WIRELESS PARTICLE COLLECTION SYSTEM

A wireless particle collection system includes a dust collector and at least one power tool coupled to the dust collector. The power tool is associated with a unique identifier contained in a wireless signal transmitted from the power tool upon an activation event of the tool. The unique identifier is recognized by the dust collector, and the dust collector activates or de-activates upon receipt of the wireless signal.

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Description
BACKGROUND

1. Field of the Invention

Example embodiments of the present invention generally relate to a wireless particle collection system, and to a tool transceiver, vacuum transceiver and blast gate transceiver of the system.

2. Description of Related Art

Power tools that can create dust during operation are often coupled to motorized air handling devices to help remove the dust. The vacuuming process is referred to as dust extraction and the vacuum device is known as a dust collector. Historically, the dust collector was manually switched on before the tool operation and again manually switched off after the tool operation was completed. This operation was often tedious for the user since there was always a manual activation/deactivation involved with a distant dust collector. Alternately, the tool user may leave the dust extraction unit on continuously creating adverse noise, premature failure due to wear, and inefficient use of electricity.

To address these problems, an automated dust collection system has been developed. This is a wired system electrically connecting “blast gates” and a vacuum motor to a main controller. The blast gates serve to selectively isolate or connect ducting between power tools and a vacuum source.

In the wired system, each blast gate is associated with a piezo element sensor that senses the vibration of a given power tool that is associated with tool turn-on. A signal from the piezo element that represents “ON” is sent to the main controller. The main controller in turn sends a power signal over the wiring to energize a gate motor to open the blast gate in the ducting connected to the energized power tool, and an electric signal to power the vacuum motor.

However, a wired dust collection system has limitations as to distance and location of the power tools, and has limited flexibility. For example, additional wiring will be necessary when adding additional power tools to the wired system.

SUMMARY

An example embodiment of the present invention is directed to a wireless particle collection system. The system includes a dust collector and at least one power tool coupled to the dust collector. The power tool is associated with a unique identifier contained in a wireless signal transmitted from the power tool upon an activation event of the tool. The unique identifier is recognized by the dust collector, and the dust collector activates or de-activates upon receipt of the wireless signal.

Another example embodiment is directed to a particle collection system. The system includes a plurality of dust collectors, a plurality of power tools, a vacuum conduit system coupled between the dust collectors and the power tools for providing a vacuum pressure to the power tools, and the vacuum conduit system including a plurality of blast gates for selectively controlling the vacuum pressure to the power tools. Each of the power tools is associated with a given dust collector and blast gate, with each power tool having its own unique identifier recognizable by its corresponding dust collector and blast gate. An address related to the unique identifier and included in a wireless signal is transmitted in response to an activation event of a given power tool. The signal with the address is received by the tool's corresponding dust collector and blast gate to activate or deactivate the dust collector and open or close the blast gate.

BRIEF DESCRIPTION OF THE DRAWINGS

Example embodiments of the present invention will become more fully understood from the detailed description given herein below and the accompanying drawings, wherein like elements are represented by like reference numerals, which are given by way of illustration only and thus do not limit the example embodiments.

FIG. 1 is a block diagram of a particle collection system with wireless controls in accordance with an example embodiment.

FIG. 2 is a block diagram of the system to illustrate sensing of tool activation/deactivation and wireless signal transmission in more detail.

FIG. 3 is a block diagram of a particle collection system with wireless controls in accordance with another example embodiment.

FIG. 4 is a block diagram of the system of FIG. 3 to illustrate an alternative wireless transmission path.

FIG. 5 is a block diagram of a particle collection system with wireless controls in accordance with another example embodiment.

FIG. 6 is a block diagram of a tool transceiver in accordance with the example embodiments.

FIG. 7 is a block diagram of a vacuum transceiver in accordance with the example embodiments.

FIG. 8 is a block diagram of a blast gate transceiver in accordance with the example embodiments.

FIG. 9 is a block diagram of a battery-powered blast gate transceiver in accordance with the example embodiments.

FIG. 10 is a block diagram of a remote control device in accordance with the example embodiments.

FIG. 11 is a block diagram of a relay device in accordance with the example embodiments.

FIG. 12 is a block diagram of a battery-powered relay device in accordance with the example embodiments.

 DETAILED DESCRIPTION

The example wireless particle collection system described in more detail hereafter senses power tool operation and remotely activates and/or deactivates a dust collector at optimum times. Activation of the dust collector may alternatively be accomplished manually via a key fob that is independent of tool operation.

The example system can be understood as a network of wireless, independent devices that can communicate with other devices in the network. The devices include a plurality of transceivers, with a given transceiver acting as a primary transmitter and other transceivers acting as receivers (“listening devices”). The primary transmitter, upon a tool activation event, broadcasts a signal that is understood by certain ones of the listening devices. The broadcast signal includes a unique identifier associated with a particular tool and recognized by a group of the receivers so as to associate the primary transmitter with the receivers.

