U.S. patent application number 17/247514 was filed with the patent office on 2021-04-08 for connected pump system controller and method of use.
The applicant listed for this patent is Pentair Flow Technologies, LLC. Invention is credited to Michael Bishop, Hassan Khalid.
Application Number | 20210102534 17/247514 |
Document ID | / |
Family ID | 1000005278224 |
Filed Date | 2021-04-08 |
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United States Patent
Application |
20210102534 |
Kind Code |
A1 |
Bishop; Michael ; et
al. |
April 8, 2021 |
CONNECTED PUMP SYSTEM CONTROLLER AND METHOD OF USE
Abstract
A method for monitoring a system and controlling a pump coupled
to plumbing is provided. The method includes the steps of
determining that a fault has occurred in the system, transmitting a
first message to a remote server over a first wireless network, the
first message including information related to the fault, sending
the information related to the fault via the first wireless network
to an internet enabled device, receiving a second message from the
remote server via the first wireless network, the second message
including the information related to the fault, and shutting down
the pump via a microcontroller configured to control operation of
the pump.
Inventors: |
Bishop; Michael; (Twin
Lakes, WI) ; Khalid; Hassan; (Greenfield,
WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Pentair Flow Technologies, LLC |
Delavan |
WI |
US |
|
|
Family ID: |
1000005278224 |
Appl. No.: |
17/247514 |
Filed: |
December 15, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15832669 |
Dec 5, 2017 |
10865787 |
|
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17247514 |
|
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62430748 |
Dec 6, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H04W 88/16 20130101;
F04B 2205/06 20130101; G06Q 20/12 20130101; H04W 84/18 20130101;
G06Q 30/0633 20130101; G05B 15/02 20130101; F04B 49/065 20130101;
F04B 49/08 20130101; F04B 51/00 20130101; H04W 76/15 20180201 |
International
Class: |
F04B 51/00 20060101
F04B051/00; G05B 15/02 20060101 G05B015/02; F04B 49/06 20060101
F04B049/06; F04B 49/08 20060101 F04B049/08 |
Claims
1. A method for monitoring a system and controlling a pump coupled
to plumbing, the method comprising: determining that a fault has
occurred in the system; transmitting a first message to a remote
server over a first wireless network, the first message including
information related to the fault; sending the information related
to the fault via the first wireless network to an internet enabled
device; receiving a second message from the remote server via the
first wireless network, the second message including the
information related to the fault; and shutting down the pump via a
microcontroller configured to control operation of the pump.
2. The method of claim 1, wherein the information is related to at
least one of water leak detection or water flow rate.
3. The method of claim 1, wherein shutting down the pump comprises
shutting down the pump automatically without user intervention.
4. The method of claim 1, further comprising receiving instructions
to shut down the pump from a user interface accessed via the
internet enabled device.
5. The method of claim 1, further comprising receiving instructions
from a user interface accessed via the internet enabled device to
clear an alert.
6. The method of claim 1, further comprising receiving instructions
from a user interface accessed via the internet enabled device to
clear the fault.
7. The method of claim 1, wherein the first message includes
information indicating that the system requires maintenance.
8. The method of claim 1, further comprising: establishing a second
wireless connection to communicate with the internet enabled device
over a second wireless network; receiving instructions from the
internet enabled device over the second wireless connection; and
configuring a pressure switch to connect to the first wireless
network based on the instructions, wherein the pressure switch
includes a pressure sensor, the microcontroller, and a wireless
gateway module.
9. The method of claim 1, further comprising: storing the
information related to the fault on the remote server; and
accessing the information related to the fault via the internet
enabled device.
10. The method of claim 1, receiving a message from the remote
server at the internet enabled device, the message including
information indicating that further operation of the pump is
inhibited until the fault is addressed.
11. A system for controlling operation of a pump coupled to
plumbing, the system comprising: a pump; and a pressure switch
coupled to the pump, the pressure switch comprising: a printed
circuit board; a power supply in electrical communication with the
printed circuit board; a wireless gateway module coupled to the
printed circuit board, wherein the wireless gateway module is
configured to establish a first wireless connection to a first
wireless network, and transmit a message to a remote server over
the first wireless network; a pressure sensor; and a
microcontroller coupled to the wireless gateway module, the printed
circuit board, the power supply, and the pressure sensor, wherein
the microcontroller is configured to execute computer readable
instructions, wherein execution of the computer readable
instructions cause the microcontroller to: determine a pressure in
at least a portion of the plumbing based on a signal from the
pressure sensor; control operation of the pump based on the
pressure; determine that a fault has occurred in the system based
on the signal from the pressure sensor; automatically inhibit
operation of the pump without user intervention; and prevent the
pump from restarting for a minimum amount of time after
automatically inhibiting operation of the pump in response to
determining that the fault has occurred in the system.
12. The system of claim 11, wherein the microcontroller powers the
pump when the pressure is determined to be less than a cut-in
pressure.
13. The system of claim 11, wherein the pump is prevented from
restarting during the minimum amount of time regardless of whether
a cut-in pressure has been reached.
14. The system of claim 11, wherein the pump is prevented from
restarting if a number of times the pump has restarted during a
period of time exceeds a restart limit.
15. A system for monitoring operation of a pump coupled to
plumbing, the system comprising: a pump; a printed circuit board; a
power supply in electrical communication with the printed circuit
board; a wireless gateway module coupled to the printed circuit
board, wherein the wireless gateway module is configured to
establish a first wireless connection to a first wireless network
and transmit a message to a remote server over the first wireless
network; a pressure transducer; and a microcontroller coupled to
the wireless gateway module, the printed circuit board, the power
supply, the pressure transducer, and the pump, wherein the
microcontroller is configured to execute computer readable
instructions, wherein execution of the computer readable
instructions cause the microcontroller to: establish, using an
internet enabled device, a second wireless connection to
communicate with the system over a second wireless network; receive
instructions from the internet enabled device that cause the
wireless gateway module to connect to the first wireless network;
control operation of the pump based on a signal from the pressure
transducer; determine that a fault has occurred in the system;
generate a first message related to operation of the pump; and send
the first message to the remote server via the first wireless
network.
16. The system of claim 15, wherein operation of the pump is
inhibited in response to determining that the fault has occurred in
the system.
17. The system of claim 15, wherein the first message includes
information related to the fault.
18. The system of claim 15, wherein the information is related to a
water flow rate.
19. The system of claim 15, wherein execution of the computer
readable instructions further causes the microcontroller to:
determine a pressure in the plumbing based on the signal from the
pressure transducer; and control operation of the pump based on the
pressure.
20. The system of claim 15, wherein the microcontroller provides
power to the pump when the signal drops below a threshold.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/832,669, filed Dec. 5, 2017, which claims
priority to U.S. Provisional Patent Application No. 62/430,748,
filed Dec. 6, 2016, the entire contents of which are incorporated
herein by reference.
BACKGROUND
[0002] Some homes rely on well water as the primary water source.
This can include drinking and cooking water, as well as water for
showers, baths, toilets, and even heat. Thus, a loss of water can
impact a number of residential systems. Homes that rely on well
water often employ pump control systems to maintain adequate water
pressure. For example, a homeowner may install a robust control
system, such as an IntelliDrive.RTM. continuous water pressure
system from Sta-Rite by Pentair. Such a robust system may be
configured to automatically detect faults, and present information
about the fault to the homeowner and/or a technician to assist in
trouble shooting, and may even be capable of providing such
information remotely. However, such systems are often costly and
difficult to install.
[0003] Many homes may be equipped with less robust (and less
costly) pump controllers, such as a pump that is controlled via a
simple pressure switch that turns the pump on when the water
pressure falls below a cut-in (or cut-on) pressure (e.g., 20 pounds
per square inch (psi)) and turns the pump off when the pressure
exceeds a cut-out (or cut-off) pressure (e.g., 40 psi). Such
pressure switches may be adjustable via one or more adjustment
nuts. For example, one nut may control the magnitude of the cut-in
and cut-out pressure (e.g., this can be used to adjust the
cut-in/cut-out pressures from 20/40 psi to 30/50 psi), and another
nut may control the width of the range between the cut-in and
cut-out pressure (e.g., this can be used to adjust the gap between
cut-in and cut-out from 20 psi to 25 psi). Some pressure switches
are also equipped with a mechanical low water cut-off that prevents
the switch from providing power to the pump when there is not
enough water available for pumping and/or when the water pressure
is very low. When the low water cut-off is triggered, this
typically causes a low water pressure and/or a loss of water
availability throughout the home. Additionally, when the low water
cut-off on such switches is triggered, there is no mechanism for
alerting a homeowner or technician that the pump has been disabled.
