Monitoring device for air filtration system

Abstract

Aspects herein include a monitoring device for a filtration system. An embodiment of a monitoring device may include a first fluid conduit and a first pressure sensor, where the first pressure sensor is in fluid communication with the first fluid conduit. The monitoring device may also include a second fluid conduit and a second pressure sensor, where the second pressure sensor is in fluid communication with the second fluid conduit. The monitoring device may also include a control circuit in electronic communication with the first pressure sensor and the second pressure sensor. The monitoring device can further comprise a shell, and the first pressure sensor, the second pressure sensor and the control circuit are all arranged in the shell. Other embodiments are also included herein.

Description

[0001] This application was filed on October 23, 2019, as a PCT international patent application in the name of Donaldson Company, Inc., a United States national corporation and applicant designated in all countries, and United States citizens Wade A. Wessels, Peter P. Vitko, and Brent R. Nelson, inventors designated in all countries, and claims the priority of United States Provisional Patent Application No. 62 / 750,638, filed on October 25, 2018, the entire content of which is incorporated herein by reference. Technical Field

[0002] Embodiments herein relate to a monitoring device for a filtration system and related methods, where the systems include the monitoring device. Background Art

[0003] Many industries encounter particulate matter suspended in the atmosphere. In some industries, this particulate matter is a valuable product (e.g., starch), and it would be beneficial if the suspended particulate matter could be recovered and reintroduced into the processing. For other industries (e.g., metal or wood processing), it may be necessary to remove particulate matter from the air to provide a clean working environment.

[0004] Particulate matter can also affect the intake air flow to the engines of motor vehicles or power generation equipment, the gas flow directed to gas turbines, and the air flow to various different combustion furnaces. In these contexts, particulate matter can cause substantial damage to the internal workings of the various different mechanisms involved if it reaches them.

[0005] A wide variety of air filter or gas filter arrangements have been developed for removing particulate matter. In some scenarios, systems for cleaning air or other gas flows carrying particulate matter include air filter assemblies having filter elements disposed within a housing. The filter elements can be bags, sleeves, or cartridges containing a suitable filter medium (e.g., fabric, pleated paper, etc.). The gas flow contaminated with particulate matter typically passes through the housing such that the particulate matter is captured and retained by one or more of the filter elements. Summary of the Invention

[0006] Embodiments include a monitoring device for a filtration system and related methods, where such systems include the monitoring device. In an embodiment, there is provided a monitoring device for a filtration system. The monitoring device may include a first fluid conduit and a first pressure sensor, where the first pressure sensor is in fluid communication with the first fluid conduit. The monitoring device may further include a second fluid conduit and a second pressure sensor, where the second pressure sensor is in fluid communication with the second fluid conduit. The monitoring device may further include a control circuit in electronic communication with the first pressure sensor and the second pressure sensor. The monitoring device may further include a housing, where the first pressure sensor, the second pressure sensor, and the control circuit are all disposed within the housing.

[0007] In an embodiment, there is provided a filtration system. The air filtration system may include a housing configured to receive therein a filter element through which a fluid flows, the filter element including an upstream side and a downstream side. The system may further include a monitoring device including a first fluid conduit in fluid communication with the upstream side of the filter element and a first pressure sensor, where the first pressure sensor is in fluid communication with the first fluid conduit. The monitoring device may further include a second fluid conduit in fluid communication with the downstream side of the filter element and a second pressure sensor, where the second pressure sensor is in fluid communication with the second fluid conduit. The monitoring device may further include a monitoring device control circuit in electronic communication with the first pressure sensor and the second pressure sensor. The monitoring device may further include a housing, where the first pressure sensor, the second pressure sensor, and the control circuit are all disposed within the housing.

[0008] In an embodiment, there is provided a method for remotely monitoring a pre-installed dust collector system. The method may include mounting a monitoring device on an outer surface of a housing of the pre-installed dust collector system. The monitoring device may include a first fluid conduit and a first pressure sensor, where the first pressure sensor is in fluid communication with the first fluid conduit. The monitoring device may further include a second fluid conduit and a second pressure sensor, where the second pressure sensor is in fluid communication with the second fluid conduit. The monitoring device may further include a control circuit in electronic communication with the first pressure sensor and the second pressure sensor. The monitoring device may further include a housing, where the first pressure sensor, the second pressure sensor, and the control circuit are all disposed within the housing.

