CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of US Provisional Application 62/941,834, filed November 28, 2019, the entirety of which is incorporated fully herein by reference.

FIELD

[0001] Embodiments of the disclosure relate to data acquisition and communication devices. In particular, embodiments herein relate to apparatus and systems for remote data acquisition and communication having modular plug-and- play components.

BACKGROUND [0002] Remote data monitoring systems employing one or more sensors are used in a number of different applications. For example, an oil or gas pipeline may have many sensors (e.g. temperature, pressure, flow rate) located at various locations along the pipeline. Additionally, sea water temperature, salinity, and current can also be sensed at many locations. Sensors used in the above applications are typically monitored from one or more remote locations. In other words, operators or observers do not need to physically visit a sensor to obtain the data generated by the sensors, which are instead sent to the remote monitoring location or otherwise made available for remote access by users. Such remote sensing has been widely used for many years. The widespread use of the Internet has made such practices extremely pervasive across many industries.

[0003] The development of the “cloud” has increased the capabilities of remote sensing systems. The cloud is simply computing and memory capacity that is accessible to many users in many locations. Such users typically access this shared computing and memory capacity through the Internet or some other computer network system. Cloud systems also may be accessed via cellular network systems, satellite communication systems, or combinations of these and other systems.

[0004] Despite the widespread use of remote sensing systems that utilize the cloud and internetworked systems, there remain common limitations on such systems. Sensors come in many different configurations and there is a lack of standardization of mechanical connections, data formats, communications protocol configurations, and communication networks used by sensing systems. This lack of standardization results in many sensors being effectively locked into an existing system, which may be a system designed and implemented many years ago. This can result in slow data response times and limited data transmission. It can also limit a particular sensor to operating only as part of a particular system, as opposed to being compatible with a variety of systems.

[0005] This can pose problems in many industries and areas of research in which access to as much data as possible is desirable. There is a great deal of potential data available, but the shortcomings of present data monitoring systems leave most operators unable to fully take advantage of the data. An operator, for example, may be forced to use a number of different communications systems and networks to obtain data from different groups of sensors. Such varied communications systems and networks may not be compatible with each other, requiring a further step of consolidation before data can be combined and/or compared.

[0006] Conventional systems also fail to take full advantage of the potential data available at remote sensors. Take, for example, a powered sensor at a remote oil pumping station. If the pumping station loses power, the sensor may also lose power. But if the sensor is limited to sending a particular type of data (e.g. pressure or temperature), the power loss is likely to appear only as an error signal. An operator will not know the cause of the error signal. Yet the sensor “knows” that it has lost power. If that information could be transmitted to the operator, this relatively standard type of sensor would also become a rapid means of detecting a loss of power at the pumping station. Such data is potentially available at many sensors, but may not be available to operators due to the inherent limitations of the current technology.

[0007] In order to update sensors of a conventional data monitoring system, technicians typically must visit every remote sensor and either replace the sensor or install new hardware to upgrade the sensor to a new standard. The new standard might provide substantial improvements over the former one, but the process of making such a change can be time consuming and costly. Many remote sensors are located in locations that can be difficult and costly to access.

[0008] Expansion of the capabilities of current data monitoring systems is also difficult. If an operator wants a new sensor installed at a site, a trained technician typically must go to the site to install the sensor. Once the sensor is installed, the operating system of the data monitoring system must be updated to accept data from the new sensor. This process may take days to accomplish and can result in substantial delay before the new data is available.

[0009] Further, current systems are typically only designed to be capable of communicating using a limited number of communications protocols, such as via a cellular network, Wi-Fi, Bluetooth, and the like. Incorporating components into remote data communication systems to enable them to use multiple communications protocols can unnecessarily increase the costs of such systems if only one protocol is required. Additionally, conventional communication systems may be sealed to protect the internals of the system from the environment. This makes accessing the communications hardware housed inside the system, for example to repair or replace components, difficult or impractical.

[0010] Data communication systems such as that disclosed in Applicant’s US Patent Application No. 15/718,766 (the 766 Application), which is incorporated herein in its entirety, permit the coupling of a data communications head with a variety of sensors having standardized fittings compatible with the communications head. While this permits substantial versatility and customizability regarding what sensors may be used with the communications head and the types of data collected and transmitted, the disadvantage of such a system is that the electronic connections of the communications head and the sensors may be damaged during coupling and decoupling thereof. Additionally, the mechanical connection between the communications head and sensor, which is designed to be made up and broken down many times, may permit accidental disconnection, for example if personnel bump into the communications head. The connection may also permit theft of the communications head by removal from the sensor.

[0011] Moreover, in order to couple the communications head of the 766 Application with a sensor, the communications head must be pre-programmed with the appropriate data processing protocols for receiving the data from the sensor and translating the data to the appropriate data format before connection with the sensor. Such pre-programming often takes place off-site, for example when the communications head is manufactured. Thus, if the communications head is to be used with a different sensor, it must be removed from the site and reprogrammed with the appropriate protocol.

[0012] Further, while device taught in the 766 Application permits the communications head to be used with a number of interchangeable sensors, it is still limited in the number of communications networks and protocols it is capable of using to transmit and receive data.

[0013] There is a need for an improved system and method of monitoring and obtaining data from remote sensors that permits operators to easily modify, replace, or update remote sensors, communications hardware and protocols, and accessories thereof without the need for trained technicians. Such a system preferably reduces the risk that components are damaged during the installation or replacement of components.

SUMMARY

[0014] Generally, apparatus and systems for data monitoring and communication are provided herein capable of facilitating the connection between a communicator and one or more sensors in a plug-and-play fashion. The communicator has a communicator connector compatible with a sensor connector of the one or more sensors, the communicator and sensor connectors providing coupling and sealing mechanisms that can be configured to couple with a variety of sensors having a compatible connection while protecting the electrical connections of the communicator and sensors. The communicator can form a removable, semi- permanent, or permanent connection with the sensor. In embodiments having removable connections, the communicator and sensor connections provide consistent reseal ability of the connections when replacing or changing sensors. Legacy sensors can be made compatible with the communicator via sensor adapters. The sensors and/or sensor adapters have information regarding the data characteristics of the sensor stored in machine readable memory thereon, and the communicator is configured to receive said data characteristic information and acquire the appropriate data processing protocols from an external source, such as from the sensor and/or sensor adapters, or from the cloud. The modular nature of the system allow an operator to easily replace sensors of the system, including to a completely different type of sensor if desired.

[0015] The communications system can further comprise interchangeable communications modules, such that the system is capable of communicating data over a variety of communications networks and adopting a variety of communications protocols.

[0016] Various accessories, such as an external solar panel or an expansion hub to permit connection of the communicator to multiple sensors, can be used to expand the capabilities of the communications system.

[0017] The system can be designed to meet intrinsically safe design requirements, such that the system may be used in hazardous environments, for example in the presence of flammable gases.

