Device and process to assist alignment of an open path gas detector

Abstract

Systems and methods are provided for alignment of a gas detection system through active monitoring of the detection signal measured by a light sensor of a receiver. The light sensor can be configured to receive a beam of focused light generated by a transmitter and to produce a detection signal based on the intensity of the received light beam. A processing unit can continuously receive the produced detection signal as the orientation of the receiver relative to a transmitter of the gas detection system is modified. Based on the received detection signal the alignment of the receiver relative to the transmitter can be determined to be acceptable or not acceptable. An alert signal based on the determination of whether the alignment of the receiver relative to the transmitter is acceptable can be produced, and used to provide an indication to an operator aligning the gas detection system.

Description

DEVICE AND PROCESS TO ASSIST ALIGNMENT OF AN OPEN PATH GAS DETECTORBACKGROUND

[0001] Open path gas detectors are advanced monitoring devices designed to detect the presence of hazardous gases or vapors over a wide area. Unlike traditional point sensors that cover specific locations, open path detectors create a beam of light (e.g., infrared light) between a transmitter and a receiver across an open space, such as a worksite. When gas or vapor molecules intersect this beam, they absorb infrared light, triggering the detector to raise an alarm. This technology enables the detection of a variety of gases, including flammable, toxic, and combustible substances, making open path gas detectors valuable for industrial facilities, oil and gas installations, and other settings where a rapid and comprehensive gas monitoring solution is crucial for safety and environmental protection. In order to accurately detect the presence of hazardous gases or vapors, the transmitter and receiver of the open path gas detectors must be properly aligned. Given that there is often a substantial distance between the transmitter and receiver, alignment of these two devices is not always straightforward.SUMMARY

[0002] Devices, systems, and processes are provided herein for the alignment of a receiver and a transmitter in an open path gas detector system. By utilizing the signal intensity measured at the receiver during the alignment process, the acceptable alignment range of a device (e.g., a receiver) may be accurately determined, and an operator may then use this information to position the receiver at the center of the alignment range in a given axis. For instance, an operator may be informed, using an indicator, when the receiver has reached the edge of anacceptable alignment range (also referred to as an “orientation range”). This technique may then be repeated in other axis (e.g., vertical, horizontal). In order to assist an operator with such a signal-based alignment process, and because the detection signal may have a substantially flat profile in the acceptable alignment range, an alignment device that tracks the individual positions at which the acceptable alignment range is reached may be utilized. By tracking the positions at the edge of the alignment range, an operator may then easily place the receiver at the center of the alignment range.

[0003] In one aspect, the present disclosure provides a gas detection system. The gas detection system may include a receiver having a light sensor configured to receive a beam of focused light generated by a transmitter and to produce a detection signal based on the intensity of the received light beam. The gas detection system may also include a processing unit configured to continuously receive the detection signal as the orientation of the receiver relative to the transmitter is modified, determine if the alignment of the receiver relative to the transmitter is acceptable based on the received detection signal, and produce an alert signal based on the determination of whether the alignment of the receiver relative to the transmitter is acceptable.

[0004] In another aspect, the present disclosure provides a method of aligning a gas detector. The method may include receiving, using a receiver, a beam of focused light generated by a transmitter as the orientation of the receiver relative to the transmitter is adjusted, producing a detection signal based on the intensity of the received light beam, and determining an acceptable alignment range of the receiver relative to the transmitter based on the received detection signal.

[0005] In yet another aspect, the present disclosure provides a method of aligning a gas detector. The method may include receiving, using a receiver, a beam of focused light generated by a transmitter as the orientation of the receiver relative to the transmitter is adjusted, producing a detection signal based on the intensity of the received light beam,locating a first contact point between a reference signal and the detection signal, locating a second contact point between the reference signal and the detection signal, and adjusting the orientation of the receiver such that the received detection signal is substantially in the middle between the first contact point and the second contact point.

[0006] The current subject matter will be better understood by reference to the following detailed description when considered in combination with the accompanying drawings which form part of the present specification.BRIEF DESCRIPTION OF DRAWINGS

[0007] FIG. 1 A is an illustration depicting a perspective view of a receiver of an open path gas detection system and associated alignment device shown attached to a physical structure, in accordance with one aspect of the present disclosure.

[0008] FIG. IB is an illustration depicting a perspective view of the receiver and alignment device of FIG. 1A shown detached from any physical structure, in accordance with one aspect of the present disclosure.

[0009] FIG. 2A is an illustration depicting a front, perspective view a receiver of an open path gas detection system and associated alignment device, the receiver is shown without various attachment components, in accordance with one aspect of the present disclosure.

[0010] FIG. 2B is an illustration depicting a rear, perspective view of the receiver and alignment device of FIG. 2A, in accordance with one aspect of the present disclosure.

