Note: Descriptions are shown in the official language in which they were submitted.
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REMOTE FIRING SYSTEM
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application
No. 60/537,153, filed January 16, 2004, which is expressly incorporated herein
by
reference.
FIELD OF THE INVENTION
This invention relates generally to remote firing systems and, more
particularly, to
safety communication of remote firing systems.
BACKGROUND OF THE INVENTION
Blasting machines are devices used to trigger detonators. A detonator, in
turn,
triggers a main charge explosive. The use of blasting machines created a
significantly
safer and more efficient environment for the detonation of explosives in
mining,
construction, and military applications. Blasting machines replace the
traditional lit fuse
method of initiating explosives. Blasting machines typically use a lead line
comprised of
a pair of copper wires or a shock tube. The use of a blasting machine
increases safety by
allowing a greater standoff between the operator and the explosive charge, a
shorter lag
time between the initiation of the firing sequence and the actual detonation
of the
explosive, as well as a reduction in the number of accidental ignition sources
that could
trigger a blast unintentionally. Blasting machines make detonation of
explosives more
efficient by creating a more reliable and consistent source of initiation,
reducing the
amount and cost of materials used, as well as allowing for faster setup
thereby reducing
overall manpower time as compared to traditional fuses.
FIGURE lA depicts a plan view of an open pit mine 100. Three separate groups
of explosives 118 A-C, known as shots, are situated in various locations
throughout the
mine. Each shot 118 A-C is tethered to a blasting machine (not pictured) and
operator 116 A-C by a lead line 126 A-C. This allows the operator 116 A-C to
initiate a
blasting sequence, transmitting a signal with a blasting machine through the
lead
line 126 A-C to the detonators in the shot 118 A-C.
A danger area 124 A-C is associated with loose rock, known as fly rock, which
can be thrown to great distances by the explosive force released upon
detonation of the
shot 118 A-C. To ensure safety, the blasting machine and operator 116 A-C must
be
located outside of the danger area 124 A-C created by the explosion.
Similarly,
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vehicles 114 A-C and other mine employees 112 A-B must also be' located
outside of the
danger area 124 A-C of each shot 118 A-C. Mine personnel (not shown), known as
spotters, guard areas of ingress that cannot be observed by the blasting
machine operator,
preventing other mineworkers or equipment from entering the danger area 124A-C
during
a shot. As can be appreciated by FIGURE lA, overlapping danger areas 124 A-C
from
each shot 118 A-C can create significant portions of a mine that pose a risk
to both
vehicles 114 A-C and mine personnel 112 A-B when blasting ensues. To ensure
that a
blasting machine and operator 116 A-C are outside of a danger area 124 A-C,
long
lengths of lead line 126 A-C are used, typically between 300 and 600 meters.
It is desirable to minimize the amount of time a mine is evacuated (downtime)
because of the great expense associated with a non-producing mine. Shooting
multiple
shots close in time minimizes downtime. Typically, separate shots 118 A-C will
use
separate blasting machines and operators 116 A-C to minimize downtime and
maximize
e~ciency. FIGURE lA further illustrates the typical one to one relationship of
shot 118 A-C to blasting machine and operator 116 A-C. For each shot 118 A-C,
a
separate blasting machine and operator 116 A-C are used to initiate a signal
on a
dedicated lead line 126 A-C.
FIGURE 1B depicts a cross-sectional view of a subterranean mine 150. As in
surface mining, blasting machines and lead lines can be used to detonate
explosives in a
subterranean mine. Shots are placed in headings 156 A-D of working shafts 154
A-D.
These working shafts 154 A-D connect to the main shaft 152. The main shaft 152
leads
to the surface. Due to the dangers of cave-ins for subterranean mining, entire
mines are
generally shut down and evacuated prior to detonation of explosives. This
requires
evacuation of both the operator 116 J and mine personnel 112 C to the surface;
some
equipment 158 can be removed as well. To ensure that all mine personnel are
outside of
the mine, mining companies frequently employ safety interlock devices such as
a tag
board. Subterranean mines can have multiple headings 156 A-D, each of which
may, or
may not, have a shot placed in it. As in the surface mining example (FIGURE
lA) this
adds complexity to firing shots, as each individual shot requires a distinct
lead line and
blasting machine. Ideally, the operator would FIRE the shot from the surface
to avoid a
possible cave-in. However, in large mines this might require unreasonably long
or
expensive lead lines. Thus, shorter lead lines can be used, forcing the
operator to FIRE
the shot underground in a less safe environment.
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More recently, the introduction of a remote control blasting machine has
further
increased the safety and efficiency of blasting. A remote control blasting
machine
essentially separates a traditional blasting machine into two components, a
remote
device 182 and a controller device 184. FIGURE 1 C depicts a remote control
blasting
machine system 180. An operator 196 manipulates a controller device 184,
transmitting a
signal 186 to a remote device 182. The remote device 182 is coupled to a
shortened lead
line 198. The shortened lead line 198 is coupled to a detonator line 194 which
is coupled
to a detonator 192 placed in a main explosive charge 188. The explosive charge
188 is
capped with stemming 190. Stemming 190 consists of gravel and rock chips and
is used
to focus the energy of the explosion into fracturing new rock rather than just
exploding
out of the top of the hole in which the explosive is placed. FIGURE 1 C
further illustrates
a communication that includes commands transmitted from a controller device
184 and
received by a remote device 182 (illustrated by an arrow 186). The remote
device 182
affirms a received signal, but provides no additional information beyond this
affirmation.
An additional safety and efficiency concern of remote control blasting
machines is
associated with deployment of the remote device 182. Information sent using
radio
frequencies is the typical method for communication between a controller
device 184 and
a remote device 182. Topographical features or atmospheric conditions can
attenuate
effective radio frequency communication range. This attenuation can result in
ineffective
placement of a remote device 182 or controller device 184 and create
uncertainty in a
blasting sequence, thereby reducing safety and efficiency. If weather changes
or the
movement of equipment at a mine disrupt communication, a shot may not fire,
leaving an
unexpected live explosive charge in the field where workers will be returning.
This is a
significant disadvantage associated with remote control blasting machines and
is
especially troublesome in subterranean mines 150 where electromagnetic
attenuation is a
more significant problem than in surface mining 100.
