Device for collecting statistical data for maintenance of small-arms

[0001] This is a continuation-in-part patent application of application Ser. No. 10/720,778, filed Nov. 24, 2003 now U.S. Pat. No. 7,100,437, entitled “A DEVICE FOR COLLECTING STATISTICAL DATA FOR MAINTENANCE OF SMALL-ARMS”, which is hereby incorporated herein by reference.

[0002] 1. Field of the Invention

[0003] This invention relates generally to the field of usage monitors for small-arms and more specifically to a device for determining wear in small-arms through data collection and statistical analysis.

[0004] 2. Description of Related Art

[0005] Many devices have been proposed to monitor the number of rounds fired an automatic or semi-automatic weapon. In general these devices are meant to warn the shooter before the magazine becomes empty. Some of these devices count the number of rounds in a magazine; others assume that a full magazine has been inserted and count the number of rounds fired using a shot detector. A few devices have been proposed that record the time and date when a weapon was fired, particularly for use in criminal investigations. Yet other devices are currently in use on paint-ball guns for scoring, timekeeping and billing purposes. Although all of these devices are able to impart useful information about small-arms use over short periods none can provide information that can be related to wear of the barrel or internal mechanisms that are an essential part of any maintenance program.

[0006] Maintenance of small-arms is of particular concern to law enforcement, the military and to competitive shooters. Wear gradually degrades the accuracy of a firearm and in extreme cases can lead to the bursting of a barrel and injury to the shooter. Wear can also lead to jamming, particularly in automatic and semi-automatic firearms. Maintenance schedules based on time in service completely ignore the firing schedule of a firearm. When used in training thousands of rounds can be fired in a period of several months while in other periods a firearm may remain completely unused. A monitor that can be used to relate the firing history to barrel wear would allow maintenance to be based on usage, thereby benefiting all users of small-arms.

[0007] Some attempts have been made to record such data. In patents by Davis et al, (1975, U.S. Pat. No. 3,914,996) and by Gartz (1999, U.S. Pat. No. 5,918,304) an electronic apparatus is disclosed for determining the wear of the gun tube of an artillery weapon. Wear in an artillery gun tube is governed not only by the number of rounds fired but also by the charge, which may be varied with each round. Davis et al used a strain transducer to detect that a shot had been fired and applied a weighting function, proportional to the strain level, to determine the charge. The weighted number of shots fired was then stored in memory so that barrel wear could be estimated.

[0008] The approach of Davis et al fails to take into account the effects of temperature on barrel wear. If a series of rounds are fired the gun tube is heated and wear, which results from the abrasive properties of the propellant, corrosion by the expanding gases and thermal gradients through the tube wall, is greatly accelerated. It is also of limited applicability to small-arms where the shock and vibration of ordinary handling could produce many false counts.

[0009] In U.S. Pat. No. 4,001,961 (Johnson et al, 1977) a shot counter is attached to a firearm for use in a maintenance program. As an example, they cite the replacement of the extractor after 15,000 rounds have been fired. Firing is detected by a micro-switch on the trigger, an inductance or piezoelectric transducer in the buffer, or an inertial switch that responds to recoil. The switches complete an electric circuit containing a battery that allows an electrochemical plating process to proceed while the transducers are used in a passive system, providing the electric potential that drives the plating. Usage is monitored by comparing the thickness of the plated layer at one end of a transparent tube to a color-coded scale on or adjacent to the tube. As in the previous citation there has been no thought given to avoiding false counts through handling.

[0010] Avoiding false counts is addressed in a patent by Hudson et al (1979, U.S. Pat. No. 4,146,987). An inertial switch comprising a pivoting, eccentric mass, a mechanical counter and a spring that allows a threshold acceleration to be set. This purely mechanical system is relatively large and difficult to implement on small-arms. It is also likely to undergo a change in threshold as the contact surface between the spring and the shaft wear during use. Clearly an electronic device is preferable for use with small-arms where size and weight are important concerns.

[0011] An example of an electronic shot counter for small-arms is that patented by Home and Wolf (1991, U.S. Pat. No. 5,005,307). Two micro-switches are used to provide input to a micro-controller that counts the rounds remaining in a magazine. An LCD display is used to indicate this count. Insertion of a new magazine is sensed by the first switch and the count is reset. Firing is detected by a second switch on the gun's slide. Doubtless this device could be modified to count the cumulative number of shots fired, however, slide movement while unloaded or when chambering the first round from a new magazine will result in false counts.

[0012] A number of other patents add desirable features to the teaching of Home and Wolf. The aforementioned device cannot differentiate whether a round is in the chamber when a new magazine is inserted; Herold et al (1997, U.S. Pat. No. 5,642,581) resolve this ambiguity by allowing the user to increment the count indicated by the counting device; Villani (2000, U.S. Pat. No. 6,094,850) teaches the use of an additional switch within the chamber to automatically adjust the count. Neither device can differentiate between a round that has been fired and one that has been ejected without firing as required when a weapon is to be made safe.

