GB2599635A

GB2599635A - Connected macerator

Info

Publication number: GB2599635A
Application number: GB2015488.6A
Authority: GB
Inventors: Kerr Miller Matthew; Brownlee Steve; Partington Garry
Original assignee: Vernacare Ltd
Current assignee: Vernacare Ltd
Priority date: 2020-09-30
Filing date: 2020-09-30
Publication date: 2022-04-13
Also published as: AU2021354944A1; GB202015488D0; WO2022069856A1; CA3194280A1; EP4221897A1

Abstract

A system (100, Fig 1) having at least one pulp macerator and sensors n to sense operational parameters of each macerator and transmit a message to an associated controller. Each controller interprets the message and any further messages from respective sensors, and compares this/these state(s) to stored sensor states and determines an operation to execute based on the results of the comparisons. Communication 200 between controllers, transfers to operator interface 202 via terminal 201 and vice versa. Sensors may be optical, liquid, pressure, RF tag, microphone, user ID, ultrasonic or magnetic sensors. Each macerator may comprise an actuator to respond to controller command and may be of linear, rotary, audio transducer, display screen, gas or liquid valve, air compressor, water pump and/or cutter motor actuators. The controller may also store time interval information between messages of a particular type to establish frequency, which when above a certain threshold allows an alert to be sent.

Description

CONNECTED MACERATOR

Introduction

The present invention relates to macerators and in particular, but not exclusively, to macerators for use in disposing of soiled moulded paper pulp articles such as bedpans, urine bottles and the like to small particles, to enable them to be discharged into a sewer. The present invention relates in particular to a connected macerator system which utilises various sensors to sense operational parameters of respective macerators. This allows operational faults within one or more macerators to be identified quickly and effectively.

Background

The use of moulded paper pulp bedpans, urine bottles and the like has been known for many years. After use, the soiled article is disposed of in a macerator. A typical macerator takes the form of a generally cylindrical, upright drum having a rotatable cutting blade disposed at its base and rotatable by means of a motor. In use, an article to be macerated is placed in the drum and a lid closes off the aperture. During the operation cycle, water is fed into the container and the motor is operated, causing the blade to rotate. The articles within the macerator are reduced to small particles, at a size which allows them to be discharged into a sewer.

The very nature of the task which macerators perform means that they are repeatedly in use at all times of the day and night. The soiled articles could potentially be infectious or hazardous, and so it is important that waste is disposed of quickly and efficiently, with minimal human contact. This is particularly relevant in the case of infectious diseases, as in the current era of COVID-19.

If a macerator is malfunctioned and unable to be used, it would likely be necessary to transport soiled articles to be macerated to an operative macerator, thereby increasing the risk of cross-contamination and infection during such transport. Optionally, soiled articles are left to build up in a sluice room until the macerator is repaired or soiled articles are stored in bags until they can be disposed of properly this is poor hygiene practice and increases the risk of exposure to the waste.

It is therefore desirable for macerators to be readily and quickly repairable in the event of such a malfunction to avoid being out of action for a prolonged period of time, and to avoid unnecessary increased risk of cross infection.

Aspects and embodiments of the invention were devised with the foregoing in mind.

Summary

Disclosed herein is a system comprising a controller and one or more pulp macerator apparatus. Each pulp macerator apparatus comprises a sensor configured to sense an operational parameter of a respective pulp macerator apparatus and transmit a message representative of the sensor state to the controller, and a further sensor configured to sense a further operational parameter of the respective pulp macerator apparatus and transmit a further message representative of the further sensor state to the controller. The controller is configured to receive and interpret the message and the further message, perform a comparison between the sensor state represented by the message and a stored sensor state, perform a further comparison between the further sensor state represented by the further message and a stored further sensor state, and determine an operation to execute based on the result of the comparison and the further comparison.

The ability to diagnose, and potentially fix, issues remotely, without the need for physical human intervention at the site of a macerator may assist in the quick and effective repair of the macerator. It would also be beneficial to predict potential operational faults in advance and divert soiled articles away from potentially problematic equipment. This could also prove beneficial to the maintenance engineer, as faults may be identified prior to attending to the equipment, thereby minimising contact with potentially hazardous materials. The operation to execute may be determined to be an operation to do nothing.

The stored sensor states may be set by a manufacturer during assembly to indicate an optimal state, or threshold states before a further operation may take place. For example, this can be that before a lid is opened, an ultrasonic sensor must report a 'blocked' status which may indicate that a user is attempting to place an object in the macerator, which, subject to other sensor messages, leads to the opening of the lid by the controller. In an illustrative example, the ultrasonic sensor may be configured to detect the presence of a users foot. In this manner multiple sensor messages may be used to determine what the next operation should be. For example, a macerator may determine that although the lid is closed, the water level within the device is not yet high enough to activate the macerator. As such, the controller may determine that it should not take any further steps until the liquid level reaches the predetermined height. This prevents accidental activation, ensuring safe and correct operation of the device.

