Patent Application
20120107140
Pool pumps are used to move water in one or more aquatic applications, such as pools, spas, and water features. The aquatic applications include one or more water inlets and one or more water outlets. The water outlets are connected to an inlet of the pool pump. The pool pump generally propels the water though a filter and back into the aquatic applications though the water inlets. For large pools, the pool pump must provide high flow rates in order to effectively filter the entire volume of pool water. These high flow rates can result in high velocities in the piping system connecting the water outlets and the pool pump. If a portion of the piping system is obstructed or blocked, this can result in a high suction force near the water outlets of the aquatic applications. As a result, foreign objects can be trapped against the water outlets, which are often covered by grates in the bottom or sides of the pool. Systems have been developed to try to quickly shut down the pool pump when a foreign object is obstructing the water outlets of the aquatic applications. However, these systems often result in nuisance tripping (i.e., the pool pump is shut down too often when there are no actual obstructions).
Some embodiments of the invention provide a method of operating a safety vacuum release system (SVRS) with a controller for a pump including a motor. The method can include measuring an actual power consumption of the motor necessary to pump water and overcome losses, calculating an absolute power variation based on the actual power consumption, and incrementing a dynamic counter value if the absolute power variation is negative. The method can also include calculating a relative power variation based on the actual power consumption and identifying a dynamic suction blockage if the dynamic counter exceeds a dynamic counter threshold value and/or the relative power variation is below a negative threshold. The method can further include triggering the SVRS when the dynamic suction blockage is identified in order to shut down the pump substantially immediately.
Some embodiments of the invention provide a method including filtering the actual power consumption with a fast low-pass filter to obtain a current power consumption and incrementing an absolute counter value if the actual power consumption and/or the current power consumption are greater than a threshold power curve. The method can also include identifying a dead head condition if the absolute counter value exceeds an absolute counter threshold value and triggering the suction vacuum release system when the dead head condition is identified in order to shut down the pump substantially immediately.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.
In some embodiments, the on-board controller 16 can be enclosed in a case 28. The case 28 can include a field wiring compartment 30 and a cover 32. The cover 32 can be opened and closed to allow access to the on-board controller 16 and protect it from moisture, dust, and other environmental influences. The case 28 can be mounted on the motor 14. In some embodiments, the field wiring compartment 30 can include a power supply to provide power to the motor 14 and the on-board controller 16.
In some embodiments, the motor 14 can include a coupling 58 to connect to the on-board controller 16. In some embodiments, the on-board controller 16 can automatically operate the pool pump 10 according to at least one schedule. If two or more schedules are programmed into the on-board controller 16, the schedule running the pool pump 10 at the highest speed can have priority over the remaining schedules. In some embodiments, the on-board controller 16 can allow a manual operation of the pool pump 10. If the pool pump 10 is manually operated and is overlapping a scheduled run, the scheduled run can have priority over the manual operation independent of the speed of the pool pump 10. In some embodiments, the on-board controller 16 can include a manual override. The manual override can interrupt the scheduled and/or manual operation of the pool pump 10 to allow for, e.g., cleaning and maintenance procedures. In some embodiments, the on-board controller 16 can monitor the operation of the pool pump 10 and can indicate abnormal conditions of the pool pump 10.
The on-board controller 16 operates the motor 14 to provide a safety vacuum release system (SVRS) for the aquatic applications. If the on-board controller 16 detects an obstructed inlet 18, the on-board controller 16 can quickly shutdown the pool pump 10. In some embodiments, the on-board controller 16 can detect the obstructed inlet 18 based only on measurements and calculations related to the power consumption of the motor 14 (e.g., the power needed to rotate the motor shaft 56). In some embodiments, the on-board controller 16 can detect the obstructed inlet 18 without any additional inputs (e.g., without pressure, flow rate of the pumped fluid, speed or torque of the motor 14).
In some embodiments, the settings category 110 can include a time setting 122, a minimum speed setting 124, a maximum speed setting 126, and a SVRS automatic restart setting 128. The time setting 122 can be used to run the pool pump 10 on a particular schedule. The minimum speed setting 124 and the maximum speed setting 126 can be adjusted according to the volume of the aquatic applications. An installer of the pool pump 10 can provide the minimum speed setting 124 and the maximum speed setting 126. The on-board controller 16 can automatically prevent the minimum speed setting 124 from being higher than the maximum speed setting 126. The pool pump 10 will not operate outside of these speeds in order to protect flow-dependent devices with minimum speeds and pressure-sensitive devices (e.g., filters) with maximum speeds. The SVRS automatic restart setting 128 can provide a time period before the on-board controller 16 will resume normal operation of the pool pump 10 after an obstructed inlet 18 has been detected and the pool pump 10 has been stopped. In some embodiments, there can be two minimum speed settings—one for dead head detection (higher speed) and one for dynamic detection (lower speed).