[0013] Other inventors have sought to eliminate micro-switches in order to reduce cost and complexity while improving accuracy, reliability and sensor life. U.S. Pat. No. 5,406,730 (1995, Sayre) describes the use of an inertial switch in combination with an acoustic sensor to detect firing. Handling shocks cannot cause false counts because an acoustic signal must occur simultaneously before the count is incremented. Similarly, an acoustic signal from a weapon fired nearby cannot increment the count unless a simultaneous recoil is detected. Brinkley, in U.S. Pat. No. 5,566,486 (1996), discloses an inertial switch that is adjustable; this makes it possible to set the acceleration level that will trigger a count so that recoil can be differentiated from handling shock. An additional benefit of this device is it ability to be adjusted to work on weapons with different recoil characteristics. A stated use of Brinkley's shot counter is to record the number of shots fired during a firearm's lifetime for use in its maintenance.

[0014] The patent of Harthcock (1994, U.S. Pat. No. 5,303,495) teaches the use of a Hall-effect device for counting shots fired from small-arms. A micro-processor records in non-volatile memory the time and date of each shot fired along with the direction, from a Hall-effect compass, for crime lab analysis. In common with many of the previously described devices this counter cannot distinguish between the firing of a round, the chambering of the first round after the last shot in a magazine has been fired or the ejection of an unfired round.

[0015] The most technologically advanced devices for monitoring the firing of a projectile have been developed for use in paintball guns. When used in commercial applications it is important to record the number of rounds fired and the amount of time that a gun has been used. It is also desirable to provide information such as firing rate, maximum firing rate and battery condition to the user and to communicate these data, along with the gun's identification number, back to a control center. These features are all taught in U.S. Pat. Nos. 6,590,386 (2003, Williams) and 6,615,814 (2003, Rice and Marks). Both patents teach the use of a temperature sensor that is used to monitor the pneumatic canister that powers the projectiles. Williams differs from Rice et al in the use of a detachable device that fits onto the muzzle end of the barrel and additionally measures projectile velocity.

[0016] Since barrel temperature is known to be a critical factor in determining the rate of wear it is preferable that this parameter be monitored during firing if an accurate assessment of a weapon's condition is to be made. None of the patents cited have means to measure this temperature nor do they have a way to determine the number of rounds fired at a particular temperature. None address data storage and its presentation so that it can be easily interpreted by the user or by an armorer. Further shortcomings of the aforementioned devices is their inability to be easily adapted for use on different weapons. With the exception of Williams's device all are difficult to retrofit to a variety of small-arms. Furthermore, those devices that utilize inertial switches, thereby avoiding the miscounts that are inherent in other sensing systems, cannot easily be altered to accommodate accessories such as night-vision scopes or noise suppressors that substantially change the mass of a weapon.

[0017] The invention provides a system and method for collecting data on small-arms usage in the form of a device which is mounted to the firearm so as to be able to sense at least an impulse in the firearm due to firing. In one embodiment the device is mounted to the barrel of the gun, although in other embodiments it may be mounted elsewhere. The device has a means to mount the electronics onto or within a gun so that it is protected from the heat of the barrel (in embodiments mounted to the barrel); an impulse sensor; a processor and memory. The processor accepts impulse signals from the sensor, and uses either a hold-off delay or a windowing time to determine and store information related to the firing of the firearm. This information may be any combination of temperature, firing rate, firing intervals and time data for subsequent analysis, and, optionally, information identifying the weapon to which the device is attached. The device preferably has an interface to transfer data from the device to a computer or other data collection device.

[0036] Detailed descriptions of various embodiments of the invention are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.

[0037] A first embodiment of the invention utilizes a “hold-off delay” technique to sense shots fired by the firearm, and avoid miscounts due to extra impulses generated by the firearm during firing. A signal threshold is used to distinguish between signals which represent shots and extraneous impulses due to knocking the weapon against other objects or the like.

[0038] In one embodiment of the invention, the shot counter of the invention is mounted to the barrel of the firearm. Since it is preferable to measure the barrel temperature during firing, if the shot counter is to accumulate data on this parameter, it must have a thermal sensor be in thermal communication with the barrel. This is preferably done by having the shot counter itself mounted to the barrel.

[0039] However, during heavy firing of an automatic weapon the gun barrel can reach temperatures of 400° C. or higher. Most commercial electronics are designed to operate at temperatures no higher than 125° C. and eutectic tin-lead solders melt at 183° C. Consequently, the shot counter must be thermally isolated from the barrel. This may be accomplished by separating the device from the barrel and using a remote temperature sensor or by insulating the device from the barrel and providing sufficient surface area for free convection cooling to be effective.

[0040] One of many possible mounting schemes is shown in figure one. In this embodiment the shot counter's case 12 is attached to the barrel 11 by clips 16 via insulators 13 and adhesive layer 14. The clips 16 may be threaded into nipples (not shown) that are retained within insulator 13 or they may be designed to simply clip into place; these and other mounting schemes are widely practiced. It is advantageous to use a material such as stainless steel for clips 16 since this may be easily formed, has a high yield strength and a low thermal conductivity, however, many other materials may be used.

