DUPLEX CONTROL OF REDUNDANT PASSIVELY-ACTUATED ELECTRONIC DEVICES

Abstract

The present application generally relates a system for duplex control of redundant passively-actuated electronic devices. In one embodiment, the system comprises a housing, a controller mounted inside the housing, an input/output (I/O) interface integrated with the housing that includes a first port configured to electrically couple a power input to the controller, a second port configured to electrically couple a first pump to the controller, and a third port configured to electrically couple a second pump to the controller, and a set of relays connected to the second port and the third port. In response to a current sensing circuit sensing that a first current indicates that the-first pump has shut off, the controller may activate the second pump and deactivate the first pump by controlling the set of relays to disconnect the power source from the first pump and to connect the second pump to the power source.

Description

FIELD

The present disclosure relates to electronic control and more particularly to duplex control of passively-actuated electronic devices.

BACKGROUND

Generally speaking, a sump pump is traditionally installed in a pit or well that is located where water needs to be removed. It has the name “sump pump” because a sump refers to a low space that often collects some type of liquid (e.g., water) and a pump is the mechanical means that transfers fluid from one position to another. By funneling water into a pit with a sump pump, the sump pump can function to control the movement of water from the pit to a desired location. In this respect, a basement that may be prone to flooding or water egress due to the water table or soil structure of the building site can shepherd water into the pit and use a sump pump installed in the pit to control the transport water to another particular location. That is, the sump pump functions to pump water that otherwise would accumulate in a home outside of the home to a water-tolerant location.

The background description provided here is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from the detailed description and the accompanying drawings.

FIG. 1 is a schematic view of an example duplex system and its environment.

FIG. 2 is a schematic view of a controller for the duplex system of FIG. 1.

FIG. 3 is a schematic view of an· example portion of the controller of FIG. 2.

FIG. 4 is a graphical view of a non-duplexing mode for the duplex system of FIG. 1.

FIG. 5 is a graphical view of a duplexing mode for the duplex system of FIG. 1.

In the drawings, reference numbers may be reused to identify similar and/or identical elements.

DETAILED DESCRIPTION

Duplex System

FIG. 1 is an example of an environment for a duplex system 100. The duplex system 100 includes a housing 110 with an input/output (I/0) interface 120 (also referred to as the interface 120). The interface 120 allows the duplex system 100 to receive various electrical connections as input while communicating across one or more electrical connections as output. The interface 120 includes a plurality of ports 122-126 that enable a controller 200 of the duplex system 100 to monitor and to control multiple electronic devices.

As shown in FIG. 1, the electronic devices are two pumps 10, 10a-b. Each pump 10 is electrically coupled to a port 124, 126 of the interface 120 to enable the controller 200 to passively control the operation of the pumps 10. For instance, each pump 10 includes an electrical power cable that is able to plug into a port 124, 126 of the interface 120. FIG. 1 illustrates each port 124, 126 as having a female connector to matingly receive a male connector (i.e., plug) of the power cable for a pump 10. Although two pumps 10 are shown for illustrative purposes, the functionality of the duplex system 100 may be scaled to control a greater number of electrical devices (e.g., three, four, five, or ten). In various implementations, the port 124 may have three electrical connections, including line (L), neutral (N), and protective earth (PE, also referred to as ground).

The duplex system 100 (e.g., via the controller 200) “passively” controls the operation of the electrical devices (e.g., the pumps 10) by controlling whether one or both pumps 10 are connected to a power source. In other words, the duplex system 100 is an intermediary that receives a power input 20 and selectively functions as a power source to transfer some form of the power input 20 to the pumps 10. In this manner, the duplex system 100 is capable of selecting which set of pumps 10 (e.g., one or a plurality of pumps) has power to operate and when that power will be transferred.

The duplex system 100 therefore has a multiplexing mode and a non-multiplexing mode. A multiplexing mode refers to a mode where the duplex system 10 provides power to multiple devices at the same time such that some set of the multiple devices may operate simultaneously. On the other hand, a non-multiplexing mode refers to a mode where the duplex system 10 provides power to one device at a time. For simplicity of explanation, the multiplexing mode is described with respect to two electrical devices as a duplex mode while the non-multiplexing mode is described accordingly as a non-duplexing mode.

In the duplexing mode shown in FIGS. 1-5, the controller 200 enables both pumps 10 to be connected to the power source. That is, in the duplex mode, two pumps may simultaneously operate. In other words, there may be a situation where the rate of water filling the well/sump is too great for a single pump. For example, a storm causes a basement to flood and water to quickly rise in the sump containing the pumps 10. In this situation, the duplex system 100 may operate in a duplexing mode that provides power to multiple pumps 10 (e.g., to both pumps 10a, 10b). Here, in the duplexing mode, both pumps 10a, 10b may then simultaneously operate to pump water out of the basement.

FIGS. 1-5 also illustrate that the duplex system 100 is capable of a non-duplexing mode. A non-duplexing mode generally refers to a mode where electrical devices (e.g., the pumps 10) are not able to operate at the same time. For instance, in the non-duplexing mode, only one pump 10 receives power from the duplex system 100 at a time. This means that either the first pump 10a is functioning alone while the duplex system 100 has the second pump 10b disconnected from the power source or vice versa (i.e., the second pump 10b is functioning alone while the first pump 10a is disconnected from the power source).

