Method and apparatus for low power, micro-electronic mechanical sensing and processing

• US 20020011937A1
• Filed: 07/02/2001
• Published: 01/31/2002
• Est. Priority Date: 05/15/1998
• Status: Active Grant

• Current Assignee: Martin Tanenhaus, Robert McDowell, Tom Nelson
• Original Assignee: Martin Tanenhaus, Robert McDowell, Tom Nelson
• Inventors: McDowell, Robert, Nelson, Tom, Tanenhaus, Martin
• Granted Patent: US 6,469,639 B2
• Time in Patent Office: Days
• US Class Current: 340/870.05
• CPC Class Codes: G08C 15/00 Arrangements characterised by the use of multiplexing for the transmission of a plurality of signals over a common path

Abstract

A method and apparatus for low-power sensing and processing are provided. A method preferably includes collecting a plurality of sensor signals. The plurality of sensors include sensed data representative of at least shock and vibration. The method also includes converting the plurality of sensor signals into digital data, processing the digital data, generating a data communications protocol for communicating the digital data, and simultaneously and remotely detecting the generated communications protocol having the processed data to determined the occurrence of at least one predetermined condition. An apparatus preferably includes a low-power, data acquisition processing circuit responsive to a plurality of sensor signals representative of at least shock and vibration for acquiring and processing the sensed data. The data acquisition processing circuit preferably includes a plurality of data inputs, an analog-to-digital converter responsive to the plurality of data inputs for converting each of the plurality of sensor signals from an analog format to a digital format, a digital signal processor responsive to the analog-to-digital converter for processing the digitally formatted data, a data communications processor responsive to said digital signal processor for generating and processing data communications, a battery, and a power management controller at least connected to the battery, the digital signal processor, and the data communications processor for controlling power management of the data acquisition processing circuit.

Claims

1. A method of monitoring a device comprising the steps of:

collecting a plurality-of sensor signals representative of sensed data from a plurality of micro-electrical mechanical sensors, the plurality of micro-electrical mechanical sensors generating sensed data representative of at least shock and vibration;

converting the plurality of sensor signals into digital data;

processing the digital data;

generating a data communications protocol for communicating the digital data; and

simultaneously and remotely detecting the generated communications protocol having the processed data to determined the occurrence of at least one predetermined condition.

2. A method as defined in claim 1, further comprising sensing an initial wake-up condition prior to the step of collecting the plurality of sensor signals.

3. A method as defined in claim 2, further comprising remotely communicating the processed digital data.

4. A method as defined in claim 3, wherein the step of remotely communicating the processed digital data includes transmitting the processed digital data by the use of an RF transmitter and receiving the transmitted RF data prior to the step of simultaneously and remotely detecting.

5. A method as defined in claim 4, wherein the at least one other parameter includes at least one of the following:

temperature, strain, humidity, acoustic, angle, magnetic field, seismic, chemical content and/or variation, and tilt.

6. A method as defined in claim 5, further comprising storing the processed digital data until remotely accessed.

7. A method as defined in claim 6, further comprising storing the unprocessed digital data until remotely accessed and displaying processed and unprocessed digital data after being remotely accessed.

8. A method as defined in claim 7, further comprising operatively sampling the plurality of sensors and analyzing the processed digital data at predetermined scripted real time intervals.

9. A method as defined in claim 8, further comprising operatively generating a data report and generating an alarm condition when predetermined threshold conditions occur.

10. A method as defined in claim 9, further comprising managing the relatively low amount of power required to process the digital data.

11. A method as defined in claim 1, further comprising projecting a plurality of exceeded sensed values responsive to sensing at least one sensor exceeding a predetermined sensor threshold.

12. A method of monitoring a device comprising the steps of:

collecting a plurality of sensor signals representative of sensed data from a plurality of micro-electrical mechanical sensors, the plurality of micro-electrical mechanical sensors generating sensed data representative of at least shock, vibration, and at least one other parameter;

converting the plurality of sensor signals into digital data;

processing the digital data; and

simultaneously and remotely detecting the processed data to determined the occurrence of at least one predetermined condition.

