Patent Publication Number: US-2023152139-A1

Title: Gas flow, pressure and btu/hour analyzer with a smart device

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Patent Application No. 62/787,007, filed Dec. 31, 2018 and U.S. Design Patent Application No. 29/675,362, filed Dec. 31, 2018, each of which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The subject disclosure relates to a system having an analyzer coupled with a smart device that can measure and record fluid flow, fluid pressure and BTU/hour as delivered to a gas device. The system may also measure temperature and movement of a connected appliance during commissioning, start-up, repair and normal use. 
     2. Background of the Related Art 
     Many appliances run on gas such as natural gas or propane. The applications are wide including standby home generators, commercial kitchens, home kitchens, boilers, furnaces, roof top unit HVAC units, fireplaces, pool heaters and the like. In order for such applications to work properly, proper gas flow is required. For example, improper gas flow can cause a surging effect in generators. Low gas flow may also cause an appliance to run inefficiently and, thereby, raise the cost of operating the appliance. 
     It can be difficult to identify gas flow issues whether it be at the time of commissioning the appliance, upon start-up or during normal usage. Service technicians typically install a manometer that only measures the pressure of the gas in the supply network. Whether mechanical or digital, a manometer can be difficult and time consuming to install. As for logging data, one relies on the service technician to maintain the data manually. 
     SUMMARY 
     In view of the above, a need exists for a system that quickly and easily installs into the supply network for identification of gas supply issues at the equipment level. The system would also be user friendly and allow for data logging and reporting of a plurality of parameters over an extended period of time. 
     In one embodiment, the system is a portable 3-in-1 gas flow meter, digital manometer, and calculator that helps service technicians and installers perform equipment start-up, commissioning, and quickly diagnose gas flow, pressure or capacity issues for gas burning equipment. The system streamlines the start-up and commissioning process of gas burning device while logging data via wireless technology that can be viewed immediately on a tablet, computer or smart phone using a software application. As a result, the system replaces a manometer, flow meter and calculator to boost efficiency and accuracy of the start-up, commissioning and troubleshooting processes. 
     The present disclosure includes a method of installing and servicing a gas appliance comprising the steps of temporarily installing an analyzer upstream from an inlet of the gas appliance and connecting a smart device to the analyzer using a short range wireless communication protocol. The analyzer has at least one sensor that communicates at least one signal to the smart device using the short range wireless communication protocol. The short range wireless communication protocol is selected from the group consisting of: Bluetooth; near-field communication (NFC); WIFI; radio broadcasting; satellite communication; RADAR; cellular communication; infrared communication; wireless local area network (WLAN); and the like. Preferably, the smart device stores and displays data related to the at least one signal, the at least one signal being: a first signal related to a flow of gas being supplied to the gas appliance; and a second signal related to a pressure of the gas being supplied to the appliance; and the smart device calculates a gas flow capacity based on the first signal. The first signal can be generated by a differential pressure sensor and the second signal is generated by a barometric pressure sensor. When the smart device is connected to the Internet contemporaneously with the analyzer being temporarily installed, the smart device can relay the data related to the at least one signal and the gas application to the Internet for access by a use. The method may also include providing: a first quick-connect fitting for an inlet of the analyzer; and a second quick-connect fitting for an outlet of the analyzer; and providing indicia on the analyzer configured to identify the inlet and the outlet of the analyzer. In one embodiment, indicia on the analyzer indicates a warning condition, a power on/off condition, and a wireless communication active status. 
     The subject technology is also directed a system for monitoring gas flow and pressure to a gas appliance in a fluid network comprising an analyzer. The analyzer has a housing defining an inlet, an outlet, and an interior in fluid communication with the inlet and the outlet. At least one sensor is coupled to the analyzer and configured to generate at least one signal related to gas being supplied to the gas appliance. A smart device communicates with the analyzer and has a user interface configured to monitor, store and display data. The smart device can present any or all of a plurality of parameters such as the flow of gas, a capacity of the flow of gas, a temperature, a pressure of the gas and the like to a user based on signals from sensors. 