The transceivers of the system include at least one transceiver operatively connected to a power tool, and a transceiver operatively connected to a dust collector (sometimes referred to as a vacuum). In another example, the system can include a transceiver operatively connected to a blast gate. The system or network of independent devices may include multiple dust collectors, multiple power tools and/or blast gates.

In an example, the transceivers of the dust collectors and blast gates act as listening devices for the signal broadcast from the tool transceiver. The system or network may allow the addition or removal of devices, such as blast gates for example, with simple programming to add or remove the unique identifier that may be stored in memory for association with a common unique identifier contained in the signal broadcast by the tool transceiver upon a tool activation event. The association can be understood as a process to make designated vacuum and/or blast gate receivers respond to the signal transmitted by the tool transmitter. Thus, a power tool may be associated with one or more blast gates and one or more dust collectors. Conversely, a given blast gate or dust collector may be associated with one or more power tools.

FIG. 1 is a block diagram of a particle collection system 10 with wireless controls in accordance with an example embodiment. The system 10 may include a tool transceiver device 100, referred to hereafter as a “tool transmitter 100” unless otherwise indicated. In FIG. 1, the tool transmitter 100 is in electrical connection with a machine such as a power tool 500. An activation or deactivation event of the power tool 500 causes the tool transmitter 100 to generate a wireless signal 700, such as an RF signal, that is broadcast within the system 10. The wireless signal 700 can be an activation or deactivation signal, as required by the situation. The wireless signal 700 is detected by a vacuum transceiver device 200, referred to hereafter as a “VAC receiver 200” unless otherwise indicated. VAC receiver 200 is in electrical connection with a vacuum source, hereafter “dust collector 400”. The VAC receiver 200 may be arranged between a plug 60 and an AC mains line 65 that powers both the VAC receiver 200 and dust collector 400, for example. Alternatively, the VAC receiver 200 could be integrated within the microelectronics of the dust collector 400.

In an example, the wireless signal 700 may be based on the ZigBee standard and contains coded keys to differentiate one tool transmitter 1001 from another tool transmitter 100n, n=1−N, allowing a work site to utilize multiple power tool/vacuum devices concurrently. As an example, the wireless signal 700 includes a unique identifier (such as a serial number/code or association number, for example) for the power tool 500. The power tool 500 may in turn be associated with one or more the dust collectors 400. The unique identifier could be a unique address contained within the wireless signal transmitted by the tool transmitter 100 and recognized by the VAC receiver 200. The VAC receiver 200 includes a memory element (not shown). The memory element includes a set of tool unique identifiers with which the VAC receiver (and in turn, the dust collector) is associated.

In another embodiment and as to be described in more detail hereafter, system 10 may optionally include one or more blast gates 350 (a single blast gate 350 shown in dotted line fashion). A blast gate 350, if present, is provided in a given vacuum conduit 550 between the power tool 500 and a given dust collector 400. Each blast gate 350 has a blast gate receiver 300 configured to control the blast gate 350 and adapted to recognize the unique identifier in the wireless signal 700 transmitted by tool transceiver 100. The blast gate receiver 300 includes a memory element (not shown). The memory element includes a set of tool unique identifiers with which the blast gate is associated.

In a further embodiment and as to be described in more detail hereafter, system 10 may optionally include one or more relay devices 800 (a single relay device 800 is shown in dotted line fashion). The relay device 800 functions as a range extender to extend the system area and/or network range. The relay device 800 is configured to re-transmit or repeat any signal it receives, and is thus adapted to recognize the unique address in the wireless signal 700 transmitted by tool transceiver 100 and to retransmit the signal to distant devices outside the signal range, such as to a distant VAC receiver 200 and/or blast gate receiver 300.

In another example, a wireless signal 705 may be generated by a transceiver of a remote control device such as a key fob 600 or other remote device that is recognized by the VAC receiver 200, for example. The wireless signal 700, 705 generated by the tool transmitter 100 or key fob 600 is received by the VAC receiver 200 (and optionally one or both of the blast gate receiver 300 and relay device 800) and activates the dust collector 400 and/or optionally the blast gate 350 (and/or optionally a distant dust collector 400/blast gate 350 outside the range of wireless signal 700 via relay device 800 repeating the signal). Once the power tool 500 operation terminates, another wireless signal (not shown) may be generated by the tool transmitter 100/key fob 600 to deactivate the dust collector 400 (and optionally close blast gate 350 and/or a remote device outside the signal range via relay device 800). The transmission of a ‘deactivation signal’ may be immediate, or may be delayed for a period after the power tool 500 turns off in order to clear the remaining dust out of the vacuum conduit 550. The delay may be incorporated in a circuit within the tool transmitter 100, or it may be incorporated in the VAC receiver 200 circuitry. In an example, the delay duration may be part of a coded wireless signal 700 transmitted by the tool transmitter 100 to the VAC receiver 200.

