Modular gas monitoring system

Monitoring systems and apparatuses and methods for using same are generally described. A gas monitoring system may include a base component and a module component. The module may be configured to be operably coupled to the base component through corresponding interface connectors. The system may be monitor for gases and generate alarms relating thereto, when the module is connected to the base. The base and/or module may have limited or no functionality when disconnected from the module and/or base. The module may include components that typically have an increased potential for upgrades, replacement, maintenance, or other modifications. The base may include components that typically have a lower rate of being upgraded, replaced, or requiring maintenance. In this manner, high maintenance components may be arranged in a module that has a smaller and more portable form factor as compared to the base and the system overall.

BACKGROUND

Gas monitoring devices are used in industrial work environments where individuals may be at risk of exposure to a number of hazardous substances and environmental conditions, such as toxic gases, highly combustible gases, and oxygen-depleted environments. Typical gas monitoring devices often include one or more gas sensors, a processing component and firmware to analyze the gas sensor information, a display to present gas detection information to a user, and alarms to alert the user to any hazardous conditions and/or device status. In addition, the gas monitoring devices may include bump testing and calibration functionality to ensure they are calibrated and performing properly.

Gas monitoring devices are life-critical equipment in many industrial environments. Accordingly, manufacturers are continually developing improved components and firmware that are, for example, more efficient, more accurate, more sensitive, or longer lasting. However, it is often difficult and/or cost-prohibitive to update gas monitoring devices in the field. In addition, typical gas monitoring devices do not allow for individual electronic components to be updated. As a result, industrial users often do not obtain updated systems until they purchase a new gas monitoring device, which may take many years to occur. Accordingly, industrial users and workers would benefit from a system that allows for system-critical components of a gas monitoring device to be replaced and/or updated efficiently and cost-effectively without requiring the replacement of the entire gas monitoring device or the purchase of multiple pieces of equipment.

SUMMARY

In an embodiment, a gas monitoring system may include a module having a mobile form factor. The module may include a memory configured to store a firmware application and data, a processor operably coupled to the memory and configured to execute firmware to control the gas monitoring system, and at least one sensor. The gas monitoring system may include a base having at least one power source and at least one base interface. In one aspect, the gas monitoring system may include at least one module interface arranged within the base and configured to interface with the at least one base interface, thereby operably coupling the module to the base. The module may be configured to receive power from the base and to control the base responsive to being connected to the base.

In an embodiment, a method of monitoring gas using a gas monitoring apparatus may include detecting at least one concentration of at least one gas using the gas monitoring apparatus. The gas monitoring apparatus may include a module having a mobile form factor. The module may include a memory configured to store a firmware application and data, a processor operably coupled to the memory and configured to execute firmware to control the gas monitoring apparatus, and at least one sensor. The gas monitoring apparatus may include a base having at least one power source and at least one base interface. In one aspect, the gas monitoring apparatus may include at least one module interface arranged within the base and configured to interface with the at least one base interface, thereby operably coupling the module to the base. The module may be configured to receive power from the base and to control the base responsive to being connected to the base. In one aspect, the method may include generating at least one alarm configured to alert a user to a hazardous condition based on the at least one concentration of the at least one gas.

DETAILED DESCRIPTION

The described technology generally relates to a gas monitoring system (the “system”) that includes a base component (the “base”) and a separate module component (the “module”). The module may be configured to be operably coupled to the base component through corresponding interface connectors. In some embodiments, the module may also be configured to be operably coupled to a docking station and/or a data transfer device through corresponding interface connectors to connect the module to the docking station and/or the data transfer device. In some embodiments, the module may be connected to the docking station and/or the data transfer device through a cradle. In some embodiments, the module may also be coupled wirelessly and/or through wired connections to other modules, to other system elements, and/or to external elements.