The system may further comprise a terminal, wherein the controller further comprises a communications module operable to transmit a message to the terminal, the message comprising information representative of a pulp macerator apparatus state. The controller may relay sensor information to the terminal in response to an event (such as sensor information not being in line with the established optimal conditions) or as a routine transmission to establish logs of activity and/or functionality.

The message may comprise information relating to more than one pulp macerator state.

The communications module of the system may be further operable to receive an instruction from the terminal. This two-way communication enables the terminal to take action based upon the messages received by the terminal from the controller. This could be preventative / prophylactic action based upon predictions of potential faults or maintenance derived from logs created from the messages, reactive action based upon those messages; or prescriptive action as defined by an operator.

The operation may then further comprise receiving an instruction from the terminal, such that in certain circumstances the controller may request instructions from the terminal or otherwise expect some input from the terminal responsive to sending a message. Further, the controller may wait for a predetermined timeout interval for a response, after which it may revert to pre-programmed instructions, which may be, for example, to revert to a dormant state, continue with another operation, repeat an operation or request further input from the terminal.

The instruction provided to the controller may comprise one or more of: a third operation; a yet further stored sensor state for use in a comparison operation; an instruction for determining an operation to execute; and a command to carry out the operation and or second operation or a command to reconfigure the controller with the stored sensor states or instructions for a determination operation.

The combination of these different categories of instructions may allow the terminal to remotely resolve various issues that have been identified by the terminal by analysis of the messages from the controller. The terminal may also remotely reconfigure the predetermined parameters of the comparison operations, and/or the determination operation, in response to said analysis.

Further, the system may further comprise an actuator within each of the one or 5 more pulp macerator apparatus, each actuator configured to actuate responsive to a command from the controller. The operation and or second operation or instruction may comprise one or more of: polling the sensor and or further sensor for a message; receiving and interpreting a message from the and or further sensor; performing a comparison between the stored and or further stored sensor state and a message from the sensor and or further sensor; sending a command to the actuator; and or transmitting the message to the one or more terminals.

These actuators may serve to carry out remote operations such as opening and closing a lid, pressuring seals or operating rotors. Such remote and automatic activation reduces interaction between humans and the machine, thus reducing contact and complexity of use by the user. By ensuring that both a next operation and or the instruction provided also comprise the routine operations of the macerator apparatus, the terminal or controller may individually determine the resumption of normal activity.

The operation and or second operation may further comprise carrying out the instruction received from the terminal responsive to receiving the instruction, to enable remote fault resolution and maintenance.

The terminal may be configured to: receive and interpret the message from the controller; collate information representative of the one or more pulp macerator apparatus states and individual sensor states thereof based upon the message from the controller; compare the collated information to a series of stored system data representative of various potential pulp macerator states; determine a corrective action based upon the comparison; and execute the corrective action.

Thus, the terminal is configured to reciprocate the communicative features of the controller such that messages may be sent from one to the other. The terminal is operable to perform analysis on the messages, be that analysis of historic information provided by messages received in the past or dynamic analysis of messages received in real time. This analysis may then be used for a determination of a corrective action, if such action is required.

The determination may comprise: recognising a combination of sensor states in the collation of sensor states by comparison with the stored sensor states; identifying an emergent property indicated by the combination of sensor states; and determining a corrective action based upon the emergent property.

The emergent property may be an event or entity that is not directly sensed by the sensors, and instead can be identified by a pattern of sensor messages which in combination identify the emergent property. The system may then determine that an alert should be sent to notify an operator of the emergent property, or may identify that the emergent property is indicative of a less serious fault than the sensor messages would ordinarily indicate and therefore not send an alert.

The system may further comprise an operator interface operable to communicate with the terminal, thus enabling an operator to review the collated information and issue new commands or instructions based upon the collated information. This also allows for emergency alerts to be provided to a user in response to a critical failure.

The corrective action may include one or more of: sending corrective instructions to the controller; sending alerts to the operator interface; and/or waiting for commands from the operator interface.

This enables the terminal to manage faults or potential faults with the pulp macerator apparatus with or without operator input.

Corrective instructions may comprise one or more of: polling a sensor for a message; receiving and interpreting a message from a sensor; performing a comparison between a predetermined sensor state and a message from a sensor; sending a command to an actuator; one or more further operations; one or more predetermined sensors states for use in a comparison operation; instructions for a determination operation; and for commands to carry out the further operations or commands to reconfigure the controller with the predetermined sensor states or instructions for a determination operation.

This enables the terminal to remotely address faults, remotely reconfigure, or remotely operate the pulp macerator apparatus as necessary for optimal operation and maintenance.

Each sensor of the system may comprise one or more of: an optical sensor; a liquid sensor; a pressure sensor; an RF tag sensor; a microphone; a user identification sensor; an ultrasonic sensor; and/or a magnetic sensor.

