(12) INTERNATIONAL APPLICATION PUBLISHED UNDE
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`R THE PATENT COOPERATION TREATY (PCT)
`
`(19) World Intellectual Property Organization
`International Bureau
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`(43) International Publication Date
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`10 May 2012 (10.05.2012)
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`
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`1] )PPO
`ar
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`Sa"
`PCT
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`(10) International Publication Number
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`WO 2012/058770 Al
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`
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`(51)
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`17 February 2011 (17.02.2011)
`
`Drive, Edmonton, Alberta T6H 4K5 (CA). MOORE,
`International Patent Classification:
`Brian [CA/CA]; 234 Ockenden Place, Edmonton, Alberta
`GO1D 21/00 (2006.01)
`GOLL 19/00 (2006.01)
`T5K 218 (CA).
`G01B 21/32 (2006.01)
`GO1L 5/00 (2006.01)
`@
`(74) Agent: WOODRUFF,Nathan, V.; 200, 10328 - 81 Av-
`GOLE 17/00 (2006.01)
`GOP 1/00 (2006.01)
`enue NW, Edmonton, Alberta T6E 1X2 (CA)
`GOIL 1/00 (2006.01)
`H04W 84/18 (2009.01)
`27) Tnbecnanoushinapieaunn Numberot/CA2011/050100 (81) Designated States (unless otherwise indicated, for every
`kind of national protection available): AE, AG, AL, AM,
`(22)
`InternationalFiling Date:
`AO,AT, AU, AZ, BA, BB, BG, BH, BR, BW, BY, BZ,
`CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM, DO,
`DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT
`HN, HR, HU,ID,IL,IN,IS, JP, KE, KG, KM, KN, KP,
`KR, KZ, LA, LC, LK, LR, LS, LT, LU, LY, MA, MD,
`ME, MG, MK, MN, MW, MX, MY, MZ, NA, NG, NI
`NO, NZ, OM, PE, PG, PH, PL, PT, RO, RS, RU, SC, SD,
`SE, SG, SK, SL, SM, ST, SV, SY, TH, TJ, TM, TN, TR,
`TT, TZ, UA, UG, US, UZ, VC, VN, ZA, ZM, ZW.
`(g4) Designated States (unless otherwise indicated, for every
`kind of regional protection available): ARIPO (BW, GH,
`GM, KE, LR, LS, MW, MZ, NA, SD, SL, SZ, TZ, UG,
`
`..
`(25) Filing Language:
`(26) Publication Language:
`i.
`(30) Priority Data:
`5 November2010 (05.11.2010)
`61/410,734
`Inventors; and
`(72).
`(71) Applicants : SLUPSKY, Steven [CA/CA]; 21 Marlboro
`Road, Edmonton, Alberta T6J
`2C7
`(CA). SELL-
`ATHAMBY,Christopher [CA/CA]; 12511 Grandview
`
`English
`English
`
`US
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`WO2012/058770Ax[IMIIMIMININNIMUMAAMATIMLAATAA
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`[Continued on next page]
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`(57) Abstract: A wireless sensor device in-
`cludes a processor connected to a wireless
`transmitter and at least one sensor, and a
`power source connected to power the pro-
`cessor and the wireless transmitter. The
`processor has two or more states. An inter-
`nal control element senses at least one pre-
`determined condition. The internal control
`element switches the processor between
`states based on the occurrence ofat least
`one predetermined condition. A molded
`body encloses at least the processor,
`the
`wireless transmitter, and the internal con-
`trol sensor. The internal control sensor is
`physically isolated within the molded
`body.
