Abstract:
A data acquisition system includes a product for shipment to an end user, a sensor system removably connected to the product for recording environmental conditions to which the product is exposed, and a computing device, which upon being connected to the product, is operable to retrieve the recorded environmental conditions. The product may be operable to control the operation of the sensor system, or the sensor system may be operable to record environmental conditions independent of the operation of the product.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a data acquisition system for articles in transit. More particularly, the present invention relates to a system for recording environmental conditions to which a product is subjected during transport. 
     2. Brief Description of Related Developments 
     Consumer and industrial products are frequently distributed to end users throughout the world. A particular distribution network may include air travel, water travel, and land travel. The various modes of travel may utilize airplanes, cargo ships, trucks, and rail transport. While in the distribution network, products may be subject to a number of environmental conditions including for example, vibration, shock, temperature, humidity, barometric pressure, etc. While the products may be conveyed by various types of transport, and subjected to various environmental conditions, it is important that they arrive at an end user&#39;s location in good condition. 
     One method of ensuring delivery in good condition is to package the products appropriately. In some enterprises, a department or some other functional entity may be dedicated to making certain that product packaging functions effectively. In order to do so successfully, information regarding the range of environmental conditions that a product may experience is required. One way to gather this information is to include a general purpose data gathering instrument, also referred to as a data recorder, data saver, or data logger, in the package with a product. The instrument typically gathers environmental data during transport. Upon arrival at a destination, the data may be retrieved and analyzed. Once acquired, the data may be used to enhance not only the packaging design but also the design of the product itself may be improved if desired. 
     General purpose recording instruments are disadvantageous in that they are usually expensive and as a result may only be used on a sample basis. They may also be bulky, making integration into a particular packaging design difficult, and in some instances requiring modification of the packaging. If an enterprise uses multiple packaging designs, the integration or modification may have to be done for each type of design. In addition, extracting data from the instrument may require special interfaces and software. 
     It would be advantageous to provide a data acquisition system that is inexpensive and easily integrated into an existing product so that it may be used to track a large sample population, or ideally each individual product as it travels through the distribution network to the end user. It would also be advantageous to provide a data acquisition system that may be used without modifying existing packaging. It would be additionally advantageous to provide a data acquisition system from which data may be easily retrieved in a usable format. 
     SUMMARY OF THE INVENTION 
     The present invention provides for a data acquisition system that addresses the above-identified limitations. 
     In one embodiment, the present invention is directed to a data acquisition system, including a product for shipment to an end user, a sensor system removably connected to the product for recording environmental conditions to which the product is exposed, and a computing device, which upon being connected to the product, is operable to retrieve the recorded environmental conditions. 
     In another embodiment, the present invention is directed to a product for shipment to an and user, including a sensor system removably connected to the product for recording environmental conditions to which the product is exposed, and a communication port for communicating with a computing device, which upon being connected to the product, is operable to retrieve the recorded environmental conditions. 
     In still another embodiment, the present invention is directed to a sensor system for removable connection to a product for shipment to an end user, the sensor system including an interface to the product, and one or more sensors for recording environmental conditions to which the product is subjected. The sensor system is operable to provide the recorded environmental conditions to a computing device, upon the computing device being connected to the product. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein: 
         FIG. 1  shows a schematic diagram of a data acquisition system in accordance with the teachings of the present invention; and 
         FIG. 2  is a block diagram of a sensor system integrated as part of the data acquisition system. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIG. 1 , a data acquisition system  100  incorporating features of the present invention is illustrated. Although the present invention will be described with reference to the embodiment shown in the drawings, it should be understood that the present invention can be embodied in many alternate forms of embodiments. In addition, any suitable size, shape or type of elements or materials could be used. 
     Data acquisition system  100  generally includes a data recording function performed by components within a product  105 , and a data retrieval and analysis function represented by an enterprise  140  communicating with product  105  through a network  145 . 
     The present invention provides an integrated sensor system that is easily and inexpensively integrated into an existing product, allowing it to be used to track a large sample population, or each individual product as they pass through a distribution channel. The present invention may be implemented without altering existing packaging for product  105  and also provides for data retrieval in an advantageous manner. 
     In the embodiment shown in  FIG. 1 , product  105  is generally one that is conveyed through a distribution channel. Product  105  generally includes a microcontroller  110 , typically having a microprocessor  115 , on-board memory  120 , an analog to digital converter (A/D)  125 , a real time clock interrupt controller (RTC)  130 , and a universal asynchronous receiver transmitter (UART)  135 . Microcontroller  110  may be connected to a communications network  145 , that may include any network suitable for communication, for example, the Internet, the Public Switched Telephone Network (PSTN), a wireless network, a wired network, a virtual private network (VPN) etc. Communication may be executed using any suitable protocol, including X.25, ATM, TCP/IP, etc. 