[0041] Insulator 13 may be made from any material that has sufficient strength and a low thermal conductivity. Ceramic materials meet these requirements, particularly glass ceramics which have a conductivity of less than 1 W/m° C. Stainless steel may also be used if its higher conductivity, typically 10 to 20 W/m° C., is countered by the addition of cooling fins on the insulator.

[0042] Case 12 may be attached to insulator 13 by any means that does not form an efficient thermal conduction path. A high-temperature silicone adhesive 14 is preferred as this class of material can withstand temperatures of over 400° C., has excellent adhesion to most materials and is resistant to attack by most common solvents. Useful alternate adhesives include cyano-acrylates and high-temperature epoxies. Mechanical fasteners with low thermal conductivity, for example ceramic or stainless steel machine screws, can also be used.

[0043] A thermocouple can be used as the temperature sensor. This may be embedded within the contact surface of insulator 13 with the bead 18 positioned so that it will contact the barrel 11. Alternatively a spring or compliant material can be used to maintain the thermocouple bead in contact with the barrel. If an infrared device 19 is used it is sufficient to provide a path for thermal radiation to reach the detector.

[0044] The shot counter case 12 is provided with a plurality of contacts 15a–c for communication to an external device such as a laptop or hand-held computer. These contacts must be electrically isolated from case 12 by an insulating material 17. It is important to minimize the size of the electrical isolation in order to prevent the escape of electromagnetic radiation and to minimize radio-frequency interference. This is of great concern in military applications where an enemy combatant could use RF emissions to target a shooter. A display, such as an LCD, is a common source of RF emissions—for this reason a display is an optional part of the shot counter depending on its intended use.

[0045] A second mounting scheme for the shot counter is shown in figure two. In this embodiment a segmented insulating material 23a–d is clamped around the barrel 11 by a strap 26. This clamp may be tightened by any well-known means such as an eccentric lever, cam, thermal expansion, stretching, etc. It may also mechanically retain case 22 against insulator segment 23a although mechanical fasteners and adhesives can equally well be used. The insulating segments 23a–d accommodate small variations in the diameter of the barrel 11 and simplify installation.

[0046] Insulating material 23a–d must be able to withstand contact with barrel 11 as temperatures rise to 400° C. and above. There is, however, a significant thermal gradient radially outwards from the barrel 11 through the insulators 23a–d to the strap 26. Another insulating layer, 28, that has lower conductivity than material 23a–d but is less able to survive the high temperatures adjacent to barrel 11, may optionally be used to further reduce heat-transfer to the strap 26. Similarly, a layer of low conductivity material 29 may be disposed between insulator 23a and case 22. Materials that may be used for layers 28 and 29 include silicones and Muscovite mica. Insulation of any insulating layer may be further improved by surface roughening, the creation of air pockets, sintering with minimal densification and other processes known to those versed in the art.

[0047] The temperature sensor (not visible) projects from the case 22 through insulators 29 and 23a to barrel 11. If a thermocouple is used as a sensor a spring or compliant material can be used to maintain it in contact with the barrel. If an infrared device is used it is sufficient to provide an opening for thermal radiation to reach the detector.

[0048] As in the first embodiment contacts 25a–c are provided for communication. A display may optionally be provided.

[0049] The shot counter may be incorporated within a weapon or adapted to be mounted on an attachment rail as illustrated in FIG. 3. The electronics of the shot counter are enclosed within the case 32 that is attached to mounting rail 36, underneath the heat shield 38, in any of several widely used manners. A contact (not visible) within the mounting rail 36 connects temperature sensor 34 to the electronics within case 32. If the temperature sensor 34 is a thermocouple a spring 33 is used to hold it against the barrel (not shown). Contacts and a display may be provided.

[0050] Many other mounting methods may be envisaged for the shot counter. It may be embedded within a hand grip or stock, clipped or strapped onto the weapon or inserted within the space between the barrel heat-shield and the hand-grip or rail interface system.

[0051] FIG. 16 shows such an embodiment, where the shot counter of the invention 160 is incorporated within the hand grip 161 of an automatic pistol 162. In such a mounting, it is more difficult to directly sense barrel temperature through a thermal sensor in the counter case itself. Instead, a remote sensor 163 may be placed in contact with, or adjacent to the barrel 164, and connected to the shot counter by any connection known to the art, such as wires, fiber optics, inductive, IR or wireless connection, etc.

[0052] The operation of the shot counter will next be explained with reference to the block diagram of figure four. Power is supplied by one or more batteries 42. Since it is desirable to minimize the size and weight of the shot counter while maximizing the intervals between battery replacement zinc-air batteries are preferred. These have the highest charge density that is currently available.

