Note: Descriptions are shown in the official language in which they were submitted.
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MAINTAINING REDUNDANT DATA ON A GAS METER
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Patent
Application Serial No.
15/356,594, filed on November 20, 2016, and entitled "MODULAR METERING
SYSTEM,"
which is a continuation-in-part U.S. Patent Applicatio n Serial No.
14/301,986, filed on June 11,
2014, and entitled "SYSTEMS, DEVICES, AND METHODS FOR MEASURING AND
PROCESSING FUEL METER MEASUREMENTS," now U.S. Patent No. 9,874,468, which
claims the benefit of U.S. Provisional Application Serial No. 61/835,497,
filed on June 14, 2013,
and entitled "DIGITAL METER BODY MODULE FOR ROTARY GAS METER." The content
of these applications is incorporated herein in its entirety.
BACKGROUND
[0002] Utility companies deliver a wide range of resources to customers.
These resources
include fuel gas for heat, hot water, and cooking. It is normal for the
utility to install its own
equipment on site to measure consumption of the fuel gas. This equipment often
includes a gas
meter to measure or "meter" an amount of fuel gas the customer uses (so the
utility can provide an
accurate bill). Likely, the gas meter is subject to certain "legal metrology"
standards that
regulatory bodies promulgate under authority or legal framework of a given
country or territory.
These standards are in place to ensure the gas meter provides accurate and
repeatable data,
essentially to protect consumers from inappropriate billing practices. In the
past, gas meters made
use of mechanical "counters" to meter consumption of fuel gas. These
mechanisms could leverage
flow of the fuel gas into an essentially immutable measure of consumption.
Advances in
technology allow for electronics to replace these mechanisms. These
electronics can provide even
more accurate data, both for billing and for use in diagnostics of device
health and the like. But,
despite these benefits, failures in the electronics or disruptions to power
necessary for these devices
to operate may result in loss of data that frustrates accurate measures of
consumption and,
consequently, may lead to unnecessary disputes with customers and lost
revenue.
SUMMARY
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[0003] The subject matter of this disclosure relates to improvements to
ensure that metrology
hardware may continue to record data in lieu of power on the device. Of
particular interest herein
are embodiments that can concomitantly generate data and energy from
mechanical movement on
the device. This mechanical movement may correspond with mechanisms, like
counter-rotating
impellers, that leverage positive displacement as means to measure precisely
the volume of fuel
gas.
DRAWINGS
[0004] Reference is now made briefly to the accompanying figures, in which:
[0005] FIG. 1 depicts a schematic diagram of an exemplary embodiment of an
encoder device;
[0006] FIG. 2 depicts a schematic diagram of an example of the encoder
device of FIG. 1;
[0007] FIG. 3 depicts a schematic diagram of an example of the encoder
device of FIG. 1;
[0008] FIG. 4 depicts a schematic diagram of memory for use in the device
of FIG. 1;
[0009] FIG. 5 depicts a schematic diagram of an example of the encoder
device of FIG. 1;
[0010] FIG. 6 depicts a perspective view of the encoder of FIG. 5 on an
exemplary gas meter;
[0011] FIG. 7 depicts a perspective view of the gas meter of FIG. 6 in
partially-exploded form;
[0012] FIG. 8 depicts a schematic diagram of exemplary structure for a
power unit for use in
the encoder device of FIG. 1; and
[0013] FIG. 9 depicts a perspective view of exemplary structure for the gas
meter.
[0014] Where applicable like reference characters designate identical or
corresponding
components and units throughout the several views, which are not to scale
unless otherwise
indicated. The embodiments disclosed herein may include elements that appear
in one or more of
the several views or in combinations of the several views. Moreover, methods
are exemplary only
and may be modified by, for example, reordering, adding, removing, and/or
altering the individual
stages.
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DETAILED DESCRIPTION
[0015] This discussion describes embodiments with hardware to harvest
energy. The
embodiments may include devices that can meter flow of materials. These
devices include gas
meters, which this discussion uses to illustrate the concepts herein. The
hardware integrates into
the gas meter to maintain data that might otherwise be lost due to problems
with power or
electronics. Other embodiments are with the scope of this disclosure.
