the flowchart of FIG.
7.
[0142] Accordingly, the steps of FIG. 7 determine the time interval
used by the timer discussed hereinabove in describing FIG. 6. That
is, the time interval (either for fast mode, or slow mode)
determined in FIG. 7 is used to determine when the timer expires in
step 604 (FIG. 6)
[0143] Referring now to the steps of FIG. 7, for a given sensor 20
these step are described as follows: [0144] Step 700: A
determination is made as to whether the fast mode has already been
set; i.e., the timer interval has been set to its shortest
duration. If so, then FIG. 7 terminates since in the present
embodiment, since once the fast mode is set it is set for the
duration of the drying process. [0145] Step 704: Assuming the fast
mode has not yet been set, in the present step, the micro-processor
40 of the sensor receives measurements/readings from the sensor's
components 48 and 52 (i.e., obtaining capacitance, resistance
values of the circuit 70 (FIG. 2) having the sensor therein, and a
relative humidity value output by the humidity component 52). Note
that the capacitance and resistance values obtained are used to
obtain the R value trigger type as shown in Appendix A. [0146] Step
708: The micro-processor 40 determines whether a charge timer value
has been communicated from the controller 28 to the sensor for
currently being used as trigger for changing, e.g., from the slow
mode to the fast mode. [0147] Step 712: If a charge timer has been
set, then the micro-processor 40 accesses an elapsed time since the
kiln drying process commenced for determining whether the charge
timer designated elapsed time has been exceeded. Note that the time
at which in-kiln wood/lumber drying commenced can be communicated
from the controller 28 to each of the sensors 20 in the kiln.
Accordingly, as one skilled in the art will understand, each
sensor's micro-processor 40 can use its own clock to iteratively
determine elapsed times of the drying process. [0148] Step 714: If
the determination in step 712 is positive, then the maximum time
limit for step 612 (FIG. 6) is set (by the micro-processor 40) to
the value for the fast mode instead of the initial slow mode, e.g.,
the maximum time limit is reduced from, e.g., 15 minutes to 5
minutes [0149] Step 718: The timer (or some timer operably
associated with the micro-processor 40) is activated for commencing
to determine when a next instance of the maximum time limit is
exceeded so that the micro-processor 40 (for this sensor 20) can be
notified to provide a new data packet to the transceiver 64 for
wirelessly transmitting to the corresponding hub 24 as per steps
615 through 624 of FIG. 6. [0150] Step 722: After step 718, the
present step is iteratively performed for determining whether the
current maximum time limit is exceeded by its timer (assuming the
timer is counting up to a designated time value indicative of the
time interval offset, or alternatively, if this timer counts down
the time interval, when the timer expires). Once the present step
results in a positive determination, then step 700 is again
performed. [0151] Step 724: A determination is made as to whether a
humidity level trigger has been set by the kiln operator (or the
controller 28 independent of the operator). [0152] Step 728: If a
humidity level trigger has been set, then the micro-processor 40
accesses an the humidity level trigger value and a current humidity
value obtained from the humidity component 52 for determining
whether the humidity level trigger value has been exceeded by the
current humidity value. If yes, then steps 714 through 722 are
performed as described above. If not, then step 732 following is
performed. [0153] Step 732: A determination is made as to whether
an R value level trigger has been set by the kiln operator (or the
controller 28 independent of the operator). [0154] Step 736: If an
R value level trigger has been set, then the micro-processor 40
accesses an the R value level trigger value and a current impedance
(for the sensor's circuit 70) obtained from the analog measurements
components 48 for determining whether the R value level trigger
value has been exceeded by the current impedance value. If yes,
then steps 714 through 722 are performed as described above. If
not, then steps 718 and 722 are performed.
[0155] FIG. 7 is particularly useful for kiln operators that want
to increase the transmission of wireless sensor data packets after
a certain number of hours has transpired, regardless of other
ambient conditions. The reason that the operators are likely want
such increases in transmission rate is that mills may want to begin
a detailed examination of the drying rate early in the drying
process in order to manage kiln fans and heating. Many mills
believe such management improves final dried wood/lumber quality.
Other mills may use such an increase in transmission rate as a
backup in case other environmental conditions are not met. So, if a
predetermined number of hours of a kiln wood/lumber drying process
has transpired, no matter what, the mill may wish to increase the
transmission rate to provide more data packets to the controller 28
and the operator.
