Patent Grant
6928864
The present invention involves a tool assembly and components from which the tool assembly is assemblable, which are typically of an elongated tubular shape adapted for insertion into wells for field monitoring of conditions in the wells; and in particular a rotatably engageable connector to couple and electrically interconnect components, data collection, processing and storage functions, networkability and adaptation for use in very small holes.
An ever increasing emphasis is being placed on systematic monitoring of environmental conditions in relation to ground and surface water resources. Examples of some situations when monitoring of conditions of a water resource may be desired include environmental monitoring of aquifers at an industrial site to detect possible contamination of the aquifer, monitoring the flow of storm water runoff and storm water runoff drainage patterns to determine effects on surface water resources, monitoring the flow or other conditions of water in a watershed from which a municipal water supply is obtained, monitoring lake, stream or reservoir levels, and monitoring ocean tidal movements.
These applications often involve taking data over an extended time and often over large geographic areas. For many applications, data is collected inside of wells or other holes in the ground. A common technique is to drill, or otherwise excavate, a number of monitoring wells and to insert down-hole monitoring tools into the wells to monitor some condition of water in the wells. Although such monitoring wells are sometimes very deep, they are more often relatively shallow. For example, a significant percentage of monitoring wells are less than 50 feet deep. The cost of drilling monitoring wells, even when relatively shallow, is significant, especially given that a large number of wells is often required. The down-hole monitoring tools also represent a significant cost.
One way to reduce costs is to use smaller diameter monitoring wells, because smaller diameter holes are less expensive to drill. One problem with smaller diameter holes, however, is that there is a lack of tools, and especially high performance tools, that are operable in the holes. For example, only tools with very limited capabilities are available for use in 1 inch diameter holes. There is a need for high performance tools for use in such small diameter holes.
One reason for the high cost of monitoring tools is that they use expensive components and designs that frequently require significant amounts of expensive machining. The tools often require the assembly of components to form a tool assembly for insertion into the monitoring wells, and significant manufacturing expense is often required to provide structures for coupling the components and for electrically interconnecting the components. These problems become even more pronounced when trying to provide a tool at reasonable cost for use in a small diameter monitoring well. Furthermore, assembly and disassembly of components of the down-hole tools frequently require the use of wrenches or other tools, and sometimes special tools. This complicates use of the down-hole monitoring tools, and providing features on the down-hole tools to accommodate tools required for assembly and disassembly often requires machining, which significantly adds to manufacturing costs. Furthermore, electrical interconnections between components typically require special keying of the components, or of the electrical connectors between the components, which result in difficulty of use and a possibility for tool damage or malfunction due to misalignment. There is a significant need for new designs for coupling and electrically interconnecting components to permit easier assembly of down-hole monitoring tools without the need for complex structures that are difficult to manufacture.
In addition to the high cost of monitoring wells and down-hole monitoring tools, a significant amount of ongoing labor is typically required to maintain the tools and to obtain and use data collected by the tools. For example, it is frequently necessary to have someone visit the monitoring wells at periodic intervals to make sure that the tools are still working and to obtain data collected by the tools. The data must then be analyzed for use. The frequency between visits to a well may be a function of a number of variables, such as the reliability of the tools, the frequency with which batteries need to be replaced, and the capacity of the tools to collect and store data. Moreover, many down-hole tools are difficult to service and must be returned to manufacturers or distributors for even relatively simple service tasks, such as changing batteries in the tool. There is a significant need for tools that require less attention and that are easier to service.
Many of the available down-hole monitoring tools also lack significant flexibility in the way they can be used. For example, many tool designs are not designed for remote communication, for networkability or for being powered by the variety of different power sources that may be suitable for different field applications. There is a need for down-hole monitoring tools having greater flexibility.
One object of the present invention is to provide a high performance tool assembly, and components thereof, operable for field applications to monitor at least one condition in a well or other hole having a diameter of 1 inch or smaller.
Another object is to provide a tool assembly, and components thereof, operable for field applications to monitor at least one condition in a well or other hole and with a high capacity for logging data prior to requiring servicing of the tool assembly and components. A related object is to provide such a tool assembly, and components thereof, operable to log data with low power consumption to prolong operation of the tool on battery power prior to requiring a change of batteries. Another related object is to provide such a tool assembly, and components thereof, operable in a manner to conserve computer memory during data logging operations.
Another object of the invention is to provide a tool assembly, and components thereof, operable for field applications to monitor at least one condition in a well or other hole and which is easy to use and service. Related objects are to provide such a tool assembly, and components thereof, in which field assembly and disassembly of the tool assembly is accomplishable without the use of tools and in a manner so that batteries are easy to access for replacement.
Still another object of the invention is to provide a tool assembly, and components thereof, operable for field applications to monitor at least one condition in a well or other hole and being easily networkable in a network controllable by at least one of the tool assemblies. A related object is to provide a network of such tool assemblies and a method for using the network to perform field monitoring applications.
These and other objects are addressed by various aspects of the present invention as described and claimed herein.
In one aspect, the present invention provides a tool assembly, and components thereof, adapted for insertion into a small diameter well or other hole to provide high performance monitoring of at least one condition in the well or other hole. At least one component of the tool assembly includes a computing unit including a processor and memory having stored therein instructions readable and executable by the processor to direct at least one operation, and preferably substantially all operations, of the tool assembly, including direction of obtainment of sensor readings from a sensor in the tool assembly. In a preferred embodiment, the tool assembly and its components are adapted for use in monitoring wells and other holes having a hole diameter of 1 inch, and in some cases even smaller. The tool assembly, and components thereof, typically have a substantially tubular shape of a substantially constant outside diameter of smaller than about 1 inch, and preferably even smaller. In general, even when the component or the tool assembly has other than a tubular shape of constant outside diameter, a cross-section of the tool assembly, and of each of the components, taken substantially perpendicular to a longitudinal axis at any longitudinal location along the tool assembly/component, fits entirely inside a circle having diameter of smaller than about 1 inch. In preferred embodiments, the component cross-section fits inside an even smaller circle, with a circle of smaller than about 0.75 inch being particularly preferred. In one embodiment, the tool assembly is connectable with an external power source when deployed for operation. The ability to power the tool assembly with an external power source significantly enhances the flexibility of the tool and permits the tool to be deployed for longer periods and enhances utility of the tool assembly for network applications, providing significant advantages over existing monitoring tools designed for insertion into small diameter holes size. The connection to an external power source is made via dedicated conductors in a cable from which the tool assembly is suspended during use. In a preferred embodiment, the tool assembly has the flexibility to be connected with at least two different external power sources, including a higher voltage external power source that is stepped down for use by the tool assembly and a lower-voltage external power source that can be used directly by the tool assembly.