`
`(54) Title: WIRELESS SENSOR DEVICE
`
`
`
`MoteScan
`App
`
`MoteScan
`App
`
`
`
`
`
`FIG. 4
`
`APPLE 1049
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`APPLE 1049
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`1
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`WO 2012/058770 A1IMMUN CUNTMONIT TAM AAT AACA
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`ZM, ZW), Eurasian (AM, AZ, BY, KG, KZ, MD, RU, TJ, Published:
`aeTeanae "GhiheGayhae a ue un —__with international search report (Art. 21(3))
`LV, MC, MK, MT, NL, NO, PL, PT, RO, RS, SE, SI, SK,
`SM, TR), OAPI (BF, BJ, CF, CG, CL CM, GA, GN, GQ,
`GW, ML, MR,NE, SN, TD, TG).
`
`2
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`WO 2012/058770
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`PCT/CA2011/050100
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`TITLE
`
`[0001] Wireless sensor device
`
`FIELD
`
`[0002]
`
`A wireless sensor device, which may be referred to as a wireless mote herein, for
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`attachment to a component of equipmentor a structure for determining status and sensing one or
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`more changes occurring at that component, such as strain, vibration, development of cracking,
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`progression of cracking and temperature. The sensor is sealed so that it may be operated in
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`either hazardous or non-hazardous environments.
`
`BACKGROUND
`
`[0003]
`
`Sensors are used to determine and monitor status and conditions of equipment and the
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`environment at that equipment. For example, a sensor may be used to monitor temperature,
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`humidity, atmosphere at an environment or other ambient conditions. Other sensors are used to
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`monitor physical parameters of equipment, and the status of the equipmentitself, including
`
`determining strain, vibration, and development of cracking.
`
`[0004]
`
`Sensors also may be used to log data. Powerset al. in United States Patent 5,381,136
`
`(1995) describe a remote logger unit for monitoring a variety of operating parameters along a
`
`fluids distribution or transmission system. An RF link is activated by which a logger unit alerts a
`
`central controller when predetermined operating limits are exceeded. Farther logger units
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`transmit data via closer logger units in daisy chain fashion.
`
`[0005]
`
`Arms
`
`in United States patent 6,588,282 (2003) describes peak strain linear
`
`displacement sensor for monitoring strain in structures. The device records data and can report
`
`strain history for the structure to which it is attached. A displacement sensor is constrained so
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`that it shows maximum movementin one direction resulting in deformation of the structure to
`
`whichit is attached.
`
`[0006]
`
`Hamelet al. in United States Patents 7,081,693 (2006) and 7,170,201 (2007) describe
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`devices for powering a load by harvesting energy as electrical energy from an ambient source,
`
`storing said electrical energy, and switching the storage device to provide electrical energy when
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`required to a load such as a sensor. The example is provided of powering a sensor for monitoring
`
`tire pressure and transmitting that data.
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`3
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`PCT/CA2011/0350100
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`[0007]
`
`Arms et al. in United States Patent 7,696,621 (2010) and in a conference presentation,
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`"Wireless Strain Sensing Networks," 2nd European Workshop on Structural Health Monitoring,
`
`Munich, Germany, Jul. 7-9, 2004, describe a RFID tag packaging system for an electronic device
`
`located within a cavity in an adjacent flexible material. The dimensions of the flexible material
`
`are chosen so as to provide protection of the electronic device from loading applied to the device.
`
`[0008]
`
`A preferred approach to maintenance is “Condition-Based Maintenance” (CBM).
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`Equipment downtime, both scheduled and unscheduled, is an important factor of productionloss.
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`In addition, according to a study by Optimal Maintenance Decisions Inc. (OMDEC), a leader in
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`condition-based maintenance (CBM) managementsolutions, failures in the field are three times
`
`more costly to repair (considering overtime, rescue, and expedited shipping of parts) than
`
`scheduled (or preventive) maintenance operations.
`
`[0009]
`
`Hence, CBM is replacing preventive maintenance in many industrial operations as a
`
`result of gains in productivity. Condition-based maintenance (CBM)is a maintenance system
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`prevalent in industrial mining and energy operations. CBM monitors equipment to establish an
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`optimal maintenance cycle (based on the predictions of when a machine will fail using strain and
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`vibration measurements, for example).