[0009] In an embodiment, a kit including a monitoring device is provided. The kit may include a first fluid conduit and a first connector for connecting the first fluid conduit to a first existing fluid conduit of a filtration system. The kit may include a second fluid conduit and a second connector for connecting the second fluid conduit to a second existing fluid conduit of the filtration system. The kit may further include a monitoring device. The monitoring device may include a first pressure sensor for sensing the pressure within the first fluid conduit. The monitoring device may further include a second pressure sensor for sensing the pressure within the second fluid conduit. The monitoring device may further include a monitoring device control circuit in electronic communication with the first pressure sensor and the second pressure sensor. The monitoring device may further include a housing, wherein the first pressure sensor, the second pressure sensor, and the control circuit are all disposed within the housing.

[0010] This Summary is a general overview of some teachings of the present application and is not intended to be an exclusive or exhaustive treatment of the subject matter. Further details may be found in the detailed description and the appended claims. After reading and understanding the following detailed description and viewing the drawings that form a part of the detailed description, other aspects will be apparent to those of ordinary skill in the art, and each of these aspects should not be considered limiting. The scope of this disclosure is defined by the appended claims and their legal equivalents. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Aspects may be more fully understood in connection with the following drawings, in which:

[0012] Figure 1 is a schematic perspective front view of an air filtration system having a monitoring device in accordance with various different embodiments herein.

[0013] Figure 2 is a schematic cross-sectional view of some aspects of an air filtration system in accordance with various different embodiments herein.

[0014] Figure 3 is a schematic perspective rear view of an air filtration system having a monitoring device in accordance with various different embodiments herein.

[0015] Figure 4 is a schematic view of a monitoring device in accordance with various different embodiments herein.

[0016] Figure 5 is a schematic view of the components of a monitoring device in accordance with various different embodiments herein.

[0017] Figure 6 is a schematic view of the components of a monitoring device in accordance with various different embodiments herein.

[0018] Figure 7Schematic diagram of a data communication environment of a filtration system according to various different embodiments herein.

[0019] Figure 8 Schematic diagram of a data communication environment of a filtration system according to various different embodiments herein.

[0020] Figure 9 Schematic perspective front view of an air filtration system having a monitoring device according to various different embodiments herein.

[0021] Figure 10 Schematic perspective front view of an air filtration system having a monitoring device according to various different embodiments herein.

[0022] Although the embodiments are susceptible to various modifications and alternative forms, details thereof have been shown by way of example and will be described in detail. However, it should be understood that the scope herein is not limited to the specific embodiments described. On the contrary, the invention will cover modifications, equivalents, and alternatives falling within the spirit and scope herein. Detailed Description

[0023] As described above, there are many scenarios where it is useful to filter particulate matter from an air stream, and there are many different types of air filtration systems to achieve this effect. In one type of air filtration system, the system has a clean air chamber (or clean / downstream side) and a dirty air chamber (or dirty / upstream side). These two chambers can be separated by a structure that can be referred to as a tube sheet. In many cases, the tube sheet has a plurality of openings such that air can pass between the clean air chamber and the dirty air chamber. The filter element can be positioned above the openings such that the particulate-laden air (dirty air) introduced into the dirty air chamber must pass through the filter element to move into the clean air chamber. The particulate matter in the dirty air is collected on the filter element as the air moves through the filter element. The clean air is discharged from the clean air chamber into the environment or recycled for other uses.

[0024] As the filter element captures particulate matter, the flow through the system is inhibited and periodic cleaning of the filter element can be performed to increase the airflow through the system. The cleaning can be achieved by the following steps: periodically sending a short air jet (such as pressurized air) pulse into the interior of the filter element (which can include filter cartridges, filter bags, etc.) to reverse the airflow through the filter element, thereby causing the collected particulate matter to leave the filter element. In some cases, the pressurized air can be directed into a pulse collector as described below: for example, U.S. Patent No. 3,942,962 (Duyckinck), U.S. Patent No. 4,218,227 (Frey), U.S. Patent No. 6,090,173 (Johnson et al.), U.S. Patent No. 4,395,269, U.S. Patent No. 6,902,592 (Green et al.), U.S. Patent No. 7,641,708 (Kosmider et al.), and U.S. Patent Application Publication No. US2006 / 0112667A1, the contents of all of these patent applications are incorporated herein by reference.

[0025] Keeping these air filtration systems in optimal operating condition can include periodic maintenance, including but not limited to replacing / cleaning the filter element, monitoring and replacing the pulse valve, etc. The monitoring aspect of the system can provide cues related to the optimal time to perform such maintenance activities and determining any other issues that may affect the performance of the filtration system. It can be more advantageous to be able to remotely monitor such systems, as the observed information from many different systems can be aggregated and analyzed and then utilized to improve the accuracy of determination (such as the appropriate time to perform system maintenance).