In another aspect, the computing unit is capable of directing that sensor readings be taken according to at least two different sampling schedules, each having a different time interval between sensor readings, with the computing unit being capable of directing a change from one sampling schedule to another sampling schedule based on determination by the computing unit of the occurrence of a predefined event. For example, the predefined event could be a predefined change between consecutive sensor readings, passage of a predefined period of time, or receipt of a predefined control signal from a remote device. In this way, sensor readings may be taken more frequently when the need occurs due to the occurrence of a transient event of interest. This situation might occur, for example, when the tool assembly is monitoring for the presence of storm runoff water. When a sensor reading indicates that storm runoff has commenced, the sampling frequency can be increased to provide more detailed information about the storm runoff event. By taking very frequent sensor readings only during the transient event of interest, significant power and memory space are conserved. Additional memory space can be conserved by not tagging each data record with a time tag, but only tagging an occasional data point to indicate a change to a new sampling schedule.
In another aspect of the present invention, the tool assembly, and the components thereof, permit sensor readings to be taken and sensor reading data to be logged with low power consumption. Signals are processed at a voltage of smaller than about 4 volts, and preferably a voltage of about 3 volts or smaller. The processor also operates at a compatibly low voltage. Furthermore, a number of factors are designed to conserve power during operation, thereby permitting longer operation prior to requiring battery replacement. Also, notwithstanding operation at the lower voltage, in one embodiment the tool assembly permits the flexibility to use a higher voltage external power source to supply power to operate the tool. In this embodiment, the higher voltage power is stepped down in the tool assembly. Optionally, the power may be stepped down in a manner to maintain separate groundings for the electronics of the tool assembly and for the higher voltage external power source. For some sensors, such as electrochemical sensors in direct contact with an aqueous liquid, maintaining separate groundings is important to prevent interference with operation of the sensor. In another embodiment, a lower voltage external power source may alternatively be used, providing for significant flexibility in the use of the tool assembly.
In another aspect of the invention, components of the tool assembly are assemblable and disassemblable without any keying required between components. In one configuration, components of the tool assembly are assemblable and disassemblable through rotatable engagement and rotatable disengagement, respectively, of the components in a manner not requiring the use of wrenches or other tools. Electrical interconnection of the components is automatically made through the simple rotatable engagement. Electrical interconnection is made through a multiple connector unit, which in one embodiment comprises a small elastomeric strip with a number of small, parallel conductive paths. The multiple connector unit is sandwiched between two sets of electrical leads, which each typically comprise conductive features on an insulating substrate, in a way to make isolated electrical interconnections between the two sets of electrical leads. The rotatable engagement feature significantly simplifies use of the tool assembly and also permits design of the tool assembly for easy access to batteries and other components for ease of servicing. In other configurations, electrical connections may be established between components through means other than rotatable connectors. The configuration would provide alignment between components along a common axis and exert a sufficient compressive force in order to maintain an electrical connection.
In yet another aspect of the invention, the tool assembly is networkable in a communications network with a number of other like tool assemblies. Interconnections may be established between the tool assemblies through use of one or more network junction boxes to which each of the tool assemblies is connectable. The networked tool assemblies may be configured as a monitoring system for monitoring one or more measurable conditions. The monitoring system may comprise a central controller, such as a personal computer or palm top computer, which is also connectable to the communications network and may be employed to perform various functions with regards to monitoring of the networked tool assemblies as well as providing an interface through which a system user may initiate various functions.
The central controller may be configured to interface with one or more different types of communications networks such that the lines of communication may be established with the tool assemblies. In one configuration of the invention, the communications network may comprise a programming cable which is directly connectable between a communications port on the central controller and one or more tool assemblies. The connection to the tool assembly may be made directly or through use of some sort of connection box.
Another configuration of the communications network may comprise the use of the public switch telephone network (PSTN). As such, the central controller is equipped with a modem such that an outgoing call may be placed, and the node on the communications network to which each of the tool assemblies is connected may further comprise a modem/controller, which also provides for establishing connections over the PSTN. When a telephonic connection is established between the central controller and modem/controller, messages may be exchanged between these components.
In yet another configuration of the communications network, radio transceivers may be in electrical connection with both the central controller and a remotely located network junction box which provides a further connection to each of the tool assemblies connected to the network. The transceivers provide for the conversion of electrical signals to radio signals such that lines of communications are established between the central controller and the various tool assemblies connected to the communications network.
As was discussed above, the central controller may be configured to include a number of processing modules which are employable to provide monitoring functions for the various tool assemblies. One module which may be included provides for the performance of various communications functions with regards to tool assemblies connected to the network such as identifying tool assemblies connected to the communications network, and which further provides for generating and addressing messages, which are sent from the central controller to the various tool assemblies. The communications module may further provide for the receipt of messages from the tool assembly and the performance of various functions with regards to confirming whether certain tool assemblies connected to the network have provided desired information.
Another processing module which may be included as part of the central controller relates performance of certain functions to view and amend parameters which one or more of the tool assemblies employ in performing monitoring functions. Through an interface such as an interactive screen display, parameter information may be viewed and/or amended. In the event that communications information has been amended, the communications module may then be employed for delivering the amended parameter information to the selected tool assembly.
Further included in the central controller may be a test processing module. This module may be employed to perform various functions with regards to the tests the tool assemblies perform. Functionality is provided as part of this testing module to view tests, which are currently loaded on a particular tool assembly. Interactive screen displays are also provided for creating new tests, amending existing tests or manually initiating existing tests. Various information, which may be entered via the test processing module, includes a schedule for performing automated testing. Information provided via the interactive screen display is converted by the communications module to a message, which is transmittable over the communications network to selected tool assemblies.
The test processing module may be further employed to extract information from a selected tool assembly. Particular tests may be selected for a tool assembly and messages generated which include the programming for the test. These message are then transmittable to the selected tool assembly. The tool processing module may be further employed for extracting data. Various display and/or outputs functionality is included in the central controller for displaying the extracted test data in a desired format.