Thus allowing sensing of any operational parameter of the pulp macerator apparatus that is necessary for operation. A microphone may be provided to allow the use of voice recognition to identify a user, and to allow control of the macerator apparatus using speech recognition. A user identification sensor may also be provided to identify the user by other traits, such as facial recognition. Optionally or additionally, the user identification device may provide means for input of personal identification information.

Each actuator of the system may comprise one or more of: a linear actuator; a rotary actuator; an audio transducer; a display screen; a remotely operated gas valve; a remotely operated liquid valve; an air compressor; a water pump; and/or a cutter motor.

This may provide for automation of the macerator apparatus without, or at least minimizing, human intervention once the object to be macerated is inserted by the user.

The terminal of the system may be network-based and configured to 5 communicate with more than one pulp macerator apparatus. Accordingly control and coordination of the one or more pulp macerator apparatus may take place at a lower level in the architecture than the operator interface.

The controller may be operable to store a count of the number of messages of a particular type from any sensor. Whether an alert will be sent as part of the determined operation is then determined based on whether the count exceeds a predetermined value. This allows one-off non-critical faults to be recorded without disrupting normal operation, but relays an alert to the terminal if a particular fault repeats a certain number of times.

The controller may further store the time interval between the messages of a particular type to establish how frequently a particular type of message is received.

The determined operation may only include an alert to be sent if the particular type of message is received above a predetermined rate and the count of the number of particular messages exceeds a predetermined value. Thus, the system may determine that a particular fault has exceeded an allowed frequency before sending an alert.

The sensor of the system may be operable to send a message to the controller responsive to a change in the sensed parameter. By sending a message in the 'event-driven' paradigm, the system may respond more rapidly to faults using less processing power and/or data bandwidth than if it were polling sensors at a set rate.

List of Figures Figure 1 depicts a macerator apparatus in accordance with the present disclosure, illustrating locations and types of sensors. Dashed lines illustrate liquid waste flow, dot-dashed lines indicate water flow, and solid lines indicate gas flow; Figure 2 depicts a network which may be a wireless or wired network comprising at least one macerator apparatus, a terminal and an operator interface; and Figure 3 shows a process control flow diagram of the steps taken by the various sensors and control units in response to a sensor message in accordance with the present disclosure.

Description

The system 100 as shown in figure 1 includes a maceratora housing in the form of an open-topped drum 101 supported on a framework. In the illustrated embodiment the drum is cylindrical in shape, and comprises an upper drum portion and a lower drum portion.

A closure panel is mounted on the upper end of the framework and is provided with an aperture or opening which is aligned with the open top 102 of the drum.

The closure panel is also provided with a releasably closable, hingedly and pivotally mounted lid 103 which is configured to sealingly close the aperture during a macerating cycle. The mounting of the lid is motorised by an actuator 104 controlled by a controller 203 comprising a communication module. The actuator is provided with sensors 204 operable to detect that the actuator is inhibited from motion, for example by detecting an overvoltage condition.

One of the lateral sides of the lid 103 is also provided with a recess for receipt of a solenoid-actuated locking bolt 105 to retain the lid 103 in a closed position when desired. The solenoid-actuated locking bolt 105 is mounted in the closure panel, and is further provided with a sensor which is operable to detect whether or not the latch is engaged. The closure panel is further provided with a sensor 106 which is operable to detect whether the lid is in an open or closed configuration. The lid open/closed sensor messages are used by the controller 203, in conjunction with the messages from the latch sensor and the motor sensor to effectively operate the lid actuator as required, and detect faults as they occur.

The aperture of the closure panel is provided with a peripherally-extending inflatable seal 107 which is inflatable when desired by means of an actuated valve 108 and air compressor 109 at the appropriate point in the macerating cycle. The actuated valve 108 is configured to open responsive to a command from the controller 203, enabling pressurisation of the inflatable seal 107 by the air compressor 109. The inflatable seal is in fluid communication with a pressure sensor 110 operable to monitor the air pressure within the seal. The controller 203 is configured to cease operation of the apparatus if the seal pressure reduces below a predetermined threshold during an inappropriate phase of the apparatus operation cycle.

The lid is generally planar and an oval projection extends from its undersurface. The shape and size of the projection is configured to fit into the aperture and provides a fluid-tight seal with the inflatable seal when the latter is inflated. The undersurface of the projection is also provided with a spray head 111 by means of which water can be introduced into the drum when appropriate, as will be explained. The spray head is in fluid communication with a water pump 112 controlled by the controller 203.

The closure panel is also provided with an inlet 113 having a cap for filling a tank 114 within the macerator housing with disinfectant and/or deoderising fluid. The tank is provided with a liquid level sensor 115 in communication with the controller 203, and configured to send 301 a message to the controller 203 when the liquid level is low. The tank is in fluid communication with a pipe 116 that connects the aforementioned water pump to the spray head, via a further pump 117 configured to pump the disinfectant and/or deoderising fluid into said pipe.

