Modular, configurable, intelligent sensor system

• US 8,615,374 B1
• Filed: 06/09/2006
• Issued: 12/24/2013
• Est. Priority Date: 06/09/2006
• Status: Expired due to Fees

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Discenzo, Frederick M.
• Primary Examiner(s): JENNISON, BRIAN W
• Application Number:
  US11/423,167
• Time in Patent Office: 2,755 Days
• Field of Search: 340/521, 219/497, 702/127, 702/104, 702/187, 702/189, 702/22, 702/81
• US Class Current: 702/127
• CPC Class Codes: G01D 21/02 Measuring two or more variables by means not covered by a single other subclass
• CPC Class Codes: G06F 15/00 Digital computers in general details G06F1/00 – G06F13/00; Data processing equipment in general

Abstract

The claimed subject matter provides a system and/or method that facilitates providing real-time in situ measurements in an environment. A sensor module can employ real-time in situ measurements associated with a parameter within the environment. A sensor operation module communicatively coupled to the sensor module via an interface can analyze the real-time in situ measurements, wherein at least one of the sensor module and the sensor operation module allows expansion for at least one module.

Claims

1. A system, comprising:

an expandable sensor device, comprising;

a sensor operation module configured to analyze real-time in situ measurements;

a first sensor module configured to provide a first real-time in situ measurement associated with a first parameter within an environment, wherein the first sensor module is configured to be removably coupled to the sensor operation module via a first interface;

at least one additional sensor module configured to be removably coupled to at least one of the sensor operation module or the first sensor module via at least one additional interface, wherein the at least one additional sensor module is further configured to provide at least one additional real-time in situ measurement associated with at least one additional parameter within the environment; and

wherein the at least one additional sensor module includes a reservoir control module that includes a reservoir and is configured to take a sample associated with the environment that is to be measured, the sample is an operating fluid employed by a machine or a process, and the reservoir control module contains an amount of a replacement fluid, a reagent, a catalyst, a filter, or an additive configured to be administered to the operating fluid to extend an operation life of the machine or the process.

2. The system of claim 1, wherein at least one of the first parameter or at least one additional parameter is associated with at least one of a process, a food process, a factory, an application, a plant, a food product production, a product production, an industrial automation environment that produces a product, a process plant, a packaging and bottling facility, a commercial kitchen, an institution, a full service restaurant, a fast service restaurant, or an automated equipment that at least one of produces, alters, or packages a food product.

3. The system of claim 1, wherein at least one of the first parameter or at least one additional parameter is associated with at least one of an incoming raw material, a cooking oil, a wash water, a cooking water, a storage tank, a bioprocess, a microbial digestion system, a fermenting process, a beverage making, a blending, a gas control, a cooking, a food package, a food packaging line, a food ingredient dispenser, a food distribution, a food storage, a food transport, a waste stream, an up-stream food chemical/additive manufacturing, a grower, a picker, a food manufacturer, a restaurant, a home, a waste recovery operation, a hauler, a cafeteria, a consumable food, a beverage, a bio-fluid, a packaging, an animal food, a by-product of a food process, a food waste, a pharmaceutical, a bio-process, a medical process, a water supply, a water treatment, a waste water treatment, a food ingredient, an additive, or a food waste scrap.

4. The system of claim 1, wherein the sensor operation module includes a sensor operation component configured to provide a data manipulation based on analysis of the real-time in situ measurements.

5. The system of claim 4, wherein the sensor operation component is further configured to adjust an operational parameter associated with the machine or process based at least in part upon analysis of the real-time in situ measurements.

6. The system of claim 4, wherein the sensor operation component is further configured to control at least one of the process, an application, the first sensor module, or the at least one additional sensor module based on analysis of the real-time in situ measurements.

7. The system of claim 1, wherein at least one of the first sensor module or the at least one additional sensor module includes a multi-element sensor.

8. The system of claim 7, wherein the multi-element sensor includes at least one sensing element that is fabricated with a suite of at least one of a micro-electronic sensor element or a micro electro-mechanical element.

9. The system of claim 8, wherein the sensing element is configured to continuously detect at least one of the following in real-time:

a starch;

a moisture;

a density;

a bio-agent;

an oxidation;

a temperature;

a viscosity;

an acidity;

a dielectric;

polar material;

an amount of dissolved water;

a capacitance;

a pH;

an additive depletion;

a metal ion;

a density;

a sugar;

a salt;

an enzyme;

a gas;

a pressure;

a toxin;

a foreign material;

entrapped air;

a crystalline form, an ice crystal;

an contaminant;

a sugar amount;

a sugar type;

an additive presence;

an additive concentration;

a current;

a vibration;

an acoustic signal;

a voltage;

an electro-magnetic field;

an optical characterstic;

an odor;

a solid form material;

a powder;

an airborne component;

or an electro-chemical characteristic.

10. The system of claim 8, wherein the multi-element sensor includes at least one coating on the at least one sensor element that at least one of protects against harsh environments or materials, is less susceptible to contamination or fouling, provides selective sensing, provides component specific sensitivity, provides bio-selective sensing, or provides for controlled accelerated degradation.

