Diagnostic and control system for dust collector

Claim 2

An integrated system for controlling operation of a dust collector and for detecting cleaning failures within the dust collector, comprising: a) receive means for receiving a plurality of signals representing a plurality of measured parameters of the dust collector; b) processing means for monitoring and controlling operation of the dust collector, comprising: i) monitoring means for processing the signals representing the measured parameters in order to determine operating conditions and cleaning failures of the dust collector; and ii) control means for generating control signals in response to the operating conditions in order to maintain the operation of the dust collector and for generating diagnostic signals in response to the cleaning failures; and c) output means for transmitting the control signals to the dust collector, and for transmitting the diagnostic signals to an output device in order to provide an indication of the cleaning failures.

Claim 3

The system of claim 1 further comprising display means for providing a visual indication of the measured parameters.

Claim 4

The system of claim 2 wherein: a) the receive means comprises means for receiving a signal representing a temperature within the dust collector; and b) the display means comprises means for providing a visual indication of the temperature.

Claim 5

The system of claim 3 wherein: a) the processing means comprises means for determining if the temperature is greater than a predefined temperature value; and b) the display means comprises means for providing a visual indication of a temperature condition if the temperature is greater than the predefined temperature value.

Claim 6

The system of claim 2 wherein: a) the processing means comprises means for determining a service interval; and b) the display means comprises means for providing a visual indication of the service interval.

Claim 7

The system of claim 2 wherein: a) the processing means comprises means for determining if current to a fan in the dust collector is greater than a predefined current value; and b) the display means comprises means for providing a visual indication of a fan overcurrent condition if the fan current is greater than the predefined current value.

Claim 8

The system of claim 2 wherein: a) the processing means comprises means for determining if a user-defined fault has occurred within the dust collector; and b) the display means comprises means for providing a visual indication of the user-defined fault.

Claim 9

The system of claim 2 wherein: a) the receive means comprise means for receiving current signals representing currents supplied to a motor operating a fan for the dust collector; a) the processing means comprises means for processing the current signals in order to determine a direction of rotation of a fan for the dust collector; and b) the display means comprises means for providing a visual indication of the fan rotation direction.

Claim 10

The system of claim 2 wherein: a) the receive means comprises means for receiving a signal representing a current supplied to a motor which powers a source of air flow within the dust collector; b) the processing means comprises: i) means for measuring the monitored motor current to obtain a corresponding current value; and ii) means for associating the sampled current value with a corresponding air flow rate; and c) the display means comprises means for outputting an indication of the air flow rate.

Claim 11

The system of claim 1, further comprising storage means for storing the plurality of signals for subsequent analysis.

Claim 12

The system of claim 1, further comprising: a) means for coupling a plurality of the systems one each to a plurality of dust collectors; b) means for coupling together the plurality of systems and corresponding dust collectors in a daisy chain configuration; and b) means for interfacing the daisy chain configured systems and dust collectors to a computer for selectively monitoring and controlling the plurality of dust collectors using the computer.

Claim 13

The system of claim 1 wherein: a) the receive means comprises: i) means for receiving a first signal representing an air pressure in a manifold of the dust collector; ii) means for receiving a second signal representing an attempt to clean one or more filters in the dust collector with a reverse burst of air pressure delivered from the manifold; and iii) means for receiving a third signal representing the manifold air pressure during the cleaning; and b) the processing means comprises means for processing the first, second, and third signals and for indicating a cleaning failure if a decrease in the manifold air pressure does not occur during the cleaning.

Claim 14

The system of claim 12 wherein the processing means further comprises means for determining which element of a cleaning system, including the manifold, in the dust collector resulted in the cleaning failure.

Claim 15

The system of claim 1 wherein: a) the receive means comprises: i) means for receiving a first signal representing a clean air chamber pressure or a differential air pressure between a dirty air chamber and a clean air chamber in the dust-collector; ii) means for receiving a second signal representing an attempt to clean one or more filters in the dust collector with a reverse burst of air pressure delivered from a manifold; and iii) means for receiving a third signal representing the differential air pressure or the clean air chamber pressure during the cleaning; and b) the processing means comprises means for processing the first, second, and third signals and for indicating a cleaning failure if an increase in the differential air pressure or the clean air chamber pressure does not occur during the cleaning.

Claim 16

The system of claim 14 wherein the processing means further comprises means for determining which element of a cleaning system, including the manifold, resulted in the cleaning failure.