`
`[0010]|While preventive maintenance repairs machinery every given time period, even if the
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`machineis still operational, CBM can extend that time period. The optimal maintenance cycle
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`determines the best time to shut down a machine for preventive repair. Finding the balance
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`between repairing often and continuing to produce ts the tricky part.
`
`[OO11]
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`As an example, strain and fatigue measurements reveal risks of yield failures and
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`cracking, changes in material properties, and remaining equipmentlife, making them incredibly
`
`useful for CBM if monitored.
`
`[0012]
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`In the mining industry, strain and vibration are not generally monitored by built-in
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`systems, mainly due to the complexity of sensor installation and computational intensity of the
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`data processing. CBM relies heavily on regular or continuous measurements of parameters that
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`allow operators to determine when the machine will fail (1.e. strain and vibration).
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`[0013]
`
`Electronic
`
`sensors measure physical quantities
`
`(such as
`
`strain,
`
`temperature,
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`acceleration, crack propagation, pressure, etc.) and convert
`
`them into signals read by an
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`instrument(the reader varies depending on the type of sensor).
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`[0014]
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`For example, strain gauges consist of a foil pattern (often in a tight zigzag) insulated in
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`a flexible material and attached to an object under strain. As the object deforms, the resistance of
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`the foil wires changes, allowing a Wheatstone bridge circuit (a measuring instrument used to
`
`measure an unknownelectrical resistance) to record the variations.
`
`[0015] existing CBM_solutions have been historically inaccurate,Unfortunately, are
`
`
`
`
`
`
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`expensive or non-viable, and/or produce poor signal transmission and short battery life.
`
`[0016]
`
`CBM’s reliance on high data volume dictates a need to monitor continuously (or at
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`least often) strain and loading. To understand fully a machine’s state requires monitoring of
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`cracks and crack growth. However, monitoring the hundreds of machines used every day in a
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`mining operation requires many sensors and many more wires, which are difficult and expensive
`
`to install and maintain.
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`[0017]|Manysolutions have not reliably predicted when a machine will fail. This parameteris
`
`probably the most important when it comes to CBM,since CBMrelies on accurate predictions of
`
`failure. The inability to predict correctly when a machine will fail can have grave consequences
`
`on unplanned downtimeas well as operatorsafety.
`
`[0018]
`
`Some solutions offer accurate predictions, but at high costs, whether in the stages of
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`installation and setup, longevity and data collection, or analysis and data post-processing.
`
`[0019]
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`Yet other solutions offer poor signal transmission due to low range or lack of direct
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`line of sight. Power supplies dictate operating conditions and longevity of the solution. Most
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`solutions require too much power to operate for long periods of time, or are too delicate to
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`operate in the harsh conditions of mining operations. Conditions can include extreme
`
`temperatures, constant vibration, and quick acceleration.
`
`SUMMARY
`
`[0020]
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`According to an aspect,
`
`there is provided a wireless sensor device, comprising a
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`processor connected to a wireless transmitter and at least one sensor, and a power source
`
`connected to power the processor and the wireless transmitter. The processor has two or more
`
`states. There is at least one internal control element for sensing one or more predetermined
`
`conditions, the internal control element switching the processor between states based on the
`
`occurrence of at least one predetermined condition. A molded body encloses at
`
`least the
`
`processor, the wireless transmitter, and the internal control sensor such that the internal control
`
`sensoris physically isolated within the molded body.
`
`Q2
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`[0021]
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`According to another aspect, the molded body may also enclose at least one of the
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`powersource and one or more sensors connected to the processor.
`
`[0022]
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`According to another aspect, the processor may be connected wirelessly to a sensor
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`that is external to the molded body or to an external sensor by conductors where a portion of the
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`conductors is enclosed in the molded body, or both.
