U.S. patent application number 10/831114 was filed with the patent office on 2005-08-04 for bathing unit system controller having abnormal operational condition identification capabilities.
Invention is credited to Gaudreau, Daniel, Laflamme, Benoit.
Application Number | 20050168902 10/831114 |
Document ID | / |
Family ID | 34701320 |
Filed Date | 2005-08-04 |
United States Patent
Application |
20050168902 |
Kind Code |
A1 |
Laflamme, Benoit ; et
al. |
August 4, 2005 |
Bathing unit system controller having abnormal operational
condition identification capabilities
Abstract
A controller for identifying an abnormal operational condition
in a bathing unit system that includes a power source and a set of
bathing unit components. The controller comprises a power control
device and a processing module. The power control device is capable
of acquiring a first state and a second state. In the first state,
said power control device enables the power source to supply power
to the set of bathing unit components, and in the second state,
said power control device prevents the power source from supplying
power to the set of bathing unit components. The processing module
is operative for detecting an abnormal operational condition
associated with the bathing unit system, and more particularly with
the controller itself. Upon detection of an abnormal operational
condition associated with the controller, the processing module
causes the power control device to acquire the second state.
Inventors: |
Laflamme, Benoit; (Quebec,
CA) ; Gaudreau, Daniel; (St-Jean Chrysostome,
CA) |
Correspondence
Address: |
FETHERSTONHAUGH - SMART & BIGGAR
1000 DE LA GAUCHETIERE WEST
SUITE 3300
MONTREAL
QC
H3B 4W5
CA
|
Family ID: |
34701320 |
Appl. No.: |
10/831114 |
Filed: |
April 26, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10831114 |
Apr 26, 2004 |
|
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10768130 |
Feb 2, 2004 |
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Current U.S.
Class: |
361/115 |
Current CPC
Class: |
A61H 33/005 20130101;
G05B 23/0235 20130101 |
Class at
Publication: |
361/115 |
International
Class: |
H01H 073/00 |
Claims
1. A controller for a bathing unit system, the bathing unit system
including a power source and a set of bathing unit components, said
controller comprising: a) a power control device that interfaces
between the power source and the set of bathing unit components,
said power control device capable of acquiring either one of a
first state and a second state, wherein: i. in the first state,
said power control device enables the power source to supply power
to the set of bathing unit components, and; ii. in the second
state, said power control device prevents the power source from
supplying power to the set of bathing unit components; b) a
processing module in communication with said power control device,
said processing module being operative for: i. detecting an
abnormal operational condition associated with the bathing unit
system; ii. causing said power control device to acquire said
second state upon detection of an abnormal operational condition
associated with the bathing unit system.
2. A controller as defined in claim 1, wherein said processing
module comprises: a) a control unit operative for controlling the
set of bathing unit components; and b) a diagnostic unit operative
for: i. detecting an abnormal operational condition associated with
the bathing unit system; ii. upon detection of an abnormal
operational condition, issuing a signal to said power control
device for causing said power control device to acquire said second
state.
3. A controller as defined in claim 2, wherein said abnormal
operational condition detected by said diagnostic unit is
associated with said controller of the bathing unit system.
4. A controller as defined in claim 1, wherein said processing
module is operative for detecting an abnormal operational condition
of said bathing unit system when a temperature of the water in said
bathing unit system is above a predetermined temperature level.
5. A controller as defined in claim 3, wherein said diagnostic unit
includes a signal frequency detection unit operative for detecting
an abnormal operational condition of said controller when the
frequency of a particular signal issued by said control unit does
not correspond to a predetermined frequency value.
6. A controller as defined in claim 3, wherein said diagnostic unit
includes a power detection unit operative for detecting an abnormal
operational condition of said controller when the power level
supplied by the power source falls below a predetermined power
level.
7. A controller as defined in claim 6, wherein the predetermined
power level is stored in a memory unit of said controller.
8. A controller as defined in claim 3, wherein said controller
includes a thermal detection unit operative for detecting an
abnormal operational condition of said controller when an internal
temperature of said controller exceeds a predetermined temperature
value.
9. A controller as defined in claim 8, wherein said predetermined
temperature value is stored in a memory unit of said
controller.
10. A controller as defined in claim 8, wherein said predetermined
temperature value is defined by a thermal fuse.
11. A controller as defined in claim 3, wherein said diagnostic
unit includes an optical detection unit operative for detecting an
abnormal operational condition of said controller upon detection of
the presence of electric arcs within said controller.
12. A controller as defined in claim 1, wherein said power control
unit is operative to acquire the second state upon receipt of an
emergency-off command signal from a user.
13. A controller as defined in claim 1, wherein said processing
module includes an input for receiving command signals from a user,
said processing module being responsive to an emergency off command
signal received at said input for causing said power control device
to acquire said second state.
14. A controller as defined in claim 1, wherein said power control
device is selected from the group consisting of a power contactor,
a latching relay, a non-latching coil and a plurality of
relays.
15. A controller as defined in claim 2, wherein each bathing unit
component in the set of bathing unit components is adapted for
acquiring an activated state and a non-activated state, wherein in
the activated state a bathing unit component is operative for
drawing power from the power source, said controller comprising: a)
a plurality of actuators associated to respective bathing unit
components; and b) an input for receiving command signals from a
user of the bathing unit system such that said control unit is
operative for controlling said plurality of actuators at least in
part on the basis of said command signals, for causing the bathing
unit components in the set of bathing unit components to acquire
either one of the activated state and the non-activated state.
16. A controller as defined in claim 15, wherein each of said
plurality of actuators each includes a relay.
17. A controller as defined in claim 15, wherein said command
signals received at said input are entered by a user via a control
panel.
18. A controller as defined in claim 1, wherein the set of bathing
unit components includes at least one bathing unit component
selected from the set consisting of a heating module, a pump, an
ozonator, a power supply, a CD player and an air blower.
19. A controller as defined in claim 2, wherein said control unit
is powered independently from said power control device, whereby
when said power control device is in said second state, said
control unit continues to receive power for operation.
20. A controller as defined in claim 2, wherein said diagnostic
unit includes an energy storage unit.
21. A controller as defined in claim 1, wherein said controller
includes an output module, wherein upon detection by said
processing module of an abnormal operational condition of the
bathing unit system, said output module is operative for conveying
information to a user indicative of an error condition.
22. A controller as defined in claim 21, wherein said information
indicative of an error condition includes information indicative of
an abnormal operational condition.
23. A controller as defined in claim 21, wherein said output module
is operative for conveying the information indicative of the error
condition in a visual format.
24. A controller as defined in claim 21, wherein said output module
is operative for conveying the information indicative of the error
condition in an audio format.
25. A controller as defined in claim 21, wherein said output module
is included on a control panel of the bathing unit system.
26. A controller as defined in claim 21, wherein said output module
is included on said controller.
27. A method for monitoring a bathing unit system, the bathing unit
system including a power source, a set of bathing unit components
and a power control device that interfaces between the power source
and the set of bathing unit components, the power control device
capable of acquiring either one of a first state and a second
state, wherein in the first state, the power control device enables
the power source to supply power to the set of bathing unit
components, and in the second state, the power control device
prevents the power source from supplying power to the set of
bathing unit components, said method comprising: a) detecting an
abnormal operational condition associated with the bathing unit
system; b) causing the power control device to acquire the second
state upon detection of an abnormal operational condition
associated with the bathing unit system.
28. A method as defined in claim 27, wherein said abnormal
operational condition is associated with a controller of the
bathing unit system.
29. A method as defined in claim 28, comprising detecting an
abnormal operational condition of the controller when a temperature
of the water in the bathing unit system is above a predetermined
temperature level.
30. A method as defined in claim 28, comprising detecting an
abnormal operational condition of the controller when the frequency
of a particular signal does not correspond to a predetermined
frequency value.
31. A method as defined in claim 28, comprising detecting an
abnormal operational condition of the controller when a power level
supplied by the power source falls below a predetermined power
level.
32. A method as defined in claim 31; wherein the predetermined
power level is stored in a memory unit of the bathing unit
system.
33. A method as defined in claim 31, wherein the predetermined
temperature value is defined by a thermal fuse.
34. A method as defined in claim 28, comprising detecting an
abnormal operational condition of the controller when an internal
temperature of the controller exceeds a predetermined temperature
value.
35. A method as defined in claim 34, wherein the predetermined
temperature value is stored in a memory unit of the bathing unit
system.
36. A method as defined in claim 28, comprising detecting an
abnormal operational condition of the controller upon detection of
the presence of electric arcs within the controller.