As part of the operations of at the monitoring system described herein, at least one of the tool assemblies in the network is capable of transmitting a communication signal in the network to cause at least one other of the tool assemblies to perform a monitoring operation comprising obtainment of a sensor reading. In one embodiment, the communication signal is transmitted when the transmitting tool assembly determines that a predefined event has occurred. In one embodiment, the receiving tool assembly is directed to change its sampling schedule to a schedule with a shorter interval between sensor readings when more frequent sensor readings are desired due to an identified transient condition. In one embodiment, the transmitting tool assembly communicates directly with the receiving tool assembly. In another embodiment, a personal computer, palm top computer or other network controller may receive and process the transmitted signal and transmit a control signal to direct the receiving tool assembly to perform the desired operation. One example of when the tool assemblies may advantageously be deployed in a network is to monitor water availability in a municipal water supply system. For example, tool assemblies indicating pressure sensors can be located in different portions of the water supply network, such as various streams, rivers, aquifers, reservoirs, etc. that contribute to the water supply. Based on analysis of pressure readings provided by the various tool assemblies, the capacity of different portions of the water supply to provide water to satisfy a projected demand can be determined, and water can be supplied from different portions of the water supply system as appropriate. As another example, a network of the tool assemblies can be placed in monitoring wells surrounding a contaminated site, and pressure can be monitored to identify infiltration of water into the contaminated site and the characteristics of the infiltration and/or the infiltrating fluids. As yet another example, a network of the tool assemblies could be located in different injection and withdrawal wells of a solution mining operation, to monitor the quality of injected fluids and the quality of produced fluids, to monitor the overall performance of the operation.
These and other aspects of the present invention are discussed in greater detail below.
a-d are system diagrams, which show the various configurations of the communication network.
In one aspect, the present invention provides a tool assembly and components that are assemblable to make the tool assembly. The tool assembly, and each of the components from which the tool assembly is assemblable, are adapted for insertion into a well or other hole for the purpose of monitoring at least one condition present in the well or other hole. At least one component of the tool assembly includes a computing unit capable of directing at least one operation of the tool assembly, and preferably substantially all operations of the tool assembly, the computing unit includes a processor and memory having stored therein instructions readable and executable by the processor to direct operation of the tool assembly. The tool assembly also includes a sensor, which may be located in the same component with the computing unit or may be located in a different component. The sensor is capable of providing sensor readings to the computing unit, with each sensor reading including generation by the sensor of at least one sensor output signal, which includes sensor reading data, processable by the computing unit, corresponding to at least one monitored condition. The sensor may also be referred to as a transducer and a monitored condition may be referred to as a measurand.
The tool assembly also permits interconnection with a cable including a plurality of electrical conductors, or conductive lines, operably connectable with the computing unit and through which the tool assembly can communicate with a remote device and/or through which power can be supplied to the tool assembly from an external power source, such as to provide power to operate the computing unit.
Referring now to
With continued reference to
The control component 102 is engageable at one end with the cable component 104 and is engageable at the other end with the sensor component 106, to form the fully-assembled tool assembly 100. As shown in
As seen best in
In the three-component tool assembly 100, as shown in
With continued reference to
With continued reference primarily to
As shown in
With continued reference primarily to
With continued reference primarily to
The embodiment of the tool assembly discussed so far with reference to
One important aspect of the present invention is an electrical connector that can be used to make electrical interconnections between the components of the tool assembly without keying. The electrical connector includes two connector portions that in one configuration of the invention are engageable by rotatable engagement of complementary engagement structures, one located on each of the connector portions. Although the configuration described herein employs connectors which are engageable by rotatable engagement, other types of engagement, which do not require keying shall fall within the scope of the present invention. For example, connectors which provide for alignment of components along a common axis, and apply a compressive force to keep the components in place, such as snaps and latches, fall within the scope.
With regards to the rotatable connector, each connector portion includes a set of electrical leads. The engagement structure also includes a multiple connector unit that, when the complementary engagement structures are rotatably engaged, is sandwiched between and contacts the sets of electrical leads of the two connector portions. The two connector portions may be integral with or separately connected to electronic components to be electrically interconnected. A significant advantage of the electrical connector of the present invention is that it requires no keying to orient the two connector portions to make the desired electrical interconnection between the two sets of electrical leads. Furthermore, because the connector portions are engageable by simple rotatable engagement of the engagement structures, the electrical connector is readily adaptable for use in a variety of applications. Although the electrical connector may be used to electrically interconnect a wide variety of electronic components, the electrical connector will be described herein primarily with reference to the tool assembly of the present invention.
By using the electrical connector of the present invention, electrical interconnections can be made between components through simple rotatable engagement of the components, facilitating ease-of-use and efficient manufacturability. The tool assembly is easy to assemble because the components are physically secured to each other and electrical interconnection is made between the components simply by rotatably engaging the components. No keying between the components is required to orient the components for engagement or electrical interconnection, which significantly simplifies assembly of the tool assembly. The rotatable engagement and electrical interconnection of components using the electrical connector will now be discussed in greater detail in relation to coupling of the cable unit 104 and the control component 102 with reference to FIGS. 6 and 9-14. As will be appreciated, the same principles apply equally to engagement of any two components by rotatable engagement according to the present invention. For example, a similar electrical connector structure is used in coupling the control component 102 and the sensor component 106 and in coupling the control/sensor component 222 and the cable component 104 (in the two-component tool assembly 220 shown in FIGS. 7 and 8).
The multiple connector unit 144B is a small elongated strip with a plurality of isolated conductive paths through which isolated electrical connections can be made to the electrical leads 230 of the printed circuit board 176.
It is also desirable that the multiple connector unit 144B be sufficiently deformable so that it readily conforms to the surface of the printed circuit board 176 to make good electrical contact with the electrical leads 230 and without significant damage to the electrical leads 230. In that regard, the core 248 is preferably made of a deformable material, and preferably an elastomerically deformable material, such as a natural or synthetic rubber or another thermosetting or thermoplastic polymeric material. A preferred elastomeric material is silicone rubber. Multiple connector units that are elastomerically deformable are sometimes referred to as elastomeric electrical connectors. One source for such elastomeric electrical connectors is the Zebra™ elastomeric connector line from Fujipoly America Corp., of Kenilworth, N.J., U.S.A. Another source is the Z_Axis Connector Company of Jamison, Pa., U.S.A., which has several lines of elastomeric electrical connectors.
Reference is now made primarily to
To briefly summarize, electrical interconnection of the control component 102 and the cable component 104 is made through contact between the conductive strips 244 of the multiple connector unit 144B and the electrical leads 230 on the printed circuit board 176 simply by rotatably engaging the complementary threaded structures 124B and 188 of the control component 102 and the cable component 104, respectively. No keying is required to orient the control component 102 and the cable component 106, and no keyed cable connections are required. This absence of keying significantly simplifies assembly of the tool assembly of the present invention for ease of use. Furthermore, the manufacturing complexity required to make a keyed arrangement is avoided, simplifying manufacturing and reducing manufacturing costs.