     In one embodiment, the system includes a second pressure sensor configured to generate a second signal related to a pressure of the gas being supplied to the appliance. The system may also include a third pressure sensor configured to generate third signal related to an ambient barometric pressure. Preferably, the first pressure sensor is a differential flow through pressure sensor with an inlet port and an outlet port. 
     The housing can have an interior divided into a flow portion and an electronics portion with an inlet passage and an outlet passage extending between the flow portion and the electronics portion. The first pressure sensor is in the electronics portion with the inlet port being aligned to the inlet passage and the outlet port being aligned to the outlet passage. A flow tube extends between the inlet and the outlet in the flow portion. The flow tube has: an outlet orifice aligned with the inlet passage; an inlet orifice aligned with the outlet passage; and an obstruction member between the outlet orifice and the inlet orifice to create a pressure differential so that gas flow from the inlet to the outlet passes through the flowtube with a scavenge portion of the gas flow passing out the outlet orifice, through the inlet passage and into the inlet port of the differential pressure sensor and when the scavenge portion exits the outlet port, the scavenge portion passes though the outlet passage into the inlet orifice back into the fluid network. 
     The system may also have a printed circuit board (PCB) in the interior having the first pressure sensor mounted thereto as well as a wireless communication module and memory configured to store data related to the first signal and the second signal. Preferably, a safety shut-off valve connects to the fluid network and is in communication with the analyzer and/or the smart device so that the analyzer and/or the smart device selectively actuates the safety shut-off valve based upon the first signal being outside a predetermined value such as an over-flow, over-pressure, over-temperature, over-capacity, or excessive movement condition. Quick connect fittings on the analyzer make it easy to temporarily put the analyzer into the fluid network. The housing can defines clip mounts and for a battery pack. 
     It should be appreciated that the subject technology can be implemented and utilized in numerous ways, including without limitation as a process, an apparatus, a system, a device, a method for applications now known and later developed or a computer readable medium. These and other unique features of the system disclosed herein will become more readily apparent from the following description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that those having ordinary skill in the art to which the disclosed technology appertains will more readily understand how to make and use the same, reference may be had to the following drawings. 
         FIG.  1 A  is a perspective view of an analyzer, a smart device, a battery pack for the analyzer and a power cord for the smart device and/or analyzer in accordance with the subject disclosure. 
         FIG.  1 B  illustrates an analyzer with an attached battery pack installed into a fluid network of a gas device in accordance with the subject disclosure. 
         FIG.  2 A  is a top view of an analyzer with quick-disconnect fittings in accordance with the subject disclosure. 
         FIG.  2 B  is an end view of an analyzer in isolation in accordance with the subject disclosure. 
         FIG.  2 C  is a side view of an analyzer in isolation in accordance with the subject disclosure. 
         FIG.  2 D  is a bottom view of an analyzer in isolation in accordance with the subject disclosure. 
         FIG.  3    is an exploded perspective view of an analyzer in accordance with the subject disclosure. 
         FIG.  4 A  is a top view of a printed circuit board (PCB) for an analyzer in accordance with the subject disclosure. 
         FIG.  4 B  is a side view of a printed circuit board (PCB) for an analyzer in accordance with the subject disclosure. 
         FIG.  4 C  is a bottom perspective view of a printed circuit board (PCB) for an analyzer in accordance with the subject disclosure. 
         FIG.  4 D  is a bottom view of a printed circuit board (PCB) for an analyzer in accordance with the subject disclosure. 
         FIG.  5    is a cross-sectional view of an analyzer in accordance with the subject disclosure. 
         FIG.  6    is a flow diagram of a process utilizing the analyzer and smart device of  FIG.  1   . 
         FIG.  7 A  is a screenshot of selecting various settings in accordance with the subject disclosure. 