SUMMARY OF THE INVENTION
In accordance with this invention, a remote firing system, a controller
device, a
remote device, and a method for remotely detonating explosives is provided.
The system
form of the invention includes a remote firing system that comprises a set of
remote
devices. Each remote device is capable of communicating a safety data
structure that
contains a system identifier for identifying the remote firing system from
other remote
firing systems and a device identifier for identifying a remote device from
other remote
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devices. The remote firing system fiu~ther includes a controller device for
causing the set
of remote devices to trigger detonators. The controller device is capable of
selecting a
subset of the set of remote devices for triggering detonators and further
being capable of
communicating the safety data structure that contains a system identifier for
identifying
the remote firing system from other remote firing systems and device
identifiers for
identifying the subset of remote devices to control.
In accordance with further aspects of this invention, a device form of the
invention includes a controller device that includes a set of selection and
information
panels that correspond with a set of remote devices. A subset of selection and
information panels is selectable to cause a corresponding subset of remote
devices to be
selected for detonating explosives. The controller device further includes a
communication module for transmitting and receiving safety communication. The
communication module is capable of communicating with the subset of remote
devices to
indicate their selection for detonating explosives by the controller device.
In accordance With further aspects of this invention, a device form of the
invention includes a remote device that includes a communication module for
transmitting and receiving a safety data structure that contains a system
identifier for
identifying a remote firing system that comprises the remote device and a
device
identifier for identifying the remote device. The remote device further
includes a switch
for selecting either shock-tube detonator initiation or electric detonator
initiation.
In accordance with further aspects of this invention, a method form of the
invention includes a method for remotely detonating explosives. The method
includes
selecting a subset of a set of selection and information panels on a
controller device to
cause a corresponding subset of remote devices to be selected for detonating
explosives.
The method further includes issuing an arming command by the controller device
to the
subset of remote devices to cause the subset of remote devices to prepare for
detonation.
The method yet further includes issuing a firing command by the controller
device to the
subset of remote devices by simultaneously selecting dual fire switches
together on the
controller device to cause the subset of remote devices to detonate
explosives.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention
will
become more readily appreciated as the same become better understood by
reference to
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the following detailed description, when taken in conjunction with the
accompanying
drawings, wherein:
FIGURE lA is a pictorial diagram showing a plan view of an open pit surface
mine, wherein conventional blasting techniques are employed;
FIGURE 1B is a pictorial diagram showing a cross-sectional illustration of a
subterranean mining operation;
FIGURE 1 C is a pictorial diagram illustrating a remote control blasting
machine
with conventional communication capability;
FIGURE 2A is a pictorial diagram illustrating a remote firing system using
safety
communication according to one embodiment of the present invention;
FIGURE 2B is a pictorial diagram illustrating multiple remote firing systems
using safety communication between multiple remote devices and a single
controller
device in each remote firing system, according to one embodiment of the
present
invention;
1 S FIGURE 3A is a pictorial diagram of a controller device user interface, in
accordance with one embodiment of the present invention;
FIGURE 3B is a pictorial diagram illustrating a remote device user interface,
in
accordance with one embodiment of the present invention;
FIGURE 4A is a block diagram illustrating various inputs and outputs for both
the
controller device and the remote device of a remote firing system, in
accordance with one
embodiment of the present invention;
FIGURE 4B is a block diagram showing various inputs, outputs, and internal
control modules for a controller device, in accordance with one embodiment of
the
present invention;
FIGURE 4C is a block diagram showing various inputs, outputs, and internal
control modules for a remote device, in accordance with one embodiment of the
present
invention;
FIGURES SA-50 are process diagrams illustrating an exemplary method formed
in accordance with this invention for remotely detonating explosives by
employing a
remote firing system.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As discussed hereinbefore, blasting machines have improved the safety and
efficiency of detonating explosive charges in mining, construction, and
military
applications. Both typical lead-line blasting machines (tethered systems) and
remote
control blasting machines have provided significant increases in safety and
efficiency
over prior techniques. However, still greater increases in efficiency and
safety can be
achieved through various embodiments of the present invention.
FIGURE 2A illustrates the constituent parts of a remote firing system 200 that
include a remote device 208 and a controller device 202 that interoperate to
provide
safety communication in accordance with one embodiment of the present
invention. The
inputs 210 may include for example, user commands or safety interlock device
signals.
The remote device 208 is coupled to a lead line 212 to transmit a signal that
initiates a
detonator.
The term safety communication used hereinabove and hereinbelow means any
suitable communication occurring between a remote device and a controller
device that
indicates that interoperation is safe. One suitable safety communication
occurs when a
safety data structure is transmitted from a first piece of equipment and
received at a
second piece of equipment and transmitted from the second piece of equipment
and
received by the first piece of equipment. In one embodiment of the present
invention a
safety data structure containing blasting information can be transmitted from
the
controller device 202 and received by the remote device 208, and another
safety data
structure containing blasting information can be transmitted from the remote
device 208
and received by the controller device 202. Blasting information contained
within the
safety data structure includes the battery condition of a device; armed or
ready status of a
device; error detection codes; system, device, index identification; and
timing information
among other pieces of information. These pieces of information, any of which
could
form part of a safety data structure, are not exhaustive or exclusive and
additional suitable
pieces of blasting information can be contained by the safety data structure.
FIGURE 2B illustrates a remote firing system comprising multiple remote
devices
interoperating with a controller device using safety communication. One
embodiment of
the present invention includes the use of an electronic key. An electronic key
is a device
that provides the means of gaining or preventing control of another device
electronically,
mechano-electronically, opto-electronically, or some combination thereof. When
an
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electronic key is coupled to a piece of equipment in a remote firing system,
information
contained on the electronic key is preferably electronically accessible by the
piece of
equipment. This information provides various suitable identifications, such
as, whether
the electronic key permits access to a controller device or a remote device;
programming
level access to a remote device; identification of a unique remote firing
system; and an
index identifying the last programming event for that particular electronic
key. The
electronic keys 230, 232, 246, 248, and 250 provide one or more suitable
pieces of
identification information. For example, three pieces of suitable
identification
information delimited by colons: DEVICE:SYSTEM:INDEX. Preceding the first
delimiter is the device identifier. After the first and before the second
delimiter is the
system identifier. After the second delimiter is the incremented index. For
example, a
string of O:A:T1 represents a controller device identified as 0, on remote
firing system A,
last programmed with index Tl .