Rather, the fault is often only discovered when an occupant tries
to use water (e.g., by turning on the faucet), and the pressure is
significantly lower than expected or no water flows. If the
homeowner is away when the water pumping system experiences a
fault, such as loss of power, loss of flow, loss of pressure, etc.,
some robust pump control systems may not be configured to alert the
homeowner remotely, and typical pressure switches are completely
incapable of alerting the user to a fault, as they are simple
electromechanical devices. A delay in the homeowner being notified
about a fault in the pumping system can result in other systems in
the home being compromised, such as a hot water heater, a sprinkler
system, a boiler, etc., that relies on the availability of water.
Simple pressure switches are also incapable of notifying a
homeowner or technician about why a fault occurred. For example,
whether the fault is due to low water pressure, damage or wear in
the pressure switch, damage or wear in the pump, a fault in the
power supply (e.g., in the homes electrical grid), the wiring
between the switch and pump, or other points of potential failure,
the result is generally the same, a loss of water pressure.
[0004] Accordingly, new systems and methods for providing
individuals with the ability to monitor and control the status of a
pressure switch, and in particular, to overcome the shortcomings
relating to the troubleshooting of the pressure switch and the
notification of individuals when a problem occurs are
desirable.
SUMMARY
[0005] In accordance with some embodiments of the present
disclosure, systems and methods for monitoring operation of a water
pump coupled to plumbing are provided.
[0006] In accordance with some embodiments of the present
disclosure a system for controlling operation of a pump coupled to
plumbing is provided. The system includes a pump and a pressure
switch coupled to the pump. The pressure switch includes a printed
circuit board, a power supply in electrical communication with the
printed circuit board, a wireless gateway module, a pressure
sensor, and a microcontroller. The wireless gateway module is
coupled to the printed circuit board, and is configured to
establish a first wireless connection to a first wireless network
and transmit a message to a remote server over the first wireless
network. The microcontroller is coupled to the wireless gateway
module, the printed circuit board, the power supply, and the
pressure sensor, and is configured to execute computer readable
instructions. The computer readable instructions cause the
microcontroller to determine a pressure in at least a portion of
the plumbing based on a signal from the pressure sensor; control
operation of the pump based on the pressure, determine that a fault
has occurred in the system based on the signal from the pressure
sensor, automatically inhibit operation of the pump without user
intervention, and prevent the pump from restarting for a minimum
amount of time after automatically inhibiting operation of the pump
in response to determining that the fault has occurred in the
system.
[0007] In accordance with some embodiments of the present
disclosure a system for monitoring operation of a pump coupled to
plumbing is provided. The system includes a pump, a printed circuit
board, a power supply in electrical communication with the printed
circuit board, a wireless gateway module, a pressure transducer,
and a microcontroller. The wireless gateway module is coupled to
the printed circuit board, and is configured to establish a first
wireless connection to a first wireless network and transmit a
message to a remote server over the first wireless network. The
microcontroller is coupled to the wireless gateway module, the
printed circuit board, the power supply, the pressure transducer,
and the pump. The microcontroller is configured to execute computer
readable instructions that cause the microcontroller to establish,
using an internet enabled device, a second wireless connection to
communicate with the system over a second wireless network, receive
one or more instructions from the internet enabled device that
cause the wireless gateway module to connect to the first wireless
network, control operation of the pump based on a signal from the
pressure transducer, determine that a fault has occurred in the
system, generate a first message related to operation of the pump,
and send the first message to the remote server via the first
wireless network.
[0008] In some embodiments, the pressure switch is mounted to the
pump.
[0009] In some embodiments, the pressure switch is configured to
receive a signal indicative of a motor current of the pump.
[0010] In some embodiments, execution of the computer readable
instructions further cause the microcontroller to: determine that a
first fault occurred based on the motor current; and determine that
a second fault occurred based on the signal output from the
pressure sensor.
[0011] In some embodiments, the housing comprises a base and a
cover, the cover comprising at least one through-hole and the base
comprising at least one recess.
[0012] In some embodiments, the cover is configured to be securely
coupled to the base by a coupling element passing through the at
least one through hole and into the at least one recess.
[0013] In some embodiments, the pressure switch further comprises a
relay electrically connected between the one or more electric power
inputs and the water pump, and wherein execution of the computer
readable instructions further cause the microcontroller to: cause
the relay to complete a circuit between the one or more electric
power inputs and the water pump in response to pressure in at least
the portion of the plumbing being less than a cut-in pressure; and
cause the relay to interrupt the circuit between the one or more
electric power inputs and the water pump in response to pressure in
at least the portion of the plumbing being greater than a cut-out
pressure.
[0014] In some embodiments, the pressure sensor is a pressure
transducer.
[0015] In some embodiments, the internet enabled device is a mobile
computing device.
[0016] In some embodiments, the power supply is a switched-mode
power supply.
[0017] In some embodiments, the wireless gateway module is
configured to communicate directly with the internet enabled
device.
[0018] In some embodiments, the second wireless connection is a
Wi-Fi connection, and wherein execution of the computer readable
instructions further cause the microcontroller to: configure the
wireless gateway module to function as a discoverable node for a
peer-to-peer Wi-Fi connection for a predetermined time in response
to the microcontroller transitioning from an off state to an on
state; receive a request to connect to the node from the internet
enabled device; and in response to the request to connection to the
node, establish the second wireless connection with the internet
enabled device.
[0019] In some embodiments, the first wireless connection is a
Wi-Fi connection, and wherein the wireless gateway module is
configured to communicate with a wireless access point in a local
area network (LAN) to establish the first wireless connection.
[0020] In some embodiments, execution of the computer readable
instructions further cause the microcontroller to: receive the one
or more instructions from an application executed by the internet
enabled device over the second wireless connection, wherein the one
or more instructions includes an instruction indicating a service
set identifier (SSID) associated with the wireless access point in
the LAN; and configure the pressure switch to connect to the first
wireless network based on the SSID.
[0021] In some embodiments, execution of the computer readable
instructions further cause the microcontroller to receive a command
corresponding to a selection made via a user interface presented by
the internet enabled device.
[0022] In some embodiments, the command includes at least one
instruction to cause the pressure switch to change at least one of
a plurality of device settings.
[0023] In some embodiments, the wireless gateway module is
configured to receive the command over the first wireless
connection.
[0024] In some embodiments, execution of the computer readable
instructions further cause the microcontroller to change the at
least one of the plurality of device settings based on the
command.
[0025] In some embodiments, the remote server is a cloud-based
server.
[0026] In some embodiments, execution of the computer readable
instructions further cause the microcontroller to: generate a
second message, wherein the second message includes information
related to a status of the system; and send the second message to
the remote server via the first wireless network.
[0027] In some embodiments, execution of the computer readable
instructions further cause the microcontroller to: generate a
second message, wherein the second message includes information
related to a change in a status of the system; and send the second
message to the remote server via the first wireless network.
[0028] In some embodiments, execution of the computer readable
instructions further cause the microcontroller to: generate a
second message, wherein the second message includes information
indicating that the system requires maintenance; and send the
second message to the remote server via the first wireless
network.
[0029] In some embodiments, execution of the computer readable
instructions further cause the microcontroller to: generate a
second message, wherein the second message includes a request for
maintenance; and send the second message to the remote server via
the first wireless network.
[0030] In some embodiments, the remote server is further configured
to send a request for maintenance based on the second message to a
service provider automatically without user intervention in
response to receive the second message.
[0031] In some embodiments, execution of the computer readable
instructions further cause the microcontroller to: generate a
second message, wherein the second message includes a request for
replacement parts; and send the second message to the remote server
via the first wireless network.
[0032] In some embodiments, the remote server is further configured
to send a request for replacement parts to a parts supplier
automatically without user intervention in response to receive the
second message.
[0033] In some embodiments, the remote server is further configured
to send payment information with the request for replacement
parts.
