U.S. patent application number 17/248951 was filed with the patent office on 2021-06-03 for pumping system with two way communication.
The applicant listed for this patent is DANFOSS POWER ELECTRONICS A/S, PENTAIR WATER POOL AND SPA, INC.. Invention is credited to Lars Hoffmann Berthelsen, Edward Brown, Kenneth N. Clack, Dennis Dunn, Daniel J. Hruby, David MacCallum, Alberto Morando, Kevin Murphy, Ronald B. Robol, Einar Kjartan Runarsson, Robert W. Stiles, JR., Christopher R. Yahnker.
Application Number | 20210164477 17/248951 |
Document ID | / |
Family ID | 1000005404782 |
Filed Date | 2021-06-03 |
United States Patent
Application |
20210164477 |
Kind Code |
A1 |
Stiles, JR.; Robert W. ; et
al. |
June 3, 2021 |
PUMPING SYSTEM WITH TWO WAY COMMUNICATION
Abstract
A pumping system including a pump, a motor coupled to the pump,
an automation system, and a pump controller located remotely from
the automation system. The pump controller is coupled to at least
one pump and the motor, and the pump controller is in digital
communication with the motor, the automation system, and at least
one auxiliary device. The pump controller transmits data to, and
receives data from, the automation system and at least one
auxiliary device over at least one communication link and operates
the motor based on information entered into the automation system
and received from the automation system. The pump controller
selectively alters an operation of the motor based on the
information received from one of the automation system or
parameters received from the at least one auxiliary device. During
a lockout state, the pump controller selects one of ignoring,
delaying, or rescheduling a water
Inventors: |
Stiles, JR.; Robert W.;
(Cary, NC) ; Berthelsen; Lars Hoffmann; (Kolding,
DK) ; Robol; Ronald B.; (Savannah, GA) ;
Yahnker; Christopher R.; (Valencia, CA) ; Hruby;
Daniel J.; (Sanford, NC) ; Murphy; Kevin;
(Quartz Hill, CA) ; Brown; Edward; (Moorpark,
CA) ; MacCallum; David; (Camarillo, CA) ;
Dunn; Dennis; (Moorpark, CA) ; Clack; Kenneth N.;
(Sanford, NC) ; Runarsson; Einar Kjartan;
(Soenderborg, DK) ; Morando; Alberto;
(Soenderborg, DK) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PENTAIR WATER POOL AND SPA, INC.
DANFOSS POWER ELECTRONICS A/S |
Cary
Graasten |
NC |
US
DK |
|
|
Family ID: |
1000005404782 |
Appl. No.: |
17/248951 |
Filed: |
February 15, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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17247755 |
Dec 22, 2020 |
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17248951 |
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12973732 |
Dec 20, 2010 |
10871163 |
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17247755 |
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11608860 |
Dec 11, 2006 |
7854597 |
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12973732 |
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11286888 |
Nov 23, 2005 |
8019479 |
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11608860 |
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10926513 |
Aug 26, 2004 |
7874808 |
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11286888 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04D 15/0066 20130101;
F04B 49/20 20130101; F04D 15/0077 20130101; F04B 49/103 20130101;
F04D 13/06 20130101; F04D 27/004 20130101; E04H 4/1245 20130101;
F04B 49/06 20130101 |
International
Class: |
F04D 15/00 20060101
F04D015/00; F04D 13/06 20060101 F04D013/06; F04B 49/20 20060101
F04B049/20; F04B 49/10 20060101 F04B049/10 |
Claims
1. A pumping system comprising: a pump; a motor coupled to the
pump; an automation system; and a pump controller located remotely
from the automation system, the pump controller coupled to at least
one of the pump and the motor, the pump controller in digital
communication with the motor, the automation system, and at least
one auxiliary device, the pump controller transmitting data to and
receiving data from the automation system and the at least one
auxiliary device over at least one communication link, the pump
controller operating the motor based on information entered into
the automation system and received from the automation system,
wherein the pump controller selectively alters an operation of the
motor based on the information received from one of the automation
system or parameters received from the at least one auxiliary
device, and during a lockout state, the pump controller selects one
of ignoring, delaying, or rescheduling a water operation requested
from one of the automation system or the at least one auxiliary
device.
2. The pumping system of claim 1, wherein the pump controller
alters the operation of the motor based on one or more of
parameters received from a sensor arrangement and parameters
received from the at least one auxiliary device.
3. The pumping system of claim 1, wherein the information entered
into the automation system is entered into the automation system
via a user interface.
4. The pumping system of claim 1, wherein the at least one
communication link includes a wireless link.
5. The pumping system of claim 1, wherein the at least one
communication link includes at least one computer network, the at
least one computer network including at least one of a local area
network, a wide area network, and the Internet.
6. The pumping system of claim 1, wherein the at least one
communication link provides at least one of half-duplex and
full-duplex communication.
7. The pumping system of claim 1, wherein the information received
from the automation system includes at least one of flow rate,
pressure, motor speed, power consumption, filter loading, chemical
levels, water temperature, alarms, operational states, time, energy
cost, turnovers per day, and relay or switch positions.
8. The pumping system of claim 1, wherein the pump controller
operates the motor at a minimum flow rate required to maintain
adequate filtration until a higher flow rate is required by a
different water operation.
9. The pumping system of claim 1, wherein the at least one
auxiliary device includes a user interface to reprogram operating
parameters.
10. The pumping system of claim 1, wherein the at least one
auxiliary device includes at least one of a water heating device, a
chemical dispersion device, a water dispersion device, a filter, a
second pump, a vacuum device, a valve, a switch, a lighting device,
a relay, a sensor, a timing device, or a communication panel.