13. A method as defined in claim 12, further comprising sensing an initial wake-up condition prior to the step of collecting the plurality of sensor signals.

14. A method as defined in claim 12, further comprising remotely communicating the processed digital data.

15. A method as defined in claim 14, wherein the step of remotely communicating the processed digital data includes transmitting the processed digital data by the use of an RF transmitter and receiving the transmitted RF data prior to the step of simultaneously and remotely detecting.

16. A method as defined in claim 12, wherein the at least one other parameter includes at least one of the following:

temperature, strain, humidity, acoustic, angle, magnetic field, seismic, chemical content and/or variation, and tilt.

17. A method as defined in claim 12, further comprising storing the processed digital data until remotely accessed.

18. A method as defined in claim 17, further comprising storing the unprocessed digital data until remotely accessed and displaying processed and unprocessed digital data after being remotely accessed.

19. A method as defined in claim 12, further comprising operatively sampling the plurality of sensors and analyzing the processed digital data at predetermined scripted real time intervals.

20. A method as defined in claim 19, further comprising operatively generating a data report and generating an alarm condition when predetermined threshold conditions occur.

21. A method as defined in claim 19, further comprising generating a data communications protocol having the processed digital data and communicating the data communications protocol having the processed digital data responsive to remote access.

22. A method as defined in claim 12, further comprising managing the relatively low amount of power required to process the digital data.

23. A method as defined in claim 12, further comprising projecting a plurality of exceeded sensed values responsive to sensing at least one sensor exceeding a predetermined sensor threshold.

24. An apparatus for monitoring a device, the apparatus comprising:

a plurality of micro-electrical mechanical sensors positioned to sense a plurality of parameters including at least shock, vibration, and at least one other parameter and to provide a corresponding plurality of sensor data signals representative of the plurality of monitored parameters;

a low-power, data acquisition processing circuit responsive to the plurality of sensor signals for acquiring and processing the sensed data, said low-power, data acquisition processing circuit including a plurality of data inputs, an analog-to-digital converter responsive to the plurality of data inputs for converting each of the plurality of sensor signals from an analog format to a digital format, a digital signal processor responsive to said analog-to-digital converter for processing the digitally formatted data, a data communications processor responsive to said digital signal processor for generating and processing data communications, a battery for providing portable power to said data acquisition processing circuit, and power management controlling means at least connected to said battery, said digital signal processor, and said data communications processor for controlling power management of said data acquisition processing circuit; and

a remote data communications detector responsive to said data acquisition processing circuit for remotely detecting the processed digital data.

25. An apparatus as defined in claim 24, at least one wake-up sensor circuit connected to the low-power, data acquisition processing circuit for sensing an initial wake-up condition to thereby wake-up the low-power, data acquisition processing circuit from a sleep-type low power condition.

26. An apparatus as defined in claim 25, wherein said at least one wake-up sensor circuit includes a wake-up sensor for providing a sensing signal responsive to a wake-up condition, a buffer circuit connected to the wake-up sensor for providing a buffered sensing signal, and a threshold detecting circuit connected to said buffer circuit for detecting when a buffered sensing signal reaches a predetermined threshold to thereby provide a wake-up signal to the low-power, data acquisition processing circuit.

27. An apparatus as defined in claim 24, wherein the at least one other parameter includes at least one of the following:

temperature, strain, humidity, acoustic, angle, magnetic field, seismic, chemical content and/or variation, and tilt.

28. An apparatus as defined in claim 24, wherein said digital signal processor includes a memory portion, and wherein said memory portion includes projecting means for projecting the sensed value when at least one sensor exceeds a predetermined sensor threshold.