[0034] In some embodiments, the pressure switch is configured for
use with at least one of a sump pump controller, a residential
water pump controller, a pool pump controller, and an automated
pool controller.
[0035] In some embodiments, the second wireless connection is a
cellular connection, and the wireless gateway is further configured
to communicate with the remote server using the cellular
connection.
[0036] In some embodiments, the message includes information
related to energy efficiency of the water pump.
[0037] In some embodiments, the pressure switch further comprises a
temperature sensor, and wherein the message includes information
related to an ambient temperature in the vicinity of the pressure
switch based on an output of the temperature sensor.
[0038] In some embodiments, the message include information related
to water leak detection.
[0039] In some embodiments, the message includes information
related to a water flow rate.
[0040] In some embodiments, the message includes information
related to managing energy use of the water pump with respect to
energy grid capacity.
[0041] In some embodiments, the message includes water quality
parameters.
[0042] In some embodiments, the fault corresponds to a low water
condition, and wherein execution of the computer readable
instructions further cause the microcontroller to interrupt power
to the water pump in response to the fault.
[0043] In some embodiments, execution of the computer readable
instructions further cause the microcontroller to implement a short
cycle protection delay.
[0044] In some embodiments, the fault corresponds to an overcurrent
condition, and wherein execution of the computer readable
instructions further cause the microcontroller to interrupt power
to the water pump in response to the fault.
[0045] In some embodiments, the fault corresponds to an
overpressure condition, wherein execution of the computer readable
instructions further cause the microcontroller to interrupt power
to the water pump in response to the fault.
[0046] In some embodiments, the remote server is further configured
to store up to 50 occurrences of fault conditions.
[0047] In some embodiments, the remote server is further configured
to store an installation record for the pressure switch, the
installation record comprising at least one of a pump size, a pump
type, a pump setting, a casing depth, a well depth, a check valve
location, a drawdown, and a pressure switch serial number.
[0048] In accordance with some embodiments of the present
disclosure a method for monitoring a system and controlling a pump
coupled to plumbing is provided. The method includes the steps of
determining that a fault has occurred in the system, transmitting a
first message to a remote server over a first wireless network, the
first message including information related to the fault, sending
the information related to the fault via the first wireless network
to an internet enabled device, receiving a second message from the
remote server via the first wireless network, the second message
including the information related to the fault, and shutting down
the pump via a microcontroller configured to control operation of
the pump.
DESCRIPTION OF THE DRAWINGS
[0049] The invention will be better understood and features,
aspects and advantages other than those set forth above will become
apparent when consideration is given to the following detailed
description thereof. Such detailed description makes reference to
the following drawings.
[0050] FIG. 1A is an exploded view of a pressure switch in
accordance with some embodiments of the present disclosure.
[0051] FIG. 1B is a top perspective view of the pressure switch of
FIG. 1A
[0052] FIG. 1C is a right side view of the pressure switch of FIG.
1A.
[0053] FIG. 1D is a rear view of the pressure switch of FIG.
1A.
[0054] FIG. 1E is a front view of the pressure switch of FIG.
1A.
[0055] FIG. 1F is a top perspective view of the interior of the
pressure switch of FIG. 1A.
[0056] FIG. 1G is another top perspective view of the interior of
the pressure switch of FIG. 1A.
[0057] FIG. 1H is a cutaway side view of the pressure switch of
FIG. 1A.
[0058] FIG. 1I is another top perspective view of the interior of
the pressure switch of FIG. 1A.
[0059] FIG. 1J is another cut away side view of the pressure switch
of FIG. 1A.
[0060] FIG. 2 is a communication block diagram in accordance with
some embodiments of the present disclosure.
[0061] FIG. 3 is another communication block diagram in accordance
with some embodiments of the present disclosure.
[0062] FIG. 4A is an example of an internet enabled device in
accordance with some embodiments of the present disclosure.
[0063] FIG. 4B is an example of another internet enabled device in
accordance with some embodiments of the present disclosure.
[0064] FIG. 5 is a block diagram in accordance with some
embodiments of the present disclosure.
[0065] FIG. 6 is an example of a process for configuring a pressure
switch in accordance with some embodiments of the present
disclosure.
[0066] FIG. 7 is an example of a process for controlling operation
of a pump in accordance with some embodiments of the present
disclosure.
DETAILED DESCRIPTION
[0067] Before any embodiments are described in detail, it is to be
understood that the invention is not limited in its application to
the details of construction and the arrangement of components set
forth in the following description or illustrated in the following
drawings, which is limited only by the claims that follow the
present disclosure. The invention is capable of other embodiments,
and of being practiced, or of being carried out, in various ways.
Also, it is to be understood that the phraseology and terminology
used herein is for the purpose of description and should not be
regarded as limiting. The use of "including," "comprising," or
"having" and variations thereof herein is meant to encompass the
items listed thereafter and equivalents thereof as well as
additional items. Unless specified or limited otherwise, the terms
"mounted," "connected," "supported," and "coupled" and variations
thereof are used broadly and encompass both direct and indirect
mountings, connections, supports, and couplings. Further,
"connected" and "coupled" are not restricted to physical or
mechanical connections or couplings.
[0068] The following description is presented to enable a person
skilled in the art to make and use embodiments of the invention.
Various modifications to the illustrated embodiments will be
readily apparent to those skilled in the art, and the generic
principles herein can be applied to other embodiments and
applications without departing from embodiments of the invention.
Thus, embodiments of the invention are not intended to be limited
to embodiments shown, but are to be accorded the widest scope
consistent with the principles and features disclosed herein. The
following detailed description is to be read with reference to the
figures, in which like elements in different figures have like
reference numerals. Skilled artisans will recognize the examples
provided herein have many useful alternatives and fall within the
scope of embodiments of the invention.
[0069] Additionally, while the following discussion may describe
features associated with specific devices, it is understood that
additional devices and or features can be used with the described
systems and methods, and that the discussed devices and features
are used to provide examples of possible embodiments, without being
limited.
[0070] FIG. 1A shows an example of an exploded view of a pressure
switch 100 in accordance with some embodiments of the present
disclosure. In some embodiments, a base 102 can be configured to
support and contain a printed circuit board (PCB) 108. In some
embodiments, The PCB 108 can be electrically coupled to a
microcontroller 114 and a wireless gateway module 116.
Alternatively, in some embodiments, the microcontroller 114 can
include a wireless gateway module, and the wireless gateway module
116 can be omitted. In some embodiments, spacers 110a, 110b can be
affixed to the PCB 108 and an inner frame 112. The spacers 110a,
110b can aid in the protection of the PCB 108 and associated
components. In some embodiments, the inner frame 112 can be in
contact with a cover 104. In some embodiments, the cover 104 can be
coupled to the base 102 via coupling elements 106a and/or 106b. In
some embodiments, the inner frame 112 can also be coupled to the
PCB 108. In some embodiments, the pressure switch 100 can include a
pressure transducer within a transducer housing 120 that outputs a
pressure signal that is provided to the microcontroller 114. In
some embodiments, the pressure switch can include a relay that can
control power to a pump based on control signals from the
microcontroller 114. In some embodiments, terminals on the relay
122 can be electrically connected to posts 124a, 124b, which can be
configured to be electrically connected to a source of power (e.g.,
a household electrical grid) and the pump, respectively. For
example, posts 124a can be connected to wires and/or a cable
carrying 230 volts alternating current (V AC), and posts 124b can
be connected to wires and/or a cable that provides an electrical
connection between the relay 122 and the pump. Note that although
pressure switch 100 is described as including the microcontroller
114, this is merely an example, and any suitable type of hardware
processor or combination of hardware processors can be used to
monitor and/or control the pressure switch 100.
[0071] FIGS. 1B to 1E show example views of the outside of the
pressure switch 100 in accordance with some embodiments of the
present disclosure. In some embodiments, the pressure switch 100
can have a housing that can include the base 102 and the cover 104.
In some embodiments, the base 102 can be coupled to the cover 104
via coupling elements 106a and/or 106b. In some embodiments,
removal of the coupling elements 106a and/or 106b can allow access
to the interior of the pressure switch 100 through the removal of
the cover 104, which may facilitate routine maintenance.
Additionally, in some embodiments, this can provide easy access to
the interior components of the pressure switch 100 should
replacement of any part(s) be necessary. In some embodiments, the
housing of the pressure switch 100 can have one or more openings
that allow access to the interior of the pressure switch 100.