[0018] The electrical components used in the system are selected to operate within temperature, space and safety parameters.

[0019] In a broad aspect, a data monitoring system for monitoring one or more processes is provided, comprising: a communicator having a communication module configured to communicate with one or more communication network; a processor; a first connector; a first electrical connection; a sensor assembly having a sensor; a sensor memory containing information regarding data characteristics of the sensor; a second connector configured to connect directly or indirectly to the first connector; a second electrical connection configured to connect directly or indirectly with the first electrical connection; and a process connector for connecting the sensor to the one or more processes; wherein the communicator is configured to receive the information regarding data characteristics from the sensor assembly and acquire a data processing protocol corresponding to the data characteristics of the sensor assembly from an external source.

[0020] In an embodiment, the data processing protocol is stored on the sensor memory and the communicator acquires the data processing protocol from the sensor memory.

[0021] In an embodiment, the data processing protocol is stored on a cloud network and the communicator acquires the data processing protocol from the cloud network.

[0022] In an embodiment, the sensor assembly further comprises a sensor adapter comprising: a first adapter connector having the second connector; and a second adapter connector for coupling with the sensor; wherein the sensor memory is located in the sensor adapter.

[0023] In an embodiment, the first connector has a first portion of an alignment mechanism, and the second connector has a second portion of the alignment mechanism.

[0024] In an embodiment, the first portion of the alignment mechanism comprises one of a key and keyway, and the second portion of the alignment mechanism comprises an other of the key and keyway, such that coupling the first portion and second portion aligns the first electrical connection of the communicator with the second electrical connection of the sensor.

[0025] In an embodiment, the system further comprises a locking mechanism for securing the communicator to the sensor assembly.

[0026] In an embodiment, the locking mechanism comprises a locking ring having a radially inwardly extending locking pin, the locking ring rotatably secured to the first connector, and a locking groove formed in the second connector for receiving the locking pin.

[0027] In an embodiment, the system further comprises a retaining pin for insertion through a first retaining aperture of the locking ring and a second retaining aperture of the second connector for securing the communicator to the sensor and preventing rotation of the locking ring.

[0028] In an embodiment, the sensor assembly comprises two or more sensor assemblies; the communicator further comprises one or more accessory ports; the two or more sensor assemblies are connected to the communicator via the first connection and the one or more accessory ports; and the communicator is configured to receive the information regarding data characteristics from each of the two or more sensor assemblies and acquire one or more data processing protocols corresponding to the data characteristics of the two or more sensor assemblies from the external source [0029] In an embodiment, the sensor assembly comprises two or more sensor assemblies; the communicator is connected to a hub having one or more hub ports, each hub port configured to connect to a corresponding sensor assembly of the two or more sensor assemblies; and the communicator is configured to receive the information regarding data characteristics from each of the two or more sensor assemblies and acquire one or more data processing protocols corresponding to the data characteristics of the two or more sensor assemblies from the external source.

[0030] In an embodiment, the communicator module is removably connected with the communicator.

[0031] In another broad aspect, a method of connecting one or more sensor assemblies to a data monitoring network for monitoring one or more processes comprises: coupling a process connector of the one or more sensor assemblies to the one or more processes; connecting a communicator to the one or more sensor assemblies such that a first electrical connection of the communicator is directly or indirectly connected to a second electrical connection of the sensor; receiving at the communicator information regarding data characteristics of the one or more sensor assemblies from the one or more sensor assemblies; and acquiring at the communicator one or more data processing protocols corresponding to the data characteristics of the one or more sensors from an external source.

[0032] In an embodiment, the step of acquiring the one or more data processing protocols comprises acquiring the data processing protocols from the one or more sensor assemblies.

[0033] In an embodiment, the step of acquiring the one or more data processing protocols comprises acquiring the data processing protocols from a cloud network.

[0034] In an embodiment, at least one of the one or more sensor assemblies comprises a sensor adapter having a communicator end configured to connect to the communicator and a sensor end configured to connect to a sensor of the sensor assembly, and the information regarding data characteristics of the at least one sensor assembly is stored on the sensor adapter.

[0035] In an embodiment, the communicator is connected to a hub having one or more hub ports, and at least one of the one or more sensor assemblies is connected to the communicator via the hub. [0036] In another broad aspect, a communicator for use in a data monitoring system for one or more processes is provided, comprising: a communication module configured to communicate with one or more communication networks; a processor; a first connector; configured to connect directly or indirectly with a second connector of a sensor assembly; and a first electrical connection configured to connect directly or indirectly with a second electrical connection of the sensor assembly; wherein the communicator is configured to receive information regarding data characteristics from the sensor assembly and acquire a data processing protocol corresponding to the data characteristics of the sensor assembly from an external source. [0037] In an embodiment, the data processing protocol is stored in the sensor assembly and the communicator acquires the data processing protocol from the sensor assembly. [0038] In an embodiment, the data processing protocol is stored on a cloud network and the communicator acquired the data processing protocol from the cloud network. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1A is a perspective view of an embodiment of a data monitoring system comprising a communicator connected to a compatible sensor; [0040] Figure 1B is a perspective view of an embodiment of a data monitoring system comprising a communicator connected to a sensor via a modular sensor adapter;

[0041] Figure 2 is an exploded perspective view of a communicator of a data monitoring system capable of coupling with a variety of communications modules;

[0042] Figure 3 is a perspective view of an embodiment of a data monitoring system for use with various sensors and a variety of accessories compatible therewith;

[0043] Figure 4 is a perspective view of an embodiment of a hub and an expansion cable of the data monitoring system;

[0044] Figure 5A is a cross-sectional perspective view of a communicator connector of a communicator coupled with a sensor connector of a compatible sensor;

[0045] Figure 5B is a cross-sectional perspective view of the communicator connector of Figure 5A;

[0046] Figure 5C is an exploded perspective view of the communicator connector of Figure 5A;

[0047] Figure 5D is a cross-sectional perspective view of the sensor connector of Figure 5A;

[0048] Figure 5E is a perspective view of the communicator connector and sensor connector of 5A prior to being coupled or after decoupling;

[0049] Figure 5F is a perspective view of a communicator connector and sensor connector having respective retaining apertures for receiving a retaining pin; [0050] Figure 6A is a cross-sectional perspective view of a sensor adapter for connection to a legacy sensor to integrate the legacy sensor into the data monitoring system;

[0051] Figure 6B is a cross-sectional perspective view of the sensor adapter of Figure 6A; [0052] Figure 6C is a perspective view of the sensor assembly of Figure

6A and a communicator with an alignment mechanism aligned therebetween;

[0053] Figure 6D is a perspective view of the sensor assembly and communicator of Figure 6C;

[0054] Figure 7A is an exploded perspective view of an embodiment of a compatible sensor of the data monitoring system;