[0011] FIG. 2C is an illustration depicting a top view of the receiver and alignment device of FIGs. 2A-2B, in accordance with one aspect of the present disclosure.

[0012] FIG. 3A is an illustration depicting a perspective view of an alignment device, in accordance with one aspect of the present disclosure.

[0013] FIG. 3B is an illustration depicting a front view of the alignment device of FIG. 3 A, in accordance with one aspect of the present disclosure.

[0014] FIG. 3C is an illustration depicting a side view of the alignment device of FIGs. 3A- 3B, in accordance with one aspect of the present disclosure.

[0015] FIG. 3D is an illustration depicting a rear view of the alignment device of FIGs. 3A- 3C, in accordance with one aspect of the present disclosure.

[0016] FIG. 3E is an illustration depicting an exploded view of the alignment device of FIGs.3 A-3D, in accordance with one aspect of the present disclosure.

[0017] FIG. 4A is an illustration depicting a cutout view of an alignment device in an initial start configuration, in accordance with one aspect of the present disclosure.

[0018] FIG. 4B is an illustration depicting a cutout view of the alignment device of FIG. 4A with a driver, a position pointer, and a first drag pointer having been rotated clockwise to a first orientation limit of the receiver, in accordance with one aspect of the present disclosure.

[0019] FIG. 4C is an illustration depicting a cutout view of the alignment device of FIG. 4B with the driver, the position pointer, and a second drag pointer having been rotated counterclockwise to a second orientation limit of the receiver, in accordance with one aspect of the present disclosure.

[0020] FIG. 4D is an illustration depicting a cutout view of the alignment device of FIG. 4C with a slider pointer having been slid counterclockwise to the center of the first orientation limit and the second orientation limit, in accordance with one aspect of the present disclosure.

[0021] FIG. 4E is an illustration depicting a cutout view of the alignment device of FIG. 4D with the driver and the position pointer having been rotated clockwise to match the position of the slider pointer, in accordance with one aspect of the present disclosure.

[0022] FIG. 5A is an illustration depicting a cutout view of a receiver of an open path gas detector having an LED indicator in an inactive state, in accordance with one aspect of the present disclosure.

[0023] FIG. 5B is an illustration depicting a cutout view of a receiver of an open path gas detector having an LED indicator in an activated state, in accordance with one aspect of the present disclosure.

[0024] FIG. 6A is an illustration depicting a schematic of an open path detector having a transmitter and a misaligned receiver, in accordance with one aspect of the present disclosure.

[0025] FIG. 6B is an illustration depicting the acceptable alignment range of the receiver of FIG. 6A, along with its current alignment position in that range, in accordance with one aspect of the present disclosure.

[0026] FIG. 6C is an illustration depicting a schematic of the open path detector of FIG. 6A, with the receiver having undergone a realignment, in accordance with one aspect of the present disclosure.

[0027] FIG. 6D is an illustration depicting the acceptable alignment range of the receiver of FIG. 6C, along with its alignment position change compared to FIG. 6B (shown using a dotted arrow), in accordance with one aspect of the present disclosure.

[0028] FIG. 7 is flowchart of a method of aligning a gas detector.

[0029] FIG. 8 is flowchart of another method of aligning a gas detector.

[0030] FIG. 9 is flowchart of a process for determining if the orientation of the receiver relative to the transmitter is acceptable based on the received detection signal, in accordance with one aspect of the present disclosure.

[0031] FIG. 10 is a graphical depiction of an example reference signal and a sample signal plotted at various misalignment positions in a axial direction, in accordance with one aspect of the present disclosure.

[0032] FIG. 11 is an illustration depicting a receiver of an open path gas detector interacting with a system network and a system device, in accordance with one aspect of the present disclosure.

[0033] The current subject matter will be better understood by reference to the following detailed description when considered in combination with the accompanying drawings which form part of the present specification.DETAILED DESCRIPTION

[0034] As described above, an open path gas detector is a device used to detect the presence of specific gases or vapors in the air over a large area or along a defined path. Unlike singlepoint gas detectors that are stationed at fixed locations, open path gas detectors offer more expansive coverage by utilizing a beam of electromagnetic radiation (e.g., infrared light) to monitor vapor and gas concentrations along a designated path of interest. Accordingly, one of the advantages of open path gas detectors is their ability to monitor large areas, making them well-suited for outdoor and open environments. Given their quick response times and ability to detect a wide range of gases, including toxic, flammable, and explosive substances, open path gas detectors are useful in several industries, such as oil and gas, chemical manufacturing, and environmental monitoring.