The upper surface of the lid is also covered with a moulded plastics cover to provide a smooth outer surface which is less likely to harbour contaminated material and which is easier to clean.

The lower drum portion comprises a base wall which comprises a generally planar wall portion and a generally frusto-conical wall portion having a circular outlet aperture 118. The lower drum portion is provided with a liquid level sensor 119, in electrical communication with the controller 203, operable to detect that the drum has filled to a predetermined volume.

A macerator blade 120 is rotatably mounted immediately above the generally planar base wall with its rotational axis perpendicular to the generally planar wall portion. The macerator is rotatable by means of a cutter motor 121 mounted to the undersurface of the planar wall portion and controllable by the controller 203. The cutter motor is provided with a sensor that is operable to detect that the motor is inhibited from motion, for example by detecting an overload signal.

A releasably closable fluid valve 122 is mounted on the undersurface of the frusto-conical wall portion and has fluid valve closure member 123 whose position is controllable to selectively open or close the outlet aperture 118. The valve is configured to open and close responsive to pressure provided via an air valve 124 controlled by the controller 203, and the aforementioned air compressor 109 which is in fluid communication with the air valve. A pressure sensor 125 is in fluid communication with both the air valve 124 and the fluid valve closure member 123. The fluid valve 122 is in turn connected to an outlet pipe 126 for discharging the macerated contents of the drum into a sewer. A pressure sensor 126 is provided in fluid communication with the outlet pipe and operable to detect an overpressure in the outlet pipe. The outlet pipe 126 and pressure sensor are both in mutual fluid communication with the drum 101. The sensor is further operable to send 301 messages to the controller 203. The pressure sensor 127 for the outlet pipe is linked to the drum by a hollow pipe 128 that is configured to intersect with the drum above the intended maximum fluid level. This connection ensures that the sensor is arranged to sense gaseous pressure and that fluid cannot pass from the drum, past the pressure sensor and to the outlet pipe, thereby bypassing a drain valve.

A water cistern 129 is also provided within the macerator and is supplied with 10 water from an inlet 130 at the rear of the macerator.

A display panel at the front of the closure panel is also provided to indicate the status and/or condition of the macerator. In some embodiments the display panel comprises a touch responsive input surface.

An external module is optionally mounted on the macerator comprising an RFID sensor configured to detect an ID token. The module is further operable to send messages to the controller 203.

A housing for electrical and electronic components is mounted on the opposite side of the frame and a motion and/or proximity sensor, for example in the form of an ultrasonic transmitter/detector, is mounted to the front of the macerator frame near the 20 base The operation of the macerator is controlled electronically by means of a programmed controller 203 (not visible) mounted within the housing.

The macerator is connected to an exterior water tank 129 which is configured to provide water to the drum via a water pump 112. The water tank is provided with a liquid level sensor 131, which is in electrical communication with the controller 203.

The following table sets out sensor locations and functions for the described embodiment in accordance with the invention.

Sensor location Fau Potential Cause Multiple machines single °tato Low water Capacitive Top of Sends signal Triggers Mains water Low water liquid sensor water tank to PCB when message if tank isn't supply pressure, dirty water isolated, low water level is sufficient filled with water. Won't start until filled. water pressure, blocked filter, sensor fault supply, hardwater supply.

Low Capacitive liquid Deoderis-er fluid tank Detects when liquid level is low -particularly over prolonged period, Trigger info message -not necessaril y an error message but optionally can get machine to stop -configurati on choice for distributor. Deodoriser tank empty. Sensor issue N/a deodoriser sensor Hopper full Capacitive liquid Water tank Detects whether tank is empty before starting new cycle -detects overflow if drainage issue. Stops cycle from starting. Machine cannot start until error has been cleared, Repeated error would flag misuse. Misuse, non maceratable products used, competitor products, blocked drain, sensor issue, diaphragm fault, waste drains incorrectly installed. Misuse, lack of staff training, incompatible products used, site drain issue, competitor products used.

sensor Lid cannot move Lid motor Machine stopped. Lid motor fault.

Clutch on lid. Lid open and lid closed sensors issue. Sensor magnet positions, Lid movement physical restriction.

Lid cannot close Magnet sensor & current sensing by PCB Magnet on lid & PCB Detects when lid is fully closed, Message triggered if happens repeatedly Obstructed. Machine over filled. Sensor / magnet issue, Lid seal not fully deflated, lid lock extended. N/a Lid cannot open Magnet sensor & current sensing by PCB Magnet on lid & PCB VVhen current increases (motor struggling), indicates lid cannot open. Message triggered if happens repeatedly Obstructed, Something on lid, lid seal not fully deflated, lid lock N/a engaged. Sensor / magnet issue Drain valve pressure Pressure sensor Pressure switch in pneumatic s Detects when drain seal hasn't reached target pressure. Machine stopped. Air leak, faulty air pump, solenoid valve issue, diaphragm fault, pressure sensor fault, Altitude of install location Altitude of install location.

assembly Blocked drain Pressure sensor Main frame Trips at 40 mbar of pressure. Machine stopped -message triggered, Misuse, non maceratab-le products used, competitor products, blocked drain, pressure sensor issue, diaphragm fault, waste drains Misuse, lack of staff training, incompatible products used, site drains issue, competitor products used.

incorrectly installed.