In some embodiments, the system may be fully functional, for example, to monitor for gases and generate alarms relating thereto, when the module is connected to the base. In some embodiments, the base may have limited or no functionality when disconnected from the module. For example, the base may be configured to provide display and alarm testing functions when disconnected from the module. In some embodiments, the module may have limited functionality when disconnected from the base. For instance, the module may be configured to provide gas detection, bump and calibration functions, and to communicate with a docking station and/or computing devices when disconnected from the base. In some embodiments, the base may perform all or some of the functions described herein (for instance, have “full functionality”) when disconnected from the module. In some embodiments, the module may perform all or some of the functions described herein (for instance, have full functionality) when disconnected from the base.

In some embodiments, the module may be configured to include components that typically have an increased potential for upgrades, replacement, maintenance, or other modifications (“high maintenance components”) compared with components within the base. For example, high maintenance components may include gas sensors and firmware. Alarms, displays, or the like may typically have a lower rate of being upgraded, replaced, or requiring maintenance (“low maintenance components”) than other system components, for example, in comparison to high maintenance components. In some embodiments, the low maintenance components may be arranged within the base. The module may be configured as a smaller and more portable component as compared to the base, which may generally be larger and heavier than the module. In some embodiments, the module may have a mobile or ultra-mobile form factor that is configured to facilitate portability, for example, by being able to be easily carried by a user. In some embodiments, the base may have a stationary or substantially stationary form factor. For example, the base may be and/or may be installed within a stationary or substantially stationary object or structure, such as a wall, a vehicle, mining equipment, or the like. In this manner, high maintenance components may be arranged in a module that has a smaller and more portable form factor than the base or the system overall. For example, if new or updated components of the module are available, the module may be disconnected from the base in the field, transported to a location where the module may be updated, and then transported back to the field and connected to the base. In another example, if new or updated components of the module are available, the module may be disconnected from the base and the entire module replaced with a new module having the new or updated components. As such, industrial users may obtain an upgraded system without having to replace the entire system or transport the entire system to a different location. In addition, gas detection and processing functions, which are typically performed by high maintenance components, in the module may be separated from comparatively lower-level functions, which are typically low maintenance components, such as display and alarm functions, in the base.

In some embodiments, the base may be configured to operate with different types of modules, for example, having different gas sensors, firmware, or the like. In this manner, a single base station may be used to provide different systems and/or functions depending on the type of module connected to the base station.

Accordingly, systems configured according to some embodiments may allow industrial users and system manufacturers to easily, efficiently, and cost-effectively upgrade their systems and use a wider range of gas detection and processing functions with a single base in the field than is available using conventional gas detection technology.

FIG. 1depicts a gas monitoring system according to some embodiments. As shown inFIG. 1, a system105may include a module110and a base115. The module110may include various components, such as a battery120a, data logs120b(for example, data for bump tests, calibrations, measurement data, datalog data, diagnostics, errors, alarm events, instrument settings, sensor settings, or the like), communication transceivers120c(for example, wireless communication transceivers), gas sensors120d, a pump120e(for example, a sampling pump for aspirated operation), firmware120f, and/or a module interface connector150. The module110may also include a non-transitory memory and processing hardware for executing the firmware120f, generating and storing the data logs120c, controlling the functions of the system105, and/or executing a bootloader application. Illustrative memory elements and processing hardware may include, without limitation, a CPU505, ROM510, RAM515, and/or a memory device525(for instance, flash memory) depicted inFIG. 5. In some embodiments, the firmware120fmay be upgraded via the bootloader application over a communication protocol, such as Modbus or through wireless communications. In some embodiments, certain of the components of the gas detection system may be for internal use only or customer (or user) facing components, as indicated according to legend190.

In some embodiments, the system105may be configured to operate in different modes depending on the type of module110that is installed in the base115. Non-limiting types of modes may include a diffusion mode and an aspirated mode.

In some embodiments, the system105may be configured to communicate with other systems, for instance, through the communication transceivers120c. The system105may be able to transmit and/or receive information to/from other systems including, without limitation, alert messages (for instance, alarms, gas concentrations, faults, low battery conditions, device and/or component identification, or the like) and/or ongoing status messages (for instance, “on,” “working,” identifiers, or the like).