[0053] Since power consumption is of critical importance a low-power microprocessor 40 that has a sleep mode has preferably been used. In this embodiment at least three A/D inputs and at least two timers are required although these requirements can be reduced if different sensors and timing schemes are employed. It is also advantageous to have on-board non-volatile memory for data storage. An example of a processor that meets these requirements is the PIC18LF2320 by MicroChip Inc. This is a RISC processor with 256 bytes of onboard EEPROM and 8192 bytes of program memory. In sleep mode its power consumption can be as low as 0.2 μA while in operation it is less than 600 μA when operating at a clock speed of 4 MHz. This clock speed represents a good compromise between processing speed and power consumption within this device.

[0054] Three inputs are provided to the microprocessor 40 that make it possible to sense that a shot has been fired and to measure the temperature of the barrel. In one embodiment a piezo-electric accelerometer 43 is used to detect firing. This accelerometer is most effectively mounted with its base attached to the case of the shot counter (not shown) and oriented along the axis of the barrel so that the recoil of the gun, which occurs whenever a shot has been fired, produces a measurable charge. It may also be mounted orthogonal to the axis, if desired. This charge may be measured as a voltage at one of the A/D inputs 41a of the microprocessor 40. An accelerometer is especially useful in this application since it consumes no power. In addition, it can be tuned to provide peak response in the frequency range of interest.

[0055] Referring now to figure five the details of the accelerometer mounting will be described. An accelerometer typically consists of a piezo-electric ceramic slab 51 that is loaded by a mass 52 and mounted within a case 53. Tuning may be accomplished by mounting the accelerometer 16 on a thick layer of a soft material such as silicone rubber 54. The relationship between the stiffness of the mounting layer 54 and the mass of the accelerometer 16 determines the system's frequency response.

[0056] From FIG. 6 it may be seen that signals at frequencies well below resonance 61 are unamplified while those well above the accelerometer's resonance frequency 62 are attenuated—the compliant mounting acts as a mechanical low-pass filter. Impacts on the barrel or the action of an automatic or semiautomatic weapon excite resonances within the barrel that could lead to a false indication that a shot has been fired if an accelerometer is used as a sensor. By setting the resonance frequency of the accelerometer to be below the lowest resonance frequency of the barrel most false counts can be eliminated. For weapons such as an M4 carbine or an M16 this frequency should be below 3 kHz and more preferably below 1 kHz. For other weapons the barrel's resonance should be measured to determine the appropriate cut-off frequency. Mechanical filtering, as characterized by response curve in FIG. 6, requires no power. While the same response could be achieved using an electrical low-pass filter or resonant circuit this would require the addition of a charge amplifier, increasing the power consumption and limiting the battery life.

[0057] As an alternative embodiment to the accelerometer measuring physical impulses in the firearm, an RF detector can detect a radio-frequency impulse caused by the explosion of gunpowder. Schematically, this would be the same as shown in FIG. 4, except that element 43 would detect radio impulses instead of physical impulses. The impulse signal output would remain essentially the same as shown for the accelerometer in FIG. 7, except that there would not be any follow-up pulses 72 and 73, and the method of processing the signals is the same. The RF sensor could be a small dipole antenna, coupled to a detector such as a diode.

[0058] The remaining inputs to the shot counter will now be described with reference to figure four. Elevated barrel temperature has been shown to increase the rate of barrel wear which leads to inaccuracy of the weapon. Thus it is important to know the temperature of the barrel as each shot if fired. Temperature may be measured with a thermocouple 45 and a thermistor 46 using well-known techniques. The thermocouple consists of two wires of different materials joined to form a measurement junction 45a that produces a voltage proportional to the junction temperature. Measurement junction 45a is held against the gun barrel when the shot counter is mounted so that its temperature may be measured. A leaf-spring (not shown) is easily adapted for this purpose.

[0059] The opposite end of the thermocouple leads are typically mounted on copper pads to form reference junctions 45b and 45c. These reference junctions 45a and 45b also produce a voltage that is proportional to their temperature and, as a result, it is necessary to know their temperature if the temperature at the measurement junction 45a is to be determined. This is accomplished by providing an isothermal block 44 that is electrically, but not thermally, isolated from the reference junctions 45b, 45c by a very thin electrically insulating layer. In printed circuit cards block 44 is usually a large copper feature such as a buried ground plane. In addition thermistor 46 is also electrically, but not thermally, isolated from the isothermal block 44. By using the resistance of the thermistor 46 the temperature of the isothermal block 44 can be determined and the voltage produced at the reference junctions 45b and 45c can be compensated for.

[0060] Compensation can be accomplished with the addition of discrete components within the device or, preferably, using logic within the microprocessor 40. Discrete devices are not favored because they consume power unnecessarily. The voltage produced by the thermocouple 44 is conditioned using an op-amp 47 and input to one of the A/D converters 41b of the microprocessor 40. The voltage from the thermistor 46 is conditioned by a second op-amp 48 and input to a second A/D converter 41c. Look-up tables within the microprocessor are then used to compensate for the reference junction temperature and accurately determine the temperature at the measurement junction 45a.