In some embodiments, the speed category 112 can be used to input data for running the pool pump 10 manually and/or automatically. In some embodiments, the on-board controller 16 can store a number of manual speeds 130 and a number of scheduled runs 132. In some embodiments, the manual speeds 130 can be programmed into the on-board controller 16 using the up-arrow button 82, the down-arrow button 84 and the enter button 90. Once programmed, the manual speeds 130 can be accessed by pressing one of the speed buttons 64 on the user interface 60. The scheduled runs 132 can be programmed into the on-board controller 16 using the up-arrow button 82, the down-arrow button 84, and the enter button 90. For the scheduled runs 132, a speed, a start time, and a stop time can be programmed. In some embodiments, the scheduled runs 132 can be programmed using a speed, a start time, and a duration. In some embodiments, the pool pump 10 can be programmed to run continuously.
The external control category 114 can include various programs 134. The programs 134 can be accessed by the external controller 98. The quantity of programs 134 can be equal to the number of scheduled runs 132.
The features category 116 can be used to program a manual override. In some embodiments, the parameters can include a “quick clean” program 136 and a “time out” program 138. The “quick clean” program 136 can include a speed setting 140 and a duration setting 142. The “quick clean” program 136 can be selected by pressing the “quick clean” button 74 located on the user interface 60. When pressed, the “quick clean” program 136 can have priority over the scheduled and/or manual operation of the pool pump 10. After the pool pump 10 has been operated for the time period of the duration setting 142, the pool pump 10 can resume to the scheduled and/or manual operation. If the SVRS has been previously triggered and the time period for the SVRS automatic restart 128 has not yet elapsed, the “quick clean” program 136 may not be initiated by the on-board controller 16. The “time out” program 138 can interrupt the operation of the pool pump 10 for a certain amount of time, which can be programmed into the on-board controller 16. The “time out” program 138 can be selected by pressing the “time out” button 72 on the user interface 60. The “time out” program 138 can be used to clean the aquatic application and/or to perform maintenance procedures.
In the priming category 118, the priming of the pool pump 10 can be enabled or disabled. If the priming is enabled, a duration for the priming sequence can be programmed into the on-board controller 16. In some embodiments, the priming sequence can be run at the maximum speed 126. The priming sequence can remove substantially all air in order to allow water to flow through the pool pump 10 and/or connected piping systems.
In some embodiments, a temperature sensor (not shown) can be connected to the on-board controller 16 in order to provide an anti-freeze operation for the pumping system and the pool pump 10. In the anti-freeze category 120, a speed setting 144 and a temperature setting 146 at which the pool pump 10 can be activated to prevent water from freezing in the pumping system can be programmed into the on-board controller 16. If the temperature sensor detects a temperature lower than the temperature setting 146, the pool pump 10 can be operated according to the speed setting 144. However, the anti-freeze operation can also be disabled.
In some embodiments, the on-board controller 16 can filter the actual power consumption 202 using a fast low-pass filter to obtain the current power consumption 204. The current power consumption 204 can represent the actual power consumption 202; however, the current power consumption 204 can be substantially smoother than the actual power consumption 202. This type of signal filtering can result in “fast detection” (also referred to as “dynamic detection”) of any obstructions in the pumping system (e.g., based on dynamic behavior of the shaft power when the inlet 18 is blocked suddenly). In some embodiments, the fast low-pass filter can have a time constant of about 200 milliseconds.
In some embodiments, the on-board controller 16 can filter the signal for the actual power consumption 202 using a slow low-pass filter to obtain the lagged power consumption 206. The lagged power consumption 206 can represent the actual power consumption from an earlier time period. If the inlet 18 is obstructed at the time instance 200, the actual power consumption 202 will rapidly drop. The current power consumption 204 can substantially follow the drop of the actual power consumption 202. However, the lagged power consumption 206 will drop substantially slower than the actual power consumption 202. As a result, the lagged power consumption 206 will generally be higher than the actual power consumption 202. This type of signal filtering can result in “slow detection” (also referred to as “dead head detection” or “static detection”) of any obstructions in the pumping system (e.g., when there is an obstruction in the pumping system and the pool pump 10 runs dry for a few seconds). In some embodiments, the slow low-pass filter can have a time constant of about 1400 milliseconds.
The signal filtering of the actual power consumption 202 can be performed over a time interval of about 2.5 seconds, resulting in a reaction time between about 2.5 seconds and about 5 seconds, depending on when the dead head condition occurs during the signal filtering cycle. In some embodiments, the static detection can have a 50% sensitivity which can be defined as the power consumption curve calculated from a minimum measured power plus a 5% power offset at all speeds from about 1500 RPM to about 3450 RPM. When the sensitivity is set to 0%, the static detection can be disabled.
The relative power consumption 208 can also be used to determine a “relative power variation” (also referred to as a “power variation percentage”). The relative power variation can be calculated by subtracting the lagged power consumption 206 from the current power consumption 204 and dividing by the lagged power consumption 206. When the inlet 18 is blocked, the relative power variation will be negative as shaft power decreases rapidly in time. A negative threshold can be set for the relative power variation. If the relative power variation exceeds the negative threshold, the SVRS can identify an obstructed inlet 18 and shut down the pool pump 10 substantially immediately. In one embodiment, the negative threshold for the relative power variation can be provided for a speed of about 2200 RPM and can be provided as a percentage multiplied by ten for increased resolution. The negative threshold for other speeds can be calculated by assuming a second order curve variation and by multiplying the percentage at 800 RPM by six and by multiplying the percentage at 3450 RPM by two. In some embodiments, the sensitivity of the SVRS can be altered by changing the percentages or the multiplication factors.
In some embodiments, the on-board controller 16 can include a dynamic counter. In one embodiment, a dynamic counter value 210 can be increased by one value if the absolute power variation is negative. The dynamic counter value 210 can be decreased by one value if the absolute power variation is positive. In some embodiments, if the dynamic counter value 210 is higher than a threshold (e.g., a value of about 15 so that the counter needs to exceed 15 to trigger an obstructed inlet alarm), a dynamic suction blockage is detected and the pool pump 10 is shut down substantially immediately. The dynamic counter value 210 can be any number equal to or greater than zero. For example, the dynamic counter value 210 may remain at zero indefinitely if the shaft power continues to increase for an extended time period. However, in the case of a sudden inlet blockage, the dynamic counter value 210 will rapidly increase, and once it increases beyond the threshold value of 15, the pool pump 10 will be shut down substantially immediately. In some embodiments, the threshold for the dynamic counter value 210 can depend on the speed of the motor 14 (i.e., the thresholds will follow a curve of threshold versus motor speed). In one embodiment, the dynamic detection can monitor shaft power variation over about one second at a 20 millisecond sampling time to provide fast control and monitoring.
In one embodiment, the SVRS can determine that there is an obstructed inlet 18 when both of the following events occur: (1) the relative power variation exceeds a negative threshold; and (2) the dynamic counter value 210 exceeds a positive threshold (e.g., a value of 15). When both of these events occur, the on-board controller 16 can shut down the pool pump 10 substantially immediately. However, in some embodiments, one of these thresholds can be disabled. The relative power variation threshold can be disabled if the relative power variation threshold needs only to be negative to trigger the obstructed inlet alarm. Conversely, the dynamic counter can be disabled if the dynamic counter value needs only to be positive to trigger the obstructed inlet alarm.
The on-board controller 16 can evaluate the relative power consumption 208 in a certain time interval. The on-board controller 16 can adjust the dynamic counter value 210 of the dynamic counter for each time interval. In some embodiments, the time interval can be about 20 milliseconds. In some embodiments, the on-board controller 16 can trigger the SVRS based on one or both of the relative power consumption 208 and the dynamic counter value 210 of the relative counter. The values for the relative power consumption 208 and the dynamic counter value 210 when the on-board controller 16 triggers the SVRS can be programmed into the on-board controller 16.
In some embodiments, the on-board controller 16 can include an absolute counter. If the actual power consumption 202 and/or the current power consumption 204 is below the threshold value, a value of the absolute counter can be increased. A lower limit for the absolute counter can be set to zero. In some embodiments, the absolute counter can be used to trigger the SVRS. The threshold value for the absolute counter before the SVRS is activated can be programmed into the on-board controller 16. In some embodiments, if the absolute counter value is higher than a threshold (e.g., a value of about 10 so that the counter needs to exceed 10 to trigger an obstructed inlet alarm), a dead head obstruction is detected and the pool pump 10 is shut down substantially immediately. In other words, if the actual power consumption 202 stays below a threshold power curve (as described below) for 10 times in a row, the absolute counter will reach the threshold value of 10 and the obstructed inlet alarm can be triggered for a dead head condition.
For use with the absolute counter, the threshold value for the actual power consumption 202 can be a threshold power curve with a sensitivity having a percentage multiplied by ten. For example, a value of 500 can mean 50% sensitivity and can correspond to the measured minimum power curve calculated using second order approximation. A value of 1000 can mean 100% sensitivity and can correspond to doubling the minimum power curve. In some embodiments, the absolute counter can be disabled by setting the threshold value for the actual power consumption 202 to zero. The sensitivity in most applications can be above 50% in order to detect a dead head obstruction within an acceptable time period. The sensitivity in typical pool and spa applications can be about 65%.
In some embodiments, the SVRS based on the absolute counter can detect an obstructed inlet 18 when the pool pump 10 is being started against an already blocked inlet 18 or in the event of a slow clogging of the inlet 18. The sensitivity of the SVRS can be adjusted by the scaling factor for the maximum power consumption 212 and/or the value of the absolute counter. In some embodiments, the absolute counter can be used as an indicator for replacing and/or cleaning the strainer 42 and/or other filters installed in the piping system of the aquatic applications.
In some embodiments, the dynamic counter and/or the absolute counter can reduce the number of nuisance trips of the SVRS. The dynamic counter and/or the absolute counter can reduce the number of times the SVRS accidently shuts down the pool pump 10 without the inlet 18 actually being obstructed. A change in flow rate through the pool pump 10 can result in variations in the absolute power consumption 202 and/or the relative power consumption 208 that can be high enough to trigger the SVRS. For example, if a swimmer jumps into the pool, waves can change the flow rate through the pool pump 10 which can trigger the SVRS, although no blockage actually occurs. In some embodiments, the relative counter and/or the absolute counter can prevent the on-board controller 16 from triggering the SVRS if the on-board controller 16 changes the speed of the motor 14. In some embodiments, the controller 16 can store whether the type of obstructed inlet was a dynamic blocked inlet or a dead head obstructed inlet.
The actual power consumption 202 varies with the speed of the motor 14. However, the relative power consumption 208 can be substantially independent of the actual power consumption 202. As a result, the power consumption parameter of the motor shaft 56 by itself can be sufficient for the SVRS to detect an obstructed inlet 18 over a wide range of speeds of the motor 14. In some embodiments, the power consumption parameter can be used for all speeds of the motor 14 between the minimum speed setting 124 and the maximum speed setting 126. In some embodiments, the power consumption values can be scaled by a factor to adjust a sensitivity of the SVRS. A technician can program the power consumption parameter and the scaling factor into the on-board controller 16.
An object in the vessel 302, for example a person 314 or a foreign object, may accidently obstruct the outlet 310 or the inlet 18 may become obstructed over time. The on-board controller 16 can detect the blocked inlet 18 of the pool pump 10 based on one or more of the actual power consumption 202, the current power consumption 204, the relative power consumption 208, the dynamic counter, and the absolute counter. In some embodiments, the on-board controller 16 can trigger the SVRS based on the most sensitive (e.g., the earliest detected) parameter. Once an obstructed inlet 18 has been detected, the SVRS can shut down the pool pump 10 substantially immediately. The on-board controller 16 can illuminate an LED 96 on the user interface 60 and/or can activate an audible alarm. In some embodiments, the on-board controller 16 can restart the pool pump 10 automatically after the time period for the SVRS automatic restart 128 has elapsed. In some embodiments, the on-board controller 16 can delay the activation of the SVRS during start up of the pool pump 10. In some embodiments, the delay can be about two seconds.
If the inlet 18 is still obstructed when the pool pump 10 is restarted, the SVRS will be triggered again. Due to the pool pump 10 being started against an obstructed inlet 18, the relative power consumption 208 may be inconclusive to trigger the SVRS. However, the on-board controller 16 can use the actual power consumption 202 and/or the current power consumption 204 to trigger the SVRS. In some embodiments, the SVRS can be triggered based on both the relative power consumption 208 and the actual power consumption 202.
In some embodiments, the SVRS can be triggered for reasons other than the inlet 18 of the pool pump 10 being obstructed. For example, the on-board controller 16 can activate the SVRS if one or more of the actual power consumption 202, the current power consumption 204, and the relative power consumption 208 of the pool pump 10 varies beyond an acceptable range for any reason. In some embodiments, an obstructed outlet 20 of the pool pump 10 can trigger the SVRS. In some embodiments, the outlet 20 may be obstructed anywhere along the inlet pipe 306 and/or in the inlet 312 of the pool or spa 300. For example, the outlet 20 could be obstructed by an increasingly-clogged strainer 42 and/or filter system 308.
In some embodiments, the number of restarts of the pool pump 10 after time period for the SVRS automatic restart 128 has been elapsed can be limited in order to prevent excessive cycling of the pool pump 10. For example, if the filter system 308 is clogged, the clogged filter system 308 may trigger the SVRS every time the pool pump 10 is restarted by the on-board controller 16. After a certain amount of failed restarts, the on-board controller 16 can be programmed to stop restarting the pool pump 10. The user interface 60 can also indicate the error on the display 62. In some embodiments, the user interface 60 can display a suggestion to replace and/or check the strainer 42 and/or the filter system 308 on the display 62.
It will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the invention are set forth in the following claims.
This application is a divisional of U.S. application Ser. No. 12/572,774 filed on Oct. 2, 2009, which claims priority under 35 U.S.C. §119 to U.S. Provisional Patent Application No. 61/102,935 filed on Oct. 6, 2008, the entire contents of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61102935 | Oct 2008 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12572774 | Oct 2009 | US |
| Child | 13350167 | US |