11. The pumping system of claim 10, wherein the at least one
auxiliary device includes two auxiliary devices and the pump
controller determines which of the two auxiliary devices to operate
first and for how long.
12. A pumping system comprising: a pump; a motor coupled to the
pump; a control system including a remote keypad and display; and a
pump controller located remotely from the control system, the pump
controller coupled to at least one of the pump and the motor, the
pump controller in digital communication with the motor and the
control system, the pump controller transmitting data to and
receiving data from the control system over at least one
communication link, the pump controller operating the motor based
on information entered into the remote keypad and received from the
control system, wherein the pumping system performs a number of
turnovers of at least one of a pool and a spa over a specified time
period, wherein an amount of water movement is associated with
operation of at least one auxiliary device, and wherein the pumping
system considers the amount of water movement in determining
whether the number of turnovers over the specified time period is
achieved.
13. The pumping system of claim 12, wherein the pump controller is
capable of operating the motor without receipt of the information
from the control system.
14. The pumping system of claim 12, wherein the pump controller
transmits an operational status of the pumping system to the
control system.
15. The pumping system of claim 12, wherein the pump controller
transmits data to the control system and receives data from the
control system based on a serial communication specification.
16. The pumping system of claim 12, wherein the pump controller
transmits problem data for at least one component of the pumping
system to the control system.
17. The pumping system of claim 12, wherein the pump controller
receives service data for at least one component of the pumping
system from the control system.
18. The pumping system of claim 12, wherein the at least one
communication link includes a cable that is at least one of
insulated, shielded, water tight, and includes two wires.
19. A pumping system comprising: a pump; a motor coupled to the
pump; a control system, the control system including a remote
keypad and display; and a pump controller located remotely from the
control system, the pump controller coupled to at least one of the
pump and the motor, the pump controller in digital communication
with the motor and the control system, the pump controller
transmitting data to and receiving data from the control system
over at least one communication link, the pump controller operating
the motor based on information entered into the remote keypad and
received from the control system, wherein the information received
from the control system includes an operational state including at
least one of a filtration mode, a vacuum mode, and a heating
mode.
20. The pumping system of claim 19, further comprising at least one
remote auxiliary device in communication with at least one of the
control system and the pump controller, wherein the at least one
remote auxiliary device includes a heater, wherein the information
received from the control system for the heating mode is that the
heater is operating or needs to operate, and wherein the pump
controller alters an operation of the motor to provide an increased
flow rate necessary for proper operation of the heater.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 17/247,755, filed Dec. 22, 2020, which is a
continuation of U.S. patent application Ser. No. 12/973,732, filed
Dec. 20, 2010, which is a continuation of U.S. patent application
Ser. No. 11/608,860, filed Dec. 11, 2006, which is a
continuation-in-part of U.S. patent application Ser. No.
11/286,888, filed Nov. 23, 2005 and a continuation-in-part of U.S.
patent application Ser. No. 10/926,513, filed Aug. 26, 2004, the
entire disclosures of which are incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to control of a
pump, and more particularly to control of a variable speed pumping
system for a pool.
BACKGROUND OF THE INVENTION
[0003] Conventionally, a pump to be used in a pool is operable at a
finite number of predetermined speed settings (e.g., typically high
and low settings). Typically these speed settings correspond to the
range of pumping demands of the pool at the time of installation.
Factors such as the volumetric flow rate of water to be pumped, the
total head pressure required to adequately pump the volume of
water, and other operational parameters determine the size of the
pump and the proper speed settings for pump operation. Once the
pump is installed, the speed settings typically are not readily
changed to accommodate changes in the pool conditions and/or
pumping demands.
[0004] Conventionally, it is also typical to equip a pumping system
for use in a pool with auxiliary devices, such as a heating device,
a chemical dispersion device (e.g., a chlorinator or the like), a
filter arrangement, and/or an automation device. Often, operation
of a particular auxiliary device can require different pump
performance characteristics. For example, operation of a heating
device may require a specific water flow rate or flow pressure for
correct heating of the pool water. It is possible that a
conventional pump can be manually adjusted to operate at one of a
finite number of speed settings in response to a water demand from
an auxiliary device. However, adjusting the pump to one of the
settings may cause the pump to operate at a rate that exceeds a
needed rate, while adjusting the pump to another setting may cause
the pump to operate at a rate that provides an insufficient amount
of flow and/or pressure. In such a case, the pump will either
operate inefficiently or operate at a level below that which is
desired.
[0005] Thus, operation of the pump at particular performance
characteristics could optimize energy consumption. For example,
two-way communication between the pool pump and various auxiliary
devices could to permit the pump to alter operation in response to
the various performance characteristics required by the various
auxiliary devices. Therefore, by allowing the pool pump to
communication with the various auxiliary devices, the pump could
satisfy the demand for water while optimizing the overall system
energy consumption.
[0006] Accordingly, it would be beneficial to provide a pump that
could be readily and easily adapted to communicate with various
auxiliary devices to provide a suitably supply of water at a
desired pressure to pools having a variety of sizes and features.
Further, the pump should be responsive to a change of conditions
(i.e., a clogged filter or the like), user input instructions,
and/or communication with the auxiliary devices.
SUMMARY OF THE INVENTION
[0007] In accordance with one aspect, the present invention
provides a pumping system including a pump, a motor coupled to the
pump, an automation system, and a pump controller located remotely
from the automation system. The pump controller is coupled to at
least one pump and the motor, and the pump controller is in digital
communication with the motor, the automation system, and at least
one auxiliary device. The pump controller transmits data to, and
receives data from, the automation system and at least one
auxiliary device over at least one communication link and operates
the motor based on information entered into the automation system
and received from the automation system. The pump controller
selectively alters an operation of the motor based on the
information received from one of the automation system or
parameters received from the at least one auxiliary device. During
a lockout state, the pump controller selects one of ignoring,
delaying, or rescheduling a water operation requested from one of
the automation system or the at least one auxiliary device.