Alternatively, in some embodiments, the pressure switch 100 can be
sealed. For example, it may be beneficial for the housing to be
compliant with the NEMA 3 or 3R standards, as defined by the
National Electrical Manufacturers Association (NEMA).
[0072] FIGS. 1F-1J show views of various portions of the inside of
the pressure switch 100 in accordance with some embodiments of the
present disclosure. In some embodiments, the base 102 of the
pressure switch 100 is shown. The coupling elements 106a, 106b
allow the base 102 to coupled to the cover 104. The inner frame 112
can cover the PCB 108 when pressure switch 100 is assembled. The
spacers 110a, 110b can be affixed to the PCB 108. The spacers 110a,
110b can, for example, protect individual components that are
coupled to the PCB 108 by inhibiting the inner frame 112 from
contacting the individual components. Although shown with
particular dimensions, these are merely an example, and the PCB 108
can be configured to be different shapes and sizes, and can include
a plurality of through-holes. The PCB 108 can be electrically
coupled to the microcontroller 114. The PCB 108 can also be
electrically coupled to the wireless gateway module 116. As
described above, the wireless gateway module 116 can be part of, or
separate from, the microcontroller 114. In some embodiments, for
example, as shown in FIGS. 1H and 1J, an inlet 126 in the base 102
can be configured to be coupled to a plumbing system (e.g.,
including one or more pipes, tubes, valves, etc.) that is in fluid
communication with a water supply (e.g., a well). In some such
embodiments, the transducer can measure the water pressure in the
plumbing system.
[0073] In some embodiments, the wireless gateway module 116 can be
configured to send and receive data from a remote computing device
(e.g., a server, a mobile device, etc.). In some embodiments, the
wireless gateway module 116 can communicate with the remote
computing device using a router and/or modem that provides a
connection between a local area network (LAN) to which the wireless
gateway module is connected and a wide area network (WAN), such as
the Internet. For example, the wireless remote gateway module 116
can be configured to connect to a wireless LAN (e.g., a Wi-Fi
network) via a wireless router, and the router can be connected to
a WAN via a modem. Additionally or alternatively, in some
embodiments, the wireless gateway module 116 can be configured to
act as a modem that is capable of providing a connection to a WAN
without connecting first to a LAN. For example, the wireless
gateway module 116 can be configured to act as a cellular modem
that can communicate over a cellular network (e.g., a 3G network, a
4G network, etc., complying with any suitable standard, such as
CDMA, GSM, LTE, LTE Advanced, WiMAX, etc.), which can provide
access to the Internet. In such an example, the wireless gateway
module 116 can communicate with a remote computing device (e.g., a
server, a mobile device, etc.) without being connected to a
LAN.
[0074] In some embodiments, the pressure switch 100 can be
configured to have a shape and size that allows the pressure switch
100 to replace an existing pressure switch. In some embodiments, by
using a similar footprint to the existing pressure switch, the
pressure switch 100 can be easily and quickly installed withy out
requiring modifications. For example, a pump that is controlled by
a pressure switch that is adjustable via two adjustment nuts
(sometimes referred to herein as a legacy pressure switch), can be
reconfigured to be controlled by the pressure switch 100. In such
an example, the legacy pressure switch can be removed (e.g., by
interrupting power to the legacy pressure switch via a circuit
breaker, disconnecting the wires and/or cable providing power to
the legacy pressure switch, disconnecting the wires and/or cable
providing power from the legacy pressure switch to the pump, and
disconnecting the legacy pressure switch from the plumbing). After
removing the legacy pressure switch, the pressure switch 100 can be
installed in its place (e.g., by connecting the wires and/or cable
from the power supply to posts 124a, connecting the wires and/or
cable providing power from the pressure switch 100 to the pump to
posts 124b, connecting the pressure switch 100 to the plumbing via
inlet 126, and reconnecting power from the power supply to the
pressure switch 100 through the circuit breaker). Although the base
102 and the cover 104 shown in FIGS. 1A to 1J as having particular
shapes, these are merely examples, and the base 102 and the cover
104 can be configured to be different shapes and/or sizes.
[0075] FIG. 2 illustrates an example of a wireless monitoring and
control system for communicating information to and/or from
pressure switch 100 to an internet enabled device in accordance
with some embodiments of the present disclosure. In some
embodiments, the wireless gateway module 116 can be positioned
within the pressure switch 100 (e.g., as described above in
connection with FIGS. 1A to 1J). In some embodiments, the wireless
gateway module 116 can communicate with a router/modem 202, which
can communicate with a cloud based server 204. In some embodiments,
router/modem 202 can include any suitable combination of networking
devices (e.g., one or more wireless routers, one or more wired
routers, one or more Ethernet switches, one or more cable modems,
one or more cellular modems, one or more optical network terminals,
etc.). Additionally or alternatively, router/modem 202 can include
one or more combined devices, such as a combined wireless router
and cable modem. In some embodiments, the router/modem 202 can
include a standard, off-the-shelf router and/or modem used for
connecting to the Internet via an internet service provider (ISP).
In some embodiments, the cloud based server 204 can communicate
with an internet enabled device 206 using any suitable network or
combination of networks. In some embodiments, the internet enabled
device 206 can be any suitable computing device that can
communicate with the cloud based server 204 via any suitable
network or combination of networks. For example, the internet
enabled device 206 can be a smartphone, a tablet computer, a
wearable computer, a laptop computer, a personal computer, a server
computer, a virtual machine being executed by a physical computing
device, a virtual personal assistant, a device providing access to
a virtual personal assistant (e.g., a smart speaker), etc. In some
embodiments, the internet enabled device 206 can communicate with
cloud based server 206 via a LAN (e.g., via a router/modem, such as
router/modem 202, or a different router/modem that is located
remotely from router/modem 202 and is part of a different local
area network). In some embodiments, the pressure switch 100 can
send and receive information (e.g., messages) to and from the
internet enabled device 206 via the cloud based server 204. In some
embodiments, the cloud based server 204 can store data received
from, or directed to, the pressure switch 100 for later access
(e.g., by the pressure switch 100 and/or by the internet enabled
device 206). Note that in some embodiments, the pressure switch 100
can connect to the router/modem 204 via another device, such as a
hub that coordinates communications between connected devices
(e.g., Internet of things devices) and the router. For example,
such a hub can connect to one or more connected devices via a
ZigBee connection, and can receive messages over a ZigBee mesh
network from the pressure switch 100 and relay the content of the
message to the router in a format that is suitable for transmission
over the Internet (e.g., a message formatted in compliance with
TCP/IP).
[0076] In some embodiments, communications to and/or from the
pressure switch 100, the router/modem 202, the cloud based server
204, and/or the internet enabled device 206 can be sent over a
communication network, which can be any suitable communication
network or combination of communication networks. For example, the
communication network can include a Wi-Fi network (e.g., an 802.11x
network, which can include one or more wireless routers, one or
more switches, etc.), a peer-to-peer network (e.g., a Bluetooth
network, a ZigBee.RTM. network, a Z-Wave.RTM. network, a
proprietary RF connection, etc.), a cellular network (e.g., a 3G
network, a 4G network, etc., complying with any suitable standard,
such as CDMA, GSM, LTE, LTE Advanced, WiMAX, etc.), a wired
network, an EnOcean.RTM. network, etc. In some embodiments, the
communication network can be a LAN, a WAN, a public network (e.g.,
the Internet), a private or semi-private network (e.g., a corporate
or university intranet), any other suitable type of network, or any
suitable combination of networks. Communications links between the
pressure switch 100, the router/modem 202, the cloud based server
204, and/or the internet enabled device 206 can each be any
suitable communications link or combination of communications
links, such as wired links, fiber optic links, Wi-Fi links,
Bluetooth links, cellular links, etc.