[0016] FIG. 1 depicts a schematic diagram of an exemplary embodiment of an
encoder device
100. This embodiment is part of metrology hardware, identified generally by
the numeral 102.
The metrology hardware 102 may embody devices that quantify a value that
defines flow
parameters of resource 104, typically as it flows in a conduit 106. These
devices may include an
indexing unit 108 that couples with a metering unit 110 to exchange a digital
signal Si. The
metering unit 110 may couple with the conduit 106 to locate a flow mechanism
112 in the flow of
resource 104. As also shown, the encoder device 100 may include a data
processing unit 114 with
an interface unit 116 that couples with the flow mechanism 112. The interface
unit 116 may
include a sensor unit 118 and a power unit 120 that generate a data signal Di
and power signal Pi,
respectively.
[0017] Broadly, the encoder device 100 is configured to generate redundant
data in lieu of
power or other disruptions on the metrology hardware 102. These configurations
can essentially
"back-up" data that corresponds to precise volume of material that flows
through the metrology
hardware 102. This feature outfits the metrology hardware 102 to maintain
consistent records of
consumer consumption, even with power disruptions or outages that might
normally foreclose
activities by the metrology hardware 102 to collect and retain data of this
type.
[0018] The metrology hardware 102 may be configured to measure or "meter"
flow of
material. These configurations often find use in residential and commercial
locations to quantify
demand for resource 104 at a customer. It is possible that metrology hardware
102 is found in
custody transfer or like inventory management applications as well. For
purposes of this
discussion, resource 104 may be fuel gas (like natural gas); but the metrology
hardware 102 may
measure consumption of other solid, fluids (e.g., water), and solid-fluid
mixes. The conduit 106
may embody pipes or pipelines. These pipes may form part of a distribution
network that
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distributes fuel gas 104 to customers. The distribution network may employ
intricate networks of
piping that cover vast areas of towns or cities with hundreds or thousands
customers. In most
cases, utilities maintain responsibility for upkeep, maintenance, and repair
of the gas meter 102.
Notably, this disclosure contemplates use of more than one of encoder device
100 on the gas meter
102.
[0019] The units 108, 110 may be configured to cooperate to generate data
that defines
consumption of fuel gas 104. These configurations may embody standalone
devices that connect
with one another to exchange data or other information. Electronics on the
indexing unit 108 may
process the digital signal Si. These electronics may reside inside a plastic
or composite housing
that attaches or secures to parts of the metering unit 110. These parts may be
part of a cast or
machined body, preferably metal or metal-alloy, which mates with the conduit
106 to receive fuel
gas 104. This "meter" body may enclose flow mechanics 112, for example,
mechanisms that move
in response to flow of fuel gas 104 from inlet to outlet on the meter body.
Exemplary mechanisms
may embody counter-rotating impellers, diaphragms, or like devices with
movement that can
coincide with a precise volume of the fuel gas 104; but this disclosure
contemplates others as well.
[0020] The data processing unit 114 may be configured to quantify flow
parameters for fuel
gas 104. These configurations may employ computing devices that process data
to generate
values, like volumetric flow, flow rate, velocity, energy, and the like. These
processes may also
account for (or "correct for") conditions that prevail at the gas meter 102.
These conditions may
describe characteristics of fuel gas 104 or the environment, including ambient
temperature,
absolute pressure, differential pressure, and relative humidity, among others.
The processes may
use data for these characteristics to ensure accurate and reliable values for
billing customers.
[0021] The interface unit 116 may be configured to generate data for use to
determine
volumetric flow. These configurations may include a device that can couple
with impellers 112.
This device may include hardware that "talks" with corresponding hardware that
co-rotates with
the impellers 112. This feature may leverage non-contact modalities or
technology, like
magnetics, ultrasonics, or piezoelectrics; however, this disclosure does
contemplates technologies
not yet developed as well. In one implementation, the metering unit 110 may
include one or more
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magnets that co-rotate with the impellers 112. The rotation may change a
magnetic field to
simulate corresponding devices of the interface unit 116 to generate the
signals Di, Pi noted herein.
[0022] The units 118, 120 may be configured to convert rotation of the
impellers 112 into
useable form. On the sensor unit 118, these configurations may include
hardware that leverages
the "Wiegand effect" to generate the data signal Di, for example, as output
voltage or "pulses" that
track with each rotation of magnets that occurs concomitantly with rotation of
the impellers 112.