[0055] Figure 7B is a side cross-sectional view of the sensor of Figure 7A coupled with a communicator connector of a communicator of the data monitoring system;

[0056] Figure 7C is a detail of a side cross-sectional view of the sensor and communicator connector of Figure 7B, with the sensor partially coupled therewith, showing details of the electrical and mechanical connection therebetween;

[0057] Figure 8 is a detail of a side elevation view of a sensor of the data monitoring system coupled to a communicator, the sensor installed in a process for monitoring thereof;

[0058] Figure 9 is a perspective view of a communicator connected to a first sensor via a communicator connector and to a second sensor via an accessory port;

[0059] Figure 10A is a perspective view of a process having five sensors installed;

[0060] Figure 10B is a perspective view of the process and sensors of Figure 10A with each sensor connected to a respective communicator;

[0061] Figure 11A is a perspective view of a communicator connected to multiple sensors installed in a process;

[0062] Figure 11 B is a zoomed out perspective view of the system depicted in Figure 11 A; [0063] Figure 12 is a schematic diagram of a communicator of the data monitoring system;

[0064] Figure 13 is an embodiment of a PCB board for a communicator connector;

[0065] Figure 14 is an embodiment of a retaining ring for securing a communicator to a sensor;

[0066] Figure 15 is an embodiment of a retaining ring for securing a sensor to a sensor adapter, which is removable using a corresponding tool; and

[0067] Figure 16 is a perspective view of the body of a sensor and the body of a communicator connector during a CNC manufacturing process.

DETAILED DESCRIPTION [0068] The present disclosure relates to embodiments of a data monitoring system comprising one or more communicators capable of coupling with various sensors, communications modules, and accessories. The communicator is capable of connection to a variety of sensors, including sensors not designed specifically for the system, and interchanging between communications modules as desired without manual reprogramming, calibration, or other time-consuming setup procedures.

[0069] Referring to Figs. 1-3 and 9-11B, a data monitoring system 2 for acquiring, communicating, and processing of sensor data comprises at least one communicator 10 and one or more sensor assemblies 50 connected to respective processes 4 for collection of data therefrom.

[0070] In an embodiment, as shown in Figs. 1A-2, the communicator 10 can comprise a generally cylindrical body 12 configured to be coupled with a top cap 14 and a bottom cap 16, forming the mechanical foundation of the communicator 10. In embodiments, the body 12 and top and/or bottom caps 14,16 can have seals such that when the body 12 and top and bottom caps 14,16, are connected, the internal components of the communicator 10 are protected and sealed from the environment. The caps 14,16 can be removably coupled with the body 12 to permit access to the internal components of the communicator 10, or can be permanently connected thereto to prevent tampering therewith.

[0071] The communicator 10 further comprises an internal circuit board (PCB) 20 supporting electronic components of the communicator 10 such as a processor and a machine-readable memory. In embodiments, the communicator 10 also houses an internal power source 22 such as one or more batteries or capacitors for providing power to the electrical components of the communicator 10, as well as devices connected to the communicator 10 such as sensors 52 and accessories. In preferred embodiments, the internal power source 22 is rechargeable and replaceable, and a power generating mechanism 24, such as a solar panel, configured to provide energy to the power source 22. As best shown in Fig. 2, the solar panel 24 can be a flexible sheet covering the inner wall of the body 12, which can be translucent or transparent for permitting light to reach the solar panel 24. In embodiments, the solar panel 24 is attached to the outside wall of the body 12, and a power cable is permitted to enter the body 12 while maintaining the seal of the internals of the body 12 from the environment. As the solar panel 24 is external to the body 12, the body 12 in such embodiments does not need to be translucent or transparent. In other embodiments, the communicator 10 can receive power from an external source, with the internal power source 22 functioning as backup power or omitted completely.

[0072] The communicator 10 can also house or otherwise be connected to a communication module 26. As shown in Fig. 2, in embodiments, the communications module 26 can be removably connected to the body 12 and interchangeable, such that the communications components of the communicator 10 can be adapted to utilize the communication networks available at the process site. The communications module 26 used can be selected to suit end user location, process measurement type, and data management requirements. Each communication module 26 can be configured to enable communication via one or more of a number of appropriate communications networks and protocols including, but not limited to cellular, Wi-Fi, Lorawan, satellite, etc. For example, communications modules 26A, 26B, 26C, and 26D can be provided for sending and receiving data over a cellular network, Bluetooth, WLAN/Wi-Fi, and satellite network, respectively.

[0073] The communications modules 26 can be configured to be easily replaced. For example, the fasteners used to secure the communications modules 26 to the body 12 can be clearly visible and accessible, while fasteners not intended to be removed in regular use, such as for maintaining the structural integrity of the communicator 10, can be covered or hidden. A gasket for creating a seal between the communications modules 26 and body 12 can be configured to remain intact with the communicator 10 such that it is not forgotten when a new communications module 26 is installed. For example, the gasket can be secured to the body 12 with an adhesive. By providing interchangeable communication modules 26, the size and power consumption of the communicator 10 can be minimized while still providing the versatility of being able to connect to many types of communications networks by swapping communication modules 26.

[0074] The machine-readable memory of the communicator 10 can comprise firmware and/or confirmation information stored therein to permit the communicator 10 to interface with the communications modules 26. When the communications module 26 is interchanged with a new module, the firmware can be updated either over-the-air, downloaded from the communications module 26, or updated directly by a technician. Further, the firmware of the communicator 10 can be configured to detect that a new communications module 26 has been connected and adjust the function of the communicator 10 accordingly. [0075] In embodiments, the communications modules 26 can contain the requisite information and protocols to communicate via the corresponding communications network, such that the processor of the communicator 10 can read and acquire said protocols from the communications modules 26 instead of having them pre-loaded onto the memory of the communicator 10. In this manner, the communications modules 26 can be installed and interchanged with the communicator 10 in a plug-and-play fashion.

[0076] The communicator 10 can have a first or communicator connector 28 for permitting mechanical and electrical connection to an external device, such as a sensor assembly 50. The communicator connector 28 can be connected at a first end to the body 12 or top or bottom caps 14,16 via any suitable connection mechanism 27, such as threading, screws, welding, friction fit, or formed integrally therewith. Further, the communicator connector 28 can have a first electrical connection 30 that is connected to the processor and other electrical components of the communicator 10 for sending and receiving data and instructions to the sensor assembly 50, or another device connected to the communicator connector 28.

[0077] The communicator 10 is configured to receive data from a sensor 52, convert the data for a desired common format of the data monitoring system 2, and transmit the converted data via a communication medium or network, such as the Internet, a cellular network, WLAN/Wi-Fi, Bluetooth, or any other suitable network, for example to a central data storage center or monitoring site.