[0026] Many filtration systems are robustly constructed such that their service life can extend for decades with proper maintenance. However, this thereby means that advanced technologies including sensors and processors are implemented slowly when they are only set as part of the original equipment.

[0027] According to multiple different embodiments herein, a monitoring device is included, and the monitoring device can be easily installed on existing filtration systems lacking such monitoring capabilities. In this way, existing filtration systems can be retrofitted to include advanced monitoring capabilities.

[0028] Now referring to Figure 1 , a schematic perspective front view of an air filtration system 100 having a monitoring device 150 is shown in accordance with multiple different embodiments herein. In this example, Figure 1 the air filtration system 100 depicted in Figure 1 is generally box-shaped and includes an upper wall panel 116, and two pairs of opposing side wall panels 117 (

[0029] The air filtration system 100 includes a dirty air duct 111 for receiving dirty or contaminated air (i.e., air having particulate matter therein) into the air filtration system 100. A clean air duct 113 (see, for example Figure 2 ) may be provided for discharging clean or filtered air from the air filtration system 100. The air filtration system 100 includes access openings 112 for a plurality of filter elements ( Figure 1 , not shown in the figure). In use, each of the access openings 112 is sealed by a cover (not shown) such that the dirty air entering the air filtration system 100 does not escape through the access openings 112.

[0030] The air filtration system 100 may also include a hopper 118 for collecting particulate matter separated from the dirty air stream, as described herein. The hopper 118 may include sloped walls to facilitate the collection of particulate matter and, in some embodiments, may include a driven auger or other mechanism for removing the collected particulate matter.

[0031] In some embodiments, the air filtration system 100 may include a fan 132 to move air through the air filtration system 100. However, in other embodiments, air may be drawn through the system by a fan or other device that is not part of the air filtration system 100. The air filtration system 100 may include an existing control box 140, which may include existing control circuitry for the filtration system.

[0032] A monitoring device 150 may be connected to a first fluid conduit 152, a second fluid conduit 154, and a third fluid conduit 156. The fluid conduits may provide fluid communication between multiple different parts of the filtration system (such as the dirty / upstream side, the clean / downstream side, a compressed air source, etc.) and sensors / transducers that may be within or otherwise associated with the monitoring device 150. The first fluid conduit 152 may be connected to an existing fluid conduit 162 of the air filtration system, which provides fluid communication with the fluid flow region upstream of the filter element. In some embodiments, the first fluid conduit 152 may be connected to the existing fluid conduit 162 using a fitting 166 (such as a T-joint, a split joint, or other connection structure). The second fluid conduit 154 may be connected to an existing fluid conduit 164 of the air filtration system, which provides fluid communication with the fluid flow region upstream of the filter element. In some embodiments, the second fluid conduit 154 may be connected to the existing fluid conduit 164 using a fitting 168 (such as a T-joint, a split joint, or other similar connection structure).

[0033] In some embodiments, there is no electrical connectivity between the existing control box 140 and / or components therein (such as the existing control circuitry and monitoring device 150). While not being bound by theory, it is believed that this electrical separation can provide a safety advantage because the existing control box 140 and components therein are responsible for operating the filtration system 100, while the monitoring device 150 is only responsible for monitoring the filtration system 100. In this way, the monitoring device 150 cannot be used as a means to obtain control over the operation of the filtration system 100.

[0034] Now referring to Figure 2 , a schematic cross-sectional view of some aspects of an air filtration system 100 in accordance with several different embodiments herein is shown. The interior of the air filtration system 100 includes a tube sheet 222 that divides the interior of the housing into a clean air chamber 224 and a dirty air chamber 226. The air filtration system 100 includes a clean air conduit 113 through which clean air exits the clean air chamber 224 during operation of the air filtration system 100.

[0035] The depicted air filtration system 100 includes a pulse collector 230 and a filter element 240 in the dirty air chamber 226 (dirty side or upstream side). The pulse collector 230 is attached to the tube sheet 222 above an opening ( Figure 2 not shown) in the tube sheet 222 such that air pulses pass from a pulse generator 250 through the pulse collector 230 into the internal volume of the filter element 240. Air can be provided to the pulse generator 250 from a compressed air manifold 248 which itself can receive air from an air compressor or a central source of plant compressed air.

[0036] Now referring to Figure 3 , a schematic rear perspective view of an air filtration system having a monitoring device in accordance with several different embodiments herein is shown. Figure 3 Shown are Figure 1 and Figure 2 many of the same elements as shown, but shown in a rear perspective view.