[0035] Open path gas detectors operate by monitoring the atmosphere between a transmitter and a receiver unit. An open path gas detection system may include a transmitter unit, which typically contains the source of the detection signal (e.g., infrared (IR) or ultraviolet (UV) light source, laser). The transmitter may also include optical components such as mirrors, lenses, and beam splitters to help produce a beam of light that travels across the open path. The receiver may be positioned opposite to the transmitter and may be equipped with a detector, such as a photodetector or photodiode. The detector may be capable of measuring the intensity of the light signal received after it has interacted with the gas molecules in the open path. A control and processing unit may be in communication with the transmitter and receiver to manage the operation of the open path gas detector system. The control and processing unit may be specifically positioned within the receiver, and may also include electronics for signalamplification, filtering, and data processing. Both the transmitter and the receiver may be enclosed in a weatherproof or explosion-proof housing for protection from harsh environmental conditions.

[0036] When the gas detector is in operation, the transmitter may emit a specific wavelength of light, which may be absorbed by the target gas if it is present in the open path. Without being bound by theory, the degree of absorption may depend on the concentration of the gas, its specific absorption characteristics, and the path length of the open path. The emitted light beam from the transmitter may travel across the open path to the receiver. If the gas of interest is present in the path, some of the light may be absorbed, causing a reduction in the intensity of the light reaching the receiver, provided the receiver is properly aligned with the light beam. The receiver may detect the attenuated light signal and convert it into an electrical signal (i.e., a detection signal). The control and processing unit may then process this detection signal, or alternatively, may provide this signal to a system device for processing. The received signal may be compared to a reference signal (baseline) obtained when no gas is present in the path. Any difference between the received signal and the reference signal may be used to calculate the concentration of the target gas in the open path. Alarms may be triggered if the concentration of the target gas exceeds predefined thresholds. For instance, the detector may provide outputs in the form of concentration measurements, alarms, and status indicators. Such data may be transmitted to a central control system for real-time monitoring and logging.

[0037] The entire functionality of an open path gas detector system relies on the proper alignment of the receiver relative to the beam of light being produced by the transmitter. If the receiver is even slightly misaligned with the light beam, measurement accuracy may be reduced, and in some cases, gas detection may be impracticable. Accordingly, achieving precise alignment between the transmitter and receiver in an open-path gas detection system iscrucial for achieving accurate gas measurements over the widest range of environmental conditions.

[0038] Unfortunately, the present disclosure recognizes that many existing optical alignment tools (e.g., laser pointers, collimators, optical alignment fixtures, etc.) come with considerable disadvantages. As one example, many of these devices rely on emitted lasers or scopes positioned on either the transmitter or receiver that may themselves be misaligned with the devices to which they are attached. So, for example, a scope attached to a receiver may show a user that the receiver is perfectly aligned, but this scope may itself be misaligned with the direction that the receiver light detection element is actually oriented. In such an example, the operator may not know that the receiver is misaligned until the receiver is activated. And even if the device appears to be functioning properly, given the flat signal profile typically associated with the operable range of the detection signal, the operator may have no way of knowing whether the receiver is perfectly centered or instead positioned near the edge of the operable range of the device (such that a minor shift in the orientation of the receiver will render it inoperable). Put simply, these prior methods assume that the beam of these tools travel the same path as the gas detection beam, which is limited by the precision of the alignment tool in conjunction with the gas detection unit, the skills of the operator aligning the system, and environmental conditions. These existing alignment devices may also be expensive, sensitive, and difficult to use, even with proper training.

[0039] In order to address these deficiencies, among others, the present disclosure provides, in part, systems, devices, and methods that help operators to perform the alignment of a device in an open path gas detector quickly and accurately, using simple techniques and equipment. Such advantages are achieved by providing operators real-time feedback on the alignment of the receiver by making its acceptable operating range (i.e., the range where the field of view of the receiver includes the light beam to an operable extent) known to the operator based on the realmeasurement signals received at the receiver. By indicating to the operator whether the receiver is properly aligned based on the detection signal, the device may be adjusted to the center of the acceptable operating range, which will prevent misalignment of the receiver. An alignment device is also provided herein to assist the operator in tracking the orientation limits of the acceptable operating range of the receiver, so that the center of said range may be easily determined.

[0040] While the present disclosure is primarily described with regard to adjusting the orientation of the receiver, it should be readily appreciated that similar techniques may be utilized for the alignment of the transmitter in an open path gas detection system. Furthermore, the techniques described herein may be utilized when adjusting the position of the transmitter, additionally or instead of adjusting the orientation of the receiver. Furthermore, it should be appreciated that the alignment techniques and devices described herein may be utilized outside of the example open path gas detector systems described, and may be generally applicable to systems that require alignment of two devices.

[0041] FIG. 1A depicts various items of an open path gas detection system 100, including a receiver 110 and an associated receiver attachment device 150. The receiver attachment device 150 may attach the receiver 110 to a physical structure 170, as shown. The physical structure 170 (e.g., pipe, building exterior) may provide a stable base from which the receiver 110 may be adjusted to be properly aligned with a transmitter (not depicted). As will be further described, an alignment device 130 may be used when modifying the alignment or position of the receiver 110 in order to assist an operator attempting to align the receiver 110 with said transmitter.