[0078] Sensors 52 can be connected to, or formed integrally with, a second or sensor connector 54, forming a sensor assembly 50 configured to be mechanically connected to the communicator connector 28 via the sensor connector 54. The sensor connector 54 comprises a second electrical connection 56 compatible with the first electrical connection 30 of the communicator 10. The sensor assembly 50 has a process connector 58 for securing the sensor assembly 50 to a process 4 to be monitored by the sensor 52. In the embodiment depicted in

Figs. 5A and 5D, the process connector 58 is part of the sensor 52. The sensor assembly 50 further houses electronic components such as a sensor memory for storing data collected from the sensor 52 and information regarding characteristics of the data collected by the sensor 52. In the depicted embodiment, the sensor memory is located within the sensor connector 54. In embodiments, the sensor memory further contains protocols for processing the data collected by the sensor 52. Such protocols can comprise instructions and an Application Programming

Interface (API) for reading and converting the data collected by the sensor 52 to the common data format of the data monitoring system 2. When the sensor assembly 50 is connected to a communicator 10, the processor of the communicator 10 can obtain from the sensor assembly 50 the information regarding the characteristics of the data collected by the sensor 52 and, if required, download from the sensor assembly 50 the appropriate protocol for processing the data collected by the sensor 52. In other embodiments, after obtaining the information regarding the data collected by the sensor assembly 50, the communicator 10 can obtain the corresponding protocol for processing the data from another external source, such as from a remote server accessible via the communication network used by the communicator 10 (the “cloud” or “cloud network”), a device used by the operator such as a mobile phone or laptop, or another communicator 10 of the data monitoring system 2.

[0079] The communicator 10 and sensor assembly 50 can be coupled with each other via an alignment mechanism to ensure that the first and second electrical connections 30,56 are axially and/or rotationally aligned. For example, with reference to Figs. 5A, 5B, 5D, 6A, and 7B, the communicator connector 28 can have a radially protruding axial key or spline 32 that can be received in a corresponding axial keyway or groove 60 formed in the sensor connector 54, or vice versa.

[0080] Referring to Figs. 6C, 6D, and 7C, the alignment mechanism of the communicator and sensor connectors 28,54 can be configured to pre-align the electrical connection 56 of the sensor assembly 50, such as pins, with the corresponding electrical connection 30 of the communicator 10 as the communicator and sensor connectors 28,54 are coupled, thereby reducing the likelihood that first and second electrical connections 30,56 are damaged due to misalignment. By choosing appropriate CNC tooling and dimensional tolerances, a highly accurate alignment mechanism, comprising a key-and-keyway arrangement between the communicator and sensor connectors 28,54, can be created that aligns the first and second electrical connections 30,54 as the communicator and sensor connectors 28,54 are engaged and coupled. The alignment mechanism not only aligns the electrical connections 30,54, but acts to prevent inadvertent counter rotation of the communicator 10 and sensor assembly 50 once assembled that may damage the electrical connections 30,54 or disturb the contact therebetween.

[0081] Additionally, a locking mechanism can be used to couple the communicator 10 and sensor assembly 50 in a removable, semi-permanent, or permanent manner, depending on the requirements of the monitoring system 2. In one embodiment, with reference to Figs. 5A to 5E, the locking mechanism can comprise a locking ring 34 rotatably retained on the communicator connector 28 by a retaining ring 36 seated in an annular groove 37 formed in the communicator connector 28. The locking ring 34 can have a radially inwardly extending locking pin 38 that is configured to be inserted into and follow a locking groove or cam 62 formed in the sensor connector 54. In the depicted embodiment, the locking groove 62 is a helical groove that draws the locking ring 36 and communicator 10 toward the sensor assembly 50 as it is rotated. A pin seat 64 can be located at a terminal end 63 of the locking groove 62 in which the locking pin 38 may be seated to prevent the locking pin 38 from unintentionally backing out of the locking groove 62. For example, the locking groove 62 can hook toward a communicator end 55 of the sensor assembly 50 at the terminal end of the groove 62. A spring 40, such as the wave spring shown in Figs. 5B and 5C, can be located between the locking ring 34 and a radial shoulder 42 of the communicator connector 28 to bias the locking ring 34 away from the sensor assembly 50, such that the locking pin 38 will be forced into the pin seat 64 once it has reached the terminal end of the locking groove 62. An operator will feel a “click” when the locking pin 38 is seated in the pin seat 64, thereby providing a positive indication that the communicator 10 and sensor assembly 50 are secured together.

[0082] In embodiments, with reference to Fig. 5F, a first retaining aperture 66 can radially extend through the locking ring 34 and a second retaining aperture 68 can extend radially inwardly into the sensor connector 54. The first and second retaining apertures 66,68 can be positioned to align with each other when the locking pin 38 has reached the end of the locking groove 62. A retaining pin 70 can be inserted through the aligned retaining apertures 66,68, thus locking the communicator 10 and sensor assembly 50 together. In embodiments, the retaining pin 70 can be designed to provide a friction or interference fit such that the pin 70 can only be removed by drilling it out, shearing, or another destructive means, thereby providing semi-permanent securement of the communicator 10 with the sensor assembly 50. For example, the pin 70 can be designed such that it must be hammered or otherwise forcefully inserted into the retaining apertures 66,68 such that it is irremovable except by drilling out.

[0083] In another embodiment, with reference to Figs. 7A to 7C, the locking mechanism can be a spring-and-groove lock comprising a circular retaining spring 72 configured to be received in a first annular spring lock groove 42 of the communicator connector 28 and a second annular spring lock groove 74 of the sensor connector 54. The retaining spring 72 can be a coil spring having a generally circular circumferential profile that becomes deformed when compressed. The retaining spring 72 can be positioned in the second spring lock groove 74 of the sensor connector 54 and the sensor connector can be coupled with the communicator connector 28. As the sensor connector 54 is inserted into the communicator connector 28, or vice versa, the retaining spring 72 is radially compressed between the connectors 28,54 until it reaches the first spring lock groove 42, at which point the retaining spring 72 is at least partially uncompressed and rests in the first and second spring lock grooves 42,74, thereby locking the retaining spring 72 within the spring lock groove 42,74. The sensor assembly 50 and communicator 10 are thereby mechanically secured together by the retaining spring 72 until at least a threshold axial decoupling force is applied between the communicator 10 and sensor assembly 50 to deform and unseat the retaining spring 72 from the spring lock grooves 42,74, such that the communicator 10 and sensor assembly 50 can be separated. By adjusting the dimensions of the retaining spring 72 and spring lock groove 42,74, the force exerted by the spring 72 on the communicator and sensor connectors 28,54 when they are connected and disconnected can be adjusted, thus changing the requisite threshold decoupling force. In embodiments, the threshold coupling and decoupling force can also be selected to require that a tool, such as a flathead screw driver, be used to connect and disconnect the communicator 10 and sensor assembly 50.

