BACKGROUND OF THE INVENTION This invention relates to a device and method for monitoring the angular motion of a rotatable disk, and specifically a device and apparatus for monitoring and deriving power consumption information from the rotatable disk in a standard watt-hour meter.

As is well known in the art, one type of widely used watt-hour meter employs a horizontally disposed rotatable disk which rotates in response to the consumption of electrical energy. Also included in such watt-hour meters are a plurality of dials which electro-mechanically record the number of rotations of the rotatable disk, thereby keeping track of power consumption. In the past, various alternatives to electro- mechanically recording power consumption have been employed to increase the accuracy of the measurement as well as to provide remote sensing capabilities. For example, systems have been designed which use electromagnetic energy (EM) to monitor rotations of the disk by means of the detection of a non-reflective mark on the surface of the disk, or the transmission of the energy through an aperture in the disk. The EM source is usually mounted on the watt-hour meter structure so that its emitted energy impinges upon the surface of the disk. A sensor is positioned so that when the mark, or aperture, passes the EM source, the sensor detects the resulting drop-off in reflected energy, or the transmission of energy through the disk. Some sort of processing circuitry then derives and accumulates energy consumption data from the resulting signal. This data may then be communicated to remote locations by various techniques, including encoded transmission over power lines, or infrared transmission. Examples of such systems are described in U.S. Patent No. 4,399,510 to Hicks, U.S. Patent No. 4,301,508 to Anderson, et al., and U.S. Patent No. 4,350,980 to Ward. Some systems have been developed which have the ability to determine not only the number of rotations, but also the direction of rotation of the disk. This capability is desirable for the detection of unauthorized access to and tampering with power monitoring equipment. Two such systems are described in U.S. Patent No.

4,678,907 to ipski et al., and U.S. Patent No. 4,321,531 to Marshall. Each of these systems employs two photosensitive sensors and associated circuitry to determine the direction of rotation. While such systems have proven to be effective in some applications, the present invention has the advantage of achieving the same capability using only one sensor.

SUMMARY OF THE INVENTION An apparatus for recording information about the angular motion of a rotatable disk disposed in a first structure is provided. The disk has regions with differing properties with respect to electromagnetic energy. The apparatus includes first means for emitting a first sequence of electromagnetic energy pulses in a first direction toward the disk. The first emitting means are mounted on the first structure adjacent a first side of the disk. The apparatus also includes second means for emitting a second sequence of electromagnetic energy pulses in a second direction toward the disk, the second emitting means also being mounted on the first structure adjacent the first side of the disk. The first and second directions are such that the first and second sequences of electromagnetic energy pulses reflect from the first side of the disk in different areas, the areas being separated in the direction of rotation of the disk. Photosensitive means are mounted on the first structure so that they can receive the electromagnetic energy pulses from both the first and second emitting means at a single point. The photosensitive means generate a signal in response to the received electromagnetic energy pulses. A controller coupled to the photosensitive means then processes the signal to determine the number of rotations of the disk, and the direction of rotation of the disk.

In one embodiment of the invention, the first and second emitting means comprise infrared emitting diodes (IREDs), and the photosensitive means comprise a photo diode. Regions on the first side of the disk have differing reflective properties with respect to infrared energy. The controller is coupled to the IREDs causing them to emit infrared pulses in a particular sequence. The pulses reflect from the first side of the disk and are received by the photo diode which generates a signal, the characteristics of which depend upon the regions from which the infrared pulses are reflected. In a particular embodiment, the first structure comprises a standard watt-hour meter.

It should be understood that the invention can be configured not only in a reflective mode as described above, but also in a transmissive mode. In such an

embodiment, the first and second emitting means would be disposed on the opposite side of the rotatable disk from the photosensitive means, the first and second emitting means being spatially separated in the direction of rotation of the disk. Instead of a non- reflective, radiation-absorbing region, the disk would have at least one aperture through which the photosensitive means could sense pulses of electromagnetic energy from the first and second emitting means.

A method for deriving information about the rotation of a rotatable disk using an embodiment of the above-described apparatus is also provided. Electromagnetic energy from the first emitting means is reflected from the first side of the disk and received by the photosensitive means at a first point. A first signal pulse corresponding to the received electromagnetic energy is then generated. Electromagnetic energy from the second emitting means is then reflected off of the disk and received by the photosensitive means at the same point. A second signal pulse corresponding to the received electromagnetic energy is then generated. These steps are repeated, generating a pulse train comprising the first and second signal pulses. The pulse train is then processed to determine the number of rotations of the disk, and the direction of rotation of the disk. For a particular application, the pulse train repetition period and pulse durations are constrained in accordance with the sampling theorem Nyquist rate, depending on the maximum rate of rotation of the disk and its reflective (or transmissive) features.

A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 depicts an assembly designed according to the present invention adapted for mounting in a standard watt-hour meter.

Figs. 2a-2g show various views of the assembly of Fig. 1. Fig. 3 is a schematic diagram of a particular embodiment of the present invention.

Fig. 4 is a state diagram illustrating the operation of a particular embodiment of the present invention.

