Device for automatically reading a glow tube

The disclosure provides a wireless gauge reader system for use on an existing electrical substation where the substation has a window through which at least one glow tube is visible. The system includes a frame fastened to the substation that surrounds at least a portion of the window, and a door in connection with the frame that allows the door to open and close. The door includes a wireless gauge reader (WGR) that has an optical sensor that is positioned to view the glow tube when the door is closed. The WGR also has a transmitter to transmit a wireless signal based on the illumination state of the glow tube. Various aspects of the connection of the door to the frame are disclosed.

TECHNICAL FIELD

The present disclosure relates to devices and methods for automatically reading a gauge and transmitting that reading.

BACKGROUND

Industrial and other facilities may include monitor and/or control devices, such as gauges or glow tubes to track parts of processes or systems. Readings from such devices are periodically taken to ensure such processes/systems are operating as desired. This can consume considerable time and manpower.

Systems may be upgraded by replacing an entire device (e.g., gauge or glow tube) with a replacement device having a built in transmitting capability. A drawback to such an approach is that replacement of an entire gauge can be invasive. In the event the gauge is utilized in an active process, the process may have to be shut down entirely while the gauge is replaced with a transmitting unit. Further, once a transmitting unit is installed, such a unit may have to be independently tested to ensure it is transmitting a correct signal. In addition, a transmitting unit may require wiring from the transmitter to a central location. This can require additional labor, and assumes suitable wiring paths are available at the site.

Even overcoming these deficiencies, the replacement of the device may not be desirable, however. The operators of the facility often like to keep their equipment in as an original state as possible because they have several years of training and familiarity with the equipment.

What is therefore needed is a retrofit device that maintains the original device, while allowing automatic readings to be transmitted and the operators to independently read the device to confirm the operational status of the equipment.

SUMMARY

The present invention provides an elegant solution to the needs described above and provides numerous additional benefits and advantages as will be apparent to persons of skill in the art. One aspect provides a wireless gauge reader system for use on an existing electrical substation where the substation has a window through which at least one glow tube is visible. The system includes a frame fastened to the substation, and a door in connection with the frame that allows the door to open and close. The door includes a wireless gauge reader (WGR) that has an optical sensor that is positioned to view the glow tube when the door is closed. The WGR also has a transmitter to transmit a wireless signal based on the illumination state of the glow tube.

In one embodiment, the connection of the door to the frame includes at least one channel on the frame and the door is disposed of at least partially in the channel and adapted to slide along the channel. In another embodiment this connection includes at least one channel on the door and the frame is disposed of at least partially in the channel and the door is adapted to slide along the frame. In yet another embodiment the connection is a hinge connected to the frame and the door, and the door is adapted to rotate about the hinge. And in yet another embodiment, the connection is a pivot connecting the frame to the door, and the door is adapted to rotate about the pivot.

The door may be constructed so as to block a portion of light from entering the window when the door is closed. The door may also block glare that would otherwise interfere with taking an accurate reading of the glow tube. The alignment of the WGR to the glow tube is maintained when the door is opened and then closed, and it is also maintained when the WGR is removed and replaced.

The system may also include a wireless receiver that receives the wireless signal from the WGR, and that receiver may be connected to a network and adapted to report the illumination status of the glow tube over the network. That network may be a cellular network, a public network or a private network.

The WGR may also have a field of view that includes more than one glow tube, and the wireless signal is based on the illumination state of the multiple glow tubes. The door may include a second WGR. The frame of the system may be mounted to the substation by a variety of fasteners, including but not limited to, screws, bolts, rivets, adhesives, magnets, suction cups or hook-and-loop fasteners. The WGR may also include a processor connected to the optical sensor that processes an image of the glow tube captured by the optical sensor.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Following is a non-limiting written description of example embodiments illustrating various aspects of the invention. These examples are provided to enable a person of ordinary skill in the art to practice the full scope of the invention without having to engage in an undue amount of experimentation. As will be apparent to persons skilled in the art, further modifications and adaptations can be made without departing from the spirit and scope of the invention, which is limited only by the claims.

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. Particular example embodiments of the present invention may be implemented without some or all of these features or specific details. In other instances, components well known to persons of skill in the art have not been described in detail in order not to obscure unnecessarily the present invention.

FIG. 8illustrates a power substation10that has a glow tube15within a compartment20, and a window25that allows the operator of the power substation10to view the glow tube15. When the glow tube15is illuminated, this signifies that the power substation circuit is live with current. Sometimes when the power substation power supply is shut off, there is back feed from downstream generators which can maintain live current in the circuit. The glow tube15, therefore is a safety device that indicates to the operator the status of the circuit. The glow tube15, however, may not illuminate very brightly, so the operator may need to cup his hands around the window25, to block out light and glare, so as to more vividly see the illumination of the glow tube15.

The four wireless gauge reader system embodiments detailed below, can be easily mounted to an existing power substation10with little installation effort. The retrofit does not require modification (or perhaps minimal modification) of the original equipment, while still allowing the operator to view the glow tubes15easily without affecting the efficacy of the wireless gauge reader system.