[0042] FIG. IB depicts the same open path detection system 100 with the receiver 110, the alignment device 130, and the receiver attachment device 150 shown without the structure 170, for clarity purposes. As shown, the receiver attachment device 150 may include multiplevertical set screws 152, 154 and multiple horizontal set screws 156, 158. These set screws 152, 154, 156, 158 may function as orientation adjustment components, permitting an operator to modify the vertical orientation (using set screws 152, 154) and the horizontal orientation (using set screws 156, 158) of the receiver 110. For instance, by rotating set screw 154 in a clockwise or counterclockwise direction, the receiver 110 may reorient in downward and upward directions. It should be readily appreciated that alternative orientation adjustment devices and configurations may be relied on to alter the orientation of the receiver 110.

[0043] FIGs. 2A-2C depict a receiver 210 of an open path gas detection system attached to a receiver attachment device 250 (only a portion of which is depicted) along with an associated alignment device 230. As shown, the receiver may include a housing 212 enclosing a light detector 214. In order to properly function, the light detector 214 may need to be properly aligned with a light beam produced by a transmitter (not depicted). Although not visible in these depictions, the receiver 210 may include various internal components (e.g., a processing unit, memory, communications unit) to assist with the processing of the received light beam as well as the required communication with external devices and operators. As will be further described, the alignment device 230 may function to assist an operator with the process of aligning the receiver 210.

[0044] FIGs. 3 A-3E depict an alignment device 330 for use in, for example, an open path gas detector system. The alignment device 330 may generally function to track the limits of the acceptable orientation range of an adjusted device, such as a receiver of an open path gas detector system. The alignment device 330 may achieve this by marking the maximum positions that an associated set screw is turned in both the clockwise and counterclockwise directions, thereby allowing an operator to determine the middle (i.e., the optimal orientation position) of these two marked positions. The flat profile of the detection signal over the operable orientation range of a typical receiver makes it challenging to determine the center ofthe operable orientation range relying on only the detection signal, which is part of the reason why further utilizing an alignment device may be beneficial. As shown, the alignment device 330 may include a number of components, including for example, a position pointer 332 having a head socket 334, a first drag pointer 336, a second drag pointer 338, a slider pointer 340, a disc plate 342 having an extended hub 343, an attachment component 344, and a fixing screw 346. The alignment device 300 may generally be configured to receive and thereby contact a driver shaft 348 of a driver, such as an Allen wrench, screwdriver, or similar device. The driver shaft 348 may extend through the alignment device 330 and couple to an orientation adjustment component of, for example, a receiver of an open path gas detector system (not depicted). Rotation of the driver shaft 348 in a clockwise or counterclockwise direction may subsequently cause an intended orientation change in the receiver to which it is coupled.

[0045] The position pointer 332 may specifically include an extended pointer arm and a head socket 334 that is configured to receive the driver shaft 348 in a manner that the driver shaft 348 may extend through the head socket 334 and couple to an orientation adjustment component in an open path gas detection system. The head socket 334 may be configured to contact and rotate with the driver shaft. For instance, the head socket may have a matching size and / or shape with the driver shaft 348. As will be further described, the position pointer 334 may function to provide both a reference point, matching the radial position of the driver shaft 348, and also as a contact point to rotate the first drag pointer 336 and second drag pointer 338. Similar to the position pointer 334, each drag pointer 336, 338 may be configured to rotate on the same axis as the driver shaft 348. However, unlike the position pointer 334, each drag pointer 336, 338 may be configured to retain their respective radial positions unless contacted by the position pointer 334. The first drag pointer 336 may be configured to contact and rotate with the position pointer 334 when rotated in a clockwise direction, whereas the second drag pointer 338 may be configured to contact and rotate with the position pointer 338 when rotatedin a counterclockwise direction. In this manner, each drag pointer 336, 338 may be used to mark a different limit in the operable orientation range of the gas detector device to which the alignment device 330 is being used with. In some aspects, rather than relying on a position pointer, the alignment device 330 may instead simply rely on the driver shaft 348 to mark both positions and to contact and move the drag pointers 336, 338.

[0046] The attachment component 344 may be configured to removably attach the alignment device 330 to the frame or attachment device connecting the structure to the detection device (e.g., receiver) of the gas detection system. By using the attachment component 344, the disc plate 342 and its extended hub 343 may be held in a stationary position while the driver shaft 348 is rotated. While the attachment component 344 is depicted as a clip-type mechanism, it should be readily appreciated that any suitable attachment mechanism known in the art may be utilized to provide this temporary connection. The first drag pointer 336 and the second drag pointer 338 may be configured to rotate around the stabilized extended hub 343 of the disc plate 342. The disc plate 342 may include reference markings, lettering, designs, patterns, or be otherwise configured to assist an operator in tracking the various pointers positioned above its surface. The disc plate 342 may be rotatable, with a fixing screw 346 to secure its position relative to the driver shaft 348. The slider pointer 340 may be configured to couple to an edge of the disc plate and to movably slide around the edge of the disc plate 342, and thereby provide yet another adjustable marker for an operator to utilize.