The device identifier, coded on an electronic key, increases the safety of
operating
multiple remote devices through a single controller device. In one embodiment
of the
present invention, the controller device 226 or 228 is used preferably to
operate one to
eight remote devices, although less or more remote devices are possible.
Preferably,
remote devices are non-operational when a controller device electronic key is
coupled to
the remote devices. Further, the controller device operates preferably in a
programming
mode when a remote device electronic key is coupled to the controller device
if the
controller is in key programming mode. When a remote device is coupled to a
compatible remote device electronic key or when a controller device is
coupled' to a
compatible controller device electronic key, the devices preferably operate
normally. As
illustrated in FIGURE 2B, the controller electronic keys 230 and 232 include
the device
identifier O and identify controller devices 226 and 228. The remote
electronic keys 246,
248, and 250 include the identifiers X and Z.
The remote firing system identifier serves to increase the safety of
concurrent
operation of multiple remote firing systems 220. Each remote firing system 222
and 224
is designated by a unique identifier such as A and B. (See electronic keys 230
and 232.)
In one embodiment of the present invention, the system identifier includes the
serial
number of the controller device. Remote devices coupled to remote device
electronic
keys with suitable system identifiers and indexed identifiers (discussed
below) function
normally. Remote devices coupled to remote device electronic keys preferably
discard a
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transmission received from a controller device on a different system with
different system
identifiers. In FIGURE 2B, the safety communication of system A (illustrated
by
arrows 252, 234, 236, and 254) occurs among the system A controller and
compatible
remote devices, and system B safety communication (illustrated by arrows 238
and 256)
occurs among the system B controller and compatible remote devices. Further,
the
controller device preferably operates with a controller device electronic key
containing
the same system identifier as stored internally on the controller device.
The indexed identifier information stored on an electronic key represents the
most
recent programming event of the electronic key. Each time an electronic key is
reprogrammed on a controller device, the identifier is indexed and updated on
the
elecaronic key and stored internally on the controller device. This prevents
more than one
remote firing system device electronic key from carrying identifier
information that is
identical (same device identifier, same system identifier, and same indexed
identifier) as
another electronic key. For example, if a first electronic key is programmed
to 4:A:T1,
an attempt to program a second electronic key with the same identifiers will
result in the
index identifier being incremented. The identification information that would
be stored
on the second electronic key is 4:A:T2. Any suitable incrementing process can
be used,
such as time stamping. The electronic key with the most recent indexed
identifier
preferably allows a remote device to function while the electronic key with
the older
indexed identifier will not allow the device to function, despite both keys
otherwise
identifying the same device and system identifiers:
Electronic keys with the same device identifier and indexed identifier are
possible,
but preferably exist on different systems, by design, maintaining the robust
nature of the
unique electronic key scheme. For example, if the first electronic key is
4:A:T2, a second
key, with an identical device identifier and indexed identifier, 4 and T2,
preferably be
programmed on system B (more precisely, the system identifier can be
programmed on
any system other than system A) yielding 4:B:T2. If the second key were
programmed
with a device identifier 4 and a system identifier A, the indexed identifier
would be
incremented yielding 4:A:T3. Essentially, each electronic key contains a
unique set of
identifiers distinguishing a controller or remote device, a remote firing
system, and the
most recent set of programming. This creates an additional level of safety by
creating
unique electronic keys and preventing multiple, unintended detonations that
could
otherwise result if duplicate electronic keys were present in a remote firing
system.
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In one embodiment of the present invention, electronic key identification
information is transmitted as a component of the safety data structure for a
transmission
by a piece of remote firing system equipment. A received safety data structure
is parsed
and the extracted identification information is compared to the information
stored on an
electronic key coupled to the receiving piece of equipment. For example, while
each
remote device 240, 242, and 244 in FIGURE 2B actually receives transmissions
from the
controller devices 226 and 228, the arrows 234, 236, and 238 indicate
selective data flow
among controller devices and remote devices containing electronic keys with
suitable
system identifiers. The arrows 234 and 236 represent data transmission from
controller
device 226 with a system identifier A and the indexed identifier Tl. Arrow 238
represents data transmission by controller device 228 with a system identifier
B and index
Tl.
T'he transmission from controller device 226, if received by the remote
device 242, is preferably discarded by remote device 242 because the system
identifier is
not compatible. This same transmission from controller device 226, if received
by the
remote devices 240 and 244, is accepted because the system and indexed
identifiers are
compatible. The transmission from controller device 228 is preferably accepted
by
remote device 242, while preferably being discarded by remote devices 240 and
244.
Transmissions from the remote devices 240, 242, and 244 will preferably be
discarded by
controller devices 226 and 228 with uncompatible system identifiers. To recap,
unless
the system and indexed identifiers on the electronic keys coupled to both a
controller
device and one or more remote devices are compatible, the controller and
remote devices
preferably discard a received transmission. Preferably remote devices discard
transmissions that do not identify as originating from a controller device.
This allows the
operator to control, with a single controller device, multiple uniquely
identified remote
devices. Multiple remote firing systems can be deployed contemporaneously 220
because they are unlikely to conflict with one another due to different system
identifiers.
In one embodiment of the present invention, the remote devices of the firing
system can be semi-permanently assigned a device identity as an alternative to
assuming
the identity associated with the identification information stored on a
coupled electronic
key. This semi-permanent programming causes the remote device to function
normally
preferably with remote device electronic keys having a specified device
identifier that
suitably relates to the semi-permanently programmed device identifier stored
internally
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on the remote device. Additional safety results from semi-permanent
programming of
remote devices for particular applications where the remote device is not
frequently
moved. As an example of semi-permanent programming, if electronic key 4:A:T2
is
coupled to an unprogrammed remote device, the remote device will assume the
identity
4:A:T2 and discard received transmissions that do not include compatible
identifiers.