While the tool transmitter 100 and key fob 600 are described herein as primarily transmit devices and the VAC receiver 200 is described primarily as a receiver devices, each of the devices in this embodiment can be transceivers to enable two-way communication between the power tool 500/key fob 600 and the dust collector 400. In an example, receiver side circuitry in the VAC transceiver 200 confirms reception of the activation or deactivation signal, and then transmits such confirmation to be received by receiver-side circuitry in the tool transceiver 100.

FIG. 2 is a block diagram of the system 10 to illustrate sensing of tool activation/deactivation and wireless signal transmission in more detail. In an example method, the dust collector 400 is wirelessly activated when a particle-generating power tool 500, such as a saw is activated. In this example, the tool transmitter 100 is arranged between a wall plug 50 and the power tool 500 in the AC mains line 55 which provides power to both tool transmitter 100 and power tool 500.

The tool transmitter 100 monitors tool (saw) activation by sensing current in the AC mains line 55 to the power tool 500. Upon sensing the current, the tool transmitter 100 transmits the wireless signal 700. The VAC receiver 200 receives the signal and “recognizes” the unique identifier of the tool 500 from the signal. Upon receipt of the signal 700, the VAC receiver 200 acts as a switch to permit power to activate the dust collector 400, permitting dust or wood shavings to be suctioned by dust collector 400 via the vacuum conduit 550.

Alternately, other devices such as a switch integral to the power tool 500 may trigger the transmission of a wireless signal. Accordingly the functions of the tool transmitter 100 can be integrated within the microelectronics of the power tool 500. In further embodiments, the transmission may be an IR signal, an ultrasonic signal or may be a carrier line (mains) signal. FIG. 2 thus represents an entry-level wireless system 10 in which there is a one-to-one correspondence between dust collector 400 and power tool 500.

FIG. 3 is a block diagram of a particle collection system 10′ with wireless controls in accordance with another example embodiment. In addition to the entry-level system 10 as shown in FIGS. 1 and 2, where a dust collector 400 is dedicated to a specific power tool 500, many machine or woodworking shops connect a plurality of tools 500n (n=1 to N) to a single dust collector 400. To isolate the dust collector 400 from a tool 500n that may not be activated (not generating dust so not needing suction) a blast gate 350n is employed. The blast gate 350n blocks airflow between the dust collector 400 and an “off” tool, while allowing airflow between the dust collector 400 and an “on” tool. Blast gates typically are manually actuated or electrically actuated using a solenoid that controls a motor for opening and closing the gate.

In FIG. 3, there are shown a plurality of power tools 5001-500N connected to a common dust collector 400 via a corresponding blast gate 3501-300N to a vacuum conduit system 550. Each blast gate 350n has a corresponding blast gate transceiver operatively connected thereto, hereafter referred to as a “blast gate receiver n” for purposes of clarity. Upon a given tool transmitter 100n, sensing a current indicating tool turn on, a signal 700 is received by the VAC receiver 200 and also by all blast gate receivers 300 including the associated blast gate receivers 300n. As to be described in further detail hereafter, not all of the receivers in the system will act upon receiving the wireless signal 700. Only those receivers having an association with a given transmitter 100n (or a key fob 600 or other transmitter), will act on the signal 700.

Similar to the example described in FIG. 2, in the example of FIG. 3 the signal 700 transmitted by a given tool transmitter 100n includes a unique identifier such as a coded unique address that is recognized by the VAC receiver 200 and the corresponding blast gate receiver 300n. The identifier is stored in memory of the VAC receiver 200 and in memory of the respective blast gate receiver 300n, for example, to associate the given power tool 500n to its blast gate receiver 300n and to the dust collector 400.

Thus, in one example, upon sensing current to power tool 500n, tool transmitter 100n sends an activation signal 700 to both the VAC receiver 200 and blast gate receiver 300n. The blast gate 350n opens upon a control power signal sent from the blast gate receiver 300n to a motor of the blast gate 350n, and the dust collector 400 is concurrently activated as the VAC receiver 200 switches the AC mains 65 to its motor, so clear dust from the operation of power tool 500n. When power tool 500n is deactivated for longer than a given or preset period of time, tool transmitter 100n sends a deactivation signal to close blast gate 350n and deactivate the dust collector 400.

Concurrently, other tools 500n may be activated, causing their respective blast gates 350n to operate and activating the dust collector 400 if it is not already active. After a period of power tool inactivity, which in an example could be in a range between about 4-10 seconds, or fixed at a particular time such as 7 seconds, a respective deactivation signal to close the respective blast gates 350n and turn off the dust collector 400 is transmitted. In one example, this time delay may timed and the deactivation signal emitted by the tool transmitter 100n. Alternatively, the tool transmitter 100n may send an immediate signal indicating tool deactivation, with the delay being timed by the blast gate receiver 300n or VAC receiver 200. In a further alternative, the time period may be user selectable, such as by key pressure on a button on the power tool or remote device, via DIP switches or by a control signal issued by the tool transmitter 100n or by a remote device such as key fob 600, for example.

