Intrinsically-safe sensor system

Patent metadata

Field	Value
Publication number	US-12140504-B2
Application number	US-202217805500-A
Country	US
Kind code	B2
Filing date	Jun 6, 2022
Priority date	Jul 9, 2021
Publication date	Nov 12, 2024
Grant date	Nov 12, 2024

Abstract

An intrinsically-safe sensor system, as well as a method for assembling the intrinsically-safe sensor system and a method for monitoring sound corresponding to a source using the intrinsically-safe sensor system, are provided herein. The intrinsically-safe sensor system includes a number of sensors, including a microphone, as well as a processor for processing sensor data obtained from the sensors. The intrinsically-safe sensor system also includes a memory component for storing the sensor data obtained from the sensors, a power source, a communication connection for communicably coupling the intrinsically-safe sensor system to a remote computing system, and a connector including internal and external connection regions for internally and/or externally connecting one or more additional devices to the intrinsically-safe sensor system on demand. The intrinsically-safe sensor system further includes an enclosure, as well as potting material for encapsulating an internal region of the intrinsically-safe sensor system that resides within the enclosure.

First claim

What is claimed is:

1. An intrinsically-safe sensor system, comprising:
a plurality of sensors, comprising a microphone;
a processor for processing sensor data obtained from the plurality of sensors;
a memory component for storing the sensor data obtained from the plurality of sensors;
a power source;
a communication connection for communicably coupling the intrinsically-safe sensor system to a remote computing system;
a connector comprising an internal connection region for internally connecting an additional device to the intrinsically-safe sensor system and an external connection region for externally connecting another additional device to the intrinsically-safe sensor system on demand;
an enclosure; and
potting material for encapsulating an internal region of the intrinsically-safe sensor system that resides within the enclosure;
wherein:
a) proper functioning of the intrinsically-safe sensor system is verified using a test fixture before the internal region of the intrinsically-safe sensor system is encapsulated using the potting material;
b) at least a portion of the connector and at least a portion of the microphone are exposed to an external environment rather than being encapsulated in the potting material, and wherein the intrinsically-safe sensor system comprises resistors that are electrically coupled to the connector and resistors that are electrically coupled to the microphone to increase the intrinsic safety of the intrinsically-safe sensor system;
c) the power source comprises a battery, wherein the battery is installed within the intrinsically-safe sensor system using a battery shim on a circuit board of the intrinsically-safe sensor system, and wherein the battery shim comprises a positioning mark for positioning and aligning a battery holder for the battery on the circuit board; or
d) the intrinsically-safe sensor system comprises updatable firmware and configuration parameters, and wherein the intrinsically-safe sensor system updates the updatable firmware and configuration parameters in response to input received from the remote computing system via the communication connection.

2. The intrinsically-safe sensor system of claim 1 , wherein the plurality of sensors comprises two or more microphones that are positioned such that a directionality of sound waves recorded by the two or more microphones can be determined.

3. The intrinsically-safe sensor system of claim 1 , wherein the connector is fully configurable and supports a plurality of communication protocols for connecting any of a plurality of additional devices to the intrinsically-safe sensor system.

4. The intrinsically-safe sensor system of claim 1 , wherein the plurality of sensors further comprises at least one of a pressure sensor, a temperature sensor, a fluid flow sensor, a motion sensor, a conductivity/resistivity sensor, or a capacitive sensor.

5. An intrinsically-safe sensor system, comprising:
a plurality of sensors, comprising a microphone;
a processor for processing sensor data obtained from the plurality of sensors;
a memory component for storing the sensor data obtained from the plurality of sensors;
a power source;
a communication connection for communicably coupling the intrinsically-safe sensor system to a remote computing system;
a connector comprising an internal connection region for internally connecting an additional device to the intrinsically-safe sensor system and an external connection region for externally connecting another additional device to the intrinsically-safe sensor system on demand;
an enclosure; and
potting material for encapsulating an internal region of the intrinsically-safe sensor system that resides within the enclosure;
wherein a port of the microphone is aligned with a through hole within a circuit board to which the microphone is attached, wherein an elastomer tubing is compressed between an opening within a wall of the enclosure and the through hole within the circuit board to prevent the port of the microphone from being obstructed by the potting material, and wherein the port of the microphone is acoustically coupled to the external environment via a metal fastener that extends through the opening within the wall of the enclosure, through the elastomer tubing, and within proximity to the through hole within the circuit board.

6. The intrinsically-safe sensor system of claim 5 , wherein the acoustic coupling of the port of the microphone with the external environment via the metal fastener serves to dampen ambient sounds recorded by the microphone.

7. A method for monitoring sound corresponding to a source using an intrinsically-safe sensor system, the method comprising:
attaching an intrinsically-safe sensor system to a source for which sound monitoring is desired, wherein the intrinsically-safe sensor system comprises components that are at least partially encapsulated within potting material and contained within an enclosure, wherein the components comprise two or more microphones that are positioned such that a directionality of sound waves recorded by the two or more microphones can be determined; and wherein each microphone is installed within the intrinsically-safe sensor system such that a port of the microphone is aligned with a through hole within a circuit board to which the microphone is attached, wherein an elastomer tubing is compressed between an opening within a wall of the enclosure and the through hole within the circuit board to prevent the port of the microphone from being obstructed by the potting material, and wherein the port of the microphone is acoustically coupled to the source via a metal fastener that extends through the opening within the wall of the enclosure, through the elastomer tubing, and within proximity to the through hole within the circuit board;
monitoring sound emitted by the source using the two or more microphones of the intrinsically-safe sensor system; and
determining the directionality of the sound based, at least in part, on the positioning of the two or more microphones.

8. The method of claim 7 , comprising installing each microphone within the intrinsically-safe sensor system by:
aligning the port of the microphone with the through hole within the circuit board;
compressing the elastomer tubing between the opening within the wall of the enclosure and the through hole within the circuit board to prevent the port of the microphone from being obstructed by the potting material; and
acoustically coupling the port of the microphone to the external environment via the metal fastener that extends through the opening within the wall of the enclosure, through the elastomer tubing, and within proximity to the through hole within the circuit board.

9. The method of claim 7 , wherein the intrinsically-safe sensor system comprises a connector comprising an internal connection region for internally connecting an additional device to the intrinsically-safe sensor system and an external connection region for externally connecting another additional device to the intrinsically-safe sensor system on demand, and wherein the method further comprises connecting at least one additional device to the intrinsically-safe sensor system using the connector.

10. The method of claim 7 , wherein the intrinsically-safe sensor system comprises a communication connection, and wherein the method further comprises sending data to and receiving data from at least one remote computing system via the communication connection.

11. The method of claim 7 , further comprising monitoring one or more additional conditions of interest corresponding to the source using at least one additional type of sensor that is installed within the int

Assignees

• Exxonmobil Technology & Engineering Company

Inventors

• Goschy Patrick E

Classifications

• G01M3/243 Primary

  for pipes · CPC title

• G01M3/2815 Primary

  using pressure measurements · CPC title