Abstract:
An oven analyzer for profiling a conveyor oven is disclosed that accurately and precisely determines the physical characteristics of an oven and stores such information so that it can be outputted to a computer for analysis. In one embodiment, the oven analyzer includes a pallet that moves through the conveyor oven. The pallet houses an electronic data logger that is coupled to multiple sensors. The electronic data logger has memory for storing information obtained from the sensors. A first sensor is a temperature sensor that detects the ambient temperature within the oven. A second sensor is mounted within a metal mass of known thermal characteristics and detects the ovens ability to heat an object. A third sensor detects the position of the pallet within the oven. The electronic data logger stores the data received from the sensors in the memory for selective output to a computer for analysis or printing.

Description:
RELATED APPLICATION DATA 
     This application is a continuation of U.S. application Ser. No. 09/524,197 now abandoned, filed Mar. 13, 2000, which is a continuation of U.S. patent application Ser. No. 09/032,890, filed on Feb. 27, 1998, which is now U.S. Pat. No. 6,062,728, issued May 16, 2000. 
    
    
     FIELD OF THE INVENTION 
     This invention pertains to test equipment for sensing, collecting and analyzing physical parameters associated with a conveyor oven. 
     BACKGROUND OF THE INVENTION 
     Conveyor ovens are used in a variety of industries including the electronics, baking, and painting industries. Generally, conveyor ovens have multiple heating zones through which products pass. The heating zones are thermally isolated from each other by air curtains or other means. Such thermal isolation allows each zone to be maintained at a temperature that differs from other zones in the oven. A particular advantage of conveyor ovens with multiple heating zones is that the products can be heated to different temperatures at different times as they pass through the oven. In all industries that use conveyor ovens, it is important that the ovens behave consistently over time. However, after extended use, the ovens tend to degrade in performance. Some causes of this degradation include dust accumulating on oven fans and/or process bi-products, such as fluxes, accumulating on fans or blocking exhaust ports. 
     In the electronics industry, conveyor ovens are used to mount integrated circuits and other electronic components to printed circuit boards (PCBs). The multiple heat zones allow the PCB to be gradually raised in temperature so as to prevent thermal stress to the components and the PCB itself. Solder is placed on the PCB at predetermined points where integrated circuits are to be mounted, prior to running it through the oven. As the PCB passes through the heat zones, the solder melts, bonding the integrated circuits to the PCB. Conventionally, prior to a production run, a large number of test PCBs of the same type were passed through the oven under different heating conditions to ensure the temperature profile of the oven matched the requirements of the PCB. Each PCB was analyzed after its pass and the best setting for the oven was determined based on this analysis. This test process resulted in a significant number of test boards being scrapped due to improper heating or overuse. Other industries using conveyor ovens have experienced similar problems in setting the ovens for a production run. 
     To better determine optimal temperature settings and maintain existing or known settings without the need for test boards, electronic data loggers (also called data collectors) have been developed that mount to a test PCB. The test PCB has various thermocouples strategically placed thereon, which the data logger monitors. Using the data loggers, the optimal temperature of the oven can be determined. However, known data loggers have not been used to track overall oven performance, primarily because the focus of data loggers is on measuring the temperature of the product passing through the oven, not the oven itself. Additionally, known data loggers do not adequately track temperature as a function of position in the oven. Although temperature data can be collected, it is difficult to determine at what points or location in the oven the temperature data was collected. 
     Some companies have attempted to track oven performance by mounting a grid of thermocouples throughout the oven. If oven temperatures change over time, the user can detect these changes and take corrective action. However, the oven temperature is not the only factor in overall oven performance. The amount of air flow in the oven is also a factor in how the oven heats products. For example, many ovens (e.g., convection ovens) use forced air to heat products. Products heated in a convection oven heat more quickly than the same products heated in a standard (non-convection) oven. Consequently, reduced or increased air flow can also degrade oven performance, and temperature monitoring devices are incapable of monitoring such a degradation. 
     Accordingly, an object of the present invention is to provide an apparatus and method for accurately profiling oven performance. A further object is to provide such an apparatus and method that take into account both air temperature and air flow. A further object is to provide such an apparatus and method that can accurately correlate temperature data to positions within the oven. Still a further object is to provide such an apparatus and method that are easy to use and convenient. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to an oven analyzing apparatus and method for profiling oven performance that accurately determine and store the physical characteristics of an oven. The stored information then can be downloaded to a computer for further analysis. 