By being able to function in both a duplexing mode and a non-duplexing mode, the duplex system 100 is situationally adaptive. This may be advantageous because electrical, mechanical, and electro-mechanical devices, such as pumps 10, have components which experience stress and strain by cyclical operation. That is, cycling a pump off and on creates some form of stress on the pump 10. When this stress occurs repeatedly, it is nearly inevitable that the cyclical loading will cause some aspect of the pump to fail (e.g., due to cumulative stress and strain over time). Because of this, operating electrical/mechanical devices intelligently is in the best interest for the longevity of these devices. For example, even though a duplexing mode may provide an owner of the pumps 10 with a greater capability of throughput, that high throughput may not be necessary all of the time. In other words, dual pumps 10a, 10b may only be needed on certain occasions while a single pump 10 may be able to keep a basement dry a majority of the time. Here, it would be in the interest of the owner to operate the number of pumps 10 that the situation calls for to minimize the time and resources needed for upkeep and maintenance of the pump system.

The duplex system 100 is configured to recognize the situational needs for the pump system and to passively control the power supplied to the pumps 10 to address these situation needs. For example, if the duplex system. 100 recognizes that a situation is occurring where the pumping capacity of multiple pumps 10 is required, the duplex system 100 can operate in the duplexing mode to enable both of the pumps 10a, 10b to operate to be address the situation. Similarly, if the duplex system 100 recognizes that a situation is occurring where the pumping capacity of only one device is required, the duplex system 100 can operate in the non-duplexing mode to fulfill that requirement. Therefore, by having a duplexing and non-duplexing mode, the duplex system 100 is able to intelligently tailor the power supplied to the pumps 10.

To further minimize the stress or strain on the pump system (e.g., pumps 10), in the non-duplex mode, the duplex system 100 is also configured to alternate between pumps 10. Alternating between pumps 10 offers the duplex system 100 several advantageous. For example, by alternating between pumps 10, the duplex system 100 can attempt to balance the running time of each pump 10. For example, the duplex system 100 may supply power to the first pump 10a for a first period of time or first operating event, then discontinue power to the first pump 10a and supply power to the second pump 10b for a second period of time or second operating event (e.g., subsequent to the first period or first operating event), and then discontinue power to the second pump 1Ob and supply power to the first pump 10a for a third period of time or third operating event (e.g., subsequent to the second period or second operating event). This pattern (e.g., shown in FIGS. 4 and 5) of alternating back and forth between which pump 10 is supplied power may then be repeated any number of times while the duplex system 100 is in the non-duplex mode.

An operating event refers to a parameterized control situation. As an example, sump pumps are often configured to be OFF (i.e., not running or idle) when an operational switch 12 is in one particular state and to be ON (i.e., running) when the switch is in another state. Here, an operating event would refer to an event that begins when the operational switch 12 triggers the pump 10 to be ON according to a first parameter (e.g., the float reaches a first water level) and ends when the operational switch 12 triggers the pump 10 to be OFF (or idle) according to a second parameter (e.g., the float reaches a second water level). In this respect, during the non-duplex mode, the duplex system 100 may supply power to a pump 10 for a duration of an operating event before alternating the supply power to another pump 10.

An operational switch 12 functions to actively control an associated device such as a pump 10. An operational switch 12 may be mounted on or integrated with its associated device. For example, FIG. 1 depicts a first float switch 12a as an operational switch 12 associated with the first pump 10a and a second float switch 12b as an operational switch 12 associated with the second pump 10b. In this example, each of these float switches 12 are directly coupled to or integrated with their associated pump 10.

An operational switch 12 that actively controls a device is in contrast to a passive control device such as the duplex system 100. In the pump system associated with the duplex system 100, the pump 10, when electrically coupled to the duplex system 100 (e.g., at the second port 124) is not going to actually tum ON and operate unless the pump is (i) supplied adequate power from the duplex system 100 and (ii) switched to an ON state by an operational switch 12 (e.g., a float switch). In this respect, if the duplex system 100 is not supplying power to a pump 10, the pump 10 will not operate even if the operational switch 12 attempts to switch the pump 10 to an ON state because the pump 10 will not have power from the duplex system 100.

One commonly used type of operational switch 12 is a float switch. A float switch typically includes a float that triggers a switch (e.g., a physical switch) when the float reaches a particular position. The float switch may be configured to switch the pump ON when the float rises to a designated first water level (e.g., an on water level) and then to switch the pump OFF when the float reaches a designated second water level (e.g., an off water level). As an example, as a float rises past the first water level, a float switch triggers (or switches) the pump 10 that the float is associated with to an ON state (an operating state) and, as the float descends past the second water level, the position of the float triggers the float switch to switch the pump 10 that it is associated with to an OFF state (e.g., a non-operating state or idle state). The first water level and the second water level are generally configurable such that they may be different water levels or refer to the same water level (e.g., shown in FIG. 1 as the “single level”). Although a mechanical float is described as triggering the operational switch 12 for the pump 10, other fluid sensing devices may be configured to function as the operational switches.

In addition to being able to balance the run time between pumps 10, the ability to alternate between pumps 10 enables the duplex system 100 to react to situations such as pump failure. That is, the duplex system 100 may recognize that a pump 10 is failing to operate or has failed to operate even though it is supplied power (by the duplex system 100) and being switched ON by an operational switch 12. In this failure situation, the duplex system 100 can recognize a failing pump 10 (e.g., via the current sensing circuit) and reroute or change the power it is supplying to another pump 10 (e.g., a pump 10 that is capable of operation). Moreover, by disconnecting the failing pump from power, the duplex system 100 allows the failing pump to be in a safe mode where maintenance or upkeep can be performed on the failing pump without risk of an electrical issue (e.g., an electrical shock to a maintenance worker).