The remote device preferably returns to a non-operational state when the
electronic key is
removed. If this same unprogrammed remote device is then semi-permanently
programmed as system device number 6, the electronic key 4:A:T2 will not be
recognized
as valid when coupled to the remote device because the key has a system device
identifier
number 4 and not number 6. The semi-permanently programmed remote device will
however preferably f-anction normally (assuming a received transmission
includes
suitable identifiers) with any of the following electronic keys: 6:A:T1,
6:A:T5, 6:C:T1,
6:S:T9, for example. This is because they all have the same device identifier
as the
semi-permanently programmed system device identifier stored internally on the
remote
device. The number 6 identifier programmed is preferably nonvolatile and
persists until
the device is reset to an unprogrammed state or is semi-permanently programmed
to a
different device identity. In one embodiment of the present invention, semi-
permanent
system device identity programming is achieved preferably through the use of a
master
electronic key.
FIGURE 3A illustrates an exemplary front panel for a controller device user
interface 300 in accordance with one embodiment of the present invention. Any
suitable
number of remote devices are controllable from the controller device user
interface 300.
One suitable number of remote devices, in accordance with one embodiment of
the
present invention, is eight remote devices. The left portion of the controller
device user
interface 300 encompasses the selection and information panel 304 A-H for
eight remote
devices. Each remote device panel 304 A-H includes a membrane switch 306 A-H
that
allows selection or deselection of the associated remote device. Further, each
remote
device panel 304 A-H includes labeling and an LED indicator for the READY
state 308,
ARMED state 310, battery condition 312, and selected state 314 of the
associated remote
device.
The right portion of the controller device user interface 300 includes a
controller
device interface, an informational interface, and a user input section
interface. The
controller device interface includes an external antenna connection port 316,
an electronic
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key interface 318, and a programming port 320. The informational interface
includes the
controller device battery status panel 322, including labeling and an LED
indicator for
slow charge 324, fast charge 326, 20% remaining battery capacity 328, 40%
remaining
battery capacity 330, 60% remaining battery capacity 332, 80% remaining
battery
capacity 334, and 100% remaining battery capacity 336. These percentages of
remaining
battery capacity are arbitrarily selected and other percentages, or different
styles of
display, can be substituted in other embodiments without departing materially
from the
presentinvention.
The informational interface includes a panel 338 containing labeling and
indicator
LEDs for the device power 340, electronic key status 342, device transmitting
344, and
device receiving 346. w
The user input selection interface comprises a panel 348 for placing a
controller
device in the ON state, the panel 348 including labeling and a membrane switch
350. The
user input selection interface further comprises a panel 352 for placing a
controller device
in the OFF state, the panel 352 including labeling and a membrane switch 354.
The user
input selection interface further comprises a pane1356 for selecting a status
query
operation with a membrane switch 360, the panel 356 including labeling and an
LED
indicator 358.
The user input selection interface further comprises a panel 362 for placing
the
controller device battery status panel 322 in an ON or OFF state by cycling a
membrane
switch 366, the panel 362 including labeling and an LED indicator 364. The
user input
selection interface further comprises a panel368 for selecting an ARM command
operation with a membrane switch 372, the panel 368 including labeling and an
LED
indicator 370. The user input selection interface further comprises a panel
374 for
selecting a DISARM command operation with a membrane switch 378, the panel 374
including labeling and an LED indicator 376. The user input selection
interface further
comprises dual panels 380 and 386 for selecting a FIRE command operation with
dual
membrane switches 384 and 390, the panels 380 and 386 including labeling and
LED
indicators 3 82 and 3 88.
Combinations of the aforementioned LED indicators can be used to indicate
device conditions. One example of this feature is flashing of all LED's when
the device is
placed in the ON state, indicating the initiation of a self testing operation.
Other suitable
combinations are possible.
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FIGURE 3B illustrates an exemplary front panel for a remote device user
interface 390. The remote device user interface 390 includes indicator panels
392 and
398 for selection of a method for initiating a detonation. The methods include
shock-tube
detonator initiation or electric detonator initiation, among others. The shock-
tube
S detonator initiation panel 392 includes labeling and LED indicators 394 and
396 for
READY and ARMED status. The electric detonator initiation pane1398 includes
labeling and LED indicators 402 and 400 for READY and ARMED status. A switch
404
selects an initiation method panel 392 or 398, and, in accordance with one
embodiment of
the present invention, is a mechanical toggle switch. The remote device user
interface 390 further includes a remote device battery status panel 406. The
panel 406
includes a switch 408, for activating a battery status display 410 such as a
digital
voltmeter for example, and in accordance with one embodiment of the present
invention,
is a mechanical momentary push button switch. Other types of suitable switches
and
battery status displays can be used. A panel 412, for placing the remote
device in an ON
or OFF state, comprising a remote device power switch 414, labeling and an LED
indicator 416 is included on the remote device user interface 390. The remote
device user
interface 390 fiuther comprises a battery charger panel 418 and an electronic
key
panel 426. The battery charger panel 418 includes labeling and an indicator
LED 420 for
indicating connectivity to a battery charger. Two additional indicator LEDs
422 and 424
and labeling, indicating slow and fast charging rates, are included on the
battery charger
panel 418. The electronic key panel 426 includes a connection port 428, to
couple an
electronic key; three LED indicators 430, 436, and 432; and labeling to
indicate remote
device transmission, electronic key status, and remote device receiving in
accordance
with the safety communication ability of various embodiments of the present
invention.
The remote device user interface 390 further includes a port 438 for
connecting an
external antenna, and a programming port 440.
The remote device user interface 390 further includes a connection port 442
for
connection of a lead line to the initiation circuitry. This port is located on
the left
sidewall of the remote device and comprises of two female banana plug
connectors and
two binding posts. Other suitable connectors or suitable locations for the
connection
port 442 can be used.
In one embodiment of the present invention, combinations of the aforementioned
remote device user interface 390 LED indicators are used to indicate various
device
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conditions. One example is the slow charge LED 422 being on and fast charge
LED 424
being off to indicate a fully charged battery. Other combinations are
possible.
FIGURE 4A is a block diagram of a remote firing system. A controller
device 450 and at least one remote device 452 use safety communication to
communicate
via a transmission medium 454. Signals from an interlock device 456, user
inputs 458,
information stored on an electronic key 460, and signals received via the
transmission
medium 454 are processed by the controller device 450. Similarly, information
stored on
an electronic key 462, user inputs 464, and signals received from the
transmission
medium 454 are processed by the remote device 452. Additionally, the remote
device 452 produces a signal for initiating explosives. This signal is
transmitted from the
remote device, though a lead line 466 and a chain of components 468,
terminating in a
main explosive charge (not shown).
