Clogged dust filter monitor

• US 10,639,577 B1
• Filed: 01/17/2019
• Issued: 05/05/2020
• Est. Priority Date: 01/17/2018
• Status: Active Grant

• Current Assignee: Filtersmarts, Inc.
• Original Assignee: Filtersmarts, Inc.
• Inventors: Wilson, Jr., David Joel, Morris, Douglas, Walker, David Daniel
• Primary Examiner(s): Clemente, Robert
• Application Number:
  US16/251,060
• Time in Patent Office: 474 Days
• CPC Class Codes: B01D 2273/18 Testing of filters, filter elements, sealings
• CPC Class Codes: B01D 2273/26 Making use of optical waves, e.g. for measurements
• CPC Class Codes: B01D 46/0086 Filter condition indicators
• CPC Class Codes: B01D 46/4245 Means for power supply or devices using electrical power in filters or filter elements
• CPC Class Codes: B01D 46/429 Means for wireless communication
• CPC Class Codes: F24F 11/39 Monitoring filter performance
• CPC Class Codes: G01N 2021/0168 for the measurement cycle
• CPC Class Codes: G01N 2021/1772 Array detector
• CPC Class Codes: G01N 2021/5965 using selected detectors in an array
• CPC Class Codes: G01N 21/59 Transmissivity G01N21/25 takes precedence

Abstract

A clogged filter detector is provided. In some embodiments, the clogged filter detector may comprise a transmitter, a sensor, and a transmitter resistor array configured to modify the output strength of the transmitter. In some embodiments, the clogged filter detector may comprise a transmitter, a sensor, and a sensor resistor array to configured to adjust the strength of the signal output by the sensor. The clogged filter detector may also include one or more processor configured to adjust the strength of a beam output by the transmitter based on a saturation level.

Claims

1. A clogged filter detector comprising:

a transmitter configured to emit a beam of electromagnetic radiation;

a sensor configured to receive the beam of electromagnetic radiation after the beam passes through a filter; and

a transmitter resistor array comprising a plurality of resistors, and configured to adjust an output strength of the transmitter by selectively controlling one or more of the plurality of resistors.

2. The clogged filter detector of claim 1, further comprising one or more processor configured to determine a saturation level of the sensor by the beam of electromagnetic radiation after passing through the filter and whether the saturation level is at a saturation point of the sensor.

3. The clogged filter detector of claim 2, wherein the transmitter resistor array is configured to adjust the output strength of the transmitter so that the beam of electromagnetic radiation detected by the sensor is below the saturation point of the sensor.

4. The clogged filter detector of claim 3, wherein the output strength of the transmitter is adjusted during a calibration reading.

5. The clogged filter detector of claim 3, wherein the output strength of the transmitter is adjusted so as to maximize the output strength without resulting saturation of the sensor.

6. The clogged filter detector of claim 2, wherein the transmitter resistor array is configured to adjust the output strength of the transmitter to a highest output strength selected from among output strengths that result in the sensor being below the saturation point of the sensor.

7. The clogged filter detector of claim 6, wherein the one or more processor is configured to associate the selected highest output strength of the transmitter with a clogging level corresponding to a lower output strength of the transmitter selected from among the output strengths that result in the sensor being below the saturation point of the sensor.

8. The clogged filter detector of claim 1, wherein the transmitter resistor array is configured to adjust the output strength of the transmitter during an initial calibration of the filter.

9. The clogged filter detector of claim 8, wherein the transmitter resistor array is configured to adjust the output strength of the transmitter at a time later than the initial calibration of the filter.

10. The clogged filter detector of claim 2, wherein the transmitter resistor array is configured to increase the output strength of the transmitter after the saturation level of the sensor falls below a predefined threshold.

11. The clogged filter detector of claim 10, wherein the transmitter resistor array is configured to increase the output strength of the transmitter to a level which does not result in the saturation level reaching the saturation point.

12. The clogged filter detector of claim 1, further comprising one or more processor configured to determine a saturation level of the sensor receiving the beam of electromagnetic radiation,

wherein the transmitter resistor array is configured to increase the output strength of the transmitter so as to be below a saturation point of the sensor.

13. The clogged filter detector of claim 1, further comprising one or more processor configured to determine a saturation level of the sensor receiving the beam of electromagnetic radiation after passing through the filter,

wherein the one or more processor is configured to provide a notification after the saturation level of the sensor falls below a threshold.

14. The clogged filter detector of claim 1, further comprising a potentiometer electrically connected to the sensor output;

and

one or more processor configured to convert a level of the potentiometer to a logarithmic scale.

15. The clogged filter detector of claim 2, wherein the one or more processor is configured to determine the saturation level of the sensor more frequently when the saturation level falls below a predefined threshold.

16. The clogged filter detector of claim 1, wherein the transmitter and the sensor are misaligned along a direction of a flow of air across the filter.

17. The clogged filter detector of claim 1, further comprising a sensor resistor array comprising a plurality of sensor array resistors, and configured to selectively reduce a strength of a signal output by the sensor by selectively controlling one or more of the plurality of sensor array resistors.

18. A clogged filter detector comprising:

a transmitter configured to emit a beam of electromagnetic radiation;

a sensor configured to receive the beam of electromagnetic radiation after the beam passes through a filter; and

a sensor resistor array comprising a plurality of resistors, and configured to adjust the strength of a signal output by the sensor by selectively controlling one or more of the plurality of resistors after the electromagnetic beam passes through the filter.

19. The clogged filter detector of claim 18, further comprising one or more processor configured to determine a saturation level of the sensor receiving the beam of electromagnetic radiation.

20. The clogged filter detector of claim 19, wherein the sensor resistor array is configured to reduce the strength of the signal output by the sensor after the one or more processor determines that the saturation level is at a saturation point of the sensor.

21. The clogged filter detector of claim 19, wherein the sensor resistor array is configured to increase the strength of the signal output by the sensor after the one or more processor determines that the saturation level is below a predefined saturation level.

22. The clogged filter detector of claim 18, wherein the sensor resistor array is further configured to adjust the strength of the signal output by the sensor based on the strength of the beam of electromagnetic radiation received by the sensor.

23. A clogged filter detector comprising:

a transmitter configured to emit a beam of electromagnetic radiation;

a sensor configured to receive the beam of electromagnetic radiation after the beam through a filter; and

one or more processor configured to adjust an output strength of the beam of electromagnetic radiation based on a saturation level of the sensor.

24. The clogged filter detector of claim 23, wherein the one or more processor is configured to reduce the output strength of the beam of electromagnetic radiation if the sensor is at or above a saturation point.