[0061] Power consumption by the op-amps 47 and 48 is limited by making use of a remote enable line 49 to turn them on and off. It has been found that a period of less than 10 milli-seconds is sufficient to make temperature measurements. When a shot has been detected the microprocessor output 41d drives the enable line 49 high so that the temperature can be read. After a period of less than 10 milli-seconds the enable line 49 is driven low and no further power is consumed by the op-amps 47 and 48.

[0062] The data collection and storage scheme will now be described with reference to FIGS. 8a and 8b. While it is possible to store all data sequentially it is preferable to store data in the form of histograms. Much less memory is required for data in this form making it possible to use on-chip EEPROM or other non-volatile memory and thereby reducing the size, power consumption, complexity and cost of the shot counter.

[0063] FIGS. 8a and 8b show two histograms that each have 20 intervals or bins. The choice of the number of bins that are used is arbitrary and limited only by the available on-chip memory. Whenever a shot has been fired the interval from the previous shot is calculated, compared to the limits of the interval histogram in FIG. 8a, and the appropriate bin is incremented within memory. If the shot-counter has been awakened from sleep mode the shot interval is indeterminate and the wake bin is incremented. In addition to incrementing the shot count and the interval histogram the barrel temperature is calculated and the appropriate bin within the temperature histogram in FIG. 8b is incremented. In this embodiment each memory location uses a 16-bit word for the count giving a maximum of >65 thousand shots per bin. In order to make the shot counter adaptable to a wide range of small arms the limits on the bins are user programmable and stored within on-chip EEPROM or other non-volatile memory along with the collected data and all input parameters.

[0064] FIG. 7 shows a typical accelerometer signal response to a single shot fired by a typical automatic or semi-automatic weapon. The first peak 71 is the result of the shot itself, the second peak 72 is generated by the bolt hitting the back of the bolt housing, and the third peak 73 is generated by the bolt forcing the next round into the chamber and rotating the lock closed. This third peak 73 may not be present in some weapon types after the final round contained within a magazine has been fired.

[0065] The logic used by the shot counter in response to a signal similar to that of FIG. 7 will next be described, with respect to the embodiment of the invention using a hold-off delay technique to avoid miscounts. FIG. 9 illustrates the interrupts used by the system. The microprocessor employs four interrupts sources: Master Slave Serial Port (MSSP) which is used for communication with an external device such as a PC or palmtop computer; Timer 0 (TMR0), which produces an interrupt every millisecond when active; Timer 1 (TMR1) which is used to control a programmable hold-off delay after a shot has been sensed; and Interrupt 0 (INT0) which occurs when a signal is detected that exceeds a threshold level. Only MSSP and INT0 can wake the processor from sleep mode.

[0066] INT0 is generated by the onboard comparator. This comparator uses the internal, programmable, reference voltage as one input and the signal from the piezo-electric accelerometer as the other. This allows the user to alter the threshold level so that shocks produced by normal handling are not registered as shots. It also allows the shot counter to be adjusted to work on a wide variety of small-arms.

[0067] When an interrupt is received the interrupt handler routine 100 is initiated as shown in FIG. 9. Values in critical registers are saved and further interrupts are disabled in step 102. If, in step 104, the MSSP port is found to be active a command has been detected on the communication bus and the program executes the MSSP service routine 300.

[0068] The sequence of operations of the MSSP service routine 300 is shown in FIG. 10. The input is read from the serial port in step 302 and compared with a first command in step 304. If true, the command is executed in step 306 and the program returns from subroutine 300. If false, the command tracker is incremented to test for a second command at 308. The input is compared to the next command in step 310 and, if true, the command is executed in step 312. The program then returns from subroutine 300. If the test is false the command tracker is incremented to test for the next command at 314. This sequence is repeated multiple times until the test for the last command is completed in step 316 and executed if true at 318. Finally, subroutine 300 returns control to the interrupt handler routine.

[0069] Further operation of the interrupt handler routine 100 will now be described with reference to FIG. 9. If the routine has executed the MSSP service routine 300 then the program branches to 112 where critical parameters are restored and control is passed to the main program. If, however, the MSSP port has not been found to be active then the TMR0 interrupt is tested at 106. If the TMR0 interrupt is active the program executes the TMR0 interrupt service routine 400.

[0070] The sequence of operations of the TMR0 interrupt service routine 400 is shown in FIG. 11. As stated previously, TMR0 produces an interrupt every millisecond and is used for timing purposes. When control passes to the service routine 400 the TMR0 tracker is incremented and the timer TMR0 is restarted 402. After this event subroutine 400 returns control to the interrupt handler routine.

[0071] Referring once again to FIG. 9 the continuing operation of the interrupt handler routine 100 will be described. If the routine has executed the TMR0 interrupt service routine 400 then critical parameters are restored and control is passed to the main program at step 112. If, however, the TMR0 interrupt has not been found to be active the INT0 interrupt is tested at 108. If the INT0 interrupt is active the program executes the INT0 interrupt service routine 500.