[0037] Now referring to Figure 4, which shows a schematic diagram of the monitoring device 150 according to multiple different embodiments herein. The monitoring device 150 may include a first socket 402 or a fitting for receiving a tube or other conduit that is part of the first fluid conduit 152. The monitoring device 150 may also include a second socket 404 or a fitting for receiving a tube or other conduit that is part of the second fluid conduit 154. Although not shown in this figure, it will be understood that the monitoring device 150 may also include a third socket or a fitting for receiving a tube or other conduit that is part of the third fluid conduit 156. Additionally, multiple different embodiments herein may include a greater or lesser number of sockets and / or fluid conduits.

[0038] In multiple different embodiments, the monitoring device 150 may be mounted on the surface of the air filtration system 100, such as on the outer surface of the air filtration system. For example, in some embodiments, the monitoring device 150 may be mounted on the sidewall panel 117. However, the monitoring device 150 may also be mounted in other locations, including the top wall or bottom wall and inside the filtration system 100, and may also be mounted outside the filtration system 100 (such as on a separate plate physically separated from other components of the system). The monitoring device may be mounted using a variety of different hardware, including but not limited to using fasteners, adhesives, magnets, etc. In a particular embodiment, an adhesive layer 406 is used to mount the housing of the monitoring device 150, which may be, for example, a pressure-sensitive adhesive (PSA).

[0039] Now referring to Figure 5 , which shows a schematic diagram of the elements of the monitoring device 150 according to multiple different embodiments herein. It will be understood that multiple different embodiments may include a greater or lesser number of components, and this schematic diagram is merely exemplary. The monitoring device 150 may include a housing 502 and a control circuit 504.

[0040] The control circuit 504 may include a variety of different electronic components, including but not limited to a microprocessor, a microcontroller, an FPGA (field programmable gate array) chip, an application-specific integrated circuit (ASIC), etc.

[0041] In multiple different embodiments, the monitoring device 150 may include a first pressure sensor 506 (as used herein, unless the context otherwise indicates, a pressure sensor shall include a pressure transducer) and a first fluid conduit 152, which includes an internal portion 508 and an external portion 510. The first fluid conduit may be in fluid communication with the dirty air chamber 226.

[0042] In multiple different embodiments, the monitoring device 150 can include a second pressure sensor 514 and a second fluid conduit 154, and the second fluid conduit includes an internal portion 516 and an external portion 518. The second fluid conduit can be in fluid communication with the clean air chamber 224.

[0043] In multiple different embodiments, the monitoring device 150 can include a third pressure sensor 522 and a third fluid conduit 156, and the third fluid conduit includes an internal portion 524 and an external portion 526. The third fluid conduit can be in fluid communication with the compressed air manifold 248. Thus, the third fluid conduit can be in fluid communication with a compressed gas source.

[0044] The pressure sensors herein can be of various types. The pressure sensors can include, but are not limited to, strain pressure sensors, capacitive pressure sensors, piezoelectric pressure sensors, etc. In some embodiments, the pressure sensors herein can be MEMS-based pressure sensors.

[0045] The processing power of the control circuit 504 and its components can be sufficient to perform a variety of different operations, including a variety of different operations on data from sensors such as pressure sensors 506, 514, and 522, including but not limited to averaging, time averaging, statistical analysis, normalization, aggregation, sorting, deletion, traversal, transformation, compaction (such as eliminating selected data and / or converting data to a finer-grained form), compression (such as using a compression algorithm), merging, insertion, timestamping, filtering, discarding outliers, calculating trends and trend lines (linear, logarithmic, polynomial, power, exponential, moving average, etc.), predicting the EOL (end of life) of the filter element, identifying EOL conditions, predicting performance, predicting the cost associated with replacing the filter element and the cost associated with not replacing the filter element, etc.

[0046] The normalization operation performed by the control circuit 504 can include, but is not limited to, adjusting one or more values based on another value or another set of values. Merely as an example, the pressure drop data reflecting the pressure drop across the filter element can be normalized by considering the air flow rate or an index value used therefor.

[0047] In multiple different embodiments, the control circuit can calculate the time to replace the filter element and generate a signal related to the replacement time. In multiple different embodiments, the control circuit can calculate the time to replace the filter element and issue a notification related to the replacement time through a user output device. In multiple different embodiments, the control circuit can calculate the time to replace the filter element based on signals from the first pressure sensor and the second pressure sensor. In multiple different embodiments, the control circuit can calculate the time to replace the filter element based on signals from the first pressure sensor, the second pressure sensor, and an external input. The external input can be received from a system user or from a remote location through a data communication network.