[0156] In a further embodiment, additional control (e.g., software)
may be used to control the kiln. For example, Kilnscout is an
advanced, wireless sensor that records moisture content,
temperature, humidity, and wind velocity to determine the optimum
push rate for drying lumber. The sensor itself transmits this data
to a central computer program for analysis. In addition, the
central software collects other information from the kiln. This
includes push rate, temperature drop across the load (TDAL),
moisture data from the in-line planer systems, and various
temperature and humidity sensors in fixed locations throughout the
kiln. The software uses all of these inputs to determine proper
push rate for optimum results. It employs a feedback loop for
real-time micro-adjustments to push rate.
[0157] It is noted that push rate drives overall productivity for
lumber producers. Slower rates cause production to decrease.
Increased rates improve productivity, but can cause quality
concerns. Therefore, it is a continuous struggle to find the
optimum production rate. Added to this complexity is the
ever-changing nature of incoming wood and environmental conditions
throughout production.
[0158] KilnScout is a rugged, wireless sensor that is placed in a
lumber kiln to measure moisture content, temperature, humidity, and
wind velocity. It measures data in fixed time increments. At the
conclusion of a measurement cycle, it sends the data to receiver
hubs located on the kiln walls. This data is pushed to a computer
in the control room. Key data is stored in SQL to be shared with
various other internal and external systems. Users can set
parameters so that data received that are outside certain control
limits can trigger alerts via text, email and on-screen
notifications. Information from other systems also report to
KilnScout. Examples include temperature, humidity, temperature drop
across loads, push rates, species, spot check quality control data,
etc. All of this is combined with internally generated data to
create a profile of the lumber drying in the kiln. Thresholds for
certain data can be created so that the system can make intelligent
decisions on when to increase the push rate for lumber so that
drying times can be reduced. Feedback is constantly received so
micro-adjustments can be made in real-time. The feedback loop is
important as variation in the process and material must be
recognized and overcome.
[0159] Important to all of this are features for alerting and
messaging. As described above, text, email, and on-screen
notifications are central to the success of the system. Users look
to optimize results and expect the system to perform. Any deviation
in expected outcome of quality and/or production can be quickly
identified and acted upon.
[0160] Deficiencies in the related art include not enabling users
to quickly and accurately assess conditions inside a lumber kiln.
Continuous kilns are even more difficult to understand. Users rely
upon fixed meters on the side of the kiln walls to make judgments
on production quality. These fixed meters include temperature and
humidity. All of these meters gather indirect atmosphere
measurements that are used to infer the materials' actual state as
it moves through production.
[0161] Using KilnScout, the user can measure the material directly.
The sensor moves with the material through the production process.
Measurements from the sensor, combined with readings from other
external meters on the kiln, are collected by KilnScout's software
program. The software determines optimum process rates by analyzing
all of the available data. No longer is the process a black box for
the user as key data is continuously displayed on a PC.
[0162] The present disclosure has been presented for purposes of
illustration and description. Further, the description herein is
not intended to limit the present disclosure to the form disclosed
herein. Consequently, variation and modification commiserate with
the above teachings, within the skill and knowledge of the relevant
art, are within the scope of the present disclosure. The present
disclosure is further intended to enable others skilled in the art
to utilize the present disclosure, or other embodiments derived
therefrom, e.g., with the various modifications required by their
particular application or uses of the present disclosure.
APPENDIX A
Introduction
[0163] This Appendix describes the use, operation and the circuit
model of the sensor 20.
Sensor 20 Operation
[0164] There are two pushbuttons on the sensor 20, each with a red
LED in the center. [0165] POWER button (left) Holding this button
for over 1 second toggles power on and off. [0166] CONTROL button
(right) Used to trigger a measurement, initiate calibration, clear
flags, and enter or leave test mode. The pushbuttons can sense
"clicks" and "holds." A "click" is a quick button press (0.1 to 0.5
sec), and a "hold" is a single button press that lasts longer than
1 second. The number of sequential clicks is counted by the
microcontroller and used to select various functions. [0167] LED
flashes are brief (20 ms) to minimize power consumption.
[0168] For the impedance determined by one of the analog
measurements components 48, there are the following: [0169] An
analog input for impedance measurement. [0170] An impedance output
from the analog measurements component 48 for measuring impedance,
e.g., from a sine wave generator output for such impedance
measurements. [0171] Sensor antenna which may be a 1/4 wave wire
antenna.
Control Button and LED
[0172] A control button (not shown) is provided on the sensor 20;
the button is used as follows: [0173] 1 click Force immediate
impedance measurement followed by 3 radio transmissions over the
next 30 to 40 seconds. [0174] 4 clicks Initiate impedance
calibration. A 10K calibration resistor must be connected across
the measurement terminals. Calibration will not occur if the
calibration resistor is not connected. [0175] 6 clicks Clear flag
byte. This clears the over/under-temperature flags and low battery
flag. [0176] The "calibration valid" flag is not affected.