37. A method as defined in claim 27, comprising causing the power
control device to acquire the second state upon receipt of an
emergency-off command signal from a user.
38. A method as defined in claim 27, wherein the power control
device is selected from the group consisting of a power contactor,
a latching relay, a non-latching coil and a plurality of
relays.
39. A method as defined in claim 28, wherein each bathing unit
component in the set of bathing unit components is adapted for
acquiring an activated state and a non-activated state, wherein in
the activated state a bathing unit component is operative for
drawing power from the power source, said method comprising causing
the bathing unit components in the set of bathing unit components
to acquire either one of the activated state and the non-activated
state, at least in part in response to command signals received
from a user.
40. A method as defined in claim 39, wherein said command signals
are entered by a user via a control panel.
41. A method as defined in claim 27, wherein the set of bathing
unit components includes at least one bathing unit component
selected from the set consisting of a heating module, a pump, an
ozonator, a power supply, a CD player and an air blower.
42. A method as defined in claim 27, comprising conveying to a user
via an output module, information indicative of an error condition,
upon detection of an abnormal operational condition of the bathing
unit system.
43. A method as defined in claim 42, wherein the information
indicative of an error condition includes information indicative of
an abnormal operational condition.
44. A method as defined in claim 42, comprising conveying the
information indicative of the error condition in a visual
format.
45. A method as defined in claim 42, comprising conveying the
information indicative of the error condition in an audio
format.
46. A method as defined in claim 42, wherein the output module is
included on a control panel of the bathing unit system.
47. A method as defined in claim 42, wherein the output module is
included on a controller of the bathing unit system.
48. A bathing unit system comprising: a) a power source; b) a set
of bathing unit components in communication with said power source;
and c) a controller, comprising: i. a power control device that
interfaces between said power source and said set of bathing unit
components, said power control device capable of acquiring either
one of a first state and a second state, wherein: (a) in the first
state, said power control device enables said power source to
supply power to said set of bathing unit components, and; (b) in
the second state, said power control device prevents said power
source from supplying power to said set of bathing unit components;
ii. a processing module in communication with said power control
device, said processing module being operative for: (a) detecting
an abnormal operational condition associated with the bathing unit
system; (b) causing said power control device to acquire said
second state upon detection of an abnormal operational condition
associated with the bathing system.
49. A bathing unit system as defined in claim 48, wherein said
processing module comprises: a) a control unit operative for
controlling said set of bathing unit components; and b) a
diagnostic unit operative for: i. detecting an abnormal operational
condition associated with the bathing unit system; ii. upon
detection of an abnormal operational condition, issuing a signal to
said power control device for causing said power control device to
acquire said second state.
50. A bathing unit system as defined in claim 49, wherein said
abnormal operational condition detected by said diagnostic unit is
associated with said controller of said bathing unit system.
51. A bathing unit system as defined in claim 50, wherein said
processing module is operative for detecting an abnormal
operational condition of said controller when a temperature of the
water in said bathing unit system is above a predetermined
temperature level.
52. A bathing unit system as defined in claim 50, wherein said
diagnostic unit includes a signal frequency detection unit
operative for detecting an abnormal operational condition of said
controller when the frequency of a particular signal issued by said
control unit does not correspond to a predetermined frequency
value.
53. A bathing unit system as defined in claim 50, wherein said
diagnostic unit includes a power detection unit operative for
detecting an abnormal operational condition of said controller when
the power level supplied by the power source falls below a
predetermined power level.
54. A bathing unit system as defined in claim 53, wherein the
predetermined power level is stored in a memory unit of said
controller.
55. A bathing unit system as defined in claim 50, wherein said
controller includes a thermal detection unit operative for
detecting an abnormal operational condition of said controller when
an internal temperature of said controller exceeds a predetermined
temperature value.
56. A bathing unit system as defined in claim 55, wherein said
predetermined temperature value is stored in a memory unit of said
controller.
57. A bathing unit system as defined in claim 55, wherein said
predetermined temperature value is defined by a thermal fuse.
58. A bathing unit system as defined in claim 50, wherein said
diagnostic unit includes an optical detection unit operative for
detecting an abnormal operational condition of said controller upon
detection of the presence of electric arcs within said
controller.
59. A bathing unit system as defined in claim 48, wherein said
power control unit is operative to acquire the second state upon
receipt of an emergency-off command signal from a user.
60. A bathing unit system as defined in claim 48, wherein said
processing module includes an input for receiving command signals
from a user, said processing module being responsive to an
emergency off command signal received at said input for causing
said power control device to acquire said second state.
61. A bathing unit system as defined in claim 48, wherein said
power control device is selected from the group consisting of a
power contactor, a latching relay, a non-latching coil and a
plurality of relays.
62. A bathing unit system as defined in claim 49, wherein each
bathing unit component in said set of bathing unit components is
adapted for acquiring an activated state and a non-activated state,
wherein in the activated state a bathing unit component is
operative for drawing power from the power source, said controller
comprising: a) a plurality of actuators associated to respective
bathing unit components; and b) an input for receiving command
signals from a user of the bathing unit system such that said
control unit is operative for controlling said plurality of
actuators at least in part on the basis of said command signals,
for causing the bathing unit components in the set of bathing unit
components to acquire either one of the activated state and the
non-activated state.
63. A bathing unit system as defined in claim 62, wherein each of
said plurality of actuators each includes a relay.
64. A bathing unit system as defined in claim 62, wherein said
command signals received at said input are entered by a user via a
control panel.
65. A bathing unit system as defined in claim 48, wherein said set
of bathing unit components includes at least one bathing unit
component selected from the set consisting of a heating module, a
pump, an ozonator, a power supply, a CD player and an air
blower.
66. A bathing unit system as defined in claim 49, wherein said
control unit is powered independently from said power control
device, whereby when said power control device is in said second
state, said control unit continues to receive power for
operation.
67. A bathing unit system as defined in claim 49, wherein said
diagnostic unit includes an energy storage unit.
68. A bathing unit system as defined in claim 48, wherein said
controller includes an output module, wherein upon detection by
said processing module of an abnormal operational condition of the
bathing unit system, said output module is operative for conveying
information to a user indicative of an error condition.
69. A bathing unit system as defined in claim 68, wherein said
information indicative of an error condition includes information
indicative of an abnormal operational condition.
70. A bathing unit system as defined in claim 68, wherein said
output module is operative for conveying the information indicative
of the error condition in a visual format.
71. A bathing unit system as defined in claim 68, wherein said
output module is operative for conveying the information indicative
of the error condition in an audio format.
72. A bathing unit system as defined in claim 68, wherein said
output module is included on a control panel of the bathing unit
system.
73. A bathing unit system as defined in claim 68, wherein said
output module is included on a control panel of said bathing unit
system.
74. A bathing unit system as defined in claim 68, wherein said
output module is included on said controller.
75. A system for monitoring a controller, the controller being
operative for managing a set of components by controlling the power
supplied by a power source to each of the components, said system
comprising: a) a power control device that interfaces between the
power source and the set of components, said power control device
capable of acquiring either one of a first state and a second
state, wherein: i. in the first state, said power control device
enables said power source to supply power to said set of
components, and; ii. in the second state, said power control device
prevents said power source from supplying power to said set of
components; b) a processing module in communication with said power
control device, said processing module being operative for: i.
detecting an abnormal operational condition associated with the
controller; ii. causing said power control device to acquire said
second state upon detection of an abnormal operational condition
associated with the controller.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending
U.S. patent application Ser. No. 10/768,130, which was filed on
Feb. 2, 2004.
FIELD OF THE INVENTION
[0002] The present invention relates to controllers suitable for
use in bathing unit systems and, more particularly, to controllers
adapted for detecting abnormal operational conditions in bathing
unit systems.
BACKGROUND
[0003] Bathing unit systems that include control systems are well
known in the art. Examples of such bathing unit systems include
whirlpools, hot tubs, bathtubs, therapeutic baths and swimming
pools, among others. Typically, these bathing unit systems include
various functional components, such as water pumps, heating
modules, filter systems, air blowers, ozone generators, and
lighting systems, among others. It is generally, the control system
of the bathing unit system that actuates and manages the various
functional components of the bathing unit system for setting the
different operational characteristics of these functional
components. For example, the control system can control the
activation and de-activation of the water pumps and of the heating
module in order to maintain the water within the water receptacle
at a desired temperature.
[0004] Generally, bathing unit control systems include a controller
to which the various bathing unit components are connected. This
controller is adapted to control the power supplied from a power
source to each one of the various components. More specifically, in
response to signals received from a user of the bathing unit
system, for example via a control panel, and/or in response to
signals received from various sensors, the controller will activate
or de-activate the various bathing unit components by supplying
power, or ceasing to supply power, to those components.