29. An apparatus as defined in claim 24, wherein the plurality of data inputs includes at least 16 data inputs connected to the analog-to-digital converter.

30. An apparatus as defined in claim 29, wherein the at least 16 data inputs comprises at least 24 data inputs connected to the analog-to-digital converter.

31. An apparatus as defined in claim 24, wherein the combination of said power management controlling means and the type of said battery combine to provide means for extending the life of said battery during normal system operational use for at least an estimated four-year life and so that said data acquisition processing circuit operatively draws less than 200 milliamperes of current, and wherein said power management controlling means includes at least a sleep mode, an ultra-low power awake mode, and a low-power awake mode.

32. An apparatus as defined in claim 24, wherein said data processing circuit further includes at least one RF transmitter for transmitting RF data communications from said data processing circuit, and wherein said remote detector includes an RF receiver for receiving RF data communications from said data processing circuit.

33. An apparatus as defined in claim 24, wherein at least one of said plurality of micro-electrical mechanical sensors includes at least one accelerometer.

34. An apparatus as defined in claim 24, wherein said data communications processor of said data acquisition processing circuit comprises at least one micro-controller, and wherein said digital acquisition processing circuit further includes a separate memory circuit connected to said digital signal processor and said at least one micro-controller for storing the processed data therein until remotely accessed by said remote detector.

35. An apparatus as defined in claim 34, wherein said micro-controller further monitors said digital signal processor before and after said digital signal processor processes the digital converted data.

36. An apparatus as defined in claim 35, further comprising at least one computer responsive to said remote detector, said at least one computer including a display for displaying unprocessed and processed data from said data acquisition processing circuit.

37. An apparatus as defined in claim 34, wherein said data acquisition processing circuit further includes at least one RF transmitting circuit responsive to said micro-controller for transmitting RF data communications, and at least one RF receiving circuit connected to said micro-controller for receiving RF data communications, and wherein said micro-controller, said at least one RF transmitting circuit, and said RF receiving circuit define at least portions of a wireless local area network circuit.

38. An apparatus as defined in claim 34, wherein said data acquisition processing circuit further includes a real time clocking circuit for providing real time thereto, and wherein said power management controlling means is responsive to command signals from said data communications processor at predetermined real time intervals to increase power supplied to said data acquisition processing circuit.

39. An apparatus as defined in claim 38, wherein said memory circuit of said data acquisition processing circuit includes script operating means responsive to said real time clocking circuit for operatively sampling said plurality of data inputs, processing the digital data, and analyzing the processed data at predetermined scripted real time intervals.

40. An apparatus as defined in claim 38, wherein said script operating means further operatively generates a data report and generates an alarm condition when predetermined threshold conditions occur.

41. An apparatus as defined in claim 24, further comprising an image sensor connected to said data acquisition processing circuit for sensing images.

42. An apparatus as defined in claim 24, further comprising a single, compact, and rugged housing having said data acquisition processing circuit positioned entirely therein for withstanding harsh environmental conditions.

43. An apparatus for monitoring a device, the apparatus comprising:

a plurality of sensors positioned to sense a plurality of parameters including at least shock and vibration and to provide a corresponding plurality of sensor data signals representative of the plurality of monitored parameters;

low-power, data acquisition processing means responsive to the plurality of sensor signals for acquiring and processing the sensed data, said low-power, data acquisition processing means including a plurality of data inputs, analog-to-digital converting means responsive to the plurality of data inputs for converting each of the plurality of sensor signals from an analog format to a digital format, digital signal processing means responsive to said analog-to-digital converting means for processing the digitally formatted data, data communications processing means responsive to said digital signal processing means for generating and processing data communications, a portable power source for providing portable power to said data acquisition processing means, and power management controlling means at least connected to said portable power source, said digital signal processing means, and said data communications processing means for controlling power management of said data acquisition processing means; and

a remote data communications detector responsive to said data acquisition processing means for remotely detecting the processed digital data.