         FIG.  7 B  is a screenshot of selecting a parameter for display in accordance with the subject disclosure. 
         FIG.  7 C  is a screenshot displaying pressure in accordance with the subject disclosure. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The subject technology overcomes many of the prior art problems associated with monitoring and evaluating gas burning devices, whether it be in a residential or commercial setting, natural gas, propane and the like. The advantages, and other features of the technology disclosed herein, will become more readily apparent to those having ordinary skill in the art from the subject disclosure. 
     In brief overview, the subject technology can temporarily or permanently be installed to monitor and record vital parameters related to the operation of gas burning devices at commissioning, initial start-up and during the operational life of the device. The subject technology is compact, easy to install, bundles a variety of functions, and records, shares and displays data. The subject technology can monitor any combination or all of gas flow, gas flow capacity, gas pressure, barometric pressure, temperature of the system and/or inside the appliance as well as movement of the appliance. 
     Referring now to  FIGS.  1 A and  1 B , an isolated perspective view and an installed view of a system  100  for monitoring gas flow and pressure to a gas device  10  are illustrated. In  FIG.  1 B , the gas device  10  is a residential back-up generator. The system  100  includes an analyzer  130  that connects in-line with a fluid network  12  providing gas to the device  10 . The analyzer  130  is powered by a battery pack  108 . The fluid network  12  includes flexible tubing  14  that terminates in connectors  16  for coupling to the analyzer  130 . The fluid network  12  also includes a shut-off  18  to close flow during maintenance or installation/removal of the analyzer  130 . 
     The system  100  also includes a smart device  102  for communicating with the analyzer  130 . The smart device  102  has a user interface touch-screen  104  as well as other buttons, microphones, ports (e.g., USB, power etc.) and the like for customary input-output operations. The smart device  102  is configured to monitor, store and display graphs and summaries of the signals received from the analyzer  130 . The smart device  102  is also capable of WiFi connections so that data and other parameters may be shared and sent by email. 
     The system  100  has a DC power supply  106  with a power cord  107  for connecting the analyzer  130  to a power outlet when available. Alternatively, the analyzer  130  can be powered by the battery pack  108  with a power cord  110 . The battery pack  108  is configured to selectively clip to the analyzer  130  without impeding operation thereof. The system  100  may also include various fittings, flexible tubing, pipes and the like for permanently or temporarily connecting the analyzer  130  into the fluid network. 
     Referring to  FIGS.  2 A- 2 D , various views of the analyzer  130  in isolation are shown. The analyzer  130  has a housing  132  defining an inlet  134  and an outlet  136 . As only shown in  FIG.  2 A , the analyzer  130  may also include a female and male quick-disconnect fitting  133   a,    133   b  to allow quick and easy installation in a fluid network. Nipples  135  insert between the inlet  134  and outlet  136  and fittings  133   a,    133   b.  When the fluid network includes flexible tubing with complimentary quick-disconnect fittings, the analyzer  130  can be repeatably connected and disconnected. When the analyzer  130  is removed, the quick-disconnect fittings of the fluid network can be coupled together to return the fluid network to an operational condition. The inlet  134  and the outlet  136  can be ¾ inch female NPT or any other required size to conveniently couple to the fluid network. Preferably, the housing  132  is aluminum that is anodized black. In one embodiment, SnapFast® quick-disconnect fittings available from Dormont are used for speedy installation and removal without leaking. 
     Still referring to  FIGS.  2 A- 2 D , the housing  132  has a divided interior  138  (see  FIG.  3   ) extending between the inlet  134  and the outlet  136 . As best seen in  FIGS.  2 A and  3   , the interior  138  is enclosed by a lid  140 . Screws  142  thread into mounting holes  144  to secure the lid  140  to the housing  132 . The lid  140  includes a directional arrowhead  146  so that during installation, it is easy to identify the proper orientation of the analyzer  130 . Similarly, the housing  132  also has an arrow  152  formed therein as best seen in  FIG.  2 D . The lid  140  also includes three annunciator LEDs  148   a - c  with respective labels  150   a - c.  In one embodiment, the LEDs  148   a - c  are blue, red and green respectively. Label  150   a  is a wireless communication icon. Label  150   b  is an “!” to indicate a warning condition. Label  150   c  is a power on/off icon. The lid  140  also includes ample areas  156  for including other information such as trademarks, barcodes and the like. 