[0177] The sensor 20 includes a control LED status light (not
shown). Operation of the control LED is as follows: [0178] 1 Flash
An impedance measurement has been made. Three random radio
transmissions will follow to the corresponding hub 24 for
wirelessly transmitting a data packet thereto. [0179] 2 Flashes
Power just turned off. [0180] 3 Flashes Power just turned on.
[0181] 4 Flashes Calibration was successful. [0182] 6 Flashes Flag
byte was cleared. [0183] Long flash Just entered test mode.
Power Button and LED
[0184] The sensor 20 includes a power button (not shown); operation
of this button is as follows: [0185] Hold Toggle power on and off.
[0186] If power is off, a hold of the power button causes the
control LED to flash 3 times. Power to the sensor 20 is now on.
[0187] If power is on, a hold of the power button causes the
control LED to flash 2 times. Power to the sensor 20 is now
off.
[0188] There is a power LED on the sensor 20. The following are
indicated by this LEC: [0189] 1 Flash Occurs every 4-5 seconds when
power is on. [0190] 3 Flashes Just left test mode.
Radio Data Packets
[0191] The sensor 20 measures complex currents, battery voltage,
and temperature every, e.g., 5 minutes (or as instructed by the
controller 28) and transmits the results to its corresponding hub
24. In one embodiment, the transceiver component 64 sends one type
of data packet, length 46 bytes, which contain the following
information: [0192] LEN (1 byte) Total data length in bytes,
including this byte and CRC. Always 0x2E. [0193] ID (4 bytes)
Unique sensor 20 identifier. [0194] Resistance (8 bytes) Eight
measurements are provided: [0195] R1H, R1L 1953.1250 Hz at high
amplitude (R1H), 1953.1250 Hz at low amplitude (R1L); [0196] R2H,
R2L 2929.6875 Hz at high amplitude (R2H), 2929.6875 Hz at low
amplitude (R2L); [0197] Capacitance (8 bytes) Eight measurements
are provided: [0198] C1H, C1L 1953.1250 Hz at high amplitude (C1H),
1953.1250 Hz at low amplitude (C1L); [0199] C2H, C2L 2929.6875 Hz
at high amplitude (C2H), 2929.6875 Hz at low amplitude (C2L);
[0200] FLAGS (1 byte) Flag byte. Bits are as follows: [0201] D0
1=low battery level (4.00V) occurred (for the batteries 54). [0202]
Cleared by the following actions to the sensor 20: power-on reset,
pushbutton reset, and "clear flags" command issued by the
controller 28 to the sensor 20. [0203] D1 1=sensor 20 calibration
invalid. [0204] Cleared when calibration sensor 20 has been
completed and is valid. [0205] D2 1=fast (1-minute) impedance
sampling by the sensor 20 in normal mode. [0206] 0=normal
(5-minute) sampling of impedance by the sensor 20. [0207] Can only
be set or cleared when the sensor 20 is in test mode. [0208] D3, D4
reserved, always 0 at this time. [0209] D5 1=The temperature
measurement at the sensor 20 dropped below -40 C. The controller 28
clears this data field by issuing a "clear flags" command to the
sensor. [0210] D6 1=temp exceeded 125 C. Cleared by "clear flags"
command from the controller 28 to the sensor 20. [0211] D7 1=temp
exceeded 130 C. Cleared by "clear flags" command from the
controller 28 to the sensor 20. [0212] VBATT (2 bytes) Battery 54
voltage in units of 10 mV. This data field is an unsigned integer.
Each measurement for this field is made during an impedance
measurement (by the analog measurements component(s) 48) while
battery current drain is at maximum. [0213] TEMP (2 bytes)
Temperature in degrees C. with 1-degree resolution at the sensor
20. This data field is a signed integer. [0214] CRC (2 bytes) CRC.
This is used by the controller 28 to verify that the serial data
channel from the radio receiver has no errors. The radio receiver
always checks that there are no radio channel errors.
[0215] Radio transmissions from the sensor 20 are repeated randomly
three times with 11-14 seconds delay between, each transmission.
Repeated transmission of the same data packet improves the
probability of it being received by the sensor's corresponding hub
24 in the presence of multiple wireless transmissions from other
sensors 20, radio fading, etc. In one embodiment, the corresponding
hub 24 transfers each data packet instance received to the
controller 28, the sensor ID, and a timestamp to avoid duplicately
processing a data packet, or to detect that a measurement has been
missed.