The power unit 120 may embody hardware that can generate energy in response to
the co-rotating
magnets as well. This hardware may embody a device with a thin wire conductor
that wraps
around a solid or hollow magnetic core, but other configurations may prevail
as well. For both
units 118, 120, this disclosure contemplates other types of devices known now
or hereinafter
developed.
[0023] FIG. 2 depicts a schematic diagram of exemplary topology for the
encoder device 100
of FIG. 1. The encoder device 100 may include a power management unit 122 that
interposes
between the data processing unit 114 and the power unit 120. The power
management unit 122
may include a conditioning unit 124 and a storage unit 126. The conditioning
unit 124 may include
circuitry necessary to format the power signal Si for use on the device. This
circuitry may include
inverters, converters, rectifiers, amplifiers, and like devices that can
operate on the power signal
Si to make it more useful or consistent with other parts of the topology,
including for use by the
storage unit 126. Examples of the storage unit 126 may include devices that
retain energy, like a
battery. Other devices may include capacitors, particularly those with low
leakage voltage and
like parameters to retain and distribute power for extended periods of time.
[0024] FIG. 3 depicts a schematic diagram of exemplary topology for the
encoder device of
FIG. 1. The data processing unit 114 may including computing components, like
a processor 128
that couples with a timing circuit 130 and with memory 132. Data in the form
of executable
instructions 134 and resident data 136 may reside on memory 132. The
components 128, 130, 132
may integrate together as a micro-controller or like integrated processing
device with memory and
processing functionality. The timing circuit 130 may embody a micro-power chip
with an
oscillator that counts time as a real-time clock. The chip may couple with its
own power supply,
often a lithium battery with extensive lifespan (e.g., > 2 years). A counter
may couple with the
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oscillator. The counter processes signals from the oscillator to output time
increments, preferably
at accuracy that comports with national standard clocks. Generally, memory 132
may embody
memory devices that are volatile or non-volatile, as desired. Preference may
be given to non-
volatile devices for data that requires long-term retention, particularly
during periods of pro-longed
power outage or like disturbances. Executable instructions 134 may embody
software, firmware,
or like computer programs that configure functionality on the processor 128.
This functionality
may process data from the incoming data signal Di of the sensor unit 118 and
from the timing
circuit 130. These processes may generate data that defines flow parameters
(e.g., flow and
volume) for the resource 104 as it transits through the body 106. The
processes may also transmit
the data as the digital signal Si, for example, to the indexing unit 112 for
use with a display, or for
broadcast to a meter reader device or onto a network that provides the utility
with access to the gas
meter 102. The utility may use the data to generate bills for customers or to
perform diagnostics
to check heath and other operating characteristics of the gas meter 102.
[0025] FIG. 4 depicts a schematic diagram of an example of memory 132 to
illustrate different
types of resident data 136 on the encoder device 100. This stored data may
also include raw data
138 that corresponds with "counts," for example, pulses the sensor unit 118
generates in response
to each rotation of the impellers 112. This count data correlates well with
volumetric flow of fuel
gas 104, but is generally not "corrected" to account for certain environmental
conditions at or near
the gas meter 102. In one implementation, the power unit 120 may operate with
each rotation of
the impellers 112 so that the power signal Si is sufficient to operate
computing components 128,
130 at least to write the uncorrected data 136 to the memory 130. This feature
retains data in
memory 132 that defines customer consumption independent of power available on
the gas meter
102. Utilities may recover the uncorrected data 138 to calculate (or estimate)
customer use that
occurs during power outage or other issues that may frustrate operation of the
gas meter 102 to
properly generate and deliver data, e.g., via the digital signal Si.
[0026] Other data found on memory 132 may also prove useful for operation
of the gas meter
102. The data may embody correction data 140, for example, data that
functionality of the
processor 128 may use to compensate for low-flow conditions that occur across
the metering unit
112. The data may include "logged" data that functionality of the processor
128 actively stores
or reads to the memory 132. This logged data may embody measured data 142,
typically data that
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defines values for temperature, pressure, or like variables. These values may
originate from
sensors on or in proximity to the gas meter 102. The logged data may also
include calculated data
144, for example, data that defines values for flow parameters of fuel gas
104. These values may
quantify flow, volume, and like parameters that are useful to generate
accurate, reliable data that
defines volumetric flow of fuel gas 104 to satisfy customer demand. In one
implementation,
functionality of the processor 128 may also create event data 146 that
captures or defines operating
conditions on the gas meter 102. For example, the event data 146 may identify
issues or problems
on the device, effective consumer demand, as well as replacement or
maintenance that occurs on
the device. Still other data may prove useful to identify the gas meter 102.