11. The system of claim 1, wherein the at least one additional sensor module includes at least one of the following:

a display module;

a power module;

a memory module;

a communication module;

a processor module;

an additive/oil reservoir control module;

an additive/oil fluid reservoir module;

an electronics amplifier and digital processor module;

an IR module;

an NIR module;

a Raman module;

a tHz module;

a turbidity module;

an incubation module;

an incubation module with a controlled environment for at least one of temperature, pressure, reagents, or nutrients;

or a multi-element sensor module.

25. The system of claim 1, wherein the sensor operation module is further configured to instruct the reservoir control module to administer the amount of the replacement fluid, the reagent, the catalyst, the filter bed, or the additive to the operating fluid based at least in part upon analysis of the real-time in situ measurements.

26. The system of claim 1, wherein the sensor operation module is further configured to determine the amount of the replacement fluid, the reagent, the catalyst, the filter bed, or the additive based at least in part upon analysis of the real-time in situ measurements.

27. The system of claim 1, wherein the reservoir control module is further configured to determine an amount of the sample to take.

28. The system of claim 1, wherein the reservoir control module is further configured to determine when to discharge the sample from the reservoir.

29. The system of claim 1, wherein the first interface and the at least one additional interface form a backplane.

30. The system of claim 29, wherein the backplane is a fluid backplane configured to allow at least one fluid to flow between at least two of the sensor operation module, the first sensor module, or the at least one additional sensor module.

31. The system of claim 30, wherein the flow is bi-directional.

32. The system of claim 31, wherein the flow is in a single direction.

12. A system, comprising:

means for sensing that is expandable, comprising;

means for analyzing real-time in situ measurements;

means for providing a first real-time in situ measurement associated with a first parameter within an environment, wherein the means for providing a first real-time in situ measurement is configured to be removably coupled to the means for analyzing via a first means for interfacing;

at least one additional means for providing at least one additional real-time in situ measurement associated with at least one additional parameter within the environment, wherein the at least one additional means for providing at least one additional real-time in situ measurement is configured to be removably coupled to at least one of the means for providing a first real-time in situ measurement or the means for analyzing via at least one additional means for interfacing; and

wherein the at least one additional means for providing at least one additional real-time in situ measurement includes a means for controlling a reservoir that includes the reservoir and is configured to take a sample associated with the environment that is to be measured, the sample is an operating fluid employed by a machine or a process, and the means for controlling the reservoir contains an amount of a replacement fluid, a reagent, a catalyst, a filter, or an additive configured to be administered to the operating fluid to extend an operation life of the machine or the process.

13. The system of claim 12, wherein the means for analyzing is further configured to adjust an operational parameter associated with the machine or process based at least in part upon analysis of the real-time in situ measurements.

14. The system of claim 12, wherein at least one of means for providing a first real-time in situ measurement or the means for providing at least one additional real-time in situ measurement includes a means for sensing a plurality of parameters.

15. The system of claim 14, wherein the means for sensing a plurality of parameters comprises at least one of a micro-electronic sensor element or a micro electro-mechanical element.

16. The system of claim 14, wherein the means for sensing a plurality of parameters is configured to continuously detect at least one of the following in real-time:

a starch;

a moisture;

a density;

a bio-agent;

an oxidation;

a temperature;

a viscosity;

an acidity;

a dielectric;

polar material;

an amount of dissolved water;

a capacitance;

a pH;

an additive depletion;

a metal ion;

a density;

a sugar;

a salt;

an enzyme;

a gas;

a pressure;

a toxin;

a foreign material;

entrapped air;

a crystalline form, an ice crystal;

an contaminant;

a sugar amount;

a sugar type;

an additive presence;

an additive concentration;

a current;

a vibration;

an acoustic signal;

a voltage;

an electro-magnetic field;

an optical characteristic;

an odor;

a solid form material;

a powder;

an airborne component;

or an electro-chemical characteristic.

17. The system of claim 14, wherein the means for sensing a plurality of parameters includes at least one coating that at least one of protects against harsh environments or materials, is less susceptible to contamination or fouling, provides selective sensing, provides component specific sensitivity, provides bio-selective sensing, or provides for controlled accelerated degradation.

18. The system of claim 12, wherein the means for analyzing is further configured to instruct the means for controlling the reservoir to administer the amount of the replacement fluid, the reagent, the catalyst, the filter bed, or the additive to the operating fluid based at least in part upon analysis of the real-time in situ measurements.

19. The system of claim 12, wherein the means for analyzing is further configured to determine the amount of the replacement fluid, the reagent, the catalyst, the filter bed, or the additive based at least in part upon analysis of the real-time in situ measurements.

20. The system of claim 12, wherein the means for controlling the reservoir is further configured to determine an amount of the sample to take.

21. The system of claim 12, wherein the means for controlling the reservoir is further configured to determine when to discharge the sample from the reservoir.

22. The system of claim 12, wherein the first means for interfacing and the at least one additional means for interfacing form a backplane.

23. The system of claim 22, wherein the backplane is a fluid backplane configured to allow at least one fluid to flow between at least two of the means for analyzing, the means for providing a first real-time in situ measurement, or the means for providing at least one additional real-time in situ measurement.

24. The system of claim 23, wherein the flow is bi-directional.