A GAS MONITOR AND METHOD OF DETECTING GAS, INCLUDING A RIPENING MONITOR
20230228723 · 2023-07-20
Inventors
- Michael Potas (St. Peters, AU)
- Gennadiy Volkov (St. Peters, AU)
- Alex Hatzimihali (St. Peters, AU)
- Joshua Dunford (St. Peters, AU)
- Jonathan Shannon (Pyrmont, AU)
- Alex Matthews (St. Peters, AU)
- Jason Robert Potas (St. Peters, AU)
Cpc classification
G01N33/0008
PHYSICS
International classification
Abstract
A gas monitor configured to monitor at least one target gas in an environmental mixture, by separating and concentrating the target gas and then adjusting for the concentration factor. The adjustment may also take into account sensor sensitivities to other gases. Methods for adjustment of target gas results and increasing accuracy of monitoring are described.
Claims
1. A method of measuring the concentration of a target gaseous or aerosolised compound in a gaseous environment, the method including the steps of: extracting a selected sample quantity of the gaseous environment into a target gas measurement system; separating the target gas or aerosolised compound from the quantity of sample gas, into a store; sensing, with a target gas sensor, the amount or concentration of the target gaseous or aerosolised compound in the store; receiving in a processor, data from the target gas sensor relating to the amount or concentration of the target gaseous or aerosolised compound; converting, in a processor, the target gas sensor data, with a conversion algorithm, to obtain environmental concentration data of the target gaseous or aerosolised compound; storing in a data store or displaying on a display, the environmental concentration data, or transmitting the environmental concentration data to a remote server or processor.
2. The method in accordance with claim 1 further including the step of measuring with a sample gas sensor the quantity of the gas sample in the gas measurement system.
3. The method in accordance with claim 1 including the step of receiving, into a processor, data relating to the selected quantity of sample gas.
4. The method in accordance with claim 1 wherein the algorithm takes into account data from a sample gas sensor relating to a sample gas quantity and/or one or more physical qualities taken from the group consisting of: temperature, volume, pressure, and humidity.
5. The method in accordance with claim 1 wherein the amount or concentration of the target gas is calculated by subtracting a baseline target gas amount from a peak target gas amount in the store.
6. The method in accordance with claim 1 wherein the amount or concentration of the target gas is calculated by measuring an area under a concentration data curve over time from release from the store.
7. The method in accordance with claim 1 further including the step of extracting the gas from the store to a target gas sensor unit, for sensing the amount of target gaseous or aerosolised compound.
8. The method in accordance with claim 1 further including the step of conditioning a sample amount of the gaseous environment to a selected physical state to provide a conditioned gas sample for input to the separation step.
9. The method in accordance with claim 1 further including the step of sensing any one or more of the group consisting of: oxygen, carbon dioxide, carbon monoxide or volatile organic compounds in the target gas.
10. The method in accordance with claim 1 wherein the conditioning step includes dehumidifying the gas sample
11. The method in accordance with claim 1 wherein the separation step is conducted in a concentrator module, in which the store is disposed, to store a storage matrix.
12. The method in accordance with claim 11 wherein the storage matrix is activated carbon.
13. The method in accordance with claim 1 wherein ethylene is the target gas and the separation step is adsorption of ethylene.
14. The method in accordance with claim 1 wherein the sensing step includes desorption from the store of, and sensing in the target gas sensor of, ethylene.
15. The method in accordance with claim 1 wherein the sensing step includes sensing of a second gas component such that the conversion step includes adjustment of the concentration data by reference to a target sensor sensitivity to the second gas.
16. The method in accordance with claim 1 further including an assessment step in which the processor compares the amount or concentration of the target gas to a threshold level or rate of increase.
17. The method in accordance with claim 1 further including an alarm actuation step in which a wireless module transmits an alarm to a display or loudspeaker and amplifier on a mobile device or computer.
18. The method in accordance with claim 17 wherein the alarm step is taken if the threshold level or rate of increase is exceeded.
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Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0095] In order to enable a clearer understanding, a preferred embodiment of the technology will now be further explained and illustrated by reference to the accompanying drawings, in which:
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DETAILED DESCRIPTION OF AN EXAMPLE EMBODIMENT
[0111] Referring to the drawings there is shown an embodiment of gas monitoring system generally indicated at 10. The architecture of one ripening monitor system 10 is shown schematically in
[0112] Output of a target gas sensor of the system are shown in
[0113] In
[0114] Conditioner Module
[0115] The conditioner module is described herein, but it is to be understood that it is an optional feature of the technology.
[0116] Control of the gas sample air temperature, humidity and pressure provides the advantage of preventing condensation (that may affect gas sensor response downstream), as well as reducing the measurement variables to provide a more accurate gas component reading on a target gas sensor.
[0117] To that end, it can be seen that the system 10 provides an inlet 12 for receiving a gas sample from either a bottle of purified aerosolised or gaseous compound or mixture or from the environment in a chamber such as the interior of a room, building, toilet cubicle, or ambient atmosphere, shipping container or trucking container or refrigerator or produce storage room or cool room, or from a combination of the above (all not shown). This received gas sample is conditioned in one or two conditioner modules described below, and analysed downstream of those conditioner modules to assess the concentration of the target gas.
[0118] The inlet 12 is in fluid communication with a conditioner module 15, a flow control module 17 and/or pump 8, depending on the embodiment being discussed. Any one of those elements may include a valve 11 connected to the inlet 12, and one of a wide variety of mechanical pumps 8 capable of moving the gas sample through the system at a controlled rate, with or without a regulator (not shown). One type of pump 8 contemplated is a peristaltic pump, and another type of pump contemplated is a piston pump. Other types of pump 8 are contemplated as being of utility in the system include diaphragmatic pumps, and balloon pumps, screw pumps and others that can transfer gas from one place to another in a controlled fashion.
[0119] The conditioning module 15 includes a tube or chamber 4 into which a sample gas is introduced for conditioning.
[0120] The conditioning module 15 further includes a temperature modulation module 13 disposed in the walls of the tube or chamber. The temperature modulation module includes a heater element 18, and a Peltier cooler 19.
[0121] There is an exhaust outlet 5 disposed in the conditioning module chamber 4 to remove gas. There is also a drain 3 for removal of water and excess moisture and/or ice. The exhaust outlet 5 and drain 3 may be provided adjacent a valve 2 and 52.
[0122] The temperature modulation module 13 further includes a sensor module 16 which includes a temperature sensor 20, a humidity sensor 22, a flow sensor 14, pressure sensor 62 and which also may include an agitator (not shown) to facilitate the mixing of the gas undergoing pre-conditioning.
[0123] In operation, the conditioner, which is connected to the main controller 25, is caused by the main controller 25 to actuate the Peltier cooler 19 to freeze the water in the sample gas in the chamber 4 to reduce the humidity, and then warming at least a portion of the walls of the chamber 4 by actuation of the heating elements 18 and opening valve 2 as part of a defrost cycle to drain the water from the conditioner module 15.
[0124] Main Controller
[0125] There is provided a main controller 25 for, among other things, controlling the conditioning of the sample gas. The main controller 25 includes a microcontroller, in one form being a 32-bit ARM microprocessor, with analogue or digital inputs, and for conditioning the sample gas it is configured to interface with the sensor module 16 and the temperature modulation module 21 and the flow control module 17, or in some embodiments, pump 8.
[0126] Data connections 23 are made between the sensor module 16, the temperature modulation module 21, the flow control module 17, or pump 8, and the main controller 25. The data connections 23 may also be wireless or optical or indeed any suitable connections for sending data.
[0127] One of the other tasks of the main controller 25 is to control the temperature and humidity in the conditioning module 15. In operation, data from the sensor module 16 is provided to the conditioning controller 25, and corrections may be made to final gas component readings to account for gas conditions sensed by the sensor module 16.
[0128] Hoses
[0129] Between the conditioning module 15 and other components described herein, there are gas transport hoses 27 connected with barbed attachments and o-rings (not shown) so as to transport the gas and aerosolised compounds and mixtures.
[0130] The transport hoses 27 connect so as to transfer the sample gas from the conditioning module 15 to a concentrator module 30 which is identified on the Figures (at least
[0131] Concentrator Module
[0132] A concentrator module 30 shown as part of the system 10 in
[0133] The concentrator unit 30 is configured to receive the gas sample (conditioned or not, depending on the embodiment being discussed) through the inlet 9, such that in operation, a gas component of interest, in this case, ethylene, can be adsorbed in the activated carbon of the separator 35 as part of an adsorption process.
