Abstract:
An apparatus and method for indicating a process temperature anomaly during a power outage comprising employing a power source separate from that powering the process, setting a temperature set point; sensing presence and absence of power powering the process, sensing process temperature; and indicating to users that an absence of power was sensed and that the temperature sensed during the absence of power was below (or above) the temperature set point.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to and the benefit of the filing of U.S. Provisional Patent Application Ser. No. 61/108,791, entitled “Process Under/Over Temperature Indicator”, filed on Oct. 27, 2008, and the specification and claims thereof are incorporated herein by reference. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
     Not Applicable. 
     COPYRIGHTED MATERIAL 
     Not Applicable. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention (Technical Field) 
     The present invention relates to methods and apparatuses for ensuring that a product or products being manufactured have not fallen out of bake/cure/freeze or like specifications during a power failure event. 
     2. Description of Related Art 
     Power outages, such as from lightning strikes, can last from a few minutes to several hours or longer. After a power outage, persons maintaining a production facility usually go around and reset the ovens/freezers/chambers so that the devices can continue the cure/bake-out or similar cycles (sometimes an oven or freezer can be missed, but this is rare) and to make sure that the units are on. If the power outage lasts more than the chamber&#39;s insulation can maintain internal temperature (thermal inertia), the process will go out of specification even if maintenance does reset the chamber. Not knowing the chamber&#39;s downtime may give a false sense of security when one comes back into work and the chamber is on, which may lead to catastrophic results (e.g., severe delamination while going over a wave solder machine, moisture trapped under a coating thereby causing corrosion, adhesives not bonding properly, and premature failure of the manufactured article (quite possibly in the field), etc.). The present invention provides a direct solution to this problem. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention is of an apparatus and method for indicating a process temperature anomaly during a power outage, comprising: employing a power source separate from that powering the process; setting a temperature set point; sensing presence and absence of power powering the process; sensing process temperature; and indicating to users that an absence of power was sensed and that the temperature sensed during the absence of power was below (or above) the temperature set point. 
     Further scope of applicability of the present invention will be set forth in part in the detailed description to follow, taken in conjunction with the accompanying drawing, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating one or more preferred embodiments of the invention and are not to be construed as limiting the invention. In the drawings: 
         FIG. 1  is a schematic diagram of the preferred sensor and indicator of the invention; and 
         FIG. 2  is a diagram of the preferred front panel of the invention used in conjunction with a four-way switch. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is of an apparatus for indicating a process temperature anomaly during a power outage. Because ovens and freezers are often no longer equipped with a chart recorder, an extremely cost-effective device is preferred, both to manufacture and to incorporate into cure/bake-out/freezer procedures. The present invention was designed to be compact, user-friendly, extremely cost-effective to build, and easy to calibrate. 
     The attached schematic of  FIG. 1  shows one embodiment of the present invention for ovens. As shown in  FIG. 1 , the invention comprises: batteries B 1 -B 6  (preferably 1.5 volt rechargeable); comparators U 1 -U 2  (preferably in dual comparator type LM393); flip-flop U 3  (preferably type CD4013); voltage reference VR 1  (preferably a type LT1004 voltage reference, or alternatively a Zener diode); switch SW 1  (preferably relay type SP4T, but two-way, three-way, or greater can be employed, as well as a hard-wired set point); switch SW 2  (preferably momentary type DPDT); jack J 1  (preferably matching wall transformer (not shown)); capacitor C 1  (for reset time delay); diodes D 1 -D 2  (preferably silicon); transistor Q 1  (preferably type 2N2222A); light emitting diodes (LEDs) LED 1 -LED 2 ; resistors R 1 -R 19 ; thermocouple cold junction compensator and matched amplifier (preferably type LTK001; improves the low-level signal output of thermocouple and reduces or eliminates non-linearities inherent in them); cold junction compensator U 4 ; amplifier U 5 ; and thermocouple jack TC 1 . R 16 -R 18  are picked preferably to ensure an approximate desired output of 10 mV/° C. One pole in SW 2  is preferably used in conjunction with R 19  to add an LED check function. When the user resets the unit, the “Process Suspect” LED (see  FIG. 2 ) will light. 