[0077] FIG. 3 illustrates another example of a wireless monitoring
and control system for communicating information to and/or from
pressure switch 100 to an internet enabled device in accordance
with some embodiments of the present disclosure. In some
embodiments, the wireless gateway module 116 can be positioned
within the pressure switch 100, and can communicate with cloud
based server 204 without the user of the router/modem 202. For
example, in some embodiments, the wireless gateway module 116 can
be configured to act as a cellular modem. Additionally or
alternatively, in some embodiments, the wireless gateway module 116
can communicate with the internet enabled device 206 directly
(e.g., via a peer to peer connection such as a Bluetooth
connection, a ZigBee Connection, a Z-Wave connection, a Wi-Fi
connection in which the wireless gateway module and/or the internet
enabled device acts as a discoverable node such as an ad hoc Wi-Fi
connection or a Wi-Fi Direct connection, etc.) and/or indirectly
(e.g., using a LAN, a WAN, the Internet, a combination of networks,
using a mesh network such as a mesh Wi-Fi network, a mesh ZigBee
network, a mesh Z-Wave network, etc.). As described above in
connection with FIG. 2, the internet enabled device 206 can
communicate with the cloud based server 204 via any suitable
network or combination of networks. In some embodiments, the
pressure switch 100 can send and receive information (e.g.,
messages) to and from the internet enabled device 206 via the cloud
based server 204 or via a peer connection or mesh network.
[0078] In some embodiments, the cloud based server 204 can store
the received data in a location associated with the pressure switch
100 (e.g., in a particular table, in connection with a particular
address, etc.). Additionally or alternatively, the cloud based
server 204 can store the data in a location associated with a
particular user account associated with the pressure switch 100. In
some embodiments, the cloud based server 204 can store any suitable
number of records, such as a particular number of most recent
pressure readings (e.g., 50, 100, 1,000, etc.), pressure for a
particular recent time period (e.g., over the last day, week,
month, year, etc.), a particular number recent faults that have
occurred (e.g., twenty, 50, 100, etc.). Note that although cloud
based server 204 is described herein as being a cloud server, this
is merely an example, and actions described as being performed by
cloud based server 204 can be performed by a physical server that
is under control of a service provider associated with the pressure
switch 100. Note that the configurations shown in FIGS. 2 and 3 are
not mutually exclusive, as the wireless gateway module 116 can be
configured to communicate both via a LAN and via a cellular modem.
In some embodiments, it may be beneficial to use a service, such as
a software-as-a-service platform provided by Arrayent.RTM. (of
Redwood City, Calif.) to provide firmware, software, and/or
hardware (e.g., one or more servers) for facilitating communication
between the pressure switch 100 and the internet enabled
device.
[0079] In some embodiments, as described below in connection with
FIG. 6, a user can create a user account by accessing the cloud
based server 204 from the internet enabled device 206, and can
associate with the pressure switch 100 with the account. In some
embodiments, the pressure switch 100 can provide status information
to the cloud based server 204, and the user can access information
associated with the user account from any suitable internet abled
device 206, which may or may not be the same internet abled device
206 that was used to create the account.
[0080] FIG. 4A shows an example 400 of an internet enabled device
in accordance with some embodiments of the present disclosure. As
shown in FIG. 4A, the internet enabled device can be a smartphone.
In some embodiments, a user can install an application on the
smartphone 400 allowing the user to access information associated
with the user account administered by the cloud based server 204.
Additionally or alternatively, in some embodiments, a user can use
an internet browser installed on smartphone 400 to access a web
page through which the user can to access information associated
with the user account administered by the cloud based server
204.
[0081] FIG. 4B shows another example 402 of an internet enabled
device in accordance with some embodiments of the present
disclosure. As shown in FIG. 4B, the internet enabled device can be
a personal computer 402 that is connected to the Internet. In some
embodiments, a user can install an application on the personal
computer 400 allowing the user to access information associated
with the user account administered by the cloud based server 204.
Additionally or alternatively, in some embodiments, a user can use
an internet browser installed on personal computer 400 to access a
web page through which the user can to access information
associated with the user account administered by the cloud based
server 204.
[0082] FIG. 5 shows an example of a block diagram of a system
including a pressure switch 500 in accordance with some embodiments
of the present disclosure. As shown in FIG. 5, the pressure switch
500 can include a pressure input 504, which can be in fluid
communication with a pressure transducer 506. In some embodiments,
pressure input 504 can be any suitable input and can include any
suitable hardware, such as a flange, a vale, etc. For example, as
described above in connection with FIGS. 1A to 1J, pressure input
504 can be implemented by the inlet 126. In some embodiments, the
pressure transducer 506 can be a transducer that can measures
pressures of any suitable range of magnitudes. For example, the
pressure transducer 506 can be configured to measure pressures from
0 psi to 100 psi, 0 psi to 150 psi, 0 psi to 300 psi, etc.
Additionally, in some embodiments, the pressure transducer 506 can
be configured to measure pressures below 0 psi (e.g., created by
negative pressure in the plumbing system for which pressure is
being measured), or starting from above 0 psi. In some embodiments,
the pressure transducer 506 can generate a variable current and/or
variable voltage indicative of the measured pressure. For example,
the pressure transducer 506 can provide a current between 4
milliamperes (mA) and 20 mA based on the pressure measured at the
pressure input 504. As another example, the pressure transducer 506
can provide a voltage between 0 volts (V) and 5 V based on the
pressure measured at the pressure input 504. In some embodiments,
the value output by the pressure transducer 506 can be mapped to
pressure using a linear relationship to the range of pressures
which the pressure transducer 506 is configured to measure. For
example, if the pressure transducer 506 is configured to measure
pressures from 0 psi to 100 psi, and output current between 4 mA
and 20 mA or between 0 V and 5 V, the pressure measured by the
pressure transducer 506 can be calculated based on an even
subdivision of the range into 100, 1,000, 10,000, etc.
Alternatively, in some embodiments, the value output by the
pressure transducer 506 can be mapped to pressure using a
non-linear relationship to the range of pressures which the
pressure transducer 506 is configured to measure. For example, if
the pressure transducer 506 is configured to measure pressures from
0 psi to 100 psi, and output current between 4 mA and 20 mA or
between 0 V and 5 V, the pressure measured by the pressure
transducer 506 can be calculated based on a logarithmic scale, an
exponential scale, etc.
[0083] In some embodiments, a signal output from the pressure
transducer 506 can be provided as an input to a microcontroller
512. As described above in connection with microcontroller 114 of
FIGS. 1A to 1J, 2 and 3, in some embodiments, the pressure switch
500 can be implemented with a microcontroller that is configured to
act as a wireless gateway module. For example, microcontroller 512
can be implemented using a single-chip wireless microcontroller,
such as the CC3200MOD microcontroller available from Texas
Instruments.RTM. (of Dallas, Tex.), which can include a
CC3200R1M2RGC microcontroller from Texas Instruments.RTM.. In some
embodiments, pressure switch 500 can include one or more antennas
520 that is configured to send and/or receive wireless signals,
such as signals for communicating over Wi-Fi, Bluetooth, ZigBee,
Z-Wave, etc. In some such embodiments, the antenna(s) 520 can
receive signals from the wireless gateway module and can transmit
the signals into the surrounding environment. In some embodiments,
the antenna(s) 520 can be an integral part of the microcontroller
512 and/or within the wireless gateway. Alternatively, in some
embodiments, the antenna 520(s) can be mounted to a PCB and
electrically connected to the microcontroller 512 and/or the
wireless gateway, and/or can be mounted to the housing of the
pressure switch 500 and electrically connected to the
microcontroller 512 and/or the wireless gateway. In some
embodiments, the pressure switch 500 can communicate with an
internet enabled device 502 using the antenna(s) 520. For example,
the pressure switch 500 can use the antenna(s) 520 to communicate
with the internet enabled device 502 locally using a direct
connection (e.g., over a Bluetooth connection, over a direct Wi-Fi
connection such as an ad hoc Wi-Fi connection or Direct Wi-Fi
connection), and/or an indirect connection (e.g., over a LAN, over
a mesh network, etc.). As another example, the pressure switch 500
can use the antenna(s) 520 to communicate with the internet enabled
device 502 remotely (e.g., over the Internet via a LAN, a mesh
network, etc.). Note that although pressure switch 500 is described
as including the microcontroller 512, this is merely an example,
and any suitable type of hardware processor or combination of
hardware processors can be used to monitor and/or control the
pressure switch 100.
[0084] In some embodiments, the pressure switch 500 can include a
temperature sensor 508 that can output a signal indicative of the
temperature of the pressure switch 500, the pump 516, and/or the
ambient temperature of the surrounding environment. For example,
temperature sensor 508 can be used to monitor whether the pump is
potentially overheating. As another example, temperature sensor 508
can be used to monitor whether water in the plumbing system may be
in danger of freezing.
