Leak detector

• US 10,175,135 B2
• Filed: 06/08/2012
• Issued: 01/08/2019
• Est. Priority Date: 08/12/2011
• Status: Active Grant

• Current Assignee: Mueller International LLC (Mueller Water Products Incorporated)
• Original Assignee: Mueller International LLC (Mueller Water Products Incorporated)
• Inventors: Dintakurt, Ganapathi Deva Varma, Yusuf, Shabbir, Mercer, Steven James
• Primary Examiner(s): Nghiem, Michael
• Assistant Examiner(s): Ngo, Peter
• Application Number:
  US13/492,794
• Publication Number:
  US 20130041601A1
• Time in Patent Office: 2,405 Days
• Field of Search: 702 51
• CPC Class Codes: B26F 1/14 Punching tools; Punching dies
• CPC Class Codes: E03B 7/003 Arrangement for testing of watertightness of water supply conduits
• CPC Class Codes: E03B 7/071 Arrangement of safety devices in domestic pipe systems, e.g. devices for automatic shut-off
• CPC Class Codes: E03B 9/02 Hydrants; Arrangements of valves therein; Keys for hydrants
• CPC Class Codes: E03B 9/06 Covers
• CPC Class Codes: G01F 17/00 Methods or apparatus for determining the capacity of containers or cavities, or the volume of solid bodies measuring linear dimensions to determine volume G01B
• CPC Class Codes: G01M 3/00 Investigating fluid-tightness of structures
• CPC Class Codes: G01M 3/24 using infrasonic, sonic, or ultrasonic vibrations
• CPC Class Codes: G01M 3/243 for pipes
• CPC Class Codes: H01Q 1/225 used in level-measurement devices, e.g. for level gauge measurement
• CPC Class Codes: H01Q 1/2291 used in bluetooth or WI-FI devices of Wireless Local Area Networks [WLAN] H01Q1/241 takes precedence; WLAN in general H04W
• CPC Class Codes: H01Q 1/38 formed by a conductive layer on an insulating support patch antennas H01Q9/0407; microstrip dipole antennas H01Q9/065; microstrip slot antennas H01Q13/106; transmission line microstrip antennas H01Q13/206; manufacturing reflecting surfaces using insulating material for supporting the reflecting surface H01Q15/142
• CPC Class Codes: H01Q 1/42 Housings not intimately mechanically associated with radiating elements, e.g. radome
• CPC Class Codes: Y02A 20/15 Leakage reduction or detection in water storage or distribution
• CPC Class Codes: Y10T 83/04 Processes

Abstract

A leak detector includes a sensor assembly including at least one sensor configured to sense acoustic signals; and at least one printed circuit board coupled to the sensor assembly and configured to support a processing device, the processing device comprising at least a microcontroller unit (MCU) and a digital signal processor (DSP), wherein the MCU is configured to continually receive acoustic signals from the sensor assembly, and wherein the DSP is configured to remain in a sleep mode except when the MCU wakes the DSP from the sleep mode at predetermined times.

Claims

1. A leak detector comprising:

a sensor assembly including at least one sensor configured to sense acoustic signals; and

at least one printed circuit board coupled to the sensor assembly and configured to support a processing device, the processing device comprising at least a processor, a storage module, the processor comprising at least a microcontroller unit (MCU) and a digital signal processor (DSP), the storage module comprising a database configured to store the acoustic signals from the sensor assembly;

wherein the MCU is configured to

continually receive the acoustic signals from the sensor assembly,

wake the DSP at predetermined times based on a sensing schedule, and

wake the DSP during a detected event, the detected event comprising at least one selected from the group of a large leak and a burst in a pipe;

wherein the DSP is configured to remain in a sleep mode except when the MCU wakes the DSP from the sleep mode;

wherein the processing device is configured to derive a probability that an event exists by comparing new acoustic signals to stored acoustic signals, the event comprising at least one selected from the group of a large leak and a burst in a pipe, wherein the stored acoustic signals comprise live data collected on a pipe network; and

wherein the processing device is further configured to provide a probability indication, the probability indication expressed as a percentage of a likelihood that the event exists.

2. The leak detector of claim 1, wherein, during the predetermined times, the DSP is configured to process the sensed acoustic signals.

3. The leak detector of claim 2, wherein the DSP compares a strength of the sensed acoustic signals with a baseline waveform, and wherein the DSP determines a severity of a leak based at least on an extent to which amplitude of the sensed acoustic signals exceeds the baseline waveform.

4. The leak detector of claim 3, wherein the DSP compares the sensed acoustic signals with the baseline waveform within a predetermined frequency bandwidth.

5. The leak detector of claim 1, further comprising a first crystal oscillator coupled to the MCU and a second crystal oscillator coupled to the DSP.

6. The leak detector of claim 1, wherein the at least one printed circuit board is further configured to support a sensor interface coupled between the sensor assembly and the MCU.

7. The leak detector of claim 1, wherein the sensor assembly comprises at least an acoustic sensor and a pressure sensor.

8. The leak detector of claim 7, wherein the pressure sensor is configured to detect the burst in the pipe.

9. The leak detector of claim 8, wherein the MCU is configured to analyze a high-speed pressure transient profile of the pressure sensor to detect the burst.

10. The leak detector of claim 7, wherein the sensor assembly further comprises a temperature sensor.

11. The leak detector of claim 1, wherein the sensor assembly is configured to detect acoustic signals from water pipes having a diameter greater than twelve inches.

12. The leak detector of claim 1, wherein the sensor assembly is configured to detect acoustic signals from water pipes having a diameter less than twelve inches.

13. The leak detector of claim 1, wherein the at least one printed circuit board is further configured to support a communication device for wirelessly communicating acoustic signals to a host.

14. The leak detector of claim 13, wherein the at least one printed circuit board comprises a first circuit board and a second circuit board, the first circuit board configured to support the MCU and DSP, and the second circuit board configured to support the communication device.

15. The leak detector of claim 1, wherein the DSP is configured to convert the acoustic signals to a time domain using a Fast Fourier transform process.

16. The leak detector of claim 1, wherein the sensor assembly comprises at least a hydrophone that continually senses acoustic signals.

17. The leak detector of claim 1, wherein the MCU is configured to correlate acoustic waveforms associated with events unrelated to leaks in order to remove any presence of the correlated waveforms from the sensed acoustic signals.

18. The leak detector of claim 1, further comprising memory for storing the acoustic signals.

19. The leak detector of claim 1, further comprising a power source configured to provide power to the processing device.

20. The leak detector of claim 1, wherein the processing device further comprises a health status detecting module configured to determine a health status and an integrity status of the leak detector each time the MCU wakes the DSP from the sleep mode.

21. The leak detector of claim 1, wherein the at least one sensor comprises a plurality of sensors, the leak detector further comprising a summing amplifier communicating with each sensor in the sensor assembly, the summing amplifier configured to generate a sum of signals received from the plurality of sensors.

22. A method comprising:

placing a digital signal processor (DSP) in a sleep mode, the DSP being incorporated in a leak detector;

determining whether a host-initiated request is received from a host and awakening the DSP when the host-initiated request is received;

determining whether a sensing schedule has been received;

awakening the DSP for a predetermined sensing period when a predetermined time has occurred based on the sensing schedule;

determining whether an indication of an urgent event related to a leak in a water main has been received by a microcontroller unit (MCU) and awakening the DSP when the MCU receives the indication of the urgent event;

enabling the DSP to receive newly-acquired acoustic signal data upon awakening;

enabling the DSP to analyze acoustic signal data when awakened, the acoustic signal data comprising previously-stored acoustic signal data and the newly-acquired acoustic signal data, wherein the previously-stored acoustic signal data comprises live data collected on a pipe network;

determining a probability of existence of an urgent event based on the acoustic signal data, the probability expressed as a percentage of a likelihood that the urgent event exists; and

returning the DSP to the sleep mode when it is determined that the host-initiated request is not received, when it is determined that the predetermined sensing period has concluded, and when it is determined that no urgent event related to a leak in a water main has been detected by the MCU.

23. The method of claim 22, wherein awakening the DSP comprises the step of turning on a processor of the DSP.

24. The method of claim 23, wherein turning on the processor of the DSP comprises utilizing a real time clock to turn on the processor.

25. The method of claim 22, further comprising the step of communicating the analyzed acoustic signals to the host.

26. The method of claim 25, wherein the step of communicating the analyzed acoustic signals comprises communicating wirelessly using one of a radio frequency protocol and a cellular protocol.

27. The method of claim 25, wherein the step of communicating the analyzed acoustic signals comprises communicating to the host through at least one intermediate node.

28. The method of claim 22, wherein the newly-acquired acoustic signal data comprises a sum of signals received from a plurality of sensors, the sum generated by a summing amplifier.