[0008] In accordance with another aspect, the present invention
provides a pumping system including a pump, a motor coupled to the
pump, a control system including a remote keypad and display, and a
pump controller located remotely from the control system. The pump
controller is coupled to at least one pump and the motor, and the
pump controller is in digital communication with the motor and the
control system. The pump controller transmits data to, and receives
data from, the control system over at least one communication link,
and the pump controller operates the motor based on information
entered into the remote keypad and received from the control
system. The pumping system performs a number of turnovers of at
least one pool and a spa over a specified time period, and an
amount of water movement is associated with operation of at least
one auxiliary device. The pumping system considers the amount of
water movement in determining whether the number of turnovers over
the specified time period is achieved.
[0009] In accordance with another aspect, the present invention
provides a pumping system including a pump, a motor coupled to the
pump, a control system, the control system including a remote
keypad and display, and a pump controller located remotely from the
control system. The pump controller is coupled to at least one pump
and the motor, the pump controller is in digital communication with
the motor and the control system, and the pump controller transmits
data to and receives data from the control system over at least one
communication link. The pump controller operates the motor based on
information entered into the remote keypad and received from the
control system, and the information received from the control
system includes an operational state including at least one of a
filtration mode, a vacuum mode, and a heating mode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing and, other features and advantages of the
present invention will become apparent to those skilled in the art
to which the present invention relates upon reading the following
description with reference to the accompanying drawings, in
which:
[0011] FIG. 1 is a block diagram of an example of a variable speed
pumping system in accordance with the present invention with a pool
environment;
[0012] FIG. 2 is another block diagram of another example of a
variable speed pumping system in accordance with the present
invention with a pool environment;
[0013] FIG. 3 is a schematic illustration of example auxiliary
devices that can be operably connected to an example means for
controlling the motor;
[0014] FIG. 4 is similar to FIG. 3, but shows various other example
auxiliary devices;
[0015] FIG. 5 is a perceptive view of an example pump unit that
incorporates the present invention;
[0016] FIG. 6 is a perspective, partially exploded view of a pump
of the unit shown in
[0017] FIG. 5; and
[0018] FIG. 7 is a perspective view of an example means for
controlling the pump unit shown in FIG. 5.
DESCRIPTION OF EXAMPLE EMBODIMENTS
[0019] Certain terminology is used herein for convenience only and
is not to be taken as a limitation on the present invention.
Further, in the drawings, the same reference numerals are employed
for designating the same elements throughout the figures, and in
order to clearly and concisely illustrate the present invention,
certain features may be shown in somewhat schematic form.
[0020] An example variable-speed pumping system 10 in accordance
with one aspect of the present invention is schematically shown in
FIG. 1. The pumping system 10 includes a pump unit 12 that is shown
as being used with a pool 14. It is to be appreciated that the pump
unit 12 includes a pump 16 for moving water through inlet and
outlet lines 18 and 20.
[0021] The swimming pool 14 is one example of a pool. The
definition of "swimming pool" includes, but is not limited to,
swimming pools, spas, and whirlpool baths, and further includes
features and accessories associated therewith, such as water jets,
waterfalls, fountains, pool filtration equipment, chemical
treatment equipment, pool vacuums, spillways and the like.
[0022] A water operation 22 is performed upon the water moved by
the pump 16. Within the shown example, water operation 22 is a
filter arrangement that is associated with the pumping system 10
and the pool 14 for providing a cleaning operation (i.e.,
filtering) on the water within the pool. The filter arrangement 22
is operatively connected between the pool 14 and the pump 16
at/along an inlet line 18 for the pump. Thus, the pump 16, the pool
14, the filter arrangement 22, and the interconnecting lines 18 and
20 form a fluid circuit or pathway for the movement of water.
[0023] It is to be appreciated that the function of filtering is
but one example of an operation that can be performed upon the
water. Other operations that can be performed upon the water may be
simplistic, complex or diverse. For example, the operation
performed on the water may merely be just movement of the water by
the pumping system (e.g., re-circulation of the water in a
waterfall or spa environment).
[0024] Turning to the filter arrangement 22, any suitable
construction and configuration of the filter arrangement is
possible. For example, the filter arrangement 22 can include a sand
filter, a cartridge filter, and/or a diatomaceous earth filter, or
the like. In another example, the filter arrangement 22 may include
a skimmer assembly for collecting coarse debris from water being
withdrawn from the pool, and one or more filter components for
straining finer material from the water. In still yet another
example, the filter arrangement 22 can be in fluid communication
with a pool cleaner, such as a vacuum pool cleaner adapted to
vacuum debris from the various submerged surfaces of the pool. The
pool cleaner can include various types, such as various manual
and/or automatic types.
[0025] The pump 16 may have any suitable construction and/or
configuration for providing the desired force to the water and move
the water. In one example, the pump 16 is a common centrifugal pump
of the type known to have impellers extending radially from a
central axis. Vanes defined by the impellers create interior
passages through which the water passes as the impellers are
rotated. Rotating the impellers about the central axis imparts a
centrifugal force on water therein, and thus imparts the force flow
to the water. Although centrifugal pumps are well suited to pump a
large volume of water at a continuous rate, other motor-operated
pumps may also be used within the scope of the present
invention.
[0026] Drive force is provided to the pump 16 via a pump motor 24.