[0005] The various functional components of a bathing unit system
are susceptible to abnormal operational conditions, in which they
operate in manners that do not correspond to their respective
normal operational conditions. An abnormal operational condition
may result, for example, from an operational failure in one or
multiple components of the bathing system. Such an operational
failure in a functional component can be due to a mechanical or
electronic malfunction in the component, or to the component
experiencing operating conditions in which it was not designed to
operate. Traditional control systems are generally able to detect
and control abnormal operational conditions that result due to a
failure of one or more of the various bathing unit components.
[0006] Abnormal operational conditions may also occur within the
controller of a bathing unit system. Unfortunately, traditional
control systems are not equipped to detect and control abnormal
operational conditions that occur due to a failure of the
controller. An operational failure within the controller may be
caused by, for example, corrupted software or a circuit
overheating, among other possibilities. When the controller
experiences such an operational failure, the controller may be
damaged and/or lose its ability to control the activation and
de-activation of the various functional components of the bathing
unit system. In such a case, it is desirable that there be an
emergency feature for preventing further damage to the bathing unit
system, and preventing harm to users of the bathing unit
system.
[0007] In light of the above, there is a need in the industry to
provide a controller suitable for a bathing system that alleviates
at least in part the problems associated with existing
controllers.
SUMMARY
[0008] In accordance with a broad aspect, the invention provides a
controller for a bathing unit system.
[0009] The bathing unit system includes a power source and a set of
bathing unit components. The controller comprises a power control
device and a processing module. The power control device interfaces
between the power source and the set of bathing unit components and
is capable of acquiring either one of a first state and a second
state. In the first state, the power control device enables the
power source to supply power to the set of bathing unit components,
and in the second state, said power control device prevents the
power source from supplying power to the set of bathing unit
components. The processing module is in communication with the
power control device and is operative for detecting an abnormal
operational condition associated with the bathing unit system and,
upon detection of an abnormal operational condition of the bathing
system, causing the power control device to acquire the second
state.
[0010] In a non-limiting example of implementation, the controller
includes an output module, wherein upon detection by the processing
module of an abnormal operational condition of the bathing unit
system, the output module is operative for conveying information to
a user indicative of an error condition.
[0011] In accordance with another broad aspect, the invention
provides a method for monitoring a bathing unit system that
includes a power source, a set of bathing unit components and a
power control device for interfacing between the power source and
the set of bathing unit components. The power control device is
capable of acquiring a first state and a second state. In the first
state, the power control device enables the power source to supply
power to the set of bathing unit components, and in the second
state, the power control device prevents the power source from
supplying power to the set of bathing unit components. The method
comprises detecting an abnormal operational condition associated
with the bathing unit system and causing the power control device
to acquire the second state upon detection of an abnormal
operational condition associated with the bathing unit system.
[0012] In accordance with yet another broad aspect, the invention
provides a bathing unit system comprising a power source, a set of
bathing unit components in communication with the power source, a
power control device and a processing module. The power control
device interfaces between the power source and the set of bathing
unit components and is capable of acquiring a first state and a
second state. In the first state, the power control device enables
the power source to supply power to the set of bathing unit
components, and in the second state, the power control device
prevents the power source from supplying power to the set of
bathing unit components. The processing module is in communication
with the power control device, and is operative for detecting an
abnormal operational condition associated with the bathing unit
system and causing said power control device to acquire the second
state upon detection of an abnormal operational condition
associated with the bathing unit system.
[0013] In accordance with yet another broad aspect, the invention
provides a system for monitoring a controller that is operative for
supplying power from a power source to a set of operational
components. The system comprises a power control device and a
processing module. The power control device interfaces between the
power source and the set of operational components and is capable
of acquiring a first state and a second state. In the first state,
the power control device enables the power source to supply power
to the set of operational components, and in the second state, the
power control device prevents the power source from supplying power
to the set of operational components. The processing module is in
communication with the power control device, and is operative for
detecting an abnormal operational condition associated with the
controller and causing the power control device to acquire the
second state upon detection of an abnormal operational condition
associated with the controller.
[0014] These and other aspects and features of the present
invention will now become apparent to those of ordinary skill in
the art upon review of the following description of specific
embodiments of the invention in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] A detailed description of the embodiments of the present
invention is provided herein below, by way of example only, with
reference to the accompanying drawings, in which:
[0016] FIG. 1 is a block diagram of a bathing unit system that is
equipped with a controller, in accordance with a non-limiting
example of implementation of the present invention;
[0017] FIG. 2 is a block diagram of the controller of FIG. 1 in
accordance with a non-limiting example of implementation of the
present invention;
[0018] FIG. 3 is a flow chart depicting a process for monitoring
the bathing unit system in accordance with a non-limiting example
of implementation of the present invention;
[0019] FIG. 4 is a block diagram of a diagnostic unit in accordance
with a non-limiting example of implementation of the present
invention; and
[0020] FIG. 5A-5C are block diagrams of various embodiments of an
output module suitable for use with a controller in accordance with
specific non-limiting examples of implementation of the present
invention.
[0021] In the drawings, the embodiments of the invention are
illustrated by way of examples. It is to be expressly understood
that the description and drawings are only for the purpose of
illustration and are an aid for understanding. They are not
intended to be a definition of the limits of the invention.
DETAILED DESCRIPTION
[0022] FIG. 1 illustrates a block diagram of a bathing unit system
10 in accordance with a specific example of implementation of the
present invention. It is to be understood that the expression
"bathing unit system", as used for the purposes of the present
description, refers to spas, whirlpools, hot tubs, bath tubs,
therapeutic baths, swimming pools and any other type of bathing
receptacle that can be equipped with a control system for
controlling various operational settings.
[0023] The Bathing Unit System 10
[0024] The bathing unit system 10, shown in FIG. 1, includes a
water receptacle 18 for holding water, a plurality of jets 20, a
plurality of drains 22, a control system and a plurality of bathing
unit components. The bathing unit components shown in FIG. 1
include water pumps 11 and 12, filter 26, air blower 24, and
heating module 60. It should be understood that the bathing unit
system 10 can include more or less bathing unit components without
departing from the spirit of the invention. For example, although
not shown in FIG. 1, the bathing unit system 10 could also include
an ozonator, lighting components for lighting up the water in the
water receptacle 18, multimedia components such as a CD/DVD player
and/or any other components suitable for use in a bathing unit
system 10.
[0025] In normal operation, water flows from the water receptacle
18, through one or more drains 22 and is pumped by water pump 12
through the heating module 60 where the water is heated. The heated
water then leaves the heating module 60 and re-enters the water
receptacle 18 through one or more jets 20. This cycle of water
leaving the water receptacle 18 through one or more drains 22,
passing through the heating module 60 and re-entering the water
receptacle 18 through one or more jets 20 is repeated continuously
while the water pump 12 is active.
[0026] In addition, in normal operation, the water also passes
through a cycle wherein the water flows from the water receptacle
18, through one or more drains 22 and is pumped by water pump 11
through a filter 26. After having been filtered, the water then
re-enters the water receptacle through one or more jets 20. This
cycle of water leaving the water receptacle 18 through drains 22,
passing through the filter 26 and re-entering the water receptacle
18 through jets 20 is repeated continuously while the water pump 11
is active, in order to keep the water clean from particulate
impurities.
[0027] In the non-limiting embodiment shown, the control system
includes a control panel 32, a controller 30, an (optional)
auxiliary I/O device 51 and a plurality of sensors 70 that monitor
the various components of the spa.
[0028] The plurality of sensors 70 are operative for monitoring
various operational conditions of the bathing unit system 10. For
example, the sensors 70 may include temperature sensors for
monitoring the temperature of the water, and liquid level sensors
for monitoring the water level at various locations in the bathing
unit system 10. Other sensors that are suitable for use within a
bathing unit system 10 can also be included without departing from
the spirit of the invention.
[0029] The control panel 32 is typically in the form of a user
interface that allows a user to enter command signals for
controlling the various operational settings of the bathing unit
system 10. The control panel 32 can include buttons, levers or any
other device known in the art for enabling a user to enter input
commands for controlling the various operational settings of the
bathing unit system 10. In addition, in a non-limiting embodiment,
the control panel 32 can include a screen for conveying information
to a user, such as the water temperature, the ambient air
temperature and the time, among other possibilities.