     In one aspect of the present invention, the oven analyzing method and apparatus employ a pallet that moves with a conveyor through a conveyor oven. The pallet houses an electronic data logger that is coupled to multiple sensors. A first sensor is a temperature sensor that detects the ambient temperature within the oven. A second sensor is mounted within a metal mass of known thermal characteristics and detects the ovens ability to heat an object. A third sensor detects the position of the pallet within the oven. The electronic data logger stores the data received from the sensors. The stored data can then be downloaded to a computer, which can analyze the data to create an oven profile. The oven profile can be compared to other stored profiles of the same oven to detect oven degradation. 
     In another aspect of the invention, the pallet has a hole therethrough and the metal mass is suspended within the hole. The hole allows the metal mass to be heated by air below and above the pallet. Additionally, the metal mass is thermally isolated from the pallet so that the most accurate data concerning the oven&#39;s ability to heat the mass is obtained. 
     In yet another aspect of the invention, the position sensor senses position within the oven by using a Reed switch that is actuated when the pallet passes a magnet or magnets mounted to the oven. Thus, accurate position data and conveyor speed can be calculated. 
     Various advantages and features of novelty which characterize the invention are particularized in the claims forming a part hereof. However, for a better understanding of the invention and its advantages, refer to the drawings and the accompanying description in which there are illustrated preferred embodiments of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of an oven analyzer of the present invention as viewed from above and toward the front and one side, and having a plurality of thermally isolated metal masses coupled to a pallet for detecting an oven&#39;s ability to heat and a plurality of ambient temperature sensors and position sensors. 
     FIG. 2 is a cross-sectional view of an ambient temperature sensor taken along lines  2 — 2  of FIG.  1 . 
     FIG. 3 is a cross-sectional view of a mass sensor taken along lines  3 — 3  of FIG.  1 . 
     FIG. 4 is a partial top view of the pallet as identified in FIG.  1 . 
     FIG. 5 is a schematic top view of a conveyor oven with the oven analyzer of FIG. 1 loaded in its operative position. 
     FIG. 6 is a circuit diagram of the oven analyzer of FIG.  1 . 
    
    
     DETAILED DESCRIPTION 
     FIGS. 1-4 show an oven analyzer  10  according to a currently preferred embodiment of the invention. The oven analyzer  10  includes a flat pallet  12  with a raised housing  14  mounted thereto. The housing  14  is a rectangular box including a base portion  16  and a cover  18  connected to the base portion by a hinge  20 . Opposite the hinged edge of the cover is a latch (not shown) that releasably secures the cover in a closed position. The base portion  16  includes tabs  24  extended outwardly therefrom. Screws  26  extend through the tabs for securing the housing  14  to the pallet  12 . The oven analyzer  10  also includes sensors shown generally at  28  for sensing temperature and position of the oven analyzer  10  as it passes through a conveyor oven, as is further described below. An electronic data logger  30  (not shown in FIG. 1, but represented in the electrical schematic of FIG. 6) is removably stored within the housing  14 . The data logger  30  is a thin planar device that monitors, collects, and stores information from sensors  28 , as is further described below. 
     Although the pallet  12  can be made from a wide variety of materials, it preferably has high thermal and mechanical stability and low thermal conductivity. The pallet may be made from a material that includes carbon for electrostatic dissipation and a glass-reinforced resin that is thermally stable above solder melting points (approximately 350° F. to 600° F.). A suitable pallet material is available from a French company, Von Roll Isola, Inc., with offices in North Clarendon, Vt., sold under the trademark CDM-ESD. The pallet has channels  32  etched therein for running signal conductors  33  (see FIG. 6) from the sensors  28  to the data logger  30  within the housing  14 . Holes, shown generally at  34  and  35 , extend through the pallet  12  and are circular and square in shape, respectively. Other hole shapes may be used instead, but the thermal impact on the sensors should be taken into account. Sensors  28  are mounted within the holes  34  so that the sensors are exposed to ambient air above and below the pallet  12 . The pallet  12  includes a cover  36  secured to a pallet base  37  by screws  38 . The cover  36  covers the tabs  24  and the signal conductors within the channels  32 . The illustrated pallet cover  36  is made from the same material as the pallet base  37 , but other materials may be used. 
