Automated network of sensor units for real-time monitoring of compounds in a fluid over a distributed area

• US 5,832,411 A
• Filed: 02/06/1997
• Issued: 11/03/1998
• Est. Priority Date: 02/06/1997
• Status: Expired due to Term

• Current Assignee: Raytheon Company (Rtx Corporation)
• Original Assignee: Raytheon Company (Rtx Corporation)
• Inventors: Newcomb, Russell R., Wurzbach, James A., Ciambrone, David F., Schatzmann, Lawrence A.
• Primary Examiner(s): Voeltz, Emanuel Todd
• Assistant Examiner(s): WACHSMAN, HAL D
• Application Number:
  US08/794,389
• Time in Patent Office: 635 Days
• Field of Search: 364/510, 364/509, 364/505, 364/506, 364/550, 364/551.01, 364/496.5, 364/564, 364/571.01, 364/571.03, 364/579, 364/580, 364/803, 364/569, 205/787, 205/775, 204/406, 204/408, 204/418, 204/429, 422/68.1, 422/82.01, 422/82.02, 422/83, 422/98, 422/70, 436/149-154, 73/31.01, 73/31.02, 73/31.06, 73/29.05, 73/23.2, 73/23.21-23.23, 73/23.31, 73/23.36, 73/23.4, 324/446, 324/691, 324/693, 340/603, 340/618, 340/620, 340/632-634
• US Class Current: 702/23
• CPC Class Codes: G01N 33/0075 for multiple spatially distributed sensors, e.g. for environmental monitoring transmission systems for measured values G08C

Abstract

A plurality of sensor units are distributed over an area and communicate via a network with a central monitoring unit. The sensor units include sensor arrays that provide them with raw data in response to the presence of selected compounds in the ambient fluid. The raw sensor data is then processed to compute a local profile, which (a) illustrates a change in the compounds in the fluid from their normal state (change detection) , (b) indicates the presence and total concentration of foreign compounds in the fluid (presence detection), or (c) details the composition and concentrations of defined classes or individual species of compounds in the fluid (composition detection). The local profiles from the individual sensor units are then used to compute a spatial and temporal map for the compounds in the fluid. This map can then be used for a variety of purposes including tracking and predicting the flow of compounds through the area, identifying the source of compounds in the area, monitoring abatement, and controlling industrial processes.

Claims

1. A system for monitoring the composition and concentration of compounds in a fluid, comprising a plurality of sensor units distributed over an area and a central monitoring unit that communicate over a network in real-time, each said sensor unit comprising a) a power source, b) a connector that connects a sensor array to said unit, said sensor array comprising one or more sensor elements which respond to the same compound to different degrees to generate respective data signals that deviate from a baseline response in the presence of one or more compounds in the fluid, c) an interface that measures the data signals produced by each of the array'"'"'s sensor elements, d) a processor that formats the data signals into an output data stream, and e) an I/O circuit that places the output data stream onto the network, said sensor units and said central monitoring unit processing in real-time the sensor units'"'"' data signals to first compute a local profile for each said sensor unit and then compute a spatial and temporal map of the compounds in the fluid over the area, said local profiles indicating whether a total concentration of the one or more compounds detected at each said sensor unit exceeds a threshold without detecting the individual compounds and their concentrations.

2. A system for monitoring the composition and concentration of compounds in a fluid, comprising a plurality of sensor units distributed over an area and a central monitoring unit that communicate over a network in real-time, each said sensor unit comprising a) a power source, b) a connector that connects a sensor array to said unit, said sensor array comprising one or more sensor elements which respond to the same compound to different degrees to generate respective data signals that deviate from a baseline response in the presence of one or more compounds in the fluid, c) an interface that measures the data signals produced by each of the array'"'"'s sensor elements, d) a processor that formats the data signals into an output data stream, and e) an I/O circuit that places the output data stream onto the network, said sensor units and said central monitoring unit processing in real-time the sensor units'"'"' data signals to first compute a local profile for each said sensor unit and then compute a spatial and temporal map of the compounds in the fluid over the area, said local profiles and the spatial and temporal map including the local compositions of the compounds and their concentrations at the respective sensor units, said central monitoring unit performing a gradient analysis on the temporal map to track a path of increasing concentration leading back to a source of the compounds.