In the one example, the drive force is in the form of rotational
force provided to rotate the impeller of the pump 16. In one
specific embodiment, the pump motor 24 is a permanent magnet motor.
In another specific embodiment, the pump motor 24 is an induction
motor. In yet another embodiment, the pump motor 24 can be a
synchronous or asynchronous motor. The pump motor 24 operation is
infinitely variable within a range of operation (i.e., zero to
maximum operation). In one specific example, the operation is
indicated by the RPM of the rotational force provided to rotate the
impeller of the pump 16. In the case of a synchronous motor 24, the
steady state speed (RPM) of the motor 24 can be referred to as the
synchronous speed. Further, in the case of a synchronous motor 24,
the steady state speed of the motor 24 can also be determined based
upon the operating frequency in hertz (Hz).
[0027] A means for controlling 30 provides for the control of the
pump motor 24 and thus the control of the pump 16. Within the shown
example, the means for controlling 30 can include a variable speed
drive 32 that provides for the infinitely variable control of the
pump motor 24 (i.e., varies the speed of the pump motor). By way of
example, within the operation of the variable speed drive 32, a
single phase AC current from a source power supply is converted
(e.g., broken) into a three-phase AC current. Any suitable
technique and associated construction/configuration may be used to
provide the three-phase AC current. The variable speed drive
supplies the AC electric power at a changeable frequency to the
pump motor to drive the pump motor. The construction and/or
configuration of the pump 16, the pump motor 24, the means for
controlling 30 as a whole, and the variable speed drive 32 as a
portion of the means for controlling 30, 130 are not limitations on
the present invention. In one possibility, the pump 16 and the pump
motor 24 are disposed within a single housing to form a single
unit, and the means for controlling 30 with the variable speed
drive 32 are disposed within another single housing to form another
single unit. In another possibility, these components are disposed
within a single housing to form a single unit.
[0028] Further still, the means for controlling 30 can receive
input from a user interface 31 that can be operatively connected to
the means for controlling 30 in various manners. For example, the
user interface 31 can include a keypad 40, buttons, switches, or
the like such that a user could input various parameters into the
means for controlling 30. In addition or alternatively, the user
interface 31 can be adapted to provide visual and/or audible
information to a user. For example, the user interface 31 can
include one or more visual displays 42, such as an alphanumeric LCD
display, LED lights, or the like. Additionally, the user interface
31 can also include a buzzer, loudspeaker, or the like. Further
still, as shown in FIG. 5, the user interface 31 can include a
removable (e.g., pivotable, slidable, detachable, etc.) protective
cover 44 adapted to provide protection against damage when the user
interface 31 is not in use. The protective cover 44 can include
various rigid or semi-rigid materials, such as plastic, and can
have various degrees of light permeability, such as opaque,
translucent, and/or transparent.
[0029] The pumping system 10 can have additional means used for
control of the operation of the pump. In accordance with one aspect
of the present invention, the pumping system 10 includes means for
sensing, determining, or the like one or more parameters indicative
of the operation performed upon the water. Within one specific
example, the system includes means for sensing, determining or the
like one or more parameters indicative of the movement of water
within the fluid circuit.
[0030] The ability to sense, determine or the like one or more
parameters may take a variety of forms. For example, one or more
sensors 34 may be utilized. Such one or more sensors 34 can be
referred to as a sensor arrangement. The sensor arrangement 34 of
the pumping system 10 would sense one or more parameters indicative
of the operation performed upon the water. Within one specific
example, the sensor arrangement 34 senses parameters indicative of
the movement of water within the fluid circuit. The movement along
the fluid circuit includes movement of water through the filter
arrangement 22. As such, the sensor arrangement 34 includes at
least one sensor used to determine flow rate of the water moving
within the fluid circuit and/or includes at least one sensor used
to determine flow pressure of the water moving within the fluid
circuit. In one example, the sensor arrangement 34 is operatively
connected with the water circuit at/adjacent to the location of the
filter arrangement 22. It should be appreciated that the sensors of
the sensor arrangement 34 may be at different locations than the
locations presented for the example. Also, the sensors of the
sensor arrangement 34 may be at different locations from each
other. Still further, the sensors may be configured such that
different sensor portions are at different locations within the
fluid circuit. Such a sensor arrangement 34 would be operatively
connected 36 to the means for controlling 30 to provide the sensory
information thereto.
[0031] It is to be noted that the sensor arrangement 34 may
accomplish the sensing task via various methodologies, and/or
different and/or additional sensors may be provided within the
system 10 and information provided therefrom may be utilized within
the system. For example, the sensor arrangement 34 may be provided
that is associated with the filter arrangement and that senses an
operation characteristic associated with the filter arrangement.
For example, such a sensor may monitor filter performance. Such
monitoring may be as basic as monitoring filter flow rate, filter
pressure, or some other parameter that indicates performance of the
filter arrangement. Of course, it is to be appreciated that the
sensed parameter of operation may be otherwise associated with the
operation performed upon the water. As such, the sensed parameter
of operation can be as simplistic as a flow indicative parameter
such as rate, pressure, etc.
[0032] Such indication information can be used by the means for
controlling 30 via performance of a program, algorithm or the like,
to perform various functions, and examples of such are set forth
below. Also, it is to be appreciated that additional functions and
features may be separate or combined, and that sensor information
may be obtained by one or more sensors. With regard to the specific
example of monitoring flow rate and flow pressure, the information
from the sensor arrangement 34 can be used as an indication of
impediment or hindrance via obstruction or condition, whether
physical, chemical, or mechanical in nature, that interferes with
the flow of water from the pool to the pump such as debris
accumulation or the lack of accumulation, within the filter
arrangement 34.