     As best seen in  FIGS.  2 C and  2 D , the housing  132  forms four mounting indentations  158  that are configured to securely and selectively engage four upstanding arms  109  of the battery pack  108  for clip mounting the battery pack  108  to the analyzer  130 . The analyzer  130  also includes a power jack  154  for electrically connecting a power source such as the power supply  106  or the battery pack  108 . Wires extending from the power source can be held in place by a clip  157 , which is held in place by a screw  159 . In one embodiment, the analyzer  130  has a button  161  that can reset the communication and/or other hardware. 
     Referring now to  FIG.  3   , an exploded perspective view of an analyzer  130  is shown. The interior  138  is divided into an upper portion  160  and a lower portion  162 . The upper part  160  includes a porous vent  164  to the environment so that the upper portion  160  is at ambient pressure. A printed circuit board (PCB) assembly  200  mounts on threaded shoulders  166  in the upper portion  160 . A standoff  174  forms a throughole  175  is in fluid communication with the lower portion  162  (e.g., the fluid network  12  when connected). A seal  168  and o-ring  170  extend around the throughole  175  to the PCB assembly  200  so that a pressure sensor can make a direct reading of pressure in the fluid network  12 . The button  161  also mounts on the PCB assembly  200  and fits in a recess  163 . 
     The upper portion  160  also include a pair of access passages  176   a,    176   b,  each sealed with an o-ring  178 . The passages  176   a,    176   b  also allow fluid to flow between the upper portion  160  and the lower portion  162 . To make sure that the upper portion  160  is otherwise sealed to the elements, a large o-ring  180  mounts in the upper portion  160  for sealing against the lid  140 . 
     An elongated flowtube  182  is sealingly coupled in the lower portion  162  of the interior  138 . Couplings  184  thread into the housing  132  to fix the flowtube  182  in place with o-ring seals  186 . The flowtube  182  forms two orifices  188   a,    188   b  aligned with the passages  176   a ,  176   b.  As best seen in  FIGS.  2 B and  5   , the flowtube  182  includes a wagon wheel  183  intermediate the passages  176   a,    176   b.  The wagon wheel  183  creates a pressure drop so that portion of the gas flow from the inlet  134  to the outlet  136  is scavenged to pass through the first port  176   a  and orifice  188   a,  then routed back via the second orifice  188   b  and port  176   b  as described in more detail with respect to  FIG.  5   . The flowtube  182  also includes directional flow arrows  190  for proper orientation during assembly. 
     Referring now to  FIGS.  4 A-D , various views of the PCB assembly  200  in isolation are shown. The PCB assembly  200  has a plurality of electronic components such as a processing module and memory module for data storage, processing and input/output operations. Various communication modules, such as a Bluetooth module and a WiFi module  206 , provide short range as well as local and/or wider area networks communication ability. 
     The PCB assembly  200  includes two barometric pressure sensors. One pressure sensor generates a signal related to the flow of gas being delivered to the appliance. By being in fluid communication with throughole  175 . The other pressure sensor is in the upper portion of the interior  138  and, as a result, reads ambient barometric pressure. The power jack  154  and reset button  161  are also mounted on the PCB assembly  200 . The PCB assembly  200  further includes various electronic components such as resistors and capacitor but not explicitly discussed as one of ordinary skill in the art would be able to employ such components to accomplish the function of the PCB assembly  200  described herein. 