Lid lock Lid closed sensor/sal enoid sensor Lock Solenoid should engage automatically engage, if not error message. Stop machine, but fault likely to continue. Message to send engineer, Potential short circuit on solenoid. Faulty microswitch, wiring fault, sensor magnet position, physical damage. N/a mechanis-m.

Check lid (lid opened/un locked during cycle) Microswitc h Attached to lock mechanis-m and lid closed sensor. Detects whether lock pin is locked or unlocked. Immediate message sent. Drain/vent blocked N/a Solenoid sensor/lid down sensor Blocked blades Inverter has overload signal fed to PCB Inverter sensing & control software. Reverse first to free blockage then stop if not cleared, Message sent. Regular blocked blades (2 or more in 24 hours) will flag message. Mis-use, Overloaded, Incompatible products, competitor products, inverter fault, motor fault, mechanical seal fault, Misuse, lack of staff training, incompatible products used, competitor products used, site electrical supply issues.

Lid seal pressure Pressure sensor Lid Detects when lid seal hasn't reached Won't start at lower than 5psi Air leak, damaged lid seal, faulty Altitude at install location.

target pressure. or stops if drops. Flagged if happens more than once in 1 hour. air pump, solenoid valve issue, pressure sensor fault, Altitude of install location Membrane communic ation Sensor to check that communic ations with Membrane is valid Chassis Diagnoses there is communicati on with Membrane N/A Not currently in use, as only pertinent with membrane not e-paper display. N/a Power fail No sensor When machine is turned on, power fail message displayed. Cycle will continue when power returns if mid-way. Message flagged for multiple failures in 24 hours. Message sent when power is restored. Mains supply unstable, faulty wiring, electrical storms, local maintenance engineering work. Electrical storms, generator tests, unstable site electrical supply.

Foot sensor (info only) Ultrasonic sensor Detects when object (foot) is between it and the floor, Causes the opening and closing of the lid. Mechanism for opening and closing lid N/a Lid open (info only) Magnet sensor Magnet on lid, sensor on Detects when lid is fully open. Sends signal. Used by PIC program to identify lid state N/a chassis.

RFID (info only) Additional module. External of machine, Machine locked until acceptable ID is swiped. Gain access to machine for 1 min. Unauthorised person trying to access. N/a Daily report low / no cycle count. GSM module PCB If GSM connected and signal ok then machine will send out daily status message. Machine powered but not being used. Ward not in use, no pulp No pulp on site.

available.

Service GSM PCB Set point If not cleared If not cleared call module (20k) for number of cycles reached. scheduled maintenance is overdue or no maintenance contract in place. scheduled maintenance is overdue or no maintenance contract in place.

No daily GSM PCB If GSM Corns signal Corns signal message module connected and signal ok then machine will send out daily status message. fault, machine powered off or uninstalled. fault.

In operation the controller 203 receives messages from the sensors 204 and determines operations based upon the sensor messages, an illustrative sequence of events is set out below in accordance with an embodiment of the invention.

The user inserts a foot into an indicated area at the base of the macerator, whereupon a sensor detects that the foot is present. In response to receiving the message from the sensor that an object has been detected, the controller 203 then checks the hopper sensor and motor sensor messages to confirm that the hopper is empty and that the motor is stationary. In response to identifying that these conditions are met, the controller 203 sends a command to the lid motor to open the lid.

In some embodiments, the macerator may additionally identify the user by means of voice recognition, facial recognition, use of a PIN, or by RF tag. The identification of a user may then be used to identify a set of operations that the user is authorized to initiate. Optionally or additionally, faults occurring after the user identification may be used to identify a training need for the identified user.

The controller 203 then awaits or polls the lid closure sensor to determine whether the lid has successfully opened. If the sensor does not indicate that the lid has opened, then the controller 203 sends a command to the lid motor to close. The lid closure sensor is again polled or a change in state of the sensor awaited by the controller 203. If the lid does not close, the user is presented with an option to reset the system and displays that a lid fault has occurred. The controller 203 stores that a lid fault has occurred, along with the time index of the fault.

If the lid successfully opens, then the user may insert an object to be macerated.

In some embodiments, the products may comprise an RF tag which can be read by the macerator RF tag sensor to identify the products to be placed in the macerator by the user.

Once this has been completed or the user otherwise wishes to advance the macerator cycle, the user may re-insert their foot into the indicated area. In response to detecting the foot, the controller 203 will command the lid motor to close.

The controller 203 again awaits or polls the lid closure sensor to determine whether the lid has successfully closed. If the sensor indicates that the lid has failed to close, the controller 203 issues a command to the lid motor to open the lid, and awaits or polls the lid closure sensor to determine whether the lid has reached the fully open state. If it fails to reach the open state, the fault is again presented to the user on the display panel and the user is given the option to reset the system.