[0033] The example of FIG. 1 shows an example additional operation
38 and the example of FIG. 2 shows an example additional operation
138. Such an additional operation (e.g., 38 or 138) may be a
cleaner device, either manual or autonomous. As can be appreciated,
an additional operation involves additional water movement. Also,
within the presented examples of FIGS. 1 and 2, the water movement
is through the filter arrangement (e.g., 22 or 122). Such,
additional water movement may be used to supplant the need for
other water movement, as will be discussed further herein.
[0034] Within another example (FIG. 2) of a pumping system 110 that
includes means for sensing, determining, or the like one or more
parameters indicative of the operation performed upon the water,
and the means for controlling 130 can determine the one or more
parameters via sensing, determining or the like parameters
associated with the operation of a pump 116 of a pump unit 112.
Such an approach is based upon an understanding that the pump
operation itself has one or more relationships to the operation
performed upon the water.
[0035] It should be appreciated that the pump unit 112, which
includes the pump 116 and a pump motor 124, a pool 114, a filter
arrangement 122, and interconnecting lines 118 and 120, may be
identical or different from the corresponding items within the
example of FIG. 1. In addition, as stated above, the means for
controlling 130 can receive input from a user interface 131 that
can be operatively connected to the controller in various
manners.
[0036] Keeping with the example of FIG. 2, some examples of the
pumping system 110, and specifically the means for controlling 30,
130 and associated portions, that utilize at least one relationship
between the pump operation and the operation performed upon the
water attention are shown in U.S. Pat. No. 6,354,805, to Moller,
entitled "Method For Regulating A Delivery Variable Of A Pump" and
U.S. Pat. No. 6,468,042, to Moller, entitled "Method For Regulating
A Delivery Variable Of A Pump." The disclosures of these patents
are incorporated herein by reference. In short summary, direct
sensing of the pressure and/or flow rate of the water is not
performed, but instead one or more sensed or determined parameters
associated with pump operation are utilized as an indication of
pump performance. One example of such a pump parameter is input
power. Pressure and/or flow rate can be calculated/determined from
such pump parameter(s).
[0037] Although the system 110 and the means for controlling 30,
130 there may be of varied construction, configuration and
operation, the function block diagram of FIG. 2 is generally
representative. Within the shown example, an adjusting element 140
is operatively connected to the pump motor and is also operatively
connected to a control element 142 within the controller 130. The
control element 142 can operate in response to a comparative
function 144, which receives input from a power calculation
146.
[0038] The power calculation 146 is performed utilizing information
from the operation of the pump motor 124 and controlled by the
adjusting element 140. As such, a feedback iteration is performed
to control the pump motor 124. Also, it is the operation of the
pump motor and the pump that provides the information used to
control the pump motor/pump. As mentioned, it is an understanding
that operation of the pump motor/pump has a relationship to the
flow rate and/or pressure of the water flow that is utilized to
control flow rate and/or flow pressure via control of the pump.
[0039] As mentioned, the sensed, determined (e.g., calculated,
provided via a look-up table, graph or curve, such as a constant
flow curve or the like, etc.) information can be utilized to
determine the various performance characteristics of the pumping
system 110, such as input power consumed, motor speed, flow rate
and/or the flow pressure. In one example, the operation can be
configured to prevent damage to a user or to the pumping system 10,
110 caused by an obstruction. Thus, the means for controlling
(e.g., 30 or 130) provides the control to operate the pump
motor/pump accordingly. In other words, the means for controlling
(e.g., 30 or 130) can repeatedly monitor one or more performance
value(s) 146 of the pumping system 10,110, such as the input power
consumed by, or the speed of, the pump motor (e.g., 24 or 124) to
sense or determine a parameter indicative of an obstruction or the
like.
[0040] Turning now to FIGS. 3-4, in accordance with an aspect of
the present invention, the pumping system 10, 110 can include one
or more auxiliary devices 50 operably connected to the means for
controlling 30, 130. As shown in FIGS. 3-4, the auxiliary devices
50 can include various devices, including mechanical, electrical,
and/or chemical devices, that can be connected to the means for
controlling 30, 130 in various mechanical and/or electrical
manners. In one example, the auxiliary devices 50 can include
devices configured to perform an operation upon the water moved by
the water pump 12, 112. Various examples can include a water
heating device 52, a chemical dispersion device 54 for dispersing
chemicals into the water, such as chlorine, bromine, ozone, etc.,
and/or a water dispersion device 56, such as a water fountain or
water jet. Further examples can include a filter arrangement 58 for
performing a filtering operation upon the water, a second water
pump 60 with a second pump motor 62 for moving the water, and/or a
vacuum 64 device, such as a manual or automatic vacuum device for
cleaning the swimming pool.
[0041] In another example, the auxiliary devices 50 can include a
user interface device capable of receiving information input by a
user, such as a parameter related to operation of the pumping
system 10, 110. Various examples can include a remote keypad 66,
such as a remote keypad similar to the keypad 40 and display 42 of
the means for controlling 30, a personal computer 68, such as a
desktop computer, a laptop, a personal digital assistant, or the
like, and/or an automation control system 70, such as various
analog or digital control systems that can include programmable
logic controllers (PLC), computer programs, or the like. The
various user interface devices 66, 68, 70, as illustrated by the
remote keypad 66, can include a keypad 72, buttons, switches, or
the like such that a user could input various parameters and
information. In addition or alternatively, the user interface
devices 66, 68, 70 can be adapted to provide visual and/or audible
information to a user, and can include one or more visual displays
74, such as an alphanumeric LCD display, LED lights, or the like,
and/or a buzzer, loudspeaker, or the like (not shown). Thus, for
example, a user could use a remote keypad 66 or automation system
70 to monitor the operational status of the pumping system 10,
110.