`
`[0023]
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`According to another aspect, at
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`least one internal control element may be an
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`accelerometer, and at least one predetermined condition may be the detection of one or more
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`predetermined accelerations. At least one internal control element may be an RF transponder,
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`and at
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`least one predetermined condition may be the introduction or removal of an RF
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`interrogator fromits detection radius. At least one internal control element is a magnetic sensor,
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`and at least one predetermined condition may be the introduction or removal of a magnetic
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`element on an outer surface of the molded body.
`
`[0024]
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`According to another aspect, the molded body may enrobe at least the processor, the
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`wireless transmitter, and the internal control sensor in a single piece construction.
`
`[0025]
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`According to another aspect, the at least one sensor may measureat least one ofstrain,
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`cracks, crack propagation, motion, shock, acceleration,tilt, inclination, pressure, light, radiation,
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`sound and chemical compounds.
`
`[0026]
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`According to another aspect, the processor may be programmed to process sensor data
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`from the sensing element according to an algorithm and transmit the processed data by the
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`wireless transmitter. The algorithm may be a Rainflow algorithm that generates a histogram of
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`discrete stress ranges.
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`[0027]|According to another aspect, the wireless transmitter may be a wireless transceiver.
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`[0028]|According to another aspect, the wireless sensor device may comprise an attachment
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`for attaching the wireless sensor to an object. The attachment may be at least one of a magnet,at
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`least one welding flange, strapping, or an adhesive compound.
`
`[0029]
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`According to another aspect, the sensor may be a bolt tightness sensor.
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`[0030]|According to another aspect, the processor may be configured to operate as a node in a
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`mesh network.
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`[0031]|According to another aspect, there is provided a method of operating a wireless sensor
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`device, comprising the steps of:
`
`providing a wireless sensor device as described above;
`
`configuring the internal control element
`
`to switch the processor between states upon the
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`PCT/CA2011/0350100
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`occurrence of at least one predetermined condition; and applying at least one predetermined
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`condition to the internal control element.
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`[0032]|These and other features will become more apparent from the following description in
`
`which reference is made to the appended drawings, the drawingsare for the purpose of
`
`illustration only and are not intended to be in any waylimiting, wherein:
`
`FIG. 1 shows schematically a basic wireless mote set-up.
`
`FIG. 2 showsschematically a wireless mote.
`
`FIG. 3 showsa wireless mote situated adjacent to and surrounding a sensor.
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`FIG.4 showsa series of wireless motes in communication with a coordinator.
`
`FIG.5 illustrates one method for management of data received from wireless motes
`
`shown in FIGS.1 through 4.
`
`FIG. 6 showsa schematic of the synchronization of motes.
`
`FIG.7 illustrates an algorithm for quasi-asynchronous to isochronous to synchronous
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`conversion of data from wireless motes.
`
`FIG.8 is a side elevation view in section of a tension bolt sensor.
`
`FIG.9 is a perspective view of a load washercell.
`
`FIG. 10 is a graph depicting a random load history of a piece of heavy machinery
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`driving on a haul road.
`
`FIG. 11 is a graph depicting the results of a cycle counting algorithm.
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`FIG.12 is a graph depicting a histogram ofdiscrete stress ranges.
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`FIG.13 is a bock diagram of a wireless mote with internal control elements.
`
`FIG. 14 1s a state diagram of the microprocessor that changes states based on a
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`gesture.
`
`FIG. 15 is a state diagram of the microprocessor that changes states based on
`
`different gestures.
`
`FIG. 16 is a state diagram of the microprocessor that changes states based on a
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`gesture and an event.
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`FIG. 17 is a block diagram of a computer connected to a data coordinator using a
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`wired connection.
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`FIG. 18 is a block diagram of a computer connected to a gateway using a wireless
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`connection.
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`FIG. 19 is a block diagram of functions performed by the software installed
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`FIG. 20 is a block diagram showing the wireless mote wirelessly receiving power
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`from an external powersource.
