DEVICES, SYSTEMS AND METHODS FOR DETERMINING CONCENTRATIONS OF OXYGEN AND CARBON DIOXIDE FROM COMBUSTION SOURCES
20210215729 ยท 2021-07-15
Inventors
Cpc classification
F01N2560/025
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N2560/022
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T10/40
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F02D41/1438
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
G01N2035/00702
PHYSICS
F01N11/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
A portable oxygen and carbon dioxide analyzer device includes a lightweight housing with physical dimensions rendering the analyzer device portable. The analyzer device meets Environmental Protection Agency (EPA) and International Organization for Standardization (ISO) criteria for linearity, repeatability, and response time. The analyzer device can be used for emissions testing without the need of a temperature controlled environment. The analyzer device is meant to be used at the testing location which can be hundreds of feet (meters) above ground level. The analyzer device is light weight and physically small to facilitate transportation to the testing location. The analyzer device uses an algorithm programed into its digital controller to compensate for ambient temperature and pressure fluctuations during the testing procedure. The analyzer device has analog and digital outputs and internal data logging capabilities to facilitate calibration and monitoring of flue gas component concentrations.
Claims
1. An apparatus for determining concentrations of oxygen and carbon dioxide from combustion sources comprising: a housing that is sized for portability; an analog voltage output; a microprocessor; an oxygen sensor in electrical communication with the microprocessor; a carbon dioxide sensor in electrical communication with the microprocessor; a plurality of fittings for connecting tubing to the housing; and an A/C power source.
2. The apparatus of claim 1, wherein the housing is compact and weighs less than one kilogram.
3. The apparatus of claim 1, wherein the plurality of fittings comprises an inlet fitting and an outlet fitting.
4. The apparatus of claim 1, wherein the apparatus comprises a sensor block comprising a plurality of openings, wherein a first of the plurality of openings houses and secures the oxygen sensor and a second of the plurality of openings houses and secures the carbon dioxide sensor.
5. The apparatus of claim 4, wherein the sensor block is made of ABS plastic and is located inside the housing.
6. The apparatus of claim 1, wherein the microprocessor receives a one or more digital outputs from the oxygen sensor and the carbon dioxide sensor, which are then provided as inputs to a correction algorithm.
7. The apparatus of claim 6, wherein the correction algorithm uses calibration gases comprising oxygen and carbon dioxide to calculate span values for use in creating correction values; or the correction algorithm uses nitrogen or a gas mixture that does not contain oxygen or carbon dioxide to determine a zero value.
8. The apparatus of claim 7, wherein the correction algorithm creates one or more correction values that are offset from a known temperature by measuring the temperature of the combustion gases when values of the calibration gases are measured, and if the temperature drifts during measurement of the combustion gases the algorithm corrects the drift in temperature.
9. The apparatus of claim 6, wherein the correction algorithm creates one or more correction values that are offset from a known pressure by measuring the pressure of the combustion gases when values of the calibration gases are measured, and if the pressure drifts during measurement of the combustion gases the algorithm corrects the drift in pressure.
10. The apparatus of claim 1, further comprising a real time clock (RTC) employed by the microcontroller and powered by a battery to maintain current date and time values when the device is powered down.
11. The apparatus of claim 1, wherein the microcontroller has a non-volatile memory to which data can be written for permanent storage.
12. The apparatus of claim 11, wherein the non-volatile memory is a Secure Digital (SD) card.
13. A method for determining concentrations of oxygen and carbon dioxide from combustion sources comprising: measuring oxygen and carbon dioxide concentrations using a device comprising: a housing that is sized for portability; an analog voltage output; a microprocessor; an oxygen sensor in electrical communication with the microprocessor; a carbon dioxide sensor in electrical communication with the microprocessor; a plurality of fittings for connecting tubing to the housing; and an A/C power source; converting digital readings from the microcontroller to proportional analog voltage outputs; transforming alternating current line voltage from internal or external power sources to low direct current voltage to provide power for the microcontroller and a buffer; processing oxygen and carbon dioxide readings using the microcontroller programmed with one or more calibration algorithms; applying correction factors to oxygen and carbon dioxide readings; communicating corrected oxygen and carbon dioxide readings to a display or analog output; displaying oxygen and carbon dioxide readings on a display; and buffering voltage and/or current outputs.
14. The method of claim 13, wherein the method further comprises recording voltage and/or current outputs using a chart recorder and/or external data logger.
15. The method of claim 13, wherein the method further comprises maintaining current date and time values when powered down.