[0042] In still yet another example, the auxiliary devices 50 can
include various miscellaneous devices for interaction with the
swimming pool. Various examples can include a valve 76, such as a
mechanically or electrically operated water valve, an electrical
switch 78, a lighting device 80 for providing illumination to the
swimming pool and/or associated devices, an electrical or
mechanical relay 82, a sensor 84, including but not limited to
those sensors 34 discussed previously herein, and/or a mechanical
or electrical timing device 86. In addition or alternatively, the
auxiliary device 50 can include a communication panel 88, such as a
junction box, switchboard, or the like, configured to facilitate
communication between the means for controlling 30, 130 and various
other auxiliary devices 50. The various miscellaneous devices can
have direct or indirect interaction with the water of the swimming
pool and/or any of the various other devices discussed herein. It
is to be appreciated that the various examples discussed herein and
shown in the figures are not intended to provide a limitation upon
the present invention, and that various other auxiliary devices 50
can be used.
[0043] The pumping system 10, 110 can also include means for
providing two-way communication between the means for controlling
30, 130 and the one or more auxiliary devices 50. The means for
providing two-way communication can include various communication
methods configured to permit information, data, commands, or the
like to be input, output, processed, transmitted, received, stored,
and/or displayed in a two-way exchange between the means for
controlling 30, 130 and the auxiliary devices 50. It is to be
appreciated that the means for providing two-way communication can
provide for control of the pumping system 10, 110, or can also be
used to provide information for monitoring the operational status
of the pumping system 10, 110.
[0044] The various communication methods can include half-duplex
communication to provide communication in both directions, but only
in one direction at a time (e.g., not simultaneously), or
conversely, can include full duplex communication to provide
simultaneous two-way communication. Further, the means for
providing two-way communication can be configured to provide analog
communication, such as through a continuous spectrum of
information, or it can also be configured to provide digital
communication, such as through discrete units of data, such as
discrete signals, numbers, binary numbers, non-numeric symbols,
letters, icons, or the like.
[0045] In various digital communication schemes, the means for
providing two-way communication can be configured to provide
communication through various digital communication methods. In one
example, the means for providing two-way communication can be
configured to provide digital serial communication. As such, the
serial communication method can be configured to send and receive
data one unit at a time in a sequential manner. Various digital
serial communication specifications can be used, such as RS-232
and/or RS-485, both of which are known in the art. The RS-485
specification, for example, can include a two-wire, half-duplex,
multipoint serial communication protocol that employs a specified
differential form of signaling to transmit information. In addition
or alternatively, the digital serial communication can be used in a
master/slave configuration, as is known in the art. Various other
digital communication methods can also be used, such as parallel
communications (e.g., all the data units are sent together), or the
like. It is to be appreciated that, despite the particular method
used, the means for providing two-way communication can be
configured to permit any of the various connected devices to
transmit and/or receive information.
[0046] The various communication methods can be implemented in
various manners, including customized cabling or conventional
cabling, including serial or parallel cabling. In addition or
alternatively, the communication methods can be implemented through
more sophisticated cabling and/or wireless schemes, such as over
phone lines, universal serial bus (USB), firewire (IEEE 1394),
ethernet (IEEE 802.03), wireless ethernet (IEEE 802.11), bluetooth
(IEEE 802.15), WiMax (IEEE 802.16), or the like. The means for
providing two-way communication can also include various hardware
and/or software converters, translators, or the like configured to
provide compatibility between any of the various communication
methods.
[0047] Further still, the various digital communication methods can
employ various protocols including various rules for data
representation, signaling, authentication, and error detection to
facilitate the transmission and reception of information over the
communications method. The communication protocols for digital
communication can include various features intended to provide a
reliable exchange of data or information over an imperfect
communication method. In the example of RS-485 digital serial
communication, an example communication protocol can include data
separated into categories, such as device address data, preamble
data, header data, a data field, and checksum data.
[0048] The means for providing two-way communication can be
configured to provide either, or both, of wired or wireless
communication. In the example of RS-485 digital serial
communication having a two-wire differential signaling scheme, a
data cable 90 can include merely two wires, one carrying an
electrically positive data signal and the other carrying an
electrically negative data signal, though various other wires can
also be included to carry various other digital signals. As shown
in FIGS. 5 and 7, the means for controlling 30, 130 can include a
data port 92 for connection to a data cable connector 94 of the
data cable 90. The data cable 90 can include a conventional metal
wire cable, though it could also include various other materials,
such as a fiber optic cable. The data cable 90 can be shielded to
protect from external electrical interferences, and the data cable
connector 94 can include various elements to protect against water
and corrosion, such as a water resistant, twist lock connector. The
data port 92 can even include a protective cover 95 or the like for
use when the data cable 90 is disconnected. Further still, the
various auxiliary devices 50 can be operably connected to the means
for controlling 30, 130 directly or indirectly through various data
cables 91.
[0049] In addition or alternatively, the means for providing
two-way communication can be configured to provide analog and/or
digital wireless communication between the means for controlling 30
and the auxiliary devices 50. For example, the means for
controlling 30, 130 and/or the auxiliary devices can include a
wireless device 98, such as a wireless transmitter, receiver, or
transceiver operating on various frequencies, such as radio waves
(including cellular phone frequencies), microwaves, or the like. In
addition or alternatively, the wireless device 98 can operate on
various visible and invisible light frequencies, such as infrared
light. As shown in FIG. 4, the wireless device 98 can be built in,
or provided as a separate unit connected by way of a data cable 93
or the like.
[0050] In yet another example, at least a portion of the means for
providing two-way communication can include a computer network 96.