The base115may include various components, such as a display125a, alarms125b, a human machine interface (HMI)125c, warnings125d, battery charge indicator125e, a battery125f, and a base interface connector125g. The module interface connector150may be connected to the base interface connector125gto operably couple the module110to the base115. Non-limiting examples of alarms125bmay include, without limitation, audio and/or visual local high gas alarm, local low gas alarm, local positive over-range alarm, local negative over-range alarm, and/or a remote gas alarm. The warnings125dmay be configured to get the attention of users in the area of the system105, such as through flashing lights or warning tones that are different than alarm tones. Non-limiting examples of warnings may include audio and/or visual low battery warning, calibration due warning, bump due warning, bump fail warning, zero fail warning, local system error warning, RAM test failure warning, flash test failure warning, sensor checksum failure warning, pump test warning, and/or instrument checksum failure warning.

In some embodiments, the module110may be electrically and physically connected to the base115. In some embodiments, the module110and the base115may be configured to communicate through the interface connectors150and125g. The interface connectors150and125gmay be configured to communicate using any communication protocol known in the art. In some embodiments, the module interface connectors150and125gmay be configured to communicate using a serial communications protocol, such as the Modbus communication protocol. In some embodiments, the base115may include an indicator (not shown) configured to indicate whether the module110is and/or is not connected (or properly connected) to the base115. In some embodiments, the system105may only function, or may only function to monitor gases, when the module110is connected to the base115. In some embodiments, the module110and/or the base115may be configured to interface with additional devices, for example, through the interface connectors150and125g. In some embodiments, the additional devices may include a maintenance device, such as a calibration adapter.

In some embodiments, neither the module110nor the base115is capable of operating independently. For instance, in some embodiments, the module110may only operate when installed in the base115or the cradle130(i.e., for docking functions), and the base may only operate when the module is connected thereto. In such embodiments, only a complete system105(for instance, a system having a base115with a module110connected thereto) is capable of performing gas detection and alarm functions.

In some embodiments, the module110may be operably coupled to a docking station140. In some embodiments, the module110may be operably coupled to the docking station140through a cradle130, for instance, by connecting the module interface connector150to interface connector135of the cradle. The cradle130may be operably coupled to the docking station140. In some embodiments, the docking station140may be configured to provide docking station functions to the module110. In an embodiment using a cradle130, the docking station140may be configured to provide the docking station functions to the module110through the cradle. Illustrative and non-limiting examples of docking station functions may include bump and calibration testing, reporting, information presentation via computing devices150d,150ein communication with the docking station, and other docking station functions as would be known to a person having ordinary skill in the art.

In some embodiments, the docking station140may be configured as an iNet™-compatible docking station as provided by Industrial Scientific Corporation of Pittsburgh, Pa., United States. In some embodiments, the docking station140may be configured as a DS2 Docking Station™ provided by Industrial Scientific Corporation. The docking station140may be in communication with various networks, such as the Internet170aand/or an Ethernet network170b. Through the networks170a,170b, the docking station140may be in communication with various management systems and/or software, including, without limitation, DSX™ Docking Station servers150cand software155cand iNet™ administrative consoles165a, databases165b, servers165c, and control systems165d.

The module110may be in communication with various computing devices150a,150b, for example, through communication transceiver120e. The module110may communicate with the computing devices150a,150busing various communication protocols and/or software as would be known to a person having ordinary skill in the art. In some embodiments, the module110may communicate with the computing devices150a,150busing Device Upgrading Service Software (DUSS) and/or Accessory Software (AccSW) as provided by Industrial Scientific Corporation for, among other things, upgrading the firmware120fof the module. Calibration and/or bump testing of the module110may be performed using various calibration and/or bump testing devices145, for example, in addition to any calibration and/or bump testing functionality provided through the docking station140.