FIGURE 4B is a block diagram of internal functional modules, inputs, and
outputs
for a controller device 450. The internal functional modules include an
electronic key
module 502; a programming port module 504; a self test module 506; a battery
status
module 508; a controller device user interface module 510; a timer module 512;
a remote
device selection module 514; a controller device mode module 516; a controller
device
command module 518; and a communications module 520 for transmitting and
receiving
safety communication. Inputs to the controller device can be received as
information
stored on an electronic key 522 coupled to the controller device key module
502;
information from an interlock device 524 coupled to the programming port
module 504;
information from user inputs 526 selecting remote devices through the remote
device
selection module 514, controller device operating mode through the controller
device
controller device mode module 516, and commands through the command module
518.
Safety communication is preferably achieved by transmitting and receiving a
safety data
structure through an external antenna 528 coupled to the communications module
520.
Other devices, including but not limited to radio repeaters and leaky feeder
systems, can
be connected in place, or in addition to, of the external antenna 528 without
departing
materially from the present invention.
Preferably, the electronic key module 502 serves as a coupling interface
between
the controller device 450 and the external electronic key 522. Information
stored on the
electronic key 522 is read into the controller device's internal memory (not
shown) for
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processing by the controller device 450, or the controller device 450 can
write
information onto the electronic key 522 through the electronic key module 502.
Preferably, the programn:~ing port module 504 serves as a coupling interface
between the controller device 450 and an external programming device (not
shown),
such as a digital computer, or the interlock device 524. The external
programming device
(not shown) may allow, for example, information stored in certain memory
locations to
be read out of the controller device 450; information to be written into
certain memory
locations on the controller device 450; or modification of internal controller
device
settings; among others. Many operations can be conducted through the
programming
port module 504. The programming port module 504 can be implemented using a 14-
pin
DIN type connector or other suitable connectors, designating various
conductors for
functionality such as battery charger contacts, external interlock device 524
input
contacts, programming function contacts, and contacts for additional future
functionality,
among others.
Preferably, the self test module 506 tests the internal circuitry and
functionality of
the controller device 450 for faults. The self test module 506 indicates
component
failures by flashing indicator LEDs on the controller device user interface
panel 300, as
discussed previously. Other suitable methods of indicating self test results
can be used.
Preferably, the battery status module 508 displays the status and condition of
a
battery (not shown) in the controller device 450. The battery status module
508 may
include a battery capacity display, such as a gas-gauge style digital display;
battery
condition indicators, such as the previously discussed flashing indicator
LED's on the
controller device user interface pane1300; and recharge rate indicator LEDs,
among
others. Other suitable displays and indicators can be used.
The timer module 512 can be implemented mechanically, with discrete
electronics, with software, or by some combinations thereof. Preferably, the
timer
module 512 is used for controller device features requiring elapsed time
information. For
example, the timer module 512 is a software implemented, countdown timer
triggering
the execution of a DISARM command if the controller device 450 has transmitted
an
ARM command and has not transmitted a FIRE command within a specified time
period.
Preferably, the communications module 520 serves to, enable safety
communication between the controller device 450 and other system devices
through a
transmission medium. Preferably, the communications module 520 includes a 5-
watt
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maximum power radio transceiver for transmission and reception of radio
frequency
signals in the kHz to MHz range. Any suitable power or frequency range can be
used for
the transceiver without departing materially from the present invention.
Further, other
suitable methods of communication can be used.
Preferably, the controller device user interface module 510 includes all user
input
into the controller device 450 not included in the remote device selection
module 514,
controller device mode module 516, or controller device command module 518.
This
module includes functions such as turning a battery meter ON or OFF, among
others.
Preferably, the remote device selection module 514 serves as an interface for
the
user allowing specific remote devices to be either selected or de-selected by
the user.
Preferably, multiple remote devices can be contemporaneously selected and
operated
from a single controller device.
Preferably, the controller device command module 518 serves as the user
interface
to selectively initiate command signals. The available commands may include
ARM,
FIRE, DISARM, and STATUS (querying the status of remote devices), among
others.
Other suitable commands can be used without materially departing from the
present
invention.
Preferably, the controller device mode module 516 serves as the user interface
for
selecting the operating mode of the controller device 450. The controller
device mode
module 516 may include NORMAL (signifying normal operation mode),
PROGRAMMING (signifying programming mode), and QUERY (signifying safety
communication query mode, such as the SAFETY POLLTM query facility offered by
Rothenbuhler Engineering Co.), among others. The NORMAL mode is preferably the
default mode and is used for detonating explosives. The PROGRAMMING mode
preferably allows the controller device 450 to function as a programming
device for
programming electronic keys. Or other programmable options. The QUERY mode is
preferably used to automatically test safety communication between the
controller
device 450 and selected remote devices (not shown.) Additional suitable modes,
or
suitable modification of the listed modes, can be included into the controller
device mode
module 516.
FIGURE 4C is a block diagram of the internal functional modules, inputs, and
outputs for a remote device 452. The internal functional modules include
modules such
as an electronic key module 532; a remote device user interface module 534; a
self test
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module 536; a programming port module 538; a battery status module 540; a
timer
module 542; a communications module 544; a remote device output mode module
546;
and a remote device operating mode module 548; among others. Inputs to the
remote
device 452 include information contained on an electronic key S50 coupled to
the
electronic key module 532. Additional information can be received from user
inputs 552
for selecting an output mode (through the output mode module 546), and for
selecting an
operating mode (through the operating mode module 548.) Additionally, safety
communication can be received or transmitted by an external antenna 554
coupled to the
communications module 544. As previously discussed, suitable alternatives can
be used
in place of an external antenna. A signal initiating a shot is output to a
chain of
devices 556 terminating in a main explosive charge (not shown) as will be
appreciated by
one skilled in the art.
Preferably, the electronic key module 532 serves as a coupling interface
between
the remote device 452 and an electronic key 550. Further, information stored
on the
electronic key 550 can be read into the remote device's internal memory (not
shown) for
processing by the remote device 452 through the electronic key module 532.