[0047] FIGs. 4A-4E depict a cutout view of an alignment device 430, consistent with FIGs. 3 A-3E, being used to align a receiver in an open path gas detector system. FIG. 4A depicts the alignment device 430 in an initial start configuration. As can be seen, the alignment device 430 has been stabilized through the use of an attachment component, and position pointer 434 has been arranged to a start position with the first drag pointer 436 and second drag pointer 438 positioned on opposite sides, contacting the position pointer 434. The shaft of the driver 448 isshown extending through the alignment device 430 and coupling to an orientation adjustment component (e.g., a set screw) of the receiver. In order to reach this starting position, an operator may have placed alignment device 430 on one of the orientation adjustment components of the receiver, attached the attachment component to the holding structure (i.e., receiver attachment mechanism), moved the disc plate of the alignment device 430 to a zero position, fixed the disc plate using the lateral fixing screw, and moved the drag pointers 436, 438 into position on the disc plate so that the drag pointers 436, 438 are in contact with the position pointer 434 from both sides respectively. Prior to any of these steps, an operator may first roughly align the receiver and the transmitter, such as by using a visual estimate or by relying on a rudimentary scope.

[0048] FIG. 4B depicts the driver 448 having rotated the set screw of the receiver in a clockwise direction (as shown by the included arrow). The position pointer 434 and a first drag pointer 436 have also been rotated clockwise direction, matching the change in angular position of the driver 448. The driver 448 is shown having reached a first orientation limit of the receiver at this position, which may be communicated to the operator using an indicator that informs them that no further rotation in the clockwise direction is necessary.

[0049] FIG. 4C depicts the driver 448 having rotated the set screw of the receiver in a counterclockwise direction, starting from the first orientation limit and proceeding to a second orientation limit (as shown by the included arrow). While the first drag pointer 436 remains marking the first orientation limit, the position pointer 434 and the second drag pointer 438 have been rotated counterclockwise to a second orientation limit of the receiver. Again, once the driver 448 has reached a second orientation limit of the receiver, an indicator can provide an indication to the operator and therefore inform them that no further rotation in the counterclockwise direction is necessary.

[0050] With both orientation limits for this receiver now known and marked, the operator can determine the halfway point between the two positions, thereby identifying the center of the operable orientation range of the device. FIG. 4D depicts a slider pointer 440 having been slid counterclockwise (as shown by the included arrow) along the disc plate to mark the center of the first orientation limit and the second orientation limit. It should be readily appreciated that other marking techniques may be relied on for this step, including simply having the operator visually determine the center position. FIG. 4E depicts the driver 448 and the position pointer 434 having been rotated clockwise to match the position of the slider pointer 440, and thereby having positioned the receiver in the center of its operable orientation range. This same process may be repeated on orientation adjustment components (e.g., set screw) configured to adjust different axis of the receiver.

[0051] It should be readily appreciated that alternative techniques, components, and devices to the mechanical device depicted in FIGs. 3A-4E can be used to track the orientation of the device as well as the orientation limits determined using the detection signal. For instance, other techniques of angle detection that may be utilized including tilt sensors or tilt meters, which may be used to measure the angle of inclination or tilt of the device relative to the vertical or horizontal axis. By attaching an inclinometer to the moving part (e.g., receiver, transmitter), the horizontal and vertical angles can be measured, tracked, and used for alignment. Another possible method is to use potentiometers or variable resistors to measure the angle of movement. For example, by attaching a potentiometer to the moving part (e.g., receiver, transmitter) in a way that its resistance changes with movement, the angles can similarly be measured, tracked, and used for alignment. Magnetic or ultra-sonic components may also be used to track this motion. Further yet, laser or optical measurement systems may be used, and may include a light source, attached to the moving part (receiver or transmitter), that emits a laser or light beam onto a photosensitive target and analyzes the light signal to determine theangle of the target relative to the light source. Due to the small angular deviations and in order to help achieve a higher resolution, the length of the light beam can be extended by a mirror system. Alternatively, the photosensitive target may be attached to the moving part being aligned (e.g., receiver, transmitter). Further still, a rotary encoder may be attached to the device being aligned and used to measure the rotation, and by knowing the geometry, the corresponding angle can be calculated. Instead, an accelerometer may be used, and by integrating the acceleration signal over time, the angle of movement may be calculated. Another option is to use computer vision, by relying on image processing techniques that may be used with cameras to track movement of markers or features on the moving part (e.g., receiver, transmitter), thereby allowing for angle measurement. Such alignment components and devices may be configured to provide an orientation signal to a processing unit, such as a processing unit on the receiver. The alignment signal may contain information regarding the orientation of the receiver, such that the processing unit can track the orientation of the receiver as it is being adjusted.

