Method and apparatus for configuring and synchronizing a wireless machine monitoring and communication system

• US 6,301,514 B1
• Filed: 05/06/1998
• Issued: 10/09/2001
• Est. Priority Date: 08/23/1996
• Status: Expired due to Term

• Current Assignee: Computational Systems Incorporated (Emerson Electric Company)
• Original Assignee: CSI Technology Incorporated (Emerson Electric Company)
• Inventors: Czyzewski, Zbigniew, Pearce, James W., Canada, Ronald G., Davidson, Taylor L. Jr., Robinson, James C.
• Primary Examiner(s): Gordon, Paul P.
• Application Number:
  US09/073,626
• Time in Patent Office: 1,252 Days
• Field of Search: 700/108, 700/109, 700/110, 700/174, 702/56, 340/825.06, 340/825.08
• US Class Current: 700/108
• CPC Class Codes: G01H 1/003 of rotating machines G01H1/10 takes precedence
• CPC Class Codes: G07C 3/00 Registering or indicating the condition or the working of machines or other apparatus, other than vehicles

Abstract

A method of configuring and synchronizing a wireless machine monitoring system that has at least one chain, that includes at least one machine monitor and at least one repeater is disclosed. The wireless machine monitoring system may further include a master repeater that is in communication with the chain and a command station that is in communication with the master repeater. The wireless machine monitoring system is configured so that only one element of the system is communicating at any given time. In addition, bit error rate transmission tests are performed on the elements of the system to determine their ability to communicate at different transmission power levels. Thus, power consumption of battery powered elements is minimized by decreasing the amount of time the devices are active and by configuring the communicating elements to transmit at the lowest acceptable power level. An installation and configuration unit is provided for installing and configuring the machine monitors and the repeaters within each chain of the wireless machine monitoring system.

Claims

1. A method for configuring a wireless machine monitoring system having at least one chain of a plurality of programmable transceiver devices including a machine monitor, a relay repeater and an Installation and Configuration Unit (“

ICU”

), the method comprising he steps of;

(a) positioning the ICU in a physical location within wireless communications range of a first transceiver device and receiving data transmitted by the first transceiver device with the ICU;

(b) calculating a test bit error rate for test data transmitted from the first transceiver device to the ICU;

(c) comparing the test bit error rate to an acceptable bit error rate to determine whether the test bit error rate is acceptable; and

(d) mounting a second transceiver device where the ICU is positioned if it is determined that the test bit error rate is acceptable.

2. The method of claim 1 further comprising:

(e) determining a minimum transmit power level for the first transceiver device that results in a test bit error rate equal to or less than the acceptable bit error rate for data transmitted from the first transceiver device and received by the second transceiver device; and

(f) configuring the first transceiver device to communicate at the minimum transmit power level.

3. The method of claim 1 further comprising the step of the ICU requesting a user to record the serial numbers and the logical locations of the first and second transceiver devices.

4. The method of claim 1 further comprising the step of the ICU prompting a user to record physical locations of the first and second transceiver devices.

5. The method of claim 1 where in the step of positioning the ICU further comprises the step of repositioning the ICU until it is determined that the ICU is positioned such that the bit error rate is acceptable for wireless communications between first and second transceiver devices.

6. The method of claim 1 further comprising the step of downloading configuration parameters to the first and second transceiver devices.

7. The method of claim 1 further comprising the step of placing the first and second transceiver devices in a low power consumption mode once wireless communication is established between the first and second transceiver devices.

8. The method of claim 1 further comprising:

(e) determining a minimum transmit power level for the first transceiver device that results in a bit error rate equal to or less than the acceptable bit error rate for data transmitted from the first transceiver device and received by the second transceiver device; and

(f) configuring the first transceiver device to communicate at the minimum transmit power level;

(g) determining a second minimum transmit power level for the second tansceiver device for data transmitted from the second to the first transceiver device; and

(h) configuring the second transceiver device to communicate at the second minimum transmit power level.