[0048] In multiple different embodiments, if a predetermined alarm condition is met, the control circuit activates an alarm. The alarm condition can include one or more of the following: the maximum value of the signal received from the first pressure sensor, the minimum value of the signal received from the first pressure sensor, the maximum value of the signal received from the second pressure sensor, the minimum value of the signal received from the second pressure sensor, the maximum difference between the value of the signal received from the first pressure sensor and the value of the signal received from the second pressure sensor, and the minimum difference between the value of the signal received from the first pressure sensor and the value of the signal received from the second pressure sensor.

[0049] In multiple different embodiments, the control circuit 504 can be configured to calculate a value related to the fluid flow rate through the filtration system based on the value provided by the first pressure sensor and the value provided by the second pressure sensor. In some embodiments, the control circuit 504 can be configured to calculate a value related to the fluid flow rate through the filtration system based on the static pressure value, where the static pressure value is based on a signal from at least one of the first pressure sensor and the second pressure sensor. In some embodiments, the control circuit can be configured to calculate a value related to the fluid flow rate through the filtration system based on the pressure difference value and the static pressure value, where the pressure difference value is determined based on signals from both the first pressure sensor and the second pressure sensor, and the static pressure value is determined based on a signal from one of the first pressure sensor and the second pressure sensor.

[0050] The fluid flow rate of the system is determined by the characteristics of the power source. For fan-based applications, the relationship between static pressure and fluid flow is generally inverse in nature. Due to the operating characteristics of the fan, as the system resistance increases, the fluid flow rate decreases as measured by static pressure, and vice versa. Since the fluid flow rate of the fan directly affects the fluid flow rate of other parts of the system, the fluid flow rate index of the fan and thus the filtration system can be calculated using the static pressure at a fixed location in the system. Generally, the static pressure in the fluid pipe is proportional to the square of the fluid flow rate. As an example, the flow rate index value can be calculated according to the equation Calculated as follows, where FRP = flow rate index value, Ps is the static pressure value, Pi is the system design point static pressure, and Qi is the optional system design point fluid flow rate.

[0051] In some embodiments, the fan curve can also be used to calculate the flow rate value. The fan curve can be used to correlate the static pressure with the flow rate. In a number of different embodiments, the monitoring device 150 can store the fan curve in a memory (the fan curve can be written into the memory when manufacturing the monitoring device 150, or it can be received / updated when the monitoring device 150 is installed on the filtration system in the field or after installation based on data received via a network connection).

[0052] In some embodiments, the monitoring device 150 can include additional sensors, such as an accelerometer. For example, the monitoring device 150 can include a triaxial accelerometer 530. The triaxial accelerometer 530 can be used to detect vibrations transmitted from the filtration system to the monitoring device 150. These vibrations can be caused by a variety of different events, such as periodically sending short pressurized air jet pulses into the interior of the filter element to reverse the airflow through the filter element and / or (a plurality of) valves, thereby opening or closing them to achieve the same effect.

[0053] In some cases, mounting the accelerometer in the monitoring device 150 helps it receive vibrations from the filtration system with minimal vibration attenuation in terms of frequency range and amplitude. In some embodiments, the accelerometer can be arranged within the housing such that the vibration occurring on the contact surface of the monitoring device housing is attenuated by less than 50% compared to the vibration occurring on the accelerometer. In some embodiments, the accelerometer can be arranged within the housing such that the vibration occurring on the contact surface of the monitoring device housing is attenuated by less than 10% compared to the vibration occurring on the accelerometer.

[0054] In a number of different embodiments, the monitoring device 150 can include a power supply circuit 532. In some embodiments, the power supply circuit 532 can include a number of different components, including but not limited to a battery 534, capacitors, a power receiver such as a wireless power receiver, a transformer, a rectifier, etc.

[0055] In a number of different embodiments, the monitoring device 150 can include an output device 536. The output device 536 can include a number of different components for visual and / or audio output, including but not limited to lights such as LED lights, a display screen, a speaker, etc. In some embodiments, the output device can be used to provide notifications or warnings to the system user, such as the current system status, problem indications, required user intervention, the appropriate time to perform maintenance actions, etc.