This data may embody
identifying data 148, often values that serve to distinguish the gas meter
102, or its hardware, from
others. These values may include serial numbers, model numbers, or software
and firmware
versions. For security and integrity, the values may include cyclic redundancy
check (CRC)
numbers, check-sum values, hash-sum values, or the like. These values can
deter tampering to
ensure that the encoder device 100 or gas meter 102 will meet legal and
regulatory requirements
for purposes of metering fuel gas 104.
[0027] FIG. 5 depicts a schematic diagram of exemplary structure for the
encoder device 100
of FIG. 1. The structure may include an enclosure 150 with a peripheral wall
152, for example, a
thin-walled member made of plastic or composite material. This thin-walled
member may form
an interior cavity 154, preferably sealed to enclose the units 118, 120 inside
of the enclosure. This
construction may serve to protect the devices and provide adequate structure
to secure the
enclosure 150 to the gas meter 102. The data processing unit 114 may also
reside in the cavity
154. It may benefit the design to include potting material as well to secure
the data processing
unit 114 and the units 118, 120 to the peripheral wall 152 or other structure
in the cavity 154. A
data connection 156 may connect with the data processing unit 114. The data
connection 156 may
embody a cable or wiring harness compatible with signals in digital or analog
form, although
preference may be given to construction that can transmit power as well. The
cable 156 extends
away from the thin-walled member to a connector 158. In one implementation,
the connector 152
can interface with parts of the indexing unit 112, which can process data or
communicate with
remote devices.
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[0028] FIG. 6 depicts a perspective view of the encoder device 100 of FIG.
5 resident on an
example of structure for the gas meter 102. This structure may include a meter
body 160, typically
of cast or machined metals. The meter body 160 may form an internal pathway
that terminates at
openings 162 with flanged ends (e.g., a first flanged end 164 and a second
flanged end 166). The
ends 164, 166 may couple with complimentary features on a pipe or pipeline to
locate the meter
body 160 in-line with the conduit 106. As also shown, the meter body 160 may
have covers 168
disposed on opposing sides of the device. The enclosure 152 may mount to one
of the covers 168
to communicate with the metering unit 114 found inside the meter body 156.
Fasteners, like
adhesives or potting materials, may provide secure attachment without
interfering with operation
of the units 118, 120.
[0029] FIG. 7 shows the perspective view of FIG. 6 with the gas meter 102
in partially-
exploded form. The meter device 112 may comprise a mechanical assembly, shown
here having
a cylinder cover plate 170 that secures to the meter body 160. The cover plate
170 encloses and
seals an inner cavity 172 on the meter body 160. The interior cavity 172
houses a pair of impellers
174. The mechanical assembly may embody a gear assembly 176 having a pair of
gears 178. The
gears 178 may couple with the impellers 174, typically by way of one or more
shafts that extend
through the cover plate 168 to engage with the impellers 174. A magnetic
device 180 may couple
to one of the gears 178, shown here as an annular ring. But construction for
the magnetic device
180 may vary as necessary to accommodate structural and design considerations.
As noted above,
the cover 168 may locate the encoder device 100 in proximity to the magnetic
device 180 to
stimulate response of the units 118, 120, as well as to provide access to the
mechanical assembly.
In one implementation, the impellers 174 counter-rotate in response to flow of
fuel gas 104. This
movement displaces a fixed volume of fuel gas 104 that transits the meter body
160 between
flanged ends 164, 166. The rate at which the impellers 174 rotate relates to
the rate at which fuel
gas 104 flows through the meter body 160. For many applications, the rate of
rotation of the
impellers 174 is directly proportional to the flow rate of fuel gas 104 so
that with each full
revolution of the impellers 174 and, in turn, corresponding impeller shafts, a
precise volume of
fuel gas 104 moves through the meter body 160.