[0085] In some embodiments, the pressure switch 500 can include a
current transformer 510, which can be used to monitor current being
drawn by the pump 516. For example, the microprocessor 510 can
receive a signal from the current transformer 510, and based on the
magnitude of the current output by the transformer can calculate
the current being drawn by the pump 516. In such an example, the
current transformer 510 can be used to determine whether an
overcurrent condition has occurred, whether the pump is not drawing
the amount of current expected (e.g., which may indicate a low
water level or a problem with the pump), the amount of power being
used by the pump, etc.
[0086] In some embodiments, the pressure switch 500 can include a
relay 514 that can selectively provide power for operation of a
pump 516 to which the pressure switch 500 is connected. For
example, the relay 500 can be connected to both a source of power
(e.g., a household electrical grid) and wires and/or a cable
connected to the pump 516, and based on a signal from the
microcontroller 512, can either provide power to the pump or
inhibit power from being provided to the pump 516.
[0087] In some embodiments, the pressure switch 500 can include a
power supply 518 that can provide power for operation of the
microcontroller 512 and/or any other suitable low voltage devices
within the pressure switch 500. For example, as described below,
the pressure switch 500 can receive input power at 230 V and 60
Hertz (Hz), which is not suitable for operation of the
microcontroller 512, which is typically a low voltage device (e.g.,
operating at 3.3 V DC, 5 V DC, 12 V DC, 24 V DC, etc.). In some
embodiments, power supply 518 can receive AC power (e.g., at 230 V,
60 Hz), convert the AC power to low voltage DC power, and
distribute power to one or more other components of the pressure
switch 500, such as the microcontroller 512 (via the transformer
510), and the relay 514.
[0088] In some embodiments, the pump 516 can be any suitable pump.
For example, the pump 516 can be a single phase, 230 V, 15 A pump.
However, this is merely an example, and a variety of pumps can be
used with the pressure switch 500.
[0089] In some embodiments the microcontroller 512 can coordinate
operation of the pressure switch 500, such as by controlling the
relay 514 to selectively provide power to the pump 516 based on an
output of the pressure transducer 508 and/or the temperature sensor
508. Additionally or alternatively, in some embodiments, the
microcontroller 512 can monitor operation of the pressure switch,
for example, to determine whether a fault has occurred, such as a
loss of power to the power supply 518, a loss of water pressure
below a particular value (e.g., below 5 psi, to 0 psi, below 0 psi,
etc.). In some embodiments, microcontroller 512 can periodically
(at regular and/or irregular intervals) provide information to
cloud based server 204. For example, microcontroller 512 can
monitor operation of the pressure switch 500 and provide
information related to its operation to the cloud based server 204
every minute, every five minutes, every 15 minutes, every 30
minutes, every hour, every 12 hours, once per day, etc. As another
example, microcontroller 512 can monitor operation of the pressure
switch 500 and provide information related to its operation to the
cloud based server 204 when a particular condition is met, such as
when pressure falls below a particular threshold, when pressure
rises above a particular threshold, when temperature falls below a
particular threshold, when temperature rises above a particular
threshold, when current through the relay 514 falls below a
particular threshold, when current through the relay 514 rises
above a particular threshold, when voltage of the signal received
at the power supply 518 falls below a particular threshold, when
voltage of the signal received at the power supply 518 rises above
a particular threshold, etc. In such an example, the pressure
switch 500 and provide information related to its operation to the
cloud based server 204 when the condition is detected, when the
condition has persisted for a particular length of time (e.g., one
second, five seconds, one minute, etc.), or at any other suitable
time. As yet another example, microcontroller 512 can monitor
operation of the pressure switch 500 and provide information
related to its operation to the cloud based server 204 in response
to a request from the cloud based server 204. In such an example, a
user interacting with cloud based server 204 can request status
information related to operation of the pressure switch 500, and
the cloud based server 204 can request the information from the
pressure switch 500.
[0090] In some embodiments, the microcontroller 512 can use one or
more criteria to reduce the likelihood that the pump will be
damaged due to short cycling in which the pump is cycled between on
and off relatively quickly. For example, the microcontroller 512
can keep the pump 516 running for a minimum amount of time when it
is turned on regardless of whether the cut-out pressure has been
reached. As another example, the microcontroller 512 can keep the
pump 516 off for a minimum amount of time after it has interrupted
power to the pump regardless of whether the cut-in pressure has
been reached. As yet another example, the microcontroller 512 can
limit the number of times the pump 516 is cycled between on and off
in a particular time period (e.g., every hour).
[0091] In some embodiments, the pressure switch 500 can include any
suitable memory (not shown), which can include any suitable storage
device or devices that can be used to store instructions, values,
etc., that can be used, for example, by a hardware processor (e.g.,
microcontroller 512) to control operation of the relay 514, to
monitor operation of the pressure switch 500, to communicate
information to the cloud based server 204, etc. For example, memory
can include any suitable volatile memory, non-volatile memory,
storage, or any suitable combination thereof. For example, the
memory can include RAM, ROM, EEPROM, one or more flash drives, one
or more hard disks, one or more solid state drives, one or more
optical drives, etc. In some embodiments, the memory can have
encoded thereon a computer program for controlling operation of a
hardware processor (e.g., microcontroller 512) in the form of
computer executable instructions that, when executed by the
hardware processor, cause the hardware processor to perform one or
more actions as indicated by the instructions. For example, in some
such embodiments, the microcontroller 512 can execute at least a
portion of the computer program to control operation of the relay
514 based on signals received from the pressure transducer 506, to
monitor operation of the pressure switch 500, to transmit
information to the cloud based server 204, etc. In some
embodiments, any suitable computer readable media can be used for
storing instructions for performing the functions and/or processes
described herein. For example, in some embodiments, computer
readable media can be transitory or non-transitory. For example,
non-transitory computer readable media can include media such as
magnetic media (such as hard disks, floppy disks, etc.), optical
media (such as compact discs, digital video discs, Blu-ray discs,
etc.), semiconductor media (such as RAM, Flash memory, electrically
programmable read only memory (EPROM), electrically erasable
programmable read only memory (EEPROM), etc.), any suitable media
that is not fleeting or devoid of any semblance of permanence
during transmission, and/or any suitable tangible media. As another
example, transitory computer readable media can include signals on
networks, in wires, conductors, optical fibers, circuits, any other
suitable media that is fleeting and devoid of any semblance of
permanence during transmission, and/or any suitable intangible
media.
[0092] In some embodiments, the pressure switch 500 can include
energy storage (not shown), such as a battery, an ultracapacitor, a
fuel cell, etc. In some embodiments, the microcontroller 500 can
use power from the energy storage to continue to operate (e.g., to
send information related to the status of the pressure switch 500)
when power to power supply 518 is interrupted.
[0093] FIG. 6 shows an example 600 of a process for configuring a
pressure switch in accordance with some embodiments of the present
disclosure. As shown in FIG. 6, process 600 can begin at 602, by
optionally removing an existing (e.g., legacy) pressure switch that
is being used to control operation of a pump. For example, if a
homeowner is retrofitting an existing pump system, a qualified
person (who may or may not be the homeowner) can, at 602, remove
the existing pressure switch (e.g., a legacy pressure switch) from
the pump system. In some embodiments, removing the existing
pressure switch can involve any suitable steps performed in any
suitable order, such as interrupting power to the existing pressure
switch, disconnecting wires and/or a cable providing power to the
existing pressure switch, disconnecting wires and/or a cable
providing power to the pump from the existing pressure switch,
disconnecting a pressure input to the existing pressure switch,
and/or disconnecting a physical connector securing the existing
pressure switch to the pump system.
[0094] At 604, process 600 can include installing a pressure switch
implemented in accordance with some embodiments of the present
disclosure. For example, process 600 can include installing the
pressure switch 100 or the pressure switch 500. In some
embodiments, In some embodiments, installing the pressure switch
can involve any suitable steps performed in any suitable order,
such as, securing the pressure switch to the pump system,
connecting a pressure input to the pressure switch, connecting
wires and/or a cable to provide power to the pump from the pressure
switch, connecting wires and/or a cable to provide power to the
existing switch (e.g., from the residential electric system),
and/or providing power to the pressure switch (e.g., by closing a
circuit interrupted when disconnecting the existing power
switch).