3. A system for monitoring the composition and concentration of compounds in a fluid, comprising a plurality of sensor units distributed over an area and a central monitoring unit that communicate over a network in real-time, each said sensor unit comprising a) a power source, b) a connector that connects a sensor array to said unit, said sensor array comprising one or more sensor elements which respond to the same compound to different degrees to generate respective data signals that deviate from a baseline response in the presence of one or more compounds in the fluid, c) an interface that measures the data signals produced by each of the array'"'"'s sensor elements, d) a processor that formats the data signals into an output data stream, and e) an I/O circuit that places the output data stream onto the network, said sensor units and said central monitoring unit processing in real-time the sensor units'"'"' data signals to first compute a local profile for each said sensor unit and then compute a spatial and temporal map of the compounds in the fluid over the area, said local profiles and the spatial and temporal map including the local compositions of the compounds and their concentrations at the respective sensor units, said central monitoring unit comparing the composition and concentration at each said sensor unit at different times to track the flow of the compounds across the area, at least one of said sensor units further comprising a wind sensor for detecting the wind speed and direction at the sensor unit, said sensor units and the central monitoring unit using the local profiles, the flow across the area, and the wind conditions to predict the progression of the compounds across and outside the area.

4. A system for monitoring the composition and concentration of compounds in a fluid, comprising a plurality of sensor units distributed over an area to monitor the compounds'"'"' local compositions and concentrations at different points in a process that destroys the compounds and a central monitoring unit that communicate over a network in real-time, each said sensor unit comprising a) a power source, b) a connector that connects a sensor array to said unit, said sensor array comprising one or more sensor elements which respond to the same compound to different degrees to generate respective data signals that deviate from a baseline response in the presence of one or more compounds in the fluid, c) an interface that measures the data signals produced by each of the array'"'"'s sensor elements, d) a processor that formats the data signals into an output data stream, and e) an I/O circuit that places the output data stream onto the network, said sensor units and said central monitoring unit processing in real-time the sensor units'"'"' data signals to first compute a local profile for each said sensor unit and then compute a spatial and temporal map of the compounds in the fluid over the area, said central monitoring unit interrelating the local compositions and concentrations to monitor the performance of the destruction process.

5. A system for monitoring the composition and concentration of compounds in a fluid, comprising a plurality of sensor units distributed around a source of compound emissions to monitor the local compositions of the compounds and their concentrations at different points and a central monitoring unit that communicate over a network in real-time, each said sensor unit comprising a) a power source, b) a connector that connects a sensor array to said unit, said sensor array comprising one or more sensor elements which respond to the same compound to different degrees to generate respective data signals that deviate from a baseline response in the presence of one or more compounds in the fluid, c) an interface that measures the data signals produced by each of the array'"'"'s sensor elements, d) a processor that formats the data signals into an output data stream, and e) an I/O circuit that places the output data stream onto the network, said sensor units and said central monitoring unit processing in real-time the sensor units'"'"' data signals to first compute a local profile for each said sensor unit and then compute a spatial and temporal map of the compounds in the fluid over the area, said central monitoring unit interrelating the local compositions and concentrations to monitor the abatement of the compound emissions from the source over time.

6. A system for monitoring the composition and concentration of compounds in a fluid, comprising a plurality of sensor units distributed over an area and a central monitoring unit that communicate over a network in real-time, each said sensor unit comprising a) a power source, b) a connector that connects a sensor array to said unit, said sensor array comprising one or more sensor elements which respond to the same compound to different degrees to generate respective data signals that deviate from a baseline response in the presence of one or more compounds in the fluid, c) an interface that measures the data signals produced by each of the array'"'"'s sensor elements, d) a processor that formats the data signals into an output data stream, e) an I/O circuit that places the output data stream onto the network, f) a chamber for enclosing the sensor array and a sampling mechanism for drawing compounds in the liquid into the chamber and across the sensor array and then venting the compounds out of the chamber, and g) a volume of calibration compounds, said sensor units and said central monitoring unit processing in real-time the sensor units'"'"' data signals to first compute a local profile for each said sensor unit and then compute a spatial and temporal map of the compounds in the fluid over the area, said processor causing the sensor array to be isolated in said chamber from the compounds in said fluid and then causing an amount of the calibration compounds to be released into said chamber to generate test data signals that are used to recalibrate the sensor unit.