As noted previously, the electrical connector of the present invention includes two connector portions engageable by rotatably engageable complementary engagement structures and a multiple connector unit disposed between and in contact with each of two sets of electrical leads. For the electrical interconnection between the control component 102 and the cable component 104, the two connector portions are the end portions of the components being engaged. One set of electrical leads for the electrical connector are the electrical leads 230 on the printed circuit board 176, which are in contact with the first side 240 of the multiple connector unit 144B. The other set of electrical leads required for the electrical connector, which are in contact with the second side 242 of the multiple connector unit 144B, is located on the contact end 142 of the flexible circuit unit 140. It should be noted that in the embodiment of the tool assembly 100 just described, the multiple connector units 144A,B have been incorporated in the control component 102. The multiple connector unit 144A could instead have been incorporated into the sensor component 106 and the multiple connector unit 144B could instead have been incorporated into the cable unit 104. Alternatively, the connector units 144A,B could have initially been a part of neither component and would instead be inserted between the appropriate components prior to engagement, although such an embodiment is not preferred.
Features of the flexible circuit unit 140 will now be described in greater detail, including the electrical leads for contacting the multiple connector unit 144B. Referring to
Referring now to
As shown in
As noted previously, the electrical connector of the present invention is not limited to use with the tool assembly and components of the present invention. For example, the electrical connector could be used to electrically interconnect components of other tools designed for insertion into a hole, including those used in petroleum, natural gas and geothermal wells. Also, the electrical connector could be used to electrically interconnect components for medical devices, such as tubular components for endoscopic and laparoscopic devices. For these and other situations where the tools are of an elongated tubular shape, the connector portions should preferably be integral with the components to be electrically interconnected, similar to the integral nature of the connector components in the tool assembly of the present invention. Furthermore, the electrical connectors of the invention could be used in a cable connector structure to electrically interconnect components via a cable. For example, a cable end could be fitted with a first connector portion that rotatably engages a complementary second connector portion on an electric component (which could be another cable) to connect the cable to the component. In this situation, the connector component on the cable end may include a threaded rotating sleeve as the engagement structure that rotatably engages a threaded nipple on the electrical component. In this case, the rotating sleeve could rotatably engage the threaded nipple, but the electrical leads on the cable portion would not rotate, as was the case with the electrical connections of the tool assembly of the present invention. Rather, the rotating sleeve would rotate relative to the cable end, so as not to torsionally stress the cable. Alternatively, the rotating sleeve could be on the electronic component and the threaded nipple on the cable end.
Moreover, for many applications, the electrical leads in each of the two connector portions will be thin electrical conductive features on rigid circuit boards. For example, the printed circuit board 214 in the sensor component 106 (as shown in
The present invention also includes several aspects of operation of the tool assembly, and of operation of the components of the tool assembly. During operation, the tool assembly is typically field deployed as a field monitoring unit submerged in a liquid, typically an aqueous liquid, to field monitor at least one condition of the liquid. Most often, the tool assembly will be positioned inside of a well or other hole. As an example, the well may be a monitoring well to monitor for environmental contamination, water quality or for the presence of runoff water, etc. Alternatively, the tool assembly may be contained in a fluid permeable enclosure in a drainage area, river, lake, ocean or other geographic feature where water is found. At least one, and preferably substantially all of the operations of the tool assembly are directed by the computing unit located on the main circuit board. As noted previously, the computing unit includes a processor and memory, with the memory having stored therein instructions, in the form of code, that are readable and executable by the processor to direct the operations of the tool. The memory is preferably non-volatile memory, meaning that the contents of the memory are retained without power. Preferred non-volatile memory are firmware chips, such as EPROM chips, EEPROM chips and flash memory chips. Particularly preferred are flash memory chips, which permit rapid updating of the code as necessary without removing the memory chips from the tool assembly. Although the use of firmware code is preferred for operation of the tool assembly, it is possible that the tool assembly could also be operated using software code. As used herein, software code refers to code held in volatile memory, which is lost when power is discontinued to the volatile memory. Software code is not preferred for use with the present invention because of the substantial power required to maintain the code in volatile memory. For that reason, operation of the tool assembly, and components thereof, will be described primarily with reference to the use of firmware code contained in non-volatile memory.
The computing unit also includes a real time clock/calendar, which consumes only a very small amount of power. During operation, the tool assembly is normally in a sleep mode, in which the real time clock/calendar is operably disconnected from the processor. The tool assembly is occasionally awakened to an awake mode to perform some operation involving the processor. When the tool assembly is awakened, the clock/calendar is operably connected with the processor and the processor performs some operation. The operation to be performed when the tool assembly is awakened is frequently to obtain a periodic sensor reading, to process sensor reading data and store a data record, or data point, containing the data in memory. Other operations could also be performed during the awake mode, such as communication with an external device. The tool assembly stays awake only long enough to perform the operation and then returns to the sleep mode to conserve power.
With continued reference to
With continued reference to
As noted, the ability of the computing unit to change the sampling schedule, in response to the occurrence of a predefined event, can result in significantly reduced power consumption. Such energy conservation is extremely advantageous for field deployable units, such as the tool assembly of the present invention. This is because that when the tool assembly is field deployed, it often must be powered by batteries, which are either located within the tool assembly or located elsewhere at the field location. This is true whether the tool assembly is operating independently or as part of a network with other such tool assemblies. With the tool assembly of the present invention, the sampling schedule may initially be set with a long interval between the taking of sensor readings, such as perhaps every 15 minutes, 30 minutes or even one hour or longer. When a perturbation event is identified, the sampling schedule is changed to include a shorter interval between sensor readings. For example, the shorter interval may be every 5 minutes, 2 minutes, or even 1 minute or shorter. The sampling schedule may then be returned to the original sampling schedule, having a longer interval between sensor readings, when the perturbation event has ended. In this manner, frequent sensor readings are obtained and corresponding sensor reading data points are logged only during the perturbation event, when more careful monitoring is desired. This ability to adapt the sampling schedule to the situation is referred to as adaptive schedule sampling.
In addition to conserving energy, it is also desirable to minimize the amount of memory consumed to log the sensor reading data. With the present invention, not only is energy significantly conserved, but memory space is also conserved. In some prior art devices, for example, a logging tool may have a set sampling schedule with a short interval between sensor readings. To conserve memory space, however, the tool only infrequently logs a sensor reading data point. Logging of intermediate data points occurs only if the intermediate data point is significantly different than a previously logged data point. Although this prior art technique conserves memory space, it does not conserve energy because the logging tool is required to obtain a number of data points that are not logged. Furthermore, because the time interval between logged data points varies, a previous technique has been to save a time tag with each logged data point. With the present invention, however, it has been determined that sensor reading data may be logged without consuming the memory space required to tag every data point with a time tag.