9. The method of claim 1 further comprising:

(e) determining a minimum transmit power level for the first transceiver device that results in a bit error rate equal to or less than the acceptable bit error rate for data transmitted from the first transceiver device and received by the second transceiver device; and

(f) configuring the first transceiver device to communicate at the minimum transmit power level;

(g) determining a second minimum transmit power level for the second transceiver device for data transmitted from the second to the first transceiver device; and

(h) positioning the ICU in a second physical location within wireless communication range of the second transceiver device and receiving data transmitted by the second transceiver device;

(I) performing a bit error rate calculation on data transmitted from the second transceiver device to the ICU to thereby determine a test bit error rate;

(j) comparing the test bit error rate to an acceptable bit error rate and thereby determining whether the test bit error rate is acceptable;

(k) mounting a third transceiver device at the second physical location if it is determined that the bit error rate is acceptable;

(l) determining a third minimum transmit power level for the third transceiver device that results in a bit error rate equal to or less than the acceptable bit error rate for data transmitted from the third transceiver device to the second transceiver device;

(m) configuring the third transceiver device to communicate at the third minimum transceiver power level;

(n) determining a fourth minimum transmission power level for the second transceiver device that results in a bit error rate equal to or less than the acceptable bit error rate for data transmitted from the second transceiver device to the third transceiver device; and

(o) configuring the second transceiver device to communicate at a power level based in part on the second and fourth minimum power levels.

10. The method of claim 9 wherein step (o) further comprises configuring the second transceiver device to communicate at the greater of the second and fourth minimum power levels.

11. The method of claim 9 wherein step (o) further comprises configuring the second transceiver device to transmit at the second minimum power level when communicating with the first transceiver device and to transmit at the fourth minimum power level when communicating with the third transceiver device.

12. A method for configuring a wireless machine monitoring system having at least one chain of programmable transceiver devices including a machine monitor and a relay repeater, a master repeater in communication with the at least one chain, a command station in communication with the master repeater, an Installation and Configuration Unit (“

ICU”

), and a clock contained in each transceiver device, the method comprising the steps of;

(a) synchronizing the clock of the ICU with the clock of a first transceiver device;

(b) establishing wireless ICU transmit and receive communication with the first transceiver device;

(c) determining a permanent time slot under which the first transceiver will communicate; and

(d) communicating commands from the ICU to a second transceiver device and thereby configuring the second transceiver device to communicate with the first transceiver device during the permanent time slot and to synchronize the clocks of the first and second transceiver devices.

13. The method of claim 12 further comprising the step of the ICU requesting registration of the second transceiver device by the first transceiver device whereby the first transceiver device is programmed to communicate with the second transceiver device during the permanent time slot.

14. The method of claim 12 further comprising the step of the ICU requesting operator validation of the permanent time slot for the second transceiver device.

15. The method of claim 12 further comprising using a master repeater as the first transceiver device and using a relay repeater as the second transceiver device.

16. The method of claim 12 further comprising using first and second relay repeaters as the first and second transceiver devices.

17. The method of claim 16 further comprising using a machine monitor as the second transceiver device and using a relay repeater or master repeater as the first transceiver device.

18. A method for configuring and synchronizing a wireless machine monitoring system having at least one chain including a machine monitor and a relay repeater, a master repeater in communication with the at least one chain, a command station in communication with the master repeater, and an Installation and Configuration Unit (“

ICU”

), a clock contained in each machine monitor, relay repeater, master repeater and ICU the method comprising the steps of configuring the wireless machine monitoring system by;

(a) downloading configuration parameters to the machine monitor and the relay repeater from the ICU;

(b) positioning the ICU within wireless communications range of the machine monitor and establishing wireless communication between the ICU and machine monitor;

(c) determining an acceptable bit error rate for communications between the machine monitor and the relay repeater;

(d) performing a bit error rate calculation on data transmitted by the machine monitor to the ICU;

(e) determining whether the ICU is positioned such that the bit error rate is acceptable for wireless communications between the machine monitor and the relay repeater;

(f) repositioning the ICU within wireless communications range of the machine monitor and repeating steps (d) and (e), if it is determined that the bit error rate is unacceptable for wireless communications between the machine monitor and the relay repeater,

(g) mounting the relay repeater at a first location where the ICU is positioned if it is determined that the bit error rate is acceptable for wireless communications between the machine monitor and the relay repeater and downloading configuration parameters to the relay repeater;

(h) determining a minimum transmit power level for the machine monitor based on the acceptable bit error rate;

(i) sending a transmission strength signal configuration message from the ICU to the machine monitor and thereby configuring the machine monitor to transmit at the minimum transmit power level for the machine monitor;