[0072] Referring next to FIG. 12 the INT0 interrupt service routine 500 will be described. This interrupt is generated by the comparator and indicates that an impulse has been detected which may be due to the firing of a shot. A test is performed in step 502 to determine whether the holdoff tracker is active. If true this event should be ignored, as it is likely due to the action of the bolt, and control passes back to the interrupt service routine 100 without any action. If, however, the holdoff tracker is off then the value of the TMR0 tracker is saved, the shot active tracker is set true and both TMR0 and TMR1 are started in step 504. TMR0 then provides an interrupt every millisecond for program timing and TMR1 initiates the holdoff period. Following these actions control reverts to the interrupt handler routine 100.

[0073] Referring yet again to FIG. 9 the continuing operation of the interrupt handler routine 100 will be described. If the routine has executed the INT0 interrupt service routine 500 then it branches to step 112 where critical parameters are restored and control is passed to the main program. If, however, the INT0 interrupt has not been found to be active the TMR1 interrupt is tested in step 110 where, if the TMR1 interrupt is found to be active, the program executes the TMR1 interrupt service routine 600.

[0074] Referring next to FIG. 13 the TMR1 interrupt service routine 600 will be described. TMR1 generates an interrupt when it reaches the programmable holdoff time-out. In step 602 INT0 is enabled and then TMR1 is disabled. Control then reverts to the interrupt handler routine 100.

[0075] Referring to FIG. 9 for a final time the continuing operation of the interrupt handler routine 100 will be described. Regardless of whether or not the routine has executed the TMR1 interrupt service routine 600 critical parameters are restored at 112 and control is passed to the main program.

[0076] The general operation of the shot counter will now be described with reference to FIG. 14. On power up or reset 202 the processor executes an initialization sequence 204 that reads certain values such as the hold-off and sleep delay, and comparator threshold from non-volatile memory. Other critical functions such as IO, Timer, Comparator, Interrupts, and MSSP are also established. There is no penalty or loss of data caused by a reset.

[0077] Once initialization is complete and interrupts are enabled the processor loops through the main routine beginning at step 206. If the shot active tracker is found to be true when evaluated at 208 this indicates that there has been an INT0 interrupt and the update shot information subroutine 700 is executed.

[0078] Referring next to FIG. 15 the execution of the update shot information subroutine 700 is described. In step 702 the TMR0 tracker is read to determine the number of milliseconds that have elapsed since the timer was started. This value is added to the hold off time, to determine the time that has elapsed since the last shot was detected, and assigned to the shot interval tracker. The bin tracker is then initialized. If the first-shot tracker is found to be true in step 704 the routine progresses directly to 712. Otherwise it is necessary to determine which bin in the shot interval histogram must be incremented. In this case, the bin tracker is incremented so that it points to the bin for the shortest interval and the upper limit for this bin is retrieved in 708. The value of the upper limit of this bin is compared to the elapsed time in 710. If the upper limit is less than the elapsed time the routine loops back to step 708 where it increments the bin tracker and retrieves the new upper limit. Steps 708 and 710 are repeated until the value of the upper limit for some bin is greater than the elapsed time and the routine progresses to 712.

[0079] In step 712 the bin tracker is used to retrieve the count for the appropriate shot interval, which is incremented and saved. If the bin tracker retains its initial value it is the wake-up bin that is incremented. The interval in this case is indeterminate.

[0080] Next, in step 714, the temperature of the barrel is calculated and stored. The op-amps are enabled, the voltages from the thermistor and thermocouple are read, and the op-amps are disabled. Control of power to the op-amps is necessary if battery life is to be maximized. These voltages are then converted to temperatures using look-up tables. The temperature at the reference junction, determined from the thermistor, is then used to calculate the correct temperature at the measurement junction.

[0081] Flowchart 15a is continued on flowchart 15b by matching point “A” on flowchart 15a to point “A” on flowchart 15b.

[0082] The bin tracker is then re-initialized in step 718 and the first bin's upper limit is retrieved in 720. If the bin's upper limit is less than the temperature when tested in step 722 the bin tracker is incremented in 724 and the routine loops back to step 720. Steps 720, 722 and 724 are repeated until the value of the upper limit for some bin is greater than the temperature and the routine progresses to 726. In this step the bin tracker is used to retrieve the count for the appropriate shot temperature, which is incremented and saved. Note that program flow can go from step 722 directly to step 726 the first time that the temperature is tested. Subroutine 700 returns to the main program after clearing the shot active tracker in step 728.

[0083] Referring once again to the main program 200, as shown in FIG. 10, the TMR0 tracker is next compared to the sleep variable in step 210. If the value of the TMR0 tracker is less than the programmable sleep variable then the program loops back to step 206. However, if it is greater, then there have been no recent interrupts from the comparator and step 212 is executed where the microprocessor enters its sleep mode. Just prior to sleep mode, TMR0 and TMR1 are stopped, and all interrupts are disabled except for MSSP and INT0. The program can only progress to step 214 after one of these two interrupts has occurred, waking the processor from sleep, and the interrupt handler routine 100 has been executed. Step 216 is then executed, setting the first shot tracker to indicate that a shot has been detected from sleep mode, and the main program 200 loops back to step 206.