[0084] By changing the geometry of retainer spring 72 and spring lock grooves 42,74, it is possible to design the locking mechanism to be either temporary, semi-permanent, or permanent (for example decoupling the communicator 10 and sensor assembly 50 would cause irreversible damage to the retaining spring 72 or spring lock grooves 42,74). An example of a suitable retaining spring 4 is a Bal Spring® from Bal Seal Engineering Inc.

[0085] This flexibility of designing the locking mechanisms above to be temporary, semi-permanent, or permanent allows the communicator 10 and sensor assembly 50 to be used in a variety of connection applications ranging from continuous and repetitive connector make-break cycles to a single, permanent connection. With reference to Figs. 14 and 15, the use of a self-locking ring, such as that disclosed in US Patent No. 8,479,614 incorporated herein in its entirety, or hand-installed retaining ring can make the connection more robust and secure, with disassembly requiring a common or purpose-built tool to disengage the retaining ring [0086] As one of skill in the art would understand, a variety of other locking mechanisms can be used to couple the communicator 10 and sensor assembly 50, such as locking pins, screws, and the like.

Sensor Adapter [0087] The embodiments of the communicator 10 and sensor assemblies 50 are advantageous as they can be coupled in a plug-and-play manner without requiring the communicator 10 to be pre-loaded with the appropriate protocols for receiving and processing data received from the sensor assembly 50, and the electrical connections 30,56 are aligned by the alignment mechanism. As the communicator 10 is pre-programmed to acquire the data characteristics of the sensor 52 from the connected sensor assembly 50 and obtain the appropriate data processing protocol, and the data processing protocol is stored in the sensor assembly 50 or in another external source, generic communicators 10 with no pre- loaded protocols can be connected to any compatible sensor assembly 50. Thus, the communicator 10 is capable of being configured to process and communicate the data collected at the sensor assembly 50 to the data monitoring system 2 with minimal input from a field operator. [0088] With reference to Fig. 6A and 6B, legacy sensors 52L that are not compatible with the communicator 10 and communicator connector 28 can also be used with the data monitoring system 2 to provide further ease of field configuration of the system 2 and incorporation of components therein. Components can be provided to facilitate communication between the communicator 10 of the present system 2 with various types of legacy sensors 52L, such as by incorporating SCADA or other types of electrical connections and being configured to use Modbus or other communication protocols of legacy sensors 52L. Conversely, components can be provided to adapt sensors 52 for use with legacy communicators by incorporating SCADA and Modbus or other suitable communication protocols in the components of the sensor assembly 50.

[0089] In an example embodiment, a legacy sensor 52L can be retrofitted for connection to communicator 10 and use in the present system 2 via a sensor adapter 80. The sensor adapter 80 comprises a first adapter connector 82 configured to be coupled to, or formed integrally with, a sensor connector 54 for connection to the communicator connector 28, and a second adapter connector 84 for connecting to a legacy sensor 52L. In such embodiments, the sensor connector 54, sensor adapter 80, and legacy sensor 52L form a sensor assembly 50L. As above, the sensor connector 54 can contain the electronic components of the sensor assembly 50L such as a sensor memory for storing data collected from the sensor 52L and information regarding characteristics of the data collected by the sensor 52L and, in some embodiments, protocols for processing the data collected by the sensor 52L. The electronics and software of the sensor adapter 80 can also provide a protocol and electronics interface to connect to legacy sensor systems 52L, such as those using Modbus. Thus, the communicator 10 would be able to connect to a plurality of sensor types 52, being a combination of compatible sensor assemblies 50 as well as sensor assemblies 50L comprising legacy sensors 52L, such as those using SCADA systems, simultaneously. In this manner, virtually any legacy sensor 52L can be connected to the data monitoring system 2 via a sensor adapter 80 designed to be coupled with the legacy sensor 52L, so long as the type and data characteristics of the legacy sensor 52 are known. In embodiments, legacy sensor 52L comprises an electrical interface that is compatible with the electronics on a sensor connector 54 and the sensor connector does not require additional electronics for compatibility. In other embodiments, a sensor connector 54 requires additional circuitry to interface with a legacy sensor 52L or to provide additional functionality (e.g. temperature connector as shown on Fig. 6A), in which instance the additional circuitry may be located on the circuit board 86 of the adapter 80 or with the electronics of the sensor connector 54.

[0090] Referring to Fig. 7B, a sensor connector 54 is directly coupled to a legacy sensor 52L using suitable connection methods including, but are not limited to, welding, threading, and and/or bolting. As described above the sensor connector 54 facilitates ability of the communicator connector 28 to couple with legacy sensors

52L that may not have been specifically made to connect to the communicator connector 28. [0091] The sensor connector 54 of the sensor assembly 50L can have the same alignment and locking mechanisms described above for more convenient and robust coupling with the communicator 10.

[0092] Use of sensor adapters 80 permits the communicator 10 to be used with a variety of existing sensors 52L as opposed to exclusively with sensors 52 made specifically to be connected to the communicator 10, such as those formed integrally with sensor connector 54 or otherwise made to be readily coupled therewith. The legacy sensors 52L can be connected to the monitoring system 2 in the same manner as with compatible sensors 52, wherein the communicator 10 is connected to the sensor connector 54, which is in turn connected to the sensor adapter 80 and legacy sensor 52L. The communicator 10 receives the sensor data characteristics of the sensor 52L from the sensor memory of the sensor assembly 50L. The communicator 10 can then acquire the appropriate data processing protocol from the sensor assembly 50L or another external source. [0093] Referring to Figs. 1A to 7C, the design of the communicator connector

28 and the sensor assembly 50 allows the sensor assembly 50 and sensor 52 to be manipulated independent of the communicator during the calibration, manufacture, installation, removal, or repair of the sensor 52. That is, any type of sensor assembly 50 having a compatible sensor connector 54, and sensor adapter 80 if needed, can be incorporated into the data monitoring system 2. This flexibility allows a large selection of sensor 52 and communicator 10 combinations to be used, as the combination of the type of sensor 52 and communicator 10 is not permanent and can be changed as required by the user. In fact, communicators 10 having no previous pre-programming for compatibility with certain types of sensors 52 can be coupled with any sensor assembly 50 having a compatible sensor connector 54 and a sensor adapter 80, if required. Likewise, this “adapter” function can be connected with a hub or other connection means, discussed in further detail below, to expand the numbers of sensors 52 in use with the system 2.

[0094] As such, the sensor assemblies 50 and sensor adapters 80 can be manufactured, calibrated, and stored without prior pairing to a specific communicator 10, as required in conventional systems. In prior art systems, sensor calibration tables were stored in communicators. Thus, a particular communicator would only be compatible with certain sensors, and changing sensors requires a time-consuming process of updating the calibration data on board the communicator. This process is not required in the present data monitoring system 2, as sensor data information (such as data type, calibration, etc.) is stored in the sensor memory of the sensor assembly 50 as opposed to the communicator 10.