Turning now toFIGS. 1A-1D, a first embodiment of an automatic glow tube wireless gauge reader system100is shown. The wireless gauge reader system100contains a frame105that is mounted to power substation10. The frame105may completely circumscribe the window25, but that is not necessary. Connected to the frame105is a hinge110that is also connected to a door115. A wireless gauge reader (WGR)120is connected to the door115, where the WGR120has an optical sensor and a wireless transmitter adapted to transmit a signal to a server/network (seeFIGS. 6 and 7). A handle128may also be connected to the door115to allow the operator to swing the door115out of the way of the window25to view the glow tube15. Also included in the wireless gauge reader system100may be an indicator127that may indicate the current state of the glow tube15. For example, the indicator127may be a multi-colored LED that flashes one color when the glow tube15is on and another when the glow tube15is off. The indicator127may be an LCD readout. The wireless gauge reader system100may also have an actuation button129that causes the wireless gauge reader system100to immediately take a reading of the glow tube15, which in turn may indicate the status of the glow tube15on the indicator127. The operator, therefore, can press the button129to verify the operational status of the wireless gauge reader system100by comparing the indicator127to what the operator actually views by looking through the window25at the glow tube15, when the operator swings the door115.

Turning now toFIGS. 1A-1D, a first embodiment of an automatic glow tube wireless gauge reader The signal transmitted from the WGR120to the server/network may include, for example, an image of the glow tube15, which is then processed by the server/network to determine whether the glow tube15is illuminated. The signal may also be a report regarding the illumination state of the glow tube15; in other words, the processing may be done in the WGR120with the results of that processing provided to the server/network. The optical sensor may detect the visible or infrared spectrum of light. The WGR120may also have a battery. If the power substation has additional glow tubes, the door115may have a multiple WGRs125. Alternatively, the WGR120may have a larger field of view to detect more than one glow tube and transmit the sensed data (as shown inFIG. 1Awhere WGR120views two glow tubes).FIG. 1Ashows a wireless gauge reader system100, where the door115is opened, whileFIG. 1Bshows the door115closed and inFIG. 1C, the door115is transitioning.

FIG. 1Dis a cross-sectional view of the wireless gauge reader system100taken along line1D-1D ofFIG. 1B. This illustrates that when the door115is closed, the WGR120is at a position relative130to the glow tube15. When the door115is swung open the WGR120moves from this relative position, but returns to that position when the door115is closed. It is advantageous to have the WGR120return to its initial position (i.e., the position when the door is closed) because the wireless gauge reader system100can be calibrated when it is initially installed and thereafter, when an operator swings the door115to independently view the glow tube15, the WGR120will not fall out of calibration. Likewise, when multiple WGRs (120,125) are used, the swinging of the door would return the WGRs (120,125) to their initial calibrated position.

The door115not only acts to maintain the initial calibration position of the WGR120, it also acts to block a portion of light from entering the window25when the door is closed. The door115also blocks glare that the optical sensor on the WGR120would experience. This “dark room” effect allows the optical sensor on the WGR120to operate more effectively and efficiently without interfering light pollution. And because the WGR120is operating in an ideal low light environment, it can capture and process the image of the glow tube15with very little computational power—resulting in cheaper manufacturing and operational costs. The low processing of the WGR120is ideal for battery operation because of the low power requirements.

FIG. 5illustrates the detachable mount135of the WGR120to the door115. This is helpful when the WGR120must be replaced or repaired—e.g., to replace the battery. When returning the WGR120(either the original or a replacement), the optical sensor of the WGR120is maintained in the same relative position to the glow tube15, again preserving calibration.

FIGS. 2A-2Dillustrate a second embodiment of an automatic glow tube wireless gauge reader system200. The wireless gauge reader system200contains a frame205that is mounted to power substation10. The frame205may completely circumscribe the window25, but that is not necessary. Connected to the frame205is a pivot210that is also connected to a door215. A wireless gauge reader (WGR)120is connected to the door215, where the WGR120has optical sensor and a wireless transmitter adapted to transmit sensed data to a server/network (seeFIGS. 5 and 6). If the power substation has additional glow tubes, the door215may have a multiple WGRs or a single WGR with an appropriate field of view.FIG. 2Ashows a wireless gauge reader system200where the door215is opened, whileFIG. 2Bshows the door215closed and inFIG. 2Cthe door215is transitioning.

As with the embodiment discussed above with reference toFIGS. 1A-1D, the pivot210allows an operator to swing the door215open to independently view the glow tube15, and when the door215is thereafter closed, the WGR120returns to its initial calibrated position. This is shown in greater detail inFIG. 2Dthat is a cross-sectional view of the wireless gauge reader system200taken along line2D-2D ofFIG. 2B.

