Abstract:
Non-contact magnetic, optical or RF control elements can be used to control various operational aspects, or parameters of a gas detector. The detector can be placed in a low current, or sleep, mode wherein the operational life-time is not reduced by the duration of the sleep mode. Instructions can be coupled to the detector magnetically, optically, or via RF to alter set points or other operating parameters. Information as to bump tests can also be coupled to the detector.

Description:
FIELD 
       [0001]    The application pertains to maintenance and control of portable gas detectors. More particularly, the application pertains to control devices used in combination with such detectors to inactivate, or change operating parameters of those detectors. 
       BACKGROUND 
       [0002]    Maintenance free gas detectors are popular in part because they do not need to be turned off and on, they are permanently activated. There is a need for maintenance free gas detectors to last longer on a single battery, but without creating the requirement to have a user turn the unit off and on when needed. 
         [0003]    There are multiple problems with using a manual method (like a button) of turning the detector off and on to extend battery life. Users may forget to activate the gas detector and become at risk because their gas detector will not warn them of a dangerous gas level. Additionally, a manual power control switch would give the user the ability to turn off the detector to prevent it from alarming if they know they will be around gas, placing themselves and their co-workers at risk. 
         [0004]    Other methods of turning detectors off and on, such as using the existing docking stations would require decisions to be made at the docking station, which can also result in safety risks, and require operator training. Turning the detector off with a docking station also requires costly equipment and may not be an acceptable commercial solution for certain parts of the market, specifically the contractor workforce. 
         [0005]    Additionally, there are many situations in which it is beneficial to be able to transfer instructions or data to a portable gas detector to alter its configuration, behavior or state. Generally, expensive and complex circuits, that must be powered, are used to implement such functions. 
         [0006]    In yet another circumstance, portable gas detectors are required to be bump tested regularly in order to ensure proper operation. However, bump testing is not intuitive with today&#39;s gas detectors. Some manufacturers only support a proper bump test with an expensive docking station, where a series of button presses is required to invoke the bump test. This requires training and is inherently mistake prone. 
         [0007]    A low cost alternative to this is to place detectors into a plastic bag and fill the bag with gas, but this doesn&#39;t provide the compliance records that safety auditors look for. Ideally, a bump test should be as simple as possible to execute, and it must provide the proper compliance records for auditing purposes. This is very difficult to implement on a gas detector with a single button, which is why the bump test operation is usually controlled and initiated by the docking station. The problem with an exclusively dock initiated bump station is the added cost, size, electrical requirements and complexity of using traditional docking stations for bump tests. 
         [0008]    There is thus a continuing need to improve ease of and varieties of control of portable gas detectors. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1A ,  1 B together illustrate aspects of a system in accordance herewith; 
           [0010]      FIG. 2A-2E  illustrate additional aspects of the system of  FIG. 1 ; 
           [0011]      FIG. 3A  illustrates a first state of a bump test; 
           [0012]      FIG. 3B  illustrates a second state of a bump test; 
           [0013]      FIGS. 4A , B illustrate a prior art method of bump testing; 
           [0014]      FIGS. 4C-4E  illustrate bump testing in accordance herewith; and 
           [0015]      FIGS. 5A-5F  illustrate a method of controlling and configuring a gas detector in accordance herewith. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    While disclosed embodiments can take many different forms, specific embodiments hereof are shown in the drawings and will be described herein in detail with the understanding that the present disclosure is to be considered as an exemplification of the principles hereof, as well as the best mode of practicing same, and is not intended to limit the claims hereof to the specific embodiment illustrated. 
         [0017]    In one aspect hereof, an automatic method for power cycling that is based on the presence of a simple control device within a proximity to the detector can be provided to meet the customer requirement of delivering longer battery runtime without creating the safety hazards associated with a manual method of turning the detectors off and on. Advantageously this functionality can be provided in a low cost fashion so as to be accessible by customers driven by price. 