[0030] Some non-limiting examples of the operational settings of
the bathing unit system 10 that can be controlled by the control
panel 32 include on/off settings, temperature control settings, jet
control settings, lighting settings, etc. In a non-limiting example
of implementation, the bathing unit system 10 includes
entertainment and/or multimedia components, such that the
operational settings of the bathing unit may also include audio
settings and video settings, amongst others. Consequently, the
expression "operational settings", for the purpose of the present
invention, is intended to cover operational settings for any
suitable component that is part of the bathing unit system 10.
[0031] The controller 30 is operative to control the distribution
of power supplied to the various bathing unit components on the
basis of control signals received from the various sensors 70 and
the control panel 32, in order to cause the desired operational
settings to be implemented. In the non-limiting embodiment shown,
the controller 30 is in communication with a power source 29, via
service wiring 31, for receiving electrical power from the power
source 29. As such, the controller 30 is able to control the
distribution of power supplied from the power supply 29 to the
various bathing unit components. More specifically, on the basis of
signals received from the various sensors 70 as well as command
signals received from the control panel 32, the controller 30 can
control the distribution of power to the bathing unit components in
order to cause the desired operational settings to be implemented.
In a non-limiting implementation, the power source 29 is connected
to the controller 30 via service wiring 31 which is passed through
a ground fault circuit interrupter (GFCI) 86. The GFCI 86 is
adapted for tripping in the presence of a current leakage to the
ground, such that the power source 29 is unable to provide power to
the set of bathing unit components. The ground fault circuit
interrupter (GFCI) 86 provides an added safety measure to the
bathing unit system. GFCI's are known in the art, and as such will
not be described in further detail herein.
[0032] The power source 29 is operative to supply the controller 30
with any conventional power service suitable for residential or
commercial use. In a non-limiting implementation, the power source
29 can supply 240 volts (V) AC to the controller 30 via service
wiring 31. In an alternative non-limiting implementation, the power
source 29 can supply 120 V AC to the controller 30 via service
wiring 31. In an alternative non-limiting implementation, the power
source 29 can supply 120 V and 240 V AC to the controller 30 via
service wiring 31. It is to be appreciated that other voltage
supply values or voltage supply combinations, for example depending
on geographical location, are possible without detracting from the
spirit and scope of the invention.
[0033] The auxiliary I/O device 51, as mentioned above, is an
optional component of the bathing unit control system can be in the
form of a laptop, a PDA, or a cellphone, among other possibilities.
Auxiliary I/O devices 51 can be used to perform a variety of
different functions, which will be described in more detail further
on in the description.
[0034] The Controller 30
[0035] The controller 30, in accordance with a non-limiting
embodiment of the present invention is shown in more detail in FIG.
2. FIG. 2 shows the controller 30 as being in communication with
the power source 29, the control panel 32, at least one sensor 70,
the auxiliary I/O device 51 and the plurality of bathing unit
components 47. For the sake of simplicity, the bathing unit
components shown in FIG. 2 are all referred to by reference number
47. It should be understood, however, that each of the bathing unit
components 47 shown in FIG. 2 could be representative of the water
pump 11 or 12, the heating module 60, the filter 26, the air blower
26, an ozonator (not shown) or any lighting components, and/or
audio/visual components that are included within the bathing unit
system 10.
[0036] Specific to the present invention, and as will be described
below, the controller 30 is operative for detecting an abnormal
operational condition associated with the bathing unit system 10
and, upon detection of the abnormal operational condition, is
operative for causing a power control device 33 to prevent the
power source 29 from supplying power to the set of bathing unit
components 47. As such, the controller 30 is operative for
monitoring the bathing unit system 10 for causing the power control
device 33 to cut the power to the set of bathing unit components 47
in the case where an abnormal operational condition is detected. In
a non-limiting example of implementation, the abnormal operational
condition is associated to the controller 30, itself.
[0037] In the non-limiting embodiment shown, the controller 30
includes a power control device 33, a processing module 40, a
circuit element 50 and a memory unit 48 that is in communication
with the processing module 40.
[0038] It should be understood that the processing module 40 and
the memory unit 48 can be integrated into a single physical element
or be implemented as distinct elements without detracting from the
spirit and scope of the present invention. Moreover, it is also to
be understood that the processing module 40, the memory unit 48,
and the circuit element 50 could be part of a single printed
circuit board mounted within the housing of the controller 30.
[0039] The memory unit 48 is operative for storing measurements and
values associated with normal operational conditions of the bathing
unit system 10, such that the data stored within the memory unit 48
may be used by the processing module 40 when the bathing unit
system 10 is in use. The measurements and values stored in the
memory unit 48 can be entered into the memory unit 48 via an input
port in the controller 30. For example, the auxiliary I/O device 51
can upload the data to the processing module 40 such as to cause
the measurements and values associated with normal operational
conditions of the bathing unit system 10 to be written into the
memory unit 48. The auxiliary I/O device 51 can be a laptop, a PDA
or a cellular phone, for example, and can transmit signals to the
processing module 40 over a wireless link or a wire-line link
without detracting from the sprit of the invention. For example,
the link between the auxiliary I/O device 51 and the control unit
58 can be configured to be used as a serial link such as RS-232,
RS-485 or other serial link standard. In an alternative example,
the link between the auxiliary I/O device 51 and the control unit
58 may be a wireless link such as a RF or IR link. In such an
alternative example, the controller 30 includes a receiver adapted
to receive signals over the wireless link from the auxiliary I/O
device 51. The auxiliary I/O device 51 is equipped with a
corresponding wireless transmitter to transmit the signal to the
controller receiver. In yet another embodiment, the memory unit 48
may be directly programmable by the auxiliary I/O device and the
processing module 40 may be by-passed during the programming
operation.
[0040] In an alternative embodiment, the storage in the memory unit
48 of measurements and values associated with normal operational
conditions of the bathing unit system 10 can be effected by a
self-programming operation. More specifically, during this
self-programming operation, the processing module 40 obtains
measurements and values associated to different operational
conditions of the bathing unit system 10 and stores those
measurements and values in the memory unit 48. The processing
module 40 is operative to determine whether the measurements/values
are "normal" prior to storing them in the memory unit 48. A more
detailed description of a self-programming operation is described
in more detail in the parent case filed on Feb. 2, 2004.
[0041] In yet another alternative embodiment, the measurements and
values associated with normal operational conditions of the bathing
unit system 10 can be entered into the processing module 40, and
stored in the memory unit 48, via entries submitted by the user
through the control panel 32.
[0042] In yet another alternative embodiment, the measurements and
values associated with normal operational conditions of the bathing
unit system 10 can be pre-programmed into the memory unit 48.
[0043] The memory unit 48 may be implemented using any suitable
memory device such as an EPROM, EEPROM, RAM, FLASH, disc or any
other suitable type of memory device. In a preferred
implementation, the memory unit 48 includes a non-volatile memory
component and the control unit 58 stores the measurements and
values in the non-volatile memory component of the memory unit 48.
As will be further detailed below, the information stored in the
memory unit can be used by the processing module 40 to detect the
occurrence of an abnormal operational condition of the bathing unit
system 10.
[0044] As described above, the controller 30 includes a circuit
element 50. The circuit element 50 is adapted to convert power
received from the power source 29, via service wiring 31, into a
particular voltage and/or current to be supplied to a given bathing
unit component 47 connected to the controller 30. Amongst other
elements, the circuit element 50 includes a set of actuators 52,
such as switches, relays, contactors, or triacs, each adapted to
enable or prevent the flow of an electrical current to a respective
component 47 of the bathing unit system 10. As such, each one of
the bathing unit components 47 of the bathing unit system 10 is
capable of acquiring either one of an activated state and a
non-activated state. In the activated state, the actuator 52
associated to a given bathing unit component 47 enables the bathing
unit component 47 to receive power from the power source 29 by
drawing an electrical current at a certain voltage from the
controller 30 via a respective electrical cable. The given bathing
unit component 47 is then able to utilize the received power to
perform the function for which it was designed. Conversely, in the
non-activated state, the actuator 52 associated to a given
component prevents the given component from receiving power from
the controller 30 and as such, the given component is essentially
turned off. For instance, when in the activated state, pump 12
draws an electrical current at a certain voltage from the
controller 30 in order to perform the function for which it was
designed, which is basically to pump water from water receptacle 18
through drains 22, into heating module 60, and back into receptacle
18 through jets 20. When in the non-activated state, pump 12 does
not draw any current from the controller 30 and thus does not
perform any pumping action.