[0084] The operation of the shot counter can be most easily understood by following the events that occur beginning with the processor in its sleep mode at step 212 in FIG. 14. When a shot occurs the acceleration from the recoil produces a voltage at the piezo-electric accelerometer 43 in FIG. 4. If the signal from the accelerometer 43 exceeds the threshold at the comparator 41a INT0 is activated and the interrupt handler routine 100 in FIG. 9 is activated. Interrupts are disabled in step 102 and tests on various interrupts are evaluated until INTO is found to be true in step 108. Program control then passes to the INT0 interrupt service routine 500 in FIG. 12.

[0085] The holdoff tracker has not yet been set true so step 504 is executed. Since this is the first shot detected after waking the value saved for the TMR0 tracker value is irrelevant. The shot active tracker is set true, TMR1 is started (initiating the hold-off period) and TMR0 is reset. It should be noted, however, that TMR0 is not restarted and cannot produce interrupts at this step—timing during the hold-off period is controlled by TMR1.

[0086] Control returns to the interrupt handler routine 100 at step 112 and from there to the main program 200 at step 216 as shown in FIG. 14. The first shot tracker is set true at 216 and the program loops to step 208 where the shot active tracker is found to be true. Control then passes to the update shot information subroutine 700 in FIG. 15.

[0087] At step 702 the bin tracker is initialized and the TMR0 tracker is read and added to the hold-off period to get the interval between shots. Since the shot counter has just awakened from its sleep mode the interval is indeterminate and when the value of the first shot tracker is tested in step 704 the program braches to step 712. The initial value of the bin tracker, which was assigned in step 702, points to the wake-up bin within the shot interval histogram. The value in this bin is read, incremented and returned to memory.

[0088] With the shot interval histogram updated the temperature is next read in step 714. Power is supplied to the op-amps 47 and 48 in FIG. 4 from the remote enable line 41d of the microprocessor and the voltages are read from the thermocouple 45 and thermistor 46. The barrel temperature is then calculated using look-up tables and reference junction compensation.

[0089] The sequence used to update the temperature histogram varies slightly from that used for the shot interval because all temperatures are determinate. The bin tracker is initialized in step 718 and the upper limit of each bin is tested sequentially until one is found to be greater than the calculated temperature in steps 720, 722 and 724. The subroutine then branches out of this loop to step 726 where the count in the appropriate bin is read, incremented and returned to memory. The shot active tracker is then set false and control returns to the main program 200 at step 210.

[0090] The TMR0 tracker has not yet been updated so when tested at step 210 the program loops back to 206 and continues to loop through steps 208 and 210 until an INT0 interrupt occurs. Referring now to FIG. 7 the impulse 72 will occur when the bolt impacts the back-stop, triggering the comparator to generate INT0. The interrupt handler routine 100 in FIG. 9 is activated. Interrupts are disabled in step 102 and tests on various interrupts are evaluated until INT0 is found to be true in step 108. Program control then passes to the INT0 interrupt service routine 500 in FIG. 12.

[0091] This time through subroutine 500 the holdoff tracker has been set true so step 504 is not executed. TMR1, which controls the hold-off, continues to increment and the shot active tracker is not turned on. As a result, when control returns to main program 200 it continues to loop through steps 206–210.

[0092] A final impulse 73, shown in FIG. 7, may then occur as the bolt returns and locks into position. The interrupt handler routine 100 in FIG. 9 is again activated. Interrupts are disabled in step 102 and tests on various interrupts are evaluated until INT0 is found to be true in step 108. Program control then passes to the INT0 interrupt service routine 500 in FIG. 12.

[0093] This time through subroutine 500 the holdoff tracker has been set true so step 504 is not executed. TMR1, which controls the hold-off, continues to increment and the shot active tracker is not turned on. As a result, when control returns to main program 200 in FIG. 14 it continues to loop through steps 206–210.

[0094] The next event to occur is the interrupt generated when TMR1 reaches its time-out state. The interrupt handler routine 100 in FIG. 9 is executed. Further interrupts are disabled in step 102 and interrupts are evaluated until TMR1 is found to be true in step 110. Program control then passes to the TMR1 interrupt service routine 600 in FIG. 13. The TMR0 tracker is cleared and TMR0 is restarted in step 602. This timer will be used to determine the interval to the next shot. Control then passes back through subroutine 100 to main program 200 in FIG. 14.

[0095] It must be emphasized that the number of impulses that occur during the firing of a shot may vary from the three shown in FIG. 7. The hold-off period makes it possible to accurately count shots whether a single impulse or any number of impulses are produced during firing. This makes it possible to accommodate a wide variety of small-arms simply by adjusting the user-programmable hold-off time.

[0096] If no other shot is detected before the TMR0 tracker exceeds the sleep value, which is evaluated each time the main program passes through step 210, then step 212 will be executed. The timers will then be stopped, all interrupts except INT0 or MSSP disabled, and the processor will enter sleep-mode. If, however, a shot is detected before step 212 is executed then INT0 is activated and the program enters the interrupt handler routine 100 shown in FIG. 9. Interrupts are disabled in step 102 and tests on various interrupts are evaluated until INT0 is found to be true in step 108. Program control then passes to the INT0 interrupt service routine 500 shown in FIG. 12.