[0095] At 606, process 600 can optionally include connecting an
internet enabled device (e.g., internet enabled device 206) to the
pressure switch via a peer network connection (e.g., Bluetooth,
ZigBee, Z-Wave, a direct/peer-to-peer Wi-Fi connection with the
pressure switch acting as a node in an ad hoc Wi-Fi network or a
Wi-Fi Direct connection, etc.), or through a mesh wireless
connection (e.g., ZigBee, Z-Wave, etc.). For example, in some
embodiments, a user can cause the internet enabled device to search
for Bluetooth connections, and can select an available device that
corresponds to the pressure switch. As another example, the
pressure switch, when initially powered on (e.g., from an off
state), can establish itself as a node in a peer-to-peer Wi-Fi
network (e.g., an ad hoc Wi-Fi network or a Wi-Fi Direct
connection) that accepts appropriate connection requests, and the
pressure switch may be configured to broadcast a particular service
set identifier (SSID) and/or require a particular password that are
preconfigured (e.g., from an EEPROM). The user can select the
appropriate SSID and enter a password to connect directly to the
pressure switch over a Wi-Fi connection. In such an example, the
preconfigured SSID and password may be included in a label applied
to the pressure switch, on packaging in which the pressure switch
was packaged, in literature accompanying the pressure switch,
and/or can be communicated using any other suitable technique. In
such an example, the pressure switch can act as a node in a
wireless ad-hoc network until it establishes a Wi-Fi connection
with a wireless access point (e.g., a router), or until a
particular period of time has elapsed (e.g., 15 minutes, 30
minutes, etc.). Additionally, in such an example, the pressure
switch can have a user input (e.g., a hardware button or switch)
that, when activated, causes the pressure switch to act as a
discoverable node in a peer-to-peer Wi-Fi network. As yet another
example, the pressure switch can be configured to accept new
connections as part of a mesh network, such as a ZigBee network, a
Z-Wave network, an EnOcean network, etc., and the user can utilize
an application installed on the internet enabled device to add the
pressure switch to an existing mesh network (e.g., including a
hub), or to establish a connection directly with the pressure
switch.
[0096] In some embodiments, prior to establishing the connection,
the user can (or may be required to) download an application that
can be used to configure the pressure switch. For example, a
manufacturer, distributor, seller, and/or service provider
associated with the pressure switch can provide an application that
can be used to configure the pressure switch. As another example, a
third party provide an application that can be used to configure
the pressure switch (e.g., a provider of an application and/or
system for managing connected devices). Additionally or
alternatively, prior to establishing the connection, the user can
(or may be required to) visit a particular web page that can be
used to configure the pressure switch. Such a web page can be a web
page manufacturer, distributor, seller, and/or service provider
associated with the pressure switch. Additionally or alternatively,
the web page can be a web page that is associated with the pressure
switch that is to be configured (e.g., the web address can be
uniquely identified with the particular pressure switch). In some
embodiments, when a connection is established with the pressure
switch, the pressure switch can prompt the user to download an
appropriate application, or visit a particular web page, for
configuring the pressure switch.
[0097] In some embodiments, the pressure switch can be configured
without requiring the user to establish a local connection to the
pressure switch (i.e., 606 can be omitted in come embodiments). For
example, if the pressure switch is implemented with a cellular
modem, the user can download and application and/or visit a web
page to configure the pressure switch, and information can be
provided to the pressure switch using a connection established by
the cellular modem.
[0098] At 608, process 600 can include setting up a wireless
connection (e.g., a Wi-Fi connection, a cellular connection, a
ZigBee connection, a Z-wave connection, a Bluetooth connection,
etc.) that the pressure switch can use to provide information
related to the operation of the pressure switch to the cloud based
server 204.
[0099] At 610, process 600 can include establishing a connection
between an internet enabled device (e.g., internet enabled device
206) and a service provided by the manufacturer, distributor,
seller, or service provider associated with the pressure switch, or
by a third party. For example, the service can be provided by the
cloud based server 204, which can register a user account,
associate a pressure switch with the user account, collect
information from pressure switches associated with the user
account, provide information and/or alerts to the user associated
with the user account, receive instructions from the user through
the service, send instructions to a pressure switch, send
information to someone authorized by the user (e.g., a technician
such as a plumber, the manufacturer, distributor, seller, and/or
service provider associated with the pressure switch, etc.).
[0100] In some embodiments, the internet enabled device can
download, install, and/or execute an application that can be used
to configure the pressure switch, and can create a user account
within the application, or the internet enabled device can be
directed by the application to load a web page that can be used to
create a user account. Additionally or alternatively, in some
embodiments, the internet enabled device can load a web page that
can be used to configure the pressure switch, and/or can be used to
create a user account. In some embodiments, a user can register the
pressure switch (e.g., through an application and/or web page), and
can create a user account when registering the pressure switch. In
some embodiments, a user can register multiple residential devices
with a given user account, which may include devices other than
pressure switches. In some embodiment, a user can access
information stored in the cloud based server 204 by logging in to
the user account. In some embodiments, a user account can be
associated with any suitable information. For example, the user
account can be associated with information about the user, such as
contact information (e.g., address information, one or more e-mail
addresses, one or more phone numbers, etc.). As another example,
the user account can be associated with information (e.g., a list)
identifying devices associated with the user account. As yet
another example, the user account can be associated with
maintenance information. In a particular example, the user account
can be associated with information about the pump, the water source
(e.g., well), and/or the pressure sensor, such as a pump size, a
pump type, a pump setting, a casing depth, a well depth, a check
valve location, a drawdown, etc., which may assist a technician if
maintenance is required.
[0101] In some embodiments, the user can register the pressure
switch by providing information about the pressure switch, such as
such as a model number(s), a serial number(s), information about
where the pressure switch was purchased (an online retailer, a
distributor, a big box store, after market, etc.), installer
information, etc.
[0102] In some embodiments, information provided when registering a
pressure switch can be used to provide analytic information to a
manufacturer, distributor, seller, and/or service provider
associated with the pressure switch. For example, the provided
information can be accessed by customer support personnel,
facilitating faster and/or more accurate diagnosis of a given
problem, dispatch of replacement parts, and/or dispatch of service
personnel.
[0103] In some embodiments, a user can adjust settings associated
with the user account to indicate whether the remote server (and/or
the pressure sensor) are permitted to make automated service calls,
or to automatically order replacement parts. For example, if the
pressure sensor determines that a particular type of fault has
likely occurred, the remote server can automatically request
maintenance and/or order replacement parts necessary to perform the
maintenance.
[0104] At 612, process 600 can include configuring the pressure
switch for operation. For example, through an application and/or
web page user interface accessed through the internet enabled
device, the user can configure operations of the pressure switch by
sending instructions and/or commands to the pressure switch. In a
more particular example, the user can configure one or more
operating parameters, such as a cut-in pressure, a cut-out
pressure, whether to shut down the pump if pressure falls below a
particular high pressure threshold, the low pressure threshold,
operating temperature range, etc.
[0105] As another more particular example, the user can configure
when to send alerts to the user, how to send such alerts (e.g., by
email, text message, push notification, etc.), a maximum number of
alerts to send with a particular period of time (e.g., one every
twenty four hours), for which conditions to send alerts to the
user, etc.
[0106] As yet another more particular example, the user can
configure how often the pressure switch sends updated status
information to the server during normal operation (e.g., every
minute, every five minutes, once per hour, once per day, etc.),
and/or how many data points to send when updating the status
information (e.g., whether each measurement is sent, whether
average values are sent, etc.).
[0107] In some embodiments, at least a portion of process 600 can
be executed by one or more hardware processors of the pressure
switch (e.g., microprocessor 114 and/or microprocessor 512), while
one or more other portions can be performed by a remote server
(e.g., cloud based server 204) and/or by an internet enabled device
(e.g., internet enabled device 206, internet enabled device 400,
internet enabled device 402, internet enabled device 502).
Additionally, in some embodiments, one or more portions of process
600 can be carried out by a homeowner, technician, or other
person.
