Patent Publication Number: US-7908991-B2

Title: Air powered signaling system

Description:
TECHNICAL FIELD 
     The present invention relates to air horns used to provide warning sounds over wide distances and, in particular, motor driven portable air horns. 
     BACKGROUND 
     Air horns are commonly used as warning devices because they are capable of providing very loud and distinctive sounds that carry over large distances. For example, air horns are used in the mining and construction industry to provide warnings when blasting is about to take place and to signal all clear after such operations have concluded. In addition, air horns are used in emergency situations when an accident on a worksite has occurred. Some occupational health and safety regulations mandate the use of signaling in certain situations. 
     A very common kind of portable air horn apparatus consists of an air horn attached to a valve device that can be fitted to the neck of a compressed gas canister. The valve device includes a trigger that, when operated, allows compressed gas from the canister to operate the air horn. Devices of this kind are relatively inexpensive and lightweight and can generate sound at a high volume. However, gas canisters contain a finite amount of compressed gas that allows only a few uses before the canister has to be changed. Even worse, the valve devices tend to allow leakage of the gas from the canisters, thus further reducing the number of uses of the device before replacement of the canister is necessary. Gas leakage can also lead costly or dangerous situations in which an apparatus is unexpectedly found to be inoperative due to leakage and necessary warnings cannot be given, at least until a new canister can be obtained. The unreliability of apparatus of this kind makes it unsuitable for professional use. 
     There is consequently a need for more reliable and effective apparatus of this kind. 
     SUMMARY 
     According to an embodiment of the present invention, there is provided, a portable air horn apparatus including: a housing; an air horn assembly for generating a warning sound, the air horn being mounted in the housing and receiving pressurized air from a compressor, the compressor being operable by a motor; a power source; a switch for selectively operating the motor using the power source; a microprocessor in communication with the switch, the air horn and the power source, the microprocessor including at least one port for receiving an electronic component; and wherein the microprocessor is capable of automatically loading and executing software of the electronic component. 
     According to another embodiment of the present invention, there is provided a portable air horn apparatus including: a housing; an air horn assembly for generating a warning sound, the air horn being mounted in the housing and receiving pressurized air from a compressor, the compressor being operable by a motor; a power source, the power source being removable from the housing; a switch for selectively operating the motor using the power source; a blast initiator unit; a galvanometer; and wherein the blast initiator unit and the galvanometer are provided in the housing of the portable air horn apparatus. 
    
    
     
       DRAWINGS 
       The following Figures set forth embodiments of the invention in which like reference numerals denote like parts. Embodiments of the invention are illustrated by way of example and not by way of limitation in the accompanying Figures: 
         FIG. 1  is a side view of an air horn apparatus according to an embodiment of the present invention with a portion of a housing removed; 
         FIG. 2  is a cross-section taken on the line III-III of  FIG. 1 ; 
         FIG. 3  is a block diagram of some components of the air horn apparatus of  FIG. 1 ; 
         FIG. 4  is a side view of an air horn apparatus according to another embodiment of the present invention with a portion of the housing removed; 
         FIG. 5  is a block diagram of some components of an air horn apparatus according to another embodiment; 
         FIG. 6  is a block diagram of some components of an air horn apparatus according to another embodiment; 
         FIG. 7  is a block diagram of some components of an air horn apparatus according to another embodiment; 
         FIG. 8  is a block diagram of some components of an air horn apparatus according to another embodiment; and 
         FIG. 9  is a block diagram of some components of an air horn apparatus according to another embodiment. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     The device shown in  FIG. 1  of the accompanying drawings is one embodiment of a portable air horn apparatus  10  according to the present invention. The portable air horn apparatus  10  is an improvement on the portable air horn apparatus that is disclosed in U.S. Pat. No. 7,063,040, which is herein incorporated by reference. 
     The air horn apparatus  10  includes a housing  12  having two main parts that are coupled together along a vertical axis thereof in a “clam shell” type configuration. The air horn apparatus  10  of  FIG. 1  is shown with one of the housing parts removed in order to better show the components of the apparatus  10 . The housing  12  functions to physically support the components of the apparatus so that they form a unitary whole. The housing  12  also encloses and protects most of the parts and provides an attractive and functional appearance to the apparatus. 