The system105may use various power sources to power the system and/or charge the batteries120a,125fof the components, such as a charging cable180a(for example, DC to DC, 12V, or the like), inlet power180b(for example, DC to DC, 12V, or the like), and/or inlet power180c(for example, AC to DC, 100-240V, or the like) through various charging accessories175and/or field deployable, intrinsically safe power supplies185. In some embodiments, at least one of the power sources may be arranged within the base115. In some embodiments, at least one of the power sources may be arranged within the module115. In some embodiments, the module110may be configured to receive power from the base115. In some embodiments, the module110may not include a power source and may receive power to operate from power sources arranged within the base115.

The gas sensors120dmay include any gas sensors known in the art. Non-limiting examples of sensors120dmay include catalytic sensors, electrochemical sensors, infrared (IR) sensors, and photo-ionization detection (PID) sensors.

In some embodiments, the module110may include one gas sensor120d. In some embodiments, the module110may include a plurality of gas sensors120d. In some embodiments, the module110may include 1 gas sensor120d, 2 gas sensors, 3 gas sensors, 4 gas sensors, 5 gas sensors, 10 gas sensors, 15 gas sensors, 20 gas sensors, 50 gas sensors, 100 gas sensors, 1000 gas sensors, 1-3 gas sensors, 1-5 gas sensors, 1-10 gas sensors, 1-100 gas sensors, 1-1000 gas sensors, and any value or range between any two of these values (including endpoints). Although non-limiting examples of the number of gas sensors120dare provided herein, embodiments are not so limited, as the module110may include any number of gas sensors capable of operating according to some embodiments.

In some embodiments, the module110may not include a gas sensor120e. In some embodiments, the module110may be configured to operate as a wireless receiving station with or without gas sensors120d. In some embodiments, the module110(and/or one or more other portions of the system105) may include non-gas sensors (not shown). Illustrative and non-restrictive examples of non-gas sensors may include radiation sensors, weather sensors, accelerometers, light sensors, motion sensors, video sensors, tactile sensors, or any other type of sensor known in the art.

In some embodiments including a plurality of gas sensors120d, portions of the gas sensors may be configured to detect and/or measure different types of gas. Non-limiting types of gas that may be detected by the gas sensors120dmay include oxygen, lower explosive limit (LEL) of flammable gases and vapors, carbon monoxide, hydrogen sulfide, carbon monoxide and hydrogen sulfide (COSH), ammonia, nitrogen dioxide, sulfur dioxide, volatile organic compounds (VOC), carbon dioxide, carbon monoxide with low hydrogen, chlorine, hydrogen, hydrogen cyanide, combustible gases, methane, hydrogen chloride, nitric oxide, phosphine, and combinations thereof. The gas sensors120dmay be arranged in various configurations on and within the module110. For instance, a plurality of gas sensors120dmay be arranged on multiple surfaces and/or planes of the module110. In some embodiments, at least a portion of the gas sensors120dmay include redundant sensors, for example, such as sensors using Dual Sense™ sensor technology provided by Industrial Scientific Corporation.

FIG. 2depicts an illustrative gas sensor configuration for a module having 6 sensor positions according to some embodiments. As shown inFIG. 2, a plurality of sensors205associated with sensor numbers210may be arranged on or within a module. The sensor configuration of a module may include low power sensor configurations220and/or high and low power sensor configurations230. Readings240for the sensors may be presented on a display225on the base. The legend215provides the shading and/or outline properties to indicate various types of sensors205. Non-limiting examples of sensors may include high power sensors (for instance, catalytic bead sensors, infrared sensors, or photoionization detectors) A, low power sensors (for instance, electrochemical sensors or low power infrared sensors) B/D, dual gas sensors (for instance, carbon monoxide/hydrogen sulfide sensors) C, redundant sensors E (for instance, DualSense™ sensors), and non-redundant (or “single”) sensors F.