(j) prompting by the ICU for recordation of serial numbers for the machine monitor and the relay repeater, and logical locations of the machine monitor and the relay repeater in the chain;

(k) prompting by the ICU for recordation of the physical locations of the machine monitor and the relay repeater indicative of where the machine monitor and relay repeater are physically located;

(l) synchronizing the wireless machine monitoring system by synchronizing the clocks of the machine monitor, the relay repeater, and the ICU;

(m) establishing wireless ICU transmit and receive communication with the relay repeater;

(n) transmitting signals with the ICU for requesting registration by the relay repeater of the machine monitor;

(o) selecting a permanent time slot under which the relay repeater communicates with the machine monitor;

(p) requesting operator validation of the permanent time slot under which the relay repeater and machine monitor are operational; and

(q) transmitting from the ICU to the relay repeater and the machine monitor a configuration signal and thereby configuring the relay repeater and machine monitor to operate during the selected permanent time slot.

19. The method of claim 18 further comprising providing additional machine monitors within the communication range of the relay repeater for communicating with the relay repeater and for each additional machine monitor configuring a minimum transmit power level by repeating (g)-(i) for each additional machine monitor.

20. The method of claim 18 wherein each additional machine monitor and the relay repeater are synchronized and configured by repeating steps (l)-(q) for each additional machine monitor, thereby configuring each machine monitor to operate during different permanent time slots and configuring the relay repeater to operate during all of the different permanent time slots.

21. The method of claim 18 wherein steps (a)-(l) are repeated for each additional chain in the wireless machine monitoring system.

22. The method of claim 18 wherein steps (m)-(r) are repeated while substituting the master repeater with the relay repeater and the relay repeater with another relay repeater in closer proximity to the machine monitor than the master repeater.

24. The method of claim 18 further comprising performing a plurality of bit error rate calculations on a plurality of test data transmitted by the relay repeater to a plurality of machine monitors, determining a plurality of minimum power levels, each minimum power level corresponding to an acceptable bit error rate at one of the machine monitors, and configuring the relay repeater to transmit at one or more power levels based on the plurality of minimum power levels.

25. The method of claim 18 further comprising performing a plurality of bit error rate calculations on a plurality of test data transmitted by the relay repeater to a master repeater and one or more machine monitors, determining a plurality of minimum power levels, each minimum power level corresponding to an acceptable bit error rate at the master repeater or one or more machine monitors, configuring the relay repeater to transmit at one or more power levels based on the plurality of minimum power levels.

26. The method of claim 18 further comprising performing a bit error rate calculation on test data transmitted by a master repeater to the relay repeater, determining the minimum power level that produces an acceptable bit error rate at the relay repeater, and configuring the master repeater to transmit at the minimum power level producing the acceptable bit error rate.

23. A method of configuring a wireless machine monitoring system comprising performing a bit error rate calculation on test data transmitted by a repeater to a machine monitor, determining a minimum transmit power level that produces an acceptable bit error rate at the machine monitor, and configuring the repeater to transmit at the minimum power level producing an acceptable bit error rate.

27. A method of installing a wireless machine monitoring system having at least a machine monitor and a command station, the method comprising the steps of:

(a) prompting the machine monitor to transmit a known set of data to the command station at a transmission power level;

(b) receiving the data at the command station;

(c) determining an accuracy with which the machine monitor transmitted the data; and

(d) adjusting the transmission power level of the machine monitor in response to the accuracy.

28. A method of minimizing power usage of wireless machine monitors that are in communication with a command station, the method comprising the steps of:

(a) configuring the machine monitors to transmit data at a lowest possible power level that allows for reasonably accurate data transmission; and

(b) configuring the machine monitors to only transmit or receive data intermittently.

29. An installation control unit for installing and configuring a wireless machine monitoring system comprising:

(a) a transmitter for sending configuration parameters to the machine monitoring system,

(b) a receiver for receiving data from the machine monitoring system,

(c) processing means for analyzing and storing data received from the machine monitoring system, said processing means including;

(1) means for determining a signal strength of a transmitted signal,

(2) means for assigning a machine monitor to a repeater,

(3) means for placing a machine monitor or a repeater in a configuration mode, and

(4) means for assigning a machine monitor a time slice during which to communicate, and

(d) clock means for synchronizing the operation of the machine monitoring system.

30. The installation control unit of claim 29 further comprising a display for displaying status information and a keyboard for allowing a user to input information.