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`DEETAILED DESCRIPTION
`
`[0033]
`
`There are many devices knownto those skilled in the art for sensing various properties
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`of matter, physical environment, and status of equipment. Typically, the data acquired by the
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`sensor are stored and compared to predetermined values.
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`In some cases, each reading is
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`transmitted electronically to a central processor for evaluation. Alternatively, data may be
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`transmitted electronically to a controller at intervals or when the data acquired fall outside
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`predetermined limits.
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`[0034]
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`Data may be transmitted using RF as described by Powerset al. in US 5,381,136.
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`[0035]|Sensors may be isolated from harmful environments, such as corrosive atmospheres,
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`or hazardous conditions, such as combustible gases, by containment of the sensor within a
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`housing.
`
`[0036]
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`In other sensing devices, there are requirements including available power, reliability,
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`and protection of and from the ambient environment that limit their applicability and which
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`reduce their utility.
`
`[0037]
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`In particular,
`
`sensors attached to moving components of equipment,
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`rotating
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`components, components may be subjected to severe stresses or vibrations.
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`It is desirable that
`
`sensors be small and have minimal mass to minimize imbalance that could lead to wear to
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`failure. Additionally, components at interior points of equipment can have limited visibility or
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`“line of sight” to the other sensors and data collection points and can be “blind”.
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`It is desirable
`
`that sensors have the capability to operate independently of all other devices, and capability to
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`transmit data wirelessly. Further, it is desirable that such systems be capable of operating in
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`hazardous, harsh as well as laboratory or environmentally controlled environments.
`
`[0038]
`
`The present discussion relates to a wireless mote, or sensor, that is intrinsically safe
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`and easy to install by direct attachment to a component of equipment, and easy to use asit
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`PCT/CA2011/0350100
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`contains within a protective body all components necessary for its intended purpose, such as
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`components for sensing, communications, a tap sensitive user interface, a durable power source
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`and ultra-low poweroperation. Advantages accrue from inclusion of a sensor interface and data
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`acquisition components, memory, wireless transceiver, long life battery, a magnetic sensor, and
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`capability for software over radio updates, data logging, and power management.
`
`[0039]
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`This device may be usedto sense the status of a component of equipment, and may be
`
`designed to provide someorall of the following advantages:
`
`e can be securely affixed to a component of equipment located at any position within
`
`that equipment;
`
`e
`
`is isolated from the ambient conditions so as to protect it against hazards and so that it
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`is not at risk to cause a hazard;
`
`e can acquire data, log data, store data and, when required, handle, analyze and compare
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`data;
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`e can transmit all data, accumulated blocks of data, or selected data; and
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`e can receive commands for operating the data accumulation, storage and transmission
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`functions.
`
`[0040]
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`The mote contains a source of power that may be batteries or, alternatively, a mote
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`may be capable of being recharged so as to extend its operating life. Alternatively, the mote may
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`scavenge or harvest power from its environment.
`
`[0041]
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`Further, to minimize power consumption, the mote may be capable of conserving
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`power through power management functions such as operating one or more functions only when
`
`required and selectively controlling power to one or more components.
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`[0042]
`
`The position of a mote that is attached to moving equipment at any time can be
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`determined using methods such as those described by El-Sheimyet al. in Report on Kinematic
`
`and Integrated Positioning Systems, FIX XXII International Congress, Washington, DC, Apr. 19-
`
`26, 2002.
`
`[0043]
`
`To these ends, a wireless mote 10 now will be described with reference to FIG. 1
`
`through 5. In particular, as a non-limiting example, a wireless mote will be described for
`
`monitoring strain within a component of equipment. It will be recognized that there are many
`
`other applications for which there is use of an alternative design of wireless mote 10 based on
`
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`similar design aspects.
`
`[0044]
`
`Referring to FIG. 1, at least one wireless mote 10 is in wireless communication via
`
`link 42 with a data coordinator 30, which is in turn in communication using USB interface 44
`
`with a computer 46 for receiving, logging, analyzing and processing data received from wireless
`
`mote 10.