         [0018]    When the detector is placed on, near or within the control device, the detector is placed into a lower current draw state, or sleep mode. When removed from proximity of the control device, the detector exits the sleep mode and automatically transitions to its regular operating mode. 
         [0019]    When it its sleep mode, the remaining lifetime count down circuitry in the detector is disabled. The total remaining operational life time of the detector is not shortened or compromised by the duration of the sleep mode. 
         [0020]    The control device can be of active or passive type, employing (for example) a magnet that actuates a magnetic switch inside the detector. An infra-red communication device can also be used in the control device to communicate to the detector through its existing infra-red communications port. Signals from an RFID tag are another way of controlling the sleep/operational mode of the detector. The control device can be included in an instrument docking station, or a small holster that can be worn or attached to the visor of a vehicle for easy access. 
         [0021]    A preferred, cost effective, method of building this control device, and having it meet the needs of a customer base that would value it the most would be to develop a small holster, a hibernation case, with an integral magnet. The magnet actuates a magnetic switch inside the gas detector to put the instrument into a sleep mode. 
         [0022]    The holster could attach to a sun visor in a vehicle, or be placed in a glove box, and/or be padded so it can reside in a toolbox, simultaneously protecting the detector. When the instrument is inside the holster, it should be visibly obscured such that it would be obvious to a safety manager that the detector is inside its sleep holster. This will reduce the likelihood of people wearing detectors that are deactivated. 
         [0023]    In another aspect, embodiments hereof are intended to provide low cost data transfer to a portable gas detector. Advantageously, a passive data transfer solution that is easy to manufacture, easy to use, doesn&#39;t require power and is intrinsically safe is provided. Some examples of configuration, behavior or state alterations include changing alarm setpoints, changing bump test frequency, turning the device on or off, or altering sleep/operating modes of the detector. 
         [0024]    Non-contacting magnets can be used to meet the need of a low cost, low power, easy to use and safe way to configure the detector. Data can be transferred to the instrument via a magnetic sensor in the instrument. When the detector interfaces with a passive magnet array, it reads and deciphers control data. This data instructs the detector to implement any of a number of configuration changes, including but not limited to, entering a low power mode or state, exiting low power mode or state, changing alarm set points, or, preparing for bump test. 
         [0025]    The information is contained in the orientation of the magnet(s) in a cradle or in a linear array relative to the detector. Unlike the present embodiments, prior art for configuring gas detectors has typically used either infrared or some other computer controlled method of communicating with the detector, or has used the buttons on the detector to manually reconfigure or change detector settings. 
         [0026]    In another embodiment, an angular magnetic sensor can be used to detect the angular position of a magnetic field relative to the sensor. This sensor would be located in the portable gas detector. An outside magnet or array of magnets can then be used to create a message. The orientation of each magnet represents the data packet. For example, If the magnetic encoder can decipher the orientation of the magnetic field accurate to one degree, then each magnet can encode 360 possible values, which equates to just over eight bits of information per magnet. 
         [0027]    If a singular magnet is used and the orientation of the magnet is controlled in the installation of the cradle the device can easily decipher a single control byte. For a simple device like a single gas instrument, this may provide enough information to control a few simple parameters. 
         [0028]    In yet, another embodiment, a linear array of magnets is provided, and the detector is “swiped” past the array. The data held by the angular orientation of the magnets within the array is transferred to the detector. This enables a very low cost passive data transfer solution, which is useful for transferring small packages of data like the configuration of alarm set points for a detector, the bump test frequency, or other policy settings associated with a certain location. These configurations can be customized per customer request. 
         [0029]    A third implementation involves using a simple reed switch, and a series of magnets oriented in a straightforward North or South arrangement. As the detector is swiped past the magnets, a simple timing based code can be read, similar to the self-timing nature of bar codes. 