     The PCB assembly  200  has a differential pressure sensor  210  with an input port  216  and an output port  218 . Referring additionally to  FIG.  5   , which is a cross-sectional view of the analyzer  130 , the pressure sensor ports  216 ,  218  align with the flowtube orifices  188   a ,  188   b,  via the passages  176   a,    176   b,  respectively. The wagon wheel  183  creates a pressure differential so that gas flow passes out orifice  188   a  into the input port  216 , through the pressure sensor  210 , out the output port  218  and back into flowtube  182  (e.g., the fluid network) via orifice  188   a.  The pressure sensor  210  can thus generate a differential pressure reading that can be converted into a flow reading. In one embodiment, the barometric pressure sensors are model MS560702BA03-50 from Measurement Specialties—TE Connectivity, the WiFi module  206  is model CC3200MODR1M2AMOBR from Texas Instruments, the processor/memory module  202  is model MB85RS2MTAPNF-G-BDERE1 from Fujitsu, and the differential pressure sensor  210  is model SDP800-500PA from Sensirion. 
     Referring now to  FIG.  6   , a flow diagram of a process  600  utilizing the system  100  of  FIG.  1    is shown. Preferably, the installation and use of the system is by qualified service personnel such as a plumber or electrician qualified to follow all relevant requirements, codes and standards. At step  602 , the technician uses the shut-off valve  18  to stop flow in the fluid network  12  so that the analyzer  130  can be inserted downstream into the fluid network  12 . In another embodiment, the fluid network is equipped with an automatic shut-off valve. Thus, the flow may be stopped from the smart device  102 . Additionally, the automatic shut-off valve can be automatically activated in the event that the smart device  102  receives one or more signals indicating that a shutdown is required such as by excessive appliance movement, over-temperature reading(s), excessive flow, and the like. 
     Preferably, the analyzer  130  is immediately upstream of the gas device  10 . The analyzer  130  is preferably installed vertically up or down or horizontally. In one embodiment, quick-connect fittings on flexible tubing are disconnected and coupled to the analyzer  130  with the flow aligned with orientation arrows  146 ,  152  on the lid  140  and housing  132 , which point downstream toward the gas device  10 . Once the leak tight installation is verified, the shut-off valve  18  is used to turn on the gas flow and the process  600  proceeds to step  604 . 
     At step  604 , the battery pack  108  is coupled to the analyzer  130  by snapping the upstanding arms  109  into the mounting indentations  158 . To power up the analyzer  130 , the power cord  110  is inserted in the port  154 . Alternatively, the power cord  107  of the DC power supply  106  can be used to power up the analyzer  130 . During initial power up, the green LED  148   a  is energized for 1 second, then all the LEDs  148   a - c  become energized before changing to the blue LED  148   c  blinking, which indicates normal operation. The blue LED  148   c  will double-blink to indicate communication with the smart device  102 . 
     At step  606 , the smart device  102  is linked to the analyzer  130 . In one embodiment, the smart device  102  is running a free software application specific to the analyzer  130 . The software application may be provided by the manufacturer of the system  100 . It is also envisioned that the system  100  could be permanently installed with the software application provided by the manufacturer of the gas device  10 . The software application will present an icon that allows connection with the analyzer  130 . Once selected, the smart device  102  will present any analyzers  130  in range, with respective serial numbers, so that the user can establish the desired communication link(s). 
     At step  608 , the technician customizes the analyzer and synchronizes the analyzer  130  to the smart device  102 . Various parameters and settings may be changed. Referring now to  FIG.  7 A , a screenshot  700  of selecting various parameter is shown. The smart device  102  has a touch screen  104  so that the technician can tap or select displayed boxes, radial buttons and the like to intuitively modify parameters and execute actions. The screenshot  700  has a heading section  702  that may include such information as the analyzer serial number. Another section  704  allows selecting between natural gas and propane. By default, the software application records BTU calculations with a value of 1000 for natural gas and a value of 2500 for propane. The value can be customized in the software application and in data exports as various gas suppliers may provide higher or lower values. 