DESCRIPTION OF THE SPECIFIC EMBODIMENTS Fig. 1 depicts an assembly designed according to a particular embodiment of the present invention. A housing 10 is adapted for mounting in a standard watt-hour meter. Two infrared emitting diodes (IREDs) 12 are mounted in housing 10 on either side of a photo diode 14. IREDs 12 are mounted so that the infrared energy emitted from each IRED reflects off of the surface of a rotatable disk 16 and is received by photo diode 14. The infrared energy from each IRED 12 reflects off of slightly separated areas on the bottom surface of disk 16. The areas are separated in the direction of rotation of the disk. The spread of the infrared "beam" from each IRED is roughly 25° from the center of the beam as shown by angle in the figure. Fig. 1 also illustrates the effect that a slight misalignment of the right IRED has on the angle of incidence of the reflected infrared energy. Solid line 18 represents the center axis of the infrared energy beam for the preferred mounting angle, and dashed line 20 represents the center axis of the beam for a 4° rotation in the mounting angle (angle β). The preferred mounting angle sets up an angle of approximately 28.8° between the center axis of the infrared energy beam and the vertical. As is shown in the figure, the center axis of the reflected energy deviates only slightly from the center of photo diode 14, even with a substantial misalignment. Thus, this configuration ensures that even if either, or both, of the IREDs are misaligned, infrared energy of sufficient intensity will reach the photo diode to enable proper operation. Figs. 2a-2g show various views of housing 10 of Fig. 1.

Fig. 3 is a schematic diagram of a particular embodiment of the present invention. The anodes of IREDs 12 are pulsed by NPN driver transistors Ql and Q2 under the firmware timing control of a microcontroller U3. The network comprising resistors R12, R18, R19, and thermistor RT1 determines the drive current level for

IREDs 12, with RT1 providing compensation for the variation of IRED output irradiance with temperature. The photo diode 14 receives input in the form of infrared energy reflected from a rotatable disk (not shown). Output current pulses from photo diode 14 are then conditioned by a two stage ac-coupled operational amplifier circuit 22 with a decision threshold set by a voltage divider comprising R27, R35, and R29. The resulting output is received by a comparator embedded in microcontroller U3. The comparator output is a logic high for high amplitude pulses which exceed the decision threshold, and a logic low for low amplitude pulses which do not exceed the decision threshold.

Firmware in microcontroller U3 implements a periodic sequence of drive pulses and state machine logic for processing, tracking, and decoding the power .consumption information contained in the reflected infrared energy. The firmware determines disk rotational direction and accumulates the result as encoded registration of accumulated energy consumption, matching the external watt-hour meter's electro-mechanical register.

The operation of the above-described embodiment is as follows. IREDs 12 are periodically pulsed in sequence. Sequence timing is determined by the microcontroller's crystal oscillator 13 which is stable with respect to initial tolerance, temperature, and aging to within ±, 500 parts per million. The resulting range of periods is 976.1 μs to 977.1 μs, with a preferred period of 976.6 μs. During each period, the left IRED is turned on first for a first interval. Both IREDs are then held off for a second interval. Then the right IRED is turned on for a third interval. The duration of the first interval is 17.28 μs to 17.30 μs, with a preferred duration of 17.29 μs. The duration of the second interval is 0 to 1.018 μs, with a preferred duration of 1.017 μs. The duration of the third interval is 19.32 μs to 19.34 μs, with a preferred duration of 19.33 μs. Finally, both IREDs are held off for the remainder of the period, the duration of this interval being 939.0 μs when the other intervals are the preferred durations. The output of photo diode 14 follows this pulse sequence yielding high amplitude output current pulses when receiving reflected energy from the shiny metal disk surface; and receiving much lower amplitude pulses when receiving reflected energy from a specially installed stripe of infrared absorbing paint along a particular radius on the disk's bottom surface. As the disk rotates during normal power consumption (i.e., in a counterclockwise direction), the stripe's leading edge passes through the left IRED's reflecting area, and then through the right IRED's reflecting area. As disk rotation continues, the stripe's trailing edge clears the left IRED, and then the right IRED, so that their radiated energy once again reflects off of the shinier metal disk surface to the photo diode. Due to the input sequence of pulses, the pulse train which appears at the output of the photo diode has well defined characteristics which are recognized and processed by the controller. Under exceptional conditions (e.g., tampering), the meter disk rotates in the reverse or clockwise direction. In such cases, the radiation-absorbing stripe passes over the right IRED first. The characteristics of the resulting pulse train are distinctly different from those of the pulse train produced under normal conditions. Upon the

occurrence of such an event, the controller is able to determine the direction of rotation of the disk due to the predictable variations in the photo diode signal.

It should be understood that the invention can be configured not only in a reflective mode as described above, but also in a transmissive mode. In such an embodiment, the two IREDs would be disposed on the opposite side of the rotatable disk from the photosensitive device, the IREDs being spatially separated in the direction of rotation of the disk. Instead of a radiation-absorbing stripe, the disk would have at least one aperture through which the photo diode could sense the infrared pulses from the IREDs. In a transmissive embodiment, the firmware would be suitably altered to recognize and process infrared pulses in a complementary manner with respect to the reflective embodiment described above. The present invention may also be adapted to recognize fractional rotations of the disk using multiple radiation-absorbing stripes or transmissive apertures.