The computer network 96 can include various types, such as a local
area network (e.g., a network generally covering to a relatively
small geographical location, such as a house, business, or
collection of buildings), a wide area network (e.g., a network
generally covering a relatively wide geographical area and often
involving a relatively large array of computers), or even the
internet (e.g., a worldwide, public and/or private network of
interconnected computer networks, including the world wide web).
The computer network 96 can be wired or wireless, as previously
discussed herein. The computer network 96 can act as an
intermediary between one or more auxiliary devices 50, such as a
personal computer 68 or the like, and the means for controlling 30,
130. Thus, a user using a personal computer 68 could exchange data
and information with the means for controlling 30, 130 in a remote
fashion as per the boundaries of the network 96. In one example, a
user using a personal computer 68 connected to the internet could
exchange data and information (e.g., for control and/or monitoring)
with the means for controlling 30, 130, from home, work, or even
another country. In addition or alternatively, a user could
exchange data and information for control and/or monitoring over a
cellular phone or other personal communication device.
[0051] In addition or alternatively, where at least a portion of
the means for providing two-way communication includes a
computer-network 96, various components of the pumping system 10,
110 can be serviced and/or repaired from a remote location. For
example, if the pump 12, 112 or means for controlling 30, 130
develops a problem, an end user can contact a service provider
(e.g., product manufacturer or authorized service center, etc.)
that can remotely access the problematic component through the
means for providing two-way communication and the computer network
96 (e.g., the internet). Alternatively, the pumping system 10, 110
can be configured to automatically call out to the service provider
when a problem is detected. The service provider can exchange data
and information with the problematic component, and can service,
repair, update, etc. the component without having a dedicated
service person physically present in front of the swimming pool.
Thus, the service provider can be located at a central location,
and can provide service to any connected pumping system 10, 110,
even from around the world. In another example, the service
provider can constantly monitor the status (e.g., performance,
settings, health, etc.) of the pumping system 10, 110, and can
provide various services, as required.
[0052] As stated previously herein, the means for controlling 30,
130 can be adapted to control operation of the pump 12, 112 and/or
the variable speed motor 24, 124. The means for controlling 30, 130
can alter operation of the variable speed motor 24, 124 based upon
various parameters of the pumping system 10, 110, such as water
flow rate, water pressure, motor speed, power consumption, filter
loading, chemical levels, water temperature, alarms, operational
states, or some other parameter that indicates performance of the
pumping system 10, 110. It is to be appreciated that the sensed
parameter of operation may be otherwise associated with the
operation performed upon the water, and/or can even be independent
of an operation performed upon the water. As such, the sensed
parameter of operation can be as simplistic as a flow indicative
parameter such as rate, pressure, etc., or it can involve
independent parameters such as time, energy cost, turnovers per
day, relay or switch positions, etc. The parameters can be received
by the means for controlling 30, 130 in various manners, such as
through the previously discussed sensor arrangements 34, user
interfaces 31, 131 and/or the means for providing two-way
communication.
[0053] Regardless of the methodology used, the means for
controlling 30, 130 can be capable of receiving a parameter from
one or more of the auxiliary devices 50 through the various means
for providing two-way communication discussed herein. In one
example, the means for controlling 30, 130 can be operable to alter
operation of the motor 24, 124 based upon the parameter(s) received
from the auxiliary device(s) 50. For example, where a water heater
52 requires a particular water flow rate for proper operation, the
means for controlling 30, 130 could receive a desired water flow
rate parameter from the water heater 52 through the means for
providing two-way communication. In response, the means for
controlling 30, 130 could alter operation of the motor 24, 124 to
provide the requested water performance characteristics.
[0054] However, it is to be appreciated that the means for
controlling 30, 130 can also be capable of independently
controlling the variable speed motor 24, 124 without receipt of a
parameter from the auxiliary device(s) 50. That is, the means for
controlling 30, 130 could operate in a completely autonomous
fashion based upon a predetermined computer program or the like,
and/or can receive parameters from operably connected sensor
arrangements 34 or the like. In addition or alternatively, the
means for controlling 30, 130 can receive parameters from the
onboard user interface 31, 131 and can selectively alter operation
of the motor 24, 124 based upon the parameters received.
[0055] Additionally, where the means for controlling 30, 130 is
capable of independent operation, it can also be operable to
selectively alter operation of the motor 24, 124 based upon the
parameters received from the auxiliary device(s) 50. Thus, the
means for controlling 30, 130 can choose whether or not to alter
operation of the motor 24, 124 when it receives a parameter from an
auxiliary device 50, such as a desired water flow rate from a water
heater 52 or a user input parameter from a remote user interface
device 66. For example, where the pumping system 10, 110 is
performing a particular function, such as a backwash cycle, or is
in a lockout state, such as may occur when the system 10, 110
cannot be primed, the means for controlling 30, 130 can choose to
ignore a water flow rate request from the heater 52. In addition or
alternatively, the means for controlling 30, 130 could choose to
delay and/or reschedule altering operation of the motor 24, 124
until a later time (e.g., after the backwash cycle finishes).
[0056] Thus, the means for controlling 30, 130 can be configured to
control operation of the variable speed motor 24, 124
independently, or in response to parameters received. However, it
is to be appreciated that the means for controlling 30, 130 can
also be configured to act as a slave device that is controlled by
an automation system 70, such as a PLC or the like. In one example,
the automation system 70 can receive various parameters from
various auxiliary devices 50, and based upon those parameters, can
directly control means for controlling 30, 130 to alter operation
of the motor 24, 124. It is to be appreciated that the means for
controlling 30, 130 can be configured to switch between independent
control and slave control. For example, the means for controlling
30, 130 can be configured to switch between the control schemes
based upon whether the data cable 90 is connected (e.g., switching
to independent control when the data cable 90 is disconnected).