     The sensors  28  include ambient air temperature sensors  40 . The ambient temperature sensors  40  are thermocouples that include two dissimilar metallic conductors welded together at their ends. Such thermocouples produce a voltage signal proportional to their temperature, as is well understood in the art. The ambient temperature sensors  40  detect the actual ambient air temperatures within the conveyor oven and constantly produce signals indicative of those temperatures. The sensors  40  are mounted within the holes  34  in the pallet  12 . As seen most clearly in FIG. 1, there are three ambient air temperature sensors  40  spaced-apart from each other along the orthogonal lateral axis of the pallet  12 . Such spacing of the sensors  40  allows for temperature data collection at the center, and at the right and left sides, of the conveyor oven. Thus, uneven temperatures across the oven are easily detected and stored in data logger  30 . As shown most clearly in FIGS. 2 and 4, the ambient air temperature sensors  40  are supported within the holes  34  by two parallel bars  42  extending beneath the conductor leads or legs  44  of sensor  40  to support the opposing legs  44  which form the thermocouple  40  at their juncture. FIG. 2 clearly shows the two legs  44  forming the thermocouple of a temperature sensor  40  and supported within channel  32  and secured in place by cover  36 . 
     As most clearly shown in FIGS. 1,  3  and  4 , the sensors  28  also include mass sensors  46 . Mass sensors  46  are used to detect the ovens ability to heat a metal mass by measuring the change in temperature of the mass at different points in the oven. Sensing the change in temperature of the metal mass allows for a determination of the oven&#39;s ability to heat an object, which is related to both air flow and temperature. The mass sensors  46  include a metal mass  48  with a cavity  50  centrally located therein (FIG.  4 ). A temperature sensor  52 , such as a thermocouple, is secured within the cavity by a conductive paste (not shown). The mass sensors  46  are suspended centrally within rectangular holes  35  in the pallet  12  so that the mass sensors  46  are exposed to oven air above and below the pallet. Three supporting rods  54  have one of their respective ends attached to the metal mass  48  and extend radially outwardly therefrom (FIG.  4 ). The opposite ends of the supporting rods  54  are secured within grooves  56  (See FIG. 3) in the pallet  12 . The rods are spaced about the periphery of the metal mass approximately 90 degrees apart. The cover  36  secures the rods  54  (and consequently the mass sensors  46 ) in place within their grooves. Almost any metal of high specific heat can be used for the metal masses  48 . For example, the metal masses  48  can be formed of aluminum, brass, stainless steel, steel, copper, etc. Additionally, non-metals with a high-specific heat can be used (e.g., polytetrafluoroethylene). Preferably, the supporting rods are formed from a metal that has low thermal conductivity, such as stainless steel, to thermally isolate the metal masses  48  from the pallet  12 , but other metals can be used. As shown, the metal masses are disc-shaped, but other shapes (e.g., spheres, squares, etc.) can also be used. Additionally, the metal masses are preferably sized (although not necessarily required) so that they do not reach the ambient temperature of the oven as the pallet  12  passes therethrough. 
     The sensors  28  also include position sensors  58  as shown in FIGS. 1 and 4. The position sensors  58  are used to detect the position of the pallet  12  as it passes through the conveyor oven. Such position information is stored within the electronic data logger  30 . In the illustrated embodiment, the position sensors  58  include Reed switches  64  (FIG. 4) that are activated in response to a magnetic field. As is further described below, magnets are mounted within the conveyor oven at predetermined positions along the conveyor path. As the pallet  12  passes the magnets in its travel through the oven, the position sensors  58  are activated. As shown in FIG. 1, four position sensors  58  are mounted on the pallet  12 —two on opposite sides at the front of the pallet and two on opposite sides at the rear of the pallet  12 . The position sensors  58  include a PCB  60  (FIG. 4) with a centrally located slot  62  therein. The slot  62  is sized slightly smaller than the Reed switch  64  and is used during manufacturing to easily mount the Reed switch to the PCB. The PCB is then inverted and mounted with the Reed switch down in a groove within the pallet. FIG. 4 shows the Reed switch  64  as seen through the slot  62  in the PCB  60 . Although the position sensor is shown as a Reed switch, a wide variety of sensors can be used. For example, photoelectric sensors, acoustical sensors, infrared or other optical sensors, or mechanical switches can be used in place of the Reed switches. The invention should not be limited to any particular type of sensor now available or later developed. 