Each of the devices in this embodiment can be transceivers to enable two-way communication between power tool 500N and blast gate 350n and/or dust collector 400. For example, receiver side circuitry in the blast gate transceiver 300n confirms reception of an activation or deactivation signal 700 from its tool transceiver 100n, and then transmits such confirmation to be received by receiver-side circuitry in the tool transceiver 100n.

In an example, associations may be made via DIP switches which the end-user selects to appropriately match the various devices within the system 10″. While effective, setting DIP switches may be cumbersome and could incur the cost of the switches, which may be substantial.

Another approach is to use a unique serial number and/or association number encoded in the firmware at place of manufacture for each of the devices. Each of the devices may include a string of an enterprise (TOOL, GATE, and VAC) that are powered when an association event is initiated. This event may be initiated, for example, by a switch closure by the user on one of the devices (tool transmitter 100n, VAC receiver 200, and blast gate receiver 300n). Alternately an association event may be initiated by a switch closure sequence on the key fob 600.

During an association event, a coded wireless signal with unique identifier data is transmitted, and all devices within a string exchange serial and/or association number information via wireless communication. For example, taking the system 10′ depicted in FIG. 3 prior to association, the following devices are to be associated.

VAC Receiver 200: Serial #123, Association: none Blast gate receiver 3001: Serial #321, Association: none Tool transmitter 1001: Serial #876, Association: none

Each device also may store serial numbers or “association numbers” which identify the devices to which it respond. In an example, once the devices are powered and an association event is initiated (i.e., an activation or deactivation event triggering transmission of the wireless signal), the associations are:

VAC Receiver 200: Serial #123, Association: #876 Blast gate receiver 3001: Serial #321, Association: #876 Tool transmitter 1001: Serial #876, Association: #123, #321.

When power tool 5001 is activated, tool transmitter 1001 transmits an activation signal with associations #123 and #321, which may serve as unique addresses transmitted in the header of the signals 700 broadcast to devices in the system 10. VAC Receiver 200 (having its own serial number 123 and the serial or association number of the transmitter 1001 tool transmitter 1001 stored or firmware-coded therein) and blast gate receiver 3001 (having its own serial number 321 and the serial or association number of the transmitter 1001 stored or firmware-coded therein) recognize the unique association number addresses contained in the header of the signal 700 sent by the tool transmitter 1001 and thus activate. Both may optionally transmit status to its tool transmitter 1001, as the as tool transmitter 100 (having its own serial number address 876 and the serial or association numbers of the receivers 200, 3001 stored therein) would recognize the association number address received in the confirmation wireless signal.

Additional associations may be conducted such that multiple gate/tool combinations may be associated to a particular dust collector 400. For example, the full complement of devices in FIG. 3 could be associated as follows.

Tool transmitter 1001: Serial #876, Association: #321, #123 Blast gate receiver 3001: Serial #321, Association: #876 Tool transmitter 1002: Serial #765, Association: #543, #123 Blast gate receiver 3002: Serial #543, Association: #765 Tool transmitter 100N: Serial #987, Association: #778, #123 Blast gate receiver 300N: Serial #778, Association: #987 VAC Receiver 200: Serial #123, Association: #876, #765, #987

Thus, the associations above can be considered freeform as each of the transceivers can operate in an ad-hoc mode, whereby multiple receivers (VAC, blast gate) may have multiple associations with multiple tool transmitters. Conversely, a given tool transmitter may have associations with multiple VAC receivers and blast gate receivers.

The example embodiments provide for associations to be erased or reset by a user. In an example this may be performed via a reset button provided on the tool transmitter 100n, by some key closure sequence, or an override command transmitted by the tool transmitter 100n, so as to clear associations in the primary receivers (VAC receiver 200, blast gate receiver 300n).

FIG. 4 is a block diagram of the system 10′ of FIG. 3 to illustrate an alternative wireless signal transmission path. FIG. 4 depicts a similar operation except that the signal to activate the dust collector 400 emanates from the blast gate receiver 300n (which is a transceiver) instead of the tool transmitter 100N. In either case as depicted in FIGS. 3 or 4 within the system 10′, a particular tool transmitter 100n is associated to a particular blast gate receiver 300n. This association may be via an embedded code with a unique identifier or address signal as described above, such that the signal transmitted by the tool transmitter 100N is unique to its associated blast gate 350n. Each blast gate 350n responds only to the tool transmitter 100n associated with it; i.e., tool transmitter 1002 emits a coded signal with unique address signal that only the associated gate 3502 (via its blast gate receiver 3002) is responsive to.

Thus, a wireless signal transmitted by any of the tool transmitters 100n can activate the dust collector 400, as shown in FIG. 3. In this example, any of blast gate receivers 300n could transmit dust collector 400 activation signals 720, once activated by a wireless signal 700 received from its corresponding tool transmitter 100n. Accordingly, a given blast gate receiver 300n may exhibit independent control to activate or deactivate a given dust collector 400. In an example, a given blast gate 350n could include an override button to activate the gate and enable the blast gate transceiver 300n to send an activation signal to a VAC receiver 200 to turn on the dust collector 400. This envisions a scenario in which the signal 700 issued from a tool transmitter 100n has not been received by either of the blast gate and VAC receivers 300n, 200, perhaps due to interference, for example.