44. An apparatus as defined in claim 43, at least one wake-up sensor circuit connected to the low-power, data acquisition processing circuit for sensing an initial wake-up condition to thereby wake-up the low-power, data acquisition processing means from a sleep-type low power condition.

45. An apparatus as defined in claim 44, wherein said at least one wake-up sensor circuit includes a wake-up sensor for providing a sensing signal responsive to a wake-up condition, a buffer circuit connected to the wake-up sensor for providing a buffered sensing signal, and a threshold detecting circuit connected to said buffer circuit for detecting when a buffered sensing signal reaches a predetermined threshold to thereby provide a wake-up signal to the low-power, data acquisition processing means.

46. An apparatus as defined in claim 45, wherein the plurality of sensors further sense at least one of the following:

temperature, strain, humidity, acoustic, angle, magnetic field, seismic, chemical content and/or variation, and tilt.

47. An apparatus as defined in claim 46, wherein said digital signal processor includes a memory portion, and wherein said memory portion includes projecting means for projecting the sensed value when at least one sensor exceeds a predetermined sensor threshold.

48. An apparatus as defined in claim 47, wherein the plurality of data inputs includes at least 16 data inputs connected to the analog-to-digital converter.

49. An apparatus as defined in claim 48, wherein the at least 16 data inputs comprises at least 24 data inputs connected to the analog-to-digital converter.

50. An apparatus as defined in claim 49, wherein the combination of said power management controlling means and the type of said portable power source combine to provide means for extending the life of said portable power source during normal system operational use for at least an estimated four-year life and so that said data acquisition processing means operatively draws less than 1 ampere of current, and wherein said power management controlling means includes at least a sleep mode, an ultra-low power awake mode, and a low-power awake mode.

51. An apparatus as defined in claim 50, wherein said data processing circuit further includes at least one RF transmitter for transmitting RF data communications from said data processing circuit, and wherein said remote detector includes an RF receiver for receiving RF data communications from said data processing circuit.

52. An apparatus as defined in claim 51, wherein at least one of said plurality of sensors each comprises a micro-electrical mechanical sensor, and wherein at least one of the plurality of micro-electrical mechanical sensors includes at least one accelerometer.

53. An apparatus as defined in claim 52, wherein said data communications processing means of said data acquisition processing means comprises at least one micro-controller, and wherein said digital acquisition processing means further includes data storing means connected to said digital signal processing means and said at least one micro-controller for storing the processed data therein until remotely accessed by said remote detector.

54. An apparatus as defined in claim 53, wherein said micro-controller further monitors said digital signal processing means before and after said digital signal processing means processes the digital converted data.

55. An apparatus as defined in claim 54, further comprising at least one computer responsive to said remote detector, said at least one computer including a display for displaying unprocessed and processed data from said data acquisition processing means.

56. An apparatus as defined in claim 55, wherein said data acquisition processing circuit further includes at least one RF transmitting circuit responsive to said micro-controller for transmitting RF data communications, and at least one RF receiving circuit connected to said micro-controller for receiving RF data communications, and wherein said micro-controller, said at least one RF transmitting circuit, and said RF receiving circuit define at least portions of a wireless local area network circuit.

57. An apparatus as defined in claim 56, wherein said data acquisition processing means further includes real time clocking means for providing real time thereto, and wherein said power management controlling means is responsive to command signals from said data communications processing means at predetermined real time intervals to increase power supplied to said data acquisition processing means.

58. An apparatus as defined in claim 57, wherein said data storing means of said data acquisition processing means includes script operating means responsive to said real time clocking means for operatively sampling said plurality of data inputs, processing the digital data, and analyzing the processed data at predetermined scripted real time intervals.

59. An apparatus as defined in claim 58, wherein said script operating means further operatively generates a data report and generates an alarm condition when predetermined threshold conditions occur.

60. An apparatus as defined in claim 59, further comprising an image sensor connected to said data acquisition processing means for sensing images.