[0052] As previously described, an indicator may be used to provide an indication to a user (e.g., operator) to inform the user of the alignment status of the device (e.g., receiver, transmitter), as determined by a processing unit based on the detection signal of the receiver. For instance, the processing unit may evaluate the detection signal and produce one or more alert signals that may be provided to the indicator based on the determination of whether the alignment of the receiver relative to the transmitter is acceptable. In response, the indicator may be configured to provide one or more indications in real time to an operator. FIGs. 5A-5B depict a receiver 510 with an example indicator in the form of a light-emitting diode (LED) 580 positioned on the receiver going from an inactive state (FIG. 5A) where the LED 580 is turned off to an activated state where the LED 580 is turned on (FIG. 5B).

[0053] The indicator may take many forms, such as a visual indication (e.g., light source, digital display, etc.) and / or an audio indication (e.g., sound emitted from a speaker). Instead of being positioned as a component of the receiver, the indicator may instead be included as part of a system device, such as a cellular phone, a tablet, a personal computer, smartwatch, or smart glasses device that may be accessible to the user during the alignment process. For instance, the receiver may provide either detection signal data or an alert signal to a cellular device being used by an operator, who may then reference said alert signal in the form of a display on the cellular device. Numerous other configurations are also possible. The information provided by the indicator may include not only whether the orientation of the device is in an acceptable range or not, but also information regarding when the device has reached the limit of such a range.

[0054] FIG. 6A depicts a schematic of an open path detector 600 having a transmitter 690 and a misaligned receiver 610, while FIG. 6B depicts the acceptable alignment range of the receiver of FIG 6A, along with its current alignment position 694 in that range. As can be seen, the current alignment position of the receiver 610 is capturing a sufficient amount of the transmitted light beam 692 that it would be operable, but only a slight deviation in its alignment may render it outside of the acceptable alignment range. The intensity of the detection signal produced at the receiver may be substantially uniform within an acceptable alignment range of the receiver. In other words, over the acceptable alignment range of the receiver, the intensity of the detection signal may not have a central peak to which the receiver may simply be aligned with. Given the flat profile of the detection signal received at the receiver, an operator using traditional alignment techniques may have no way of determining where the current alignment position 694 of the receiver is within the range, and may instead only be able to determine that the receiver is in fact within the alignment range. FIGs. 6C-6D depicts the same receiver 610 having been aligned using the techniques described herein, with the alignment position 694now located at the very center of the acceptable orientation range whereby even with slight deviations, the receiver and transmitter will remain within the acceptable alignment range.

[0055] FIG. 7 is flowchart of a method 700 of aligning a gas detector, in accordance with the devices, systems, and techniques previously described herein. For example, the method 700 may be implemented and performed by a processing unit as previously described, such as a processor integrated with a receiver of an open path gas detection system, or a processing unit on a system device connected thereto or in communication therewith. At 702, a beam of focused light generated by a transmitter is received, using a receiver, as the orientation of the receiver relative to the transmitter is adjusted. For example, as described, the transmitter beam may be monitored as the receiver is actively adjusted in a single axis, (e.g., an upward, downward, left, or right direction). At 704, a detection signal based on the intensity of the received light beam is produced. Again, the detection signal may directly correspond to the intensity of the received light beam, and therefore provide an indication of the orientation of the receiver relative to the light beam. At 706, an acceptable alignment range of the receiver relative to the transmitter is determined based on the received detection signal. As will be further described, there are numerous possible techniques for determining whether the alignment of the receiver is within the acceptable alignment range, which may be preconfigured.

[0056] Although not depicted, the method 700 may include additional or alternative method steps consistent with the functional descriptions provided for the systems and devices of the present disclosure. For instance, the method 700 may further include providing an indication to a user based on the determination of whether the alignment of the receiver relative to the transmitter is acceptable. Numerous techniques and devices for providing such an indication have already been described herein.

[0057] FIG. 8 is flowchart of a method 800 of aligning a gas detector, in accordance with the devices, systems, and techniques previously described herein. For example, the method 800 may be implemented and performed by a processing unit as previously described, such as a processor integrated with a receiver of an open path gas detection system, or a processing unit on a system device connected thereto or in communication therewith. At 802, a beam of focused light generated by a transmitter is received, using a receiver, as the orientation of the receiver relative to the transmitter is adjusted. For example, as described, the transmitter beam may be monitored as the receiver is actively adjusted in a single axis, (e.g., an upward, downward, left, or right direction). At 804, a detection signal based on the intensity of the received light beam is produced. Again, the detection signal may directly correspond to the intensity of the received light beam, and therefore provide an indication of the orientation of the receiver relative to the light beam. At 806, a first contact point is located between a reference signal and the detection signal. The first contact point may represent an edge of the acceptable alignment range of the receiver in the single axial direction that the orientation of the receiver is being adjusted in. At 808, a second contact point is located between the reference signal and the detection signal. Similar to the first contact point, the second contact point may represent a second edge of the acceptable alignment range of the receiver in the single axial direction that the orientation of the receiver is being adjusted in. Finally, at 810, the orientation of the receiver is adjusted such that the received detection signal is substantially in the middle between the first contact point and the second contact point. In other words, the receiver is centered between the first and second contact points in that axial direction.