[0095] In embodiments, as described below, multiple sensor assemblies 50 can be connected to a single communicator 10, further expanding the capabilities of the system 2.

[0096] Referring to Figs. 7A to 7C, in embodiments, the sensor assembly 50 coupled to the communicator 10 and sealed using a polymer or other appropriate compound. Alternatively, or additionally, the communicator connector 28 and/or the sensor connector 54 can have a seal 44 for making the connection between the sensor assembly 50 and communicator 10 suitable for operating in harsh environmental conditions. The electronic components of the communicator 10 and/or sensor assembly 50 can be protected from tampering, environmental conditions, and contamination by applying a suitable sealing or potting compound, or using a simple cover over the exposed faces of the electrical components. As best shown in Figs. 5A to 7B, to further protect electronic components when the sensor assembly 52 and the communicator 10 are separated, for example when replacing a communicator 10, one or both of the first and second electrical connections 30,56 can be sealed so as to isolate the internal electrical components while still providing an effective electrical contact.

[0097] In embodiments having a retaining spring 72 as the locking mechanism, the seal 44 between the communicator and sensor connectors 28,54 is preferably independent of the retaining spring 72, such that there is minimal sensory interference caused by the seal 44 while the communicator and sensor connectors 28,54 are being coupled. If the seal 44 engages before the retaining spring 72 during coupling, the elastomeric properties of the seal 44 may obfuscate the operator’s ability to feel the radial position of the alignment mechanism, and whether the retaining spring 72 has successfully engaged the spring lock grooves 42,74. Designing the retaining spring 72 and ring seal 44, and correspondingly the spring lock grooves 42,74 and seal seat 45, to have different outer diameters, and axially spacing the spring grooves 42,74 from the seal seat 45, permits one to better feel the retaining spring 72 engage the grooves 42,74 while rotating the communicator 10 relative to the sensor assembly 50 or vice versa to feel whether the alignment mechanism has become aligned. Likewise, in embodiments having a locking ring 34 for coupling with a locking groove 62, the components can be configured such that the locking pin 38 of the locking ring 34 engages the locking groove 62 before the seal 44 engages the sensor connector 54. This is best shown in Figs. 5A and 5D, wherein the sensor connector 54 has a sealing interface 76 configured to engage the annular seal 44 of the communicator connector 28 once the locking pin 38 meets the locking groove 62.

[0098] Referring to Figs. 7B and 8, the interface between the sensor assembly 50 and a process 4, such as fluid-conveying piping, is sealed with a process seal 59 of the process connector 58. The process seal 59 is independent of seal 44 that seals the connection between the communicator and sensor connectors 28,54. The independence of the process seal 59 from the communicator/sensor connection seal 44 allows the communicator 10 to be installed, repaired, exchanged, or upgraded without having to interrupt or disconnect the sensor 52 from the process 4, which enhances safety. For example, a pressure sensor assembly 50 is threaded into a pipe connection on a producing line, with a communicator 10 coupled thereto. The communicator 10 can be removed from the pressure sensor assembly 50 without affecting the process seal 59 between the process connector 58 of the sensor assembly 50 and the producing line 4. This advantage obviates the need for highly trained technicians to perform an exchange of communicators having sensors integrated therewith. [0099] To further enhance safety and convenience of maintenance, as described in further detail below, the electronic components used in the communicator 10 and sensor assembly 50 (with or without the sensor adapter 80) can be designed to follow intrinsically safe design principles, such that exchange of the communicator 10 is not required to be performed in a non-hazardous zone. This permits quick and inexpensive exchange of communicators 10.

HUB & ACCESSORIES

[0100] The system is also capable of expanding from a single sensor assembly 50 to a network of sensor assemblies 50 either by providing additional communicator connectors 28 on the communicator 10, or by providing an external hub 90.

[0101] Referring to Figs. 4, 11 A, and 11 B, in embodiments, the communicator 10 can be connected to an external attachment hub 90, such as via an extender cable 92. The hub 90 features multiple hub ports 91, and provides an electrical connection between the communicator 10 and a plurality of sensor assemblies 50 and/or accessories. The hub 90 can be configured such that data from multiple sensors assemblies 50 can be acquired, translated, and transmitted by a single communicator 10. The external attachment hub 90 can be expanded with additional connection blocks 96 to provide capacity to connect additional sensor assemblies 52 and/or accessories. Sensors 52 can be connected to the attachment hub 90 directly or using a suitable extender cable 92. [0102] The communicator 10 can be connected to the hub 90 via the communicator connector 28 or via one or more accessory ports 46 thereof. The accessory ports 46 are shown in Figs. 1 B and 9 through 11 B as being located at the bottom cap 16, but can be provided at any suitable location of the communicator 10. The accessory port 46 can further comprise the appropriate electronic components to provide the same functionality as the first electrical connection 30 of the communicator connector 28, that is, the ability to send data to, and receive data from, sensor assemblies 50. In embodiments, the hub 90 can have a “dummy” sensor connector 54 for coupling with the communicator connector 28 of the communicator 10, such that the communicator 10 can be coupled directly to the hub 90.

[0103] One or more of the extender cables 92 can have the alignment and locking mechanisms above for connection to the communicator 10 and sensor assemblies 50, such that the field components of the data monitoring system 2 can be easily connected, are secured, and cannot be inadvertently disconnected. As shown in Fig. 3, the extender cables 92 can have extender connections 94 similar in design and function to the communicator connector 28.

[0104] In embodiments, the functionality of the hub 90 can be incorporated into the communicator 10, such that the communicator 10 features hub ports 91 or multiple communicator connectors 28 for connecting the communicator 10 to multiple sensor assemblies 50 and/or accessories.

[0105] As described above, the communicator 10 can obtain information regarding the data characteristics of all of the sensor assemblies 50 connected to it either directly, via an accessory port 46, or via a hub 90, and acquire the appropriate data processing protocols either from the sensor assemblies 50 or from another external source. In this manner, multiple sensor assemblies 50 can be connected to the communicator 10 in a plug-and-play fashion.

[0106] The ability of the communicator 10 to connect with multiple sensors via multiple communicator connectors 28 or the hub 90, and process data from a combination of compatible sensor assemblies 50 and sensor assemblies 50 having legacy sensors 52L without requiring the pre-loading of any communication or data processing protocols, enables the data monitoring system 2 to have a greatly expanded number of data sources compared to conventional systems.

[0107] A variety of other accessories can be compatible with the communicator 10 and configured to connect thereto either via the communicator connector 28 or the accessory ports 46. For example, with reference to Fig. 3, the data transmission range of the communicator 10 can be increased by utilizing accessories such as range extending repeaters and antennae 98. An external solar panel 100 can be used where lower solar energy is available or where the communicator 10 must be mounted in a low solar energy environment (e.g. behind or inside of a building where access to sunlight is limited or blocked). The accessories can be connected to the communicator 10 via extender cables 92 or any other suitable connection.