[0045] In the non-limiting embodiment shown, the processing module
40 includes a diagnostic unit 42 and a control unit 58. It is the
control unit 58 of the processing module 40 that is operative for
controlling the distribution of power supplied to the various
bathing unit components. By controlling the actuators 52, the
control unit 58 is operative for causing each of the bathing unit
components 47 to acquire one of the activated and non-activated
states. More specifically, the control unit 58 is operative for
issuing command signals over communication line 44 for causing
respective ones of the actuators 52 to either enable or prevent the
bathing unit components 47 from receiving power, which causes the
respective bathing unit components 47 to acquire either the
activated or the non-activated state.
[0046] The control unit 58 is operative for issuing command signals
to the circuit element 50 for causing each of the bathing unit
components 47 to acquire either the activated or the non-activated
state, on the basis of signals received from the control panel 32,
signals received from the sensors 70 and optionally, signals
received from the auxiliary I/O device 51. For example, in the case
where a user enters input command signals at the control panel 32,
the control unit 58 is responsive to receipt of those input command
signals to issue signals to the circuit element 50. If a user of
the bathing unit system 10 desires that the water temperature be
increased, the user can enter an input command via the control
panel 32 indicative that the water temperature should be increased.
Upon receipt of this input command signal at the control unit 58,
the control unit 58 issues a signal to the circuit element 50 for
causing the actuator associated to the heating module to enable
power to be supplied to the heating module. As such, the heating
module acquires the activated state such that it acts to heat up
the water. Alternatively, the control unit 58 may be adapted to
receive command signals from the auxiliary I/O device 51, which
could be in the form of a laptop, a PDA or a cellular phone. It
should be appreciated that the control unit 58 can communicate with
the I/O device 51 over a wireless link or a wire-line link without
detracting from the spirit of the invention.
[0047] In yet another embodiment, the control unit 58 can issue
signals to the circuit element 50 on the basis of signals received
from the sensors 70. For example, in the case where the sensor 70
is a water temperature sensor, and the control unit 58 has been
programmed to keep the water temperature within a predetermined
temperature range, upon receipt of a signal from the sensor 70
indicative that the water temperature has fallen below the minimum
temperature value of the predetermined temperature range, the
control unit 58 issues a signal to the circuit element 50 for
causing the heating module to acquire the activated state.
Likewise, upon receipt of a signal from the sensor 70 indicative
that the water temperature has exceeded the maximum temperature
value of the predetermined temperature range, the control unit 58
issues a signal to the circuit element 50 for causing the heating
module to acquire the non-activated state.
[0048] As described above, the processing module 40 further
includes a diagnostic unit 42 that is in communication with the
control unit 58. The diagnostic unit 42 is operative for monitoring
the operational conditions of the bathing unit system 10 in order
to detect when an abnormal operational condition of the bathing
unit system 10 occurs. In a more specific case, the diagnostic unit
42 is operative to detect when an abnormal operational condition
occurs within the controller 30 itself. As will be described in
more detail further on, upon detection of an abnormal operational
condition within the controller 30, the diagnostic unit 42 is
operative for causing the power control device 33 to prevent power
from being supplied from the power source 29 to the set of bathing
unit components 47.
[0049] As shown in FIG. 2, the power control device 33 interfaces
between the power source 29 and the plurality of bathing unit
components 47. As such, the power supplied by the power source 29
to the circuit element 50, via service wiring 31, passes through
the power control device 33. The power control device 33 is adapted
for acquiring a first state and a second state. When the power
control device 33 is in the first state, it is activated, meaning
that the power source 29 is able to supply power to the set of
bathing unit components 47. In general, it is the control unit 58
that maintains the power control device 33 in the first state
during normal operation of the bathing unit system 10. However, as
described above, upon detection of an abnormal operational
condition, it is the diagnostic unit 42 of the processing module 40
that is operative for causing the power control device 33 to
acquire the second state, such that the power source 29 is
prevented from supplying power to the set of bathing unit
components 47. Consequently, when the power control device 33 is in
the second state, regardless of the positions of actuators 52, the
bathing unit components 47 do not receive any power for operation
and thus are all shut off.
[0050] As such, the power control device 33 acts as a security
feature for preventing the power source 29 from supplying power to
the plurality of bathing unit components 47 when an abnormal
operational condition occurs within the bathing unit system 10, and
more specifically within the controller 30. In general, the power
control device 33 is generally caused to acquire the second state
when the processing module 40 detects an abnormal operational
condition of the bathing unit system 10 that cannot be resolved by
the control unit 58. In a non-limiting embodiment the power control
device 33 can be a power contactor, a latching relay, a
non-latching coil, or a plurality of relays that, in combination,
are able to cut the power to the bathing unit components 47.
[0051] As shown in FIG. 2, the power source 29 supplies power to
the controller 30 via service wiring 31. The service wiring 31 can
include four conductor wires, namely a first line wire (line1), a
second line wire (line2, second phase), a neutral wire and a ground
wire. In a non-limiting example of implementation, when in the
second state, the power control device 33 cuts the power flow from
at least one of the first and second line wires, which is
sufficient to prevent power for the power source 29 from reaching
the set of bathing unit components 47. Providing a power control
device 33 that is operative to cut only one of the first and second
line wires is less costly than providing a power control device 33
that is operative to cut multiple line wires. However, in an
alternative embodiment, when in the second state, the power control
device 33 is operative to cut the power flow along three of the
power line wires, namely line1, line2 and neutral.
[0052] A more detailed explanation of the manner in which the
diagnostic unit 42 detects an abnormal operational condition of the
bathing unit system 10 will be described in more detail below with
respect to FIGS. 3 and 4.
[0053] It should be understood that although the control unit 58
and the diagnostic unit 42 are shown as separate elements, the
functionality of the diagnostic unit 42 and the control unit 58
could be integrated into a single element without departing from
the spirit and scope of the present invention. It will also be
appreciated that the functionality of the processing module 40 may
be implemented as a programmable logic block or by using any
suitable hardware, software or combination thereof.
[0054] Flow Chart of FIG. 3
[0055] Shown in FIG. 3 is a broad example of a process used by the
processing module 40 for monitoring the operational conditions of
the bathing unit system 10. At step 90, the processing module 40
monitors one or more operational conditions of the bathing unit
system 10, and more specifically, one or more operational
conditions of the controller 30. The term "operational conditions"
as used herein, refers to measurements associated to various
readings, such as temperature readings, power readings and
frequency readings, as well as to the presence of certain signals,
or abnormal environmental conditions within the controller 30.
[0056] At step 92, on the basis of the operational conditions
monitored at step 90, the processing module 40 detects whether an
abnormal operational condition of the controller 30 exists on the
basis of the operational conditions monitored at step 90. The
manner in which the processing module 40 detects the presence of an
abnormal operational condition will be described in more detail
below with respect to FIG. 4. In the case where the processing
module 40 does not detect the presence of an abnormal operational
condition, the processing module 40 returns to step 90, and
continues monitoring the operational conditions of the bathing unit
system 10. However, in the case where the processing module 40 does
detect the presence of an abnormal operational condition, the
processing module 40 proceeds to step 94, wherein it causes the
power control device 33 to acquire the second state, such that the
power source 29 is prevented from supplying power to the bathing
unit components 47.
[0057] Optionally, once the processing module 40 has caused the
power control device 33 to acquire the second state, the processing
module 40 may proceed to step 96, wherein the processing module 40
provides information to a user of the bathing unit system 10. The
information provided to a user can be indicative of the fact that
the bathing unit components 47 have all been shut down, or the
information can be indicative of the actual abnormal operational
condition that caused the power control device 33 to cause the
bathing unit components 47 to be shut down. The manner in which
information is communicated to one or more users of the bathing
unit system 10 will be described in more detail below.
[0058] It should be understood that step 90, wherein the processing
module 40 monitors the operational conditions of the bathing unit
system 10, can occur continuously, or can be initiated periodically
at preset time intervals or at random time intervals. For example,
a preset time interval could be every minute, or every 30 seconds.
In the case where step 90 is initiated at random time intervals,
the processing module 40 might include a random number generator,
for example.
[0059] Alternatively, it is within the scope of the present
invention for step 90 to be initiated following a certain
condition. For example, step 90 may be initiated upon reception by
the processing module 40 of a signal indicative of an explicit
command to enter step 90. Such a command could be entered by a user
of the bathing unit system 10 via the control panel 32, for
example. Alternatively, step 90 may be initiated upon start up of
the bathing unit system 10 or upon the activation and/or
deactivation of a bathing unit component 47. Or, step 90 can be
initiated each time the user enters a command signal at the control
panel 32. Other conditions based upon which the processing module
40 could initiate step 90 will be known to those of skill in the
art and as such will not be described in more detail herein.