Depending on the user specified configuration, the system may automatically start the macerating cycle or start dependent upon user interaction on a control panel.

The controller 203 then checks the fluid level sensor in the lower drum to determine whether the liquid level is already at the maximum allowed value for the cycle to start. If the liquid level exceeds this threshold, then the controller 203 will send commands to open the lid and alert the user to a drainage fault.

Once it is determined that the hopper is not full, the controller 203 sends a command to the solenoid-actuated locking bolt to engage, thereby securing the lid in the closed configuration.

The solenoid-actuated locking bolt sensor will send a message to the controller 203 indicating that the lock has engaged, or that the lock has failed to engage. If the lock fails to engage, and has not previously failed, the controller 203 will display a message to the user to once again insert their foot to open the lid of the macerator, at which point the cycle starts from the beginning.

If the lock has failed to engage once and now fails to engage again, then the controller 203 indicates a lid lock fault alert to the user.

If the lid lock is successful, then the controller 203 checks the liquid level in the water tank. If the liquid level in the tank is not high enough to start a cycle, the controller 203 will display a low water indicator to the user, and wait for a predetermined interval to allow the water tank to fill to an appropriate level. This ensures that a fault is not generated if, for example, the macerator cycle has recently run and the tank is still refilling.

If after this predetermined interval the tank remains unfilled, then a low water' alert is issued and the user is invited to clear the error, at which point the system returns to the automatic start or prompted start stage.

If the water level is determined to be sufficient, then the controller 203 activates the air compressor. The controller 203 then sends a command to the air valve connecting the air compressor to the inflatable seal to open, thus inflating the seal. The inflatable seal pressure sensor then sends a message to the controller 203 indicating whether or not the minimum pressure for an effective seal has been reached.

If the minimum pressure has not been reached, then the controller 203 presents a lid seal error alert to the user and prompts the user to clear the error. The controller 203 will also send commands to deactivate the air compressor and vent the inflatable seal. The controller 203 will return to the stage of determining that the lid has been properly closed, and resume the cycle from there.

If the seal is correctly inflated, then the controller 203 sends a message to the air valve connecting the air compressor to the drain valve, thus causing the drain valve to close. The pressure sensor connected to the drain valve pressure sensor then sends a message to the controller 203 indicating whether or not the minimum pressure for an effective seal has been reached.

If the minimum pressure has not been reached, then the controller 203 presents a drain valve error alert to the user and prompts the user to clear the error. The controller 203 will also send commands to deactivate the air compressor and vent the drain valve. The controller 203 will return to the stage of determining that the lid has been properly closed, and resume the cycle from there.

If the minimum pressure is reached, then the controller 203 sends a command to the water pump to begin filling the hopper with a pre-determined volume of water. The pressure sensor in fluid communication with the hopper and the drain then sends a message to the controller 203 indicative of the pressure in the drain and hopper.

If this pressure exceeds a predefined value, the controller 203 displays an alert to the user that the drain is blocked, and prompts the user to clear the fault. Once the user confirms that the fault is cleared, and if this fault has not occurred once before, the controller 203 will cause the water pump to further fill the drum with water from the water tank, thereby increasing the drain pressure.

If the fault has occurred once before, the controller 203 causes the lid seal pressure to be released and the system returns to the system state at the start of the process.

If the drain pressure is acceptable, the controller 203 issues commands to the cutter motor to rotate at a series of frequencies for a determined period.

If the cutter motor sensor detects that the motor is inhibited from motion, it sends a message to the controller 203. The controller 203 will then command the cutter motor to rotate in an opposite direction, to attempt to clear the blockage. An alert for a blocked blades fault is displayed to the user, and the user is prompted to clear the fault. If the fault has not occurred once before, then the system returns to the state at the start of the 'maceration' stage and restarts the cutting sequence.

If the fault has occurred once before, then the controller 203 deflates the inflatable seal and prompts the user to open the lid, close the lid, and resumes the cycle from the start of the maceration stage.

If the maceration stage is completed without a blocked blades fault, the controller 203 sends commands to release the pressure in the drain valve, thus opening the drain. The controller 203 then sends commands to the water pump to pump more water into the hopper, thus cleaning the drum.

The controller 203 sends commands to the water pump connecting the tank of deoderiser/ disinfectant to the inlet to the drum, to infect the deoderising/disinfecting fluid into the drum.

The controller 203 then commands the cutter motor to stop rotating, and the inflatable seal is commanded to deflate. The system increments a stored count of the number of cycles completed, and returns to the start of the cycle.

Figure 3 is a process control flow diagram which describes an illustrative sequence of events from the perspective of data and commands at the networked level. This figure is not intended to fully illustrate the working of the invention at the sensor-actuator level, but to illustrate an interaction between the networked elements.