To illustrate with an example, if the duplex system 100 is supplying power to the first pump 10a and senses that the first pump 10a is having a failure (e.g., not sensing current with the current sensing circuit), the duplex system 100 may disconnect the power source from the first pump 10a and instead supply another pump (e.g., the second pump 10b) with power from the power source. Here, if the duplex system 100 was in a non-duplex mode, the duplex system 100 would connect a disconnected pump 10 (e.g., the second pump 10b) to power and disconnect the first pump 10a from power (i.e., enabling a safe mode for the first pump 10a).

Referring further to FIG. 1, the housing 110 houses or contains (i.e., encases) the controller 200 of the duplex system 100. Here, the housing 110 is shown as a rectangular prism, but the housing 110 may take other shapes or form factors to account for the functionality of the duplex system 100. The interface 120 is integrated with the housing 110. For instance, the interface 120 is configured such that electrical connectors may be received at externally facing ports 122-128 on a surface of the housing 110. As shown in FIG. 1, these ports 122-128 may exist on the surface of multiple faces of the housing 110 and allow an electrical coupling to occur between the devices connected to the interface 120 (e.g., plugged into the interface 120 of the housing 110) and a power source of the duplex system 100. The interface 120 enables the controller 200 to control or manage the power source derived from one or more power inputs 20 (e.g., shown as a first power input 20a and a second power input 20b) and how that power source supplies power to the output devices (e.g., the pumps 10).

FIG. 1 depicts a first portion 120a of the interface 120 on one side of the housing 110 where the interface 120 receives a first power input. 20a at a first port 122. For example, the first portion 120a is shown on a face of the housing 110 that is perpendicular to the longitudinal axis of the housing 110. The first power input 20a may be considered an input to the interface 120 because the interface 120 (via the first port 122) allows the duplex system 100 to receive utility power. For example, a wall socket (also known as a receptacle) may provide 120 volts of alternating current utility power. In various implementations, the utility power may be another voltage, such as 240 volts. The utility power may be provided by an electric utility that distributes power via an electrical grid. In various implementations, the utility power may be generated locally, such as with solar panels or an electric generator based on an internal combustion engine (such as a gas generator or natural gas generator).

For example, in FIG. 1, a power cable of the duplex system 100 may extend from the first port 122 and plug into the wall socket. Accordingly, the first power input 20a being provided at the wall socket is accessible to the duplex system 100. In various implementations, the wall socket may be replaced with a hard-wired electrical connection from utility power to the duplex system 100.

The interface 120 is also configured with additional ports 124, 126 that allow the electrical devices (e.g., the pumps 10) to electrically couple with the duplex system 100. In FIG. 1, the additional ports 124, 126 are located on a side of the housing that is opposite the first port 122. In some configurations, each of these ports 124, 126 include a conventional socket (e.g., a type B socket) in order to receive a power cable from the pumps 10. In the two pump system of FIG. I, the first pump 10a plugs into the interface 120 at a socket associated with the second port 124 and the second pump 10b plugs into the interface 120 at a socket associated with the third port 126. Here, the second and third ports 124, 126 may be considered output ports 124, 126 because the duplex system 100 is configured to selectively supply power to the pumps 10 via the electrical coupling at these ports 124, 126.

In some configurations, the interface 120 further includes the ability to receive input from other power inputs 20, such as a second power input 20b like a battery. For instance, FIG. 1 depicts the interface 120 with a set of battery terminals 128 to enable the positive and negative terminals of a battery to electrically couple with the duplex system 100. Although the battery 20b is shown as being external to the duplex system 100 (e.g., not contained within the housing 110), in other designs, the battery may be internal to the duplex system 100 such that the battery is enclosed within the housing 110. By being able to receive power from a power input 20 that is not dependent on the electrical grid, the duplex system 100 is capable of powering the pumps 10 during a power outage. As examples only, the battery may have a nominal voltage of 12 volts or 24 volts.

The duplex system 100 may also be configured to communicate various types of faults, warnings, or states that relate to the duplex system itself or the devices connected to the duplex system (e.g., the pumps 10). Some examples of faults or warnings include a jammed pump, a stuck float switch, and an anomaly with a connected device such as an abnormal behavior of a pump 20 (e.g., an abnormal spike in current draw). The duplex system 100 may communicate these faults through different features of the duplex system 100 such as an audio/visual panel associated with the interface 120 or a wireless communication module.

The audio/visual panel refers to a portion of the interface 120 that includes visual indicators and/or audio input/output device(s). For instance, FIG. 1 depicts a second portion 120b of the interface 120 as having multiple visual indicators such as LED indicators. These visual indicators may be configured such that different colors or different sequences of color convey meaningful information to an operator of the duplex system 100. That is, a particular red visual indicator may indicate that one of the pumps 10 is experiencing a fault or failure. A green visual indicator may indicate that a particular pump 10 is currently operating or being provided power from the duplex system 10. There may also be colors or sequences that indicate a particular fault or recommended maintenance event. For example, a yellow visual indicator for a visual indicator associated with a particular pump 10 indicates that the duplex system 100 is recommending maintenance to that pump (e.g., replacement of a motor or a float associated with the pump).

The visual indicators may also be configured to indicate which power input 20 is being used to power the pump 10 (e.g., alternating current from the wall outlet 20a or direct current from a battery 20b) or the health of a particular power input 20. For example, if a visual indicator associated with the battery 20b is on, it means that the battery 20b is currently being used by the duplex system 100 to feed the power source. There may be a visual indicator associated with the battery 20b that indicates its level of charge in some manner. For example, if the visual indicator associated with the battery 20b is green it means the battery 20b has a healthy level of charge (e.g., 70-100% charged). If the visual indicator associated with the battery 20b is yellow, it means the battery 20b has a moderate level of charge (e.g., 35-70%). If the visual indicator associated with the battery 20b is red, it means the battery 20b has a low level of charge (e.g., 0-35%) and indicates that charging is recommended.