61. An apparatus as defined in claim 60, further comprising a single, compact, and rugged housing having said data acquisition processing means positioned entirely therein for withstanding harsh environmental conditions.

62. An apparatus for low-power, data acquisition processing responsive to a plurality of micro-electrical mechanical sensors, the apparatus comprising:

a plurality of data inputs,

an analog-to-digital converter responsive to the plurality of data inputs for converting each of the plurality of sensor signals from an analog format to a digital format,

a digital signal processor responsive to said analog-to-digital converter for processing the digitally formatted data,

a data communications processor responsive to said digital signal processor for generating and processing data communications,

a battery for providing portable power to said data acquisition processing circuit, and

power management controlling means at least connected to said battery, said digital signal processor, and said data communications processor for controlling power management of said data acquisition processing circuit.

63. An apparatus as defined in claim 62, wherein said digital signal processor includes a memory portion, and wherein said memory portion includes projecting means for projecting the sensed value when at least one sensor exceeds a predetermined sensor threshold.

64. An apparatus as defined in claim 62, wherein the plurality of data inputs includes at least 16 data inputs connected to the analog-to-digital converter.

65. An apparatus as defined in claim 64, wherein the at least 16 data inputs comprises at least 24 data inputs connected to the analog-to-digital converter.

66. An apparatus as defined in claim 63, wherein the combination of said power management controlling means and the type of said battery combine to provide means for extending the life of said battery during normal system operational use for at least an estimated four-year life and so that said data acquisition processing circuit operatively draws less than 1 ampere of current, and wherein said power management controlling means includes at least a sleep mode, an ultra-low power awake mode, and a low-power awake mode.

67. An apparatus as defined in claim 66, wherein said data processing circuit further includes at least one RF transmitter for transmitting RF data communications from said data processing circuit and at least one RF receiver for receiving RF data communications.

68. An apparatus as defined in claim 63, wherein said data communications processor of said data acquisition processing circuit comprises at least one micro-controller, and wherein said digital acquisition processing circuit further includes a separate memory circuit connected to said digital signal processor and said at least one micro-controller for storing the processed data therein.

69. An apparatus as defined in claim 68, wherein said micro-controller further monitors said digital signal processor before and after said digital signal processor processes the digital converted data.

70. An apparatus-as defined in claim 68, wherein said data acquisition processing circuit further includes at least one RF transmitting circuit responsive to said micro-controller for transmitting RF data communications, and at least one RF receiving circuit connected to said micro-controller for receiving RF data communications, and wherein said micro-controller, said at least one RF transmitting circuit, and said RF receiving circuit define at least portions of a wireless local area network circuit.

71. An apparatus as defined in claim 68, wherein said data acquisition processing circuit further includes a real time clocking circuit for providing real time thereto, and wherein said power management controlling means is responsive to command signals from said data communications processor at predetermined real time intervals to increase power supplied to said data acquisition processing circuit.

72. An apparatus as defined in claim 71, wherein said memory circuit of said data acquisition processing circuit includes script operating means responsive to said real time clocking circuit for operatively sampling said plurality of data inputs, processing the digital data, and analyzing the processed data at predetermined scripted real time intervals.

73. An apparatus as defined in claim 72, wherein said script operating means further operatively generates a data report and generates an alarm condition when predetermined threshold conditions occur.

74. An apparatus as defined in claim 73, further comprising an image sensor connected to said data acquisition processing means for sensing images.

75. An apparatus as defined in claim 72, wherein the data acquisition processing apparatus is positioned entirely in a single, compact, rugged housing for withstanding harsh environmental conditions.