[0030] FIG. 8 depicts a perspective view of exemplary structure for the
power unit 120 that
can work in conjunction with the magnetic device 180 of FIG. 7. This structure
may reside in the
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enclosure 150 along with the Wiegand sensor 118. In one implementation, the
power unit 120
may embody a thin-diameter wire 182 forming windings 184 that circumscribe a
core 186. The
windings 184 may couple with leads 188. The leads 188 may extend to the
processing unit 114,
the power management unit 122, or the energy storage unit 126. As noted
herein, the core 186
may comprise magnetic material, and be solid or hollow. The annular ring 180
have magnetic
poles Pi, P2 that are diametrically opposed from one another; but other
construction may
incorporate additional magnetic poles as well.
[0031] FIG. 9 depicts a perspective view of exemplary structure for the gas
meter 102 of
FIGS. 6 and 7. One of the covers 168 may feature a connection 190, possibly
flanged or prepared
to interface with the indexing unit 112, shown here with an index housing 192
having an end that
couples with the connection 190. The index housing 192 may comprise plastics,
operating
generally as an enclosure to contain and protect electronics to generate data
for volumetric flow of
fuel gas through the meter body 160. The index housing 192 may support a
display 194 and user
actionable devices 196, for example, one or more depressable keys an end user
uses to interface
with interior electronics to change the display 194 or other operative
features of the device.
[0032] In view of the foregoing, the improvements herein outfit flow
devices, like gas meters,
with hardware to capture and retain redundant data. This hardware uses
operative movements on
the gas meter to both harvest energy and generate data that relates to volume
flow. The energy is
useful to power computing components to store this data in memory, preferable
non-volatile. This
feature creates a retrievable store of raw volume (or flow) data. Utilities
can access the raw data
to re-create or corroborate customer consumption for periods of operation that
occur during power
"outage" or disruption on the gas meter. As a result, the utility can avoid
potential issues with
accuracy and reliability at time of billing customers.
[0033] Topology for circuitry herein may leverage various hardware or
electronic components.
This hardware may employ substrates, preferably one or more printed circuit
boards (PCB) with
interconnects of varying designs, although flexible printed circuit boards,
flexible circuits,
ceramic-based substrates, and silicon-based substrates may also suffice. A
collection of discrete
electrical components may be disposed on the substrate, effectively forming
circuits or circuitry
to process and generate signals and data. Examples of discrete electrical
components include
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transistors, resistors, and capacitors, as well as more complex analog and
digital processing
components (e.g., processors, storage memory, converters, etc.). This
disclosure does not,
however, foreclose use of solid-state devices and semiconductor devices, as
well as full-function
chips or chip-on-chip, chip-on-board, system-on chip, and like designs.
Examples of a processor
include microprocessors and other logic devices such as field programmable
gate arrays
("FPGAs") and application specific integrated circuits ("ASICs"). Memory
includes volatile and
non-volatile memory and can store executable instructions in the form of
and/or including software
(or firmware) instructions and configuration settings. Although all of the
discrete elements,
circuits, and devices function individually in a manner that is generally
understood by those
artisans that have ordinary skill in the electrical arts, it is their
combination and integration into
functional electrical groups and circuits that generally provide for the
concepts that are disclosed
and described herein.
[0034] This written description uses examples to disclose the invention,
including the best
mode, and also to enable any person skilled in the art to practice the
invention, including making
and using any devices or systems and performing any incorporated methods. An
element or
function recited in the singular and proceeded with the word "a" or "an"
should be understood as
not excluding plural said elements or functions, unless such exclusion is
explicitly recited.
References to "one embodiment" of the claimed invention should not be
interpreted as excluding
the existence of additional embodiments that also incorporate the recited
features. Furthermore,
the claims are but some examples that define the patentable scope of the
invention. This scope
may include and contemplate other examples that occur to those skilled in the
art. Such other
examples are intended to be within the scope of the claims if they have
structural elements that do
not differ from the literal language of the claims, or if they include
equivalent structural elements
with insubstantial differences from the literal language of the claims.
[0035] Examples appear below that include certain elements or clauses one
or more of which
may be combined with other elements and clauses describe embodiments
contemplated within the
scope and spirit of this disclosure.