[0056] In multiple different embodiments, the monitoring device 150 may include a memory 538 and / or a storage controller. The memory may include a variety of different types of memory components, including dynamic RAM (D-RAM), read-only memory (ROM), static RAM (S-RAM), disk storage devices, flash memory, EEPROM, battery-powered RAM such as S-RAM or D-RAM, and any other type of digital data storage component. In some embodiments, the electronic circuit or electronic component includes volatile memory. In some embodiments, the electronic circuit or electronic component includes non-volatile memory. In some embodiments, the electronic circuit or electronic component may include transistors that are interconnected to operate as a latch or flip-flop to provide positive feedback, thereby enabling the circuit to have two or more metastable states and remain in one of these states until changed by an external input. Data storage may be based on such flip-flops that contain circuits. Data storage may also be based on charge storage in a capacitor or based on other principles. In some embodiments, the non-volatile memory 538 may be integrated with the control circuit 504.

[0057] In multiple different embodiments, the monitoring device 150 may include a clock circuit 540. In some embodiments, the clock circuit 540 may be integrated with the control circuit 504. Although not shown in Figure 5 it will be understood that multiple different embodiments herein may include a data / communication bus to provide data transfer between components. In some embodiments, an analog signal interface may be included. In some embodiments, a digital signal interface may be included.

[0058] In multiple different embodiments, the monitoring device 150 may include a communication circuit 542. In multiple different embodiments, the communication circuit may include components such as an antenna 544, an amplifier, a filter, a digital-to-analog converter, and / or an analog-to-digital converter.

[0059] In multiple different embodiments, the monitoring device 150 herein is designed such that its operation can be powered only by a battery and will not be depleted over a relatively long period of time such as weeks, months, or even years. Thus, in multiple different embodiments, the operation of the monitoring device 150 can be optimized to save energy consumption.

[0060] In some embodiments, the control circuit causes a temporary change in the data recording parameter based on a signal received from the third pressure sensor. In some embodiments, the temporary change in the data recording parameter includes increasing the resolution of the recorded data. In some embodiments, the temporary change in the data recording parameter includes changing the resolution of the recorded data. In some embodiments, changing the resolution may include increasing or decreasing the sampling frequency.

[0061] In some embodiments, the first pressure sensor and the second pressure generate signals discontinuously. In some embodiments, the first pressure sensor and the second pressure generate signals at a predetermined time interval.

[0062] Now referring to Figure 6 , a schematic diagram of the components of the monitoring device 150 according to various different embodiments herein is shown. Figure 6 Comprising Figure 5 the various different components shown. As Figure 6 depicted in, the monitoring device 150 may also be in electrical communication with a DC power source, and / or may include a transformer 602. The monitoring device 150 may also include an input interface 604 and / or a user input device.

[0063] The monitoring device 150 may also include a low-energy local wireless communication component 608. In some embodiments, the low-energy local wireless communication component 608 may include a Bluetooth component. In some embodiments, the monitoring device 150 may also include a wired I / O interface 610 and one or more wire connection ports or plug sockets 612.

[0064] The monitoring device 150 may include a plurality of different other sensors. In some embodiments, the monitoring device 150 may also include a temperature sensor 614. The temperature sensor 614 may be in fluid communication with at least one of the first fluid conduit, the second fluid conduit, and the third fluid conduit.

[0065] In some embodiments, the monitoring device 150 may also include a humidity sensor 616. In some embodiments, the monitoring device 150 may also include a sound sensor 618, such as a microphone. The sound sensor 618 may be in fluid communication with at least one of the first fluid conduit, the second fluid conduit, and the third fluid conduit.

[0066] Now referring to Figure 7 , a schematic diagram of the filtration system data communication environment 700 according to various different embodiments herein is shown. The communication environment 700 may include an air filtration system 100, such as a dust collector. In some embodiments, the filtration system 100 may be within a working environment 702. The working environment 702 may represent the geographical area in which the air filtration system 100 operates. The working environment 702 may be, for example, a transportation or distribution center, a production facility, etc.

[0067] In some embodiments, wireless signals from the filtration system 100 may be exchanged with a wireless communication tower 720 (or antenna array), which may be a cellular tower or other wireless communication tower. The wireless communication tower 720 may be connected to a data network 722, such as the Internet or another type of public or private data network, a packet-switched network, or other network.

[0068] The data network can provide one-way or two-way communication with other components external to the work environment 702. For example, the server 724 or other processing device can receive an electronic signal containing data from one or more components, such as the filtration system 100. The server 724 can interface with the database 726 to store the data. In some embodiments, the server 724 (or a device that is part of a server system) can interface with the user device 728, which can allow a user to query the data stored in the database 726. The server 724 and / or the database 726 can be located in different physical locations or can be located in the cloud.