Preferably, the programming port module 538 serves as a coupling interface
between the remote device 452 and an external programming device (not shown),
for
example a digital computer. The external programming device may allow, for
example,
information stored in certain memory locations to be read out of the remote
device 452;
information to be written into certain memory locations on the remote device
452; or
modification of internal remote device settings; among others. Many other
suitable
operations can be conducted through the programming port module 538. The
programming port module 538 can be implemented using a 14-pin DIN type
connector or
other suitable connectors, designating various conductors for functionality
such as battery
charger contacts, programming function contacts, and contacts for additional
future
functionality, among others.
Preferably, the self test module 536 tests the internal circuitry and
functionality of
the remote device 452 for faults. The self test module 536 indicates component
failures
by flashing indicator LEDs on the remote device user interface panel 390, as
previously
discussed. Other suitable methods to indicate self test results can be used.
Preferably, the battery status module 540 displays the status and condition of
a
battery (not shown) in the remote device 452. The battery status module 540
may include
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a battery capacity display, such as a digital display; battery condition
indicators, such as
the previously discusses flashing indicator LEDs on the remote device user
interface 390;
and recharging rate indicator LEDs, among others. Other suitable displays or
indicators
can be used.
The timer module 542 can be implemented mechanically, with discrete
electronics, with software, or by some combination thereof. Preferably, the
timer
module 542 is used for remote device features requiring elapsed time
information. For
example, the timer module 542 is a software implemented, countdown timer
triggering a
DISARM command to disarm the remote device 452 if the remote device 452 has
been
ARMED and not FIRED within a specified time period. Preferably, the timer
module 542 serves as a backup to the timed disarm sequence in the controller
device 450
previously discussed.
Preferably, the communications module 544 serves to enable safety
communication between the remote device 452 and other system devices via a
transmission medium. Preferably, the communications module 544 includes a 1-
watt
maximum power radio transceiver for transmission and reception of radio
frequency
signals in the kHz to MHz range. Any suitable power or frequency range can be
used for
the transceiver without departing materially from the present invention.
Further, other
suitable methods of communication can be used.
Preferably, the remote device user interface module 534 includes all user
input
into the remote device 452 not included in the remote device operating mode
module 548,
or remote device output mode module 546. This module includes functions such
as
turning a battery meter ON by depressing a momentary switch, among others.
Preferably, the remote device output module 546 serves as an interface for the
user allowing method selection for initiating a remote detonation (such as
shock tube or
electric detonators), among others.
Preferably, the remote device operating mode module 548 serves as the user
interface to select the operating mode of the remote device 452. The remote
device
operating mode module 548 may include NORMAL (signifying normal operation
mode),
and PROGRAMMING (signifying programming mode), among others. The NORMAL
mode is preferably the default mode and is used for detonating explosives. The
PROGRAMMING mode preferably allows the remote device 452 to be programmed with
a semi-permanently assigned device identifier. Additional suitable modes, or
suitable
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modification of the listed modes, can be included in the remote device
operating mode
module 548.
FIGURES SA-O illustrate a method for remotely detonating explosives.
Generally, in deploying a remote control blasting machine for remotely
detonating
explosives, preparatory steps are undertaken to ensure the operability of the
device prior
to deploying it in the field. Once the device is deployed in the field and
coupled to the
explosives, several safety checks are undertaken. The device in the field is
armed and
then fired. Upon completion, a remote control blasting machine is generally
returned to a
safe environment for storage until the next use.
In FIGURE SA, from a start block a method 600 proceeds to a set of method
steps 602 between a continuation terminal ("Terminal A") and . ~ an exit
terminal
("Terminal B"). 'The set of method steps 602 prepares a remote firing system
for
operation in a mode desired by a user. This preparation includes steps to
ensure that
system devices are functional, deploying system devices in the field, and
connecting
remote devices to explosives in a safe manner.
From Terminal A (FIGURE SC), the method 600 proceeds to block 610 where a
remote firing system's devices are powered ON. At block 612 each system device
undergoes an automatic, internal, self test operation. Self testing verifies
that the internal
components of a device are operating within defined parameters. System devices
failing
the self test are replaced. See block 614. The method 600 then continues to
block 616
where the system devices' batteries are queried for remaining charge.
Sufficient charge to
operate the devices in the field for the estimated amount of time that will be
required to
place, arm, and detonate all explosives should be present. At block 618 system
devices
without sufficient charge are either recharged or replaced. The method 600
continues to
another continuation terminal ("terminal A1 ").
The processing steps between Terminals A and A1 can be accomplished either in
parallel or serially. In parallel, all devices are contemporaneously powered
ON, each
then undergoes the self test before each battery is checked for sufficient
remaining
charge, and system devices are then replaced or recharged, as needed_
Serially, each
device is powered ON, undergoes a self test, the battery's remaining charge is
checked,
and the system device is replaced or recharged, as needed, before repeating
the blocks for
the next system device. Some blocks between Terminals A and A1 can readily be
combined or further automated without departing from the present invention.
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The processing steps described in FIGURES SD-SF are preferably performed by a
manufacturer of the remote firing system, a dealer or distributor of the
manufacturer, or a
service shop for the manufacturer. The user of the remote firing system needs
not
execute the processing steps described in FIGURES SD-SF and these processing
steps
need not formed part of the use of the remote firing system in the field just
prior to
blasting activities. From terminal A1 (FIGURE SD), the method 600 enters a
decision
block 620 where a test is performed to determine whether a semi-permanent
device
identifier is to be assigned to a remote device. If the answer is YES (a semi-
permanent
device identification is to be assigned), the method 600 continues to another
continuation
terminal ("terminal A2"). If the answer is NO (a semi-permanent device
identification is
not to be assigned to a remote device), the method 600 continues to another
terminal
continuation terminal (terminal A3). From terminal A3, the method 600 proceeds
to
decision block 622 where it is determined if an electronic key is to be
programmed. If an
electronic key is to be programmed, the method continues to another
continuation
terminal ("terminal A4"). If an electronic key is not to be programmed, the
method 600
continues to another continuation terminal ("terminal AS").