         [0030]    In a further aspect hereof, a simple non-powered method is provided for communicating to a gas detector that it is being bump tested by an authorized source. Once the gas detector receives this notification, the gas detector can log information indicating that it is being bump tested. This bump test record, that is stored in the instrument, will provide the necessary compliance information in case of an audit. 
         [0031]    With this embodiment, when the user places the gas detector to be bumped close to the bump testing station, the detector receives passively encoded information from the smart bump system, at which time the detector determines that it is being bumped. The detector then records this bump test information in its internal log files. There are no other buttons to press on the detector or bump testing station. The bump test is initiated simply by being in the presence of the authorized bump testing station. In addition, the gas type can be encoded in the passive coding system so that the gas detector will know the type of gas with which it is being bump tested. If for example, the detector is fitted with an H2S sensor and a user attempts to bump test it with a station configured for SO2, this detector will know that the user is trying to bump test with the incorrect gas and the detector can warn the user. 
         [0032]    One way of implementing a smart bump system is by using a magnetic coding system, whereby a reader is implemented in the gas detector capable of deciphering the orientation of a magnetic field. The magnetic field is implemented on the bump testing station by implementing a series of, or a single magnet with the desired magnetic orientation. 
         [0033]    When the detector is brought into proximity of the magnetic field, the reader in the instrument deciphers the magnetic field orientation and the information is encoded in this orientation. In the case of a reader that is capable of deciphering the angle of a magnetic field accurate to one degree, it is possible to encode 360 states with a single magnet on the bump station. These states could represent different gasses, or in some cases, certain states could be reserved for future use. The implementation may also make use of a combination of a magnetic solution with an RFID or other passive solution. The magnetic field on the bump station could be used to trigger a switch in the gas detector, which then actuates an encoding system capable of sending more data, via RFID. The gas detector could use an internal, powered, RFID reader to read a passive RFID tag located at or, on, the bump station. 
         [0034]      FIGS. 1A ,  1 B illustrate a system  10  in accordance herewith. The system  10 , as illustrated includes a wireless portable detector  12  and an associated hibernation case  14 . 
         [0035]    Detector  12  includes an external housing  20 , with an optical display  22 , an audible output device,  22   a , a gas sensor and associated gas access ports  24 . Housing  20  can also include audible output ports  20 - 1 , - 2 . 
         [0036]    The gas detector  12  can also include one or more non-gas sensors, such as magnetic (reed switch(s) for example), optical or RF sensors  26   a ,  26   b  for control purposes. Control circuits  28   a , along with a programmable processor and control software, can be coupled the display device  22 , gas sensor  24 , magnetic, optical or RF sensors  26   a, b . Detector  12  can also include a remaining lifetime indicating storage unit  28   b.    
         [0037]    Case  14  includes a closable cover  14 - 1  and defines an internal volume  14   a  which can receive the detector  12 . The cover  14 - 1  is closable with the detector  12  in the region  14   a . One or more actuators  14   b  which could be magnetic, optical or RF are carried by the case  14 . 
         [0038]    With respect to  FIGS. 2A-2E , when the detector  12  is inserted into the case  14 , illustrated as  FIG. 1A  the actuator  14   b  interacts with at least one sensor, such as  26   a  of detector  12  and places the detector  12  into a low power draw sleep mode illustrated as in  FIG. 1B . The closed cover  14 - 1  provides optical confirmation that the detector  12  is not active. The sleep mode reduces power drawn from the battery B of detector  12  thereby extending its usable life. Additionally, the remaining lifetime indictor stored in  28   b  is not reduced while in the sleep mode thereby extending the operational life of detector  12 . 
         [0039]      FIG. 2A  illustrates an embodiment with a magnet functioning as the actuating device  14   b . As illustrated in  FIGS. 2A-2E , when detector  12  is inserted in case  14 , the cover  14 - 1  can be closed completely isolating detector  12  in the sleep mode and providing immediate visual confirmation of the non-functionality of the detector  12 . 