In some examples, a visual indicator indicates that an alert or fault state has been provided by the duplex system 100. For instance, the duplex system 100 includes wireless communication capabilities (e.g., a wireless communication module). With wireless communication capability, the duplex system 100 may communicate alerts (e.g., fault alerts) or other information to one or more wireless-enabled devices. For example, the duplex system 100 may be communicating with a remote device such as a mobile phone. The duplex system 100 may be associated with an application (e.g., a mobile application) that allows a user of the duplex system 100 to monitor and/or control the duplex system 100 (e.g., to manually switch between pumps 10 or modes such as the duplex mode and non-duplexing mode). In this respect, the user may receive alerts or notifications regarding the state of the pumps 10 or the duplex system 100. For instance, the user of the duplex system 100 receives a notification that the duplex system 100 had to switch to the battery as the power input 20 or has detected a fault with one or more pumps 20 (e.g., a motor failure). In some configurations, the duplex system 100 communicates in real-time or near real-time the current that is being sensed across the pumps 10 by the current sensing circuit.

Additionally or alternatively, the A/V panel includes audio input/output devices. For example, the A/V panel includes a speaker. Here, the speaker may allow the duplex system 100 to communicate an audible alert regarding a state of the duplex system 100 or the electrical devices connected to the duplex system 100. For instance, the duplex system 100 generates an audible sound to indicate that a fault or failure has been detected for one or more pumps 10. In another example, the duplex system 100 generates an audible sound to indicate that the duplex system 100 is currently using the battery as the power input 20 or that a device has been disconnected from the duplex system 100 (e.g., a power input 20 or pump 10 has been disconnected).

Referring to FIG. 2, the duplex system 100 includes a controller 200 that is capable of receiving power from multiple inputs 20 and to selectively power the devices connected to the duplex system 100 (e.g., shown as the first pump 10a and the second pump 1Ob). These inputs may supply alternating current (e.g., from a 120V wall outlet 20a) and/or direct current (e.g., from a battery 20b). Because the controller 200 is capable of receiving both types of current (e.g., simultaneously or individually), the controller 200 includes a power relay 210 that selects which input 20 will form the power source 102 of the duplex system 100. In other words, the controller 200 may have a default configuration to provide the 120 VAC from the wall outlet 20a to avoid consuming the energy of the battery 20b in non-emergency (or non-maintenance) operations. Here, the relay 210 would select the first power input 20a to form the power source 102 while preventing the second power input 20b from being the power source 102.

In a situation where the controller 200 decides to operate using the battery 20b to form the power source 102 (e.g., during a power outage), the relay 210 would accordingly select the battery 20b. In this situation, the controller 200 first converts the direct current from the battery 20b (e.g., 12 VDC) into alternating current using an inverter circuit 220 (e.g., shown as a DC-AC converter). This conversion is typically required to allow the power source 102 to provide power that is compatible with pumps 10 configured to use AC power.

By using the battery 20b, the battery 20b will naturally deplete its stored charge over time. Accordingly, for long-term use, the controller 200 includes a charger 230 that enables the battery 20b to charge (e.g., replenish charge). For example, while the wall outlet 20a provides power to the controller 200, the charger 230 is configured to draw an amount of power from the power provided by the wall outlet 20a and provide that power to the battery 20b to recharge. The charger 230 may also include some form of a regulator to regulate the charging rate of the battery 20b (e.g., control the power draw to recharge the battery 20b).

In some examples, the controller 200 refers to a one or more printed circuit boards (PCBs). That is, when the controller 200 “includes” a component, that component may be integrated into one or more PCBs forming the controller 200 or that component may be separate from, yet in communication with some aspect of the controller-200. That is, each component of the controller 200 does not have to be physically connected to each other (e.g., integrated in the same circuit), but can collectively form the controller 200 through a means of communication. In this sense, in some implementations, the components of the controller 200 are entirely enclosed within the housing 110. Yet in other configurations, one or more components of the controller 200 may be external to the housing 110. For instance, when the controller 200 includes a wireless communication module, that module may be connected to a port of the interface 120 such that it is external to the housing 110. Thus, the components of the controller 200 may be internal to the housing 110, external to the housing 110, or some combination thereof.

Referring further to FIGS. 2 and 3, the controller 200 includes a current sensing circuit 240 and a control circuit 250. The current sensing circuit 240 is configured to sense the current being drawn by the electrical devices connected to the duplex system 100. When the electrical devices are two pumps 10a, 10b, the current sensing circuit 240 is configured.to sense a first current drawn by the first pump 10a and a second current drawn by a second pump 10b.

In response to an operational switch 12 turning a pump 10 to an ON state (i.e., activating a power-supplied pump), the pump 10 will draw some amount of current. For instance, as shown in FIG. 2, a pump 10 generally includes a motor 14. When the pump 10 changes from an OFF state to an ON state (i.e., when an operational switch 12 turns the pump ON while the duplex system 100 is supplying power to the pump 10), the motor starts up with a spike in current generally followed by a steady state of current draw. The sensing circuit 240 is able to monitor this current and changes to the current draw to determine how the pump 10 is behaving.

Based on the pump’s behavior, the control circuit 250 may disconnect the power being supplied to that particular pump 10 and/or connect power to another pump 10 coupled to the duplex system 100. To connect or disconnect power from a particular pump 10, the control circuit 250 includes a set of relays 252. Each relay of the set is associated with a particular pump 10. This means that the first pump 10a includes at least one relay and the second pump 10b includes at least one relay.