[0097] The holdoff tracker has not yet been set true so step 504 is executed. The value of the TMR0 tracker is saved so that the interval between shots may later be calculated. The shot active tracker is set true, TMR1 is started (initiating the hold-off period) and TMR0 is reset. As noted previously TMR0 is not restarted.

[0098] Control returns to the interrupt handler routine 100 at step 112 and from there to the main program 200 within the loop through steps 206–210 as shown in FIG. 14. At step 208 the shot active tracker is found to be true. Control then passes to the update shot information subroutine 700 in FIG. 15.

[0099] At step 702 the bin tracker is initialized and the TMR0 tracker is read and added to the hold-off period to get the interval between shots. As this is not the first shot detected since the processor awoke the first shot tracker is found to be false at step 704 and the bin tracker is incremented from its initial value. The upper limit of each bin is tested sequentially until one is found to be greater than the interval between shots in steps 708 and 710. The subroutine then branches out of this loop to step 712 where the count in the appropriate bin is read, incremented and returned to memory. The temperature data is then read and stored in the appropriate bin in steps 714 through 726. The shot active tracker is cleared in step 728 and control returns to the main program 200 at step 210.

[0100] The TMR0 tracker has not yet been updated so when tested at step 210 the program loops back to 206 and continues to loop through steps 208 and 210 until an INT0 interrupt occurs. From this point onwards program flow is identical to that already described for the first shot detected from waking.

[0101] For the shot counter to be used in a program of small-arms maintenance it must be possible to easily access and interpret the collected data. This has been accomplished by providing histograms that can be displayed on a hand-held computer or down-loaded into another computing device. Subsequent analysis can apply weighting functions to predict wear-out where, for example, shots fired at high barrel temperature are weighted more heavily. Sample histograms for firing rate and temperature are shown in FIGS. 8a and 8b. Limits for each bin and the number of bins per histogram are user programmable.

[0102] As an alternative to the hold-off delay method described above, the shot counter of the invention may also use a timer window technique to avoid miscounts. FIG. 17 shows a flowchart of this method of operation. The hardware of the device described above, in its various embodiments, is equally applicable to the window time embodiment of the method described below, as to the hold-off delay method described above.

[0103] As shown in FIG. 7, a representative firearm may generate two or three impulse signals on the impulse sensor when a shot is fired. These are the impulse from the shot itself 71, the second signal 72 is generated by the bolt hitting the back of the bolt housing, and the third signal 73 is generated by the bolt forcing the next round into the chamber and rotating the lock closed. This third signal 73 may not be present in some weapon types after the final round contained within a magazine has been fired. If the method of the invention counts all impulse signals, the shot firing in FIG. 7 would be counted as three shots, which is incorrect. The hold-off delay technique described above deals with this situation by simply ignoring the later signals 72 and 73, since they would fall during the hold-off delay period. However, there is another situation which could result in a miscount, which the hold-off delay method would not prevent. This is caused by impulses which result from physical shocks other than shooting the weapon—for example, dropping the gun on a hard surface, or perhaps even roughly inserting a magazine. Such an impulse, if received as signal 71 might well be large enough to exceed the threshold level to be counted as a shot under the first embodiment described above, but would not be followed up by the other two impulses 72 and 73.

[0104] The window time embodiment of the method is more accurate than the hold-off delay method, in that 170 when it detects an impulse signal 71 from the impulse sensor it starts a window timer running 171 and starts the impulse count. The method then looks 172 for at least a second impulse 72 before the length of the timer window ends. If at least one additional signal is detected the impulse counter is incremented 173. If the window time expires 174 and the impulse count is greater than one 175 (that is, the original impulse plus at least one other was detected), the processor goes on to process and store information about the shot 176, as discussed above. If the count is equal to one, the count is reset 177, and the method waits for more impulses. There might, in fact, be more than one additional impulse, for example 73 in FIG. 7, but the method would still not over-count, since it counts a shot if there is at least one additional signal, ignoring the rest.

[0105] The timer window is chosen so as to capture all events in one shot without capturing events from a succeeding shot—in FIG. 7, a window opening at the detection of 71, and closing shortly after 73 would be preferred. Preferably, in order to minimize miscounts, the length of the timer window is 80% or less of an interval between shots at a maximum rate of fire, and even more preferably, less than 50%.

[0106] In another embodiment of the invention the time and date of firing is stored for subsequent analysis. This is of particular importance in law-enforcement where reconstruction of events may be required. Time can be kept within the microprocessor, however, less power is consumed by using a stand-alone time and date chip. Time and date can be stored as each shot is fired up to the limit of available memory.

[0107] Also, if desired, details regarding the specific weapon, including serial number, barrel number, model number and last date of service, can be recorded in the memory.

[0108] While the invention has been described in connection with a particular embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.