         [0040]    Different types of gas detectors  12   a ,  12   b  can be used with case  14  so long as they exhibit the same form factor as defined by internal region  14   a , and include appropriate sensors such as  26   b.    
         [0041]      FIGS. 3A ,  3 B illustrate another embodiment hereof. In  FIG. 3A  a bump test system  30  includes a cradle  32  with a receiving region  32   a  for a detector, such as detector  12 , and an actuating element, for example, one or more bump magnets  32   b.    
         [0042]    When the detector  12  is inserted into the region  32   a , it is brought into proximity of the magnetic field from the magnet(s)  32   b . In a single magnet embodiment, a sensor, or, reader such as  26   b  in the detector  12  deciphers the orientation of the magnetic field. In this embodiment, bump test information is encoded by orientation of the magnetic field of magnet  32   b.    
         [0043]    In the case of a sensor  26   b , with associated control circuits  28   a , which are capable of deciphering the angle of a magnetic field accurate to one degree, it is possible to encode 360 states with a single magnet, such as  32   b  on the bump station  32 . These states could represent different gasses, or in some cases, certain states could be reserved for future use. 
         [0044]      FIGS. 4A ,  4 B illustrate prior art bump testing. The detector being tested goes into alarm as it cannot distinguish a test from a hazardous event. 
         [0045]    With respect to  FIGS. 4C-4E , when the detector  12  is inserted into the bump station cradle  32 , and the orientation of the magnet  32   b  is decoded, an appropriate test gas from a container  36  can be coupled to the detector  12 , via hose  36   a . In this mode, the detector  12  recognizes that a bump test is being conducted and maintains an internal log of test activity without activating the audible alarm indicating device  22   a . If the test is passed, the detector  12  can be returned to service. If not, a warning can be provided and detector  12  can be automatically shut down. 
         [0046]    Those of skill in the art will understand that the system  30  of  FIGS. 3A ,  3 B is not limited to magnetic actuators or sensors. Alternately, optical or RF communication come within the spirit and scope hereof. 
         [0047]      FIGS. 5A-5F  illustrate a process of configuring detectors, or other instruments in accordance herewith, using magnets and magnetic sensors. When a detector  12 - 1  is inserted into configuration station  50 , it is brought into proximity of a magnetic field(s) from the magnet(s), such as magnet(s)  52 . In a single magnet embodiment, a sensor, or, reader such as  26   b  in the detector  12 - 1  deciphers the orientation of the magnetic field. In this embodiment, control or test information is encoded by orientation of the magnetic field of magnet(s)  52 . Multiple magnets can be used to provide a sequence of magnetic fields that could be detected by one or more sensors in the instrument  12 - 1 . 
         [0048]    In the case of a sensor, such as  26   b , with associated control circuits  28   a , which are capable of deciphering the angle of a magnetic field accurate to one degree, it is possible to encode 360 states with a single magnet, such as  52  on the station  50 . 
         [0049]    These states could represent for example, configurations such as, behavior or state alterations include changing alarm set points, changing bump test frequency, turning the device on or off, or altering sleep/operating modes of the detector. 
         [0050]    Magnets, such as magnet(s)  52  can be used to meet the need of a low cost, low power, easy to use and safe way to configure the detector. Data can be transferred to the instrument  12 - 1  via a magnetic sensor in the instrument. When the detector  12 - 1  interfaces with a passive magnet array, it reads and deciphers control data. This data instructs the detector to implement any of a number of configuration changes, including but not limited to, entering a low power mode or state, exiting low power mode or state, changing alarm set points, or, preparing for bump test. 
         [0051]    Removal of the detector  12 - 1  from the configuration station  50  places that instrument into the selected configuration until it is returned to the station  50 . 
         [0052]    From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims. 
         [0053]    Further, logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. Other steps may be provided, or steps may be eliminated, from the described flows, and other components may be add to, or removed from the described embodiments.