Speed and fluid flow controller

• US 7,185,528 B2
• Filed: 11/07/2005
• Issued: 03/06/2007
• Est. Priority Date: 05/31/2002
• Status: Active Grant

• Current Assignee: Teledyne Detcon, Inc. (Teledyne Technologies Incorporated)
• Original Assignee: Scott Technologies, Inc. (3M Company)
• Inventors: Bristol, L. Rodney
• Primary Examiner(s): Williams; Hezron
• Assistant Examiner(s): FITZGERALD, JOHN P
• Application Number:
  US11/270,351
• Publication Number:
  US 20060053865A1
• Time in Patent Office: 484 Days
• Field of Search: 73/310.3, 388/809
• US Class Current: 73/31.03
• CPC Class Codes: F04B 2203/0209 Rotational speed
• CPC Class Codes: F04B 2203/0213 Pulses per unit of time (pulse motor)
• CPC Class Codes: F04B 49/20 by changing the driving speed
• CPC Class Codes: F04D 15/0066 by changing the speed, e.g. of the driving engine
• CPC Class Codes: G05D 7/0676 by action on flow sources G05D7/0688, G05D7/0694 take precedence
• CPC Class Codes: H02P 6/182 using back-emf in windings
• CPC Class Codes: H02P 7/29 using pulse modulation

Abstract

A system and method for measuring fluid flow rate in a system where fluid is pumped, such as a gas monitoring instrument where gas is pumped from a space such as a room or enclosure through a conduit to a sensor. The flow of gas through a pump is determined by measuring motor back-e.m.f. which is proportional to motor speed. In a system where motor speed is regulated by pulse width modulation of the motor drive voltage, the back-e.m.f. is sampled during intervals between the drive pulses applied to the motor, and in a further aspect the sampling is done at selected, spaced-apart or infrequent intervals such as once for every ten or once for every hundred motor drive pulses. Advantageously, in an instrument that uses a microprocessor and analog-to-digital converter to measure gas-concentration, the same microprocessor and converter can provide the PWM control of the pump, in response to the back-e.m.f. generated by the pump motor between the drive pulses. The microprocessor compares the output of the analog-to-digital converter, corresponding to the back-e.m.f., which in turn corresponds to the pump motor speed, to a set-point value, representative of the desired pump motor speed. The processor then adjusts the PWM to control the pump motor to achieve and maintain the desired speed. As a result, in a gas monitor, the gas-flow rate may be maintained close to a desired gas flow rate regardless of the voltage supplied by the battery or other voltage source, regardless of the degree to which the gas is filtered, and under a wide range of operating conditions.

Claims

1. A gas monitoring apparatus, comprising:

a sensor testing gas samples for contaminants;

a pump communicating with the sensor, the pump providing the gas samples to the sensor;

a motor driving the pump;

a motor driver providing drive signals to the motor to control operation of the motor; and

a sampling unit sampling motor back electromagnetic force (EMF) during intervals between the drive signals, the motor driver adjusting the drive signals based on the back EMF sampled, wherein the motor driver comprises a controller that, during sampling of the back EMF, at least one of delays the onset of at least one drive pulse of the drive signals, increases an interval between two adjacent drive pulses, reduces a width of at least one of the drive pulses, and eliminates at least one of the drive signals.

2. The apparatus of claim 1, wherein the motor driver comprises a pulse width modulation (PWM) drive that applies PWM pulses to the motor as the drive signals.

3. The apparatus of claim 1, wherein the motor driver increases and decreases one of pulse width, frequency and amplitude of the drive signals, at different times, to increase and decrease, respectively, a flow rate of the gas samples through the sensor.

4. The apparatus of claim 1, wherein the sampling unit continuously adjusts the drive signals to adjust continuously a speed of the motor such that gas samples are provided at a substantially steady flow rate to the sensor.

5. The apparatus of claim 1, further comprising a microprocessor that calculates an actual motor speed and compares the actual motor speed with a desired motor speed, and based thereon, adjusts the drive signals to change the actual motor speed.

6. The apparatus of claim 1, wherein the sampling unit samples of the back EMF at spaced apart intervals between the drive signals at a rate lower than a pulse rate associated with the drive signals.

7. The apparatus of claim 1, wherein the sampling unit samples the back EMF at infrequent intervals between the drive signals.

8. The apparatus of claim 1, further comprising a microprocessor providing a control signal to the motor driver and providing control pulses to the sampling unit to direct the sampling unit to sample the back EMF of the motor.

9. The apparatus of claim 1, wherein the controller adjusts at least one of a pulse width, frequency, and amplitude of the drive signals based on the back EMF.

11. The apparatus of claim 1, further comprising a battery providing power to the motor through the motor driver.

12. The apparatus of claim 1, wherein the sensor, motor, pump, motor driver and sampling unit are housed within a common handheld portable housing.

13. The apparatus of claim 1, further comprising a housing holding therein the sensor, motor, pump, motor driver and sampling unit, the housing including a port configured to draw in the gas samples.

14. The apparatus of claim 1, further comprising a housing having a port therein, the port being fitted with a length of flexible tubing having an outer end configured to receive the gas samples.