     FIG. 6 shows an electrical diagram of the oven analyzer  10 . The electronic data logger  30  includes a central processing unit (CPU)  66  coupled to a memory  68 . The CPU  66  reads the sensors  28  and stores the sensor data within the memory  68 . The electronic data logger  30  also includes a plurality of input ports  70  along one edge thereof for removably coupling the data logger  30  to the housing  14 . A suitable data logger  30  is available from Electronic Controls Design, Inc. of Milwaukie, Oreg., and is sold under the trademark SUPER M.O.L.E. GOLD®. The M.O.L.E.® also includes a data output port  71  for passing data stored in memory  68  to a computer, which can then provide the desired computations, such as calculating a temperature profile and conveyor speed as described herein. The pallet  12  includes a connector  72  mounted within the housing  14 . The connector  72  includes ports  74   a-f  that are matable to the input ports  70  of the data logger  30 . The ports  74   a-f  are coupled to the ambient temperature sensors  40 , the mass sensors  46 , and the position sensors  58 , as shown. The particular electrical connections are not important to the invention, as many different electrical connections may be used so long as the data is accurately passed from the sensors to the electronic data logger  30 . A resistor  76  and LED  78  combination is serially coupled to the four position sensors  58 . A voltage source  79  is mounted in the housing  14  and supplies current to the resistor  76  and LED when at least one position sensor is activated. Consequently, when at least one of the position sensors is activated by detection of a magnetic field in the conveyor oven, a circuit loop is closed and the LED illuminates. The LED is mounted within the housing  14 . Indicator holes  80 ,  82  (See FIG. 1) in the cover  18  and base portion  16 , respectively, of the housing allow a user to see the LED within the housing  14  when looking from in front of or above the oven analyzer  10 . To conserve input ports, two of the position sensors  58  are coupled to the same input port  74   d  as one mass sensor  46 , and two other position sensors are coupled to the same input port  74   f  as another mass sensor. When the position sensors  58  are activated, an unusual increase in voltage occurs on the input ports  74   d  and  74   f  coupled to the position sensors. This voltage increase indicates that a position sensor has been activated. During this brief period when the position sensor is activated, data from the mass sensors on the same input ports  74   d,    74   f  cannot be accurately obtained. However, the temperatures of the masses change so slowly, that such temperature information can be reasonably interpolated from temperature measurements prior to and after the unusual voltage increase. Of course, the invention may be modified to add additional ports or remove ports as needed for a particular application. 
     FIG. 5 shows a top view of the oven analyzer  10  passing through a portion of a known conveyor oven  90  (with the top of the conveyor oven removed for illustration). Although any conveyor oven may be used, the illustrated conveyor oven  90  includes opposing side rails  92 ,  94  that cover opposing linked conveyor chains  96 ,  98 . The linked chains  96 ,  98  are driven by a suitable motor (not shown). The links in the chains, such as link  99 , project a sufficient distance beyond the rails  92  and  94  so that the pallet can rest thereon. The pallet  12  rides on the linked chains  96 ,  98  to simulate products that are carried on the chains in the same fashion. Thus, the opposing conveyor chains  96 ,  98  support and carry the oven analyzer  10  through the conveyor oven  90 . The conveyor oven  90  includes a plurality of different temperature zones, as indicated generally at  100 ,  102  and  104 . Although only three temperature zones are shown, the ovens usually have additional temperature zones. Each temperature zone includes a perforated metal plate, such as metal plate  106  in zone  102 , having a grid of air holes formed therein. The air holes in the metal plate  106  are used to deliver air maintained at a desired temperature into the temperature zone. Exhaust ports  108  are formed by gaps between the zones. A fan (not shown) sucks air through the exhaust ports and recirculates the air by delivering it through the grid of holes in the metal plates. Sucking air through the exhaust ports effectively creates an air curtain between the temperature zones, allowing the zones to be maintained at different temperatures. In other words, the generated air curtains thermally isolate the zones from one another. 