76. An apparatus for monitoring a device, the apparatus comprising:

a plurality of sensors positioned to sense a plurality of parameters including at least shock and vibration and to provide a corresponding plurality of sensor data signals representative of the plurality of monitored parameters;

low-power, data acquisition processing means responsive to the plurality of sensor signals for acquiring and processing the sensed data, said low-power, data acquisition processing means including a plurality of data inputs, analog-to-digital converting means responsive to the plurality of data inputs for converting each of the plurality of sensor signals from an analog format to a digital format, and digital signal processing means responsive to said analog-to-digital converting means for processing the digitally formatted data;

at least one wake-up sensor circuit connected to the low-power, data acquisition processing means for sensing an initial wake-up condition to thereby wake-up the low-power, data acquisition processing means from a sleep-type low power condition; and

a data communications interface responsive to said data acquisition processing means for providing data communications from said data acquisition processing means.

77. An apparatus as defined in claim 76, wherein said at least one wake-up sensor circuit includes a wake-up sensor for providing a sensing signal responsive to a wake-up condition, a buffer circuit connected to the wake-up sensor for providing a buffered sensing signal, and a threshold detecting circuit connected to said buffer circuit for detecting when a buffered sensing signal reaches a predetermined threshold to thereby provide a wake-up signal to the low-power, data acquisition processing means.

78. An apparatus as defined in claim 77, wherein said digital signal processor includes a memory portion, and wherein said memory portion includes projecting means for projecting the sensed value when at least one sensor exceeds a predetermined sensor threshold.

79. An apparatus as defined in claim 78, wherein said data acquisition processing means further includes data communications processing means responsive to said digital signal processing means for generating and processing data communications, a portable power source for providing portable power to said data acquisition processing means, and power management controlling means at least connected to said portable power source, said digital signal processing means, and said data communications processing means for controlling power management of said data acquisition processing means

80. An apparatus as defined in claim 79, wherein the plurality of sensors further sense at least one of the following:

temperature, strain, humidity, acoustic, angle, magnetic field, seismic, chemical content and/or variation, and tilt.

81. An apparatus-as defined in claim 80, wherein the plurality of data inputs includes at least 16 data inputs connected to the analog-to-digital converter.

82. An apparatus as defined in claim 81, wherein the combination of said power management controlling means and the type of said portable power source combine to provide means for extending the life of said portable power source during normal system operational use for at least an estimated four-year life and so that said data acquisition processing means operatively draws less than 200 milliamperes of current, and wherein said power management controlling means includes at least a sleep mode, an ultra-low power awake mode, and a low-power awake mode.

83. An apparatus as defined in claim 82, wherein said data processing circuit further includes at least one RF transmitter for transmitting RF data communications from said data processing circuit, and wherein said remote detector includes an RF receiver for receiving RF data communications from said data processing circuit.

84. An apparatus as defined in claim 83, wherein at least one of said plurality of sensors each comprises a micro-electrical mechanical sensor, and wherein at least one of the plurality of micro-electrical mechanical sensors includes at least one accelerometer.

85. An apparatus as defined in claim 84, wherein said data communications processing means of said data acquisition processing means comprises at least one micro-controller, and wherein said digital acquisition processing means further includes data storing means connected to said digital signal processing means and said at least one micro-controller for storing the processed data therein until remotely accessed by said remote detector.

86. An apparatus as defined in claim 85, wherein said data acquisition processing means further includes real time clocking means for providing real time thereto, and wherein said power management controlling means is responsive to command signals from said data communications processing means at predetermined real time intervals to increase power supplied to said data acquisition processing means.

87. An apparatus as defined in claim 86, wherein said data storing means of said data acquisition processing means includes script operating means responsive to said real time clocking means for operatively sampling said plurality of data inputs, processing the digital data, and analyzing the processed data at predetermined scripted real time intervals.

88. An apparatus as defined in claim 87, wherein said script operating means further operatively generates a data report and generates an alarm condition when predetermined threshold conditions occur.

89. An apparatus as defined in claim 88, further comprising a single, compact, and rugged housing having said data acquisition processing means positioned entirely therein for withstanding harsh environmental conditions.