From terminal A2 (FIGURE SE), the method 600 proceeds to block 624 where an
appropriate master electronic key is coupled to the remote device to be
programmed with
a semi-permanent identification. At block 626, the information stored on the
master
electronic key causes the remote device to enter the PROGRAMMING mode. T'he
information stored on the master electronic key causes the remote device in
PROGRAMMING mode to assume a semi-permanent device identification. See
block 628. The method 600 then continues to block 630 where the master
electronic lcey
is removed. Once the master electronic key has been removed, the remote device
exits
PROGRAMMING mode and is now programmed semi-permanently with a device
identifier. Other suitable methods are possible to place the remote device
into the
PROGRAMMING mode to assign a device identifier. The method 600 then continues
to
terminal A1, where it loops back to decision block 620 and repeats the above-
discussed
processing steps. If additional devices are to be semi-permanently assigned
device
identifications, this loop may be continued. If additional devices are not to
be
semi-permanently assigned device identifiers, the method 600 exits the loop
and proceeds
to continuation terminal A3. From terminal A3, the method 600 proceeds to
decision
block 622, as previously discussed.
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From terminal A4 (FIGURE SF), the method 600 proceeds to block 632 where an
electronic key is coupled to a programming device. In one embodiment of the
present
invention the programming device includes a controller device. At block 634
where the
programming device is placed in a PROGRAMMING mode. The present programming
designation of the electronic key is then suitably indicated. See block 636.
The
method 600 continues to block 638 where a new programming designation is
selected on
the programming device. At block 640, the new programming designation data is
stored
on the electronic key and the key is decoupled from the programming device.
The
programming device is then taken out of PROGRAMMING mode. See block 640. The
method 600 then proceeds to terminal A3 and loops back to decision block 622,
where
the above-discussed processing steps are repeated. If additional electronic
keys are to be
programmed, the loop is repeated. If no additional electronic keys are to be
programmed,
the method 600 continues to terminal A5.
From terminal AS (FIGURE SG), the method 600 proceeds to block 670 where
suitable electronic keys are placed in the remote devices according to a blast
design. The
blast design includes the placement of explosives and pieces of a remote
firing system to
effect a desired blasting result designed by a blasting engineer. A suitable
electronic key
indicates that an electronic key with a system identification, device
identification, and
indexed identifier is placed in each system device such that the blast
engineer's plan can
be executed. It is preferred that electronic keys be coupled with the remote
devices for
them to be able to communicate with the controller device. It is preferred
that the
controller device does not need an electronic key to do status queries but it
is preferred
that the electronic key be coupled with the controller device prior to arming
or firing the
remote devices. The method 600 proceeds to decision block 644 where a test is
performed to determine whether a polling mode is used to aid the deployment of
remote
devices. If the answer is NO, (the polling mode is not being used for
deployment), the
method 600 continues to block 646 where system devices are deployed and
suitably
connected. The method 600 continues to another continuation terminal
("terminal A6").
If the answer is YES (the polling mode is used to aid in deployment), the
method 600
continues to block 648 where a controller device is deployed and suitably
coupled to
devices such as an external antenna, any external interlock devices, or
external power,
among others. From block 648, the method 600 continues to block 650, where the
polling mode is activated on the controller device. The polling mode causes
the
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controller device to query the status of remote devices automatically and
periodically.
Remote devices are then deployed. See block 652. The method 600 then proceeds
to
another continuation terminal ("terminal A7"). Other suitable polling aids can
be
implemented.
From terminal A7 (FIGURE SH), the method 600 proceeds to decision block 654
where a test is performed to determine whether deployed remote devices receive
the
periodically transmitted status query from the controller device placed
earlier at
block 648 (see FIGURE SG). If the answer is NO (the deployed remote devices do
not
receive the periodic status query), the method 600 continues to block 658
where the
deployed remote devices are suitably repositioned, replaced, or recharged. If
the answer
is YES (the deployed remote devices do receive the status .query described at
decision
block 654), the method 600 continues to block 656 where another test is
performed to
determine whether the controller device is receiving status query replies from
the
deployed remote devices. If, at decision block 656, the answer is NO (the
controller
device is not receiving status query replies from deployed remote devices),
the
method 600 enters block 658 where the remote devices are suitably
repositioned,
replaced, or recharged. From block 658 the method 600 proceeds to another
continuation
terminal ("terminal A7"). If at decision block 656 the answer is YES (the
controller
device is receiving the status query replies), the method 600 continues to
block 660 where
the polling mode is deactivated. The method 600 then proceeds to another
continuation
terminal ("terminal A8"). Repositioning the controller device at block 658 can
be a
suitable alternative to repositioning remote devices.
Summarizing the processing steps between block 654 and block 656, the
controller device automatically and periodically transmits a status query
signal as remote
devices are deployed. If the remote devices are receiving the periodic status
query, they
are in safety communication range. If they do not receive the status query,
they are either
defective, in the wrong location, or their battery has become depleted. The
remote
devices ought to be replaced, repositioned, or recharged. If the remote
devices are
receiving status queries, safety communication is confirmed by verifying that
the
controller device is receiving a reply to the status query. If the controller
device is not
receiving the reply to status query, safety communication is not established
and the
system devices ought to be repositioned, replaced, or recharged. Once the
devices are in
safety communication, the polling mode is deactivated.
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When the polling mode is not used to aid in the deployment of system devices
at
decision block 644 (FIGURE SG), the method proceeds to terminal A6 (FIGURE
SI).
The method 600 proceeds to decision block 662 where a test is performed to
determine
whether the controller and remote devices are operating iri safety
communication. If the
answer is NO (the devices are not operating in safety communication), the
method 600
proceeds to terminal A8. If the answer is YES (the devices are operating in
safety
communication), the method 600 continues to block 664 were a status query
operation is
initiated at the controller device. This transmits a single status query to
deployed remote
devices. At decision block 666 a test is performed to determine whether the
deployed
remote devices return a status in response to the status query. If the answer
is YES (the
remote devices return °a status to~ the controller); the method 600
proceeds to terminal A8.
If the answer is NO (the remote devices do not return a status to the
controller), the
method 600 proceeds to block 668 where the non-answering remote devices are
repositioned, replaced, or recharged. From block 668 tLze method 600 loops
back to
block 664 where a single status query is transmitted from the controller
device. This loop
continues until all deployed remote devices return a status to the controller,
establishing
safety communication.
From terminal A8 (FIGURE SJ), the method 600 proceeds to block 672, a suitable
electronic key is placed in the controller device. For blocks 670 and 672, a
suitable
electronic key indicates that an electronic key with a system identification,
device
identification, and indexed identifier is placed in each system device such
that the blast
engineer's plan can be executed. From block 672, the method 600 proceeds to
Terminal B. The method 600 proceeds from Terminal B in block 602 (FIGURE SA)
to
Terminal C in block 604 (FIGURE SA).