     Microcontroller  110  may be connected to an enterprise  140  through network  145 . Enterprise  140  could be an office of a manufacturer of product  105  or a provider of goods and services related to product  105 . Enterprise  140  preferably includes a computer  150  for communicating with microcontroller  110 . Enterprise  140  may also include other computers  155  connected to computer  150  through an internal network  160 . 
     Product  105  also includes an integrated sensor system  165  in accordance with the teachings of the present invention, connected to microcontroller  110 . In one embodiment, on-board memory  120  on microcontroller  110  may include programs  170  for controlling and interacting with sensor system  165 . 
     Sensor system  165  is shown schematically in FIG.  2  and has a form factor that may be easily integrated within product  105  without changing its packaging or shipping requirements. Sensor system  165  may include a microcontroller interface  205 , control circuitry  220 , memory  215 , a power source  225 , one or more sensors  230 , a sensor interface  260  to accommodate additional sensors, a communications port  265 , and a power switch  270 . 
     Microcontroller interface  205  generally provides an interface between the circuitry in sensor system  165  and microcontroller  110 . Microcontroller interface may include analog to digital and digital to analog converters, level shifters, multiplexers, demultiplexers, and any other circuitry for providing a signal path between microcontroller  110  and the circuitry of sensor system  165 . 
     Control circuitry  220  may include logic circuitry for generally controlling the operation of sensor system  165 , and may operate in conjunction with memory  215 . For example, control circuitry  220  may include a processor that operates programs found in memory  215 . Memory  215  may provide storage for measurements acquired by the one or more sensors  230 . Memory  215  may be arranged as a 128K×8, 1 Mbit flash memory with a serial address and data bus. Memory  215  may also be configured as a non-volatile memory which retains its contents in the event of a power loss. In one embodiment, the above mentioned programs  170  that may be accessed by microcontroller  110  for controlling and interacting with sensor system  165  may be stored in memory  215 , in addition or as an alternative to storing them in on-board memory  120 . 
     Power source  225  may use lithium cell construction and may be for example, a 2000 MaH lithium battery pack. In this embodiment, power source  225  supplies power to the components of sensor system  165 , and to microcontroller  110 . In another embodiment power source  225  may be a conventional power supply or a battery power supply provided as part of microcontroller  110 . 
     The one or more sensors  230  may include sensors for detecting various types of conditions, for example environmental conditions, locations, or time periods. More particularly, sensors  230  may include, for example, a humidity sensor  235 , a temperature sensor  240 , an accelerometer  245 , a timer  250 , and a global positioning system (GPS) sensor  225 . Each of the one or more sensors  230  may include suitable support circuitry, for example, amplifiers, filters, and converters, and may be capable of providing an analog output or a digital output as required. Each of the sensors  230  may be connected individually or via a bus to other circuitry, and may also be capable of generating an interrupt, alarm, or some other type of alert in the event that one or more particular conditions exist, or that any number of thresholds have been exceeded or have not been met. One or more of the sensors  230  may include a “sample and hold” capability where a particular measurement may be latched or otherwise held until read from the particular sensor. Any number of the sensors  230  may also include identifying circuitry for allowing another device to determine the presence, location, type, and capabilities of each sensor  230  having such circuitry. 
     Humidity sensor  235  may be a capacitive humidity sensor with appropriate support circuitry, an analog output humidity module, or a digital output humidity module. In one embodiment, humidity sensor is capable of sensing a range of from about 0% to about 100% relative humidity. 
     Temperature sensor  240  may be a thermistor, thermocouple, or a resistance temperature device (RTD) with suitable support circuitry. Temperature sensor  240  may be capable of measuring a temperature in the range of from about −55 to about +125 degrees C., and may provide an analog or digital output. 
     Accelerometer  245  may be multi-axial, that is, it may be capable of measuring acceleration in two or three orthogonal directions simultaneously. Accelerometer  245  may be capable of measuring a range of acceleration from about 0 to 100 g&#39;s. 
     Timer  250  may be capable of measuring elapsed time or particular time periods. Timer  250  may be a programmable device capable of starting or stopping upon receiving a trigger and of generating a signal upon the expiration of a particular period. Timer  250  may be triggered by other sensors of sensor system  165 . For example, timer  250  may be used to measure total time spent in the distribution channel, an amount of time spent at a particular humidity level, or an amount of time spent below a particular temperature threshold. 
     GPS sensor  255  is generally capable of receiving signals from the Global Positioning System and providing information related to the global location of sensor system  165 . GPS sensor  255  may include support circuitry for converting the received signals to coordinates and for conveying those coordinates to other circuitry of sensor system  165  and to microcontroller  110 . 
     Sensor interface  260  provides a connection point for any additional sensors that may be desired. Sensor interface  260  may include one or more connectors, clips, pads, or other devices for providing electrical contacts for connecting sensors to sensor system  165 . In addition, sensor interface  260  may include through holes, pins, standoffs or other mounting devices for physically supporting the additional sensors. 