[0057] Turning to the issue of operation of the pumping system
10,110 over a course of a long period of time, it is typical that a
predetermined volume of water flow is desired. For example, it may
be desirable to move a volume of water equal to multiple turnovers
within a specified time period (e.g., a day). Within an example in
which the water operation includes a filter operation, the desired
water movement (e.g., specific number of turnovers within one day)
may be related to the necessity to maintain a desired water
clarity.
[0058] Thus, in accordance with another aspect of the present
invention, the means for controlling 30, 130 can be configured to
optimize a power consumption of the motor 24, 124 based upon the
parameter(s) received from the auxiliary device(s) 50. Focusing on
the aspect of minimal energy usage (e.g., optimization of energy
consumed over a time period), within some known pool filtering
applications, it is common to operate a known pump/filter
arrangement for some portion (e.g., eight hours) of a day at
effectively a very high speed to accomplish a desired level of pool
cleaning. However, with the present invention, the system 10,110
with an associated filter arrangement 22,122 can be operated
continuously (e.g., 24 hours a day, or some other time amount(s))
at an ever-changing minimum level to accomplish the desired level
of pool cleaning. It is possible to achieve a very significant
savings in energy usage with such a use of the present invention as
compared to the known pump operation at the high speed. In one
example, the cost savings would be in the range of 90% as compared
to a known pump/filter arrangement.
[0059] Associated with operation of various functions and auxiliary
devices 50 is a certain amount of water movement. Energy
conservation in the present invention is based upon an appreciation
that such other water movement may be considered as part of the
overall desired water movement, cycles, turnover, filtering, etc.
As such, water movement associated with such other functions and
devices can be utilized as part of the overall water movement to
achieve desired values within a specified time frame (e.g.,
turnovers per day). Thus, control of a first operation (e.g.,
filtering) in response to performance of a second operation (e.g.,
running a pool cleaner) can allow for minimization of a purely
filtering aspect. This permits increased energy efficiency by
avoiding unnecessary pump operation.
[0060] Accordingly, the means for controlling 30, 130 can determine
an optimal energy consumption for the motor 24, 124 over time based
upon the parameter(s) received from the auxiliary device(s) 50 and
associated first, second, etc. operations. In one example, the
motor 24, 124 can be operated at a minimum water flow rate required
to maintain adequate water filtration until a higher flow rate is
required by a different water operation. In another example, based
upon the various water performance characteristics required by each
auxiliary device 50, the means for controlling 30, 130 can
determine in which order to perform the first, second, etc.
operations, or for how long to perform the operations. In addition
or alternatively, the means for controlling 30, 130 can optimize
operation of the motor 24, 124 based upon actual performance data
received from the auxiliary device(s) 50. For example, where a
filter arrangement 22, 122 has become clogged over time and
requires an ever-increasing water flow or pressure, the means for
controlling 30, 130 could choose to simultaneously operate various
other auxiliary devices 50 that require high water flow rates
(e.g., a heater 52 or the like). Similarly, the means for
controlling 30, 130 could choose to delay various operations based
upon receipt of actual performance data. For example, where a
filter arrangement 22, 122 has become clogged over time and
requires an ever-increasing water flow or pressure, the means for
controlling 30, 130 could choose to delay operation of an automatic
pool cleaner 64 until after the filter arrangement 22, 122 has been
cleaned.
[0061] It is to be appreciated that the means for controlling
(e.g., 30 or 130) may have various forms to accomplish the desired
functions. In one example, the means for controlling 30, 130
includes a computer processor that operates a program. In the
alternative, the program may be considered to be an algorithm. The
program may be in the form of macros. Further, the program may be
changeable, and the means for controlling 30, 130 is thus
programmable. It is to be appreciated that the programming for the
means for controlling 30, 130 may be modified, updated, etc.
through the means for providing two-way communication.
[0062] Also, it is to be appreciated that the physical appearance
of the components of the system (e.g., 10 or 110) may vary. As some
examples of the components, attention is directed to FIGS. 5-7.
FIG. 5 is a perspective view of the pump unit 12 and the means for
controlling 30 for the system 10 shown in FIG. 1. FIG. 6 is an
exploded perspective view of some of the components of the pump
unit 12. FIG. 7 is a perspective view of the means for controlling
30.
[0063] In addition to the foregoing, a method of controlling the
pumping system 10, 110 for moving water of a swimming pool is
provided. The pumping system 10, 110 includes the water pump 12,
112 for moving water in connection with performance of an operation
upon the water and the variable speed motor 24, 124 operatively
connected to drive the pump 12, 112. The method comprises the steps
of providing means for controlling 30, 130 the variable speed motor
24, 124, providing an auxiliary device 50 operably connected to the
means for controlling 30, 130, and providing two-way communication
between the means for controlling 30, 130 and the auxiliary device
50. The method also includes the steps of receiving a parameter to
the means for controlling 30, 130 from the auxiliary device 50
through the two-way communication, and selectively altering
operation of the motor 24, 124 based upon the parameter. In
addition or alternatively, the method can include any of the
various elements and/or operations discussed previously herein,
and/or even additional elements and/or operations.
[0064] It should be evident that this disclosure is by way of
example and that various changes may be made by adding, modifying
or eliminating details without departing from the scope of the
teaching contained in this disclosure. As such it is to be
appreciated that the person of ordinary skill in the art will
perceive changes, modifications, and improvements to the example
disclosed herein. Such changes, modifications, and improvements are
intended to be within the scope of the present invention.
* * * * *