US5907491A — Wireless machine monitoring and communication sys…

Claim 1

Independent Claim 191 words

A communication system for monitoring the status of a machine and communicating the machine's status through wireless signals, the system comprising: a plurality of machine monitors positioned to monitor operational characteristics of a machine, each machine monitor including: a receiver for receiving wireless signals, including command signals; at least one sensor for sensing a characteristic of the machine and generating a sensor signal corresponding to the machine characteristic that was sensed; a data processor for receiving and processing the sensor signals to produce status data and for storing status data; a transmitter for transmitting wireless status signals corresponding to the status of the machine as represented by status data; a protocol stored in said data processor; said data processor for communicating with and controlling said receiver, transmitter, and sensor and for selectively producing power-on and power-off signals for selectively powering said receiver, transmitter, and sensor signal in accordance with said protocol; an electrical power source and control circuitry responsive to said power-on and power-off signals to selectively power said receiver, transmitter and sensor; and a command station including a transceiver for transmitting wireless command signals and receiving said wireless status signals.

Claim 2

Dependent Claim 191 words

A communication system for monitoring the status of a machine and communicating the machine's status through wireless signals, the system comprising: a plurality of machine monitors positioned to monitor operational characteristics of a machine, each machine monitor including: a receiver for receiving wireless signals, including command signals; at least one sensor for sensing a characteristic of the machine and generating a sensor signal corresponding to the machine characteristic that was sensed; a data processor for receiving and processing the sensor signals to produce status data and for storing status data; a transmitter for transmitting wireless status signals corresponding to the status of the machine as represented by status data; a protocol stored in said data processor; said data processor for communicating with and controlling said receiver, transmitter, and sensor and for selectively producing power-on and power-off signals for selectively powering said receiver, transmitter, and sensor signal in accordance with said protocol; an electrical power source and control circuitry responsive to said power-on and power-off signals to selectively power said receiver, transmitter and sensor; and a command station including a transceiver for transmitting wireless command signals and receiving said wireless status signals.

Claim 3

Dependent Claim 34 words

The system of claim 1 wherein said protocol is a time-division communication protocol and said plurality of machine monitors are operable to transmit said wireless status signals in accordance with the time-division communication protocol.

Claim 4

Dependent Claim 49 words

The system of claim 2 wherein said command station is operable to transmit wireless command signals which include special request messages, said machine monitors being responsive to said special request messages to perform special functions additional to transmitting said wireless status signals in accordance with the time-division communication protocol.

Claim 5

Dependent Claim 15 words

The system of claim 3 wherein said special functions include special data sensing and transmission.

Claim 6

Dependent Claim 13 words

The system of claim 3 wherein said special functions include special data analysis.

Claim 7

Dependent Claim 13 words

The system of claim 3 wherein said special functions include special data storage.

Claim 8

Dependent Claim 13 words

The system of claim 3 wherein said special functions include special data transmission.

Claim 9

Dependent Claim 18 words

The system of claim 2 wherein said time-division communication protocol is programmed into a machine monitor before installation.

Claim 10

Dependent Claim 18 words

The system of claim 2 wherein said time-division communication protocol is programmed into a machine monitor during installation.

Claim 11

Dependent Claim 18 words

The system of claim 9, further comprising an installation control unit for programming the machine monitor during installation.

Claim 12

Dependent Claim 18 words

The system of claim 2 wherein said time-division communication protocol is programmed into a machine monitor after installation.

Claim 13

Dependent Claim 18 words

The system of claim 11, further comprising an installation control unit for programming the machine monitor after installation.

Claim 14

Dependent Claim 30 words

The system of claim 2 wherein each of said plurality of machine monitors includes a timer for selectively energizing and de-energizing the monitor in accordance with said time-division communication protocol.

Claim 15

Dependent Claim 50 words

The system of claim 13 wherein said command station includes a timer synchronized with machine monitor timers for controlling the transmission of command signals and the receipt of status signals in accordance with said time-division communication protocol, wherein the machine monitor and command station timers are operable to re-synchronize periodically.

Claim 16

Dependent Claim 35 words

The system of claim 1 wherein said protocol is a non-time division communication protocol and said wireless status signals are transmitted by said plurality of machine monitors in accordance with the non-time division communication protocol.

