Abstract:
A method and system for modifying the operation a device. The method can include obtaining a first reconfiguration kit. The first reconfiguration kit can include a portable memory device. The method can also include connecting the portable memory device to the device and transmitting information between the portable memory device and the device. The method can further include disconnecting the portable memory device from the device and returning the portable memory device to an entity associated with the provider of the portable memory device.

Description:
RELATED APPLICATIONS 
   The present application claims priority to U.S. provisional patent application Ser. No. 60/621,985 titled “METHODS AND SYSTEMS FOR MODIFYING THE OPERATION OF A COMPRESSOR VIA A PORTABLE MEMORY DEVICE,” filed on Oct. 25, 2004. 

   FIELD OF INTEREST 
   The present invention relates to configuring and modifying operating characteristics of compressors. More particularly, embodiments of the invention relate to modifying the operating characteristics of a compressor using a portable memory device. 
   BACKGROUND OF THE INVENTION 
   In traditional compressors, operating parameters (i.e., speed, pressure, power, etc.) are set with a motor/compressor sheave or gear ratios. The motor/compressor sheave or gear ratios can be set for specific parameters to enable operation of a compressor at a specific capacity up to a maximum pressure within the available power limit. The parameters are often set during manufacture or construction of the compressor and typically cannot be easily modified once set. In some situations, the only way to change the characteristics of a compressor is to change mechanical components of the compressor. 
   SUMMARY OF THE INVENTION 
   Variable compressors are often used to overcome the above-identified limitations. In some variable compressors, the bulky mechanical gear assemblies or belt/sheave assemblies are replaced with “electronic gears” consisting of a variable speed drive (“VSD”) and an electric motor. Variable compressors can then be programmed for a specific pressure and speed duty by variably setting the operating parameters of the VSD and motor. In traditional VSD controlled compressors, a controller or interface is included with the compressor to allow a user to program and customize the operation of the compressor. The controller and display, however, can be very expensive and a user can need specific training to adjust the operating characteristics of the compressors. Also, a user manually specifying operating characteristics can configure or program the compressor to operate outside approved operating parameters. 
   Embodiments of the invention provide a system for configuring operating parameters of a compressor. The system includes a compressor with a variable speed drive and a portable memory device interface and a portable memory device with a memory module and an external output port. The memory module of the portable memory device may have stored within it operating characteristics for the compressor. The external output port is connectable to the portable memory device interface of the compressor. Operating characteristics may be downloaded from the memory module of the portable memory device to the compressor. The compressor then operates according to the downloaded operating characteristics. The portable memory device can be removed or disconnected from the compressor once the operating characteristics are downloaded. The portable memory device can also be returned to a distribution or service center where it can be reprogrammed as needed. 
   Additional embodiments provide a method of configuring a compressor. The method may include connecting a portable memory device to the compressor, where the portable memory device includes operating characteristics for the compressor. The method may also include downloading the operating characteristics from the portable memory device to the compressor and modifying the operating parameters of the compressor based on the downloaded operating characteristics. The method may further include marking the portable memory device as used and removing the portable memory device from the compressor. The method may also include returning the portable memory device to a distribution or service center where it can be reprogrammed. 
   Another embodiment provides a method of configuring a variable-operating device. The method may include connecting a portable memory device to the variable-operating device, where the portable memory device includes operating characteristics for the variable-operating device. The method may also include downloading the operating characteristics from the portable memory device to the variable-operating device and modifying the operating parameters of the variable-operating device based on the downloaded operating characteristics. The method may further include marking the portable memory device as used and removing the portable memory device from the variable-operating device. The method may also include returning the portable memory device to a distribution or service center where it can be reprogrammed. 
   Yet another embodiment provides a system for modifying the operation of a compressor. The system can include a compressor controller configured to operate the compressor according to operating parameters and a portable memory device including a counter to track use of the portable memory device. The system can also include a first portable memory device interface configured to transmit information between the portable memory device and the compressor controller and to set the counter. The portable memory device configured to be connected to the first portable memory device interface, and the compressor controller configured to modify the operating parameters based on the information and to operate the compressor according to the modified operating parameters. 
   Additional embodiments provide a method of modifying the operation a first device. The method can include connecting a portable memory device to the first device. The portable memory device can include a counter value to track use of the portable memory device. The method can also include transmitting information between the portable memory device and the first device, modifying operating parameters of the first device based on the information, and setting the counter value of the portable memory device. The method can further include disconnecting the portable memory device from the first device and operating the first device with the modified operating parameters. 
   Further embodiments also provide a method of modifying the operation a device. The method can include obtaining a first reconfiguration kit. The first reconfiguration kit can include a portable memory device. The method can also include connecting the portable memory device to the device, transmitting information between the portable memory device and the device, and disconnecting the portable memory device from the device. The method can further include returning the portable memory device to an entity associated with the provider of the portable memory device. 
   Furtherstill, embodiments provide a portable memory device. The portable memory device can include a memory module configured to store a counter value for tracking the use of the portable memory device, an external output connector connectable with an external access connector of a device. The external output connector can be configured to transmit information between the device and the memory module when the external output connector is connected to the external access connector of the device. 
   Other features and advantages of the invention will become apparent to those skilled in the art upon review of the detailed description, claims, and drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings: 
       FIG. 1  is a schematic illustration of an exemplary variable-operating device. 
       FIG. 2  is a schematic illustration of an exemplary portable memory device. 
       FIG. 3  illustrates one embodiment of the variable-operating device of  FIG. 1  and one embodiment of the portable memory device of  FIG. 2 . 
       FIG. 4  is a schematic illustration of an exemplary operation modification kit including the portable memory device of  FIG. 2 . 
       FIG. 5  is a flow chart illustrating an exemplary process of modifying the operation of the variable-operating device of  FIG. 1  with the portable memory device of  FIG. 2 . 
   

   DETAILED DESCRIPTION 
   It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings. 
     FIG. 1  illustrates an exemplary variable-operating device in the form of a compressor  20 . It should be understood that the device  10  can be devices configured to provide or operate at a range of selectable operating parameters (e.g., speed, power, pressure, etc.) can be substituted for the compressor  20 . The compressor  20  can include a compressor controller, such as a variable speed drive (“VSD”)  30 . The compressor  20  can also include a memory  32 , a motor  35 , and a portable memory device interface  40 . In some embodiments, the VSD  30  drives the motor  35  to provide horsepower (“HP”) of approximately 7.5 HP to 15 HP and can generate approximately 115 pounds per square inch (“PSI”) to 150 PSI of pressure. 
   The memory  32  can be configured to store operating parameters of the VSD  30 . The memory  32  can store a HP or PSI designation that regulates how the VSD  30  operates. The memory  32  can also include possible operating parameters configurations for the VSD  30 , and the VSD  30  can select one of the configurations and operate according to the parameters specified in the configuration. It should be noted that although the memory  32  is illustrated as internal to the VSD  30 , the memory  32  can be located external to the VSD  30 . 
   In some embodiments, the portable memory device interface  40  includes an external access connector  42 . In some embodiments, the external access connector  42  includes an RJ45 female port. The portable memory device interface  40  can be configured to transmit information between an external device connected to the external access connector  42 . The information can include operating characteristics (i.e., speed characteristics, power characteristics, pressure characteristics, etc.). After obtaining operating characteristics from an external device connected to the external access connector  42 , the operating characteristics can be transmitted to the VSD  30  over a connection  45 . The VSD  30  can store the operating characteristics to the memory  32 . The VSD  30  can also modify the operating parameters stored in the memory  32  based on the operating characteristics. 
   It should be understood that the compressor  20  can include additional components or a subset of those components illustrated and described above. The functionality provided by the components described above can also be combined and distributed in a variety of configurations. 
     FIG. 2  illustrates an exemplary portable memory device  50  connectable to the compressor  20 . In some embodiments, the portable memory device  50  includes a memory module  55 , an external output connector  57 , a button or selection mechanism  59 , and an indicator  61 . The memory module  55  can include non-volatile memory such as one or more forms of ROM, one or more disk drives, RAM, other memory, or combinations of the foregoing. The memory module  55  can store operating characteristics. In some embodiments, the memory module  55  stores operating characteristics that the compressor  20  can use to set operating parameters for the VSD  30 . The operating characteristics can specify pressure and/or speed parameters at which the compressor  20  will operate. The operating characteristics can also specify, either directly or indirectly, the power consumption and thus a model designation of the compressor  20 . 
   The external output connector  57  of the portable memory device  50  can be connectable to the external access connector  42  of the compressor  20 . In some embodiments, the external output connector  57  of the portable memory device  50  can include a RJ45 male connector that is connectable to a RJ45 female connector of the external access connector  42  of the compressor  20 . It should be understood that the external output connector  57  and the external access  42  can include other mating connectors and can be connected over a wired connection or a wireless connection. When the external output connector  42  of the portable memory device  50  is engaged with the external access connector  42  of the compressor  20 , the portable memory device interface  40  can transmit operating characteristics from the memory module  55  of the portable memory device  50  to the compressor  20 .  FIG. 3  illustrates one embodiment of the portable memory device  50  connectable with an exemplary compressor  20 . 
   An operator can use the selection mechanism  59  of the portable memory device  50  to start and/or stop the transmitting of operating characteristics from the memory module  55  of the portable memory device  50  to the compressor  20 . In some embodiments, the selection mechanism  59  can also be used to set operating characteristics stored in the memory module  55  and/or to select operating characteristics to be transmitted to the compressor  20 . 
   The indicator  61  can include a light emitting diode (“LED”) that specifies the current or recent operation of the portable memory device  50 . For example, the indicator  61  can light or flash to specify a valid connection or the successful transmission of data to or from an external device, such as the portable memory device interface  40  of the compressor  20 . 
   It should be understood that the portable memory device  50  can include additional components or a subset of the components illustrated and described above. The functionality provided by the components can also be combined and distributed in a variety of configurations. 
   In some embodiments, the portable memory device  50  is included in an upgrade or reconfiguration kit.  FIG. 4  illustrates an exemplary reconfiguration kit  70  that includes the portable memory device  50 , a model designation decal  75 , a portable memory device record card  80 , a return mechanism  85 , and a warning and/or instruction card  90 . In some embodiments, the return mechanism  85  can include an envelope, box, bag, or shipping packaged that allows a user to return the portable memory device after using the reconfiguration kit  70 . 
     FIG. 5  illustrates an exemplary process flow for upgrading the compressor  20  using the reconfiguration kit  70 . The process steps illustrated in  FIG. 5  are exemplary in order and content, and the processing of upgrading the compressor  20  using the reconfiguration kit  70  can be accomplished with a subset of the depicted steps or additional and alternative steps. 
   Beginning at start block  99 , when a user wants to modify the operating characteristics of the compressor  20  (i.e., change pressure setting, power setting, etc.), the user can purchase and/or obtain the reconfiguration  70  (block  100 ). In some embodiments, upon purchasing the reconfiguration kit  70 , a service technician is dispatched to the site of the compressor  20  to perform the upgrade at block  105 . It should be understood the user can perform the upgrade himself or herself in addition to or in place of the service technician. 
   In some embodiments, the service technician engages an emergency stop of the compressor  20  that prevents the compressor  20  from operating while the upgrade is being performed (block  110 ). The service technician can engage the emergency stop by pressing a button, changing the position of a switch, or the like. After engaging the emergency stop, the service technician plugs the external output connector  57  of the portable memory device  50 , which includes a male RJ45 connector, into the external access connector  42  of the portable memory device interface  40  of the compressor  20 , which includes a female RJ45 connector (block  115 ). At block  120 , the service technician depresses the selection mechanism  45  on the portable memory device  50  to initiate the transmitting of the operating characteristics to the compressor  20 . 
   The portable memory device  50  can include safeguards to prevent using the portable memory device  50  in non-compliant compressors. The portable memory device  50  can also include safeguards to prevent multiple uses of the portable memory device  50 . For example, the compressor  20  can include an identification parameter. The portable memory device  50  can verify the identification parameter of the compressor  20  before transmitting operating characteristics to ensure that the compressor  20  is compatible with the portable memory device  50  (block  125 ). In some embodiments, if the compressor  20  includes an invalid identification parameter, operating parameters are not transmitted to the compressor  20 , and the modification process ends at block  130 . If the compressor  20 , however, includes a valid identification parameter, operating characteristics can be transmitted the compressor  20 . The portable memory device  50  can also include an identification parameter that is checked by the compressor  20  before operating characteristics are transmitted. 
   The portable memory device  50  can also include a counter value. The counter value can be used to track use of the portable memory device  50  and to prevent the portable memory device  50  from being used multiple times. In some embodiments, the compressor  20  checks the counter value to ensure that it is set to a predetermined value (e.g., zero) before transmitting operating characteristics at block  135 . In some embodiments, if the counter value is not generally equal to the predetermined value (e.g., zero), operating characteristics are not transmitted from the portable memory device  50  and the modification process ends (block  130 ). If the counter value is set or equal to the predetermined value (e.g., zero), however, operating characteristics can be transmitted from portable memory device  50  to the compressor  20  (block  140 ). 
   After transmitting the operating characteristics to the compressor  20 , the portable memory device  50  can be marked as used by modifying the counter value (e.g., setting the counter value to one) (block  145 ). In some embodiments, by marking the portable memory device  50  as used, the portable memory device  50  cannot be used again to upgrade or modify a compressor  20 . 
   In some embodiments, the operating characteristics transmitted from the portable memory device  50  are forwarded to the VSD  30  over the connection  45 . It should be understood that the compressor  20  or, more particularly, the portable memory device interface  40  can process the operating characteristics transmitted from the portable memory device  50  before forwarding the operating characteristics to the VSD  30 . 
   Upon receiving the operating characteristics, the VSD  30  can use the operating characteristics to set and/or modify its operating parameters (block  125 ). In some embodiments, the VSD  30  stores operating parameters based on the operating characteristics to the memory  32 . The VSD  30  can overwrite existing (if any) operating parameters previously stored in the memory  32 . The VSD  30  can also select a particular operating parameter configuration from the memory  32  based on the operating characteristics. The compressor  20 , or more particularly, the VSD  30 , then operates as modified by the operating characteristics. 
   Once the compressor  20  has been modified or upgraded, the technician removes the portable memory device  50  from the portable memory device interface  40  of the compressor  20  (block  150 ). The service technician then installs the new model designation decal  75  over the existing decal on the package at block  155 . In some embodiments, the service technician installs a new model designation decal over the existing decal to ensure that a user is aware of the operating characteristics of the compressor  20 . The warning/instruction card  90  can also include a safety statement regarding the modified operating parameters of the compressor  20  set by the operating characteristics transmitted from the portable memory device  50 . In some embodiments, a user may not safely operate the compressor  20  if the user is unaware of the current operating characteristics of the compressor  20 . 
   The service technician then disengages the emergency stop of the compressor  20  so that the compressor  20  can be operated again (block  160 ). As previously described, the service technician can disengage the emergency stop by pressing a button, changing the position of the switch, or the like. 
   The service technician can fill in appropriate information on the portable memory device record card  80 , and can mail the portable memory device  50  and record card  80  in the self addressed return envelope  85  to an entity associated with the provider of the portable memory device  50 , such as a distribution center or service center (block  165 ). The shape and size of the portable memory device  50  can configured such that it can be conveniently mailed in the return envelope  85 . In some embodiments, the portable memory device  50  can have a length of 1.5 inches, a width of 1.0 inch, and a thickness of 0.2 inches. It should be understood, however, that the size and shape of the portable memory device  50  can be different depending on the compressor  20  that the portable memory device  50  connects to. 
   After the service technician mails the portable memory device  50  and portable memory device record card  80 , the modification process is complete (block  130 ). An entity associated with the provider of the portable memory device  50  can use returned portable memory device record cards  80  to track sales and user preferences for compressor operating characteristics. The entity associated with the provider of the portable memory device  50  can also reload operating characteristics to returned portable memory devices  50 . The entity can have a ‘black box’ that can be used to modify operating characteristics stored in the portable memory device  50 . The ‘black box’ can also be used to modify safety features of the portable memory device  50 , such as an identification parameter and/or a counter value. The ‘black box’ can include a non-operational drive that has operating characteristics stored in it. The portable memory device  50  can be plugged into the ‘black box,’ and the ‘black box’ can store operating parameters and/or safety features in the portable memory device  50 . In some embodiments, the ‘black box’ can overwrite existing operating characteristics and/or safety features stored in the portable memory device  50 . The modified portable memory device  50  can then be re-kitted in a reconfiguration kit  70  and reused. 
   It should be understood that the above process of modifying the operating characteristics of the compressor  20  can be performed an infinite number of times and can take place before the compressor  20  is sold or installed or after the compressor  20  has been installed and/or used. 
   The portable memory cards  50  can also be used at distribution centers to set operating characteristics of compressors  20  as requested. For example, compressors  20  can be shipped from the factory to distribution centers with a base set of operating parameters that operate the compressor  20  at one of multiple operating configurations. Distribution centers can stock base configuration compressors  20  and when an order is received they can use the portable memory device  50  to configure a base configuration compressor  20  to the exact model ordered. By setting operating characteristics as requested, distribution centers do not need to forecast or estimate the number of each model of compressor  20  to keep in stock to service customer requests. Distribution centers can keep portable memory devices  50  with possible operating characteristics in stock and configure compressors  20  to order. A distribution center can also include a single portable memory device  50  and can include a ‘black box’ as described above to store requested operating characteristics to the portable memory device  50  as needed. In some embodiments, the portable memory devices  50  stocked by the distribution centers do not include one or more of the safety features described above and can be used more than once. The portable memory devices  50  stocked by the distribution centers can, however, include a counter value to track the number of compressors  20  configured by the portable memory device  50  for inventory and/or sales purposes. 
   The portable memory device  50  can also be used in combination with the portable memory device interface  40  as a diagnostic/trending tool. The compressor  20  can transmit operational information, such as operating duration times, operating characteristics, sensor outputs, error conditions or warnings, etc., to the portable memory device  50 . The portable memory device  50  can then be provided to an entity associated with the provider of the portable memory device  50  to provide in-field use data, service recommendations, etc. 
   It should be understood that the portable memory device  50  can also remain connected to the compressor  20  while it operates. In some embodiments, as described above, the compressor  20  can transmit operational information to the portable memory device  50  for later diagnostic, sales, marketing, etc., analysis. 
   It should also be understood that the portable memory device  50  can be a removable device such that the compressor  20  can operate when the portable memory device  50  is not connected. In other embodiments, however, the compressor  20  can only operate when the portable memory device  50  is connected. For example, the compressor  20  can use operating characteristics stored in the portable memory device  50  directly, as needed, rather than transmitting the operating characteristics and storing them internally to the memory  32 . 
   Various features and advantages of the invention are set forth in the following claims.