[0060] Diagnostic Unit 42
[0061] Shown in FIG. 4 is a more detailed diagram of a diagnostic
unit 42, in accordance with a non-limiting embodiment of the
present invention. As shown, the diagnostic unit 42 is in
communication with the power control device 33 and the control unit
58, and includes an energy storage unit 62, a signal frequency
detection unit 64, a power detection unit 66, a thermal detection
unit 68 and an optical detection unit 72.
[0062] As shown in FIG. 4, in normal operation and upon start up of
the bathing unit system 10, the control unit 78 is operative to
issue a signal to the power control device 33 over communication
link 78 for causing the power control device 33 to remain in the
first state, such that the power source 29 is able to provide power
to the set of bathing unit components 47. It is the diagnostic unit
42 that then performs steps 90 through 94 of the process described
above. As will be described in more detail below, in the case where
the diagnostic unit 42 detects an abnormal operational condition,
the diagnostic unit 42 is operative to issue a signal to the power
control unit 33 from one of the detection units 64, 66, 68 and 72
listed above, for causing the power control device to acquire the
second state, such that the power source 29 is unable to supply
power to the set of bathing unit components 47.
[0063] In the non-limiting embodiment where the power control unit
33 is a power contactor, as shown in FIG. 4, the control unit 58 is
operative to issue a signal over communication link 78 to the power
contactor for "setting" the power contactor, such that the power
contactor acquires the first state. In the first state, the power
contactor is "closed", thereby permitting the power source 29 to
supply power to the set of bathing unit components 47. Upon
detection of an abnormal operational condition within the
controller 30, at least one of the detection units 64, 66, 68 and
72 of the diagnostic unit 42 issues a signal to the power contactor
for "resetting" the power contactor, such that the power contactor
acquires the second state. In the second state, the power contactor
is "open", thereby preventing the power source 29 from supplying
power to the set of bathing unit components 47.
[0064] In accordance with the non-limiting embodiment shown in FIG.
4, the diagnostic unit 42 is operative for monitoring the following
operational conditions of the controller 30, during step 90 of the
method described above:
[0065] 1. the frequency of a certain signal;
[0066] 2. the power level supplied by the power source 29;
[0067] 3. the internal temperature of the controller 30;
[0068] 4. the presence of electric arcs within the controller 30;
and
[0069] 5. the receipt of a command signal indicative that the power
control device 33 should acquire the second state.
[0070] On the basis of these operational conditions, the diagnostic
unit 42 is operative for detecting the presence of an abnormal
operational condition within the controller 30. The manner in which
the diagnostic unit 42 detects the presence of abnormal operational
conditions will be described in more detail below with respect to
each of the detection units 64, 66, 68 and 72 listed above.
[0071] It should be understood that the processing module 40 may be
implemented as a processor, as discrete logic, as a FPGA (Field
Programmable Gate Array, as an analog circuit, or as a combination
thereof, among other possibilities.
[0072] In addition, it should be understood that each of the
diagnostic unit 42 and the control unit 58, as well as the
controller 30 itself, may be implemented as a processor, as
discrete logic, as a FPGA (Field Programmable Gate Array, as an
analog circuit, or as a combination thereof, among other
possibilities.
[0073] Frequency Detection Unit 64
[0074] As shown in FIG. 4, the diagnostic unit 42 includes a
frequency detection unit 64 that is in communication with the
control unit 58 via communication link 74. The frequency detection
unit 64 is operative to monitor the pulse frequency of a particular
signal issued by the control unit 58, where this particular signal
is characterized by a known, predetermined frequency value. In a
non-limiting example of implementation, the particular signal is
generated by the software in the control unit 58 on the basis of
the speed of software's the main program loop. The frequency
detection unit 64 monitors this particular signal in order to
ensure that the frequency of the signal generated on the basis of
the speed of the main program loop corresponds to the predetermined
frequency value. It should be understood that for the purposes of
this specification, the term "frequency value" could also encompass
a frequency range.
[0075] When the control unit 58 is functioning properly, and in
accordance with its internal command logic, the particular signal
monitored by the frequency detection unit 64 over communication
link 74 will have a pulse frequency that corresponds to a normal
frequency value or range. Conversely, when the control unit 58 is
not functioning properly, for example when the control software is
corrupt or lost, no pulse frequency will be received at the
frequency detection unit 64, or the particular signal will have a
pulse frequency that is outside of the normal frequency range. When
this happens, the frequency detection unit 64 determines that the
control unit 58 is not functioning properly, and may be unable to
properly manage the bathing unit components 47, which could lead to
a potentially dangerous situation for the user. For example, if the
heating module 60 is in an activated state, and the control unit 58
is unable to cause the heating module 60 to acquire a non-activated
state due to the fact that its internal logic is corrupt or lost,
then the water in the water receptacle 18 could overheat to a
temperature that is dangerous for a user of the bathing unit system
10.
[0076] As such, the frequency detection unit 64 is in communication
with the control unit 58 via communication link 74, and is
operative for detecting an abnormal operational condition within
the controller 30 when the frequency of the particular signal
issued by the control unit 58 over communication link 74 has a
frequency that does not correspond to a predetermined frequency
value or range. In this manner, the frequency detection unit 64
performs a "watchdog" function, with regard to the control unit's
command logic and/or software.
[0077] As mentioned above, the diagnostic unit 42 detects the
presence of an abnormal operational condition, when the frequency
detection unit 64 detects that the pulse frequency received over
communication link 74 does not correspond to a predetermined
frequency value. For example, the diagnostic unit 42 detects the
presence of an abnormal operational condition, when the frequency
detection unit 64 no longer receives a pulse frequency over
communication link 74. This could indicate, for example, that the
control unit's software has been lost.
[0078] Alternatively, the diagnostic unit 42 detects the presence
of an abnormal operational condition, when the frequency detection
unit 64 detects that the pulse frequency received over
communication link 74 is above or below a predetermined frequency
value. For example, in the case where the control unit's software
has become corrupt, such that main program loop is executed at a
much faster rate than normal, the pulse frequency of the signal
received at the frequency detection unit 64 would not correspond to
a predetermined frequency value or range. In a non-limiting example
of implementation, the predetermined frequency value or range,
against which the pulse frequency received over communication link
74 is compared, is stored in the memory unit 48 of the controller.
As such, in the case where the predetermined frequency value is a
specific frequency value, the frequency detection unit 64 detects
the presence of an abnormal operational condition of the controller
30 when the frequency of the signal received over communication
link 74 does not equal the predetermined frequency value.
[0079] Once the frequency detection unit 64 has detected an
abnormal operational condition within the controller 30, meaning
that the pulse frequency of the particular signal received from the
control unit 58 does not correspond to the predetermined frequency
value, the frequency detection unit 64 issues a signal for causing
the power control device 33 to acquire the second state. As such,
in the case where the control unit's 58 software is lost or
corrupted, the diagnostic unit 42 prevents all power from being
provided to the bathing unit components 47, thereby shutting down
the bathing unit components 47.
[0080] It should be understood that the validation of the
processing module's integrity can be done in a variety of other
ways that are know in the art.
[0081] Power Detection Unit 66
[0082] As shown in FIG. 4, the diagnostic unit 42 includes a power
detection unit 66 that receives a reading of the power supplied by
the power source 29 via communication link 76. The power 20
detection unit 64 is operative to monitor the power issued by the
power source 29 in order to ensure that this power does not fall
below a predetermined power level.
[0083] As such, the power detection unit 66 is operative for
detecting an abnormal operational condition within the controller
30 when the power level supplied by the power source 29 falls below
a predetermined power level.
[0084] Although not shown in FIG. 4, in a further, non-limiting
example of implementation, the power detection unit 66 is further
operative to monitor the power exiting from power transformer 57,
in order to monitor the lower voltage power being supplied to the
control unit 58. This lower voltage 30 power is used by the control
unit 58 to power various circuitry. As shown in FIG. 2, the
diagnostic unit 42 is operative for receiving such a power reading
from the power transformer 57, via communication link 37. As such,
the power detection unit 66 is operative for detecting an abnormal
operational condition within the controller 30 when the power level
supplied by the power transformer 37 falls below a predetermined
power level.
[0085] In a non-limiting example of implementation, the
predetermined power levels associated to the power source 29 and
the power transformer 57 are stored in the memory unit 48 of the
controller 30. As such, the power detection unit 66 detects the
presence of an abnormal operational condition of the controller 30
when the power level supplied by the power source 29 falls below
the predetermined power level stored in the memory unit 48, or the
power detection unit 66 detects the presence of an abnormal
operational condition of the controller 30 when the power level
supplied by the power transformer 57 falls below a predetermined
power level stored in the memory unit 48. The predetermined power
level or levels stored in the memory unit 48 can be pre-programmed
into the memory unit 48, or can be entered into the memory unit 48
via the control panel 32 or an auxiliary I/O device 51, or can be
entered into the memory unit 48 via a self-programming operation
performed by the processing module 40.