A third embodiment of an automatic glow tube wireless gauge reader system300is shown inFIGS. 3A-3D. This system300contains a frame305that is mounted to power substation10. The frame305may contain a channel310, into which a door315may slide. A wireless gauge reader (WGR)120(or multiple WGRs) is connected to the door315.FIG. 3Ashows a wireless gauge reader system300where the door315is opened, whileFIG. 3Bshows the door315closed and inFIG. 3Cthe door315is transitioning.

As with the embodiment discussed above,FIG. 3Dillustrates a cross-sectional view of the wireless gauge reader system300taken along line3D-3D ofFIG. 3B. The channel310allows an operator to slide the door315open to independently view the glow tube15, and when the door315is thereafter closed, the WGR120returns to its initial calibrated position.

Similar to the third embodiment, the fourth embodiment also uses a sliding door. Specifically,FIGS. 4A-4Dshow an automatic glow tube wireless gauge reader system400that includes a frame405mounted to power substation10. The door415contains a channel410into which the frame405may slide. A wireless gauge reader (WGR)120(or multiple WGRs) is connected to the door415.FIG. 4Ashows a wireless gauge reader system400where the door415is opened, whileFIG. 4Bshows the door415closed and inFIG. 4Cthe door415is transitioning. The channel410allows an operator to slide the door415open to independently view the glow tube15, and when the door415is thereafter closed, the WGR120returns to its initial calibrated position.

The frame (105,205,305,405) may be fastened to the power substation10by any suitable means. For example, screws or rivets may be used. Non-intrusive fastening such as high strength adhesives, magnets, suction cups or hook-and-loop fasteners may be preferable because they can be applied easily and do not require screws or bolts to be lagged into the power substation10, which may be dangerous.

FIG. 6illustrates the components of the WGR120. An optical sensor505is connected to a processor510that is connected to a transmitter515. The WGR120also includes a power source520. The transmitter515may be wireless and the power source520may be a battery. The indicator127is also connected to the processor510, as is the actuator button129. When multiple WGRs are used on a particular wireless gauge reader system door, the system may be simplified by having a single transmitter. The processor510may process the data taken from the optical sensor505, such that the transmitter515transmits a signal that includes an image of the glow tube15, which is then processed by the server/network to determine whether the glow tube15is illuminated. The processor510may also process the data from the optical sensor505, such that the transmitter515transmits a signal that includes the illumination state of the glow tube15—i.e., the results of that processing are provided to the server/network. The transmitting can be made on demand, at specific intervals, and through a custom interface that is operated by the substation operator. Likewise the sampling of the image of the glow tube by the WGR may be done on-demand or at specific intervals or on a predetermined schedule. The system described herein can be used with any electrical system that uses glow tubes to indicate the presence of high voltage in a circuit.

The transmitter515of the WGR120can transmit its data to a central receiver605as shown inFIG. 7. That receiver605may then be connected to a network610, which may be a public or private network. This configuration would then allow an operator of the system to view the status of its power substations on a computer in his office (610,615), or on a mobile computing device (620) out on the field. The network may include, but is not limited to, wired (shown as solid lines inFIG. 7) and wireless connections (shown as dashed lines), and can further include cellular, LAN, WAN and virtual networks.

A basic algorithm for detecting the illuminations state of the glow tube may be as follows. Upon installation/calibration, with the door closed and the glow tube known to be on, the wireless gauge reader system scans the image from the optical sensor to determine the brightest pixels and forms a line of pixels that would be down the center of the glow tube. When reading the glow tube, the wireless gauge reader system computes an image dark level by averaging every Nth pixel detected by the optical sensor. For each pixel of interest (i.e., a line of pixels down substantially the center of the glow tube) the system will: (1) perform an infinite impulse response filter with the feedback coefficient set at ¼thto smooth out the line of pixels; (2) with each filtered pixel of interest, determine the minimum and maximum brightness pixels; (3) count all filtered pixels that are greater than the dark level average; and (4) sum all filtered pixels that are greater than the dark level average. If the maximum and minimum values exceed a predetermined threshold and the sum exceeds a predetermined value then the pixel line (i.e., the glow tube) is considered on. As detailed above, this processing may be performed by the WGR and the WGR may simply report the result—on or off. The WGR may also send an image of the glow tube to the central receiver/network which then performs the processing. The processing duties may also be shared between the WGR and the central receiver/network.

The invention has been described in connection with specific embodiments that illustrate examples of the invention but do not limit its scope. Various example systems have been shown and described having various aspects and elements. Unless indicated otherwise, any feature, aspect or element of any of these systems may be removed from, added to, combined with or modified by any other feature, aspect or element of any of the systems. As will be apparent to persons skilled in the art, modifications and adaptations to the above-described systems and methods can be made without departing from the spirit and scope of the invention, which is defined only by the following claims. Moreover, the applicant expressly does not intend that the following claims “and the embodiments in the specification to be strictly coextensive.”Phillips v. AHW Corp.,415 F.3d 1303, 1323 (Fed. Cir. 2005) (en banc).