[0108] The communicator 10, sensors assemblies 50, communications modules 26 and accessories are all configured to be field swappable. That is, the communicator 10, sensor assemblies 50, and accessories can be changed or replaced in a substantially plug-and-play fashion without a trained technician.

[0109] The data monitoring system 2 provides the ability to easily change the types of sensors 52,52L used, and does not require the communicator 10 to be pre- loaded with the appropriate communication and data processing protocols to send and receive information from the sensors 52,52L. Such an ability to field swap components of the system 2 is advantageous as sensor assemblies 50,50L can be installed on site based on the process being monitored (i.e. pressure, temperature, flow, etc.), and the communicator(s) 10 can be brought in later and connected to the sensor assemblies 50,50L without pre-loading of software required to communicate with the assemblies 50,50L. Additionally, the ability to interchange communications modules 26 of the communicators 10 as need allows an operator to provide specific and varied environmental and consumer communication solutions by simply exchanging communications modules 26 based on the requirements of a particular application.

Manufacture of Components

[0110] In an embodiment, the communicator connector 28 and the sensor connector 54 are two generally tubular or cylindrical complementary components that are designed to be cost effective and easy to manufacture while facilitating the required complexity to meet all assembly requirements. The communicator connector 28 and the sensor connector 54 can be manufactured in high volume and with high precision using modern machining techniques. For example, the elements of the communicator connector 28 and the sensor connector 54 can be designed to allow an arrangement wherein the connectors 28,54 can be manufactured on a single CNC machine configured to complete the entire part. Historically, parts similar in geometric complexity to the communicator and sensor connectors 28,54 would require the use of multiple CNC machines requiring multiple set-ups, resulting in additional cost and potentially sacrificing the accuracy of the finished parts. The design of the connectors 28,54 can be selected to mitigate the need for secondary steps or regrasping of parts during machining. This design reduces costs while retaining accuracy during machining, which affects the accuracy of the connection between the connectors 24,54. More specifically, with reference to Fig. 16, by considering all of the features of the structure of the communicator and sensor connectors 28,54 (i.e. a circular engagement surface, alignment mechanism, sealing surface, spring lock grooves, annular shoulders, and/or locking ring grooves), and how they are positioned on the connectors 28,54, the machining surfaces can be arranged such that the part can be manufactured in a single set-up by grasping the raw material only once or twice in a single multi-axis capable CNC machine. For example, conventionally, an off-center hole on a circular part formerly needed to be turned on a lathe and switched to a vertical mill to machine the hole. In the present embodiment, the same part can be made on a single multi-axis CNC machine. However, care must be taken in the arrangement of the features of the part to ensure the part can be machined on such a multi-axis capable machine. [0111] With reference to Fig. 16, a person of skill in the art and familiar with the function of multi-axis CNC machines can utilize its capabilities to create parts that are fabricated on “one set-up - i.e. a single raw material part inserted and machined without secondary handling” - one raw piece goes in, and all the features are cut before the part comes out complete without anyone touching it. So, by understanding the capability of the multi-axis machine, parts that were made on multiple machines with multiple set-ups and therefore multiple times handled by the operator can often be simplified. A typical key-and-keyway alignment mechanism requires at least five set-ups: one to rough cut the part (for example turning in a lathe), one to cut “half” of the key slot in that part, one to rough cut the mating part (for example also turning it in a lathe), one to cut the key slot in this part and one to cut the actual key. The present solution eliminates the middle man (a broach set up) by imbedding the lock in the part. [0112] In embodiments, once the communicator and sensor connectors

28,54 are coupled, the precise CNC machining of the components makes it difficult to identify the interface between by visual inspection and appreciate that the communicator 10 and sensor assembly 50 can be easily separated, thus providing an additional measure of theft deterrence. Theft deterrence can be enhanced further through electronic means (i.e. a signal can be generated by the communicator 10 alerting the owner or operator that a breach of connection integrity has occurred if the communicator 10 and sensor 50 become unexpectedly separated).

DESIGN OF ELECTRONIC COMPONENTS

[0113] The electrical components of the communicator 10 and communications modules 26, such as the antennae, can be designed to function effectively in the limited space available, and while in close proximity to mechanical components that can affect RF characteristics. For example, the antennae of the communication modules 26 can be PCB mounted antennae that can be tuned. In an embodiment, the RF characteristics of the antennae are measured while the communications module 26 is installed on the communicator 10 to obtain operational parameters, and RF simulations can be run to determine the best combination of components for the circuit board. The RF characteristics can be measured again using the optimized values, and the communications modules 26 can be configured to operate at the optimized values. [0114] The RF design of the communications modules 26 vary based on the communications technology of the modules 26. In general, the physical placement of the antenna, the circuit traces between the RF module (e.g. cell modem) and the antenna and various RF matching components (filters, inductors, capacitors) must be carefully chosen and tested. Even the presence of a non-connected screw or plastic cap can affect the radiated signal.

[0115] Using a cellular communication module 26 as an example, the antenna components are typically assembled with a coaxial cable running to external test equipment, and the entire module 26 is assembled including all screws, plates, labels, etc. The tester measures overall parameters for the physical design which can then be used in RF simulator software to adjust the RF matching parts and circuit board layout to achieve an optimal solution. [0116] As an example, for the cellular communication module 26, a horizontal, PCB mounted antenna from Ethertronics (P/N P822601) was selected for its ability to allow for tuning both the high and low frequency behavior. A double “PI” filter was implemented on the board, with component values for the filter selected by simulations and followed with manual testing. [0117] The components of the communicator 10 and sensor assembly 50 can all be configured to meet intrinsically safe (IS) design requirements to limit the energy of the system and avoid igniting hazardous gases. Although the communication modules 26 require relatively high peak currents, potential regulator designs can be selected to provide the necessary output to power the communications modules 26, but with a circuit model and operating frequencies that reduce the stored energy in the switching components. Examples of switching components include a DC-DC voltage regulator that efficiently converts energy from one voltage to another, similar to a power-line transformer. In the present case, the voltage regulator switches from 5-8V and produces a regulated 3.8V. The output voltage required depends on the type of communications module 26. The circuit arrangement of the main PCB board can be designed such that power is supplied to each individual module of the communicator 10 and sensor assembly 50 (e.g. the sensors 52, accessories, and communication modules 26) through redundant blocking diodes. This arrangement includes each individual sensor 52 as well as the CPU module on the communicator 10. Such an arrangement permits individual sensors 52 and accessories to maintain their own budget of stored energy without needing to consider the total stored energy as a single unit.

[0118] For example, with reference to Fig. 12, zones “MCU IS ZONE” and the multiple “SENSOR x IS ZONE” all draw power from “VMAIN IS ZONE”, but none of them can back-feed energy into this zone due to the blocking diodes. Similarly, energy on the charging system always flows from one side to the other, with blocking diodes preventing energy flowing back.