`
`In a preferred embodiment, mote 10 has within a communications software stack 26
`
`that
`
`is compliant with a Zigbee End Device and data coordinator 30 has within a
`
`communications software stack 28 that is compliant with a Zigbee Coordinator, it is recognized
`
`that there are other wireless protocols possible. USB interface 44 could be any other form of
`
`serial communication interface such as RS-232, Ethernet, modbus or controller area network
`
`(“CAN”). Moreover, USB interface 44 could be any form of wireless interface such as
`
`Bluetooth or any one of the 802.11 “WiFi” standards. Computer 45 could be any other form of
`
`computer suchas a portable computer, smart phone such as an iPhone, Blackberry, Android, etc.,
`
`or a tablet computer such as an iPad.
`
`[0045]
`
`Referring to FIG. 2, wireless mote 10 includes a body 12 within which other
`
`components 22 are completely sealed. Body 12 isolates these other components from all
`
`hazardous environments. Body 12 is preferably a molded body having all
`
`the internal
`
`components secured within it.
`
`In a preferred example, the internal components are assembled,
`
`and an epoxy resin 55 is injected around the components to create a monolithic body
`
`encapsulating the components without any internal cavities, such that each component
`
`is
`
`embedded within the epoxy resin. It will be understood that body 12 may be manufactured from
`
`any material that isolates interior components of wireless mote 10 from the ambient environment
`
`while allowing radio coupling between antenna 18 and data coordinator 30. It has been found
`
`that body 12 manufactured from epoxy resin meets these requirements for use in several
`
`environments. Preferably, the material will be rigid, heat resistant and impermeable.
`
`[0046]
`
`Sealed within body 12 are a microcontroller 14, program memory 50, A/D converter
`
`56, interface and conditioning electronics 54, wireless transceiver 60, at least one antenna 18,
`
`and a power source 20. One or more sensors 24 may be interfaced to other components 22 within
`
`body 12 through direct connection 48 to sensor interface and conditioning component 54.
`
`Sensors 24 may be any suitable sensor, such as one or more temperature sensor/transducer,
`
`pressure transducer, accelerometer, strain gauge, crack sensor, etc. and may be powered by mote
`
`10 or have an independent power source. Other components may be included within the body
`
`10
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`such as program memory 52 which ts preferably flash memory, data memory (not shown) which
`
`is preferably flash memory, temperature sensor 62, and a power management and monitoring
`
`block 58. Referring to FIG. 3, alternatively, sensor 24 external to body 12 and may be in
`
`wireless communication via a wireless link 34 with an adjacent wireless mote 10. Wireless link
`
`34 may comprise a radio link comprising a transponder (not shown) embeddedin sensor 24 and
`
`an interrogator (not shown) embeddedin wireless mote 10. Alternatively, wireless link 34 may
`
`be an inductively coupled link.
`
`In FIG. 3, wireless mote 10 is shown attached to a surface 64 of
`
`a component 66 of equipment and situated surrounding sensor 24. Wireless mote 10 is attached
`
`at surface 64 by welding metal tabs 32 of wireless mote 10 to component 66. Alternatively, body
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`12 may be attached to surface 64 using epoxy compounds. Alternatively, a permanent magnet
`
`within body 12 may couple with a magnetic material in component 66 and maintain a force of
`
`attraction to keep the body 12 in contact with surface 64.
`
`[0047]
`
`Components 22 within the body 12 provide capability to sense at
`
`least one of
`
`tilt/vibration/acceleration integrally with wireless mote 10. A signal provided from component 22
`
`may be used to activate and control actions such as logging and temperature sensing. Such
`
`activations can be used to interface the operation or functions of the wireless mote with the user.