CRC Calculation
[0216] Data types used in the following code example are:
[0217] UINT8 unsigned integer 8-bit
[0218] UINT16 unsigned integer 16-bit
[0219] UINT32 unsigned integer 32-bit
The following code takes the receiver packet buffer PktBuffer[ ]
and calculates the 16-bit CRC:
TABLE-US-00001 UINT32 PktCRC; // Shift register for CRC
calculation. // Bits 0x00ffff00 of PktCRC are the 16-bit CRC.
//********************************************************* //
Function pktGetCRC( ) // Calculate the CRC of the received packet.
//********************************************************* UINT16
pktGetCRC ( // Return the 16-bit CRC result. UINT8 PktBuffer[ ]) //
Received packet. { UINT8 i, j; if (PktBuffer[0] != 0x2E) // Exit of
packet length is wrong. return 0; PktCRC = 0; // Zero the CRC. j =
PktBuffer[0] - 2; // Number of bytes to process for CRC. for (i=0;
i<j; i++) { // Process all bytes before the message CRC bytes.
pktByteCRC(PktBuffer[i]); // Update CRC for each byte. }
pktByteCRC(0); // Process 0's in place of the CRC bytes of the
packet. pktByteCRC(0); return (UINT16)( (PktCRC >> 8) &
0xFFFF ) ; }
//********************************************************* //
Function pktByteCRC( ) // Update the CRC for one packet byte.
//********************************************************* void
pktByteCRC( // Update the CRC for one byte of the packet. UINT8
byte) // Data byte from packet. { UINT8 i; PktCRC &=
(UINT32)0x00ffff00; // Clear low byte. PktCRC |= (UINT32)byte; //
Bring in the new data byte. for (i=0; i<8; i++) { // Process 8
new bits into the CRC. PktCRC <<= 1; // Shift all. if (PktCRC
& (UINT32)0x01000000) // If 1 was shifted out, PktCRC =
(UINT32)0x00102100; // Apply inversions. } }
The result should equal the 16-bit CRC from the received
packet.
Impedance Calculation
[0220] The sensor 20 (more particularly, the analog measurement
component 48 for obtaining impedance related values) applies to the
circuit 70 a sine wave voltage to an induced predetermined
impedance, and measures the resulting AC current of the circuit 70
through this impedance. The sensor 20 does not calculate the
impedance itself. Rather, it makes a complex measurement of the AC
current and provides the real and imaginary components thereof to
the controller 28. The phase of the current is also measured
relative to the phase of sine wave generator in the analog
measurement component 48.
[0221] Complex current measurements are made at two different
frequencies, 1953.125 Hz and 2929.6875 Hz as discussed above. At
each frequency, measurements are made at a high amplitude (for
impedances >=10K) and a low amplitude (for impedances 1K to
10K). Calibration measurements are also made at both frequencies
and both amplitudes.
[0222] During calculations, the controller 28 checks the magnitude
of the complex current. If the magnitude is too high during the
high-amplitude measurement, the measurement circuit may have been
clipping. In that case, the low-amplitude measurement must be used
instead. In particular, if the high-amplitude measurement has a
magnitude over 15500, use the low-amplitude measurement.
[0223] The circuit diagram illustrated in FIG. 8 is used as a model
for the circuit 70, wherein the external impedance in the diagram
is the wood/lumber between the metal plates 36 associated with the
sensor 20.
[0224] Referring to the circuit diagram illustrated in FIG. 8:
[0225] Fixed circuit values used are: [0226] Ro=2000 ohms Circuit
output resistance [0227] Co=0.22 uF Circuit output capacitance
[0228] The measurement frequency value must be used when converting
between reactance and capacitance. The impedance of a capacitor is
defined as imaginary and negative, which means the current phasor
through a capacitor is imaginary and positive (current leads
voltage).