15. The apparatus of claim 1, further comprising a filter joined to the pump, the filter having an inlet configured to receive the gas samples.

16. The apparatus of claim 1, further comprising a housing having control buttons provided on the housing, the control buttons being configured to control operation of the apparatus.

17. The apparatus of claim 1, further comprising a housing having a display located on the housing, the display presenting information indicative of a result of testing of the gas samples for contaminants.

18. The apparatus of claim 1, further comprising a microprocessor and a display, the microprocessor determining a low flow condition when a target motor speed is not maintained, the display providing an indication of the low flow condition.

10. A gas monitoring apparatus, comprising:

a sensor testing gas samples for contaminants;

a pump communicating with the sensor, the pump providing the gas samples to the sensor;

a motor driving the pump;

a motor driver providing drive signals to the motor to control operation of the motor; and

a sampling unit sampling motor back electromagnetic force (EMF) during intervals between the drive signals, the motor driver adjusting the drive signals based on the back EMF sampled, wherein the motor driver generates drive signals separated by different first and second intervals, the second interval being longer than the first interval, the sampling unit sampling the back EMF during the second interval.

19. A method for controlling a gas monitoring apparatus having a sensor, a pump for providing gas samples to the sensor, and a motor for driving the pump, the method comprising:

driving the pump with the motor to provide gas samples to the sensor at a predetermined flow rate;

testing the gas samples at the sensor for contaminants;

generating drive signals to power the motor;

sampling back electromagnetic force (EMF) of the motor during intervals between the drive signals;

adjusting the flow rate of gas samples to the sensor by changing the drive signals based on the back EMF sampled from the motor; and

determining a low flow condition, based on the back EMF sampled, when a target motor speed is not maintained and displaying information indicating the low flow condition.

20. The method of claim 19, wherein the generating includes providing the drive signals as a series of pulse width modulated pulses.

21. The method of claim 19, wherein the adjusting includes adjusting at least one of a pulse width, frequency and amplitude of the drive signals based on the back EMF.

22. The method of claim 19, wherein the adjusting includes increasing and decreasing one of pulse width, frequency and amplitude of the drive signals, at different times, to increase and decrease, respectively, a flow rate of the gas samples through the sensor.

23. The method of claim 19, wherein the adjusting includes continuously adjusting the drive signals to adjust continuously a speed of the motor such that the gas samples are provided at a substantially steady flow rate to the sensor.

24. The method of claim 19, further comprising calculating an actual motor speed and comparing the actual motor speed with a desired motor speed, and based thereon, adjusting the drive signals to change the actual motor speed.

25. The method of claim 19, further comprising sampling the back EMF at spaced apart intervals between the drive signals at a rate lower than a pulse rate associated with the drive signals.

27. The method of claim 19, further comprising displaying information indicative of a result of testing of the gas sample for contaminants.

26. A method for controlling a gas monitoring apparatus having a sensor, a pump for providing gas samples to the sensor, and a motor for driving the pump, the method comprising:

driving the pump with the motor to provide gas samples to the sensor at a predetermined flow rate;

testing the gas samples at the sensor for contaminants;

generating drive signals to power the motor;

sampling back electromagnetic force (EMF) of the motor during intervals between the drive signals; and

adjusting the flow rate of gas samples to the sensor by changing the drive signals based on the back EMF sampled from the motor, wherein the drive signals are separated by different first and second intervals, the second interval being longer than the first interval, the sampling of the back EMF samples occurring during the second interval.

28. A handheld portable gas monitoring instrument, comprising:

a housing sized and shaped to be handheld and portable;

a battery for powering the instrument;

a sensor for testing gas samples for contaminants;

a pump, provided in the housing and communicating with the sensor, the pump providing the gas samples to the sensor;

a motor, provided in the housing, for driving the pump;

a motor driver for providing drive signals to the motor to control operation of the motor;

a sampling unit for sampling motor back electromagnetic force (EMF) during intervals between the drive signals, the motor driver adjusting the drive signals based on the back EMF sampled; and

a microprocessor determining a low flow condition when a target motor speed is not maintained.

29. The instrument of claim 28, wherein the motor driver comprises a controller that adjusts at least one of a pulse width, frequency and amplitude of the drive signals based on the back EMF.

30. The instrument of claim 28, further comprising a microprocessor that calculates an actual motor speed and compares the actual motor speed with a desired motor speed, and based thereon, adjusts the drive signals to change the actual motor speed.

31. The instrument of claim 28, wherein the sampling unit samples of the back EMF at spaced apart intervals between the drive signals at a rate lower than a pulse rate associated with the drive signals.

32. The instrument of claim 28, further comprising a microprocessor providing a control signal to the motor driver and providing control pulses to the sampling unit to direct the sampling unit to sample the back EMF of the motor.

33. The instrument of claim 28, further comprising a port located in the housing, the port being fitted with a length of flexible tubing having an outer end configured to receive the gas samples.

34. The instrument of claim 28, further comprising control buttons located on the housing, the control buttons being configured to control operation of the instrument.

35. The instrument of claim 28, further comprising a display located on the housing, the display presenting information indicative of a result of testing of the gas samples for contaminants.

36. The instrument of claim 28, further comprising a display located on the housing, the display providing an indication of the low flow condition.