[0119] To meet IS requirements, it is desirable to lower power consumption of the communicator 10 and sensor assembly 50 while maintaining enough computational power for the communicator 10 to communicate data to and from the sensor assemblies 52, communications module 26, and accessories. To achieve, this, a processor or microcontroller (MCU) of the communicator can be selected capable of operating at low clock speeds. Examples of suitable MCUs include, but are not limited to, a ST Microelectronics 32-bit controller, STM32L476 or other suitable variants in the STM32Lxxx family. In an embodiment, the microcontroller is programmed to operate at the minimum possible clock speed while maintaining normal functionality. Software drivers for the microcontroller can be created to allow the communications tasks of the communicator 10 to be performed with minimal MCU computing resources. [0120] To determine the minimum clock speed of the MCU, an approximate solution can be implemented at a higher clock speed to create a functional starting point. The clock speed can then be lowered until the solution stops functioning. If the clock speed was considered too high, the cause of the problem can be investigated and the code can be rewritten to be more efficient. For example, code was rewritten to be more tightly coupled to particular hardware features of the MCU rather than being more modular or generic. An optimized code can be obtained after one or more solutions are tested that can function on the given processor/MCU at a sufficiently low clock speed. In addition, the power consumption of the communicator 10 can be measured using a high-precision Ammeter, and every source of current leakage can be carefully examined, and every pin on the MCU checked to verify it was operating in the least power consuming mode. Additionally, the firmware of the MCU can be configured to enable/disable the clocks to various accessories according to the need for accessories at any given time, further reducing average current consumption. When short-term computing power is needed, the clock speed can be raised on-the-fly for brief periods, allowing tasks to be performed quickly, then returning to a lower power state (dynamic clock management)

[0121] Further, to meet IS design requirements while incorporating the electronics of the communicator 10 and sensor assemblies 50 in a small physical space, appropriate inter-component clearances must be maintained. Additionally, to maintain reasonable manufacturing costs, it is desirable to implement a design that uses common manufacturing materials and techniques. Thus, the placement of components of the main circuit board 20, and the circuit boards of the communication modules 26 and sensor assemblies 50, must be carefully considered while maintaining the applicable clearance rules. Automated design rules can be implemented in PCB design software to avoid placing conducting materials in inappropriate locations. Examples of potential IS-related PCB design rules include:

• The traces from the “external” pins (not including Ground or GND) must be isolated from the “internal” pins by a clearance of 1.5 mm on a X-Y plane for voltages < 10V, and a clearance of 2.0 mm for voltages > 10V

• The traces from “external” pins must be > 0.5 mm between any other layer of the board, except ground.

• Traces from one zone must be kept away from other zones, (clearance rules above), keeping inter-layer clearances as well.

• These clearances often require larger package sizes on resistors and diodes

• Tracks on protective parts like Zener diodes must be “thick” (varies by the current capacity) to conform to standards and have multiple ground connections in the case of a failed interlayer connections (vias)

• Faults must be analyzed to ensure adequate thermal dissipation is allowed under worst case conditions

[0122] In embodiments, with reference to Fig. 13, an electrical ground is created between the external housing of the sensor assembly 50 and the internal electrical ground to reduce damage from electrostatic discharge. However, creating this electrical ground can introduce ground loops. To address this, the circuit boards for both the sensor assembly 50 and communicator 10 can include a ground ring 102. As shown in Figs. 5A and 5D, the ground ring can be electrically connected to the body of the sensor connector 54 via a conductive screw, which also serves to secure the circuit board of the sensor connector 54 to the body. A toothed washer can be located between the screw and circuit board to provide a more secure engagement. A spring loaded retaining clip can be used to provide a continual electrical connection between the ground ring 102 and mechanical housing (chassis ground) of the component. The chassis ground and signal ground on the sensor PCB is isolated, connected only with a high impedance resistor 104 which provides a mechanism to drain built-up charge but not create a significant ground loop.

[0123] The PCBs of the sensor assemblies 50 and communicator 10 can be protected from vibration using a snap ring with a polymer ring or wave spring to absorb machining discrepancies and mitigate movement of the PCBs when the components experience vibration.

Exemplary Embodiment

[0124] In an example embodiment of the data monitoring system 2, communicators 10 are configured to send and receive data to sensors 52/52L via the RS-485 communication standard, which is a multi-drop, half-duplex standard. The communicators 10 are connected to multiple sensors 52 as shown in Fig. 11A- 11 B. In order to make the components of the system 2 intrinsically safe, each sensor 52/52L is electrically isolated from the other sensors 52/52L such that the electrical properties of one sensor 52/52L do not affect those of another sensor. For example, electrical power is isolated inside each sensor 52/52L by incorporating an intrinsically safe isolator as part of the circuitry of either the sensor 52/52L or adapter 80. Such a circuit can use one or more forward biased diodes to allow current to enter the sensor, but prevent it from flowing out. Further, the communication lines between the sensors 52/52L and communicator 10 can use resistors to limit the current permitted to flow into the RS-485 data lines. The diodes and resistors can be selected to meet intrinsically safe spacing and power dissipation requirements. A block diagram of such an isolation technique is shown in Fig. 12, wherein power leaves the VMAIN IS ZONE and enters each of the sensors. The sensor network is shown in Fig. 12 as the, “IS BARRIER TOKUNET BUS”. In embodiments, the communicator 10 also uses a similar intrinsically safe barrier on its communication lines. In this manner, the communicator 10 and sensors 52/52L are able to function below the limits required to be considered intrinsically safe and rated for use in hazardous locations. Such a configuration also reduces the complexity of the system 2 and enables the sensors 52/52L to be independent of the communicator 10. [0125] Typically, protocols using the RS-485 standard require sensors on the system to be pre-configured with a “slave address” unique to each system. However, such slave addresses are short, and are not globally unique. Specifically, the slave addresses consists of an 8-bit number between 1 and 255. As such, conventional systems have enough addresses to permit sensors to have unique addresses within a closed system, for example in a specific site, but not unique addresses across all systems. This can be problematic when it is desired to monitor a large number of sensors, for example more than 255 sensors, or sensors across various multiple worksites, as two sensors may have the same address. As such, the present system 2 uses a much larger address system, for example a 32-bit address, such that each sensor 52 in the system 2 possesses a globally unique address. Moreover, the system 2 can feature a means to broadcast or query the sensors 52 of the system 2 to discover any sensors 52 that have been connected to the system. [0126] While the apparatus and system have been described in conjunction with the disclosed embodiments and examples which are set forth in detail, it should be understood that this is by illustration only and the apparatus and system are not intended to be limited to these embodiments. On the contrary, this disclosure is intended to cover alternatives, modifications, and equivalents which will become apparent to those skilled in the art in view of this disclosure.