[0069] Now referring to Figure 8 , a schematic diagram of a filtration system data communication environment 700 in accordance with multiple different embodiments herein is shown. In some embodiments, a gateway or repeater unit 810 can be disposed within the work environment 702. In some embodiments, the gateway or repeater unit 810 can communicate wirelessly with the filtration system 100. In some embodiments, the gateway or repeater unit 810 can be connected to an external data network 722, such as the Internet or a variety of different private networks. In some embodiments, the data network 722 can be a packet-switched network. In some embodiments, the gateway or repeater 810 can also include a data network router function.

[0070] In some embodiments, a pressure sensor can be located at a position remote from the monitoring device 150 but in electrical communication with the monitoring device 150, such as in electrical communication with the control circuit 504. For example, now referring to Figure 9 , a schematic front perspective view of an air filtration system 100 having a monitoring device in accordance with multiple different embodiments herein is shown. Compared to the system shown in Figure 1 , in this example, the pressure sensors are disposed at or within the joints 166, 168 of the existing fluid conduits 162, 164 of the air filtration system, and signals from the pressure sensors are sent back to the monitoring device 150 via lines 952, 954.

[0071] It will be understood that this document includes a variety of different types of filtration systems. Although Figures 1-3 a cartridge-based air filtration system is shown, it will be understood that this document also includes bag-type air filtration systems. Now referring to Figure 10, shows a schematic front perspective view of an air filtration system 1100 with a monitoring device 150 in accordance with various different embodiments herein. In this view, for ease of illustration, the connection members of the monitoring device 150 are not shown. In operation, the filter bags can be pulse cleaned periodically to maintain or reduce the operating pressure drop, and the filter bags are amenable to pulse cleaning during operation. During the pulse cleaning operation, air pulses are directed through the filter bags in a direction opposite to normal filtration operation. The action of the air pulses has two important results. First, the pulses tend to cause the filter bags to flex in response to an increase in internal pressure. This outward flexing motion is apt to mechanically remove any particulates that have accumulated in the form of a filter cake on the exterior of the bags. Additionally, increasing the airflow passing through the filter bag surface in the opposite direction is apt to cause the removal of particulates by causing air to pass through porous openings within the filter bag structure. The result of causing air to pass through the filter bags in the opposite direction during operation is apt to reduce the amount of any particulates or filter cake that forms on the exterior of the filter bags, thus returning the filter bags to a pressure drop more typical of efficient operation of the structure. A variety of internal structures within the bag filter chamber can be used for this pulse cleaning operation. The bag filter chamber can include internal fans that can direct the airflow through the housing structure in the opposite direction. Alternatively, the housing can include air openings or nozzles that can be mounted within or move from support structure to support structure to introduce the reverse pulse airflow into the interior of the bag filter chamber. The monitoring devices herein can be connected to such a filtration system such that fluid communication is established with various regions of the filtration system, such as the clean or downstream side of the filter bags and the soiled or upstream side of the filter bags, and sensors that are in fluid communication within or otherwise electrically connected to the monitoring device. Other aspects of bag air filtration systems are described in U.S. Patent No. 6,740,412, the content of which is incorporated herein by reference.

[0072] Aspects have been described with reference to a number of different specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications can be made within the spirit and scope of this disclosure. Thus, the embodiments described herein are not intended to be exclusive or to limit the invention to the exact forms disclosed in the following detailed description. Instead, the embodiments are selected and described so that those skilled in the art can understand and appreciate the principles and practices.

[0073] It should be noted that, unless the context clearly dictates otherwise, the singular forms “a / an” and “the” as used in this specification and the appended claims include plural referents. It should also be noted that, unless the context clearly dictates otherwise, the term “or” as commonly used includes “and / or”.

[0074] It should also be noted that, as used in this specification and the appended claims, the phrase "configured to" describes a system, device, or other structure that is constructed or configured to perform a particular task or adopt a particular configuration. The phrase "configured to" may be used interchangeably with other similar phrases, such as arranged and configured to, constructed and arranged to, constructed to, made and arranged to, etc.

[0075] All of the disclosures and patent applications in this specification represent the level of ordinary skill in the art to which the present invention pertains. All of the disclosures and patent applications are incorporated herein by reference to the same extent as if each individual disclosure or patent application were specifically and individually indicated to be incorporated by reference.