     A plurality of position indicating devices  110  are spaced-apart along rail  92  and are placed adjacent each of the exhaust ports  108 . The position indicating devices  110  cooperate with the position sensors  58  mounted on the pallet  12  of the oven analyzer  10 , as is further described below. For convenience, the pallet  12  has position sensors  58  mounted on both sides thereof so that the position indicating devices  110  can be positioned on either or both of the opposing rails  92 ,  94 . The illustrated position indicators  110  are magnets. Other types of position indicators can be used to cooperate or mate with the position sensors already described. As the pallet  12  passes through the conveyor oven, at least one position sensor  58  will at some point be positioned directly adjacent at least one position indicating device  110 . As a result, the position sensor  58  is activated, closing a circuit and activating LED  78  (FIG.  6 ). The illuminated LED may be seen through indicator holes  80 ,  82  in the housing  14 . The electronic data logger  30  periodically (e.g., every 100 ms) samples all of its input ports  70  (which are connected to ports  74   a-f ) and such sampled data is stored in memory  68 . Thus, the data from sensors  40 ,  46  is stored in memory  68 . The activation of the position sensor  58  is also detected by the electronic data logger  30  and stored in memory  68 . Instead of or in addition to periodic sampling, the electronic data logger may also read the mass sensors  46  and the ambient temperature sensors  40  in response to different events, such as the activation of at least one position sensor  58 . In any event, temperature information received from sensors  40 ,  46  is stored in association with position information received from a position sensor  58 . Consequently, accurate oven and mass temperature data can be correlated with a position in the conveyor oven. The oven temperature is the ambient temperature of the oven, while the mass temperature can be used to determine the oven&#39;s ability to heat (which is related to air flow). Conveyor speed can also be calculated by measuring a time lag between activation of the forward and rear position sensors  58  as they pass a given position indicator  110 . 
     The data that is accumulated in the electronic data logger  30  can be downloaded through output port  71  to a computer (not shown) after running through the conveyor oven. The data can be used for statistical process control (SPC). Statistical process control focuses on whether an overall process is performing properly, rather than on whether any particular product is within specification, as is well-known in the art. 
     A handle  112  (FIG. 1) may be mounted to the front of the pallet  12  to allow an operator to easily carry the oven analyzer  10 . Alternatively, the handle can be omitted as shown in the FIG. 5 embodiment. Additionally, a ruler (not shown) may be added along the longitudinal axis or the orthogonal axis of the pallet for convenient measuring of the oven zones. 
     The oven analyzer of the present invention provides several advantages. Foremost, the oven analyzer monitors the oven&#39;s ambient air temperature in different zones and the oven&#39;s ability to heat a known mass. It also accurately correlates such temperature information to known positions in the oven. The components for accomplishing this are all mounted to one easy-to-use pallet. Additionally, visual sensors help an operator to test the oven analyzer  10  to ensure the system is properly functioning. Furthermore, the oven&#39;s conveyor speed can be obtained through direct position and time measurements. Also, both the pallet and data logger are portable and separable from one another for ease of downloading and interchangeability of data loggers. 
     Having described and illustrated the principles of our invention with reference to preferred embodiments thereof, it will be apparent that these embodiments can be modified in arrangement and detail without departing from the principles of the invention. 
     Although a particular conveyor oven is shown (i.e., including air curtains, etc.), the present invention can be used in virtually any conveyor oven. The oven used is not of importance to the invention. 
     As described herein, the base portion  16  provides the pallet with modularity. That is, the electronic data logger  30  may be replaced without disturbing the sensor connections on the pallet  12 . Although, an electronic data logger  30  is used, the information from the sensors can be transmitted directly by cable, RF signals, or optical means to a monitoring device external to the oven. 
     Additionally, although the sensors are shown suspended in holes, they can be suspended from the pallet in other ways. For example, they can hang from the pallet or a separate supporting device may be mounted to the pallet for suspending the sensors. Still further, the sensors do not need to be suspended at all, and can be directly mounted to the pallet. 
     Moreover, although the mass sensors and ambient temperature sensors are shown mounted in separate holes, they may be mounted in the same hole. 
     In view of the wide variety of embodiments to which the principles of our invention can be applied, it should be apparent that the detailed embodiments are illustrative only and should not be taken as limiting the scope of my invention. Rather, we claim as our invention all such modifications as may come within the scope of the following claims and equivalence thereto: