Wireless sensors system and method of using same

Abstract

An apparatus, system, and methods for measuring environmental parameters are disclosed. The apparatus, system, and methods can be used for a variety of applications, including HVAC air balancing and building commissioning. The system includes a variety of wireless sensing modules and wearable modules for control, display, and storage. Parameters measured include air and water temperature, pressure, velocity, and flow. Also included are sensors for light intensity, CO concentrations, and CO2 concentrations.

Claims

1. A test and balance data gathering system comprising: two or more wireless sensor modules configured for use in a test and balance measurement procedure, each wireless sensor module comprising: one of an air pressure sensor, an air velocity sensor, an air flow sensor, an air temperature sensor, an air humidity sensor, and any combination thereof; one of one or more sensor module ports and a sensing probe; an attachment mechanism selected from the group consisting of clips, magnets, hook and loop fasteners, and adhesive dot: and a wireless radio electronic portion; and a control module comprising a microprocessor, a memory, a display, and a wireless radio electronic portion all operatively coupled together and coupled to an enclosure; wherein the two or more wireless sensor modules are configured to transmit test and balance measurements for use in a test and balance measurement procedure wirelessly to the control module; wherein the control module is configured to send and receive the test and balance measurements wirelessly from each of the two or more wireless sensor modules and is further associated with a user; wherein each of the two or more wireless sensor modules are configured to: removably couple through the attachment mechanism at a user-selected location on a heating, ventilating, and air conditioning (HVAC) system; remotely from the user, when attached at the user selected location along the HVAC system, in response to a wireless signal from the control module, take one or more test and balance measurements selected from the group consisting of an air pressure value, an air velocity value, an air flow value, an air humidity value, a temperature value, and any combination thereof using the one of the air pressure sensor, air velocity sensor, air flow sensor, air temperature sensor, air humidity sensor, and any combination thereof and one of the one or more sensor module ports and the sensing probe; and wirelessly transmit the one or more test and balance measurements to the control module which is configured to display one or more of the test and balance measurements on a first portion of the display for the measurements from a first one of the two or more wireless sensor modules and to simultaneously display one or more test and balance measurements on a second portion of the display for the measurements from a second one of the two or more wireless sensor modules; and wherein the control module is configured to in substantially real time: enable the user, through the first portion of the display and the second portion of the display, to use the test and balance measurements to observe an effect of a test and balance adjustment made by the user to a portion of the HVAC system made prior to the measurement, where the two or more sensors are only removably coupled to the HVAC system during a period of time during which testing and balancing is being performed by the user.

2. The system of claim 1, wherein the wireless radio electronic portion of each of the two or more wireless sensor modules and the control module uses an 802.15.4 protocol.

3. The system of claim 1, further comprising a thumb switch comprising a wireless radio electronic portion that is configured to, in response to being activated by a user, instruct the control module to record a data value received from one of the two or more wireless sensor modules to the memory.

4. The system of claim 1, further comprising one of a static tip type pressure probe, a pitot tube, a grip part for holding a pitot tube, a grid-type probe, and any combination thereof.

5. The system of claim 1 wherein the control module further comprises an attachment mechanism comprising two loops coupled on opposing sides of the enclosure configured to receive a stretchable fabric loop therethrough configured to fasten to a wrist of the user.

6. The system of claim 1 wherein the control module is one of a personal digital assistant (PDA), smartphone, and mobile computer.

7. A test and air balance data gathering system comprising: a first wireless sensor module comprising an air pressure sensor, an air velocity sensor, and an air flow sensor, and further comprising one or more sensor module ports, an attachment mechanism selected from the group consisting of clips, magnets, hook and loop fasteners, and an adhesive dot, and a wireless radio electronic portion; a second wireless sensor module comprising a temperature sensor, a sensing probe, an attachment mechanism selected from the group consisting of clips, magnets, hook and loop fasteners, and an adhesive dot, and a wireless radio electronic portion; a third wireless sensor module comprising an air humidity sensor and an air temperature sensor, a sensing probe, an attachment mechanism selected from the group consisting of clips, magnets, hook and loop fasteners, and an adhesive dot, and a wireless radio electronic portion; and a control module comprising a microprocessor, a memory, a display, and a wireless radio electronic portion all operatively coupled together and coupled to an enclosure; wherein the first wireless sensor module, the second wireless sensor module, and the third wireless sensor module are adapted to transmit one or more test and balance measurements wirelessly to the control module; wherein the control module is configured to send and receive test and balance measurements wirelessly from the first wireless sensor module, the second wireless sensor module, and the third wireless sensor module and is further associated with a user; wherein the first wireless sensor module is configured to: removably couple through the attachment mechanism to a first user-selected location along a heating, ventilating, and air conditioning (HVAC) system; remotely from the user, take one or more test and balance measurements selected from the group consisting of air pressure, air velocity, air flow, and any combination thereof using the one of the air pressure sensor, air velocity sensor, and air flow sensor and any combination thereof and the one or more sensor module ports; and wirelessly transmit the one or more test and balance measurements to the control module for showing on a first portion of the display; wherein the second wireless sensor module is configured to: removably couple through the attachment mechanism to a second user selected location along a heating, ventilating, and air conditioning (HVAC) system; remotely from the user, measure a value of temperature as one or more test and balance measurements using the temperature sensor and the sensing probe; and wirelessly transmit the one or more test and balance measurements to the control module for showing on a second portion of the display; wherein the third wireless sensor module is configured to: removably couple through the attachment mechanism to a third user selected location along a heating, ventilating, and air conditioning (HVAC) system; remotely from the user, measure a value of one of humidity, temperature, and both humidity and temperature using one of the humidity sensor, temperature sensor, and both the humidity sensor and temperature sensor and using the sensing probe forming the one or more test and balance measurements; and wirelessly transmit the one or more test and balance measurements to the control module for showing on a third portion of the display; and wherein the control module is configured to simultaneously: display the one or more test and balance measurements from the first wireless sensor module on the first portion of the display; display the one or more test and balance measurements from the second wireless sensor module on the second portion of the display; display the one or more test and balance measurements from the third wireless sensor module on the third portion of the display; and enable the user, through the first portion, second portion, and third portion of the display, to observe an effect of the user's adjustment made during a period of testing and balancing to the HVAC system on the HVAC system at the first user selected location, second user selected location, and third user selected location in substantially real-time.

8. The system of claim 7, wherein the wireless radio electronic portion of the first wireless sensor module, the second wireless sensor module, the third wireless sensor module, and the control module uses an 802.15.4 protocol.

9. The system of claim 7, further comprising a thumb switch comprising a wireless radio electronic portion that is configured to, in response to being activated by a user, instruct the control module to record a data value received from one of the first wireless sensor module, the second wireless sensor module, and the third wireless sensor module to the memory.

10. The system of claim 7, further comprising one of a static tip type pressure probe, a pitot tube, a grip part for holding a pitot tube, a grid-type probe, and any combination thereof.

11. The system of claim 7 wherein the control module further comprises an attachment mechanism comprisesing two loops coupled on opposing sides of the enclosure configured to receive a stretchable fabric loop therethrough configured to fasten to a wrist of the user.

12. The system of claim 7 wherein the control module is one of a personal digital assistant (PDA), smartphone, and mobile computer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the drawing figures, wherein like numerals denote like elements and wherein:

(2) FIG. 1 illustrates the system form in accordance with exemplary embodiments;

(3) FIGS. 2A and 2B illustrates the wearable control module in accordance with exemplary embodiments;

(4) FIG. 3 illustrates the thumbswitch in accordance with exemplary embodiments;

(5) FIGS. 4A, 4B, 4C illustrate head-mountable communication in accordance with exemplary embodiments;

(6) FIGS. 5A, 5B, 5C illustrate the use of repeater modules for extending the usable system range in accordance with exemplary embodiments;

(7) FIGS. 6A, 6B illustrate repeater modules in accordance with exemplary embodiments;

(8) FIGS. 7A, 7B illustrate an application for a system of temperature and humidity modules in accordance with exemplary embodiments;

(9) FIGS. 8A, 8B, 8C, 8D, 8E, 8F, 8G illustrate a multitude of measurement result display formats in accordance with exemplary embodiments;

(10) FIGS. 9A, 9B, 9C, 9D, 9E illustrate some types of temperature modules in accordance with exemplary embodiments;

(11) FIGS. 10A, 10B, 10C, 10D illustrate humidity sensor modules and related display formats in accordance with exemplary embodiments;

(12) FIGS. 11A, 11B, 11C, 11D illustrate differential air pressure sensors in accordance with exemplary embodiments;

(13) FIG. 12 illustrates measurement of water pressure and temperature in accordance with exemplary embodiments;

(14) FIG. 13 illustrates areas of different pressures in a cleanroom;

(15) FIG. 14 illustrates a system of duct air sensors in accordance with exemplary embodiments;

(16) FIG. 15 illustrates a variety of informational displays in accordance with exemplary embodiments;

(17) FIG. 16 illustrates duct air measurements in accordance with exemplary embodiments;

(18) FIG. 17 illustrates air measurement and adjustment in accordance with exemplary Embodiments;

(19) FIG. 18 illustrates air measurement in accordance with exemplary embodiments;

(20) FIG. 19 illustrates air measurement in accordance with exemplary embodiments; and

(21) FIGS. 20A, 20B, 20C illustrate sensor modules and instrument interface modules in accordance with exemplary embodiments;

(22) It will be appreciated that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of illustrated embodiments of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

(23) The description of exemplary embodiments of the present invention provided below is merely exemplary and is intended for purposes of illustration only; the following description is not intended to limit the scope of the invention disclosed herein. Moreover, recitation of multiple embodiments having stated features is not intended to exclude other embodiments having additional features or other embodiments incorporating different combinations of the stated features.

(24) The apparatus, system, and methods of the present disclosure may be used for a variety of applications in HVAC, safety, lighting, and security systems in buildings and factories, including such applications as duct static pressure adjustment, airflow damper adjustment, room-to-room pressure adjustments, water side HVAC balancing, HVAC coil efficiency measurements, and the like. Included are measurements for immediate use as well as datalogging measurements at regular intervals over an extended period of time. As set forth in more detail below, the exemplary system and methods are generally easier to use, less time consuming, and require fewer and less expensive instruments compared to traditional systems and methods that provide similar functions.

(25) FIG. 1 illustrates a system 100 in accordance with exemplary aspects of the invention. System 100 includes modules of various types for measuring environmental parameters, and then viewing, storing, and sharing the measurement results. The modules of system 100 have wired and/or wireless means of communicating information, commands, and measurement results. Illustrated system 100 includes control module 110, optional repeater module 112, optional sensor interface module 172, and a multitude of sensor modules described below, one or more of which may optionally be present in system 100. Illustrated system 100 also includes means for enhancing the usability of control module 110, including wrist display module 120, head-mounted display 121, audio module 122, thumbswitch 111, computer interface 131, PDA interface 134, and cellular data module 133. Use of system 100 improves user productivity in many ways, including: by allowing users to take measurements while using their hands for other tasks; allowing users to compare results from multiple locations concurrently; eliminating back-and-forth motion for repetitive measurements, facilitating information sharing among coworkers; easier set-up for complex and cumbersome measurements; facilitating more accurate results by maintaining measurement probes in-situ at the location of interest.

(26) Users may include team leader 101 and associate 102. Users 101 and 102 may have placed one or more sensor modules 151, 152, 153, 154, 155, 156, 157, 161, 162, 163, 164, 165 in particular locations to make specific measurements required for industrial operations. Measurement results from sensor modules 151, 152, 153, 154, 155, 156, 157, 161, 162, 163, 164, 165 are transmitted to control module 110. Not part of the present invention are traditional instruments such as, e.g., water volumetric flow meter 171. However, the present invention includes interface module 172, which may connect to an existing data output port of flow meter 171, if present. Interface module 172 may transmit measurements wirelessly to control module 110.

(27) Control module 110 establishes and maintains the network by which all system modules communicate. Control module 110 may also have other functions, including display and storage of measurement data. Repeater module 112 has the function of a wireless signal repeater. Repeater module 112 is optional in system 100. When the distance between modules becomes too great for effective wireless transmission, repeater module 112 may be placed midway between the modules to allow signals to hop. Signals from the transmitter are first received by repeater module 112, which in turn transmits over the now reduced distance to the receiver.

(28) Control module 110 is operated via keys, buttons, and/or switches on control module 110. Control module 110 may also execute certain commands which are entered by user 101 via buttons, keys, or switches on thumbswitch module 111. Control module 110 may also execute certain commands which are entered by user 101 via microphone 123 on audio module 122. The ability to input commands verbally or via thumb movements allows user 101 to use his hands for something else while still making and/or storing measurements.

(29) Also important to productivity is the ability to see or hear results without the need to use hands or arms. Control module 110 on user 101 may transmit information, including measurement results, to wrist display module 120 on user 102, and/or heads-up display module 121, and/or audio earphones 124 on audio module 122. Time and effort are saved by the ability of users 101 and 102 to both see the same measurement results at the same time despite their different locations. Other activities, including using hands for equipment repair and/or adjustment, may proceed while measurement results continue to arrive in real time.

(30) Voice communication between team members in different locations may improve productivity. Control module 110 on user 101 and display module 120 on user 102 may include microphones and speakers and the software and hardware means to transmit voice via the same RF waves that communicate measurement results. This may eliminate the need to communicate information or instructions by walking to conference, by walkie-talkie instruments, or by cell phones. Headphone module 122 on user 101, with microphone 123 and earphones 124, may also be used to for voice communication, with transmission controlled by control module 110.

(31) Productivity may be improved when information can be reviewed from a great distance. For example, a manager at a home office may be able to detect an HVAC problem by viewing measurement results at a remote location in real-time, and promptly give appropriate instructions. Building commissioners often share measurement information with colleagues across the country to compare results from similar buildings. System 100 provides means for transmission of information to remote servers 143, which may be accessed via the Internet. One way is for the control module 110 to transmit to cellular data module 133, which in turn has a connection 141 through the cellular telephone system to a remote server. A second way is for control module 110 to transmit to computer 130 via i/o module 131. Computer 130 may be directly connected to the Internet via a cable 141 or via a WiFi connection 142, both of which offer means of transmitting information from system of modules 100 to a remote server for world-wide viewing. A third way of storing information at one more remote servers is via a PDA 135 controlled by user 101. Data may be collected by PDA 135. Once stored in PDA 135, information may be transmitted to a remote server via WiFi or via the cellular data network.

(32) Module Components and Design Features

(33) Exemplary electronic modules of the present invention include electronic assemblies built from customized printed circuit boards with microprocessor-based control circuits. The modules may be in relatively small enclosures of an appropriate size and shape for a specific system function. Enclosures may be a standard product purchased from a supplier such as TEKO, or may be built to a custom design. Holes in the enclosures may be drilled to provide access for connectors, keypad, display, and mounting means such as a strap.

(34) The contents of system 100 modules may include one or more of these electronic hardware and software feature sets:

(35) embedded controller for general functions within a module.

(36) LED's and/or other display devices and related display control.

(37) Sensing electronics for analog or digital inputs.

(38) Keypad and On/Off switch and other switches, keys, or buttons.

(39) Battery and/or transformer.

(40) Audio electronics, microphone, speaker(s), drivers.

(41) Connectors for power, signals.

(42) Wired signal transmission drivers and protocols.

(43) Wireless transmission drivers and protocols, including RF point-to-point, RF multipoint, RF ZigBee, Bluetooth, WiFi, GPRS and/or other cellular data protocol.

(44) Antenna(s) appropriate for the extant protocols and frequency channel.

(45) System 100 may include a wireless sensor network (WSN). WSN's are established using standard hardware and software, included in every node of the network. For example, a ZigBit is a communications component supplied by Atmel with related software for installation in multiple modules. The modules then have the capability to create and maintain a WSN based on the ZigBee Alliance protocol, which is an open standard. ZigBee uses an international standard 802.15.4 protocol and standard ISM frequency ranges.

(46) FIGS. 2A, 2B illustrate an exemplary wearable control module 110. Loops 201 support a wrist strap 204 or a spring bracket for mounting on other convenient apparatus. Control module 110 may also be mounted via magnets, Velcro, tape, or other means to an HVAC duct, pipe, rod, wire, cable, or other structure where convenient for the user. Keypad 202 may be used to control the display, storage of measurement results in memory with time and date, and the network. Antenna 205 may be a relatively long or relatively short dipole antenna that protrudes from the enclosure, or it may be another type of antenna installed internal to the enclosure. Connectors 206 may be electrical ports for communication and/or power. Display 203 can show the results from multiple sensors from multiple locations. A variety of display formats are provided for specific applications, allowing the user to compare and contrast different conditions in different locations. Real-time feedback from adjustments of environmental controls is very beneficial to productivity.

(47) System 100 includes operating modes that were previously only available in different instruments. Control module 110 may operate in a diagnostic or debugging mode to discover and promptly fix problems. Control module 110 may also be used as a datalogger, collecting measurements regularly from multiple distributed sensors over a period of hours, days, or weeks. The data may analyzed, for example by plotting the information against time to show relationships between events. Control module 110 can operate in the debug mode or the datalogging mode or both at the same time. Two control modules 110 can operate at the same time in the same network, one operating in debug mode and one in datalogging mode.

(48) Multiple control modules 110 can operate in the same environment with different sets of network modules. Unique addresses prevent communication between the different networks.

(49) Control Module Display Formats

(50) Control module 110 includes the ability to display information in a wide variety of formats, depending on the desires of the user. Control module 110 includes means for displaying and storing measurement results from multiple sensor modules from multiple locations. FIGS. 8A, 8B, 8C, 8D, 8E, 8F, 8G illustrate some of the formats available to users. Other display format may be configured for specific measurement applications, as discussed below. In FIG. 8A, large characters facilitate viewing from a distance. In FIG. 8B, a current reading is displayed in large characters at the upper left, while smaller characters at the right list the three prior readings. This gives an indication of the trend of the parameter. In FIG. 8C, a current reading is displayed in large characters at the upper left. At the lower left are shown the current memory group selected, AA, and the sequence number of the last value stored, 123. On the right are listed statistics for the current memory group AA, average, maximum, and minimum. In FIG. 8D, results from two different temperature sensor modules, S1 and S2, are displayed side-by-side. In FIG. 8E, results from two different sensor modules are displayed side-by-side. This type of sensor module supplies both a temperature and a relative humidity. The user can therefore compare four concurrent measurements from two different locations. In FIG. 8F, concurrent results are displayed from four different sensors in four different locations. Sensor module S1 is measuring temperature in degrees Fahrenheit. S2 is measuring barometric pressure in inches of mercury, S3 is measuring percent relative humidity, and S4 is measuring differential air pressure in inches of water column. In FIG. 8G a list of datalogged measurements is shown with columns for record number, sensor number, time of record, value, and units. The date of the reading is displayed above.

(51) Control Module Construction

(52) Control module 110 may have a keypad 202 that is a membrane switch assembly as illustrated in FIG. 2A. Control module 110 may be powered by a rechargeable lithium-ion or lithium-polymer battery, which is recharged through a mini-USB port.

(53) Control module 110 may have an LCD display with LED backlight for good visibility in dark environments, embedded controller, memories, real-time clock, audio codec, speaker, microphone, connectors, keypad, and other electronic components. Control module 110 displays the results which are received wirelessly at specified intervals from various sensor modules. Control module 110 may have a provision for storing measurements by pressing a key. Control module 110 manages the wireless and or wired communications of system 100. The present invention includes programmed features to tailor the network to the environment of field users, who may not be trained in networking. Features included for network durability and practicality in industrial environments include displays of status and problem alerts, and a heartbeat system in which each module regularly reports its status to control module 110.

(54) Control module 110 may use an ATMega256 microcontroller by Atmel, but other similar microcontrollers, either 8-, 16-, or 32-bit, could have been chosen. Standard C programming techniques were used to produce the controlling program, using standard development software from, for example, Atmel. The microcontroller of control module 110 performs these functions: manages power-on and power-off sequences monitors the keypad for user inputs, the real-time clock, and the battery status feeds data and text to the display transfers data to and from the wireless network module manages the audio codec manages the mini-USB port for recharging the battery manages the mini-USB port for transmissions to and from a fixed or mobile computer. manages the WiFi or other wireless port for transmissions to and from a fixed or mobile computer. manages the wired or wireless port for transmissions to and from the Web Access Module. manages the SD data port for storing data on a tiny SD-format memory disk.
Alternate Embodiments Control module 110 features may be implemented by a PDA or smartphone or mobile computer to which is attached a network control module.
Thumbswitch Module

(55) FIG. 3 illustrates thumbswitch 111, an optional module in system 100, which can be worn on a finger via stretchable fabric loop 301. If the user is holding tools or otherwise cant move his arm to touch the keypad 202 of wearable control module 110 of FIG. 2A, he can effect a subset of keypress commands by pressing one or more buttons 302 on thumbswitch 111 as illustrated in FIG. 3. Examples of commands executed by wearable control module 110 but initiated via thumbswitch buttons 302 include storing a reading and changing a display format. One or more status indicators 303 may be present. Thumbswitch 111 may fit in different places on different fingers, giving a user the flexibility to hold tools of different shapes while maintaining the ability to press buttons 302. Wearable thumbswitch 111, together with wearable control module 110, and sensor modules that measure in-situ and need not be held, allow users the freedom to perform tasks with their hands while measuring and monitoring the environment.

(56) Optional Modules for Disseminating Information

(57) FIGS. 4A, 4B, 4C illustrate head-mountable communication and control apparatus. FIG. 4A illustrates some exemplary details of head-mountable display module 121 from FIG. 1. Small display 401 is positioned in similar fashion to rear-view mirrors worn by bicyclists. Clamp 404 grips a cap, and supports small rod 403, from which display 401 is suspended. Images may be provided by module 402, which may be optionally attached to the back of a cap, attached to the back of a collar, placed in a breast pocket, or placed in some other location. Communication with control module 110 may be wired or wireless.

(58) FIG. 4B illustrates exemplary details of audio module 122 from FIG. 1. Headphone and microphone arrangement 411 provide audio content such as measurement results and verbal messages from coworkers. Spoken commands may control operation of control module 110. FIG. 4C illustrates exemplary detail of audio module 122 from FIG. 1. Common ear bud 422 may use Bluetooth or WiFi or other protocol for communication with control module 110.

(59) The electronics of head-mounted modules 121 and 122 may be battery powered. Alternatively, the battery in control module 110 in FIG. 1 and FIG. 2 may feed the other components via a wire. Alternatively batteries may be integrated with the audio and/or video electronics modules, or external batteries may be located in a module worn on the user's belt, in his shirt pocket, clipped to the back of his shirt collar, or clipped to the back of his ball cap or helmet. Commands, measurement results, and information may be transmitted from module to module via wire or via wireless RF.

(60) Optional Repeater Module

(61) Remote sensor modules may communicate with a control module 110 in a variety of ways. Some of these are illustrated in FIGS. 5A, 5B, 5C FIG. 5A illustrates a sensor module 151 in wireless communication with control module 110 from FIG. 1 and FIGS. 2A, 2B. Control module 110 maintains a record of a unique identification number for sensor module 151. Wireless communication parameters such as signal strength and frequency are managed cooperatively by integrated hardware and software. Sensor module 151 makes regular measurements and transmits results to control module 110. Control module 110 can display the results for the user without storing them, or the user may cause the results to be stored with the value, units, sensor ID, time, and date. The user may cause the results to be stored without viewing them. The user may change the schedule of measurement. When sensor module 151 is not measuring or transmitting, it may put most of its electronic components into a sleep mode which uses very little power, such that a battery in sensor module 151 may have a relatively long useful life.

(62) As illustrated in FIG. 5B the user may require that sensor module 151 be placed at such a distance from control module 110 that wireless signals are too weak to maintain effective communication. In this situation control module 110 will display an alert to the user, who may then deploy repeater module 112 at a location somewhere between sensor module 151 and control module 110. Repeater module will be at an effective distance to receive transmissions of information from sensor module 151 and will retransmit said information, which control module 110 is near enough to properly receive.

(63) FIG. 5C illustrates that multiple repeater modules 112 may be used to extend the effective range between sensor module 151 and control module 110. 5C also illustrates that control module 110 may maintain communication with multiple sensor modules 151 at the same time, including some that are in direct communication as well as those whose messages are being repeated.

(64) FIGS. 6A, 6B illustrate two exemplary configurations for repeater modules. In FIG. 6A, repeater module 601 includes an On/Off switch 602 and one or more indicator lights 603. Repeater module 601 includes a relatively small battery and a relatively small antenna, with a correspondingly short range, relatively speaking. In FIG. 6B, repeater module 611 includes a large antenna 612 with a correspondingly longer range, relatively speaking. A large battery is included, as well as a transformer and wall electrical outlet prongs 613 for recharging the battery and/or operating while attached to mains power. A port 614 is included for attaching a cable for information transfer and/or powering from an external battery, solar panel, or other power source. A sensor 615 is included to allow repeater module 611 to measure and transmit environmental conditions from its immediate area, in addition to performing its function as repeater. A display 616 is included so a user may view status and other information. Buttons and/or keys and/or switches 617 are included to allow setup and manipulation of included functions, in addition to On/Off switch 618 and indicators 619.

(65) Sensor ModulesCommon

(66) Sensor modules are sensing instrument probes that measure environmental parameters such as temperature, humidity, and pressure. The present invention includes many different types of sensor modules to address a multitude of HVAC applications. One or more sensor modules may optionally be present in an operating system 100. The present invention offers a common platform for users and reduces the number of different instruments required for HVAC applications, saving money and time.