Claims

1. A monitoring device for a filtration system, wherein the filtration system includes a filter element and has a pulse backwashing system for pulse cleaning the filter element, and a pulse generator of the pulse backwashing system receives gas from a compressed gas source, and the monitoring device comprises: a first fluid conduit; a first pressure sensor, wherein the first pressure sensor is in fluid communication with the first fluid conduit; a second fluid conduit; a second pressure sensor, wherein the second pressure sensor is in fluid communication with the second fluid conduit; a third fluid conduit, wherein the third fluid conduit is in fluid communication with the compressed gas source and extends outside the filtration system; a third pressure sensor, wherein the third pressure sensor is in fluid communication with the third fluid conduit; and a control circuit in electronic communication with the first pressure sensor, the second pressure sensor, and the third pressure sensor; a monitoring device housing located outside the filtration system, wherein the first pressure sensor, the second pressure sensor, the third pressure sensor, and the control circuit are all disposed within the monitoring device housing, wherein the first fluid conduit includes a first internal portion disposed within the housing and a first external portion disposed outside the housing, and wherein the second fluid conduit includes a second internal portion disposed within the housing and a second external portion disposed outside the housing.

2. The monitoring device according to claim 1, wherein, the control circuit is configured to calculate a value related to the fluid flow rate through the filtration system based on the value provided by the first pressure sensor and the value provided by the second pressure sensor.

3. The monitoring device according to claim 1, wherein, the control circuit is configured to calculate a value related to the fluid flow rate through the filtration system based on one of the value provided by the first pressure sensor and the value provided by the second pressure sensor.

4. The monitoring device according to any one of claims 1-3, wherein, the first fluid conduit is in fluid communication with a fluid flow region upstream of the first filter element.

5. The monitoring device according to any one of claims 1-3, wherein, the second fluid conduit is in fluid communication with a fluid flow region downstream of the first filter element.

6. The monitoring device according to any one of claims 1-3, wherein, the control circuit causes a temporary change in the data recording parameter based on a signal received from any one of the first pressure sensor, the second pressure sensor, or the third pressure sensor.

7. The monitoring device according to claim 6, wherein, the temporary change in the data recording parameter includes changing the resolution of the recorded data, and wherein changing the resolution may include increasing or decreasing the sampling frequency.

8. The monitoring device according to any one of claims 1-3, further comprising an accelerometer, wherein, the accelerometer is in electronic communication with the control circuit.

9. An air filtration system, comprising: a filtration system housing configured to receive a filter element through which fluid flows therethrough, the filter element including an upstream side and a downstream side; A pulse backflush system for pulse cleaning a filter element, the pulse generator of the pulse backflush system receiving gas from a compressed gas source, and A monitoring device, the monitoring device comprising: A first fluid conduit in fluid communication with the upstream side of the filter element; A first pressure sensor, wherein the first pressure sensor is in fluid communication with the first fluid conduit; A second fluid conduit in fluid communication with the downstream side of the filter element; A second pressure sensor, wherein the second pressure sensor is in fluid communication with the second fluid conduit; A third fluid conduit in fluid communication with the compressed gas source and extending outside the filter system housing; A third pressure sensor, wherein the third pressure sensor is in fluid communication with the third fluid conduit; A monitoring device control circuit in electronic communication with the first pressure sensor and the second pressure sensor; and A monitoring device housing, wherein the first pressure sensor, the second pressure sensor, and the control circuit are all disposed within the monitoring device housing, wherein the first fluid conduit includes a first internal portion disposed within the housing and a first external portion disposed outside the housing, and wherein the second fluid conduit includes a second internal portion disposed within the housing and a second external portion disposed outside the housing.

10. A method for remotely monitoring a pre-installed dust collector system, wherein the pre-installed dust collector system includes a filter element and has a pulse backflush system for pulse cleaning the filter element, the pulse generator of the pulse backflush system receiving gas from a compressed gas source, the method comprising: Mounting a monitoring device on an outer surface of the housing of the pre-installed dust collector system, the monitoring device comprising: A first fluid conduit in fluid communication with the upstream side of the filter element; A first pressure sensor, wherein the first pressure sensor is in fluid communication with the first fluid conduit; A second fluid conduit in fluid communication with the downstream side of the filter element; A second pressure sensor, wherein the second pressure sensor is in fluid communication with the second fluid conduit; A third fluid conduit in fluid communication with the compressed gas source and extending outside the pre-installed dust collector system; A third pressure sensor, wherein the third pressure sensor is in fluid communication with the third fluid conduit; A monitoring device control circuit in electronic communication with the first pressure sensor and the second pressure sensor; and A monitoring device housing, wherein the first pressure sensor, the second pressure sensor, and the control circuit are all disposed within the monitoring device housing, wherein the first fluid conduit includes a first internal portion disposed within the housing and a first external portion disposed outside the housing, and wherein the second fluid conduit includes a second internal portion disposed within the housing and a second external portion disposed outside the housing.

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