[0086] It should also be understood that the power level supplied
by the power source 29 can be plugged into a formula, such that it
is the result of the formula that is compared with a predetermined
power level stored in the memory unit 48.
[0087] In a further non-limiting example of implementation that is
not shown in the Figures, the monitoring of the power can be done
directly at the power source 29.
[0088] Once the power detection unit 66 has detected an abnormal
operational condition of the bathing unit system 10, the power
detection unit 66 issues a signal for causing the power control
device 33 to acquire the second state. As such, in the case where
there is a loss of the amount of power supplied by the power source
29 or the power transformer 57 to the controller 30, which may
imply a failure of the power source 29 itself and which could lead
to problems within the controller 30, the diagnostic unit 42
prevents all power from being provided to the bathing unit
components 47.
[0089] Thermal Detection Unit 68
[0090] Referring again to FIG. 4, the diagnostic unit 42 further
includes a thermal detection unit 68 that is operative to detect
when the internal temperature within the controller 30 exceeds a
predetermined temperature value. As such, the thermal detection
unit 68 is operative to detect and prevent any abnormal occurrence
of overheating within the controller 30.
[0091] The thermal detection unit 68 can include any type of heat
sensor known in the art. For example, in a non-limiting embodiment,
the thermal detection unit 68 can include thermocouples,
thermistors, infrared sensor (thermopile) and/or thermal fuses. In
a further non-limiting example of implementation, the thermal
detection unit 68 can include a smoke detector.
[0092] As shown in FIG. 2, the controller 30 includes various
different functional components such as the processing module 40
and the circuit element 50, each of which includes electrical
circuitry. During use, this electrical circuitry generates heat.
While a certain amount of heat is normal, it is desirable to avoid
the case where the controller 30 overheats abnormally, since such
an overheat situation can cause the circuitry, and therefore the
functional components, to be damaged. Replacing a damaged
controller 30 can be both time consuming and costly for the owner
of the bathing unit system 10. Furthermore, in a worse case
scenario, the excessive overheating of the controller 30 can result
in an electrical fire within the controller, which can be very
dangerous for a user of the bathing unit system 10.
[0093] As such, in order to avoid the situation where the
controller 30 overheats abnormally, the thermal detection unit 68
is operative for detecting an abnormal operational condition within
the controller 30, when the internal temperature of the controller
30 exceeds a predetermined temperature value. It should be
understood that for the purposes of this specification, the term
"temperature value" could also encompass a temperature range.
[0094] In a first non-limiting example of implementation, such as
in the case where the temperature sensor of the thermal detection
unit 68 is a thermistor, or a thermocouple, the predetermined
temperature value is a property of the temperature sensor. For
example, the predetermined temperature can be a defined by a
thermal fuse. When the internal temperature of the controller 30
exceeds the predetermined temperature value, the thermal sensor is
triggered, thus causing the thermal detection unit 68 to detect an
abnormal operational condition of the bathing unit system 10.
[0095] In an alternative non-limiting example of implementation,
the predetermined temperature value is stored in the memory unit 48
of the controller 30. As such, the thermal detection unit 68 can
include a thermometer for taking readings of the internal
temperature of the controller 30, and can compare those readings to
the predetermined temperature value stored in the memory unit 48.
In such an embodiment, the thermal detection unit 68 detects the
presence of an abnormal operational condition within the controller
30 when the internal temperature of the controller 30 exceeds the
predetermined temperature value stored in the memory unit 48. As
described above, the predetermined temperature value stored in the
memory unit 48 can be pre-programmed into the memory unit 48, or
can be entered into the memory unit 48 via the control panel 32 or
an auxiliary I/O device 51, or can be entered into the memory unit
48 via a self-programming operation performed by the processing
module 40.
[0096] It should also be understood that the internal temperature
of the controller 30, as determined by the thermal detection unit
68 can be plugged into a formula, such that it is the result of the
formula that is compared with a predetermined temperature value
stored in the memory unit 48.
[0097] In another alternative non-limiting example of
implementation, the predetermined temperature value can be an
average temperature value that is obtained based on the temperature
within the controller 30 over a certain amount of time. In such an
embodiment, the thermal detection unit 68 is operative to regularly
measure the temperature within the controller 30, and to re-compute
the average temperature value, based on a series of temperature
measurements that are temporarily stored in the memory unit 48 and
that were taken over the certain amount of time. In this
embodiment, the thermal detection unit 68 detects an abnormal
operational condition within the controller 30 when the internal
temperature value of the controller 30 exceeds the average of the
temperature value taken over a certain amount of time. It should be
understood that the average temperature value can be taken based on
readings taken over any predetermined amount of time, such as 1
minute, or 1 hour.
[0098] In an alternative example of implementation, the thermal
detection unit 68 is operative for detecting an abnormal
operational condition within the controller 30 when the thermal
detection unit 68 detects smoke within the controller 30.
[0099] Once the thermal detection unit 68 has detected an abnormal
operational condition within the controller 30, meaning that the
internal temperature of the controller 30 exceeds the predetermined
temperature value, the thermal detection unit 68 issues a signal
for causing the power control device 33 to acquire the second
state. As such, in the case where the internal temperature of the
controller 30 becomes too hot, the diagnostic unit 42 prevents all
power from being provided to the bathing unit components 47,
thereby shutting down the bathing unit components 47. As such,
damage to the controller 30, and the possibility of a fire within
the bathing unit system 10, can be avoided.
[0100] Optical Detection Unit 72
[0101] As shown in FIG. 4, the diagnostic unit 42 also includes an
optical detection unit 72 that is operative for detecting the
presence of electric arcs within the controller 30. In general, and
as known in the art, arcing is often caused by a joint that has
been badly soldered, an overheated connection that results from a
worn out relay or other bad components, or a loose connection. In
the case where electrical arcs are present, there is the
possibility that the control unit 58 is not functioning properly.
In addition, the occurrence of electrical arcs is undesirable,
because they increase the chances of electrical fires, and can
cause damage to the controller 30. In addition, the occurrence of
electrical arcs may reduce the life expectancy of the actuators
52.
[0102] It should be understood that the optical detection unit 72
can include any type of optical sensor known in the art. For
example, in a non-limiting embodiment, the optical detection unit
72 can include infrared sensors, phototransitors, LEDs or any other
type of light sensing technology.
[0103] In use, the optical detection unit 72 is operative to detect
an abnormal operational condition of the controller 30 when there
is the presence of electrical arcs within the controller 30.
[0104] Once the optical detection unit 72 has detected an abnormal
operational condition of the controller 30, meaning that there is
the presence of electrical arcs within the controller 30, the
optical detection unit 72 issues a signal for causing the power
control device 33 to acquire the second state. As such, in the case
where electrical arcs occur within the controller 30, the
diagnostic unit 42 prevents all power from being provided to the
bathing unit components 47, thereby shutting down the bathing unit
components 47.
[0105] Emergency-Off Command Signal
[0106] In a non-limiting example of implementation, the control
unit 58 includes an input for receiving an emergency-off command
signal from a user of the bathing unit system. For example, the
emergency off command signal can be entered by a user via an
"emergency" button located on the control panel 32 or anywhere else
on the spa, or within range of the spa location. The control unit
58 is then responsive to the emergency off command signal for
causing the power control device 33 to acquire the second state.
For example, in the case where the control unit 58 issues a signal
over communication link 78 for causing the power control device to
acquire the first state, then upon receipt of the emergency-off
signal, the control unit 58 ceases to issue a signal over
communication link 78 for maintaining the power control device 33
in the first state. As such, in the absence of a signal from the
control unit 58 for causing the power control device 33 to remain
in the first state, the power control device 33 reverts to the
second state. It should be understood that the emergency-off signal
entered by a user of the bathing unit system 19 could be issued
directly to the diagnostic unit 42, or the power control device 33,
thereby bypassing the control unit 58.
[0107] In an alternative, non-limiting example of implementation,
the control unit 58 is operative for detecting when one or more of
the actuators 52 is stuck. When one or more actuators is stuck open
or closed, it means that the control unit 48 is unable to control
the bathing unit component associated with the stuck actuator 52.