(67) FIG. 1 illustrates a multitude of sensor modules attached to various HVAC fixtures where users may require measurements for solving problems and/or adjusting equipment. For example, sensor modules 151, 152, and 153 are placed in different locations of interest. Sensor module 151 has a shaft type of sensing probe that penetrates a small hole in an air duct and measures temperature. Sensor module 152 has a button shape for measuring the surface temperature of, e.g, water pipes. Sensor module 153 measures temperature and humidity, and has a shape and features to allow users to easily attach it to, e.g., air supply ceiling diffusers. Sensor modules 151, 152, 153, like other sensor modules in the present invention described below, may be designed to be relatively small and easy to place at a particular point of interest in HVAC applications. Sensor modules may be designed to remain at the point of interest, in-situ, and continue measuring and transmitting results to a location convenient to the user. Sensor modules may have unique handles and means of attachment to industrial equipment so they do not have to be held by a technician when readings are being taken. When using sensor modules instead of traditional handheld meters, users need not make repeated trips to a point of interest for follow-up measurements.

(68) As illustrated in FIG. 1, sensor modules 151-157, 161-165 may be placed in or on air ducts, air diffusers, water pipes, condenser coils, walls, floors, ceilings, desktops, or many other places in buildings and factories. It is the combination of size, shape, accessories (magnets, rings, clips, Velcro, adhesive dots, etc.), and the convenient communications link, usually wireless, to the Control Module 110, that make the sensor modules of the present invention uniquely suitable for industrial measurement applications. When used in a system 100, sensor modules 151, 152, and 153, as well as other sensor modules described below, reduce the time required for industrial procedures and improve accuracy and safety.

(69) System 100 may include wireless sensor modules for these HVAC applications: Insertion air temperature. Surface temperature. Average temperature of ducts and mixing chambers. Insertion humidity probe. Fluid pressure and temperature in pipes. Differential Water Pressure Sensor Module Differential air pressure module with unique door mount. Velocity Sensor Module. Airflow probe for inlets and outlets. Other sensor modules for CO2 concentration, CO concentration, light intensity, inclinometer, motor/fan rotor speed in RPM, switch status (open/closed).

(70) System 100 of FIG. 1 includes instrument interface module 172 which allow existing meters and sensors to be interfaced to control module 110: Instrument interface for instruments which have digital output ports, such as these instruments popular in HVAC applications: Shortridge AirData Multimeter series; TSI/Alnor EBT 720 series; Kanomax Climomaster A5xx series; other instruments with digital outputs. Instrument interface for third-party instruments and sensors which feature standard analog outputs formats: 4-20 mA; 0-to-5 volts; 0-to-10 volts.
Sensor Module Construction

(71) Sensor modules, including sensor modules 151-156 and 161-165, may include: a custom printed circuit board, one or more status LED's, sensor or sensor connector, battery, communication circuitry: One or more microcontrollers are programmed to control the LED indicator(s), power on and power-off sequences, battery power monitoring, and sensor interface. Sensor modules may use primary or rechargeable batteries, and may also provide means for mains power and/or external battery power. Sensor modules include means for attaching to key ;locations of interest and remain in-situ while delivering a stream of regular measurements.

(72) Temperature Sensor Module

(73) FIGS. 9A, 9B, 9C, 9D, 9E illustrate a temperature sensor module 901, including a sensing and radio electronics part 902 and a connected sensing probe 911 or 912 or 913. Sensor probe 911 has a sensing element 921 at the end of a stiff shaft. Sensor probe 912 has a flexible lead attached to a button-style sensing bulb 922. Sensor probe 913, for applications that require the average temperature in a space, has a thermally-conductive lead in which are located one or more temperature sensor elements 923. Each sensing probe of 911, 912, 913 may be connected to sensor module 901. Sensor module 901 includes an On./Off switch and one or more LED's or displays. Sensor module 901 may include magnet 931 and/or magnet 932 applied to one or more facets of the module for attaching to ferrous surfaces. Facet 933 may have a surface appropriate for taping or attaching or affixing sensor module 901 to a non-ferrous surface, using, for example, tape, Velcro, or other known means for attachment. Ring 934 may be present to allow clipping or hanging from lines or pipes or other available structure.

(74) FIG. 7A illustrates some applications of a temperature sensing elements shown in FIGS. 9A, 9B, 9C, 9D, 9E. Illustrated is a simplified model of an HVAC system serving part of a building. One sensor module 901 with sensor probe 911 sits on a table at location 701 to measure room temperature. Another sensor module 901 with sensor probe 911 uses a magnet to attach to ferrous fixtures at ceiling locations 702 and 703. Location 702 represents supply air temperature entering room 708, while location 703 measures the temperature of room air as it passes through a return air grille and enters a return air duct. A sensor of type 901 at location 709 measures return air temperature and another at location 710 measures fresh outside air being brought in to ventilate the building and replace stale air. In mixed air chamber 713, two air streams collide in a turbulent environment, where temperature probe 913, is used to measure the average air temperature. The mixed air exits through filter 714. Fan 715 propels the air past coil 716 and into the supply air duct. The temperature of the water in the coil pipe is approximated by the sensing probe 912, with button-style sensing bulb 922 which is held against the pipe with tape or strap. Ring 934 shown in FIG. 9A, provides means to hang the sensor module 901 near the location to be measured 718.

(75) Method for Measuring Mixed Air Proportions

(76) HVAC industry rules require a certain amount of fresh outside air for each square foot of occupied space. An air balancer must supply just enough, but not too much, outside air. Dampers 711 and 712, along with fan speeds, are varied to achieve the necessary outside air. Air balancers make a calculation to determine outside air volume by comparing the respective temperatures of supply air, return air, outside air, and mixed air. Industry practice is to measure each location (709, 710, 713, 706), then adjust the dampers, then measure again, repeating this cycle until the required relationships of temperatures are achieved. This is an iterative process that is time consuming. The current invention allows sensors to be placed as described above. As better seen in FIG. 7B module 110 provides four continuous readings from four different locations in the format shown in FIG. 7(b): return air temperature 721, outside air temperature 722, mixed air temperature 723, and supply air temperature 724 (after being cooled by coil 716). With this improved method, the required adjustments can be made relatively quickly, reducing manpower and shortening schedules.

(77) In accordance with additional embodiments of the invention, a method of measuring mixed air proportions includes the steps of:

(78) deploy temperature sensor in the air mixing chamber;

(79) deploy temperature sensor in the outside air duct;

(80) deploy temperature sensor in the return air duet;

(81) deploy temperature sensor in the supply air duct;

(82) display results from four sensor modules concurrently on control module 110;

(83) calculate the proportion of supply air that is outside air;

(84) calculate the outside air volume;

(85) calculate the desired outside air volume based on occupancy, usage type, etc.;

(86) compare the actual outside air volume to the desired outside air volume;

(87) adjust outside air damper and return air damper while observing the changes in measured air temperature on control module 110.

(88) Traditional methods require many iterations of measurements, accompanied by a lot of back and forth movement. The ability to deploy sensor modules for continuous measurements saves a lot of time and effort. Also, because it is relatively easy to achieve a precise outcome, users are less likely to take shortcuts which may retain an undesirable level of outside air.

(89) Humidity Sensor Module

(90) FIGS. 10A, 10B illustrate exemplary configurations of humidity modules that are part of system 100. Sensor module 1001 includes sensing probe 1002, which can be used with or without extension rod 1003. The longer configuration is useful for placing the sensing element 1004 at a particular location in large ducts. Sensor module 1001 with sensing element 1004 measures temperature as well as humidity. FIG. 10C illustrates four different exemplary results available from one measurement: relative humidity percent 1011; dry bulb temperature 1012; wet bulb temperature 1013; dew point temperature 1014. Optional results not shown include grains of water per cubic foot. FIG. 10D illustrates exemplary displays from two humidity modules in different locations. A user may view for comparison these results: RH from S-1 1021; dry bulb temperature from S-1 1022; RH from S-2 1031; dry bulb temperature from S-2 1032.

(91) Differential Air Pressure Sensor Module

(92) FIGS. 11A, 11B, 11C, 11D illustrate an exemplary of a differential air pressure sensor module. FIG. 11(a) illustrates a version of the sensor module with two ports, and FIG. 11 (b) illustrates; four-port version. The pressure between the ports is measured and transmitted to control module 110.

(93) Air pressures are involved in a multitude of HVAC applications, including duct static pressure and velocity pressure. Duct static pressure is the difference between the pressure of duct air and room. air. Velocity pressure is related to air velocity. It is measured as the difference between two types of orifices on the probe. FIG. 11C illustrates both of these measurements.

(94) FIG. 11C illustrates differential pressure sensor module 1101 attached via included magnet 1113, shown in FIG. 11A, to the side of an air duct An industry standard probe 1132, a static tip, is inserted through a hole in the wall of duct 1131 and oriented into the airstream such that the static pressure of the duct is present at probe output port 1134. A flexible hose 1133 is connected between port 1134 and sensor module port 1111. Sensor module port 1112 is exposed to ambient air. The sensor module then measures the difference between the pressure of the air in the duct and the pressure of the air outside the duct. The result, e.g., 1.25 inches of water column, is sent wirelessly to control module 110.