[0228] Xc=-1/(2.pi.FC)
C=1/(2.pi.F(-Xc))
Zc=-jXc [0229] Xc Capacitive reactance in ohms [0230] Zc Complex
impedance of a capacitor [0231] C Cap in Farads [0232] F Freq in Hz
[0233] Parallel/Series conversions are required to calculate the
external impedance Ze are as follows (the identifiers in the
circuit diagram illustrated in FIG. 8 (and following): ending in
"p" denote parallel measurements, and ending in "s" denote
serial):
[0233] Rp=(Rs.sup.2+Xs.sup.2)/Rs
Xp=(Rs.sup.2+Xs.sup.2)/Xs
Rs=Rp Xp.sup.2/(Rp.sup.2+Xp.sup.2)
Xs=Rp.sup.2Xp/(Rp.sup.2+Xp.sup.2) [0234] Rs, Cs External series
equivalent resistance and capacitance [0235] Xs External series
equivalent reactance [0236] Rp, Cp External parallel equivalent
resistance and capacitance [0237] Xp=-1/(2.pi.F Cp) External
parallel equivalent reactance [0238] Equations used in the
calculations are: [0239] Xo=-1/(2.pi.F Co) Circuit output reactance
[0240] Zo=Ro+j Xo Circuit Output Impedance [0241] Ze=Rs+j Xs
External impedance
[0241]
Ze=[RpXp.sup.2/(Rp.sup.2+Xp.sup.2)]+j[Rp.sup.2Xp/(Rp.sup.2+Xp.sup-
.2)] [0242] Z=Zo+Ze Total impedance [0243] I=V/Z Complex current
[0244] V=IZ Complex drive voltage Note, the calculations in this
Impedance Calculation section may be performed by the analog
measurements component(s) 48, and in one embodiment, by the
impedance chip from Analog Devices, Inc.
Calibration
[0245] For calibration of the sensor 20, a 10K ohm resistor is
connected and a calibration sequence is initiated. The sensor 20
measures the AC current through this resistor and stores the real
and imaginary results. These calibration measurements are included
in every data packet along with measurements for the unknown
impedance.
[0246] During calibration, the controller 28 first uses the
calibration current measurement, Ical, and the total calibration
impedance, Zcal, to calculate the complex excitation voltage V as
follows:
[0247] Rp, Cp External components connected in parallel during
calibration
[0248] Ze=[Rp
Xp.sup.2/(Rp.sup.2+Xp.sup.2)]+j[Rp.sup.2Xp/(Rp.sup.2+Xp.sup.2)]
External impedance during calibration
[0249] Zcal=Zo+Ze Total impedance during calibration
[0250] Ical Complex current measured during calibration
[0251] V=Ical Zcal Complex drive voltage
This complex V is constant and can be used in the calculations of
unknown impedances. Four values of V may be calculated at each
measurement frequency and at each amplitude. Capacitive reactance
changes with frequency, and the internal phase shift of the sine
wave source changes with amplitude.
[0252] The measurement units of I are not important, since V is
calculated from I and so the units of V will be correct for
calculating impedances in ohms as long as Zcal is calculated in
ohms.
Measuring External Rp, Cp
[0253] Measurement involves connecting an unknown external Rp and
Cp, measuring I, and using the known value of V to calculate Rp and
Cp.
[0254] I Complex current measured [0255] If abs(I) >15,500 then
make the results Rp, Cp invalid. This will occur at high output
amplitude when small external impedance is connected and indicates
that the AD5933 A/D converter is clipping.
[0256] Z=V/I Total impedance with unknown Rp, Cp [0257] If abs(I)
<0.5 (complex I measurement is zero) then limit Z=1e8+0i to
prevent overflows.
[0258] Ze=Z-Zo External impedance with unknown Rp, Cp
[0259] Rs=re(Z)-Ro External series resistance
[0260] Xs=im(Z)-Xo External series reactance
[0261] Rp=(Rs.sup.2+Xs.sup.2)/Rs External parallel resistance
[0262] Use the absolute value of Rp to cover cases where Rs is
small and negative (re(Z) is close to Ro). Limit Rp to 10M ohms
maximum to cover cases where Rs is very small.
[0263] Xp=(Rs.sup.2+Xs.sup.2)/Xs External parallel reactance [0264]
Use the absolute value of Xp to cover cases where Xs is small and
negative (im(Z) is close to Xo).
[0265] Cp=1/(2.pi.F(-Xp)) External parallel capacitance [0266]
Limit Cp to the range 0.1 pF to 0.1 uF to cover cases where Xp is
very large or small. If the flag byte (described above) indicates
that the sensor 20 is uncalibrated, then the Rp and Cp results are
invalid.
Wireless Setup
Battery Installation and Sensor 20 Startup
[0267] The following procedure is for installing the batteries 54
in the sensor 20 and then activating the sensor. [0268] Open the
sensor 20 back cover and install two batteries 54. The batteries
are both oriented in the same direction as marked on the battery
holders. Incorrect installation will not damage the sensor 20, but
it will not operate. [0269] Press the "RESET" button on the PCB and
check that the CONTOL LED flashes twice. [0270] Hold the POWER
button until the CONTOL LED flashes 3 times. Power is now turned on
and the unit will transmit measurements every 5 minutes.
* * * * *