FIG. 3depicts illustrative inputs and outputs for a gas monitoring system according to some embodiments. As shown inFIG. 3, a system305may receive various inputs310a-gand provide various outputs315a-f. Illustrative inputs may include, without limitation, power source inputs310a(including, for instance, temporary and continuous power source inputs), sample and/or hazardous gas input310bthat may be analyzed by the system305, bump and/or calibration gas input310cto test and/or calibrate the system, user input310dfor controlling the system or accessing system information (for instance, unit on/off, screen selection, configuration, or the like), inter-unit communication310ebetween different systems (for instance, alarm or status messages), configuration settings310f, and device and/or application communication input310g, for example, for communicating to external computing devices and/or applications.

Non-limiting examples of outputs generated by the system305may include alarms315a(for example, audio, visual, confidence signals, low battery, system error, or the like), user information315b(for example, sensor types, system status, sensor replacement, battery state, calibration needed, last calibration date, and/or exposure data), software communication315c(for example, communication to software for configuration, maintenance and service, reporting, or the like, such as iNet™, DUSS, AccSW, and/or manufacturer applications), device communication315d(For example, alarm relay messages), communication315eto other systems, and outgoing device and/or application communications315f(for example, device logs, status, alarms, or the like). The alarms315amay be configured as audio and/or visual alarms for communicating the current status of the system305to the immediately surrounding area, other systems, and/or external computing devices or applications.

FIG. 4Adepicts an image of a front view of an illustrative gas monitoring system according to a first embodiment andFIG. 4Cdepicts a graphical representation of a front view of an illustrative gas monitoring system according to a second embodiment. As shown inFIGS. 4A and 4C, a system400may include a base405and modules410a,410b. In some embodiments, the system400may use a plurality of modules410a,410b. In some embodiments, the system400may use one module410a,410b.FIGS. 4A and 4Cdepict a diffusion module410aand an aspirated module410b. The base includes a display415and buttons420configured to initiate certain system functions. Non-limiting examples of buttons420may include a power on/off button and a user interface access button.FIG. 4Bdepicts an image of a back view of an illustrative gas monitoring system according to a first embodiment andFIG. 4Ddepicts a graphical representation of a back view of an illustrative gas monitoring system according to a second embodiment. As shown inFIGS. 4B and 4D, in some embodiments, a module410aor410b, respectively, may be installed in the base405to form a complete system400. As shown inFIGS. 4A-4D, the gas monitoring system and/or components thereof may have a shape generally resembling a safety cone. For instance, the base405may have a shape generally resembling a safety cone.

FIG. 5depicts a block diagram of exemplary internal hardware that may be used to contain or implement the various computer processes and systems as discussed above, for example, as a processing circuit for module110. A bus500serves as the main information highway interconnecting the other illustrated components of the hardware. CPU505is the central processing unit of the system, performing calculations and logic operations required to execute a program. CPU505, alone or in conjunction with one or more of the other elements disclosed inFIG. 5, is an exemplary processing device, computing device or processor as such terms are used within this disclosure. Read only memory (ROM)510and random access memory (RAM)515constitute exemplary memory devices.

A controller520interfaces with one or more optional memory devices525to the system bus500. These memory devices525may include, for example, an external or internal DVD drive, a CD ROM drive, a hard drive, flash memory, a USB drive and/or the like. As indicated previously, these various drives and controllers are optional devices. Additionally, the memory devices525may be configured to include individual files for storing any software modules or instructions, auxiliary data, common files for storing groups of results or auxiliary, or one or more databases for storing the result information, auxiliary data, and related information as discussed above.

Program instructions, software or interactive modules for performing any of the functional steps as described above may be stored in the ROM510and/or the RAM515. Optionally, the program instructions may be stored on a tangible computer-readable medium such as a compact disk, a digital disk, flash memory, a memory card, a USB drive, an optical disc storage medium, such as a Blu-ray™ disc, and/or other recording medium.

The hardware may also include an interface575which allows for receipt of data from input devices such as a keyboard550or other input device555such as a mouse, a joystick, a touch screen, a remote control, a pointing device, a video input device and/or an audio input device.