In the above-recited sequence of events, each prompt to the user for interaction to clear a fault may instead direct such prompts to a terminal 201 remote from the macerator. The terminal 201 is operable to identify faults by interpretation of the sensor messages directly or by direct messaging from the controller 203 that there is an alert.

The terminal 201 is further operable to issue commands or instructions to the controller 203 that replace user input insofar as can be achieved without physical intervention. For example, although the terminal 201 may remotely clear faults, it may not necessarily remotely open and close the lid.

In the above-recited sequence of events, it is noted that the local count information (such as how many times a fault has occurred) may be 'global', in that these counts do not reset at the start of the cycle, or are confined to a single operational cycle, such that they are reset once a full cycle has been completed. These counts may also be relayed to the terminal 201 for analysis.

Figure 2 illustrates the networked nature of the invention, wherein the network 200 may be wired or wireless. The figure illustrates the flow of data from the sensor(s) to the controller(s), terminal, and finally operator interface if required, in solid lines. The dashed lines indicate possible flow of commands and instructions to the macerator apparatus.

It is anticipated that a variety of equipment may be used in the implementation of an embodiment of the invention. In an illustrative embodiment, the equipment used is set out in the below table.

Component Name Exemplary implementation Lid safety sensor Limit safety switch 8870W1D1T Inflatable seal pressure sensor IFM (RTM) pressure switch PV7004 Drum liquid sensor IFM (RTM) Sensor K06004 Deodoriser liquid level sensor IFM (RTM) Sensor with Mount KQ6004-[12154 Lid closed sensor IFM (RTM) magnetic sensor MK5122 Drain pressure sensor Pressure Transducer 9210212 Drain Valve Pressure Sensor IFM (RTM) PV004 Foot Sensor IFM (RTM) Ultrasonic sensor Tank liquid level sensor IFM (RTM) KQ6004-E12154 sensor Lid Open Sensor IFM (RTM) MK5122 Magnetic Sensor Cutter motor 0.5KW (RTM) Motor Air compressor 24V DC air compressor The terminal 201 may further analyse the sensor messages received from the controller 203, and create and store logs of the sensor messages.

The terminal 201 may further analyse the logs together with 'live' sensor messages to determine that a fault pattern has emerged that is indicative of an "emergent property", rather than that of a directly sensed property.

The controller 203 may collate the sensor messages in a message to provide to the communications module, such that one message is sent to communicate sensor messages to the terminal.

The communications module of the controller 203 may be configured to transmit and or receive messages via SMS to the terminal. The controller 203 may further sent messages indicative of an error state to the terminal, the messages comprising the device serial number, the number of cycles completed, data relating to the error, the firmware version of the device, and the time and date of the error.

In such communications, the data relating to the error may be a number that has an assigned meaning agreed between the controller 203 and the terminal.

Such an emergent property may be an event, such as a facility using the macerators incorrectly by inserting inappropriate objects that whilst not blocking the macerator irreparably, does cause a slight blockage frequently. Because this may be evidenced in both blocked blades errors and blocked drain errors, in which it is possible that this does not actually prevent operation if the fault only occurs once, this analysis would be able to flag that the products in use may not be compatible with the macerator and send 314 an alert to a user interface 202.

The user interface 202 may then be able to provide 312 instructions to the terminal 201 to alter the pattern of frequencies used by the cutter motor to macerate the products placed within it, to remedy the emergent property.

A further emergent property may be that the facility operating the macerators is not correctly training staff to use the macerators, detected by multiple macerators reporting over-full 'hoppers' or 'drums' during use, blocked blades or blocked drains.

It is further anticipated that environmental properties may be detectable by the aforementioned system, for example that the macerators have been installed in a high altitude location as evidenced by multiple pressure faults across a number of macerators.

The terminal 201 may identify multiple disparate faults amongst a plurality of macerators and determine a further emergent property that is the cause of the faults. For example, the terminal 201 may identify that multiple macerators are reporting lid lock error faults and lid seal pressure faults at an increased frequency, indicating poor staff training or lack of operator awareness.

As used herein any reference to "one embodiment" or "an embodiment" means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase "in one embodiment" or the phrase "in an embodiment" in various places in the specification are not necessarily all referring to the same embodiment.

As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, "or" refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

In addition, use of the "a" or "an" are employed to describe elements and components of the invention. This is done merely for convenience and to give a general sense of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

In view of the foregoing description it will be evident to a person skilled in the art that various modifications may be made within the scope of the invention. For example, a message between a controller and terminal may comprise information about more than one sensor state and/or more than one macerator apparatus. Additionally, embodiments in accordance with the present invention the not be limited to determining one or more direct or emergent states or properties of one or more macerator apparatus and the skilled person will recognise that embodiments in accordance with the present invention may be configured to utilise different sensors to identify different sequences of sensor activity and scenarios to determine direct or emergent states or properties.