FIG. 5 is a block diagram of a particle collection system 10″ with wireless controls in accordance with another example embodiment. FIG. 5 further expands the shop area by depicting a system 10″ with a plurality of dust collectors 400x (x=1 to N) generally the same shop location. In this example, a first group of the blast gate receivers 300x has a unique association with its corresponding tool transmitter 100x of power tools 500x. The VAC receivers 200x may have associations with multiple blast gate receivers 300xy and/or multiple tool transmitters 100x.

Although all devices (i.e., tool transmitters 100n, VAC receivers 200n, and blast gate receivers 300n) may be configured as transceivers, in the example of FIG. 5 the tool transmitters 100n are primarily transmitters, and the VAC receivers 200n and blast gate receivers 350n are primarily receivers. In all instances, the devices may act as transceivers, whereby primary receives may transmit status to primary transmitters to confirm that transmitted commands were acknowledged.

In a variation of FIG. 5, the signal to activate the dust collector 400 in system 10″ can emanate from the blast gate receiver 300n (which is a transceiver) instead of the tool transmitter 100n, as described in FIG. 4. Each blast gate 350n responds only to the tool transmitter 100x associated with it; i.e., each tool transmitter 100n transmits a coded signal with address signal that only the associated gate 350x (via its blast gate receiver 300x) is responsive to.

While not depicted, the key fob 600 may be incorporated into the system 10″ to initiate blast gate 350n and/or dust collector 400n sequences. Events initiated by a given blast gate 350n may override initiation events issued by a given power tool 500ny, such that only the key fob 600 may alter events initiated thereby.

As previously described with regard to FIG. 3, each of the devices may include a string of an enterprise (TOOL, GATE, and VAC) powered upon initiation of an association event, such as by a switch closure by the user on one of the devices (tool transmitter 100n, VAC receiver 200n, blast gate receiver 300n ), or a switch closure sequence on the key fob 600. During the association event, all devices within a string exchange serial number information via wireless communication, as previously described above.

FIG. 6 is a block diagram of a tool transceiver in accordance with the example embodiments. The tool transceiver 100 may be integrated inside a portable or stationary power tool 500 or it may be separate device connectable between the AC mains 55 and the power tool 500. The transceiver 100 may include a mains input 55, a power supply 105, a current shunt 110 and an amplifier 120. The transceiver 100 may further include a microcontroller and wireless receiver 130, for example a radio circuit; an externally visible LED 140, a resettable over-current circuit breaker 150, and mains plug 102 for the power tool.

The internal power supply 105 provides DC power for the microcontroller and radio circuit 130. In an example, voltage provided to the microcontroller and radio circuit 130 can be between about 5V to 12VDC under all conditions of acceptable mains input voltage and frequency. In an example, the power supply 105 may be a universal supply (90VAC to 240 VAC) or a different design based on a US (120 VAC nominal) or European (230VAC nominal) version.

In an example, the microcontroller and radio circuit 130 may comprise a circuit board containing a Freescale 2.4 GHz radio and microcontroller on a chip and associated circuitry. Circuit 130 may include a 3.3V regulator on-board. The regulator is used to generate regulated voltage for the microcontroller and radio circuit 130 as well as for the LED 140.

The microcontroller of circuit 130 senses the power tool 500 actuation. In FIG. 6, this sensing is performed by monitoring current flowing to the power tool 500 via the current shunt 110 and amplifier 120. When the tool 500 is actuated, current flowing through the shunt 110 is converted to a voltage. The voltage is amplified at amplifier 120 and presented to the microcontroller in circuit 130. In an example, the current shunt 110 may have a small resistance value (such as 0.01 ohms) to prevent overheating. This results in a small voltage across the shunt 110 when tool currents are flowing.

The shunt voltage is amplified at amplifier 120 to a level acceptable to the microcontroller of circuit 130. When the amplified shunt voltage exceeds a threshold, the tool 500 is considered “ON”. Thus, the microcontroller acts as a sensor to detect tool 500 activation by sensing current flow to the tool 500. In an example, other means of sensing tool activation such as vibration may be utilized.

Upon sensing activation of tool 500, the microcontroller of circuit 130 activates the radio to send a coded signal with the aforementioned unique address code indicating tool actuation. The VAC receiver 200, blast gate receiver 300, and other listening devices which can recognize the unique address code may respond to the tool's actuation codes.

When the microcontroller detects that the tool 500 operation has been suspended, the microcontroller may activate the radio of circuit 130 to send a coded signal with a unique address code indicating tool suspension. The VAC receiver 200, blast gate receiver 300, and other listening devices which can recognize the unique address code may respond to the tool's actuation codes.