`
`Further, wireless mote 10 may be attached to a rotating component of equipment, for example a
`
`rotating shaft, so as to measure the environment, behaviour and phenomenaexperienced by said
`
`component,
`
`including vibration, acceleration, etc. and so provide data on the status of said
`
`component during operation and to provide an alarm when predetermined valuesfor criteria are
`
`exceeded or to acquire data or perform a task according to the orientation or rotational position
`
`of the wireless mote 10. Component 22 could also integrate into the power management
`
`functions to wake the sensor from a low power mode to becomeactive upon the occurrence of a
`
`predetermined condition, such as sensing motion of the attached equipment. Preferably, the
`
`wake/sleep, or active/inactive state of wireless mote 10 is controlled by an elementthat is distinct
`
`from the wireless transmitter used to transmit the sensor data. For instance, wake/sleep when the
`
`sensor1s in a certain orientation or motion, or wake/sleep upon a certain magnitude of shock, or
`
`wake/sleep on a certain amount of vibration. Alternatively, the power management functions
`
`such as wake/sleep could be activated on a “gesture” which is a combination or pattern thereof of
`
`orientation, motion, shock and vibration.
`
`In yet another embodiment,
`
`the gestures, or tap
`
`sensitive interface, could be used to control other functions of the sensor. Other examples
`
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`WO 2012/058770
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`PCT/CA2011/0350100
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`include an RF transponder (such as a radio frequency identification tag), where an RF
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`interrogator that comesinto range, or leaves the range, of the RF transponder in wireless mote 10
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`would cause it to change states, and a magnetic sensor that may be either an element that senses
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`a magnetic field or a switch that is activated by a magnetic field, could be activated by a
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`magnetic element being placed on or near an external surface of the wireless mote 10. Moreover,
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`the magnetic element could be moved in a three dimensional pattern to form a gesture.
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`Generally speaking, the wireless transmitter uses a significant portion of the available power. By
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`providing these other elements, which use little or no power, to switch the wireless mote between
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`wake/sleep states,
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`it allows more power to be conserved. For example,
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`the accelerometers
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`required for the gestures require little power, or may be powered by the gestureitself, and the RF
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`transponder may be designed to be powered by the RF signal
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`it receives from the RF
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`interrogator. Similarly, the magnetic sensor requireslittle or no power between switchingstates.
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`[0048]
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`Other power management options include harvesting energy from the environment,
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`such as thermal energy, solar energy, kinetic energy, or energy from radio waves.
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`[0049]
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`Referring again to FIG. 1, other components 22 of wireless mote 10 may include
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`program memory 50 for microprocessor 14, Flash memory 52, a conditioner 54 for conditioning
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`signals from sensor 24, a temperature sensor 62, an analog-digital converter 56 for converting
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`signals from sensor 24 and temperature sensor 62, a monitor 58 for monitoring the status of
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`power source 20, an ISM radio 60 for communication between microprocessor 14 and antenna
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`18, and a magnetic on-off switch or sensor 124 capable of being activated remotely.
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`[0050]|Power source 20 may be at least one battery, or may be a rechargeable electrical power
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`storage unit for storing electrical power harvested from solar energy, vibration, heat, or an
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`inductively coupled electrical source, coupled inductively to wireless mote 10 so as maintain the
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`seal provided by body 12. Alternatively, referring to FIG. 20, wireless mote 10 may be powered
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`by an inductively coupled 104 power source 102. Power source 102 could be any form of power
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`source such as a battery. Alternatively, wireless mote 10 may recharge its internal battery
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`through inductively coupled 104 power source 102.
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`[0051]
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`Referring to FIG. 4, multiple RF channel selection capability at wireless mote 10 and
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`data coordinator 30 allows multiple networks 400 and 402 to operate within communication
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`distance of each other. Alternatively, data coordinators 30 for networks 400 and 402 maybe
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`connected to a single computer 46 to facilitate download of data from multiple data coordinators
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`WO 2012/058770
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`30 via communications software 28 to a single computer 46. A plurality of wireless motes 10
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`communicates data via communications software 28 to data coordinators 30. When a wireless
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`mote 10 1s located at a blind spot with respect to data coordinator 30, signals are transmitted via
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`one or more intermediate routers 92 as illustrated in FIG. 4 and FIG. 17. In FIG. 4, wireless
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`“mote 3” communicates in this fashion via wireless “mote 2” to coordinator 30. Wireless motes
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`10 may also be configured to operate in a mesh network to communicate data.