One way, according to the present invention, to log the sensor reading data in a manner to avoid tagging each data point with a time tag, is to switch data files and save the data points to a different data file after the sampling schedule changes. Because the sample interval between data points logged in the data file are constant, the time at which each data point was taken can be calculated. One problem with this technique, however, is that it is not easy to relate the data points between different data files. Therefore, in a preferred embodiment of the present invention, only a single data file is used to log sensor reading data. In this preferred embodiment, to avoid the requirement of a time tag with each data point, data points are tagged only when the sampling schedule is being changed. For example, the first data point logged may be tagged to indicate the time interval between sensor readings for the sampling schedule in effect and the time at which sampling is initiated. The time of any data point taken during the sampling schedule can then be calculated based on its number in sequence following the tagged data point. When the sampling schedule is changed, the data point that marks the commencement of the new sampling schedule change is tagged with information indicating the interval between sensor readings for the new sampling schedule. In this way, a continuous record in a single data file may be recorded without the burden of including a time tag for every data point. This data logging technique conserves significant memory space. Moreover, because only a single data file is used, it is very easy for the user to interrelate data points and interpret the data that has been logged. Accordingly, with a preferred embodiment for the present invention, the tool assembly significantly conserves both energy and memory space, and in a manner that facilitates easy use of the tool assembly to interpret logged data.
As noted, a significant advantage of the tool assembly of the present invention is that it has been designed with significant energy conservation features. One of those features is use of adaptive schedule sampling to avoid taking more sensor readings than is necessary. In a preferred embodiment of the tool assembly of the present invention, significant additional energy conservation is accomplished through design of the tool assembly to operate with efficient electronic components at a low voltage. Preferably the tool assembly operates at a voltage of smaller than about 4 volts, more preferably smaller than about 3.5 volts, still more preferably at a voltage of about 3.3 volts and most preferably at a voltage of about 3 volts or smaller. The tool assembly, or discrete electronic parts thereof, could operate at very low voltages. For example, the processor (and/or other electronic parts) could operate at a voltage of 2.7 volts, or even 1.8 volts. This low voltage operation is in contrast to most current logging tools, which typically operate at a voltage of 5 volts or higher. By operating the tool at a lower voltage and with high efficiency electronic parts, power consumption during operation may be considerably reduced, resulting in a significant lengthening of the life of batteries providing power to operate the tool assembly. With the present invention, current draw when the tool is awake is typically smaller than about 100 milliamps at a voltage of about 4 volts or less, requiring only about 0.4 watts of power, or less, for operation in the awake mode. In many instances, the power consumption can be even smaller. For example, when the tool assembly is designed for taking pressure readings, and includes only a pressure sensor and a temperature sensor, power consumption during operation in the awake mode may be kept at smaller than about 25 milliamps.
For the tool assembly to operate at a suitably low voltage, electronic components in the tool assembly must be properly selected. For example, the processor must be capable of operating at the low voltage. Furthermore, as discussed in more detail below, the dimensions of the processor are critical for preferred embodiments of the tool assembly when the tool assembly is designed to be insertable into a 1 inch diameter hole. It is desirable to use 1 inch wells for monitoring purposes because of the lower cost associated with drilling the wells, but there is a lack of available high-performance tools operable for use in such small holes. Although any processor satisfying power consumption and size requirements for this embodiment of the present invention could be used, the Motorola™ HC-11 processor has been identified as a preferred processor. In addition to the processor, it is also necessary to use a sensor that operates at the low voltage. A number of sensors are available that operate at voltages sufficiently low to be used with the tool assembly of the present invention. Supplies of such sensors include Lucas Nova Sensor™ and EG&G™ IC Sensors.
In addition to the computing unit, the main circuit board of the tool assembly also includes signal processing circuitry. For example, the main circuit board includes analog-to-digital converter circuitry for converting analog signals from the sensor into digital signals for use by the computing unit. The main circuit board would also include digital-to-analog converter circuitry for embodiments where the sensor requires a stimulation signal to take a sensor reading, so that digital simulation signals from the computing unit could be converted into analog signals for use by the sensor. This signal processing circuitry also must be selected to operate at the low voltage. As will be appreciated by those skilled in the art of signal processing, the circuitry associated with processing lower voltage signals typically requires more extensive filtering to ensure adequate signals for processing.
When the tool assembly transmits/receives communication signals to/from a remote device via the cable, the communication will typically be at a higher voltage than the voltage at which the computing unit operates. Typically, communication will be conducted according to a communication protocol that operates with approximately 5 volt signals, and which permits networking with a significant number of other like tool assemblies distributed over a large area. Moreover, to reduce the number of conductive lines in the cable dedicated to communication, half duplex communication is preferred. RS-485 is a preferred communication protocol for use with the present invention. It should be noted that although half duplex communication is preferred, it is possible with the present invention to conduct communications via only a single communication line, if desired. For example, communication could be conducted both directions through a single fiber optic line in the cable.
Also, it should be noted that the energy storage unit in the tool assembly, as discussed previously, must be designed to deliver power at a low voltage consistent with the low voltage signal processing requirements. In this regard, two AA cells in series typically provide power at a nominal voltage of approximately 3 volts. Alternatively, cells other than AA cells could be used that deliver power at an appropriate voltage. For example, a pair in series of AAA, N, C, D or DD cells could be used to provide a power source with a nominal voltage of about 3 volts. AAA, AA and N cells are preferred because of their small size, with AA cells being particularly preferred. Furthermore, the energy storage unit could include only a single electrochemical cell, provided that the cell is of the proper voltage. Also, any suitable cell types may be used, such as alkaline cells, nickel-cadmium cells, nickel-metal hydride or lithium cells, and the cells may be primary or secondary cells. For enhanced performance flexibility, however, lithium cells are generally preferred, primarily because lithium cells can be used over a wider temperature range, permitting the tool assembly to be used over a wider range of environmental conditions.
In another aspect of the present invention, the main circuit board also includes a capacitor or capacitors having sufficient capacitance so that when power is discontinued to the main circuit board, the capacitor(s) can continue to provide power to maintain the real time clock/calendar for at least about 30 minutes, preferably at least about 60 minutes, and more preferably at least about 90 minutes, to permit the batteries to be replaced without having to re-program the tool assembly. For example, when batteries in the tool assembly are changed, all power to the main circuit board is discontinued, but the real time clock/calendar continues to be powered by the capacitor(s) until the replacement batteries have been installed. Also, after battery power to the main circuit board is resumed, the real time clock/calendar is capable of sending an interrupt signal to the processor to cause the computing unit to resume whatever operation might have been interrupted during battery replacement. For example, the computing unit could automatically continue sampling operations according to a sampling schedule that was in effect prior to the battery replacement. The capacitor(s) are typically included on the main circuit board. Examples of capacitors that may be used include Series EL Electric Double Layer Capacitors from Panasonic, such as the Panasonic EECE0EL 104A capacitor.
Another aspect of the present invention is that the tool assembly has been designed to be insertable into a 1 inch hole, as noted previously. This is because of the significant need for high performance tools operable for use in such small diameter holes.