Referring to FIG. 3, in some examples, the control circuit 250 includes four relays 242a, 242b, 242c, and 242d. In this example, each pump 10 corresponds to a pair ot relays 252. With a pair of relays 252, one relay is configured to connect and/or to disconnect the power source 102 from a first current-carrying electrical line of the pump 10 while the other relay is configured to connect and/or to disconnect the power source 102 from a second current- carrying electrical line of the pump 10. In other words, each pump 10 may have a relay dedicated to a hot line (i.e., a power-sourcing line) of the pump 10 and also a relay dedicated to a neutral line (i.e., a return line) of the pump 10. For instance, with the two-pump system shown in FIG. 3, the first pump 10a has first and second relays 252a, 252c connected to its hot line and neutral line respectively, while the second pump 10b has third and fourth relays 252b, 252d connected to its hot line and its neutral line. The controller 200 is configured to selectively control whether each relay is open or closed and is therefore able to selectively connect the power source 102 to a particular current-carrying line of a pump 10.

The current sensing circuit 240 senses current for each pump. In various implementations, one or more current sensors may be placed at common locations (prior to the relays) to measure the cumulative current going to both pumps. For example, a single current sensor may be used on a first line of the power source; while in other implementations, one current sensor may be used on the first line while a second current sensor may be used on a second line of the power source. In various implementations, only a single relay is used to control current to a pump. In such implementations, the current sensing for a pump may be performed on one or both of (i) the current-carrying line that is being switched by the relay and (ii) the current-carrying line that is not being switched.

In various implementations, the current sensing circuit 240 performs current sensing using one or more current transformers. A current transformer is generally designed to produce an alternating current in a secondary winding that is proportional (e.g., amplified or reduced) to the current being measured in its primary winding. For instance, the primary winding of a current transformer is electrically coupled to relay 252 of the control circuit 250. In some configurations, the current sensing circuit 240 may include only a single current transformer for each pump 10. Yet in other configurations, the sensing circuit 240 mirrors that of the control circuit 250 and includes a current transformer for each relay 252 associated with a pump 10. As shown in FIG. 3, the sensing circuit 240 may include four current transformers 244a, 244b, 244c, and 244d (collectively, current transformers 244) where each of the current transformers 244 corresponds respectively to one of the four relays 252a-d of the control circuit 250. In this manner, the current sensing capabilities of the sensing circuit 240 may monitor both source and return currents associated with a particular pump 10. In various implementations, the current transformers 244 may be located on the other side of the respective relays 252. In various implementations, other current sensing mechanisms may be used in place of a current transformer: for example, a hall effect sensor, a current-sensing resistor, etc.

FIGS. 4 and 5 illustrate some examples of how the controller 200 passively controls the behavior of each pump 10 in a two pump system. FIG. 4 depicts the duplex system 100 operating in a non-duplexing mode. In this non-duplexing mode, the controller 200 is ping-ponging or alternating back and forth between the first pump 10a and the second pump 1Ob. At an initial time oft= 0, the controller 200 is supplying the power source 102 to the first pump 10a by controlling one or more relays 242 associated with the first pump 10a to be in a power source-providing position. At the same time, the controller 200 is not supplying the power source 102 to the second pump 1Ob by controlling one or more relays 242 associated with the second pump 10b to be in a power- prohibiting position. During that time when the first pump 10a is being provided power, the first float switch 12a reaches a water level height H (t0) that switches the first pump 10a to an ON state where the first pump 10a is running. During this period of running time, the sensing circuit 240 measures the current of the first pump 10a. Once the first pump 10a pumps the water to a lower water height H (t1), the float switch 12a turns off the first pump 10a.

At this time t1, the sensing circuit 240 senses that the change in current corresponds to the first pump 10a turning off. In response to sensing the first pump 10a turning off, the controller 200 disconnects the power source 102 from the first pump 10a by controlling one or more relays 242 associated with the first pump 10a to be in a power source-prohibiting position. At the same time t1 or shortly thereafter, the controller 200 connects the power source 102 to the second pump 10b by controlling one or more relays 242 associated with the second pump 10b to be in a power-providing position.

During that time when the second pump 1Ob is being provided power (after time t1), the second float switch 12b reaches a water level height H(t2) that switches the second pump 10b to an ON state where the second pump 10b is running. During this period of running time, the sensing circuit 240 measures the current of the second pump 10b. Once the second pump 10b pumps the water to a lower water height H(t3), the second float switch 12b turns off the second pump 10b.

At this time t3, the sensing circuit 240 senses that the change in current corresponds to the second pump 10b turning off In response to sensing the second pump 10b turning; off, the controller 200 disconnects the power source 102 from the second pump 10b by controlling one or more relays 242 associated with the second pump 1Ob to be in a power source-prohibiting position. At the same time t3 or shortly thereafter, the controller 200 connects the power source 102 to the first pump 10a by controlling one or more relays 242 associated with the first pump 10a to be in a power-providing position.

During that time when the first pump 10a is being provided power (after time t3), the first float switch 12a reaches a water level height H(t4) that switches the first pump 10a to an ON state where the first pump 10a is running. During this period of running time, the sensing circuit 240 measures the current of the first pump 10a. Once the first pump 10a pumps the water to a lower water height H(t5), the first float switch 12a turns off the first pump 10a.