[0134] In operation, the amount of adsorbed target gas component, (related to the concentration factor of the system), may be modified by varying the mass flow of the gas sample that passes over the activated carbon 36 by means of the main controller 25 and flow controller 17 or pump 8, or by the heat, humidity and other conditions in the conditioner 15. Once a selected mass of the sample gas has passed over the activated carbon in the separator 35, the controller 25 causes the inlet 9 to close, and/or the inlet valve 81 to close, and then heater 32, configured to heat the activated carbon in the separator 35, heats the activated carbon to break the bond of the adsorbed target gas, which results in a gas concentration effect within the concentrator unit 30. This is referred to as a decanting or release phase.
[0135] The heater element 32 is in the form of a temperature controlled outer layer or block 37 in which there is disposed an embedded heating element 51, a cooling element 53 and a temperature sensor 52. The cooling element is a Peltier element 54. As with the conditioning module 15, data connections are made between the main controller 25 and temperature sensors 34 and the heater 32. The main controller 25 is configured to vary electrical power supplied to the heater 32 such that the activated carbon can be maintained at a preferred temperature during the gas release phase. The main controller 25 is also configured to vary electrical power supplied to the chiller 31, which is done after the gas release phase to prepare for another adsorption cycle.
[0136] The heater's temperature is configured to be controlled during both adsorption and release phases of the concentration process. Temperature control of the carbon during the adsorption phase is beneficial as the gas sample adsorption rates can be impacted by temperature and humidity, and control of such will increase the accuracy of the system.
[0137] Corrections may be made to gas readings at the end of the detection process, described below, to account for changes in adsorption or release rates due to sensed gas conditions in the conditioning module 15 or in the concentrating module 30, or in the secondary conditioning module 115.
[0138] The flow controller 17 or pump 8 (in another embodiment) is controlled with influence from the readings from a gas flow sensor 16; this provides facility for more accurate control of gas flow rates in the system and improves overall target gas sensing accuracy.
[0139] In an embodiment that is not shown, a flow controller may be placed downstream of the Concentrator Unit or Sensor Unit. Mass flow may also be varied by changes to the volumetric flow rate of the flow controller 17 or by the pump 8. Changes to mass flow may be obtained by increasing the duration of phases, such as the number of seconds of the adsorption phase or release phase.
[0140] A check valve is in fluid communication with the inlet so that gas samples may only flow one way through the system, thus preventing contamination of results by double-measuring the same sample of gas.
[0141] In one embodiment the separation could include CO2 scrubbing by using a membrane and in that embodiment the store would be a separate storage chamber (not shown) to the side or end or at least adjacent to the chamber 33.
[0142] Sensor Conditioning Module
[0143] A sensor conditioning module 115 which is similar to the conditioning module 15 is provided in the embodiment shown in
[0144] In this embodiment, when provided and in use, the sensor conditioning module, which looks similar to conditioning module 15, receives target gas from the release or decanting phase from the concentrator 30. In use, the sensor conditioning module 115 is instructed by the main controller 25 to cool the sample gas down to a selected temperature by actuating Peltier elements, so that the target gas sensor reads the gas in its most sensitive zone.
[0145] The sensor conditioning module 115 also includes a pump 108 to transfer the conditioned sample gas to the analysis module 44.
[0146] As with the conditioning module 15, there is provided an exhaust outlet 55 and a drain outlet 155 for water and moisture and ice.
[0147] Sensor Module
[0148] Inlet 42 is in fluid communication with analysis chamber 44 which receives sample gases and puts them into contact with carbon monoxide sensor 46, Ethylene sensor 45 and a temperature, pressure and humidity sensor unit 48. The analysis chamber 44 is shown as passing the sample gases sequentially between these sensors (Temp/pressure/humidity unit, Ethylene, CO) but there could be a sinuous chamber, or the sensor units could be arranged in parallel with the others in one common analysis chamber 44, say, around the outside of it, so that there is a simultaneous reading of all component gases from the one sample.
[0149] The sensors 45, 46, and 48 are connected to the main controller 25 so as to transfer data thereto, either wirelessly or in a wired or other suitable way (such as optically if suitable). The connections are so that the controller 25 can provide central monitoring of the analysis process for multiple gas concentrations simultaneously, and apply any one of a plurality of correction regimes during and before and after analysis as described below.
[0150] Main Controller
[0151] The target gas result can be obtained by transmitting data from the ethylene sensor 45 into the main controller 25. The main controller 25 displays the results on a display (not shown).
[0152] To obtain a more accurate result, the gas component reading can be refined by combining the ethylene sensor 45 and correcting it with offsets or multiplication factors based on the readings from any combination of the other sensor readings in the system. As one example, the ethylene reading could be obtained by taking the ethylene sensor 45 reading, and providing a correction offset based on the carbon monoxide detected in the sample, in order to calculate a more accurate ethylene reading. This is advantageous as some ethylene sensor readings may also be impacted by carbon monoxide gas, and the present invention could be used to remove such inaccuracies in the ethylene reading.
[0153] This is done by for example,
[0154] An automatic calibration method is employed, comprising the steps of taking of a number of measurements based on various concentration multiples, wherein the concentration multiple is controlled by the main controller 25 by varying the mass flow past the concentrator prior to each gas analysis, and a calibration curve of sensor readings vs concentration multiple is obtained. An interception of the calibration curve with the Y axis may then be mathematically determined to calculate a calibration offset, and that calibration offset may be applied to ethylene readings to increase accuracy and reduce sensor drift inherent in typical electrochemical sensors.
[0155] In an alternative embodiment and as part of an automated calibration step, a known gas sample, such as from a calibration gas canister or other generated means, may be passed through the gas analysis unit 44, and gas sensor readings can be compared with the known gas sample concentrations, and any variations in readings between measured and known values may be offset from future gas sample readings in order to improve accuracy.
[0156] Overload Detection
[0157] An automatic concentration overload detection method is employed in some embodiments to prevent damage to, or inaccuracy of, the gas analysis sensors 45 and 44. This feature includes the steps of taking a first measurement based on a low (or no) concentration multiple, wherein if it is determined that the gas sample is further concentrated a sensor overload may occur, higher concentration steps may not be completed and an error message generated.
[0158] The automatic concentration overload detection method consists of reading the carbon monoxide sensor (or an alternative sensor), and abandoning the measurement if concentrations are higher than a preferred threshold.
[0159] The Sensor Unit 40 is in fluid connection to the Outlet 61, where the used gas sample is exhausted back into the atmosphere.
[0160] The system can be mounted in a housing and placed inside a chamber in which is disposed ripening produce.
[0161] The controller 25 includes a memory, processor, I/O port for data transfer and therefore can be programmed to implement control of gas measurement steps and calibrations, and monitoring of the desired atmosphere (not shown).
[0162] The calibration cycles and regimes can be programmed into the controller 25 for routine implementation, or when one gas is measured as being off design, or any one of them can be manually actuated by a remote controller such as for example, a mobile device.
[0163] The main controller 25 may connect to a central database server and upload data relating to the gas concentrations, and hence ripeness of fresh produce. The server may then process this data, and provide feedback to users on recommended actions via alerts (such as via SMS messages, push notifications, emails, or recorded phone messages), such that users of the system can reduce produce wastage due to over ripening.
[0164] Connection to the database server may be achieved via wired or wireless connection to the internet, or via connection through a third party device (such as via WiFi connection to a smartphone, wherein the smartphone connects to the internet over a 3G/4G/5G connection).
[0165] System users may also input into the database, such as via an internet-connected smartphone App (shown on
[0166] Example Method
[0167] Conditioning
[0168] Again, the conditioning step is described here, but as an optional step. Turning to
[0169] In one particular version of the present method and technology, there is provided a batch processing method. This batch processing method is described below. The continuous processing method is described in relation to
[0170] A sample gas conditioner 15 draws in a gas and holds it until it meets the right conditions. (Step 500 in
[0171] Concentrating/Separating
[0172] The target gas ethylene in the chamber 4 is transferred by pump 8 and concentrated via a separation method called carbon adsorption (Step 510 in
[0173] First, there is a separation/adsorption/store cycle. (Step 740 in
[0174] The main controller 25 holds a valve at the inlet 9 and an outlet valve 98 in the concentrator closed for a selected time, while it opens the valve 12 in the conditioner to prepare another sample quantity of gas. The pumping of sample gas and the holding cycles are repeated multiple times, and the excess gas is discarded into the cycle waste exhaust 99. The number of separation/adsorption/capture cycles is adjusted until gas readings are obtained within the midrange of the sensor 34.
[0175] Decant/Release Phase
[0176] On the last adsorption cycle, the main controller 25 actuates the heater elements 51 to heat the separator store 36 to a temperature that releases C.sub.2H.sub.4, but with minimal CO (˜115 deg C). (Sep 750 in
[0177] The concentrator outlet port 98 is opened to the gas pump 108. A pump permits hot gas extraction under a vacuum, which facilitates desorption, and extraction of gas without mixing from the previous chamber
[0178] The main controller 25 causes the port 98 to close.
[0179] Cooling Phase
[0180] The main controller 25 may actuate the Peltier units 32 so that the separator/concentrator is cooled down to a fixed sub-zero temperature in preparation for the next phase of adsorption/capture cycles. This reduces the humidity in the separator/concentrator.
[0181] Gas Sensor Conditioning and Pumping
[0182] C.sub.2H.sub.4 is stored in the sample chamber and/or conditioner tubing until cooled to a fixed temperature (20 deg C) in preparation for the gas sensors. When the gas reaches 20 deg (actively controlled), it is expelled across the gas sensors for 3 minutes at atmospheric pressure. The pump 8 is feedback controlled that ensures the gas passes the sensors at atmospheric pressure for 3 minutes
[0183] Two pumping options are possible; a piston pump permits volume changes as the gas changes temperature and has greater volume control over gas quantities than compared to a peristaltic pump
[0184] Sensor Reading and Cleaning Cycles
[0185] Once the sample air is 20 deg, it is directed past the sensor module 44 for 3 mins to obtain the reading. (Step 520 in
[0186] Following the reading cycle, fresh air is drawn by the gas pump, through the conditioner and into the gas sensor chamber for 10-30 mins to reset the sensor for improved sensor performance and lifetime.
[0187] In the reading cycle, the target sensor data is sent from sensor 45 and sensor 46 and 48 to the main controller 25. The main controller 25 records the Ethylene count (target gas) as shown in
[0188] The ethylene reading calculated may then be converted to account for the concentration of the sample. (Step 530 in
[0189] To convert the ethylene reading from the target gas sensor to the environmental concentration, a conversion algorithm is prepared and/or solved in the processor. When the amount of sample gas and its conditions are preset and predetermined, the inventors have, surprisingly, and after much hard work, found that a simple graph (in practical terms, stored as a lookup table in the memory of the controller 25) such as that shown in
[0190] GapOutput is on the Y-axis of
[0191] Changing any of the quantities in the conditioner or concentrator gives you a different slope, y-axis intercept, etc, and a new conversion algorithm can be generated by the processor by receiving data from sensors measuring those quantities.
[0192] The ethylene reading calculated above may also be adjusted to account for humidity or pressure or other readings taken from sensor unit 48, or unit 16, or CO sensor 44, and one of those correction factors is CO and is described below and shown in
[0193] To resolve this, the two sensitivities can be quantified by solution to the simultaneous equation set out below. The solution to the equations is simplified using the gas sensitivity identified on each of the sensors and the results reduced to a look-up table accessible by the main controller 25 either on board or on a cloud server.
[0194] Equally, the factors correcting for the concentration of ethylene are reduced to data on a lookup table and accessible to the main controller on board or on a cloud server accessible by a wireless module.
[0195] Maintenance
[0196] Several processes are useful for longevity and accuracy. Sensor cleaning (occurs every cycle). For each 3 minute of ethylene readings, the gas sensor is flushed with fresh air for 10-30 mins to restore the humidity and stop sensing chemical reactions.
[0197] Removal of water from dehumidification. The conditioner coil will retain ice after a while. This can be removed by heating the coil so the water evaporates or drips out.
[0198] Alerts/Alarms
[0199] As indicated by
[0200] The alarm step is taken by the processor 25 if the threshold level or rate of increase is exceeded. This allows the wireless module on the main controller 25 to alert users of ethylene concentrations and therefore impending ripeness. This allows users to get fruit to market in a decent state.
[0201] Clarifications
[0202] Modifications and improvements to the invention will be readily apparent to those skilled in the art. Such modifications and improvements are intended to be within the scope of this invention.