Depending on the bathing unit component, this can be a dangerous
situation. For example, in the case where the actuator 52
associated with the heating module is stuck with the heating module
in the activated position, the control unit 58 has no way to
prevent the water temperature from heating to an unsafe
temperature. In addition, in the case where an actuator associated
with a water pump gets stuck, heat is generated by the water pump,
which will cause the bathing unit system 10 to overheat and create
an unsafe temperature for a user.
[0108] Under normal operating conditions, the control unit 58 is in
communication with a water temperature sensor 70 that is operative
for taking measurements of the water temperature within the water
receptacle 18. As such, the control unit 58 can cause the heating
module, and the water pumps, to intermittently acquire the
activated and non-activated states, such that the water temperature
remains within a predetermined temperature range. The predetermined
temperature range can be specified by a user via the control panel
32 for example.
[0109] In the case where an actuator 52 associated to either one of
the heating module or the water pumps is stuck, such that the water
temperature will overheat, the control unit 58 will send one or
more signals to the circuit element 50, for causing the heating
module and/or the water pump to acquire a non-activated state.
Simultaneously, the control unit 58 will monitor the water
temperature sensor 70, and will notice that regardless of the fact
that the heating module and/or the water pumps should be in the
non-activated states, that the water temperature continues to rise.
In a non-limiting example of implementation, when the water
temperature sensor 70 indicates that the water temperature has
exceeded an upper threshold, the control unit 58 will realize that
something is wrong, and can cease to issue a signal to the power
control device 33, via communication link 78. In the absence of a
signal from the control unit 58, the power control device 33 will
acquire the second state, wherein it prevents the power source 29
from providing power to the bathing unit components 47. As such, in
the case where the water temperature is approaching an unsafe
temperature, the control unit 58 is operative for causing the
diagnostic unit 42 to cause the power control device 33 to acquire
the second state.
[0110] Energy Storage Unit 62
[0111] In a non-limiting embodiment, the diagnostic unit 42
includes an energy storage unit 62 that is operative for storing
energy that can be used by the diagnostic unit 42 in an emergency
situation. For example, in the case where the power source 29 fails
to provide sufficient power to the diagnostic unit 42, such that
the diagnostic unit 42 is unable to function properly, the
diagnostic unit 42 can use the energy reserved in the energy
storage unit 62 for causing the power control device 33 to acquire
the second state.
[0112] Power to Control Unit 58
[0113] Referring again to FIG. 2, the control unit 58 is in
communication with the power source 29 via service wiring 35. In
the embodiment shown, the power from the power source 29 passes
through a power transformer 57 prior to entering the control unit
58, such that the voltage can be reduced.
[0114] As shown, the control unit 58 is powered independently from
the power control device 33. This means that even when the power
control device 33 is in the second state, such that the power
supplied by the power source 29 is interrupted and the set of
bathing unit components 47 are shut down, the control unit 58
continues to receive power for operation.
[0115] It should be understood that although FIG. 2 shows that the
control unit 58 is powered by power source 29 via service wiring
35, it is within the scope of the present invention for the control
unit 58 to be powered from a second power source (not shown) that
is separate from the power source 29. For example, the bathing unit
system 10 may include a control unit power source that is dedicated
for providing power to the control unit 58.
[0116] As such, the controller 30 is designed such that when the
power control device 33 is in the second state the control unit 58
continues to receive power for operation. This enables the control
unit 58 to continue certain operational functions even when the
power control device 33 has cut off the power from the power source
29 to the set of bathing unit components 47. For example, in a
non-limiting embodiment, and as described above with respect to
optional step 96 in FIG. 3, in the case where the power control
device 33 is caused to acquire the second state, the processing
module 40, and more specifically the control unit 58, is operative
to provide information to a user. As described above, the
information provided to the user can be indicative of the fact that
there has been an emergency shutdown of the set of bathing unit
components 47, or can be indicative of the abnormal operational
condition that caused the emergency shutdown, among other
possibilities. Therefore, in accordance with optional step 96
described above with respect to FIG. 3, once the power control
device 33 has been caused to acquire the second state, such that it
prevents the power source 29 from providing power to the bathing
unit components 47, the control unit 58 conveys information to a
user indicative of an error condition.
[0117] In the specific non-limiting examples of implementation
shown in FIGS. 5A through 5C, the bathing unit system 10 includes
an output module 88 in communication with the controller 30. It is
the output module 88 that is adapted for conveying the information
indicative of the error condition to a user of the bathing unit
system 10.
[0118] In the specific example of implementation shown in FIG. 5A,
the output module 88 is a part of the control panel 32, and may
include, for example, a visual display element and/or an audio
element to respectively convey to a human operator visual and/or
audible information indicative of an error condition. The visual
display element could be, for instance, a liquid-crystal display
(LCD) or one or more light-emitting diodes (LEDs). As such, the
information indicative of an error condition may be conveyed to a
user in a visual format by displaying a message on a screen of the
output module 88, or by turning ON (or OFF) an appropriate LED or
causing an appropriate LED to blink. Alternatively, the information
indicative of an error condition may be conveyed in an audio format
such as by producing a beeping sound, or a verbal message from a
voice synthesizer.
[0119] In another non-limiting embodiment shown in FIG. 5B, the
output module 88 is in the housing of the controller 30 and is
concealed from the user under typical operation. In such an
embodiment, the output module 88 can be accessed by the user when
the user realizes that power has been cut off from the bathing unit
components 47.
[0120] In a non-limiting embodiment, the diagnostic unit 42 and the
control unit 58 are in communication with each other such that the
control unit 58 is operative to identify the abnormal operational
condition within the controller 30 that prompted the diagnostic
unit 42 to cause the power control device 33 to acquire the second
state. For example, the control unit 58 is operative to identify
whether the abnormal operational condition was caused by a thermal
overheat or a loss of power, for example. As such, the control unit
58 can convey to a user, via the output module 88, a text message
or code to identify the abnormal operational condition that caused
the power control device 33 to acquire the second state. It should
be understood that in the case where the abnormal operational
condition is an abnormal frequency of the particular signal issued
by the control unit 58, indicative that the control unit software
is corrupt, then the controller 30 may not be able to convey to the
user information indicative of the error condition.
[0121] Specific other examples of the manner in which the output
module 88 could convey information indicative of an error condition
include, without being limited to: text messages, alpha and/or
numeric codes, audible signals, IR/RF signals, color lights and
discrete LEDs amongst others.
[0122] In an alternative embodiment not shown in the drawings, the
output module 88 is positioned remotely from both the control panel
32 and the controller 30. In such a case, when the messages are
displayed in a visual format, the output module 88 may be
positioned anywhere such that the messages may be displayed
anywhere in the bathing unit system 10 or in the proximity of the
bathing unit system 10. For example, the message may be displayed
on the controller 30, on any component of the bathing system, on a
dedicated user interface, on a user operable console of the bathing
unit system 10, on an external direct wire device, on a display
device positioned on the skirt of the bathing unit system 10 or on
a device positioned remotely from the controller 30. In a specific
non-limiting implementation, the output module 88 may be positioned
remotely from the controller 30, such as within a house. Depending
on where the output module 88 is positioned, it should be
understood that the controller 42 can be in either wireless or
wire-line communication with the output module 88.
[0123] In another non-limiting embodiment shown in FIG. 5C, the
output module 88 includes a transmitter or transceiver 89 operative
to transmit a signal conveying information to a user indicative of
an error condition. The signal may include information indicative
of the abnormal operational condition within the controller 30 that
caused the emergency shutdown of the bathing unit components. The
transmitter/transceiver 89 is operative to transmit the signal over
either one of a wireless link, such as a radio frequency (RF) link
or infra-red (IR) link, or alternatively over a wire-line link. The
transmitter/transceiver 89 communicates with an auxiliary I/O
device 51, such as a laptop, a PDA or a cellular phone to convey
information indicative of the error condition to a human operator.
In a specific non-limiting implementation, the auxiliary I/O device
51 is in the form of a dedicated display module suitable to be
positioned inside a house and in wireless communication with the
transmitter/transceiver 89 of output module 88. Optionally, the
output module 88 is adapted to transmit a signal to processing
module 40 to confirm the reception of the signal from the bathing
unit system 10.
[0124] In yet another alternative embodiment, instead of conveying
the information indicative of an error condition to a user in an
audio or visual format via an output module 88, the control unit 58
could store the information indicative of the error condition in
the memory unit 48, such that a user could obtain the information
by downloading it to an auxiliary I/O device 51, such as a PDA,
cell phone or a laptop computer.
[0125] The above description of the embodiments should not be
interpreted in a limiting manner since other variations,
modifications and refinements are possible within the spirit and
scope of the present invention. The scope of the invention is
defined in the appended claims and their equivalents.
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