At this time t5, the sensing circuit 240 senses that the change in current corresponds to the first pump 10a turning off. In response to sensing the first pump 10a turning off, the controller 200 disconnects the power source 102 from the first pump 10a by controlling one or more relays 242 associated with the first pump 10a to be in a power source-prohibiting position. At the same time t5 or shortly thereafter, the controller 200 connects the power source 102 to the second pump 10b by controlling one or more relays 242 associated with the second pump 1Ob to be in a power-providing position.

During that time when the second pump 10b is being provided power (after time t5), the second float switch 12b reaches a water level height H(t6) that switches the second pump 10b to an ON state where the second pump 10b is running. During this period of running time, the sensing circuit 240 measures the current of the second pump 10b. Once the second pump 10b pumps the water to a lower water height H(t7), the second float switch 12b turns off the second pump 10b. This process then repeats this pattern during operation of the pump system unless one of the pumps 10 experiences a failure.

FIG. 5 initially follows the same non-duplexing mode sequence until time t3. After time t3,. the incoming water rate greatly increases such that the water level activates a duplexing operational switch 30. Here, the duplexing operational switch 30 refers to an operational switch that is not associated with a single pump 10, but rather triggers multiple pumps 10a, IOb to turn ON due to such a high water level (e.g., shown as a duplex level in FIG. 1). In some configurations, the duplexing (or multiplexing) operational switch 30 may be directly electrically connected to the duplex system 100.

When the duplex system 100 determines that the duplexing operational/ switch 30 has attempted to turn ON multiple pumps 10, the duplex system 100 changes to the duplexing mode and supplies power to both pump 10a, 10b. During that time when both the pumps 10a, 10b are being provided power (after time t4), the pumps 10a, 10b pump the water to a lower water height H(t6), the third float switch 30 turns off both pumps 10a, 10b. During this period of running time, the sensing circuit 240 measures the current of both pumps 10a, 10b as shown by the current magnitude from t4 to t5 being double the current magnitude of a single pump 10. With both pumps 10 being turned off, the controller 200 may return to a non-duplexing mode (e.g., to conserve the operational longevity of the pumps 10).

At t6, the same duplexing sequence occurs again. The incoming water rate greatly increases such that the water level activates a duplexing operational switch 30. This triggers the controller 200 to supply power to both pumps 10a, 10b. During that time when both the pumps 10a, 10b are being provided power after t6, the current sensing circuit 240 measures the current of both pumps 10a, 10b. Yet here, the sensing circuit 240 measures a current that is uncharacteristically low for the current that the sensing circuit 240 and/or controller 200 expects for the current of both pumps 10a, 10b. This occurs in reality because one of the pumps 10 (e.g., the second pump 10b) failed to tum on. Here, because of the measured current anomaly, the controller 200 communicates a fault alert. The fault alert may be communicated via the NV panel or wirelessly as a notification to alert an operator that a failure has occurred with the pump system. In some examples, the operator receives the alert on a wireless-enabled device such as a mobile phone.

Conclusion

The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims. In the written description and claims, one or more steps within a method may be executed in a different order (or concurrently) without altering the principles of the present disclosure. Similarly, one or more instructions stored in a non-transitory computer-readable medium may be executed in a different order (or concurrently) without altering the principles of the present disclosure. Unless indicated otherwise, numbering or other labeling of instructions or method steps is done for convenient reference, not to indicate a fixed order.

Further, although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the disclosure can be implemented in and/or combined with features of any of the other embodiments, even if that combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more embodiments with one another remain within the scope of this disclosure.

Spatial and functional relationships between elements (for example, between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including “connected,” “engaged,” “coupled,” “adjacent,” “next to,” “on top of,” “above,” “below,” and “disposed.” Unless explicitly described as being “direct,” when a relationship between first and second elements is described in the above disclosure, that relationship encompasses a direct relationship where no other intervening elements are present between the first and second elements as well as an indirect relationship where one or more intervening elements are present between the first and second elements.

The phrase “at least one of A, B, and C” should be construed to mean a logical (A ORB OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.” The term “set” does not necessarily exclude the empty set - in other words, in some circumstances a “set” may have zero elements. The term “non-empty set” may be used to indicate exclusion of the empty set - in other words, a non-empty set will always have one or more elements. The term “subset” does not necessarily require a proper subset. In other words, a “subset” of a first set may be coextensive with (equal to) the first set. Further, the term “subset” does not necessarily exclude the empty set - in some circumstances a “subset” may have zero elements.

In the figures, the direction of an arrow, as indicated by the arrowhead, generally demonstrates t e flow of information (such as data or instructions) that is of interest to the illustration. For example, when element A and element B exchange a variety of information but information transmitted from element A to element B is relevant to the illustration, the arrow may point from element A to element B. This unidirectional arrow does not imply that no other information is transmitted from element B to element A. Further, for information sent from element A to element B, element B may send requests for, or receipt acknowledgements of, the information to element A.

In this application, including the definitions below, the term “module” can be replaced with the term “controller” or the term “circuit.” In this application, the term “controller” can be replaced with the term “module.” The term “module” may refer to, be part of, or include: an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); processor hardware (shared, dedicated, or group) that executes code; memory hardware (shared, dedicated, or group) that stores code executed by the processor hardware; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.

The module may include one or more interface circuits. In some examples, the interface circuit(s) may implement wired or wireless interfaces that connect to a local area network (LAN) or a wireless personal area network (WPAN). Examples of a LAN are Institute of Electrical and Electronics Engineers (IEEE) Standard 802.11-2020 (also known as the WIFI wireless networking standard) and IEEE Standard 802.3-2018 (also known as the ETHERNET wired networking standard). Examples of a WPAN are IEEE Standard 802.15.4 (including the ZIGBEE standard from the ZigBee Alliance) and, from the Bluetooth Special Interest Group (SIG), the BLUETOOTH wireless networking standard (including Core Specification versions 3.0, 4.0, 4.1, 4.2, 5.0, and 5.1 from the Bluetooth SIG).

The module may communicate with other modules using the interface circuit(s). Although the module may be depicted in the present disclosure as logically communicating directly with other modules, in various implementations the module may actually communicate via a communications system. The communications system includes physical and/or virtual networking equipment such as hubs, switches, routers, and gateways. In some implementations, the communications system connects to or traverses a wide area network (WAN) such as the Internet. For example, the communications system may include multiple LANs connected to each other over the Internet or point-to-point leased lines using technologies including Multiprotocol Label Switching (MPLS) and virtual private networks (Ns).

In various implementations, the functionality of the module may be distributed among multiple modules that are connected via the communications system. For example, multiple modules may implement the same functionality distributed by a load balancing system. In a further example, the functionality of the module may be split between a server (also known as remote, or cloud) module and a client (or, user) module. For example, the client module may include a native or web application executing on a client device and in network communication with the server module.

Some or all hardware features of a module may be defined using a language for hardware description, such as IEEE Standard 1364-2005 (commonly called “Verilog”) and IEEE Standard 1076-2008 (commonly called “VHDL”). The hardware description language may be used to manufacture and/or program a hardware circuit. In some implementations, some or all features of a module may be defined by a language, such as IEEE 1666-2005 (commonly called “SystemC”), that encompasses both code, as described below, and hardware description.

The term code, as used above, may include software, firmware, and/or microcode, and may refer to programs, routines, functions, classes, data structures, and/or objects. Shared processor hardware encompasses a single microprocessor that executes some or all code from multiple modules. Group processor hardware encompasses a microprocessor that, in combination with additional microprocessors, executes some or all code from one or more modules. References to multiple-microprocessors encompass multiple microprocessors on discrete dies, multiple microprocessors on a single die, multiple cores of a single microprocessor, multiple threads of a single microprocessor, or a combination of the above.

The memory hardware may also store data together with or separate from the code. Shared memory hardware encompasses a single m.e.mory device that stores some or all code from multiple modules. One example of shared memory hardware may be level 1 cache on or near a microprocessor die, which may store code from multiple modules. Another example of shared memory hardware may be persistent storage, such as a solid state drive (SSD) or magnetic hard disk drive (HDD), which may store code from multiple modules. Group memory hardware encompasses a memory device that, in combination with other memory devices, stores some or all code from one or more modules. One example of group memory hardware is a storage area network (SAN), which may store code of a particular module across multiple physical devices. Another example of group memory hardware is random access memory of each of a set of servers that, in combination, store code of a particular module.

The term memory hardware is a subset of the term computer-readable medium. The term computer-readable medium, as used herein, does not encompass transitory electrical or electromagnetic signals propagating through a medium (such as on a carrier wave); the term computer-readable medium is therefore considered tangible and non-transitory. Non-limiting examples of a non- transitory computer-readable medium are nonvolatile memory devices (such as a flash memory device, an erasable programmable read-only memory device, or a mask read-only memory device), volatile memory devices (such as a static random access memory device or a dynamic random access memory device), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc).

The apparatuses and methods described in this application may be partially or fully implemented by a special purpose computer created by configuring a general purpose computer to execute one or more particular functions embodied in computer programs. Such apparatuses and methods may be described as computerized apparatuses and computerized methods. The functional blocks and flowchart elements described above serve as software specifications, which can be translated into the computer programs by the routine work of a skilled technician or programmer.

The computer programs include processor-executable instructions that are stored on at least one non-transitory computer-readable medium. The computer programs may also include or rely on stored data. The computer programs may encompass a basic input/output system (BIOS) that interacts with hardware of the special p_urpose computer, device drivers that interact with particular devices of the special purpose computer, one or more operating systems, user applications, background services, background applications, etc.

The computer programs may include: (i) descriptive text to be parsed, such as HTML (hypertext markup language), XML (extensible markup language), or JSON (JavaScript Object Notation), (ii) assembly code, (iii) object code generated from source code by a compiler, (iv) source code for execution by an interpreter, (v) source code for compilation and execution by a just-in-time compiler, etc. As examples only, source code may be written using syntax from languages including C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran, Perl, Pascal, Curl, OCaml, JavaScript®, HTML5 (Hypertext Markup Language 5th revision), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Flash®, Visual Basic®, Lua, MATLAB, SIMULINK, and Python®.

Claims

1. A system comprising: a housing;a controller mounted inside the housing;an input/output (I/O) interface integrated with the housing, wherein the I/O interface includes: a first port configured to electrically couple a power input to the controller,wherein a power source is based on the power input; a second port configured to electrically couple a first pump to the controller; anda third port configured to electrically couple a second pump to the controller, anda set of relays connected to the second port and the third port,wherein the controller includes a current sensing circuit configured to sense (i) a first current drawn by the first pump and (ii) a second current drawn by the second pump, andwherein, in response to the current sensing circuit sensing that the first current indicates that the-first pump has shut off, the controller activates the second pump and deactivates the first pump by controlling the set of relays to disconnect the power source from the first pump and to connect the second pump to the power source.

2. The system of claim 1 wherein: the first pump includes an integrated first float switch that activates a motor of the first pump;the second pump includes an integrated second float switch that activates a motor of the second pump;while the second pump is activated, the motor of the second pump is capable of operating in response to an indication from the second float switch; andwhile the first pump is deactivated, the motor of the first pump does not operate regardless of a state of the first float switch.

3. The system of claim 1 wherein the controller is configured to, in response to the current sensing circuit sensing that the second current indicates that the second pump has shut off, activate the first pump and deactivate the second pump by controlling the set of relays to disconnect the second pump from the power source and to connect the first pump to the power source.

4. The system of claim 3 wherein: the first pump includes a first float switch configured to activate a motor of the first pump;the second pump includes a second float switch configured to activate a motor of the second pump;while the first pump is activated, the motor of the first pump is capable of operating in response to an indication from the first float switch; andwhile the second pump is deactivated, the motor of the second pump is inoperable regardless of a state of the second float switch.

5. The system of claim 1 wherein: the first pump includes a first float switch configured to activate a motor of the first pump;the second pump includes a second float switch configured to activate a motor of the second pump;the motor of the first pump operates independently of a state of the second float switch; andthe motor of the second pump operates independently of a state of the first float switch.

6. The system of claim 5 wherein: the first float switch is integrated with the first pump; andthe second float switch is integrated with the second pump.

7. The system of claim 5 wherein: while the first pump is activated, the motor of the first pump is capable of operating in response to the state of the first float switch;while the first pump is deactivated, the motor of the first pump is inoperable regardless of the state of the first float switch;while the second pump is activated, the motor of the second pump is capable of operating in response to the state of the second float switch; andwhile the second pump is deactivated, the motor of the second pump is inoperable regardless of the state of the second float switch.

8. The system of claim 1 wherein the power source provides alternating current utility power to the controller.

9. The system of claim 1 wherein the I/O interface includes a set of terminals configured to electrically couple the controller to a battery source.

10. The system of claim 9 wherein the battery source includes a battery suppling direct current to the controller.

11. The system of claim 10 wherein the controller includes an inverter circuit that converts the direct current supplied from the battery source to alternating current capable of powering the first pump and the second pump.

12. The system of claim 1 wherein the controller includes a wireless communication circuit that enables the system to communicate with a remote WiFi-enabled device.

13. The system of claim 1 wherein: the controller includes a direct electrical connection with a third float switch; andthe controller is configured to, in response to activation of the third float switch, activate both the first pump and the second pump.

14. The system of claim 1 wherein the controller is configured to, in response to the current sensing circuit fails to sense the first current being drawn from the first pump while both the first pump and the second pump are active, communicate an alarm indicating a pump failure.

15. The system of claim 14 wherein the alarm includes at least one of an audible alarm and a visual fault indication.

16. The system of claim 14 wherein the controller is configured to, in response to the current sensing circuit failing to sense the first current being drawn from the first pump while both the first pump and the second pump are active, enable a safe mode that deactivates the first pump by controlling a state of the set of relays from a first state that powers both the first pump and the second pump to a second state that powers only the second pump.

17. The system of claim 1 wherein the set of relays includes: a first relay configured to connect and disconnect the power source from a first current-carrying electrical line of the first pump; anda second relay configured to connect and disconnect the power source from a first current-carrying electrical line of the second pump.

18. The system of claim 17 wherein the set of relays includes: a third relay configured to connect and disconnect the power source from a second current-carrying electrical line of the first pump; anda fourth relay configured to connect and disconnect the power source from a second current-carrying electrical line of the second pump.

19. A method comprising: measuring current being provided by a power source to a first pump, wherein the first pump is electrically coupled to a first port of an input/output (J/O) interface;identifying a first current measurement indicating that the first pump has shut off; andin response to identifying the first current measurement: activating a second pump electrically coupled to a second port of the I/O interface, wherein activating the second pump is performed by controlling a set of relays to connect the power source to the second pump, and wherein the power source is derived from a power input electrically coupled to a third port of the J/O interface; anddeactivating the first pump, wherein deactivating the first pump is performed by controlling the set of relays to disconnect the first pump from the power source.

20. The method of claim 19 further comprising: measuring current being provided by the power source to the second pump;while the second pump is activated, identifying a second current measurement that indicates that the second pump has shut off; andin response to identifying the second current measurement: activating the first pump, wherein activating the first pump is performed by controlling the set of relays to connect the first pump to the power source; anddeactivating the second pump, wherein deactivating the second pump is performed by controlling the set of relays to disconnect the second pump from the power source.

21. The method of claim 19 further comprising: receiving an indication that a third float switch has moved to an active state; andin response to the indication that the third float switch has moved to the active state, activating both the first pump and the second pump.

22. The method of claim 21 further comprising: while both the first pump and the second pump are activated, selectively identifying a third current measurement that indicates that the first pump is not operating; andin response to identifying the third current measurement, generating an alarm indicating a pump failure.

23. The method of claim 22 wherein the alarm includes at least one of an audible alarm or a visual fault indication.

24. The method of claim 22 further comprising wirelessly transmitting the alarm.

25. The method of claim 24 wherein wirelessly transmitting includes transmitting over a wireless local area network.

26. The method of claim 21 further comprising: while both the first pump and the second pump are activated, determining that a new current measurement for the first pump indicates that the first pump is not operating; andin response to the indication that the first pump is not operating, deactivating the first pump by controlling a state of the set of relays from a first state powering both the first pump and the second pump to a second state that only powers the second pump.

27. The method of claim 19 wherein the set of relays includes: a first relay that is configured to connect and to disconnect the power source from a first current-carrying electrical line of the first pump;a second relay that is configured to connect and to disconnect the power source from a second current-carrying electrical line of the first pump;a third relay that is configured to connect and to disconnect the power source from a first current-carrying electrical line of the second pump; anda fourth relay that is configured to connect and to disconnect the power source from a second current-carrying electrical line of the second pump.