As part of the confirmation, given receiver devices may also transmit wireless confirmation signals that are read by the tool transceiver 100. In one example, if the tool transceiver 100 does not receive a confirmation signal, or receives erroneous confirmation signals, the tool transceiver 100 may retransmit activation or suspension codes within its wireless signal.

The LED 140 may be included to provide visible feedback to the user as to successful transmission of the radio signal. The LED 140 may be under software control as configured by the designer. Other methods of user feedback may be employed such as audible, LCD, or graphic displays.

FIG. 7 is a block diagram of a vacuum transceiver in accordance with the example embodiments. Referring to FIG. 7, the VAC transceiver 200 is powered from the AC mains 65 and provides AC mains power to the dust collector via a switched mains output receptacle 202. The transceiver 200 includes an on/off switch 205 to control the main power for the VAC transceiver 200, as full motor current flows through switch 205. An internal power supply 210 provides DC power for a relay driver 215 and a microcontroller and radio circuit 220. In an example, voltage provided to the microcontroller and radio circuit 220 can be between about 5V to 12VDC under all conditions of acceptable mains input voltage and frequency. In an example, the power supply 210 may a universal supply (90VAC to 240 VAC) or different design based on a US (120 VAC nominal) or European (230VAC nominal) version.

The microcontroller and radio circuit 220 may include a 3.3V regulator on-board. The regulator is used to generate regulated voltage for the microcontroller and radio circuit 220, as well as for switch 230 and LED 240.

In an example, the microcontroller and radio circuit 220 may comprise a circuit board containing a Freescale 2.4 GHz radio and microcontroller on a chip and associated circuitry. The relay driver 215 receives a logic level signal from the microcontroller and radio circuit 220 to close or open the power relay 225. The relay driver 215 translates this signal to drive the power relay 225.

The VAC transceiver 200 includes a switch 230, an LED 240 and a resettable circuit breaker 250. Switch 230 may be configured as a signal level SPST membrane switch with tactile feedback that is externally activated by the user. Switch 230 closures may be used by the microcontroller and radio circuit 220 to place the VAC transceiver 200 into different operational modes. The LED 240 may provide information to the user. The resettable circuit breaker 250 opens the current path if the current rating is exceeded, and may be resettable via a pushbutton actuation, for example.

In operation, when the on/off switch 205 is activated, the microcontroller of circuit 220 controls activation or deactivation of the relay 225. When the appropriate coded signal (i.e., the wireless signal transmitted by the tool transceiver 100 or the blast gate receiver 300 containing the unique addresses) is received by the microcontroller of circuit 220, the relay 225 is activated, closing the AC mains 65 onto the switched mains output receptacle 202 and an external device (motor of the dust collector 400) is turned on.

Conversely when the appropriate coded signal is received by the microcontroller of circuit 220, the power relay 225 is deactivated, opening the mains 65 from the switched mains output receptacle 202 and the external device (motor) is turned off. The switch 230 is monitored by the microcontroller of circuit 220. Operation due to switch 230 activation may be under software control, as configured by the designer. Similarly, as the LED 240 provides user feedback, the LED 240 may be under software control as configured by the designer.

FIG. 8 is a block diagram of a blast gate transceiver 300 in accordance with the example embodiments. The blast gate transceiver 300 primarily receives wireless signals from a transmitter (such as tool transceiver 100) and opens or closes a blast gate 350 in response to the signal to allow or block vacuum suction to remove material from a cutting or grinding operation.

A power supply 305 similar to as described in FIGS. 6 and 7 provides power for a microcontroller and radio circuit 310 and also provides power for the mechanical blast gate 350 (in FIG. 8, power to gate 350 is represented by a 24V DC motor 315). A motor driver and direction mixer 320 is controlled by the microcontroller of circuit 310 to direct the motor 315 to move forward and reverse. The motor driver and direction mixer 320 simply reverses the voltage polarity across the DC motor 315. This permits opening and closing of the blast gate 350, thereby allowing or blocking a vacuum.

Sensors may be built into the blast gate 350 such the microcontroller of circuit 310 detects a fully open or fully closed blast gate 350. Operation due to sensor switch activation is under software control. Such controls may include gate opening and closing overrides. For example, the microcontroller may direct the motor 315 to suspend operation once the blast gate 350 is completely open or closed.

A current shunt 325 may be employed to detect blockages in the blast gate passage (not shown). In an example, the current shunt 325 may have a small resistance value (such as 0.01 ohms) to prevent overheating. This results in a small voltage across the shunt 325 when currents are flowing. The shunt voltage is amplified at amplifier 312 to a level acceptable to the microcontroller of circuit 310.

If debris builds in the gate passage impeding opening or closing of the blast gate 350, the motor current will rise, but the applicable “Open” gate sensor switch 330 or “Closed” gate sensor switch 335 will not have activated. The microcontroller of circuit 310 can measure this excessive current and suspend motor operation. Additionally, a warning of this condition may be issued via the LED 340, for example.