From Terminal C (FIGURE SJ), the method 600 proceeds to block 674 where at
least one remote device is selected on the controller device. (Additional
remote devices,
or combinations of remote devices, can be selected on the controller device at
block 674.)
From block 674, the method 600 continues to Term final D (FIGURE SJ). From
Terminal D (FIGURE SA) the method 600 proceeds to Terminal E (FIGURE SA) and
then proceeds to Terminal E in block 606 (FIGURE SB).
From Terminal E (FIGURE SIB), the method 600 proceeds to block 676 where the
controller device transmits an ARM signal in response to receiving an ARM
selection by
the user. The method 600 then continues to block 678 where the controller
device
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automatically transmits a status query to all remote devices after the ARM
signal has
been transmitted. At decision block 680, a test is performed to determine
whether remote
devices are armed. Arming is determined by the information contained in the
reply to the
status query. If the answer is YES (the remote devices have armed), the method
600
continues to another continuation terminal ("terminal E2"). If the answer is
NO (the
remote devices have not armed), the method 600 continues to block 682 where
the
control device indicates that the ARM signal was transmitted, but that a
confirming signal
(response to the automatic status query) was not received back from one or
more of the
remote devices. The method 600 then continues to another continuation terminal
("terminal E 1 ").
From terminal El (FIGURE SL), the method 600 proceeds to block 684 where the
controller device automatically re-queries the status of the remote devices.
At block 686,
if the controller cannot establish a confirmed remote device status from the
re-queries in
block 684, the controller device indicates an assumed ARMED status. An assumed
ARMED status indicates to a user that the controller device transmitted the
ARM
command, but that a reply was not received back from the remote device and
that the
secondary automatic attempts to confirm an ARMED status have failed. An
assumed
status also indicates that the remote device should be considered ARMED for
any misfire
procedure. From block 686, the method 600 continues to block 688 where either
the
ARM command is manually reissued or the shot is terminated for safety reasons.
If the
ARM command is to be reissued, blocks 680, 682, 684, and 686 will be repeated
until
successful arming or termination. From block 688, the method 600 proceeds to
terminal E and loops back to the above-discussed processing steps. If the
remote devices
are ARMED at block 680, the method proceeds to terminal E2.
From terminal E2 (FIGURE SL), the method 600 continues to block 690 where an
internal timer in each system device (both the remote devices and the
controller device)
begins a countdown to automatically DISARM all system devices. Preferably, if
the
countdown timer reaches the end of the countdown period without receiving a
FIRE
command, all system devices are automatically DISARMED as a safety precaution.
From block 690 the method continues to terminal F. From terminal F (FIGURE
SB), in
block 606 (FIGURE SB), the method 600 proceeds to terminal G in block 608
(FIGURE SB).
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From terminal G (FIGURE SM), the method 600 proceeds to decision block 692
where a test is performed to determine whether the countdown timer for
disarming has
elapsed in any device resulting in automatic DISARMING. If the answer is YES
(the
device countdown timer has elapsed), then the method 600 proceeds to
continuation
terminal E so that the selected remote devices can again be ARMED. If the
answer is NO
(the countdown timer has not elapsed), then the method 600 continues to block
694 where
the controller device transmits a FIRE signal in response to receiving a fire
selection from
the user command. Preferably, the fire command is issued by simultaneously
depressing,
for at least one-half second (1/2 sec.), two FIRE buttons (as shown by buttons
384, 390).
This long detent time and dual fire button arrangement increases safety by
decreasing the
chance of accidentally issuing a F IRE commands Other suitable methods for
preventing
accidental firing are possible. From block 694, the method 600 continues to
block 696
where the controller device automatically transmits a status query to the
remote devices
after the FIRE signal has been transmitted. The method 600 then proceeds to
decision
block 698 where a test is performed to determine whether the remote devices
have
FIRED. The determination is based on information contained in the reply to the
issued
status query. If the answer is YES (the remote device has FIRED), the method
600
proceeds to another continuation terminal ("terminal G2"). If the answer is NO
(the
remote device has not FIRED), the method 600 proceeds to another continuation
terminal
("terminal Gl "). Both replies to the status query indicating failures to
fire, and failures to
reply to the status query, are considered as not FIRED conditions.
From terminal G1 (FIGURE SN), the method 600 proceeds to block 700. At
block 700, the controller device indicates that a fire signal was transmitted,
but that the
confirming reply was either not received back from a remote device, or that
the reply
indicated an unsuccessful attempt to fire. At block 702 the controller
automatically
re-queries the status of the remote devices. If the controller device cannot
confirm
FIRING, the controller device indicates an assumed status. See block 704. The
method 600 then continues to block 706 where a misfire procedure is initiated.
The
misfire procedure is not part of the present invention, but does determine
what the user
does next and is included herein for context. From block 706 the method 600
proceeds to
another continuation terminal ("terminal G2").
The method 600 permits the selection of one or more remote devices, therefore
not all deployed devices may have been selected for the preceding ARM and FIRE
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method steps. From terminal G2 (FIGURE 50), the method 600 proceeds to
decision
block 708 where a test is performed to determine whether all deployed remote
devices are
FIRED. If the answer is NO (all deployed remote devices are not FIRED), the
method 600 proceeds to terminal C, where additional remote devices can be
selected,
ARMED, and FIRED. If the answer is YES (all the deployed devices are FIRED),
there
are no more remote devices to FIRE and the method 600 proceeds to another
continuation
terminal ("terminal G3"). From terminal G3 (FIGURE 50), the method 600
proceeds to
block 710 where the electronic keys are decoupled from all system devices.
When
system devices are decoupled from electronic keys, the devices become
inoperable, yet
remain ON. From block 710 the method 600 continues to block 712 where all
system
devices are powered aFF~ the remote firing system is removed from the field,
and the
remote firing system is stored. From block 712 the method 600 continues to
terminal H.
From terminal H (FIGURE SB) in block 608 (FIGURE SB), the method 600 is
completed
and proceeds to the finish block (FIGURE SB.)
While the preferred embodiment of the invention has been illustrated and
described, it will be appreciated that various changes can be made therein
without
departing from the spirit and scope of the invention.
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