(95) Also in FIG. 11C, differential pressure sensor module 1102, with four ports, is attached via included magnets to the side of air duct 1131. An industry standard probe 1141, a Pitot tube, is inserted through a hole in the wall of duct 1131 and oriented into the airstream. Pitot tube 1141 has two output ports, and there are two differential pressures typically of interest to users. Connected to the static pressure port is flexible hose 1142, which is connected to sensor module 1102 via ports 1121 and 1123. Another flexible hose 1143 is connected to sensor module 1102 port 1124. In this configuration, the sensor module transmits two results of interest to control module 110. Duct static pressure is the difference between sensor module ports 1121 and 1122. Velocity pressure is the difference between sensor module ports 1123 and 1124.

(96) Differential pressure module s 1101 and 1102 are useful in several applications, including setting duct pressure, setting room-to-room pressure, setting occupied space pressure vs. outside air, fume hoods, biosafety cabinets, and others. Most commercial and industrial buildings are specified to have a slightly positive pressure to prevent ingress of outside air, humidity, leaves, and bugs (think restaurant dining areas). The pressure drop across filters is a key measure of the cleanliness of filters. The present invention is designed to quickly and easily detect problems in these areas and alert a technician, building manager, or restaurant owner. The present invention provides results of pressure measurements from multiple locations to be reviewed and compared concurrently, which reduces the time involved in certain procedures. An exemplary application is described below.

(97) Application: Measuring and Adjusting Room-to-Room Differential Pressures

(98) The innovative capabilities of the present invention are especially important for cleanroom applications such as semiconductors, pharmaceutical, and hospitals, where multiple related pressures are specified. FIG. 13 illustrates a wafer fabrication facility 1301 with outside walls 1302, an exterior entry 1303, corridor 1304, suit-up room 1305, air wash 1306, general operations area 1307, and mini-environment for special processes 1308. The requirement for air cleanliness depends on the nature of the area. Pressure differences are one of the primary methods of controlling the direction and degree of contaminant movement. That is, a space with a great need for cleanliness will be specified to have a higher pressure than adjacent areas. Typical room-to-room pressure differences are maintained between 0.03 inches of water column and 0.06 inches of water column. For the building illustrated in FIG. 13, there may be a specification for these pressure differences:

(99) R1304 to 1303: 0.02 in. wc.

(100) R1305 to 1304: 0.03 in. wc.

(101) R1306 to 1305: 0.04 in. wc.

(102) R1307 to 1306: 0.05 in. wc.

(103) R1308 to 1307: 0.05 in. wc.

(104) Pressure differences are created by adjusting fan speeds and dampers to adjust the volume of supply air and return air for each space. The fans and dampers may be located at quite some distance from the points being measured. The pressures are interrelated, so adjusting one fan or damper can affect two or more room-to-room pressures. A conventional differential pressure sensor, usually held near a door by a technician using two hands, can measure only one or two differential pressures at a time, and the result is nowhere near the point of control, the fan or damper. The user records the measurement, moves to the point of control, makes and adjustment, and returns to make another measurement. The HVAC system is often organized such that the room characteristics are interrelated. An adjustment of one fan may affect two or three rooms, causing rooms that were in spec to go out of spec. Then the process begins again. The current industry method involves a long, drawn-out series of measurements and adjustments.

(105) System 100 allows multiple sensors to be placed where necessary. The room-to-room pressure measurements are continuously transmitted wirelessly to the wrist of the technician, who can display and store two or more measurements at the same time. In most cleanroom buildings the technician has access to the control elements from an interstitial level above the cleanrooms themselves. With the information provided by the present invention, he can quickly achieve all of the specified pressure setpoints, saving a lot of time and effort.

(106) Method of Measuring Room-to-Room Pressures

(107) In accordance with additional embodiments of the invention, a method of measuring a multitude of room-to-room differential pressures concurrently includes the steps of:

(108) deploy differential pressure sensor modules to each location of interest;

(109) link each sensor module with the control module;

(110) deploy repeater module(s) if necessary for increased range;

(111) select an appropriate display format on control module;

(112) observe differential pressure measurements in real time from a multitude of locations.

(113) Current methodologies are of two types. One way is for one person to move sequentially to each location of interest, measuring and recording results, and often returning to repeat measurements to note changes. Another method is to deploy multiple operators, each with an expensive handheld instrument, who communicate by shouting, moving for conferences, via walkie-talkies, or via cell phones. The exemplary embodiment of the present invention clearly offers a dramatic improvement in productivity for this type of application through the use of distributed sensor modules that are relatively inexpensive, together with novel formats for measurement presentation that allow quick feedback on control changes and component interactions within HVAC systems.

(114) Method for Setting Duct Static Pressure

(115) In HVAC duct systems it is important to maintain a minimum level of pressure at the extreme end of the duct system in order to maintain airflow through the duct and diffusers. For instance, a building engineer might specify that the fan generate a duct pressure that is 3 inches of water column above the ambient pressure in the building (static pressure), and that the system of valves and dampers be adjusted such that the most remote air diffuser will be supplied air at a pressure of at least 0.5 inches of water column. It is critical that the pressure at this point be carefully controlled. If too low, the diffusers will not distribute conditioned air as designed and building comfort will suffer. If too high, energy is wasted by running the fan too fast. If the technician measures only 0.4 inches of static pressure, he needs to adjust the fan and/or the dampers to increase the remote duct pressure to the minimum of 0.5 specified. However, if the pressure is higher than required, the excess fan power will use far more electricity than it should. The electric power required increases at the cube of the duct pressure increase. For instance, if the fan speed is increased to raise the remote duct pressure to 0.55 inches, only 10% higher than required, the fan will use 30% more electric power than required. (The calculation has the form of 1.11.11.1=1.3.) Current procedure requires a technician to measure the pressure at the appropriate point in the duct, and then move through the building to adjust the fan and the dampers. He then returns to measure pressure again. This cycle of measurement and adjustment will be repeated until the specified result is achieved. Sometimes the fan is a long distance from the point being measured, and on a different floor. This repetitive procedure requires a lot of time and effort, and leads to the technician settling for some safe guard-banded pressure instead of achieving the precise result desired. This is one of the main sources of wasted energy in buildings. What the technician needs for applications like this is a stream of real-time measurements taken at the point of interest and delivered to him where and when he is making the adjustment at the point of control.

(116) Method

(117) In accordance with additional embodiments of the invention, a method of achieving a desired set-point for duct static pressure includes the steps of:

(118) deploy differential pressure sensor modules to the points of interest, which may include not just the end point of a duct, but several points throughout the duct system which may be affected by a control change;

(119) link each sensor module to the control module;

(120) deploy repeater modules if necessary for range;

(121) select a useful display format;

(122) observe existing status of duct system pressures;

(123) effect changes in fan speed or damper settings;

(124) observe static pressure responses to control changes in real time from multiple locations.

(125) Pipe Fluid Pressures and Temperatures

(126) System 100 utilizes sensor modules to measure temperature and pressure of fluids in pipes. FIG. 12 illustrates the use of sensor modules in an exemplary application. Fluid 1200, e.g., water, moves through pipe 1210. Pipe 1210 includes three fixtures known as PT test points (pressure and temperature), which are sometimes implemented using a water-tight access port 1213 called a Pete's Plug. If temperature alone is desired, sensor module 901 from FIG. 9, or a similar sensor module, may be i inserted though a Pete's Plug as illustrated at location 1211. Temperature measurements will be transmitted continuously to control module 110.

(127) If pressure is desired as well as temperature, Sensor module 1221 may be inserted through a Pete's Plug as illustrated at location 1214. Sensor module 1221 allows pressure measurements to be made through a Pete's Plug. Control module 110 can display multiple pressure and temperature results from multiple locations concurrently.

(128) Valve 1212 may be adjusted to control the flow of fluid, and a user may desire to know the volumetric fluid flow. Valve 1212 may be calibrated so if the pressure drop across the valve is known, the volumetric flow, e.g., in gallons per minute, can be determined from a chart or equation. Sensor module 1221 can measure the differential pressure between locations 1214 and 1215 as well as the static pressures at each point. All results are transmitted to control module 110. It is often desirable to have these results available concurrently. It is also often desirable to have these results available from multiple locations concurrently.

(129) Method

(130) In accordance with additional embodiments of the invention, a method of measuring pressure and/or temperatures at a multitude of points in a pipe system concurrently includes the steps of:

(131) deploy pressure and temperature sensor modules to each point of interest;

(132) if desired, deploy water flow meter with connected instrument interface module;

(133) link each sensor and interface module to the control module;

(134) deploy repeater modules if necessary for range;

(135) select a useful display format;

(136) observe existing status of system pressures and temperatures;

(137) effect changes in pump speed or valve settings;

(138) observe multiple responses to control changes in real time from multiple locations in a user-friendly display format.

(139) Velocity Sensor Module and Probe Apparatus

(140) Air velocity is frequently required in HVAC. The present invention includes a velocity sensor module with unique features. A velocity sensor module, in coordination with temperature and/or humidity modules and a control module, form a system of distributed sensors that allows a user to make velocity and pressure measurements in air ducts more rapidly, more conveniently, more accurately, and more safely. The present invention may also be used to measure air velocity and pressure in applications other than ducts. The present invention uses a method based on differential air pressure, which is applicable to traditional velocity probes such as Pitot tubes.

(141) A widely used formula for air velocity is derived from fundamental laws of physics:
V=1096.7square root of (VP/d), where: V is velocity in feet per minute VP is velocity pressure in inches of water column
d is density of air in pounds per cubic foot=1.325BP/T, where BP is barometric pressure in inches of mercury
T is absolute temperature=degrees Fahrenheit+460

(142) 14 illustrates a system 1403 for making measurements of T, BP, and VP of duct air in an air duct. Often these measurements are part of a standard procedure, a velocity traverse of a duct. This procedure determines the conditions at a cross-sectional plane of a duct. Air conditions include barometric pressure, temperature and optionally humidity. Air conditions also include static pressure at one or more points on the cross-section. Conditions also include the inside dimensions of the duct, free of any insulation that may coat the duct walls. From these dimensions, a user consults standard tables and/or formulas to determine the matrix of points in the duct cross-section at which velocity must be measured. Air velocity is not uniform in the cross-sectional plane, so many, measurements must be performed at different locations and the results averaged. The average velocity times the cross-sectional area equals the airflow volume at that point in the duct system.

(143) FIG. 14 illustrates a duct traverse procedure using an exemplary embodiment of the present invention. Air or another gas flows through duct 1401 with duct walls 1402. Air velocity is not uniform across the duct as illustrated by velocity vectors 1403. The user must determine an average velocity in the duct by making and storing many measurements at specific locations 1404 located in the cross-sectional plane of the duct 1401. A user holds Pitot tube 1405 steady at each location 1404, and makes and stores a velocity reading. Then the user moves the Pitot tube to the next location for another measurement. Industry standard procedures may require measurements at 16 or more, sometimes as many as 200, separate locations in the duct.

(144) A Pitot tube 1405 has an orifice 1406 at the tip which when facing into the airstream develops total pressure. A Pitot tube has at least one other orifice 1407 that develops static pressure if not directly impacted by the passing airstream. A Pitot tube includes separate channels to conduct the two pressures outside the duct where they may be connected by hoses to velocity sensing module 1410. One hose connects the static pressure port 1409 of Pitot tube 1405 to the static pressure port 1411 on velocity sensing module 1410. Another hose connects total pressure port 1408 on Pitot tube 1405 to total pressure port 1412 on velocity sensing module 1410.

(145) Velocity sensing module 1410 includes valves, sensors, microprocessors, and other components to accurately measure total pressure, velocity pressure, and static pressure concurrently. The measured values are transmitted to control module 1430. Sensor module 1420 is inserted through a hole in duct wall 1402 and remains in-situ measuring temperature and/or humidity. The measured values are transmitted to control module 1430, which calculates and displays all of the results of interest to the user. Control module 1430 may be worn on the user's wrist, or mounted to the duct wall 1402, or otherwise placed conveniently. The user may store measurements by reaching to press the keypad of control module 1430. Alternatively, the user may store results and perform other control functions by pressing buttons on thumbswitch 1431. Stored results are stamped with the associated time and date. The user may choose from a variety of display formats, which are illustrated in FIG. 15. The present invention includes means for providing key information of different types to the operator concurrently to save set-up and measurement time and to improve understanding of the environment. Key among those innovative information displays are the concurrent measurements of velocity and static pressure.

(146) FIG. 16 illustrates some improvements provided over traditional methods. User 1601 holds a traditional velocity meter 1610 in one hand and manipulates the keypad with his thumb. Tubes 1611 and 1612 loop down from Pitot tube 1405. Tube 1611 has gotten caught on ladder. When the tubes 1611 and 1612 dangle and swing, measurement result may be less accurate. Temperature sensor 1613 is inserted through duct wall 1402 and connected to meter 1610 with a coiled cable. User 1601 stands on a ladder with his head in a dark area above the ceiling tiles. User 1601 moves his head up and down alternately, first up to position Pitot tube 1405 for a measurement at a proper matrix point, then down to view and store the results on the meter. FIG. 16 illustrates the cumbersome nature of the velocity traverse procedure. It is not uncommon for users to simplify the process by skipping the temperature measurement, which affects accuracy.

(147) When user 1601 finishes the velocity traverse matrix, he lacks a necessary measurement, static pressure. User 1601 withdraws Pitot tube 1405 and temperature sensor 1613 from the duct. User 1601 removes the temperature sensor. User 1601 disconnects tubes 1611 and 1612 from the meter. User 1601 replaces tube 1611 on the meter at a different port. User 1601 presses keys to change the meter mode from velocity to pressure. User 1601 reinserts Pitot tube 1605 into the duct and orients it into the airstream. User 1601 presses the meter to read and record the static pressure in the duct.

(148) User 1602 in FIG. 16 uses system 1403. Velocity sensor 1410 is attached to Pitot tube 1405 with stiff ,tubing that does not move during a measurement. The display of control module 1430 and the position of Pitot tube 1405 are both visible to user 1602 without moving his head. No tubes dangle from Pitot tube 1405. No coiled cable is attached to temperature sensor 1420 to present an obstacle. User 1602 has one arm and hand free to grasp a nearby fixture 1603 for improved safety. Free of cumbersome tubes and cables, and provided more visible results, his motions are faster and more precise. When user 1602 finishes traversing the matrix, he may view all of the measurement results as illustrated by FIG. 15. No setup changes are necessary to obtain static pressure. Static pressure was measured concurrently with velocity and temperature. A special interactive display mode of the Control Module facilitates the measurement and provides a convenient display of the results. An element of the present invention is the ability to display related measurements simultaneously when the technician usually requires the knowledge. An example in this case is Duct Static Pressure. FIG. 15 illustrates an exemplary embodiment of a complete display of desired information.

(149) Method of Measuring Duct Static Pressure

(150) In accordance with additional embodiments of the invention, a method of concurrently measuring temperature, velocity, and static pressure in an air duct includes the steps of:

(151) deploy insertion temperature sensor module to a suitable duct location;

(152) connect two pressure ports of a velocity sensor module to the static and total pressure ports of a Pitot tube or similar probe;

(153) link control module to temperature sensor and velocity pressure sensor;

(154) place Pitot tube inside an air duct at point of interest;

(155) multiple measurements of multiple types are received from multiple locations and displayed on control module for storage and/or dissemination and/or uploading to computer or Internet.

(156) The various embodiments are used with industry-standard Pitot tubes, which are available for purchase from Dwyer, Cole-Parmer, and other HVAC industrial supply companies. Pitot tubes vary in length from a few inches to five feet or more.

(157) The Velocity Sensor Module will also support Static Pressure measurement with industry standard static pressure probes. The present invention will support many other forms of velocity and pressure probes.

(158) Alternate Embodiments of Velocity Sensor Module

(159) Sensor module 1410 may be firmly attached to Pitot tube 1405. Sensor module 1410 may have an enclosure that envelops part of Pitot tube 1405. Said enclosure may have a part that is shaped like a bicycle handle grip to enhance usability.

(160) Air density is strongly affected by barometric pressure and temperature. Sensors for those two parameters are therefore necessary parts of an accurate velocity sensing system. The effect of humidity is less pronounced, so humidity sensors are not typically used in velocity measurement systems. The distributed and wireless nature of the present invention makes it easier for the user to utilize a humidity sensor and therefore achieve a higher than normal accuracy.

(161) Airflow Sensor Module and Capture Hood Apparatus Airflow Sensor Module

(162) The various embodiments comprise an airflow sensor module which is used with existing airflow capture hoods. FIG. 17 illustrates a damper setting procedure performed in two ways. Two rectangular ceiling diffusers 1710 are to have their airflow volume adjusted to meet the specification. Users 1 and 2 use a traditional capture hood and traditional method. User 1 holds a heavy, awkward capture hood tight against the ceiling fixture to try to capture all of the airflow, which flows across velocity grid 1723. Velocity grid 1723 works on a differential pressure principle similar to that of a Pitot tube. When airstream 1712 flows across velocity grid 1723, a pressure difference is generated between an upstream pressure in tube 1721 and a downsteam pressure in tube 1722. These tubes are connected to positive and negative pressure ports on meter 1730. Meter 1730 measures the differential pressure and calculates a velocity. The meter then multiplies the calculated velocity by the cross-sectional area of capture hood 1720, and displays a volumetric airflow, e.g., 220 cubic feet per minute (CFM). User 1 sees the result and shouts it to his teammate user 2. User 2 is on a ladder to reach and adjust the damper that controls flow to ceiling diffuser 1710. After making an adjustment, user 2 waits for user 1 to shout a changed result. This iterative process repeats until the specified airflow is reached.

(163) User 3 uses airflow sensor 1740. Airflow sensor 1740 performs the same measurement and calculation functions as meter 1730, and transmits continuous results to control module 1742 on the wrist of user 3. As user 3 adjusts the damper, he sees the changed result in real-time.

(164) The weight of airflow sensor module 1740 is a small fraction of the weight of meter 1730, because it is designed for a distributed sensing system, and needs no display, keypad, or other features that burden meter 1730. It is much easier to lift and place capture hood 1720 with airflow sensor module 1740 installed than for the same capture hood with meter 1730. This can be done by a human operator, or it can be done by a jack or stand 1750, which allows one person to perform a damper setting function normally performed by two people. A jack or stand 1750 could also be used with meter 1730, but user 2 would have to climb down the ladder once in at while to read the displayed result.

(165) FIG. 17 illustrates another long-standing problem with traditional methods and illustrates a corresponding advantage of a distributed sensing system. As with Pitot tubes, airflow sensors must include air density in the calculation. However, temperature sensor 1731 is typically poorly designed and poorly positioned to contribute an accurate figure. It takes too long, e.g. up to three minutes, for airstream 1712 to heat or cool temperature sensor 1731 to the correct temperature. Most users cannot wait that long so they forego the temperature component and accept an inaccurate result. User 3 has installed a fast-acting temperature sensor on a support strut 1724 of capture hood 1720. It measurement of temperature is transmitted to control module 1742 and is included in the airflow calculation. Optional temperature features included with control module 1742 are to lock in a particular temperature measurement for use with all subsequent measurements, or to manually enter a known air temperature for use in subsequent airflow calculations.

(166) Airflow sensor 1740 is far less expensive than meter 1730, allowing more widespread use.

(167) FIG. 18 illustrates other unique benefits of the various embodiments. A room has three supply air diffusers 1810 and one return air diffuser 1811. Jacks or stands 1750 hold four capture hoods in place. As shown in FIG.17, one operator 3 can view the airflow figures for all four diffusers at the same time on one control module 1742. He can adjust the dampers of one after another without moving the capture hoods. Airflow volumes of diffusers on the same system are often interrelated. Adjusting one damper can cause changes of all four airflows, not just the one an operator is seeking to adjust. With traditional equipment and methods, many iterative measurements are required before each diffuser achieves the specified airflow. In the embodiment, the interrelationships are revealed to the operator and corresponding adjustments can be made quickly, saving a lot of time. The ability to view multiple results concurrently offers an unexpected benefit for operators.

(168) Airflow Capture Hood

(169) A relatively small, lightweight capture hood is utilized for measuring airflow at inlets and outlets. Traditional capture hoods such as capture hood 1720 with meter 1730 in FIG. 17 weigh about 9 or 10 pounds. Replacing a traditional meter with airflow sensor module 1740 reduces the weight to about 7 pounds. The present invention includes a capture hood 1901 shown in FIG. 19 that weighs about 3 pounds. Capture hood 1901 is constructed with the same type of aluminum, carbon fiber, and modem fabrics that are used in the construction of tents and clothing for mountain climbing. Capture hood 1901 is not constrained by the need for a mounting platform for a heavy meter. Capture hood 1901 utilizes a frame that is light and relatively flexible compared to traditional capture hoods. Capture hood 1901 comprises two or more optional locations for the airflow sensor 1740, on the side or beneath the velocity grid. Quick-responding temperature sensor or temperature and humidity sensor 1741 is attached to the upper frame of capture hood 1901 where it will have early contact with the airstream. Capture hood 1901 is affixed to the diffuser such that the operator can move away for adjustments or other measurements. These new methods are not practical for heavy capture hoods, but are practical for a hood weighing only three pounds. In one embodiment, capture hood 1910 comprises a spring hook 1943 that hooks over a vane of diffuser 1710, and tension holds the light capture hood tightly against the diffuser. In another embodiment, magnets 1944 around the perimeter of capture hood 1901 attract to a ferrous strip around the ceiling diffuser. In a further embodiment, spring clamps may hold capture hood 1901 tightly against the ceiling strips between tiles. Alternatively, a thin, lightweight extensible rod 1945 may be placed between the floor and capture hood 1901, pinning it against the ceiling diffuser.

(170) Proportional Balancing

(171) Proportional Balancing of HVAC Duct Systems was discussed above. There is often a need to observe and understand how the adjustment of one diffuser damper is affecting the airflow at the other diffusers in the same duct system. This can be done by propping up a capture hood at a diffuser and wirelessly monitoring it while adjusting other dampers.

(172) Another way to monitor the change is to use a Pitot tube. It is often easier using magnets and grippers to position a Pitot tube in the duct leading to the diffuser in question than it is to jack up a capture hood against the ceiling diffuser. The Pitot tube can then wirelessly transmit a percentage change in measured velocity at a point in the duct cross-section that represents the total airflow. The important parameter is the percentage change caused by the damper adjustment, not the amount of airflow itself.

(173) The Velocity Sensor Module of the present invention will make further improvements in the time and accuracy of Proportional Balancing. Using magnets or other holding apparatus, a Pitot tube can be temporarily fixed in place at the center line of the duct feeding the furthest duct, the reference duct, as mentioned above. The air velocity measured at that point can be correlated to the airflow measured through the diffuser. When an adjustment shows that an upstream duct adjustment caused a particular change in the duct velocity, such as 5%, it can be assumed that the airflow also changed by 5%, and an airflow measurement can be avoided. The final airflow can be measured at the diffuser as usual to verify the result, but the intermediate measurements can be avoided and much time saved.

(174) Method

(175) In accordance with additional embodiments, a method of measuring at multitude of locations concurrently includes the steps of:

(176) deploy sensor modules to the points of interest, including airflow sensor modules on capture hoods, and/or velocity sensor modules on Pitot tubes or similar probes, air pressure sensors attached to duct static pressure sensing probes, and/or room-to-room pressure sensor modules, and/or other related sensor modules;

(177) link each sensor module to the control module;

(178) deploy repeater modules if necessary for range;

(179) select a useful display format;

(180) observe existing status of duct system at a multitude of locations;

(181) effect changes in fan speed or damper settings or other changes;

(182) observe duct system response in real time from multiple locations.

(183) Other Sensor Modules

(184) Various embodiments comprise other sensor modules that measure light intensity, radiation, CO2 concentration, CO concentration, motor/fan rotor speed in RPM, degree of incline (for dampers and grille degree of openness), pulse counters (for electric meters and other types), and switches (for doors open/closed and machines on/off). Other sensor modules are constructed in a fashion similar to the temperature sensors of FIG. 9. Other sensor modules are illustrated in FIG. 20A, 20B, 20C. In FIG. 20A, the sensor module 2001 may have a sensing element as an integral part of the module. Alternatively, a sensor module 2002 may have the sensing element 2020 located in a shaft-type of probe as in FIG. 20B. Alternatively, as illustrated in FIG. 20C, a sensor module 2003 may have a sensing element 2030 located at the end of a flexible cable.

(185) Instrument Interface Module

(186) The various embodiments also make existing instruments more useful in several ways. First, the result is sent wirelessly to where it is needed. Second, the control module display and viewing angle will usually be superior. Third, the control module provides a very large memory for storing measurements and provides beneficial statistics that are often missing in other instruments. Fourth, the thumbswitch allows hands-free storage of measurements. Fifth, the measurement data can be shared by multiple technicians in real-time.

(187) Digital Outputs

(188) For instance, this type of Sensor Module can utilize the digital results from existing instruments such as the AirData Multimeter from Shortridge Instruments. This allows the benefits of the present invention to be applied to the use of the third-party meter. Results can be sent wirelessly to a remote location, the user can view the results on his wrist while his hands are free for another operation, a large memory is available for storing data, and the Thumbswitch allows him to store data without moving his arm. The Interface Module is adaptable to match the electrical and mechanical output of the third-party meter. The ADM-870C meter from Shortridge Instruments provides an RS-232C serial data output through a standard round connector.

(189) Interface Module for Analog Outputs

(190) Ultrasonic fluid flowmeters and other existing instruments, sensors, and transmitter have analog outputs such as 0-5 volt, 0-10 volt, and 4-20 mA current loop. This Module uses the same basic foundation as the Digital Interface Module, but includes circuitry to convert the analog measurement to a digital value for wireless transmission.

(191) Pulse counters.

(192) Open/close switches.

(193) Instrument interface modules may have characteristics illustrated in FIG. 20C. Connector 2030 is designed specifically for the output of the instrument of interest. It is attached to the end of a flexible cable 2031 which carries signals to conversion and wireless circuitry inside module enclosure 2003.

(194) Operation in Exemplary Applications

(195) The modules (control, sensor, and, if present, thumbswitch, repeater, and other types) are collected and turned on. They automatically join a wireless network and the control module displays a Link Status showing all of the modules in the network. The technician deploys each sensor module as appropriate to the function he is performing, such as temperature, humidity, pressure, etc. The technician straps the control Module to his wrist or otherwise positions it for easy viewing. At specific intervals, the measurements made by the sensor modules are radioed to the control module and displayed. The technician may store the measurements in memory if desired, either by pressing a key on the control module's keypad or by pressing a key on the thumbswitch.

(196) The various embodiments address the key deficiencies of other HVAC instruments as noted above. Measurements can be taken at the point of interest and results delivered to the technician for immediate action as necessary. What is delivered is a stream of real-time data, not one or two occasional measurements that represent a particular point in time. The technician's hands are free to make the physical changes necessary, such as repairs or adjustments. A team of technicians can wear modules and share the results in real-time for improved team productivity. Further, an integrated walkie-talkie is available for team coordination.

(197) The various embodiments allow the technician to install a remote sensor, then move around the building to make the necessary adjustments while a stream of real-time measurements are radioed to him. Thus informed, the technician can make exactly the right adjustments to achieve a precise result. This saves a lot of time and gives a much better result.

(198) The various embodiments offer another advantage in that they can make existing instruments far more useful and productive. This is a uniqueness factor. An example is the AirData Multimeter from Shortridge. These instruments measure air pressure, temperature, velocity, and flow. Model 870C of this series of instruments has a serial output that can feed a stream of data to a wireless module which is a component in the invention. The data is then distributed wirelessly to the wrists of the technician team members, who can quickly make e necessary HVAC adjustments. Following is one example of the power of this improvement. Current practice is for one person to hold up a capture hood to an air outlet in the ceiling while another person climbs a ladder, removes a ceiling tile, and locates the damper that controls the air flow to that diffuser. The meter on the capture hood display the amount of air coming through the diffuser into the room in cubic feet per minute. The person holding up the heavy capture hood, with some difficulty because of the sight angles involved, then reads the meter's display and shouts it to his partner, who adjusts the damper accordingly, trying to achieve a specified result. Then the two repeat the procedure until the air flow is within the desired range. Finally, the one holding up the capture hood. can lower the instrument and rest. Then the team moves to the next diffuser and repeats the procedure.

(199) In the various embodiments, the airflow data is collected from the Shortridge meter and wirelessly radioed to the control module where a continuous stream of readings is viewed directly by the technician adjusting the damper. He can adjust the damper smoothly and continuously until the result is precisely at the midpoint of the desired range. The one holding up the hood does not have to read the meter or shout to his teammate; he can concentrate on holding the hood steady. The result of the invention is a faster, more accurate result achieved with less effort and stress on the team. In many cases, the invention allows one person to do the same function, using a jack or prop to hold the hood in place. This type of measurement is performed very frequently, so reducing the manpower required by about 50%, while improving the accuracy of the results, is very important to the HVAC industry. Also, fast, accurate results help reduce e energy used in the building and contribute to the energy goals of the country.

(200) These system capabilities make possible new, better methods for industrial repairs and adjustments. For instance, they eliminate the back-and-forth nature of many industrial operations where the point of interest is different from the point of control. Instead of a long cycle measurement/adjustment/measurement/etc., a real-time stream of measurements is available at the point where the adjustment is being made, saving time and facilitating a more precise final result.

(201) The distributed nature of the instrument in the present invention makes it possible for a technician to make the necessary measurements at the location of interest, transmit the measurements quickly to the location where they are most needed for decisions and adjustments, which may be a few feet or hundreds of feet away. The measurement results can be displayed on a wrist-mounted module, a head-mounted module for heads-up viewing, or annunciated in the user's ear. The user's hands during this process are free for tasks instead of being occupied by instruments.

EXAMPLES

(202) The TAB Accelerator Kit is composed of a Wrist Reporter, Dongle, and Thumbswitch. There are also accessory cables, batteries, and chargers. The Kit works in conjunction with the Shortridge AirData Multimeters, models 870C and 860C.

(203) The Wrist Reporter is worn on the wrist of the user or otherwise placed convenient to viewing. Readings from the meter are sent wirelessly to the Wrist Reporter for viewing and storage. This allows the TAB technician to finish projects more quickly with more precise measurements.

(204) Example: Climb a ladder, move the ceiling tile aside, and prepare to set the damper. Look down at your Wrist Reporter and see the flow readings changing in real time as you move the lever. When the reading matches your target, you mark the lever position and/or tighten the wing nut. You're done. No more shouting back and forth to your teammate holding the FlowHood. The Dongle takes the reading out of the AirData Multimeter and transmits it wirelessly to the Wrist Reporter. Also, it doesn't matter that the viewing angle to the meter is difficult when the FlowHood is overhead. The view that matters is the view of the Wrist Reporter.

(205) Example: Cut 50% off the time required to perform a duct traverse by freeing your hands of the ADM and by seeing velocity statistics as you proceed. Prepare the duct and pitot tube or AirFoil as usual. Then place the ADM-870C in the correct measurement mode and set it to AUTO or TREND so it reads continuously. You no longer need to crane your head to see the meter's display. Hang it on your hip using belt loops. Place the Wrist Reporter on the inside of your Wrist Reporter. Place the Thumbswitch on your finger. Now use both hands to position the probe as appropriate. When the position is correct and the measurement on your Wrist Reporter looks valid, press the Thumbswitch button to store the result. As you progress through the matrix of points, the Wrist Reporter automatically shows you the current average velocity, along with the minimum and maximum readings of the traverse.

(206) Alternative Embodiments

(207) The temperature sensing elements used may be 2252-ohm thermistors, 10K-ohm thermistors, thermocouples, or other type of temperature sensor. The enclosure may be plastic or metal. Batteries may vary.

(208) The General Purpose Sensor Module is configured for use with a variety of sensing probes, both analog and digital, to measure air and water temperatures, humidity, CO, CO2, light intensity, and other parameters.

(209) Summary of System-Related Functions and Innovations

(210) The embodiments of the present invention provide a system of modules as described above that solve or minimize long-standing industry problems. A wireless network of specialty sensors and a wearable control module allows getting data from the point of measurement to the point of control, and improves communication among team members.

(211) The present invention offers a large increase in productivity by allowing a technician to move around, climb a ladder, drill a hole, adjust a damper or valve, speed up a pump, or otherwise use his hands and feet to implement changes while knowing the immediate effects of those changes. Multiple team members can each wear a Control Module so they can each receive and view the measurement data directly, which promotes better teamwork and higher productivity.

(212) These system capabilities make possible new, better methods for industrial repairs and adjustments. For instance, they eliminate the back-and-forth nature of many industrial operations where the point of interest is different from the point of control. Instead of a long cycle measurement/adjustment/measurement/etc., a real-time stream of measurements is available at the point where the adjustment is being made, saving time and facilitating a more precise final result.

(213) The distributed nature of the instrument in the present invention makes it possible for a technician to make the necessary measurements at the location of interest, transmit the measurements quickly to the location where they are most needed for decisions and adjustments, which may be a few feet or hundreds of feet away. The measurement results can be displayed on a wrist-mounted module, a head-mounted module for heads-up viewing, or annunciated in the user's ear. The user's hands during this process are free for tasks instead of being occupied by instruments.

(214) The wireless modules provide for many different functions in different applications that previously were not possible or only possible by utilizing multiple instruments. For instance, the present invention includes a mobile, wrist-mountable module that can display two or more measurements simultaneously from different sensors in different locations and store them with the time and date of the readings. These new functions produce huge benefits for several HVAC applications. They give the technician the ability to see all of the related information at the time that he is making a decision about a repair or adjustment.

(215) The various embodiments combine two operating modes that were previously only available in different instruments. One is a diagnostic or debugging mode used by a technician to discover and promptly fix problems. The other is a monitoring or datalogging mode which collects measurements regularly from distributed sensors over a period of hours, days, or weeks. The data is analyzed later, usually plotted against time to show relationships between events.

(216) The various embodiments allow a mobile module to display the results in a diagnostic mode from sensors that are also at the same time part of a datalogging network.

Alternative Embodiments

(217) While the invention has been described with reference to specific embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the true spirit and scope of the invention. In addition, modifications may be made without departing from the essential teachings of the invention. It is intended that the invention not be limited by the specific embodiments shown and described. It is intended that the invention be limited only by the claims appended hereto.