Sensor hub comprising a rotation encoder

• US 10,077,810 B2
• Filed: 04/14/2015
• Issued: 09/18/2018
• Est. Priority Date: 04/14/2014
• Status: Active Grant

• Current Assignee: Dynapar Corporation (Fortive Corp.)
• Original Assignee: Dynapar Corporation (Fortive Corp.)
• Inventors: Langille, Mark Edward, Mitchell, Kirk Alan, Brewster, Erik John, Jadhav, Abhishek Sumeet, Ayala, Ferran Alberto, Benigni, Scott Thomas
• Primary Examiner(s): Singh, Hirdepal
• Application Number:
  US14/686,220
• Publication Number:
  US 20150294552A1
• Time in Patent Office: 1,253 Days
• Field of Search: 340679
• CPC Class Codes: F16C 41/007 Encoders, e.g. parts with a plurality of alternating magnetic poles
• CPC Class Codes: H04L 67/12 specially adapted for proprietary or special-purpose networking environments, e.g. medical networks, sensor networks, networks in vehicles or remote metering networks
• CPC Class Codes: H04W 4/70 Services for machine-to-machine communication [M2M] or machine type communication [MTC]

Abstract

A sensor hub for use in machine condition monitoring comprising a rotation sensor and a wireless communication module each operatively connected to a processing device. The rotation sensor and processing device are configured to receive power from a controller of the monitored machine. One or more additional sensors, which may be associated with the monitored machine or another machine, may also be operatively connected to the processing device. In an embodiment, the additional sensors may comprise any one or more of, or any combination of, an accelerometer, a temperature sensor, an acoustic sensor, an high frequency sensor, an humidity sensor, a barometric pressure sensor, a current sensor or a proximity sensor. The wireless communication module may support an ad hoc wireless communication protocol. Further, the wireless communication module may receive additional sensor data from one or more wireless sensor nodes associated with the monitored machine or another machine.

Claims

1. An apparatus comprising:

a rotation sensor configured to receive power from a controller of a monitored machine;

a wireless communication module;

a processing device, operatively connected to the rotation sensor and the wireless communication module, configured to receive the power from the controller of the monitored machine and to receive unprocessed sensor data directly from the rotation sensor and calculate speed and/or relative position and allow the unprocessed rotation sensor data to travel on to the controller unchanged for purpose of deterministic control of the machine and machine diagnostic sensor data to be gathered and sent, to an external processing device via the wireless communication module;

a signal path, independent of the processing device and wireless communication module, configured to provide only the directly obtained unprocessed rotation sensor data to the controller of the monitored machine whereby failure of the wireless communication module or the processing device will not prevent provision of the rotation sensor data to the controller and wherein speed and relative position data are time stamped, but only for the purposes of realignment with other time stamped data for trend analysis.

2. The apparatus of claim 1, wherein the rotation sensor, the wireless communication module and the processing device are disposed within a single housing.

3. The apparatus of claim 1, further comprising:

a first housing having the rotation sensor disposed therein;

a first connector mounted on the first housing, wherein the rotation sensor is operatively connected to the first connector;

a second housing having the wireless communication module and the processing device disposed therein; and

a second connector, complementary to the first connector and mounted on the second housing, wherein the processing device is operatively connected to the second connector,

and wherein the power from the controller of the monitored machine and the rotation unprocessed sensor data from the rotation sensor is conveyed from the first connector to the second connector and the processing device where it is summarized as speed and relative position.

4. The apparatus of claim 1, further comprising:

at least one additional sensor associated with the monitored machine or another machine and operatively connected to the processing device,

wherein the processing device is configured to receive additional sensor data from the at least one additional sensor and send the additional sensor data to the external processing device via the wireless communication module.

5. The apparatus of claim 4, wherein the at least one additional diagnostic sensors comprises any one or more of, or any combination of, an accelerometer, a temperature sensor, an acoustic sensor, a high frequency sensor, a humidity sensor, a barometric pressure sensor, a current sensor or a proximity sensor.

6. The apparatus of claim 1, wherein the processing device further comprises a time stamp module operative to provide time stamps, and wherein the processing device is operative to send the time stamps to the external processing device via the wireless communication module.

7. The apparatus of claim 1, wherein the processing device further comprises a speed calculation module operative to calculate the speed data based on the rotation sensor data.

8. The apparatus of claim 1, wherein the processing device further comprises a position calculation module operative to calculate the position data based on the rotation sensor data.

9. The apparatus of claim 1, wherein the wireless communication module supports an ad hoc wireless communication protocol.

10. The apparatus of claim 1, wherein the wireless communication module is operative to wirelessly receive additional diagnostic sensor data from a wireless diagnostic sensor node associated with the monitored machine or another machine and wirelessly send the additional diagnostic sensor data to the external processing device.

11. The apparatus of claim 1, wherein the processing device is operative to automatically and periodically send the speed data or position data or both to the external processing device via the wireless communication module.

12. The apparatus of claim 1, further comprising:

a user interface operatively connected to the processing device, wherein user input data via the user interface causes the processing device to send the speed data or position data or both to the external processing device via the wireless communication module.

13. The apparatus of claim 1, wherein the processing device is operative to send the speed data or position data or both to the external processing device via the wireless communication module responsive to a change, relative to a threshold, in an operative state of the monitored machine.

14. A system comprising:

a sensor hub comprising a rotation sensor configured to receive power from a controller of a monitored machine, a wireless communication module, and a processing device configured to receive the power from the controller of the monitored machine and operatively connected to the rotation sensor and the wireless communication module, the sensor hub further comprising a signal path, independent of the processing device and wireless communication module, configured to provide only unprocessed rotation sensor data to the controller for the sole purpose of deterministic control of the monitored machine whereby failure of the wireless communication module or the processing device will not prevent provision of the rotation sensor data to the controller; and

a wireless access point in wireless communication with the wireless communication module and operatively connected to an external processing device,

wherein the processing device is operative to receive rotation sensor data from the rotation sensor and send speed data or position data or both, based on the rotation sensor data, to the external processing device via the wireless communication module and the wireless access point.

15. The system of claim 14, further comprising:

a wireless sensor node in wireless communication with the sensor hub via the wireless communication module or with the wireless access point,

wherein the wireless sensor node is associated with the monitored machine or another machine.

16. The system of claim 14, further comprising the external processing device.

17. The system of claim 16, further comprising:

at least one wireless sensor node associated with the monitored machine or another machine and in wireless communication with wireless communication module or the wireless access point,

wherein the processing device or wireless access point is configured to receive additional sensor data from the at least one wireless sensor node and send the additional sensor data to the external processing device,

and wherein the external processing device is configured to associate the speed data or position data or both with the additional sensor data.

18. The system of claim 17, wherein the external processing device comprises information associating the at least one wireless sensor node with the monitored machine.