To clear blockages, the microcontroller of circuit 310 can cycle the blast gate 350. Known as “jiggling”, the blast gate 350 is repeatedly open and closed in an effort to jog the blockage or debris so as to clear the vacuum conduit at the blast gate 350.

An external switch 345 may be included to provide over-ride capability to open or close the blast gate 350. The external switch 345 may also be used to place the microcontroller 310 into various states, such as associations with wireless transmit devices. The external switch 345 is monitored by the microcontroller 310.

The blast gate transceiver 300 is powered from the AC mains 50. The microcontroller and radio circuit 310 control opening or closing of the blast gate 350. When the appropriate coded signal (unique address) is detected by the microcontroller and radio circuit 310, the blast gate 350 is opened. Conversely, when the appropriate coded signal is detected by the microcontroller and radio circuit 310, the blast gate 350 is closed.

The Open gate sensor switch 330 and the Closed gate sensor switch 335 are monitored by the microcontroller of circuit 310 to gauge completion of the desired operation. Motor current is also monitored; if motor current exceeds a threshold (indicating blockage of the blast gate 350) motor operation may be suspended.

FIG. 9 is a block diagram of a battery-powered blast gate transceiver in accordance with the example embodiments. Blast gate transceiver 300′ is similar to that described in FIG. 8; therefore only the differences are described in detail hereafter. At certain work sites, blast gates may need to be located in areas where access to an AC power cord is not feasible or where providing corded power would be difficult and require a lengthy cord. Thus, instead of being powered from an AC mains source, the transceiver 300′ of FIG. 9 is battery powered. This provides additional flexibility in where to place blast gates within a work area. The battery 305′ may be a replaceable battery, such as an alkaline battery. In another alternative, the battery 305′ may be a rechargeable battery pack composed of any of lead acid, NiCd, NiMH or lithium ion (Li-ion) battery cells. In a further alternative, the battery 305′ could be solar-powered, where solar cells can be charged by ambient light or by a combination of a rechargeable battery with solar cells to charge the battery. In a further alternative, the solar cells could be adapted to charge a super capacitor (at least about 1 F), with the super capacitor providing power to operate the blast gate.

FIG. 10 is a block diagram of a remote control device in accordance with the example embodiments. A remote control device such as key fob 600 may be employed in any of the embodiments described in FIGS. 1-5 to transmit a signal that is recognized by the VAC receiver 200 to activate/deactivate the dust collector 400, and recognized by a blast gate receiver 300 to open and close a blast gate 350. The key fob 600 includes a power source, which may be embodied as a 9V alkaline battery 605 for example. The battery 605 powers a microcontroller and radio circuit 610 and an LED 640 upon actuation of on and off switches 645 and 655. In an example, the microcontroller and radio circuit 610 may comprise a circuit board containing a Freescale 2.4 GHz radio and microcontroller on a chip with associated circuitry. An on-board 3.3V regulator is used to generate regulated voltage for the microcontroller and radio circuit 610 and LED 640.

FIG. 11 is a block diagram of relay device in accordance with the example embodiments; FIG. 12 is a block diagram of a battery-powered relay device. Referring to FIGS. 11 and 12, a relay device 800 may be used in any of the embodiments described in FIGS. 1-5. The relay device 800 can be understood as a range extender which provides for extending the system area and/or network range. The relay device 800 is configured to re-transmit or repeat any signal it receives.

For example, a tool transmitter 100 in one area or room of a work shop broadcasts a wireless signal. This signal may not reach an associated dust collector 400 or blast gate 350 due to range limitations of the tool transmitter 100. Accordingly, one or more relay devices 800 could be placed within the range of the tool transmitter 100 so as to relay the wireless signal to the associated dust collector 400 and/or blast gate 350, to be received by corresponding transceivers thereof.

FIG. 11 illustrates a relay device 800 in a mains-powered configuration. Device 800 includes a power supply 805 that receives AC mains from a corded plug and powers a microcontroller and radio circuit 810 and an LED 840. The relay device 800 could have its dedicated cord or could be placed in a cord connected to a given blast gate 350 or dust collector 400. Upon receiving a wireless signal, the microcontroller of circuit 810 activates the radio to re-transmit or repeat a coded signal with unique address code indicating tool actuation. The LED 840 illuminates to indicate transmission. A given VAC receiver 200, blast gate receiver 300, and other listening devices within the relay device 800's range, and which can recognize the unique address code, respond to the tool's actuation codes.

The relay device 800′ of FIG. 12 is similar in structure and operation. However, device 800′ illustrates a cordless solution in which a battery 805′ provides power to its microcontroller and radio circuit 810 and LED 840. The battery 805′ may be a replaceable battery, such as an alkaline battery. Alternatively, the battery 805′ may be a rechargeable battery pack composed of any of lead acid, NiCd, NiMH or lithium ion (Li-ion) battery cells. In a further alternative, the battery 805′ could be solar-powered, where solar cells can be charged by ambient light or by a combination of a rechargeable battery with solar cells to charge the battery. In a further alternative, the solar cells could be adapted to charge a super capacitor (at least about 1 F), with the super capacitor providing power to operate the relay device 800′.