     A central section  706  of screenshot  700  allows selection of a data sample rate between every 1 second, 1 minute or 10 minutes with associated varying time periods for which the data can be stored. A bottom section  708  provides a prompt so that the user can synchronize the internal clock of the analyzer  130  with the internal clock of the smart device  102 . The stored data (e.g., history logs) can also be deleted in the bottom section  708 . To save the adjusted settings, the user simply taps the checkmark in the heading section  702 . 
     Referring now to  FIG.  7 B , a screenshot  720  for selecting a parameter for display is shown. A heading section  722  includes an icon to return to the settings screenshot  700  as well a second icon to export data. With the smart device  102  connected to WiFi or cellular service, the uploaded data can be sent via email using a CSV attachment. A pulldown menu  724  in the central section  726  allows selection of the parameter to display. In one embodiment, the parameter is selected from the group consisting of pressure (in/H 2 O) in the fluid network and/or ambient, BTU (BTU/hr), flow (CFH), movement, temperature (° F.) and the like. Temperature is typically from a separate sensor included in the housing  132  of the analyzer  130  but could also be from a separate sensor coupled to the gas appliance  10  and communicating with the system  100 . Similarly, the system  100  may include one or more accelerometers, coupled to the analyzer  130  or gas device  10 , for detecting movement thereof. A band  728  is presented to select a time period for display such as the current reading, 1 hour of data, 4 hours of data and so on. Arrows allow scrolling through the data. A lower section  730  allows selection of one or more of the average, minimum or maximum data readings based on the sample rate set above. 
     Once properly configured, the process  600  of  FIG.  6    proceeds to step  610  to acquire gas flow, gas pressure, gas flow capacity and other selected parameters on the smart device  102  for storage and presentation on the smart device  102 . The analyzer  130  is precalibrated prior to installation. For example to calculate flow, the analyzer  130  is loaded with performance curves generated using ambient air. The performance curves are a set of differential pressure readings at across the expected range of flow values so that during operation, actual differential pressure readings can be converted to accurate flow values. 
     Referring now to  FIG.  7 C , a screenshot  740  displaying pressure is shown. Again, a heading section  742  provides the same information noted above. A band  748  is presented to select a time period for the display. A central section  748  presents the graph, which includes any or all of the average, the minimum and the maximum. In one embodiment, the minimum and the maximum are related to a certain time period of data collection such as the last minute of data. As noted above, not only can the data be stored for any or all of the parameters but the stored data can be sent via email at step  612 . 
     As can be seen, the gas flow may be monitored several different ways over long periods of time. By review of the data, in realtime or retrospectively, the technician can have confidence in the proper operation or identify issues more easily for investigation and correction. The smart device  102  generates reports, which may be customized for any particular application. A service technician/installer/electrician/plumber uses the system to verify gas flow and gas pressure at initial product start-up and during the life of operation of the appliance for troubleshooting and safety. The service technician can review various charts of the recorded parameters to note improper trends and events, leading to corrective action in a timely manner. 
     In one embodiment, the system is configured to operate in a range of 15,000 to 500,000 BTU/hour. The analyzer preferably is a black powder coated cast aluminum housing with black anodized extruded aluminum end fittings and an injection molded lid or face. The fittings may be ½″ or ¾″ NPT among other sizes. 
     It will be appreciated by those of ordinary skill in the pertinent art that the functions of several elements may, in alternative embodiments, be carried out by fewer elements, or a single element. Similarly, in some embodiments, any functional element may perform fewer, or different, operations than those described with respect to the illustrated embodiment. Also, functional elements (e.g., modules, electronics, printed circuit boards, sensors, memory, processors and the like) shown as distinct for purposes of illustration may be incorporated within other functional elements in a particular implementation. 
     While the subject technology has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the subject technology without departing from the spirit or scope of the subject technology as exemplified by the appended claims.