Because the tool assembly of the present invention, in a preferred embodiment, is designed for insertion into a 1 inch diameter hole, the outside diameter of the tool assembly must be smaller than 1 inch. Preferably, the outside diameter of the tool assembly is smaller than about 0.9 inch, more preferably smaller than about 0.8 inch and even more preferably smaller than about 0.75 inch. Particularly preferred is an outside tool diameter of smaller than about 0.72 inch. As noted previously, it is preferred that the tool assembly have a substantially tubular outside shape, with a substantially constant diameter. For such a tool assembly, there are no protrusions extending beyond the outside diameter of the tool. Similarly, should the tool assembly have other than a tubular shape, then a cross-section of the tool assembly, taken substantially perpendicular to the longitudinal axis of the tool assembly at any longitudinal location along with tool assembly, should fit entirely inside a circle having a diameter of smaller than the above referenced dimensions, depending upon the particular embodiment.
A significant aspect of the present invention is to provide an easy-to-use, high performance tool with networking capabilities for use in 1 inch diameter holes. Significant features are contained on the main circuit board disposed inside of the tool assembly. Referring again to
Although a rigid circuit board is shown in
As noted previously, the tool assembly can be used alone or in a network with other like tool assemblies.
So that there is not a significant build-up of moisture inside the cable 108 or the connector 282, the vent cap 284 preferably includes desiccant inside of the vent cap 284.
In another aspect of the present invention, a variety of devices may be interconnected with the tool assembly via the cable from which the tool assembly is suspended during use.
Another possibility for providing external power to the tool assembly the present invention is shown in FIG. 23. As shown in
With the embodiment shown in
In a preferred embodiment, the cable from which the tool assembly of the present invention is suspended during use includes at least six conductors, with at least two of the conductors being dedicated to communication (half duplex communication), at least two of the conductors being dedicated to delivery of power from a low-voltage external power source (such as described with respect to the low-voltage external power unit shown in
Referring now to
As noted previously, a significant aspect of the present invention is that the tool assembly of the present invention is, in one embodiment, networkable with other like tool assemblies. In that regard, at least one, and preferably each one, of the tool assemblies in a network is capable of transmitting, under the direction of the computing unit, a communication signal causing at least one other tool assembly (the receiving tool assembly) in the network to perform an operation, typically involving the taking of a sensor reading. Frequently, the receiving tool assembly will be directed to initiate a sampling schedule, which may involve changing from an existing sampling schedule to a new sampling schedule, as previously described. Preferably each of the tool assemblies in a network is capable of both transmitting and receiving communication signals. Furthermore, a tool assembly transmitting a communication signal is capable of saving in its memory information indicating that a communication signal was transmitted to the receiving tool assembly, and the receiving tool assembly is capable of saving in its memory information indicating that the communication signal was received from the transmitting tool assembly.
In a one embodiment, when the tool assemblies are networked, more than one, and preferably substantially all, of the tool assemblies in the network are programmed to transmit a communication signal in the network based on the occurrence of an event identified by the transmitting tool assembly as having occurred. For example, when a network of tool assemblies are deployed along a water course or other drainage area, identification by one tool assembly of the occurrence of a significant increase in a pressure sensor reading (indicating the presence of an increased head of water) causes that tool assembly to transmit a communication signal to one or more other tool assemblies in the network, directing the receiving tool assemblies to change the sampling schedule to a more frequent interval between sensor readings. This type of deployment of a network of the tool assemblies would be useful, for example, to monitor storm water runoff in areas of interest. In one embodiment, a communication signal transmitted by one tool assembly is transmitted to the other tool assemblies in the network, and the other tool assemblies are each capable of analyzing the signal and determining whether an operation is to be performed. In another embodiment, a central network controller could make the determination and send a control signal to direct that an operation be performed. For example, the tool assemblies could be connected to a network controller which would determine whether a sampling schedule change is appropriate, based on predefined criteria, for any of the tool assemblies, including the tool assembly originally identifying the occurrence of an event. The tool assembly identifying the occurrence of an event would transmit a signal and the controller would determine whether a sampling schedule change should be made in that tool assembly or any other tool assembly in the network. The controller would then send a signal or signals directing the appropriate tool assembly or tool assemblies to change the sampling schedule.
In a preferred embodiment, the tool assemblies in a network are capable of directly communicating with each other, without the need for a central network controller. If desired, however, such a central controller could be used to receive and interpret a signal generated by a tool assembly and transmit an appropriate command signal to direct one or more other tool assemblies to perform the desired operation. Such a central controller will typically be a personal computer or palm top computer, although any other suitable network controller could be used.
Not all of the tool assemblies in the network need to contain the same sensor capabilities. For example, one or more of the tool assemblies may contain a pressure sensor for monitoring for an increase in water head, and one or more other tool assemblies may contain different sensors for monitoring one or more other condition. For example, the other tool assemblies could include a turbidity sensor, a chlorophyll sensor or one or more type of electrochemical sensors for monitoring a condition indicative of the quality of water. An electrochemical sensor could, for example, monitor for pH, oxidation-reduction potential (ORP), dissolved oxygen (DO), or dissolved nitrates (or any other specific dissolved ion). In this situation, for example, when one tool assembly including a pressure sensor identifies the occurrence of a predefined increase in water head, as indicated by an increased pressure sensor reading, the tool assembly would transmit a communication signal to direct (with or without the aid of a network central controller) at least one other tool assembly to the network, including an electrochemical sensor, to either commence a sampling schedule or to change the sampling schedule to a more frequent interval between sensor readings. In this way, not only can the movement of storm water runoff be monitored, but water quality conditions of the runoff can also be monitored.
A significant aspect of the present invention is that the tool assembly is specifically designed for field deployment, such as in monitoring wells located along a water course or other drainage area, in monitoring wells in fluid communication with an aquifer or directly in a river, lake, ocean or other water feature. As typically field deployed, each of the tool assemblies is suspended from the cable.
With continued reference to
With the present invention, there is significant flexibility with respect to use of a network of the tool assemblies. As one example, reference is made to FIG. 26.
As an alternative to the networked configurations shown in
A significant design feature of the tool assembly of the present invention is that the tool assembly has been designed for use in small diameter monitoring wells. For some applications, however, the tool assemblies will be used directly in a river, lake, ocean or other water feature, where the size constraints of a small diameter monitoring well are not present. Although the tool assembly, as described previously, can be used for these applications, it is often desirable to have multiple sensor capabilities available in a single unit for these applications. In one aspect of the present invention, the tool assembly may be in the form of a tool bundle to provide multiple sensor capabilities in situations where tool size is not a significant constraint.
Referring now to
As was disclosed above the tool assemblies described herein are connectable in a network to comprise a monitoring system. A central controller may be employed as part of the monitoring system to provide centralized control and access to each of the tool assemblies connected to the network. In the network, many of the tool assemblies may be located at very remote locations with respect to the central controller such that some mode of long distance communication must be employed for the various components of the system to communicate. Disclosed below are a number of different modes communication which may be employed in the monitoring system.
Disclosed in
Disclosed in
The modem/controller 412 may comprise any number of devices. One possibility may be a palmtop computer such as a pocket PC or a Palm Pilot which includes a modem and has been configured to provide certain amount of data processing for the tool assemblies connected to the network as well as establish connections over the PSTN. The palm top computer may perform a number of different tasks in that in addition to providing a line of communication this device may provide most or all of the computing capability of the central controller locally. More specifically, the palm top computer may be configured such that all the processes of the central controller which are described in great detail below, may be performed by the palm top computer at the remote locations proximate to the tool assemblies themselves. In another configuration of the invention, the palm top computer may be employed to provide emulation functionality for allowing tool assemblies which employ a certain set of standards to communicate with a network which employs a different set of standards. Programming included in the palm top computer would allow the device to make the necessary conversions so that the different devices can communicate.
Disclosed in
Disclosed in
As part of the monitoring system described herein, the central controller 402 is specially configured to perform various functions with regards to communicating with the one or more tool assemblies connected in a network configuration. In one configuration of the invention, the central controller 402 may be a personal computer, palm top computer or other computing device upon which a monitoring system has been installed. A palm top computer may be especially advantageous because it is employable at the remote sites where the tool assemblies are located. Disclosed in
Also in connection with processor 450 is random access memory (RAM) 454, within which a number of the processing modules are loaded for performing the various functions of the monitoring system. The various processing modules may be initiated either automatically or through the receipt of various user inputs received from user interface 467. In one configuration of the invention, the user interface 467 may comprise a computer monitor, keyboard and mouse.
Returning again to the processing modules in RAM 454, included therein are communications module 456 which is employed to identify tool assemblies connected to the network as well the generation and transmission of messages over the communications network, a parameters modules 458 which is employed to display or change various parameter settings the tool assemblies employ when performing tests, tests module 460 which is employed to load automated tests schedules on to the tool assemblies, manually initiate test programs and to extract test data from selected tool assemblies, and finally a display/output module 464 which is employed to display various screen displays through the user interface such that various user commands may be received and processed.
Also included in the central controller 402 are a number of databases which are employed to store information either generated by components in the communications network or used in operations of the monitoring system. Specifically, database 466 is used to screen displays which are presented on the user interface such that system users may view system data and/or initiate various system functions. In on configuration of the invention, the monitoring system described herein maybe configured such that it operates in a Windows type environment and includes a number of pull-down menus and directory tree type structure for organizing information. For example, the communications network information may be organized in a screen display such that each COM port for the computer may be presented with its own node in a tree type directory structure. Beneath each of the COM port nodes may be a listing of the tool assemblies, which communicate with the monitoring system through that particular node. Further, below each tool assembly node in the directory tree structure may be additional nodes which provide access to additional information about the particular tool assembly. These nodes may include information about the parameters with which the tool assembly is employing to take measurements as well test information relating to the particular tool assembly.
Associated with each node in the directory structure may be a screen display which presents information about the particular selection that has been made. With use of these display tools, the system user may move between screen displays to view information or initiate various functions which will be described in greater detail below.
Also included in the central controller 402 is a tests results database 468. This database is employed store and organize information which has been extracted from the various tool assemblies.
As was described in great detail above, the tool assemblies described herein are configured to be positionable at locations remote from the central controller and to perform various tests according to programming received from the central controller. As an example, the tool assemblies may comprise a down well pressure probe which are connectable to the communications network. The down well probes include the functionality to take pressure readings at various times, store this data in a local memory and then provide this data when requested by the central controller. Disclosed in
Also in connection with the microprocessor 500 are the program flash memory 506 and the serial flash memory 507. The program flash memory 506 is employed to store the version of firmware which the tool assembly is employs for its operation. Incorporated in the firmware are a number processes which the tool assembly employs in various aspects of its operation. Some of the processes are described in greater detail below. The serial flash memory 507 is employed to download any firmware upgrades as well as store data accumulated during tests by the tool assembly. Also in connection with the processor 500 is A/D converter 501 which processes signals generated by pressure sensor 502.
In operation, the monitoring system employed for communicating with the various tool assemblies is initially installed on the central controller. Once operational, a first step to be performed is to identify the tool assemblies which are connected to the network. In order to perform this function, the communications module 454 disclosed in
Returning again to the flow chart of
If multiple tool assemblies are connected to the communications network, it is possible that two or more tool assemblies may transmit a reply message at the same time, thus creating the situation where only one or none of the reply messages is received by the central controller. As such, the central controller has been configured such that each of the tool assemblies may have multiple opportunities to reply if a particular message is not received by the central controller. Returning again to
Upon transmission of the new general message, the central controller will wait a selected time period in order to receive a reply. If no reply is received after the time period has elapsed, the central controller will retransmit the message. The central controller will again wait a period of time in order to receive a reply message. If no reply message is received after set number retries of the general message the process will end and the tool identification process will be complete.
The reply message received from the tool assemblies may include detailed information about the configuration of the tool assembly. This information may include such items as communication type, serial number of the assembly, name of the location, manufacture date of the assembly, calibration date of the assembly, hardware version installed in the assembly, firmware version, storage capacity, battery type, battery installation date, battery capacity, as well as microprocessor run time. This information is displayable for all tool assemblies which provide a reply message. In the situations where connections are being established from more than one central controller, information gathered during one connect session may be saved in a file and employed by other central controllers.
Once all of the tool assemblies on a particular COM port are identified, the monitoring system may be employed to transmit messages to one or more of these components. As was described above, each of the each of the tool assemblies runs on a energy conservation mode, or “sleep” when not communicating with the central controller or performing tests. One feature which has been incorporated into the system to further conserve energy is a selective activation process for selectively activating one or more tool assemblies when desired, without activating all the tool assemblies connected to a node. Messages which are generated by the central controller and transmitted to the individual tool assemblies are in the form of a data packets, which include an identifying byte in the header of the message. Included with the information stored about each of the tool assemblies stored in the central controller, is an multi-bit address header, which the central controller may employ when transmitting messages to particular tool assemblies. A general header may also be used in outgoing message to which all the tool assemblies will reply.
Disclosed in
Returning again to the flowchart in
Also related to the selected activation of tool assemblies, is another feature incorporated into the system which provides a level of certainty that when messages are generated and transmitted over the data network, replies are indeed received from all the tool assemblies which have been addressed. As was described above, one draw back of having an open communications network such as that described herein, is that when the central controller sends out a general message in which all the tool assemblies are to reply, the possibility exists that all of the tool assemblies will reply at the same time thus interfering with each other. According to the invention described herein, the tool assemblies is configured to provide some certainty that all reply messages from the tool assemblies are received by the central controller.
Returning again to the flowchart disclosed in
As was described above, the situation may occur where two tool assemblies do reply at precisely the same time to a general message and thus interfere with each other. As was described above, the central controller will periodically regenerate the message and transmit it so that the non-replying tool assemblies may respond. Once the messages are received, the steps disclosed in
The monitoring system described herein is employable by a system user to perform a number of different functions with regards to the one or more tool assemblies connected to the communications network. As was described in
When a system user wishes to view or amend a particular parameter of a tool assembly, the listing of tool assemblies connected to a particular communications node may be displayed on the user interface and the tool assembly may be selected in order to view sub categories for the particular tool assembly, which parameters is included. When parameters is selected, this information is then viewable. In one configuration of the invention, a screen display is provided which displays all the parameter information with regards to a particular tool assembly. Through dialog boxes presented in the screen display, various parameter information may be entered or amended. If a system user wishes to add change parameters for a particular tool assembly, a message is generated by the central controller which includes the parameter information as well as an address heading for that particular tool assembly. This generated message is then transmitted over the communications network and once received by the tool assembly, implemented into its programming. Although the discussion above with regards to parameters is directed to ways of measuring pressure in a probe, one skilled in the art would realize that depending on the type of sensor used, these change in parameters may be directed at any number of measurable values.
Yet another processing module employed in the monitoring system described herein is directed to programming and implementing tests in the tool assemblies. Using the directory tree structure described above, the system user may select to view information about tests programmed into a particular tool assembly. Tests to be performed are stored on the flash memory for the tool assembly and a listing of the tests is provided to the central controller during the initial tool assembly identification process described When this selection is made, a screen display may be presented which includes this program information. As was discussed previously, each of the tool assemblies include processing capability and memory. Stored into memory may be a number of automated tests which the tool assembly has been programmed to perform at designated intervals. When a system user selects to go into the testing mode for the system, the system user may retrieve and view information with regards to tests currently programmed into the device. This may be done for each of the tool assemblies individually. When viewing the information, the system user may have the option to manually initiate a program test or add a new test. When adding a test, certain information and/or internal information may be entered, such as the type of test (linear, event, or linear average). Other options may be to program tests using adaptive scheduling. Steps performed in employing adaptive scheduling will be described in greater detail below.
Further items which may be programmed for tests include measurement intervals for taking readings in an automated test as well as the point-in-time which a test is to begin. Once necessary information for the new test or the amended information is entered, the central controller may compile and transmit a message to the particular tool assembly instructing the assembly to load and execute the test.
As an additional feature of the system described herein, the system user may have the option of manually initiating or terminating a test. The selection may be made through a dialog box in a screen display, and in turn, the central controller will generate a message for the particular tool assembly and transmit the same. According to the protocols described above, the central controller will then wait for a reply message either indicating that the test has begun or it has been stopped according to instructions.
As was discussed above, one mode of performing tests is called adaptive scheduling. Through use of adaptive scheduling, space in the flash memory for the tool assembly may be conserved by only storing data points measured after the occurrence of significant events. A test may be programmed to be performed when a particular condition is detected, a customized monitoring program may be initiated and the data which is collected during this time period is specially identified. One example of a time when such a program may be employed is when a water table is monitored for such conditions as flooding or flash floods. When a significant event occurs which causes the water table rises, this condition is detected it may be advantageous to provide a continuous monitoring of the situation while it exists and then to discontinue the monitoring once the situation has passed.
Disclosed in
As the tool assembly continues it's monitoring, it may detect that the measured condition has changed in a significant way which requires the use of another test program. For example, if the measured water level exceeds a particular value during a rainstorm, the frequency of readings taken may need to increase. When any type of change in test occurs, another identifier is added to the data page on which the new data points begins. As with the previous program, it may include date, time and condition which required the change. As was described above, additional readings may then be taken without the necessity of adding date or time information.
As the monitoring and the taking of data points continues, it may then be detected that the measured condition falls below the threshold of value and back to a “normal”. At this point, the employment of the customized program may be discontinued and the tool assembly monitoring returned to the idle mode wherein it only takes readings periodically and does not store them in memory.
Yet another function performed by the test processing module of the central controller includes the extraction of test data from the tool assemblies. When viewing particular tests for a tool assembly a selection may be made to extract data from the tool assembly for that particular test. Specifically, a system user may select the particular tool assembly in the directory tree structure and navigate to one of the existing tests in the tool assembly. At this point, a selection may be made to extract test data from a particular tool assembly for that test. In order to perform the above functions, the central controller will generate a message which is transmitted over the communications network and detected by the particular tool assembly. Once the message is received, the tool assembly will perform steps extract the selected test data from the flash memory. This information is transmitted back to the central controller in a form of a message and through use of display/output module 464 disclosed in FIG. 30 and included in the central controller, the test information may be presented in the desired format.
One further feature of the system described herein is the functionality for a system user to update the firmware in a particular tool assembly as the firmware becomes available. Through the process described herein, it is done in a manner which ensures the integrity of the existing firmware as well as the new version which has been downloaded. To perform this process, a selection may be made to manually upgrade or replace the existing firmware. This selection may be made through use of an interactive screen display. If this selection is made, the central controller first identifies the appropriate firmware to be transferred and generates a message which includes the firmware. This message is then transmitted over the communication network to the particular tool. The steps performed by the tool assembly in downloading of the firmware is disclosed in FIG. 35.
Initially, the message is received from the central controller indicating that the firmware is to be downloaded. The tool assembly may at that point indicate that a test is being performed and the download cannot occur until the testing is complete. This is purely as an extra precaution to protect integrity of the firmware on the tool assembly. One skilled in the art would realize that the system may be configured such that the test can be performed and firmware downloaded at the same time. Once it is determined that a test is not currently running, an entire copy of the upgrade firmware is downloaded directly into serial flash memory 507, as shown in the system diagram of FIG. 31. The current version of the firmware is resident on the program flash memory 506. At any point after that the microprocessor may initiate a transfer of the upgrade firmware from the serial flash memory to the program flash memory. At this point the old firmware is overwritten. Once the transfer of the upgraded firmware is complete, a message is generated and transmitted back to the central controller indicating that the upgrade of the firmware was successful.
Various embodiments of the present invention have been described in detail. It should be understood that any feature of any embodiment can be combined in any combination with a feature of any other embodiment. Furthermore, adaptations and modifications to the described embodiments will be apparent to those skilled in the art. Such modifications and adaptations are expressly within the scope of the present invention, as set forth in the following claims.
This patent application relates to U.S. provisional patent application Ser. No. 60/156,913 filed on Sep. 30, 1999.
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