     The housing  12  is shaped to include an elongated tubular element  14  that is provided at one end of an elongated member  16 . The apparatus  10  consequently resembles a pistol with the tubular element  14  forming the “barrel” and the elongated member  16  forming a handle in the form of a “pistol grip” that can be grasped by a user in one hand to carry and operate the apparatus. 
     The two parts of the housing  12  are made of injection molded plastic and are coupled to one another along their respective edges by fasteners (not shown). The fasteners may be integrated into the two plastic housing parts to form a series of releasable catches, or alternatively, the fasteners may be separate parts, such as screws, for example, arranged to couple the two parts together. The housing  12  may alternatively be made of metal, composite or another suitable material. 
     The tubular element  14  of the housing  12  includes ends  26  and  28  and generally surrounds an air horn assembly  18 . The air horn assembly  18  includes an air horn  20 , an air compressor  22 , which is in communication with the air horn  20  and an electric motor  24  for operating the air compressor  22 . 
     An inner surface of the housing  12  includes projections (not shown) that define cavities, which are shaped to receive the motor  24 , the air compressor  22 , the air horn  20  and other components of the apparatus  10 . The components may be secured by an interference fit within the cavities or fixed to the housing  12  by fasteners (not shown), such as screws, for example. Alignment posts may further be provided to allow for easy location of the components during assembly. 
     A flexible hose  34  forms an air conduit for supplying a stream of compressed air from the compressor  22  to the air horn  20 . One end of the hose is fitted over a nipple  36  projecting from the compressor and the other is fitted over a nipple  38  that communicates with to the interior of the air horn  20 , which contains a vibratable diaphragm  40  that generates a sound that is then amplified by an elongated trumpet element  42 . A central region of the hose  34  is secured within a clip  44  attached to the air horn  20  to reduce the likelihood that the hose will become detached at one or both ends during use or transportation. 
     The electric motor  24  is a DC motor having, for example, a conventional armature  46  and magnets  48  illustrated in broken lines. A central shaft  50  extends from the motor into the air compressor  22  to rotate a compressor rotor  52  to pressurize air drawn into the compressor from the exterior. The interior of the compressor  22  is shown in more detail in the cross-sectional view of  FIG. 2  and it will be seen that the rotor  52  is provided with four vanes  54  that are slidably held within slots  55  in the rotor. The vanes may move between a retracted position, in which most of the vane is held in the slot, to an extended position, in which most of the vane projects from its associated slot. The rotor  52  is mounted off-center within a chamber  56  within the compressor and the vanes divide the free space within the chamber into four segments  58 ,  59 ,  60  and  61 . As the rotor rotates, air trapped in segment  58  (which enters the chamber via port  62 ), is moved around the chamber into a smaller volume formerly occupied by segment  59 , the smaller volume being due to the off-centre location of the rotor in the chamber. Consequently, the air is compressed and leaves the chamber  56  through a gas delivery port  64  formed within nipple  36  (see  FIG. 1 ). As the rotor continues to rotate, the free volume increases in segments  60  and  61 , so the gas in these segments is reduced in pressure and draws more air into the chamber when connected to the port  62 . 
     A manually operable on-off switch  25  is provided in the elongated member  16  of the housing  12 . The manually operable on-off switch  25  is preferably operated by a trigger  27  that can be squeezed by a user&#39;s index finger when gripping the handle. The trigger  27  is biased outwardly to the “off” position, and remains in that position until squeezed to the “on” position. Releasing the trigger causes it to return under the spring bias to the “off” position. 
     The electric motor  24  is energized by a portable energy source  66  when the manually operable trigger  27  is in the “on” position. In turn, the motor  24  drives the compressor  22  and the resulting compressed air is directed to the air horn  20  which creates a piercing sound. Consequently, in use, the user simply squeezes the trigger  25  for as long as the sound is to be made. Releasing the trigger then ends the generation of the sound. 
     The portable energy source  66  for the apparatus is provided at the lower end of the housing  12 . The portable energy source is a rechargeable nano-phosphate lithium-ion battery. Other portable energy sources may also be employed, such as non-rechargeable batteries or fuel cells. It is of course important to use an energy source that is not too bulky or heavy, otherwise the apparatus will not be portable (e.g. transportable by hand by a single user without the need for a vehicle or movable support). Normally, the bulkier and heavier the power source, the longer the apparatus remains powered and ready for use. However, it is generally desirable to make the weight of the power source 2.5 Kg or less (more preferably 1 Kg or less) in order to make the apparatus readily portable. 
     In the illustrated embodiment, the portable energy source  66  includes a body  68  that is provided with an upstanding elongated projection  70 . An upper end  78  of the upstanding projection  70  engages with an electrical connector  80  in order to couple the portable energy source  66  to electrical circuitry of the apparatus  10 . The upstanding projection  70  may alternatively be replaced with another arrangement that allows for electrical mating between the portable energy source  66  and the other air horn components. For example, a slide lock system including alignment grooves in the portable energy source  66  and electrical connector  80  may be used. 
     The body  68  of the portable energy source  66  is provided mostly outside of the housing  12  except for the top edge, which is covered by an enlarged cowling  72  forming a lower end  74  of the housing  12 . The cowling  72  removably attaches to the body  68  via releasable catches (not shown) formed on opposite sides of the cowling  72  and engaging opposite sides of the energy source  66 . The portable energy source  66  can therefore be removed from the housing  12  when desired and replaced or returned as needed. The body  68  includes a flat lower surface  76  so that the portable energy source may act as a stand for the apparatus when placed on a flat support. Additionally, when the portable energy source is a rechargeable battery, the lower surface may also be provided with contacts (not shown) for electrical connection to a charging device or docking station of a known kind. Alternatively, the portable energy source or the housing  12  may have a socket for connection to a source of current for recharging the portable power source from a suitable charger. 
     Referring also to  FIG. 3 , a microprocessor  90  is mounted in the housing  12  between the switch  25  and the motor  24 . The microprocessor  90  is part of a signaling switching circuit that manages air horn signaling control. Electrical communication between the microprocessor  90  and the switch  25 , the motor  24  and the power source  66  occurs via wires  82 ,  84  and  86 , respectively. 
     The microprocessor  90  is a plug-and-play type microprocessor and includes multiple ports (not shown) to allow for integration of various electronic components. The plug-and-play functionality of the microprocessor allows for automatic loading and execution of software when an electronic component is connected thereto. The microprocessor may also include USB connection capability. Plug-and-play type microprocessors are well known in the art and, therefore, will not be described further here. 
     In operation, manual actuation of the trigger  27  of the switch  25  causes a signal to be sent to the microprocessor  90 . The microprocessor  90  receives the signal and sends a signal to the motor  24  of the air horn assembly  18  to turn the motor  24  on. Upon receipt of the signal, the motor  24  drives the air compressor  22 , which in turn operates the air horn  20 . The microprocessor  90  draws power from the portable power source  66  to operate the switch  25  and air horn assembly  18 . As will be appreciated, when switch  25  is actuated, the motor  24  will be energized and the air horn will sound. 
     It will be appreciated by a person skilled in the art that the trigger  27  may be any type of trigger  27  that activates the switch  25 . The trigger  27  may be an electronic trigger  27  or a manual trigger  27 . The trigger  27  may be depressed and held for the duration of the sound or, alternatively, the trigger  27  may be depressed and released to generate a sound having a predetermined length. 
     The air horn apparatus  10  has many different applications including: sub-surface and open pit mining, metals and minerals processing, oil and gas applications, plant safety, forestry, general and heavy construction, blasting and demolitions, site excavation and preparation, seismic surveying, general site safety and security, crowd management and control, wildlife management and control, military, security, search and rescue, disaster relief and response, rapid response kits and professional sports. 
     The air horn apparatus  10  may also be used in heavy transportation including rail, aerodome, dockyard and logistics yard, for example, aerial construction and assembly including high steel, concrete forming, transmission line or tower assembly, for example, large scale manufacturing including ship building, rail manufacturing, automobile manufacturing and aerospace and aircraft manufacturing, for example, fisheries and other marine applications including log booming, tug, spill recovery and research, for example. 
     In addition, the air horn apparatus  10  may be used in large facility management and safety including prisons, research facilities, test facilities, firing ranges, storage yards and logistics, for example, events including auto and yacht racing, pro tournaments, Olympics and X games, for example, emergency services including in facility and on vehicle use for fire, police, homeland security, border patrol and customs, for example. 
     Referring to  FIGS. 4 and 5 , another embodiment of an air horn apparatus  100  in which like numerals refer to like parts is generally shown. Similar to the previous embodiment, this embodiment includes a microprocessor  90  that is in communication with the air horn assembly  18 , the switch  25 , which communicates with the trigger  27 , and the portable energy source  66 , however, further includes a line continuity galvanometer  92  and a blast initiator device  94 . The galvanometer  92  and blast initiator device  94  are provided in a device housing  95 , which is coupled to the portable energy source  66  and provided in electrical communication therewith. A snap-glide or similar system (not shown) is provided to couple the device body  95  to the portable energy source  66 . The body  68  of the portable energy source  66  and the device housing  95  are intrinsically sealed to meet Mine Health and Safety Administration (MHSA) standards. In this embodiment, the portable energy source  66  is a rechargeable nano-phosphate lithium-ion battery. 
     It will be appreciated by a person skilled in the art that the galvanometer  92  and blast initiator device  94  may alternatively be provided as independent units that are coupled to the portable energy source  66  between the portable energy source  66  and the lower end  74  of the housing  12 . In addition, the galvanometer  92  and blast initiator device  94  may be embedded into the body  68  of the portable energy source  66 . 
     The galvanometer  92  and the blast initiator device  94  are electrically linked to the microprocessor  90 , which monitors operation thereof, however, both the galvanometer  92  and blast initiator device  94  are operable independent of the air horn apparatus  100 . The galvanometer  92  is used to ensure line continuity of a blast circuit as well as to determine the resistance between various points in the circuit. The resistance is checked against a reference resistance and when an operator is satisfied that the blast circuit is going to operate as desired, the operator uses the blast initiating device  94  to trigger the blast. 
     The blast initiator device  94  includes a charge button (not shown) and a fire button (not shown) as well as a multi-color LED (not shown), which indicates the status of the system: charging or ready to fire. The galvanometer  92  includes an LCD display (not shown) that shows the operator line volts, provided in milliamps, and a button for initiating the circuit check. Two positive and negative terminal posts (not shown) are provided for coupling a blasting wire thereto. In addition to being used by the galvanometer  92 , the blast initiator device  94  utilizes the terminal posts for circuit connectivity. 
     Integration of the galvanometer  92 , blast initiator device  94  and air horn assembly  18  into a single portable device allows operators to carry and use one device rather than multiple independent, disparate devices, which is the current practice. 
     It will be appreciated by a person skilled in the art that the galvanometer  92  may be any galvanometer that is suitable for use at a blast site. Alternatively the galvanometer may be replaced by a blasting multimeter or blasting ohmmeter. Further, the galvanometer, blasting multimeter and blasting ohmmeter may be incorporated into a single unit and a selector switch may be provided to allow an operator to choose which device to use. 
     Because the device housing  95 , which includes the galvanometer  92  and blast initiating device  94 , is coupled to the portable energy source  66 , a unit including the portable energy source  66 , the galvanometer  92  and blast initiating device  94  may be provided separately. The unit would be interchangeable with the portable energy source  66  of the air horn apparatus  10  of  FIGS. 1 ,  2  and  3 . Therefore, the unit may be sold as an add-on to air horn apparatus&#39;  10  that have already been purchased. It may also be used with air horn apparatus&#39; that do not include a microprocessor  90 , such as the air horn apparatus described in U.S. Pat. No. 7,063,040. 
     The portable energy source  66  including the galvanometer  92  and blast initiating device  94  is suitable for many different applications including blasting applications, pyrotechnics displays and other similar applications. 
     Another embodiment of an air horn apparatus  200  is shown in  FIG. 6 . In this embodiment, an air quality sensor unit  202  is provided in communication with the microprocessor  90 . The air quality sensor unit  202  is coupled to a port (not shown) of the microprocessor  90  so that software of the air quality sensor  202  may be automatically downloaded and executed thereby. 
     The air quality sensor unit  202  includes at least one air quality sensor. Types of air quality sensors include: hazardous gas detection sensors for: H 2 S, CO, TwinTox (H 2 S), TwinTox (CO), PH 3 , SO 2 , NO 2 , HCN, CL 2 , NH 3 , ClO 2 , O 3 , IR-CO 2 , combustibles (0-100% LEL or 0-5.0% Methane gas detection) and oxygen level detection sensors, for example. 
     In operation, the air quality sensor(s) of the air quality sensor unit  202  detects unsafe breathing conditions automatically. When unsafe breathing conditions are detected, an alert signal is sent to the microprocessor  90  and the air horn assembly  18  emits a warning sound. It will be appreciated by a person skilled in the art that the air horn assembly  18  may be programmed to emit different alert tones depending on the severity of the air quality issue. For example, the air horn assembly  18  may emit repeating short bursts, such as two series of five blasts having a duration of one second each, for a low level alert, or repeating long bursts, such as two series of five blasts having a duration of five to seven seconds each, for high level alerts corresponding to situations posing imminent danger. 
     It will be appreciated by a person skilled in the art that any number and type of sensors may be provided in the air quality sensor unit  202 . Further, sensors may be replaced, added or removed from the unit  202  at any time. 
     The air horn apparatus  200  of  FIG. 6  is suitable for use in any environment where there is a danger of unsafe breathing conditions occurring. Examples include: sub-surface mining or construction, oil and gas applications, disaster response, manufacturing applications where hazardous gases are present, shipping and handling of potentially explosive materials, rail yards, graineries, sugar mills and container ships. 
     Referring to  FIG. 7 , another embodiment of an air horn apparatus  300  is shown. In this embodiment, various electronic components  304  are provided in communication with the microprocessor  90  of the air horn apparatus  300 . The electronic components  304  shown include: the air quality sensor unit  202 , a battery status indicator light  306 , light emitting diode (LED) flood lights  308  and an LED signal strobe  310 . Each electronic component  304  is connected to a port (not shown) of the microprocessor  90 . Software of the electronic components is automatically downloaded and executed by the microprocessor  90  upon connection of the electronic components thereto. 
     The battery status indicator light  306  is included to provide an operator of the air horn apparatus  300  with the ability to quickly determine how much battery life is available in the apparatus  300 . 
     The LED flood lights are included in order to provide the apparatus  300  with flood lighting capability. The LED flood lights are particularly useful in explosives storage magazines or other highly volatile atmospheric applications. 
     The LED signal strobe may be included in the apparatus  300  to provide visual signaling functionality to the apparatus  300 . The LED signal strobe would generally be employed in conjunction with the emergency signaling of the air quality sensor embodiment of  FIG. 6 . 
     It will be appreciated by a person skilled in the art that the electronic components in communication with the microprocessor  90  are not limited to those shown in  FIG. 7 . Because of the plug-and-play functionality of the microprocessor, other electronic components  304  may be provided in addition to or instead of the electronic components  304  that have been described. Examples of other electronic components include: a liquid crystal display, a time clock, an elapsed time counter, a radiation detector, a relative humidity gauge, a temperature gauge, a directional display (north/south), a pedometer or distance meter, a decimeter and a geophone (air shockwave), for example. 
     Referring to  FIG. 8 , another embodiment of an air horn apparatus  400  is generally shown. In this embodiment, the air quality sensor unit  202  includes a port  412  that is usable for data upload/download, which allows the air quality sensor unit  202  to communicate with a computer  414 . Communication with the computer  414  may occur via a cable  416 . Alternatively, wireless communication could be initiated with a remotely located computer  414  or a USB data stick that may be plugged into the air horn apparatus  400  to allow for data transfer. 
     Air quality analysis software is provided on the computer  414  to allow for efficient analysis of the air quality sensor data that is received from the air quality sensor unit  202 . The software is stored in the computer memory and may be Linux based or any other suitable format. 
     In operation, air quality data from the sensor(s) of the air quality sensor unit  202  is uploaded to the computer  414 . The software analyzes the data and provides output in a meaningful format for a user. When a wireless connection is used, real time uploading of data is possible so that remote monitoring of a work site may be performed. Downloading of data to the air horn apparatus  400  is also possible and may be used to provide alerts to operators, for example. 
     Referring to  FIG. 9 , another embodiment of an air horn apparatus  500  is shown. The air horn apparatus  500  includes radio-frequency (RF) communication capability. An RF transmitting and receiving device  518  is embedded in the air horn apparatus  500  and communicates with the microprocessor  90 . The RF transmitting and receiving device  518  allows for communication between air horn apparatus&#39;  500 . 
     In one application, the RF transmitting and receiving device  518  is used to substantially simultaneously trigger remote networked alert stations. The alert stations are generally stationary alert stations with integrated conventional air horns or programmable electronic air horns. Alternatively, the alert stations may be other air horn apparatus&#39;  500 . 
     The stationary alert stations include RF transmitting and receiving devices. This allows an all-station alert to be generated when any one alert station is activated. The alert stations may also be arranged at a work site in order to provide a functional alert perimeter, which may further function as a site security system after working hours. The stationary alert stations may be stand or wall mounted. In addition to being used as part of an air horn RF network, it will be appreciated that the stationary alert stations may, alternatively, be used independently. 
     In another embodiment, the stationary alert stations include an embedded broadcast and Push-to-Talk (PPT) communication link to allow for network-wide two way communications. 
     It will be appreciated that the stationary alert stations may include air quality sensor units or any of the other electronic components that have been previously described. 
     The embodiment of  FIG. 9  is suitable for multi-station alerting for large open area or segregated zone signaling. Some applications that are suitable for the air horn apparatus  500  include: building or structure implosions, large-shot blasting and disaster alert and work site safety alert stations for multi-level or multi-zone construction projects including high rises, ship building, underground mining and underground construction projects, for example. 
     Each of the embodiments of  FIGS. 1 to 9  has been described as having a housing that is similar to the housing  12  of  FIG. 1 . It will be appreciated that depending on the environment in which the air horn apparatus is to be used, the housing and the components may be manufactured differently in order to withstand different environmental factors. 
     In marine environments, inclement weather environments, high humidity environments and fresh water or salt spray applications, for example, an all-weather type of air horn apparatus in which the electrical and electronic components are sealed against admittance of water or moisture is used. 
     Some applications where the all-weather type housing would be useful include: fisheries, navy or coast guard operations, port operations or port security, offshore oil and gas operations, wildlife control and/or management, search and rescue operations, disaster response operations, underground mining or construction, and special events or professional sports applications, for example. 
     In industrial environments where explosive vapor protocols are required, the air horn apparatus is intrinsically sealed and manufactured to meet Atmospheric Explosives (ATEX) Directive 94/9/EC and Underwriter&#39;s Laboratory (UL) 913 Standards. 
     Some applications where the adherence to explosive vapor environment protocols may required include: sub-surface mining or construction, oil and gas applications, disaster response, manufacturing environments that include explosive vapors, shipping and handling of potentially explosive materials in environments such as rail yards, graineries, sugar mills and container ships, for example. 
     It will be appreciated by a person skilled in the art that any of the previously described air horn apparatus embodiments may be provided for use in different environments, such as all-weather or explosive vapor environments. For example, the embodiment of  FIG. 6 , which includes the air quality sensor unit  202 , would generally be provided to meet explosive vapor protocols. 
     Any of the air horn embodiments described may further be custom branded with logos, custom colors or other visual treatments. Some applications where custom branding may be desired for any of the air horn apparatus&#39; previously described include: professional sporting teams, such as NHL, NFL, NBA and CFL teams, for example, professional sporting events, such as the Olympics, professional golf tournaments, downhill skiing races, auto races, yachting and extreme sporting events, for example. In addition, custom branding may also be suitable for special events including music festivals, charitable events or auctions, for example. The custom branding may be used as a form of advertising for corporate or commercial entities. 
     In another embodiment, a temperature sensor is provided in communication with the housing  12  and the microprocessor. In this embodiment, the air horn apparatus is operable as long as the temperature detected by the temperature sensor is below a predefined maximum value. A solid state thermal switch may also be provided to protect the electronic components from damage due to overheating of the apparatus. 
     Specific embodiments have been shown and described herein. However, modifications and variations may occur to those skilled in the art. All such modifications and variations are believed to be within the scope and sphere of the present invention.