7. An automated system for continuously monitoring the composition and concentration of volatile organic compounds (VOCs) in an atmosphere, comprising a plurality of sensor units distributed over an area, a computer and a central monitoring unit that communicate over a network in real-time, each said sensor unit comprising a) power source, b) a connector that connects a sensor array to said unit, said sensor array comprising a plurality of sensor elements which respond to the same VOC to different degrees to generate respective data signals that deviate from a baseline response in the presence of VOCs in the atmosphere, c) a chamber that encloses the sensor array, d) a vapor sampling mechanism for drawing VOCs from the atmosphere into the chamber, across the sensor array and then venting them out of the chamber, e) at least one environmental sensor for sensing environmental conditions in the chamber f) an interface that measures the data signals produced by each of the array'"'"'s sensor elements, g) a processor that first compensates the data signals for the environmental conditions and then formats them into an output data stream, and h) an I/O circuit that places the output data stream onto the network, said computer determining a local VOC composition including concentrations for each said sensor unit and said central monitoring unit processing the local VOC compositions to compute the spatial and temporal composition the VOCs and their concentrations in the atmosphere over the area.

8. The system of claim 7, wherein said sampling mechanism is a passive mechanism.

9. The system of claim 7, wherein said sampling mechanism is an active mechanism, said processor controlling said sampling mechanism to draw compounds from the fluid into the chamber across the sensor array and then venting the compounds out of the chamber.

10. The system of claim 7, wherein said computer is distributed between the sensor units'"'"' processors such that each said processor first processes the compensated data signals from the sensor elements to compute the local VOC composition and then formats the local VOC composition into the output data stream that is transmitted over the network to the central monitoring unit, which then interrelates the local VOC compositions and concentration data over the area.

11. The system of claim 10, wherein said computer is included in said central monitoring unit, which first processes the compensated data signals from each of said sensor units to estimate the local VOC compositions at each said sensor unit and then interrelates the local composition and concentration data from the different sensor units over the area.

12. The system of claim 7, wherein said central monitoring unit computes a temporal map of the VOC composition over the area and performs a gradient analysis on the temporal map to track a path of increasing concentration leading back to a source of the compounds.

13. The system of claim 7, wherein said central monitoring unit computes a temporal map of the VOC composition over the area and compares the VOC composition at each said sensor unit at different times to track the flow of the VOCs across the area.

14. The system of claim 13, wherein one of said environmental sensors is a wind sensor for detecting the wind speed and direction at the sensor unit, said central monitoring unit using the local VOC compositions, the flow across the area, and the wind conditions to predict the progression of the compounds across the area and outside the area.

15. The system of claim 7, wherein said sensor units are distributed over the area to monitor the local VOC compositions at different points in a process that destroys the VOCs in the atmosphere, said central monitoring unit interrelating the local VOC compositions to monitor the performance of the destruction process.

16. The system of claim 7, wherein said sensor unit further comprises one or more environmental control mechanisms, said processor responding to the sensed environmental conditions to drive the environmental control mechanisms to maintain the environmental conditions at a baseline level.

17. A system for monitoring volatile organic compounds (VOCs) in an industrial facility, comprising:

a paint booth for painting equipment during which the evaporation of paint solvents and carriers produces VOCs that contaminate the internal atmosphere inside the paint booth;

a ventilation system for drawing air from an external atmosphere into the paint booth;

a VOC abatement system having an inlet for drawing the contaminated atmosphere from the paint booth, a mechanism for treating the contaminated atmosphere to destroy the VOCs, and an outlet for venting the treated atmosphere to the external atmosphere;

a bypass vent for selectively venting the contaminated atmosphere in the paint booth directly to the external atmosphere;

a data communications network;

a plurality of sensor units for detecting VOCs including a first sensor unit positioned in the paint booth, a second sensor unit positioned near the bypass vent, a third sensor unit positioned at the inlet to the abatement system, and a fourth sensor unit positioned at the outlet to the abatement system, each said sensor unit comprising a) power source, b) a connector that connects a sensor array to said unit, said sensor array comprising a plurality of sensor elements that respond to the same VOC to different degrees to generate respective data signals in the presence of VOCs, c) an interface that measures the data signals produced by each of the array'"'"'s sensor elements, d) a processor that formats the data signals into an output data stream, and e) an I/O circuit that places the output data stream onto the network;

a computer connected to said network that computes an ambient VOC level in the paint booth at the first sensor unit, a bypassed VOC level at the second sensor unit, an intake VOC level at the third sensor unit, and a discharged VOC level at the outlet of the VOC abatement system, said VOC levels including a composition of VOCs and their concentrations; and

a central monitoring unit in said network that a) processes the intake and outlet VOC levels to monitor the performance of the VOC abatement system and, if necessary, takes corrective action to restore its performance and b) monitors the ambient VOC level and, when it exceeds a threshold level, opens the bypass vent to vent the contaminated atmosphere to the external atmosphere and records the bypassed VOC level.

18. The system of claim 17, wherein said computer is distributed among the sensor units'"'"' processors such that each said processor first processes the data signals from the sensor elements to compute the VOC level and then formats it into the output data stream that is transmitted over the network to the central monitoring unit.

19. The system of claim 17, wherein said computer is included in said central monitoring unit, which first processes the data signals from each of said sensor units to compute the VOC levels at each said sensor unit and then processes them to monitor the abatement system and the ambient VOC level.

20. The system of claim 17, wherein each said sensor unit further comprises a chamber for enclosing the sensor array and a sampling mechanism for drawing the contaminated atmosphere into the chamber, across the sensor array and then venting the contaminated atmosphere out of the chamber.

21. The system of claim 20, wherein said sensor unit comprises one or more environmental sensors for sensing environmental conditions in the chamber, said processor compensating for the environmental conditions so that the measured data signals are approximately independent of those conditions.

22. The system of claim 21, wherein said sensor unit further comprises one or more environmental control mechanisms, said processor responding to the sensed environmental conditions to drive the environmental control mechanisms to maintain the environmental conditions at a baseline level.

23. The system of claim 17, wherein the VOC abatement system'"'"'s mechanism destroys the VOCs, said central monitoring unit taking corrective action by adjusting the operating parameters of the abatement system.

24. The system of claim 17, wherein the composition of VOCs includes the Ketones, BTEX, Acetates, Alcohols, and Aliphatic Hydro-Carbon classes of VOCs, said central monitoring unit comparing the concentrations of these VOC classes at the intake and outlet of the VOC abatement system to monitor the system'"'"'s performance.

25. The system of claim 24, wherein the computer identifies the different species in each VOC class and their respective concentrations.

26. The system of claim 17, wherein venting the contaminated atmosphere directly to the external atmosphere through the bypass vent creates a plume, a plurality of said sensor units being positioned outside the paint booth to monitor the VOC levels in the external environment, said central monitoring unit computing a temporal map of the VOC levels over an area outside the paint booth and comparing the VOC levels at each said sensor unit at different times to track the progression of the plume across the area.

27. The system of claim 26, wherein at least one of the sensor units outside the paint booth detects the wind speed and direction, said central monitoring unit using the VOC levels at the sensor units outside the paint booth, the bypassed VOC level, the progression of the plume across the area, and the wind conditions to predict the progression of the VOCs across and outside the area.

28. The system of claim 26, further comprising a plurality of similar paint booths that are positioned at different locations in the area, said central monitoring unit performing a gradient analysis on the temporal map to track a path of increasing concentration leading back to the one or more of said paint booths that are the source of the VOC plume.