The scope of the present disclosure includes any novel feature or combination of features disclosed therein either explicitly or implicitly or any generalisation thereof, not incompatible therewith, irrespective of whether or not it relates to the claimed invention or mitigate against any or all of the problems addressed by the present invention. The applicant hereby gives notice that new claims may be formulated to such features during prosecution of this application or of any such further application derived therefrom. In particular, with reference to the appended claims, features from dependent claims may be combined with those of the independent claims and features from respective independent claims may be combined in any appropriate manner and not merely in specific combinations enumerated in the claims.

G.446-449 vf3 \ 447683 \GB DOCS FOR FILING \Description.clocx

Claims

Claims: 1. A system, comprising: a controller; one or more pulp macerator apparatus, each pulp macerator apparatus comprising: a sensor configured to sense an operational parameter of a respective pulp macerator apparatus and transmit a message representative of the sensor state to the controller; a further sensor configured to sense a further operational parameter of the respective pulp macerator apparatus and transmit a further message representative of the further sensor state to the controller; wherein the controller is configured to: receive and interpret the message; receive and interpret the further message; perform a comparison between the sensor state represented by the message and a stored sensor state; perform a further comparison between the further sensor state represented by the further message and a stored further sensor state; and determine an operation to execute based on the result of the comparison and the further comparison.
The system of claim 1, further comprising: a terminal remote from the pulp macerator apparatus; wherein the controller further comprises a communications module operative to transmit a message to the terminal, the message comprising information representative of a pulp macerator apparatus state.
The system of claim 2 wherein the communications module is further operative to receive an instruction from the terminal.
4. The system of claim 3 wherein the operation comprises receiving an instruction from the terminal.
5. The system of claim 3 or 4 wherein the instruction comprises one or more of: 23 a second operation; a yet further sensor state for use in a comparison operation; an instruction for determining an operation to execute; and a command to carry out the operation and or second operation or a command to reconfigure the controller with the stored sensor states or instructions for a determination operation.
6. The system of any of claims 1 to 5, further comprising an actuator within each of the one or more pulp macerator apparatus, each actuator configured to actuate responsive to a command from the controller, and wherein the operation and or second operation or instruction comprise one or more of: polling the sensor and or further sensor for a message; receiving and interpreting a message from the and or further sensor; performing a comparison between the stored and or further stored sensor state and a message from the sensor and or further sensor; sending a command to the actuator; and or transmitting the message to the one or more terminals.
7. The system of any of claims 4 -6 wherein the first, second and or third operation further comprises carrying out the instructions received from the terminal responsive to receiving the instruction.
8. The system of claim 7, wherein the terminal is configured to: receive and interpret messages from the controller; collate information representative of the one or more pulp macerator apparatus states and individual sensor states thereof based upon the messages from the controller; compare the collated information to a series of stored system data representative of various potential pulp macerator states; determine a corrective action based upon the comparison; and execute the corrective action.
The system of claim 8 wherein the determination comprises: recognising a combination of sensor states in the collation of sensor states by comparison with the stored sensor states; identifying an emergent property indicated by the combination of sensor states; and determining a corrective action based upon the emergent property.
10. The system of claim 9 wherein the system further comprises an operator interface operable to communicate with the terminal.
11. The system of claim 10, wherein the corrective action is one or more of: sending corrective instructions to the controller; sending alerts to the operator interface; and/or waiting for commands from the operator interface.
12. The system of claim 11, wherein the corrective instructions comprise one or more of: polling a sensor for a message; receiving and interpreting a message from a sensor; performing a comparison between a stored sensor state and a message from a sensor; sending a command to an actuator; a fourth operation; one or more stored sensors states for use in a comparison operation; instructions for a determination operation; and /or commands to carry out the first, second, third and or fourth operation, or commands to reconfigure the controller with the stored sensor states or instructions for a determination operation.
13. The system of any preceding claim wherein the sensor comprises one or more of: an optical sensor; a liquid sensor; a pressure sensor; an RF tag sensor; a microphone; a user identification sensor; an ultrasonic sensor; and/or a magnetic sensor.
14. The system of any of claims 6 -13 wherein the actuator is one or more of: a linear actuator; a rotary actuator; an audio transducer; a display screen; a remotely operated gas valve; a remotely operated liquid valve, an air compressor, a water pump; and/or a cutter motor.
15. The system of any of claims 2 to 14 wherein the terminal is network-based and configured to communicate with more than one pulp macerator apparatus.
16. The system of any preceding claim wherein the controller is operable to store a count of the number of messages of a particular type from any sensor, and wherein an alert will be sent as part of the determined operation if the count exceeds a predetermined value.
17. The system of claim 16 wherein the controller further stores the time interval between the messages of a particular type to establish how frequently a particular type of message is received, and wherein the determined operation may only include an alert to be sent if the particular type of message is received above a predetermined rate and the count of the number of particular messages exceeds a predetermined value.
18. The system of any preceding claim wherein the sensor sends a message to the controller responsive to a change in the sensed parameter.