Claim 17

The system of claim 1 wherein: a) the receive means comprises: i) means for receiving a first signal representing a differential air pressure between a dirty air chamber and a clean air chamber in the dust collector; and ii) means for receiving a second signal representing a decrease in the differential air pressure; and b) the processing means comprises means for processing the first and second signals and for indicating a filter rupture if the decrease in the differential air pressure occurs at a rate greater than a predefined rate during normal operation.

Claim 18

The system of claim 1 wherein: a) the receive means comprises: i) means for receiving a first signal representing a differential air pressure between a dirty air chamber and a clean air chamber in the dust collector; and ii) means for receiving a second signal representing a decrease in the differential air pressure; and b) the processing means comprises means for processing the first and second signals and for indicating a filter rupture if the decrease in the differential air pressure occurs at a rate within predefined limits during normal operation.

Claim 19

The system of claim 1 wherein: a) the receive means comprises: i) means for receiving a first signal representing a differential air pressure between a dirty air chamber and a clean air chamber in the dust collector; and ii) means for receiving a second signal representing an initiation of a cleaning process comprising a series of pulses of a reverse burst of air pressure delivered from a manifold in the dust collector; and b) the processing means comprises means for processing the first and second signals and for indicating a degree of filter obstruction based on a change in the differential air pressure during the cleaning process.

Claim 20

The system of claim 18 wherein the processing means comprises means for indicating an obstructed filter if the differential pressure does not decrease to a value within predefined limits during the cleaning process.

Claim 21

The system of claim 18 wherein the processing means comprises means for indicating an obstructed filter if the differential pressure does not decrease to a value less than a predefined pressure value during the cleaning process.

Claim 22

The system of claim 18 wherein the processing means comprises means for indicating an obstructed filter if the differential pressure increases to a value greater than a predefined pressure value during the cleaning process.

Claim 23

An integrated system for monitoring, controlling, and programming operation of a dust collector, comprising: a) receive means for receiving signals used in monitoring and programming the operation of the dust collector, comprising: i) means for receiving a plurality of signals representing a plurality of measured parameters of the dust collector; and ii) means for receiving one or more programming signals representing desired operating parameters of the dust collector; b) processing means for monitoring and programming the operation of the dust collector, comprising: i) monitoring means for processing the signals representing the plurality of measured parameters in order to determine operating conditions of the dust collector; and ii) control means for generating control signals in response to the operating conditions and the programming signals in order to maintain the operation of the dust collector; and c) output means for transmitting the control signals to the dust collector.

Claim 24

An integrated system for monitoring, controlling, and programming operation of a dust collector, comprising: a) receive means for receiving signals used in monitoring and programming the operation of the dust collector, comprising: i) means for receiving a plurality of signals representing a plurality of measured parameters of the dust collector; and ii) means for receiving one or more programming signals representing desired operating parameters of the dust collector; b) processing means for monitoring and programming the operation of the dust collector, comprising: i) monitoring means for processing the signals representing the plurality of measured parameters in order to determine operating conditions of the dust collector; and ii) control means for generating control signals in response to the operating conditions and the programming signals in order to maintain the operation of the dust collector; and c) output means for transmitting the control signals to the dust collector.

Claim 25

The system of claim 22 wherein the means for receiving one or more programming signals comprises means for receiving signals representing set points and maintenance conditions for the operation of the dust collector.

Claim 26

The system of claim 22, further comprising display means for providing a visual indication of the measured parameters.

Claim 27

The system of claim 24 wherein the measured parameters include a temperature parameter the display means comprises means for providing a visual indication of the temperature parameter.

Claim 28

The system of claim 25 wherein: a) the processing means comprises means for determining if the temperature parameter is greater than a predefined temperature value; and b) the display means comprises means for providing a visual indication of a temperature condition if the temperature parameter is greater than the predefined temperature value.

Claim 29

The system of claim 24 wherein: a) the processing means comprises means for determining a service interval; and b) the display means comprises means for providing a visual indication of the service interval.

Claim 30

The system of claim 24 wherein: a) the processing means comprises means for determining if current to a fan in the dust collector is greater than a predefined current value; and b) the display means comprises means for providing a visual indication of a fan overcurrent condition if the fan current is greater than the predefined current value.

Claim 31

The system of claim 24 wherein: a) the processing means comprises means for determining if a user-defined fault has occurred within the dust collector; and b) the display means comprises means for providing a visual indication of the user-defined fault.

Claim 32

The system of claim 24 wherein: a) the processing means comprises means for processing the current parameters in order to determine a direction of rotation of a fan for the dust collector; and b) the display means comprises means for providing a visual indication of the fan rotation direction.

Claim 33

The system of claim 24 wherein: a) the receive means comprises means for receiving a signal representing a current supplied to a motor which powers a source of air flow within the dust collector; b) the processing means comprises: i) means for measuring the monitored motor current to obtain a corresponding current value; and ii) means for associating the sampled current value with a corresponding air flow rate; and c) the display means comprises means for outputting an indication of the air flow rate.

Claim 34

The system of claim 22, further comprising storage means for storing the signals representing the plurality of measured parameters for subsequent analysis.

Claim 35

The system of claim 22, further comprising: a) means for coupling a plurality of the systems one each to a plurality of dust collectors; b) means for coupling together the plurality of systems and corresponding dust collectors in a daisy chain configuration; and b) means for interfacing the daisy chain configured systems and dust collectors to a computer for selectively monitoring and controlling the plurality of dust collectors using the computer.

Claim 36

The system of claim 22 wherein: a) the receive means comprises: i) means for receiving a first signal representing an air pressure in a manifold of the dust collector; ii) means for receiving a second signal representing an attempt to clean one or more filters in the dust collector with a reverse burst of air pressure delivered from the manifold; and iii) means for receiving a third signal representing the manifold air pressure during the cleaning; and b) the processing means comprises means for processing the first, second, and third signals and for indicating a cleaning failure if a decrease in the manifold air pressure does not occur during the cleaning.

Claim 37

The system of claim 34 wherein the processing means further comprises means for determining which element of a cleaning system, including the manifold, resulted in the cleaning failure.

Claim 38

The system of claim 22 wherein: a) the receive means comprises: i) means for receiving a first signal representing a clean air chamber pressure or a differential air pressure between a dirty air chamber and a clean air chamber in the dust collector; ii) means for receiving a second signal representing an attempt to clean one or more filters in the dust collector with a reverse burst of air pressure delivered from a manifold; and iii) means for receiving a third signal representing the differential air pressure or the clean air chamber pressure during the cleaning; and b) the processing means comprises means for processing the first, second, and third signals and for indicating a cleaning failure if an increase in the differential air pressure or the clean air chamber pressure does not occur during the cleaning.

Claim 39

The system of claim 36 wherein the processing means further comprises means for determining which element of a cleaning system, including the manifold, resulted in the cleaning failure.

Claim 40

The system of claim 22 wherein: a) the receive means comprises: i) means for receiving a first signal representing a differential air pressure between a dirty air chamber and a clean air chamber in the dust collector; and ii) means for receiving a second signal representing a decrease in the differential air pressure; and b) the processing means comprises means for processing the first and second signals and for indicating a filter rupture if the decrease in the differential air pressure occurs at a rate greater than a predefined rate during normal operation.

Claim 41

The system of claim 22 wherein: a) the receive means comprises: i) means for receiving a first signal representing a differential air pressure between a dirty air chamber and a clean air chamber in the dust collector; and ii) means for receiving a second signal representing a decrease in the differential air pressure; and b) the processing means comprises means for processing the first and second signals and for indicating a filter rupture if the decrease in the differential air pressure occurs at a rate within predefined limits during normal operation.

Claim 42

The system of claim 22 wherein: a) the receive means comprises: i) means for receiving a first signal representing a differential air pressure between a dirty air chamber and a clean air chamber in the dust collector; and ii) means for receiving a second signal representing an initiation of a cleaning process comprising a series of pulses of a reverse burst of air pressure delivered from a manifold in the dust collector; and b) the processing means comprises means for processing the first and second signals and for indicating a degree of filter obstruction based on a change in the differential air pressure during the cleaning process.

Claim 43

The system of claim 40 wherein the processing means comprises means for indicating an obstructed filter if the differential pressure does not decrease to a value within predefined limits during the cleaning process.

Claim 44

The system of claim 40 wherein the processing means comprises means for indicating an obstructed filter if the differential pressure does not decrease to a value less than a predefined pressure value during the cleaning process.

Claim 45

The system of claim 40 wherein the processing means comprises means for indicating an obstructed filter if the differential pressure increases to a value greater than a predefined pressure value during the cleaning process.