[0058] The processing unit described herein, which may be positioned within the device being aligned or contained elsewhere in a system device (e.g., cellular phone, a tablet, a personal computer, smartwatch, or smart glasses device), may use various techniques to determine the current alignment position of the device from the detection signal produced by the receiver.Prior to any processing, a user may first instruct the processing unit to enter an alignment mode. The user may input various system variables prior to the alignment determination process, including information regarding the transmitter type, the receiver type, the distance between the two devices, and / or other system-specific or alignment-preference information.

[0059] FIG. 9 is flowchart of a process 900 for determining if the orientation of the receiver relative to the transmitter is acceptable based on the received detection signal. In this depiction, the determination is based off of the ratio of the measured sample signal (i.e., the detection signal) relative to a reference signal, which may be predetermined or preset by a user, and an LED indicator with multiple different indications is used. Determining if the orientation of the receiver is acceptable includes comparing the intensity of the detection signal to a predetermined minimum signal intensity profile. Specifically, at 902, the reference and sample signals are read. At 904, the ratio of the reference signal to sample signal is determined. If the ratio is determined to be less than 1, at 906, then the receiver is outside of the acceptable alignment range and a signal alignment error may be indicated to a user, at 907, such as by, for example, providing no indication from the indicator. If the ratio is determined to be more than 1, at 908, then the receiver is inside of the acceptable alignment range and a first LED status (e.g., display green) may be indicated to a user, at 909. If the ratio is determined to be 1, at 910, then the receiver is on the edge of the acceptable alignment range and a second LED status (e.g., display yellow) may be indicated to a user, at 911. A user (i.e., operator) may then rely on this information to mark the edges of the acceptable alignment range and to properly position the receiver using this information.

[0060] The reference signal in FIG. 9 may be predetermined, based on information such as the type and configuration of the transmitter and receiver in use. Alternatively, the reference signal may be determined based on an initial scan of the acceptable orientation range. For example, the operator may initially modify the orientation of the receiver over an area that is estimatedto include the acceptable alignment range, and the processing unit may be configured to determine the acceptable alignment range based on this information, such as by creating a reference signal based on this scan and the maximum scan signal intensity measured therein. Instead of relying on a reference signal, a simple reference value (e.g., a minimum acceptable value) may be utilized. Other methods for determining the acceptable orientation range or determining whether the receiver is currently within said range may be utilized.

[0061] FIG. 10 depicts a graph of an example reference signal 1002 and sample signal 1001 plotted at various misalignment positions in an axial direction (x axis), with each plots detection signal strength shown (y axis). As can be seen, the scope alignment (dotted vertical line) matches very closely with the middle (dotted vertical line) of the acceptable field of view (i.e., the acceptable orientation range) of the device. The acceptable orientation range is shown between two dotted vertical lines at each of the contact points between the reference signal 1002 and the sample signal 1001. As can be seen, the sample signal 1001 has a substantially flat profile that extends beyond this range. Accordingly, an operator could not simply set the orientation at a position where there is a maximum reading in the sample signal, since such a position may not be easily determined across the flat profile, and therefore may not be centered within, or may even be outside of the acceptable orientation range of the device.

[0062] FIG. 11 is a diagram depicting a receiver 1110 to be used in an open path gas detection system 1100 interacting with a system network 1170 and a system device 1180. As shown in this example, the receiver 1110 may include a light indicator 1114, a light sensor 1112, and an electronic assembly 1140 which may include a memory 1154, a processor 1150, and a communications unit 1152. In other aspects, the light indicator 1114 may take various other forms. The receiver 1110 may be configured to provide information to the system network 1170 as well as system devices 1180 via either wireless or wired connection. The information provided may include, at least, information relating to the detection signal. For instance, thereceiver 1110 may provide detection signal data to one or more servers of the system network1170, and this information may then be accessed and viewed on a system device 1180 by a user.

[0063] The system device 1180 may include various device forms, including but not limited to, computers, cell phones, operator workstations, alarm devices, or other devices described herein. The system device 1180 may be in direct electrical communication with the receiver 1110. While the light indicator 1114 is a component of the receiver 1110 in this depiction, it should be appreciated that an indicator may be additionally or alternatively included on the system device, thereby providing similar functionality to a user. Although various components are described herein as being integrated with the receiver 1110, which may be preferable for many applications, it should be appreciated that various components may instead be contained within other system devices. For instance, instead the processor 1150 may be a component of another system device (e.g., system device 1180).