[0108] FIG. 7 shows an example 700 of a process for controlling
operation of a pump in accordance with some embodiments of the
present disclosure. As shown in FIG. 7, at 702, process 700 can
measure pressure in a plumbing system that includes a pump (e.g.,
pump 516) to be controlled by a pressure switch (e.g., pressure
switch 100 and/or pressure switch 500). In some embodiments,
process 700 can measure the pressure using any suitable technique
or combination of techniques. For example, process 700 can measure
the value of a signal from a pressure transducer (e.g., pressure
transducer 506) that is in fluid communication with the plumbing
system.
[0109] At 704, process 700 can monitor operation of the pressure
switch and/or the pump which the pressure switch is to control. For
example, process 700 can monitor the ambient temperature in the
vicinity of the pressure switch, the current being drawn by the
pump when the pump is being provided with power (e.g., to detect an
overcurrent condition), cycling of the pump, etc.
[0110] At 706, process 700 can provide information related to the
measured pressure, and/or operation of the pressure switch and/or
pump to a service. For example, in some embodiments, process 700
can provide the information to a cloud based server. In some
embodiments, process 700 can provide such information periodically
(e.g., at regular and/or irregular intervals). For example, process
700 can provide the information every minute, every five minutes,
every 15 minutes, every 30 minutes, every hour, every 12 hours,
once per day, etc. As another example, process 700 can provide the
information when a particular condition is met. As yet another
example, process 700 can provide the in response to a request
(e.g., from the cloud based server 204).
[0111] If process 700 determines, at 708, that the measured
pressure is less than a cut-in pressure ("YES" at 708), process 700
can move to 710 and can provide power to the pump to cause the pump
to run, increasing the water pressure in the plumbing system.
Otherwise, if process 700 determines that the measured pressure is
equal to, or greater than the cut-in pressure ("NO" at 708),
process 700 can move to 712. Note that process 700 can instead
determine whether the measured pressure is less than or equal to
the cut-in pressure when determining whether to provide power to
the pump.
[0112] If process 700 determines, at 712, that the measured
pressure is greater than a cut-out pressure ("YES" at 712), process
700 can move to 714 and can interrupt power to the pump to inhibit
the pump from running, which may cause the water pressure in the
plumbing system to fall. Otherwise, if process 700 determines that
the measured pressure is equal to, or less than, than the cut-out
pressure ("NO" at 712), process 700 can move to 716. Note that
process 700 can instead determine whether the measured pressure is
greater than or equal to the cut-in pressure when determining
whether to interrupt power to the pump.
[0113] At 716, process 700 can determine whether a fault has
occurred. In some embodiments, process 700 can determine whether a
fault has occurred based on the measured pressure and/or the
operation of the pressure switch and/or pump. For example, if the
measured pressure is below a minimum pressure (or, alternatively,
at or below the threshold), process 700 can determine that a fault
has occurred. In such an example, the measure pressure may indicate
that there is likely not enough water being provided from the well
(or other water source) for the pump to safely operate. As another
example, if process 700 provided power to the pump, but the measure
pressure does not increase, process 700 can determine that a fault
has occurred. In such an example, if the pump is being provided
with power (e.g., the relay has been instructed to close), but
water pressure is not increasing it may indicate that there is a
problem with the pump, with the relay, with the wires connecting
the pump to the relay, etc. As still another example, if the
current being drawn by the pump is outside of a normal operating
range, process 700 can determine that a fault has occurred. In such
an example, if the current is below the normal operating range it
may indicate that the pump is not operating correctly, whereas if
the is above the normal operating range it may also indicate that
the pump is not operating correctly. As a further example, if the
voltage or frequency of the input power fluctuates more than a
predetermined amount, process 700 can determine that a fault has
occurred. In such an example, providing a power signal outside a
normal operating range may risk damaging the pump and/or the
pressure switch. As another further example, if a parameter
monitored at 704 falls outside of a range set by a user, process
700 can determine that a fault has occurred. In such an example, a
user can set ranges for various parameters such that if the value
of the parameter falls outside of the range, the pump can be shut
down and/or the user can be alerted.
[0114] If process 700 determines, at 718, that a fault has occurred
("YES" at 718), process 700 can move to 720. At 720, process 700
can cause an alert to be sent to a user or other party associated
with the user account (e.g., a service provider). Additionally or
alternatively, at 720, process 700 can interrupt power to the pump
(if power is currently being provided to the pump), and can inhibit
the pump from operating unless and until the alert or fault is
addressed.
[0115] In some embodiments, process 700 can cause any type of alert
to be provided to the user. For example, in some embodiments,
process 700 can send information indicating that an alert be sent
to the user to a server (e.g., the cloud based server 204) and/or
the information to be sent with the alert, and the cloud based
server can determine how to deliver the alert based on user
preferences. In a more particular example, the server can determine
whether to send an email, send a text message, send a push
notification (e.g., to an instance of an application associated
with the user, such as an instance of the application installed on
an internet enabled device associated with the user and/or an
instance of the application which the user used to sign in to the
user account), make a phone call, etc. In such a more particular
example, the server can compose the alert and send it using one or
more communication channels preferred by the user. In some
embodiments, process 700 can cause the alert to be sent by the
server by simply providing information indicating that a fault has
occurred, and the server can generate the alert. Additionally or
alternatively, in some embodiments, the server can receive
information from the pressure switch (e.g., related to the measured
pressure and/or operation of the pressure switch and/or pump), and
the server can determine whether a fault has occurred based on the
received information (i.e., the server can execute at least a
portion of process 700, while one or more other portions are
executed by the pressure switch).
[0116] As another example, process 700 can generate and send an
alert to the user based on user preferences. In a more particular
example, process 700 can determine whether to send an email, send a
text message, send a push notification (e.g., by sending a request
to a push notification server), make a phone call, etc., and can
send the alert to the user. In such an example, a pressure switch
executing process 700 can send the alert using the wireless gateway
module 116 via a local area network, via a cellular network,
etc.
[0117] At 722, process 700 can receive one or more instructions or
commands from a server and/or an internet enabled device, and can
change operation of the pressure switch and/or pump based on the
received one or more instructions. For example, if a fault has
occurred, a user can access a user interface provided by a service
provider (e.g., via a web page loaded by the internet enabled
device 204, an application being executed by the internet enabled
device 204, via a virtual personal assistant, via an application
program interface (API), etc.), and can select one or more
instructions to be carried out. In a more particular example, the
user can instruct the pressure switch to reset, to turn off the
pump, to turn on the pump, to clear an alert, to clear a fault, to
change a cut-in or cut-out pressure, etc. In some embodiments,
instructions can be sent from an internet enabled device to the
pressure switch without being sent first to the cloud based server
(although the instructions may pass through one or more servers
while being routed from the internet enabled device to the pressure
switch).
[0118] In some embodiments, at least a portion of process 700 can
be executed by one or more hardware processors of the pressure
switch (e.g., microprocessor 114 and/or microprocessor 512), while
one or more other portions can be performed by a remote server
(e.g., cloud based server 204) and/or by an internet enabled device
(e.g., internet enabled device 206, internet enabled device 400,
internet enabled device 402, internet enabled device 502).
[0119] In some embodiments, certain faults (or all faults) must be
addressed by the homeowner or another user (e.g., a technician)
that is physically present at the pressure switch. For example, if
an electrical problem may have occurred, or if the pump may be
inoperable, the homeowner or a technician may be required to be
present to investigate the fault before power can be provided to
the pump.
[0120] Although the present disclosure is generally directed to a
pressure switch used in connection with a pump system used to
maintain water pressure in a home that is supplied by well water,
this is merely for illustrative purposes, and the pressure switch
can be used in other contexts, such as in connection with systems
for maintaining adequate water pressure in upper floors of a high
rise apartment or office building, for controlling a gas compressor
based on pressure in a reservoir, and for use in other systems.
Additionally, although the disclosure is generally directed to a
pressure switch, one or more aspects of the present disclosure can
be in other types of devices that relate to pump control.
[0121] It will be appreciated by those skilled in the art that
while the invention has been described above in connection with
particular embodiments and examples, the invention is not
necessarily so limited, and that numerous other embodiments,
examples, uses, modifications and departures from the embodiments,
examples and uses are intended to be encompassed by the claims
attached hereto. The entire disclosure of each patent and
publication cited herein is incorporated by reference, as if each
such patent or publication were individually incorporated by
reference herein.
[0122] Various features and advantages of the invention are set
forth in the following claims.
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