It should also be understood that the interval durations discussed above represent only one embodiment of the invention. Interval durations can vary widely for different applications. For example, not only can the interval between the pulsing of the two IREDs be of zero duration, but these pulses can theoretically overlap. As long as the sampling rate is chosen so that the microcontroller can determine from which IRED a particular pulse is coming, it is not necessary to insert a positive interval between the two pulses. The maximum sampling rate is limited by such factors as the rise and fall times of the optoelectronic devices, amplifier settling times, and the amount of microcontroller time available.

The durations of the IRED pulses can also deviate substantially from the specific values of the above-described embodiment. Factors to be considered when determining interval durations for a specific application are the size of the features of the rotatable disk, the reflective (or transmissive) properties of the disk, and the maximum rotational rate of the disk. As mentioned above, the pulse train repetition period and pulse durations are constrained in accordance with the sampling theorem Nyquist rate, depending on these factors. Correct operation of the photo diode over the range of meter types, electronic component parameter variation, and operating conditions (e.g., temperature, mounting alignment, and the 20 to 30 year operational life), depends on the proper choice of the decision threshold level. The threshold level is chosen so that it lies

between pulse amplitudes estimated for the worst case (i.e., least reflective) shiny metal disk surface and the worst case (i.e., most reflective) infrared-absorbing stripe.

Fig. 4 is a state diagram illustrating the operation of the embodiment of Fig. 3 according to the firmware. When power is supplied to the invention, the circuitry comes up initially in state 5. State transitions occur according to the events L and R. The event L represents that the left IRED has been energized and a photo diode output pulse which exceeds the decision threshold was registered. The event R represents an equivalent event for the right IRED. L\R represents the occurrence of both events L and R, while a bar over this symbol represents the non-occurrence of the event. State changes do not occur where there is no change in the output pulse train.

The firmware code represented by the state diagram of Fig. 4 is included in Appendix A.

While the invention has been particularly shown and described with reference to a specific embodiment thereof, it will be understood by those skilled in the art that the foregoing and other changes in the form and details may be made therein without departing from the spirit or scope of the invention.

10

Appendix A

15 Firmware Listing

.FORM

323 323 PI State Machine 3 ₂ 3 323 Sample current PI input, flag PI sensor tamper 323 If input has changed, execute the state machine. 323

32302039FD2 323020572 3230206 BD0B6C 32302099FD0 323020B7D 323020C64 323020D AO 323020E 9FD2 3230210 B8 3230211 B8 3230212 B8 3230213 B8 323021472 32302158A 323021672 32302178A 323021872 32302198A 323021A 9FD0 323021C 6D 323021D 7C 323021E 9301 3230220 Al 323022164 32302229FD2 3230224 B8 3230225 B8 3230226 B8 3230227 B8 323022872 32302298A 323022A72 323022B 8A 323022C72 323022D 8A 323022E9FD0 32302306C 323

32302319301 323023302 323023464 323023502 323 L10:

LD A,«

323 L20: ;Reg a has new sample

323 0238 A8

323 0239 9600

323 023B 9F3C

323 023D 82

323 023E 22A1

323 0240 A6

323 0241 9847

323 0243 BD3D84

323 0246 A5

323 TBPI:

323 0247 86

323 0248 69

323 0249 8E

323 024A 71

323 024B 55

323 024C 4D

323 PD : ^• State 5: Initial PI machine state

323 024D TSTST 4,(PIL!PIR)

323 024D 9803 LD A,#(PIL1PIR)

323 024F 82 IFEQ A,[B]

323 0250 BC3D04 LD PBTAT,*t

323 0253 22A1 JMP PIDONE

323 PIC: ^• State 4: Center PI Machine State

323 0255

323 0255 9802

323 0257 82

323 0258 BC3D00

323 025B

323 025B 9801

323 025D 82

323 025E BC3D01

323 0261

323 0261 9800

323 0263 82

323 0264 BC3D05

323 0267 22A1

323

323 CW1: ;State 1: Clockwise 1 PI State

323 0269

323 0269 9802

323 026B 82

323 026C BC3D03

323 026F 224D

323 CW2: ;State 3: Clockwise 2 PI State

323 0271

323 0271 9801

323 0273 82

323 0274 BC3D01

323 0279 B9

323 027A 22A1

323 ;Count (pulse) a clockwise hole

323 027C 9F3E

323 027EAE

323 027F 8A

323 0280 A6

323 0281 BC3D04

323 028422A1

323 ^• State 0: Counter-clockwise 1 PI State

323 0286

323 02869801

323 0288 82

323 0289 BC3D02

323 028C 224D

323 ;State 2: Counter-clockwise 2 PI State

323 028E

323 028E 9802

323 029082

323 0291 BC3D0O

323 0294 9803

323 0296 B9

323 029722A1

323 ;Count (pulse) a counter-clockwise hole

323 02999F3F

323 029B AE

323 029C 8A

323 029D A6

323 029E BC3D04

323

323