[0064] In accordance with the above description, in one aspect, the present disclosure provides an alignment device for a gas detection system. The alignment device may include a position pointer having head socket configured to receive a driver shaft therethrough for coupling to an orientation adjustment component in an open path gas detection system, wherein the head socket may be configured to contact and rotate with the driver shaft. The alignment device may also include first drag pointer configured to rotate on the same axis as the position pointer, wherein the first drag pointer may be configured to contact and rotate with the position pointer when the position pointer is rotated in a clockwise direction. The alignment device may further include a second drag pointer configured to rotate on the same axis as the position pointer, wherein the second drag pointer may be configured to contact and rotate with the position pointer when the position pointer is rotated in a counterclockwise direction.

[0065] The attachment component may be configured to removably attach the alignment device to at least one of a receiver or a transmitter in an open path gas detection system. The first drag pointer and the second drag pointer may be configured to retain their respective radial positions unless contacted by the position pointer. The alignment device may further include a disc plate having an extended hub, wherein the first drag pointer and the second drag pointer are configured to rotate around the extended hub. The disc plate may be configured to maintain its radial position while the head socket undergoes a rotation. The alignment device may further include a slider pointer configured to couple to an edge of the disc plate and to movably slide around the edge of the disc plate.

[0066] While the disclosure has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit of the embodiments. Thus, it is intended that the present disclosure cover the modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents.

Claims

CLAIMSIt is claimed:

1. A gas detection system comprising: a receiver having a light sensor configured to receive a beam of focused light generated by a transmitter and to produce a detection signal based on the intensity of the received light beam; a processing unit configured to: continuously receive the detection signal as the orientation of the receiver relative to the transmitter is modified; determine if the alignment of the receiver relative to the transmitter is acceptable based on the received detection signal; and produce an alert signal based on the determination of whether the alignment of the receiver relative to the transmitter is acceptable.

2. The system of claim 1, wherein the intensity of the detection signal is substantially uniform within an acceptable alignment range of the receiver.

3. The system of claim 1, wherein determining if the alignment of the receiver relative to the transmitter is acceptable includes comparing the intensity of the received detection signal to a pre-determined minimum signal intensity profile.

4. The system of claim 1, wherein gas detection system further includes: an alignment component configured to track the orientation of the receiver.

5. The system of claim 4, wherein the alignment device is configured to provide an orientation signal to the processing unit, the alignment signal containing information regarding the orientation of the receiver.

6. The system of claim 1, further comprising: an indicator configured to receive the alert signal and to provide an indication to a user.

7. The system of claim 6, wherein the indicator is a component of the receiver.

8. The system of claim 6, wherein the indicator is configured to provide a visual indication.

9. The system of claim 8, wherein the indicator includes a light-emitting diode positioned on the receiver.

10. The system of claim 6, wherein the indicator is configured to provide an audio indication.

11. The system of claim 1, wherein the processing unit is a component of the receiver.

12. The system of claim 1, wherein the processing unit is a component within a system device in communication with the receiver.

13. The system of claim 12, wherein the system device is selected from the group consisting of a cellular phone, a tablet, a personal computer, smartwatch, or smart glasses device.

14. A method of aligning a gas detector, the method comprising: receiving, using a receiver, a beam of focused light generated by a transmitter as the orientation of the receiver relative to the transmitter is adjusted; producing a detection signal based on the intensity of the received light beam; anddetermining an acceptable alignment range of the receiver relative to the transmitter based on the received detection signal.

15. The method of claim 14, further comprising: providing an indication to a user when the orientation of the receiver is within the acceptable alignment range.

16. The method of claim 14, wherein determining the acceptable alignment range of the receiver includes comparing the intensity of the detection signal to a pre-determined minimum signal intensity profile.

17. The method of claim 14, wherein the orientation of the receiver relative to the transmitter is adjusted in a single axial direction.

18. A method of aligning a gas detector, the method comprising: receiving, using a receiver, a beam of focused light generated by a transmitter as the orientation of the receiver relative to the transmitter is adjusted; producing a detection signal based on the intensity of the received light beam; locating a first contact point between a reference signal and the detection signal; locating a second contact point between the reference signal and the detection signal; and adjusting the orientation of the receiver such that the received detection signal is substantially in the middle between the first contact point and the second contact point.

19. The method of claim 18, wherein the orientation of the receiver relative to the transmitter is adjusted in a single axial direction.

20. The method of claim 19, wherein the first contact point and the second contact point each represent an edge of an acceptable alignment range of the receiver in the single axial direction that the orientation of the receiver is being adjusted in.

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