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`[0052]
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`Referring to FIG. 17, data coordinator 30 may be connected to computer or mobile
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`device 46 using a wired connection 88 such as the 30 pin data connector on an Apple iPod,
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`iPhone or iPad or a USB connector on a portable computer. Data coordinator 30 is in wireless
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`communication with Mote 10, end devices 90,
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`router 92 and gateway 94. Alternatively,
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`computer or mobile device 46 may be in wireless communication 100 with gateway 94 using any
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`form of wireless communication available within computer 46 such as Bluetooth, Wi-Fi, or
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`cellular modemas illustrated in FIG. 18.
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`[0053]
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`Data coordinator 30 is optionally provided for high speed data downloads. Softwareis
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`installed providing an algorithm for data re-sampling to correct for time base errors. In this way,
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`time baseerrors arising from data gathering using a multiplicity of wireless motes are corrected
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`to enable alignment of time data from all wireless motes. Data coordinator 30 analyzes principal
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`components of multi-channel input. In one example, different strain gauges may measurestrain
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`in different directions at a site on a component of equipment, and data coordinator 30 is capable
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`of analyzing the data from the different strain gauges to determine the vector of the strain at that
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`site on the component. Data coordinator may be programmed to perform either Rainflow or
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`histogram analysis of data, thus determining extent and frequency of occurrence of the parameter
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`being monitored. Miner’s rule (discussed below) may be further applied to estimate or predict
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`timeto failure.
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`[0054]
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`Power management is implemented to reduce power consumption to improve lifetime
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`of power source 20. Multiple level power saving techniques may be used by programming
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`wireless mote 10 to perform one or more of the following means:
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`e operating during sampling only, so that the sensor is in an onstate only just before a
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`reading, and then 1s switched off;
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`e deep sleep mode, in which an external signal is required to reactivate wireless mote
`10;>
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`11
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`WO 2012/058770
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`PCT/CA2011/0350100
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`e operating only the Rx transmitter;
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`e operating only the Rx receiver for supervisory channel
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`received signal strength
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`indicator detection of a “wake up” code;
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`e powering only clocking modes when other modesare switched off; and
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`e operating Tx radio/Rx on a periodic basis, that is, duty cycled.
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`[0055] Magnetic sensor 124 may be used to interrupt the power to the mote circuits and to
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`reconnect. In general, motes are programmedto periodically “wake up” and go to “sleep” with
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`the objective of saving poweror to extend the life of one or more components. Typically, this is
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`done in one of two manners. The first manner is to program “on” times for reading and data
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`logging, e.g. the mote goes to “sleep” at a specific time and wakes up at a prescribed time or
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`after a prescribed interval to take readings, and the cycle is repeated. The second manner to
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`conserve poweris to be in low power mode for the majority of time and to be fully powered up
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`only at prescribed times at which it is to determine if there are messages received from controller
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`30 or an external device such as a computer; or to communicate with or download data to a data
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`management system 30 or external device. In either case the mote is not necessarily “on” and
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`capable of communicationsat all times. However, by keeping the previous state of the mote,
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`including its view of wake/sleep state, projecting forward in an external database, then a user can
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`talk to one or more motes in a virtual sense, 1.e. it becomes possible to communicate with a
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`database remote from both motes and user and thereby the database will provide the information
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`as if the mote were active and in communication with the user. Thus, for example, a user at one
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`site utilizes a coordinator (e.g. a master mote) to communicate to one or more motes, even when
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`those motesare asleep.
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`[0056]
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`A user normally would perceive that sleeping motes do not appear to exist beca