Method and apparatus for configuring and synchronizing a wireless machine monitoring and communication system

A method for configuring a wireless machine monitoring system having at least one chain of programmable transceiver devices including a machine monitor and a relay repeater, a master repeater in communication with the at least one chain, a command station in communication with the master repeater, an Installation and Configuration Unit (“ICU”), and a clock contained in each transceiver device, the method comprising the steps of:

• (a) synchronizing the clock of the ICU with the clock of a first transceiver device;
• (b) establishing wireless ICU transmit and receive communication with the first transceiver device;
• (c) determining a permanent time slot under which the first transceiver will communicate;
• and
• (d) communicating commands from the ICU to a second transceiver device and thereby configuring the second transceiver device to communicate with the first transceiver device during the permanent time slot and to synchronize the clocks of the first and second transceiver devices.

A method for configuring and synchronizing a wireless machine monitoring system having at least one chain including a machine monitor and a relay repeater, a master repeater in communication with the at least one chain, a command station in communication with the master repeater, and an Installation and Configuration Unit (“ICU”), a clock contained in each machine monitor, relay repeater, master repeater and ICU the method comprising the steps of configuring the wireless machine monitoring system by:

• (a) downloading configuration parameters to the machine monitor and the relay repeater from the ICU;
• (b) positioning the ICU within wireless communications range of the machine monitor and establishing wireless communication between the ICU and machine monitor;
• (c) determining an acceptable bit error rate for communications between the machine monitor and the relay repeater;
• (d) performing a bit error rate calculation on data transmitted by the machine monitor to the ICU;
• (e) determining whether the ICU is positioned such that the bit error rate is acceptable for wireless communications between the machine monitor and the relay repeater;
• (f) repositioning the ICU within wireless communications range of the machine monitor and repeating steps (d) and (e), if it is determined that the bit error rate is unacceptable for wireless communications between the machine monitor and the relay repeater,
• (g) mounting the relay repeater at a first location where the ICU is positioned if it is determined that the bit error rate is acceptable for wireless communications between the machine monitor and the relay repeater and downloading configuration parameters to the relay repeater;
• (h) determining a minimum transmit power level for the machine monitor based on the acceptable bit error rate;
• (i) sending a transmission strength signal configuration message from the ICU to the machine monitor and thereby configuring the machine monitor to transmit at the minimum transmit power level for the machine monitor;
• (j) prompting by the ICU for recordation of serial numbers for the machine monitor and the relay repeater, and logical locations of the machine monitor and the relay repeater in the chain;
• (k) prompting by the ICU for recordation of the physical locations of the machine monitor and the relay repeater indicative of where the machine monitor and relay repeater are physically located;
• (l) synchronizing the wireless machine monitoring system by synchronizing the clocks of the machine monitor, the relay repeater, and the ICU;
• (m) establishing wireless ICU transmit and receive communication with the relay repeater;
• (n) transmitting signals with the ICU for requesting registration by the relay repeater of the machine monitor;
• (o) selecting a permanent time slot under which the relay repeater communicates with the machine monitor;
• (p) requesting operator validation of the permanent time slot under which the relay repeater and machine monitor are operational;
• and
• (q) transmitting from the ICU to the relay repeater and the machine monitor a configuration signal and thereby configuring the relay repeater and machine monitor to operate during the selected permanent time slot.

A method of installing a wireless machine monitoring system having at least a machine monitor and a command station, the method comprising the steps of:

• (a) prompting the machine monitor to transmit a known set of data to the command station at a transmission power level;
• (b) receiving the data at the command station;
• (c) determining an accuracy with which the machine monitor transmitted the data;
• and
• (d) adjusting the transmission power level of the machine monitor in response to the accuracy.

An installation control unit for installing and configuring a wireless machine monitoring system comprising:

• (a) a transmitter for sending configuration parameters to the machine monitoring system,
• (b) a receiver for receiving data from the machine monitoring system,
• (c) processing means for analyzing and storing data received from the machine monitoring system, said processing means including:
• (1) means for determining a signal strength of a transmitted signal,
• (2) means for assigning a machine monitor to a repeater,
• (3) means for placing a machine monitor or a repeater in a configuration mode, and
• (4) means for assigning a machine monitor a time slice during which to communicate, and
• (d) clock means for synchronizing the operation of the machine monitoring system.