16. A method for determining concentrations of oxygen and carbon dioxide from combustion sources comprising: analyzing gas entering an inlet fitting in a device comprising: a housing that is sized for portability; an analog voltage output; a microprocessor; an oxygen sensor in electrical communication with the microprocessor; a carbon dioxide sensor in electrical communication with the microprocessor; a plurality of fittings for connecting tubing to the housing; and an A/C power source; analyzing gas that has been channeled to the oxygen sensor; analyzing gas that has been channeled to the carbon dioxide sensor; digitally transmitting oxygen and carbon dioxide concentrations to the microcontroller; correcting digitally transmitted concentrations, via the microcontroller, using measurements of known calibration gas values and changes in temperature and pressure; producing a voltage that is linearly proportional to the corrected oxygen or carbon dioxide concentration utilizing an analog output pin designated for oxygen or carbon dioxide measurement on the microcontroller; and discharging gas through an outlet following analysis.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Non-limiting and non-exhaustive implementations of the disclosure are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. Advantages of the disclosure will become better understood with regard to the following description and accompanying drawings where:
[0015]
[0016]
[0017]
[0018]
DETAILED DESCRIPTION
[0019]
[0020]
[0021]
[0022] Five volt DC power may be conducted from the SRP connector 303 through the main circuit board 302 to the microcontroller 304. The microcontroller 304 is connected to the main circuit board 302 through two 24 pin SRP connectors, which are not shown for clarity. The microcontroller 304 that may be used is a commercially available Teensy 3.5 microcontroller, which, among other onboard components, has 62 general purpose input/output (I/O) pins and solder points, not shown for clarity, of which two may be 12 bit digital to analog capable; many other single purpose I/O pins and solder points, not shown for clarity; a USB port 305; power regulator 306; ARM Cortex-M4 processor 307; and a micro SD card port 308. A micro SD card in the micro SD Card Port 308 is used to store data for internal data logging. The microcontroller 304 uses 3.3 volt logic, which is supplied by the power regulator 306. Several of the special purpose outputs, not shown, provide 3.3 volt output for use by external components and one of these outputs is used to feed 3.3 volt power back into the main circuit board 302. Other microcontrollers, which meet the needs of the analyzer device are within the scope of this disclosure. Incorporating the one or more of the needed components of the microcontroller 304 into the main circuit board 302 is within the scope of this disclosure.
[0023] The SRP connector 309 is used to connect the oxygen sensor 310 and carbon dioxide sensor 311 to the microcontroller 304 via the main circuit board 302. One of the pins on the SRP connector 309 is supplied 5 volts from the SRP connector 303, another pin 3.3 volts from the power regulator 306, two pins on the SRP connector 309 are grounds, and four of the pins on the SRP connector 309 are data transmission pins and connected to four of the general purpose I/O pins on the microcontroller 304.
[0024] The oxygen sensor 310 used in the analyzer device is a commercially available LuminOx Optical Oxygen Sensor. The oxygen sensor 310 has onboard sensors for measuring the pressure and temperature of the gas stream. The oxygen sensor 310 is powered by b 5 volts DC and uses Universal Asynchronous Receiver-Transmitter (UART) communications hardware to communicate the measured oxygen concentration, pressure, and temperature digitally to the microcontroller 304. Wire jumpers, not shown for clarity, are used to conduct power and transmit data between the oxygen sensor 310 and the SRP connector 309. The oxygen sensor 310 is a non-destructive type sensor meaning that it does not change any gas species during the measurement process. Oxygen sensors other than the oxygen sensor 310 chosen for use in the analyzer device and other pressure and temperature measurement schemes are within the scope of this disclosure.
[0025] The carbon dioxide sensor 311 that may be used in the analyzer device is a commercially available ExplorIR-M Carbon Dioxide Sensor. The carbon dioxide sensor 311 is powered by 3.3 volts DC and uses UART hardware to communicate the measured carbon dioxide concentration digitally to the microcontroller 304. Wire jumpers, not shown for clarity, are used to conduct power and transmit data between the carbon dioxide sensor 311 and the SRP connector 309. The carbon dioxide sensor 311 is also a non-destructive type sensor. Carbon dioxide sensors other than the carbon dioxide sensor 311 chosen for use in the analyzer device are within the scope of this disclosure.
[0026] The oxygen sensor 310 and carbon dioxide sensor 311 are held in a leak tight sensor block, such as sensor block 400 shown in
[0027] The analog output buffer 314 incorporated in the analyzer device has two functions: first it prevents shorted analog outputs from overloading the microcontroller 304 and causing permanent damage; second it amplifies the analog outputs so that a 10 volt full scale output for both the oxygen and carbon dioxide readings can be given. One volt and 10 volt full scale analog outputs are common on many analyzers and users are usually set up for one or the other so this analyzer device was made to produce both of these full scale outputs for both the oxygen and carbon dioxide measurements.
[0028] The main component of the analog output buffer 314 may be an LM2902N Quad Operational Amplifier 315, which is four Operational Amplifiers (OpAmps) on one chip. The LM2902N Quad Operational Amplifier 315 is powered by 12 volts DC supplied from the SRP connector 303. To simplify the explanation of the function of the analog output buffer 314 the discussion will be limited to the treatment of the oxygen measurement; the carbon dioxide measurement is treated identically.
[0029] First the oxygen concentration is determined by the oxygen sensor 310 and digitally transmitted to the microcontroller 304. The microcontroller 304 corrects the received concentration based on measurements of known calibration gas values and changes in temperature and pressure since the calibration gasses were initially analyzed. The analog output pin designated for the oxygen measurement on the microcontroller 304 is made to produce a voltage which is linearly proportional to the corrected oxygen concentration where a zero oxygen concentration is represented with a zero volt output and a full scale (25%) oxygen concentration is represented with a 3.3 volt output. A voltage divider circuit, i.e. two resistors in series, not shown, is used to divide the produced voltage down to a full-scale divided voltage of 1 volt. A variable resistor 316 is used to adjust the divided voltage to exactly the desired value. The divided voltage is introduced to the input on one of the OpAmps on the LM2902N Quad Operational Amplifier 315, which is wired as a unity gain follower. The output of this OpAmp is supplied to one of the pins on the SRP connector 317 and to the input of a second OpAmp on the LM2902N Quad Operational Amplifier 315. The second OpAmp is wired for a gain of 10 with a variable resistor 316 used to adjust the gain to exactly the desired value. The output of the second OpAmp is conducted to a second pin on the SRP connecter 317. Jumpers, not shown for clarity, conduct the analog voltages from the SRP connector 317 to the electrical terminal block 206. While this scheme produces 1 and 10 volt full scale analog outputs other schemes could be used to produce these or other voltage or current outputs and are within the scope of this disclosure.
[0030] The real time clock 318 is used to keep track of the date and time when the analyzer device is powered down; date and time stamps are used for internal data logging purposes. The SRP connector 319 is used to supply power and data to the display 101. The SRP connector 320 is used to connect the potentiometers 102. The outputs of the potentiometers 102 are fed back to the main circuit board 302 from pins on the SRP connector 320. The SRP connector 321 is used to connect the user interface buttons 103 to the main circuit board 302.
[0031]
[0032]
[0033] The inlet port 402, as illustrated in
[0034] The screw holes 401 on the top face of the sensor block 400 are also sized to take the same brass inserts as the screw holes 401 on the rear face of the sensor block 400, the screw holes 401 are shown in
[0035] Although the device is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail such that the disclosure will be thorough and complete, and will fully convey the scope of the claimed device to those skilled in the art. However, it should be understood, that the disclosure is not to limit the device to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the device as defined by the appended claims.
EXAMPLES
[0036] The following are examples of various embodiments of the disclosure.
[0037] Example 1 is an apparatus for determining concentrations of oxygen and carbon dioxide from combustion sources. The apparatus includes a housing that is sized for portability; an analog voltage output; a microprocessor; an oxygen sensor in electrical communication with the microprocessor; a carbon dioxide sensor in electrical communication with the microprocessor; a plurality of fittings for connecting tubing to the housing; and an A/C power source.
[0038] Example 2 includes the apparatus of for determining concentrations of oxygen and carbon dioxide from Example 1, wherein the housing is compact and weighs less than one kilogram.
[0039] Example 3 includes the apparatus of for determining concentrations of oxygen and carbon dioxide from any of Examples 1-2, wherein the plurality of fittings comprises an inlet fitting and an outlet fitting.
[0040] Example 4 includes the apparatus of for determining concentrations of oxygen and carbon dioxide from any of Examples 1-3, wherein the apparatus comprises a sensor block comprising a plurality of openings, wherein a first of the plurality of openings houses and secures the oxygen sensor and a second of the plurality of openings houses and secures the carbon dioxide sensor.
[0041] Example 5 includes the apparatus of for determining concentrations of oxygen and carbon dioxide from any of Examples 1-4, wherein the sensor block is made of ABS plastic and is located inside the housing.
[0042] Example 6 includes the apparatus of for determining concentrations of oxygen and carbon dioxide from any of Examples 1-5, wherein the microprocessor receives a one or more digital outputs from the oxygen sensor and the carbon dioxide sensor, which are then provided as inputs to a correction algorithm.
[0043] Example 7 includes the apparatus of for determining concentrations of oxygen and carbon dioxide from any of Examples 1-6, wherein the correction algorithm uses calibration gases comprising oxygen and carbon dioxide to calculate span values for use in creating correction values; or the correction algorithm uses nitrogen or a gas mixture that does not contain oxygen or carbon dioxide to determine a zero value.
[0044] Example 8 includes the apparatus of for determining concentrations of oxygen and carbon dioxide from any of Examples 1-7, wherein the correction algorithm is programmed using a programming language ARDUINO IDE.
[0045] Example 9 includes the apparatus of for determining concentrations of oxygen and carbon dioxide from any of Examples 1-8, wherein the correction algorithm creates one or more correction values that are offset from a known temperature by measuring the temperature of the combustion gases when values of the calibration gases are measured, and if the temperature drifts during measurement of the combustion gases the algorithm corrects the drift in temperature.
[0046] Example 10 includes the apparatus of for determining concentrations of oxygen and carbon dioxide from any of Examples 1-9, wherein the correction algorithm creates one or more correction values that are offset from a known pressure by measuring the pressure of the combustion gases when values of the calibration gases are measured, and if the pressure drifts during measurement of the combustion gases the algorithm corrects the drift in pressure.
[0047] Example 11 includes the apparatus of for determining concentrations of oxygen and carbon dioxide from any of Examples 1-10, wherein the apparatus further comprises a real time clock (RTC) employed by the microcontroller and powered by a battery to maintain current date and time values when the device is powered down.
[0048] Example 12 includes the apparatus of for determining concentrations of oxygen and carbon dioxide from any of Examples 1-11, wherein the microcontroller has a non-volatile memory to which data can be written for permanent storage.
[0049] Example 13 includes the apparatus of for determining concentrations of oxygen and carbon dioxide from any of Examples 1-12, wherein the non-volatile memory is a Secure Digital (SD) card.
[0050] Example 14 is a method for determining concentrations of oxygen and carbon dioxide from combustion sources. The method includes measuring oxygen and carbon dioxide concentrations using a device comprising a housing that is sized for portability; an analog voltage output; a microprocessor; an oxygen sensor in electrical communication with the microprocessor; a carbon dioxide sensor in electrical communication with the microprocessor; a plurality of fittings for connecting tubing to the housing; and an A/C power source. The method further includes converting digital readings from the microcontroller to proportional analog voltage outputs. The method further includes transforming alternating current line voltage from internal or external power sources to low direct current voltage to provide power for the microcontroller and a buffer. The method further includes processing oxygen and carbon dioxide readings using the microcontroller programmed with one or more calibration algorithms. The method further includes applying correction factors to oxygen and carbon dioxide readings. The method further includes communicating corrected oxygen and carbon dioxide readings to a display or one or more analog outputs. The method further includes displaying oxygen and carbon dioxide readings on a display; and buffering voltage and/or current outputs.
[0051] Example 15 includes the method for determining concentrations of oxygen and carbon dioxide from combustion sources of Example 14, wherein the method further comprises recording voltage and/or current outputs using a chart recorder and/or external data logger.
[0052] Example 16 includes the method for determining concentrations of oxygen and carbon dioxide from combustion sources of any of Examples 14-15, wherein the method further comprises maintaining current date and time values when powered down.
[0053] Example 17 is a method for determining concentrations of oxygen and carbon dioxide from combustion sources. The method includes analyzing gas entering an inlet fitting in a device comprising: a housing that is sized for portability; an analog voltage output; a microprocessor; an oxygen sensor in electrical communication with the microprocessor; a carbon dioxide sensor in electrical communication with the microprocessor; a plurality of fittings for connecting tubing to the housing; and an A/C power source. The method further includes analyzing gas that has been channeled to the oxygen sensor. The method further includes analyzing gas that has been channeled to the carbon dioxide sensor. The method further includes digitally transmitting oxygen and carbon dioxide concentrations to the microcontroller. The method further includes correcting digitally transmitted concentrations, via the microcontroller, using measurements of known calibration gas values and changes in temperature and pressure. The method further includes producing a voltage that is linearly proportional to the corrected oxygen or carbon dioxide concentration utilizing an analog output pin designated for oxygen or carbon dioxide measurement on the microcontroller; and discharging gas through an outlet following analysis.
[0054] The foregoing description has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. Further, it should be noted that any or all of the aforementioned alternate implementations may be used in any combination desired to form additional hybrid implementations of the disclosure.
[0055] Further, although specific implementations of the disclosure have been described and illustrated, the disclosure is not to be limited to the specific forms or arrangements of parts so described and illustrated. The scope of the disclosure is to be defined by the claims appended hereto, any future claims submitted here and in different applications, and their equivalents.