The above example embodiments therefore describe a wireless particle collection system or network having a plurality of independent devices that may associate with one another wirelessly upon a tool activation event. The example system provides flexibility in adding or removing devices there from. Tools can be associated with specific blast gates and dust collectors, and vice versa, based on a coded signal having a unique identifier therein that is recognized by devices of the string, so as to distinguish the tool transmitter of the tool from other transmission devices.

The example embodiments being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the example embodiments of the present invention.

Claims

1. A wireless particle collection system, comprising:

a dust collector, and
at least one power tool coupled to the dust collector, the at least one power tool having a unique identifier and configured to transmit a wireless signal upon sensing a tool state change event, the wireless signal including the unique identifier,
the dust collector configured to change state upon receipt of a wireless signal including a recognized unique identifier.

2. The system of claim 1, further comprising a tool transmitter for transmitting the wireless signal with the unique identifier based on a sensed current in the power tool.

3. The system of claim 2, wherein the tool transmitter is connected between an AC power source and the power tool.

4. The system of claim 2, wherein the tool transmitter is integrated within microelectronics of the power tool.

5. The system of claim 2, wherein the tool transmitter is a hand-held remote device independent of the power tool and dust collector.

6. The system of claim 1, wherein the dust collector includes a vacuum receiver for controlling a motor of the dust collector, the vacuum receiver adapted to recognize the unique identifier in the transmitted wireless signal to control the motor.

7. The system of claim 6, wherein the wireless signal is an RF-coded signal with the unique address contained in a header thereof, the unique address stored or firmware-coded within the vacuum receiver.

8. The system of claim 1, further comprising a relay device configured to receive and forward the wireless signal to the dust collector.

9. The system of claim 1, further comprising:

a vacuum conduit coupled between the dust collector and the power tool for providing a vacuum pressure to the power tool,
a blast gate coupled to the vacuum conduit for selectively controlling the vacuum pressure to the power tool, and
a blast gate receiver for controlling the blast gate, the blast gate receiver adapted to actuate the blast gate based on a wireless signal received in response to the activation event.

10. The system of claim 9, wherein

the wireless signal is an RF-coded signal with the unique address contained in a header thereof, and
the unique address is further stored or firmware-coded within the blast gate receiver.

11. The system of claim 9, wherein the transmitted wireless signal includes a command to open or close the blast gate.

12. The system of claim 9, wherein the transmitted wireless signal includes a command to the blast gate receiver to transmit a wireless signal with the address of the unique identifier to the dust collector.

13. The system of claim 9, wherein the wireless signal is simultaneously received at the blast gate and dust collector.

14. The system of claim 9, further comprising a relay device adapted to extend the range of the system and configured to receive and forward the wireless signal to a receiver or another system device.

15. A particle collection system, comprising:

a plurality of dust collectors,
a plurality of power tools,
at least one vacuum conduit coupled between the dust collectors and the power tools for providing a vacuum pressure to the power tools,
a plurality of blast gates coupled to the vacuum conduit for selectively controlling the vacuum pressure to the power tools, wherein
each of the power tools is associated with a given dust collector and blast gate, each power tool having its own unique identifier recognizable by its corresponding dust collector and blast gate, and
an address related to the unique identifier and included in a wireless signal transmitted in response to an activation event of a given power is received by the tool's corresponding dust collector and blast gate to activate or deactivate the dust collector and open or close the blast gate.

16. The system of claim 15, further comprising:

a remote control device configured to communicate with any of the power tool, dust collector and blast gates to initiate an activation event.

17. The system of claim 15, further comprising:

a relay device configured to communicate with any of the power tool, dust collector and blast gates extend system range.

18. The system of claim 17, wherein the relay device is powered by AC mains power.

19. The system of claim 17, wherein the relay device is powered by at least one of a replaceable, rechargeable, solar-powered and combination rechargeable and solar-powered battery.

20. The system of claim 15, further comprising:

a tool transmitter for transmitting the wireless signal with unique identifier based on a sensed current in the power tool.
a vacuum receiver for controlling a motor of the dust collector, the vacuum receiver adapted to recognize the unique identifier to control the motor, and
a blast gate receiver for controlling the blast gate, the blast gate receiver adapted to recognize the unique identifier to control the blast gate.

21. The system of claim 20, wherein

the wireless signal is an RF-coded signal with the unique address contained in a header thereof, and
the unique address is further stored or firmware-coded within the vacuum receiver and blast gate receiver.
Patent History
Publication number: 20100199453
Type: Application
Filed: Feb 9, 2009
Publication Date: Aug 12, 2010
Inventors: Daniele C. Brotto (Baltimore, MD), Andrew Robbins (Newark, DE), Andrew E. Seman, JR. (White Marsh, MD)
Application Number: 12/367,584
Classifications
Current U.S. Class: Fixed Position Cleaners Or Installed Cleaning Systems (15/301)
International Classification: A47L 5/38 (20060101);