Claim 17

Dependent Claim 71 words

The system of claim 1 wherein said at least one sensor includes a vibration sensor for sensing vibrations generated by the machine and producing vibration sensor signals, said data processor being operable to receive the vibration sensor signals and produce frequency domain data corresponding to said vibration sensor signals, compare the frequency domain data to predetermined criteria, and determine an alarm condition when the frequency domain data meets the predetermined criteria.

Claim 18

Dependent Claim 30 words

The system of claim 16 wherein said data processor performs a Fourier transform on the sensor signals to produce the frequency domain data in the form of a frequency spectrum.

Claim 19

Dependent Claim 16 words

The system of claim 16 wherein said data processor stores at least the frequency domain data.

Claim 20

Dependent Claim 29 words

The system of claim 18 wherein stored frequency domain data is transmitted by a monitor in accordance with a non-time-division, asynchronous communication protocol when an alarm condition is present.

Claim 21

Dependent Claim 56 words

The system of claim 1 wherein said at least one sensor further includes a tachometer sensor positioned to sense machine revolutions and produce corresponding tachometer signals, said tachometer sensor including a transmitter for transmitting a wireless tachometer signal corresponding to sensed machine revolution information, at least one monitor being operable to receive the wireless tachometer signals.

Claim 22

Dependent Claim 33 words

The system of claim 20 wherein one or more of said plurality of machine monitors is operable to selectively energize and de-energize in accordance with machine revolution information contained in said tachometer signals.

Claim 23

Dependent Claim 18 words

The system of claim 20 wherein said tachometer signals correspond to whether the machine is on or off.

Claim 24

Dependent Claim 27 words

The system of claim 20 wherein said tachometer signals comprise a time series of electrical pulses where each pulse corresponds to the beginning of a machine revolution.

Claim 25

Dependent Claim 28 words

The system of claim 1, further comprising one or more repeaters for receiving and re-transmitting said wireless signals for receipt by another repeater, monitor, or the command station.

Claim 26

Dependent Claim 25 words

The system of claim 1, further comprising a computer network connected to said command station for transferring data and controlling wireless communication within the system.

Claim 27

Dependent Claim 60 words

The system of claim 1 wherein said transmitter includes a spread spectrum transmitter and said receiver includes a spread spectrum receiver, each said transmitter and receiver using spread spectrum communication techniques to avoid interference from other radio frequency emitters, said spread spectrum techniques including the use of a first PN code for communicating according to a first spectrum spreading sequence.

Claim 28

Dependent Claim 109 words

The system of claim 26, further comprising an installation control unit for configuring a machine monitor, said installation control unit comprising: a wireless installation control unit transmitter and receiver using spread spectrum communication techniques including the use of a second PN code that is different than said first PN code; an installation control unit data processor for controlling and causing the installation control unit transmitter to transmit configuration signals to said monitor for reprogramming of the monitor data processor and for processing wireless signals transmitted by the monitor; and a user interface for inputting user commands to the installation control unit data processor to control reprogramming of machine monitors.

Claim 29

Dependent Claim 181 words

A wireless machine monitoring system comprising: a plurality of machine monitors, each monitor having at least: a) one sensor for sensing a parameter of the machine and producing digital data corresponding thereto; b) a wireless monitor transmitter and receiver; and c) a monitor data processor for controlling the operation of the sensor, transmitter and receiver, for receiving and processing the digital data according to a first processing configuration, for communicating the digital data to the transmitter and causing the transmitter to produce transmission signals corresponding to the digital data; a command station having at least: a) a command station receiver and associated circuitry for producing received digital data; and b) a command station data processor for controlling and causing the receiver and associated circuitry to receive a transmission signal and produce received digital data corresponding to the transmission signal, said command station data processor being operable to store said received digital data; and means for reprogramming the monitor data processor to change the programmed processing configuration to reconfigure the machine monitor to process the data according to a second processing configuration.

Claim 30

Dependent Claim 181 words

A wireless machine monitoring system comprising: a plurality of machine monitors, each monitor having at least: a) one sensor for sensing a parameter of the machine and producing digital data corresponding thereto; b) a wireless monitor transmitter and receiver; and c) a monitor data processor for controlling the operation of the sensor, transmitter and receiver, for receiving and processing the digital data according to a first processing configuration, for communicating the digital data to the transmitter and causing the transmitter to produce transmission signals corresponding to the digital data; a command station having at least: a) a command station receiver and associated circuitry for producing received digital data; and b) a command station data processor for controlling and causing the receiver and associated circuitry to receive a transmission signal and produce received digital data corresponding to the transmission signal, said command station data processor being operable to store said received digital data; and means for reprogramming the monitor data processor to change the programmed processing configuration to reconfigure the machine monitor to process the data according to a second processing configuration.

Claim 31

Dependent Claim 77 words

The system of claim 28 wherein said means for reprogramming includes a hand-held configuration device comprising: a wireless configuration device transmitter and receiver; a configuration device data processor for controlling and causing the transmitter to transmit configuration signals to said monitor for reprogramming of the monitor data processor and for processing wireless signals transmitted by the monitor; and a user interface for inputting user commands to the configuration device data processor to control reprogramming of machine monitors.

Claim 32

Dependent Claim 38 words

The system of claim 29 wherein the transmitters and receivers of said plurality of machine monitors and said configuration device utilize spread spectrum communication techniques including the use of PN code sequencing to define a spectrum spreading sequence.

Claim 33

Dependent Claim 35 words

The system of claim 30 wherein the PN code used for communication between a monitor and the command station is different than the PN code used for communication between a monitor and the configuration device.

Claim 34

Dependent Claim 16 words

The system of claim 28 wherein said means for reprogramming is disposed in said command station.

Claim 35

Independent Claim 108 words

A method of determining and communicating the status of a machine, the method comprising the steps of: programming a plurality of machine monitors in accordance with a communication protocol; transmitting wireless command signals from a command station to said plurality of machine monitors in accordance with the communication protocol, said command station and machine monitors comprising a machine monitoring and communication system; sensing a characteristic of the machine being monitored in accordance with said command signals to produce sensor signals; processing the sensor signals to produce machine status data; and transmitting wireless status signals representing status data to the command station in accordance with the time-division communication protocol.

Claim 36

Independent Claim 108 words

A method of determining and communicating the status of a machine, the method comprising the steps of: programming a plurality of machine monitors in accordance with a communication protocol; transmitting wireless command signals from a command station to said plurality of machine monitors in accordance with the communication protocol, said command station and machine monitors comprising a machine monitoring and communication system; sensing a characteristic of the machine being monitored in accordance with said command signals to produce sensor signals; processing the sensor signals to produce machine status data; and transmitting wireless status signals representing status data to the command station in accordance with the time-division communication protocol.

Claim 37

Dependent Claim 41 words

The method of claim 33, further comprising the step of transmitting special request messages from the command station to a machine monitor to command the machine monitor to perform special functions additional to those provided in accordance with the communication protocol.

Claim 38

Dependent Claim 15 words

The method of claim 34 wherein said special functions include special data sensing and transmission.

Claim 39

Dependent Claim 13 words

The method of claim 34 wherein said special functions include special data analysis.

Claim 40

Dependent Claim 13 words

The method of claim 34 wherein said special functions include special data storage.

Claim 41

Dependent Claim 13 words

The method of claim 34 wherein said special functions include special data transmission.

Claim 42

Dependent Claim 14 words

The method of claim 33 wherein said communication protocol is a time-division communication protocol.

Claim 43

Dependent Claim 15 words

The method of claim 33 wherein said communication protocol is a non-time division communication protocol.

Claim 44

Dependent Claim 17 words

The method of claim 33 wherein a machine monitor is programmed with the communication protocol before installation.

Claim 45

Dependent Claim 17 words

The method of claim 33 wherein a machine monitor is programmed with the communication protocol during installation.

Claim 46

Dependent Claim 17 words

The method of claim 33 wherein a machine monitor is programmed with the communication protocol after installation.

Claim 47

Dependent Claim 27 words

The method of claim 33, further comprising the step of propagating wireless command and status signals with a repeater positioned intermediate a monitor and the command station.

Claim 48

Dependent Claim 50 words

The method of claim 33 wherein said processing step includes the steps of: producing frequency domain data from said sensor signals; comparing the frequency domain data to predetermined criteria; and determining an alarm condition that is transmitted with the status signals when the frequency domain data meets the predetermined criteria.

Claim 49

Dependent Claim 36 words

The method of claim 45, further comprising the steps of: storing frequency domain data over time; and transmitting stored frequency domain data in accordance with a non-time-division, asynchronous communication protocol when an alarm condition is present.

Claim 50

Dependent Claim 22 words

The method of claim 46, further comprising the step of analyzing frequency domain data to determine the cause of the alarm condition.

Claim 51

Dependent Claim 56 words

The method of claim 33 wherein each of said plurality of machine monitors power up to receive wireless command signals, sense machine characteristics, and transmit wireless status signals only during designated periods of time as defined by a time-division communication protocol, wherein each designated period of time comprises a time slice within the time-division communication protocol.

Claim 52

Dependent Claim 22 words

The method of claim 48, further comprising the step of modifying the time-division communication protocol to accommodate changes to the communication system.

Claim 53

Dependent Claim 16 words

The method of claim 49 wherein said modifying step includes adding one or more time slices.

Claim 54

Dependent Claim 16 words

The method of claim 49 wherein said modifying step includes deleting one or more time slices.

Claim 55

Dependent Claim 14 words

The method of claim 49 wherein said modifying step includes rearranging existing time slices.

Claim 56

Dependent Claim 12 words

The method of claim 33 wherein said characteristic being sensed is vibration.

Claim 57

Dependent Claim 12 words

The method of claim 33 wherein said characteristic being sensed is speed.

Claim 58

Independent Claim 140 words

A method of periodically polling a plurality of machine monitors for machine status data in accordance with an established communication protocol, said method comprising the steps of: defining a time-division schedule of events to occur during a periodic polling sequence, said events including: transmitting wireless command signals from a command station to other communication devices including machine monitors; receiving wireless command signals by said machine monitors; sensing one or more characteristics of the machine to produce sensor signals; processing said sensor signals to produce machine status signals; and transmitting wireless status signals to the command station; assigning each communication device a time slice within the time-division schedule during which the device powers up to receive and execute commands communicated by the command signals; and polling machine monitors in accordance with said time-division schedule to determine the status of the machine.

Claim 59

Independent Claim 140 words

A method of periodically polling a plurality of machine monitors for machine status data in accordance with an established communication protocol, said method comprising the steps of: defining a time-division schedule of events to occur during a periodic polling sequence, said events including: transmitting wireless command signals from a command station to other communication devices including machine monitors; receiving wireless command signals by said machine monitors; sensing one or more characteristics of the machine to produce sensor signals; processing said sensor signals to produce machine status signals; and transmitting wireless status signals to the command station; assigning each communication device a time slice within the time-division schedule during which the device powers up to receive and execute commands communicated by the command signals; and polling machine monitors in accordance with said time-division schedule to determine the status of the machine.

Claim 60

Dependent Claim 42 words

The method of claim 55, further comprising the steps of determining when a particular machine monitor does not communicate with the command station in accordance with the time-division schedule, and executing a communication procedure for re-establishing communication with the particular machine monitor.

Claim 61

Dependent Claim 30 words

The method of claim 56 wherein said executing step includes the step of periodically powering up the particular machine monitor for increasingly longer time periods to listen for polling commands.

Claim 62

Dependent Claim 187 words

The method of claim 56 wherein said executing step includes: continuing to periodically poll machine monitors in accordance with the time-division schedule during a first predetermined time period; if communication with the particular machine monitor is not re-established within the first predetermined time period, selecting one or more repeaters to relay a command requesting the particular machine monitor to perform a transmission strength scan at a first designated time; listening during a second predetermined time period for signals transmitted by the particular machine monitor during the commanded transmission strength scan; processing transmission strength scan signals received by the selected repeaters to determine a most favorable repeater and transmission strength scan; commanding the particular machine monitor to perform a transmission scan at the most favorable transmission strength at a second designated time that is later than the first designated time; acknowledging proper receipt of the particular machine monitor's transmission scan by assigning the particular machine monitor a temporary time slice within the time-division schedule; and reconfiguring the time-division schedule to assign the particular machine monitor a permanent time slice once synchronization with the most favorable repeater is established.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2002-05-24	2002-11-23	2003-05-25	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2006-05-24	2006-11-23	2007-05-25	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2010-05-24	2010-11-23	2011-05-25	$7700.00	Window Closed / Lapsed

Wireless machine monitoring and communication system

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