     The unit of the invention is preferably powered by a small DC output wall transformer. The exact voltage is not critical, but about 6 to 12 volts is preferred. B 1 -B 6  are used to maintain operation and the flip-flop&#39;s (U 3 ) memory state during a power outage. R 1  and VR 1  are used to act as the stable voltage reference required for the R 2 /R 3 -R 6  voltage divider that forms one half of the voltage comparators circuit. The other half of the circuit is the input of a thermocouple (Type “T” is preferred) inserted into TC 1  with the other end placed into the oven. If the temperature is at or above the minimum temperature (for heating applications; reverse for cooling applications) selected via SW 1 , the output of U 2  will be “High”, reversed biasing diode D 1 , in effect leaving the “D” input of U 3  to be driven by the R 7 /R 11  combination (meaning pulled “High”). 
     In the event of a power outage, B 1 -B 6  supply power to U 1 -U 3  and reverse bias D 2 . With D 2  reverse biased, power to LED 1  (“Power On”) and LED 2  (“Process Suspect”) is turned off, conserving battery power for the active portion of the circuit. C 1  will be discharged via LED 1 , ensuring a clean reset. 
     Once power is restored, the reset circuit comprising U 1 , C 1 , and R 8 -R 10  transitions from a “Low” to a “High”, triggering the “edge-triggered” “D”-type flip-flop clock line (CL) with a time delay determined by ½t the R 8 /C 1  combination. 
     If the temperature measured by the thermocouple (in millivolts) is below the set point (for heating application, above for cooling) of the R 2 /R 3 -R 6 , U 2  will output a “Low” through D 1 , swamping the “D” input so that when the reset circuit transitions, the “Low” is passed on to the “Q” output of U 3 . R 11  is chosen to be low enough in value to help latch the flip-flop (similar to a Schmidt Trigger) but high enough in resistance to minimize quiescent current drain during a power outage, yet low enough to make the calibration step tolerable. 
     With U 3 &#39;s “Q” output “Low”, the “Q” is now “High”, turning on Q 1 , which in turn turns on LED 2  (“Process Suspect”). The flip-flop is now latched in this state and the only way to clear the “Process Suspect” light is by pressing SW 2 . 
     The device of the invention is preferably operated as follows. Upon placing the materials for process in an oven and the oven obtaining operating temperature: (1) the operator selects the desired preset temperature via SW 1 ; (2) the operator presses SW 2 , which sets the “D”-type flip-flop into the known “Set” condition, and which does an illumination “Self-Test” of LED 2 ; (3) with the flip-flop “Set”, Q is pulled low, disabling transistor Q 1  from driving LED 2  (“Process Suspect”) and turning the indicator off; and (4) the device is now armed. 
     If during the bake/cure cycle the power goes off, B 1 -B 6  supply the power for the circuit less the two LEDs. By not powering the two LEDs, battery life is significantly enhanced. Being CMOS based integrated circuits, the supply current is negligible, the LM393 supply current being only 2-3 mA and that of the CD4013 being 2.5 microA unless switching or driving another device. When the operator goes to get the materials for process, if the “Process Suspect” LED is lit, they will know that the materials for process have fallen out of specification and that they need to notify engineering or other appropriate personnel. 
     The preferred number of batteries depends on the power supply voltage minus the D 2  voltage drop and desired estimated needed runtimes (e.g., from about four days to one month). 
     By reversing the sensing leads on U 2  the device of the invention can also serve as an “Over-Temperature” device for use in freezers, thus making the device of the invention useful to not only OEM oven manufacturers but also freezer/cooler makers. 
     Features and advantages of the invention include: (1) “At-A-Glance” assurance that a power interruption did not disturb the “Bake/Cure” Cycle or that material has not thawed out; (2) Battery Back-Up—when the power went off in the prior art, the chart recorders also stopped working—furthermore, no expensive “Chart Paper” to buy; (3) Easy to use—just verify correct temperature and press the “Set” button; (4) Preferred design monitors four most common bake temperatures in a facility, and this is easily altered to accommodate others and is adaptable to freezers; (5) inexpensive to build—“Peace of Mind” is an added “Bonus”; (6) Easy to maintain and calibrate; and (7) Easily incorporated by OEM Oven/Freezer manufacturers. 
     Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference.