Automatic collection and updating of compliance data for gas detection equipment

A gas detection unit capable of automatically communicating event data is provided. The unit includes a housing, a gas detector module mounted in the housing, and a programmable processor configured to retain preselected event data of the gas detector module and to automatically initiate a wireless signal communicating the preselected event data for further transmission to a remote database in response to the detection of an available communication connection. The unit can include a low power radio module configured to transmit a low power radio signal communicating the preselected event data in response to initiation of the wireless signal by the programmable processor.

FIELD

This invention relates to gas detection equipment and systems and methods for managing/maintaining such systems.

BACKGROUND

Companies in most parts of the world have to follow government regulations and/or company policy about the use of gas detection equipment. Typically, this includes being able to show that they are compliant to these regulations and/or policies. In order to show compliance the safety manager must maintain records about the status of the gas detection equipment, including any operational failures, and be aware of any configuration changes that have been made. This data can be stored as a hardcopy or in an electronic database.

In many situations this data is not easy to collect. For remote or mobile workers in particular, the data is often stored on the gas detection unit or docking equipment and is not easily transferred to the central database storage location for recall and/or review by the safety manager. This means that the data may be infrequently transferred, and the safety manager's records are often not up to date.

Additionally, sometimes there are changes to government regulations or to company policy that require the gas detection unit's configuration be changed (e.g. Alarm set point is lowered to be cautious). For remote or mobile workers, updating these settings can be challenging because the gas detection equipment may infrequently make it back to the office for where the safety manager works so that the equipment can be updated.

Furthermore, the designs of gas detection units have to be certified to be intrinsically safe (IS) so that they can be used in an environment with flammable gas. This inherently places many restrictions on the designs of such units.

SUMMARY

In accordance with one feature of the application, a gas detection unit capable of automatically communicating event data is provided. The unit includes a housing, a gas detector module mounted in the housing, and a programmable processor configured to retain preselected event data of the gas detector module and to automatically initiate a wireless signal communicating the preselected event data for further transmission to a remote database in response to the detection of an available communication connection.

As one feature, the unit further includes a low power radio module configured to transmit a low power radio signal communicating the preselected event data in response to initiation of the wireless signal by the programmable processor.

In one feature, the low power radio module includes a wireless receiver configured to receive a low power radio signal, and the programmable processor is configured to automatically initiate the wireless signal communicating the preselected event data in response to the detection of the low power radio signal by the wireless receiver.

According to one feature, the low power radio module is configured to transmit in the ISM band from 2400 to 2800 MHZ.

In one feature, the low power radio module is configured to operate under Bluetooth protocols.

As one feature, the low power radio module is configured to operate under ultra-wide band protocols.

According to one feature, the low power radio module is configured to operate under wireless local area network protocols.

As one feature, the low power radio module is configured to operate under IEEE 802.11 standards.

According to one feature, the programmable processor is configured to automatically confirm that the preselected event data has been successfully received by the remote database.

In one feature, the programmable processor is configured to automatically update one or more parameters in response to a received wireless signal providing the one or more parameters. As a further feature, the one or more parameters comprise data that alters a list of preselected events retained by the programmable processor or an operational setting of the gas detector module.

In one feature, the programmable processor and the low power radio module are mounted in the housing.

In accordance with one feature of the application, a method is provided for managing a gas detection unit. The method includes the steps of retaining preselected event data in a gas detection unit, and automatically transmitting the preselected event data via a wireless signal in response to the detection of a wireless communications connection.

As one feature, the step of automatically transmitting includes transmitting the preselected event data via a low power wireless signal emitted from the gas detection unit.

In a further feature, the step of automatically transmitting further includes transmitting the preselected event data to the remote database via an internet connection.

According to one feature, the step of automatically transmitting further includes receiving the low power wireless signal in a device distinct from the gas detection unit and retransmitting the preselected event data via a high power wireless signal emitted from the device. As a further feature, the step of automatically transmitting further includes transmitting the preselected event data from the device to the remote database via an internet connection.

As one feature, the method further includes transmitting a wireless signal back to the gas detection unit indicating that the preselected event data has been received by the remote database.

In one feature, the method further includes transmitting a signal back to the gas detection unit providing updated parameters for the gas detection unit. In a further feature, the method further includes updating at least one of an operational setting of the gas detection unit or a list of preselected event data to be retained in the gas detection unit for later transmission therefrom in response to the updated parameters.

Other features and advantages will become apparent from a review of the entire specification, including the appended claims and drawings.

DETAILED DESCRIPTION

Several embodiments of gas detection units are shown diagrammatically at10inFIG. 1, with each gas detection unit10being capable of automatically communicating event data, such as, for example, data pertaining to the status of the unit10, operational failures of the unit10, configuration changes of the unit10, gas exposures of the unit10, testing of the unit10, and/or recalibration of the unit10, any or all of which may be required as compliance data. In the illustrated embodiments, each of the gas detection units10includes a housing12, a gas detector module14mounted in the housing and capable of detecting one or more predetermined gases, and a programmable processor in the form of a microprocessor16mounted in the housing10. The processor16is configured to retain preselected event data of the gas detector module14and to automatically initiate a wireless signal, shown schematically at18, communicating the preselected event data for further transmission to a remote database or databases20in response to the detection of an available wireless communication connection, shown generally at22.

Each of the illustrated embodiments further includes a low power radio module24configured to transmit the wireless signal18in the form of a lower power radio signal18, communicating the preselected event data in response to initiation of the wireless signal18by the programmable processor16. As used herein, the term low power radio signal is intended to indicate relatively low power radio signals that are capable of reliable communications over distances typically limited to around 100 yards or less, such as signals operating according to Bluetooth protocols in the ISM band from 2400 to 2800 megahertz, signals operating according to Zigbee protocols such as IEEE 802.15.4, signals operating under ultra-wide band protocols, such as IEEE 802.14.4a, and signals operating under so-called Wi-Fi or wireless local area network protocols, such as signals operating under IEEE 802.11 standards, and which are distinguished from relatively high power radio signals that are capable of reliable communications over distances typically of one third of a mile or greater, such as signals operating under cellular phone protocols, Citizen Band radio protocols (CB radio), Family Radio Service (FRS) protocols, General Mobile Radio Services (GMRS) protocols, or amateur Ham radio protocols.

In the illustrated embodiments, the preselected event data communicated via the wireless signal18is further transmitted via a communication network, such as, for example, via a cellular phone system, shown generally at26and/or the Internet28(such as under the standard internet protocol suite (TCP/IP)) to the remote database or databases20which can reside, for example, in a storage server30and/or a locally based computer32for current and future review by a safety manager.

In the illustrated embodiments, each of the low power radio modules24include a wireless transmitter36configured to transmit the low power radio signal18, and a wireless receiver38configured to receive a low power radio signal, shown schematically at40, with the programmable processor16being configured to automatically initiate the low power radio signal18in response to detection of the low power radio signal40by the wireless receiver38.

In the embodiment10A ofFIG. 1, the low power wireless module26is mounted in the housing12and configured as a BLUETOOTH® module26A that operates according to Bluetooth protocols. In this regard, the module26A transmits and receives in the ISM radio bands from 2400 to 2800 megahertz.

The low power wireless module24in the embodiment10B ofFIG. 1is mounted in the housing12and provided in the form of a Wi-Fi module24B that can be configured to operate under wireless local area network (WLAN) protocols, such as IEEE 802.11 standards, and/or under ultra-wide band (UWB) protocols, such as IEEE 802.15.4a, for communications with the internet28.

The low power radio module24of the embodiment10C inFIG. 1is provided in the form of a USB mobile radio module24C that is releasably connected into a USB port41in the housing12. The USB module24C is a Wi-Fi module similar to the module24B.

In each of the illustrated embodiments, the programmable processor16is further configured to automatically confirm that the preselected event data has been successfully received by the remote database20. This will include the receipt of an express confirmation of successful receipt by the database20via the wireless signal40.

The programmable processor16in each of the embodiments can also be configured to automatically update one or more parameters in response to a received wireless signal40providing the one or more parameters. In this regard, the one or more parameters can include, for example, a list of the preselected events to be retained by the programmable processor16, and/or alterations to the operational settings of the gas detector module14. Additionally, the illustrated systems can also be configured such that the configuration settings of each of the gas detector units10are confirmed as correct in response to the low power radio signal18transmitting the current configuration settings of the gas detector unit10.

In operation, the microprocessor16in each of the illustrated units10automatically stores a record of the preselected event data and automatically transmits the preselected event data from the unit10via the wireless signal18in response to the detection of the wireless communications connection22. For example, a user of embodiment10A may be driving around to different remote facilities and at least one of the facilities has a gas exposure event that is stored by the microprocessor16as one of the preselected events. When the user returns to his vehicle, where he has left his cellular phone42because it is not IS and cannot be in a hazardous environment, the gas detection unit10A detects a wireless communications connection22via a BLUETOOTH® connection22and the microprocessor16automatically transmits the preselected event data from the gas detector unit10A via the wireless signal18to the cell phone42, which data is further transmitted via the cell phone42through the cellular network26to the internet28and then via the internet28to the database20for future or current review by a safety manager. As another example, a user of embodiments10B or10C visits several facilities and at least at one of the facilities has a gas exposure event that is stored by the microprocessor16as one of the preselected events. Some time during the day the user stops at a coffee shop with a publicly available Wi-Fi system and the gas detection unit10B or10C detects the wireless communications connection22and in response thereto the microprocessor16automatically transmits the preselected event data from the gas detection unit10B or10C to the Internet28via the publicly available Wi-Fi system at the coffee shop, with the data then being further transmitted via the internet28to the database20for current or future review by a safety manager.

It should be appreciated that the low power radio modules24A,24B,24C could take on other suitable forms than those expressly described, such as for example, it could be a low power radio module configured to operate according to Zigbee under IEEE 802.15.4 standards or to operate under proprietary low power radio signal protocols.

It should be appreciated that there are many known and suitable types, forms, and constructions for each of the components14,16,20,24A-24C,30,32, and41that can be utilized in the systems and method described herein and that the details of such components are not critical to the systems and methods described herein. Furthermore, it should be understood that while specific embodiments have been shown and described above, there are other possible alternatives. For example, while each embodiment of the unit10the low power wireless modules24have been shown and described as being mounted in or on the housing12, it may be desirable in some applications for the low power wireless module24to be included in a docking module or station for the unit10, of which many suitable types, forms, and constructions are known, with the microprocessor16of the unit10initiating the low power radio module24when the gas detection unit10is docked with the docking module and an wireless communications connection is sensed by the module24. Alternatively, the programmable processor16can also be configured to transmit the event data to another programmable processor in the docking station whenever the gas detector unit10is docked with the docking station and the processor in the docking station can be configured to initiate the wireless signal in response to detection of a wireless communication connection22. Further, if the docking station can accept multiple units10, the units10can share the low power radio module24and the processor in the docking station. Accordingly, limitations to the specific embodiments illustrated and described herein should not be read into any appended claim unless expressly recited in the claim.

It should be appreciated that by providing the programmable processor to retain preselected event data of the gas detector module and to automatically initiate a wireless signal communicating the preselected event to a remote database, the systems and methods disclosed herein provide a convenient, dependable method for a safety manager to maintain appropriate compliance records and to stay up-to-date on the status of the gas detection units. It should also be appreciated that by providing the low power radio module24in the housing12of the gas detector unit10, the gas detector unit10can still maintain its battery life while being certified to be intrinsically safe (IS) because the low power radio module24will not require an unduly large battery to provide a run time long enough for a shift.