     Communications port  265  provides a communications interface to an external device such as a computer (not shown). Communications port  265  may be an RS  232 ,  422 , or universal serial bus (USB) serial port and may include a connector  275  for connection to the external device. 
     Power switch  270  is coupled to communications port  265  and is operable to apply power to communications port  265  when the external device is plugged in or otherwise connected to connector  275 . 
     Examples of the operation of the data acquisition system  100  will now be described with reference to  FIGS. 1 and 2 . In one embodiment, when sensor system  165  is connected to microcontroller  110 , power source  225  supplies power to microcontroller  110 . Microcontroller  110  recognizes that sensor system  165  is connected and accesses programs  170  from on-board memory  120  or from memory  215  to operate sensor system  165 . Microcontroller may operate exclusively to control sensor system  165 , or may control sensor system  165  while performing other operations associated with product  105 . 
     Upon recognizing that sensor system  165  is connected, under control of programs  170 , microcontroller  110  may initialize itself and cause the components of sensor system  165  to initialize. Programs  170  may then cause microcontroller to determine the presence type and capabilities of sensors  230  and set thresholds and alert parameters as appropriate for measuring particular conditions to which product  105  may be subjected. Individual ones of sensors  230  may also set up to generate interrupts upon reaching or failing to reach certain thresholds or generally upon measuring certain conditions. RTC  130  may also be programmed to generate an interrupt for microcontroller  110  on a periodic or other basis. 
     After completing the above mentioned initialization and setup procedures, microcontroller  110  may then enter a “sleep” mode having limited functionality and power requirements. For example, microcontroller  110  may disable A/D  125 , UART  135 , and a portion of on-board memory  120 , and may operate microprocessor  115  in a reduced power mode where it may only respond to certain interrupts, such as those from RTC  130  and sensor system  165 . 
     Upon receiving an interrupt from RTC  130  or sensor system  165 , microprocessor  115  may enable all circuitry of microcontroller  110 , and microcontroller  110  may operate to examine the interrupt and identify a service routine to be performed. For example, an RTC generated interrupt may be serviced by reading the current humidity from humidity sensor  235 , the current temperature from temperature sensor  240 , location information from GPS sensor  255  and a time value from RTC  130 . A date and time stamp may then be generated from the time value and associated with the temperature, humidity, and location measurements and then the measurements and associated time and date stamp may be stored in memory  215 . 
     As another example, accelerometer  245  may be programmed to generate an interrupt upon exceeding a particular acceleration value, for example, 5 g&#39;s. Upon exceeding that threshold, an interrupt is generated, microcontroller  110  identifies the type of interrupt service routine required and reads the acceleration value, location information, and time value from accelerometer  245 , GPS sensor  255 , and RTC  130 , respectively. These values may then be stored in memory  215 . 
     The contents of memory  215  may be retained until product  105  reaches a particular location, for example, a final destination, or when an end user takes possession. When desired, the contents of memory  215  may be read and used to analyze the conditions to which product  105  has been subjected. 
     In one embodiment, the contents of memory  215  may be obtained by plugging a suitable connector, connected to an external computer or other device, into connector  275  of communications port  265 . For example, plugging into connector  275  may cause power switch to energize communications port  265  and connector  275 , and may generate an interrupt to microcontroller  110 . Upon receiving the interrupt, microcontroller  110  examines the interrupt, identifies the appropriate service routine and proceeds to send the measurements stored in memory  215  to communications port  265  and out through connector  275 . 
     In another embodiment, the contents of memory  215  may be obtained by a request or communication through network  145 , for example from enterprise  140 . A user at one of the computers  155  may generate such a request, or the request may be generated automatically by one of the computers  155 , for example, upon a data entry that product  105  has arrived at an end user destination. The request may be routed through internal network  160  to computer  150  and then through network  145  to microcontroller  110 . Upon receiving the request, microcontroller  110  causes the measurements stored in memory  215  to be transmitted back to the requesting computer  155 . Optionally, the request may specify an alternate destination for the measurements and microcontroller  110  may cause the measurements to be sent to the alternate destination. 
     While the present invention has been discussed in the context of recording shipping conditions, it should be understood that the present invention may also be used to monitor conditions during any phase of the life cycle of product  105 . For example, system  100  could be used to detect improper storage or operating temperatures that may void a warranty for sensitive equipment. System  100  may also be used to sense conditions that may signify abuse of product  105 , use beyond rated specifications, or to record anomalous conditions occurring intermittently in a normal user environment. 
     The present invention advantageously provides a data acquisition system that is relatively inexpensive and that may be easily integrated into an existing product. This facilitates collecting data from a large sample population, or may even be used for every instance of a particular product. The invention also provides a data acquisition system that does not require modification of existing packaging or modification of the form factor of a product. As a further advantage, the invention provides for straightforward data retrieval through a communications port or through a network. 
     It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances.