# US 10,865,787 B2 · Connected pump system controller and method of use

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- Number: US 10,865,787 B2
- Document ID: US10865787B2
- Status: Granted
- Kind: B2
- Application number: 15/832,669
- Filed: 2017-12-05
- Published: 2018-06-07
- Granted: 2020-12-15
- Earliest claimed: 2016-12-06
- Assignees: Pentair Flow Technologies, LLC
- Applicants: Pentair Flow Technologies, LLC
- Inventors: Michael Bishop; Hassan Khalid
- Web page: https://patentgrep.com/patent/US10865787B2

## CPC

- F04B 51/00: Testing machines, pumps, or pumping installations
- F04B 49/065: {and making use of computers}
- F04B 49/08: Regulating by delivery pressure
- G05B 15/02: electric
- F04B 2205/06: Pressure in a (hydraulic) circuit
- G06Q 20/12: specially adapted for electronic shopping systems
- G06Q 30/0633: {Managing shopping lists, e.g. compiling or processing purchase lists (shipping orders G06Q10/083; order filling G06Q10/087)}
- H04W 76/15: Setup of multiple wireless link connections
- H04W 84/18: Self-organising networks, e.g. ad-hoc networks or sensor networks
- H04W 88/16: Gateway arrangements
- F04B: POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS (machines for liquids, or pumps, of rotary-piston or oscillating-piston type F04C; non-positive-displacement pumps F04D; pumping of fluid by direct contact of another fluid or by using inertia of fluid to be pumped F04F)
- G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G)
- G06Q: INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- H04W: WIRELESS COMMUNICATION NETWORKS (broadcast communication H04H; communication systems using wireless links for non-selective communication, e.g. wireless extensions H04M1/72)

## Abstract

In some embodiments of the present disclosure, systems and methods for monitoring operation of a pump are provided. In some embodiments, a system comprises: a pressure switch, comprising: a PCB within a housing; a power supply; a wireless gateway module configured to establishes a wireless connection to a wireless network; a pressure sensor; a microcontroller that: establishes a second wireless connection to a mobile device; receives instructions from the mobile device; connect to the first wireless network based on the instructions; determine pressure; control operation of the pump based on the pressure; determine that a fault has occurred, automatically stop operation of the pump, and send a message to a server over the first wireless network; and receive instructions from the mobile device via the server and the first wireless network to change a setting of the pressure switch.

## Claims

### Claim 1

A system for monitoring operation of a water pump coupled to plumbing, the system comprising:
a pressure switch, comprising:
a printed circuit board, the printed circuit board positioned within a housing;
a power supply in electrical communication with one or more components coupled to the printed circuit board, wherein the power supply is configured to receive electric power from one or more electric power inputs;
a wireless gateway module coupled to the printed circuit board, wherein the wireless gateway module is configured to establish a first wireless connection to a first wireless network, and transmit a message to a remote server over the first wireless network;
a pressure sensor;
a microcontroller coupled to the wireless gateway module, the printed circuit board, the power supply, and the pressure sensor, wherein the microcontroller is configured to execute computer readable instructions, wherein execution of the computer readable instructions cause the microcontroller to:
establish a second wireless connection to communicate with an internet enabled device over a second wireless network;
receive one or more instructions from the internet enabled device over the second wireless connection;
configure the pressure switch to connect to the first wireless network based on the one or more instructions;
receive a signal from the pressure sensor indicative of pressure in at least a portion of the plumbing;
determine the pressure in at least the portion of the plumbing based on the signal from the pressure sensor;
control operation of the water pump based on the pressure;
determine that a fault has occurred in the system;
in response to determining that the fault has occurred in the system, automatically inhibiting operation of the pump without user intervention;
generate the message, wherein the message includes information related to the fault;
establish a connection to the first wireless network; and
send the message to the remote server via the first wireless network; and
the remote server, wherein the remote server is configured to:
receive the message;
store the received message in a file structure associated with the pressure switch;
receive a request from the internet enabled device to access information related to the fault; and
send the information related to the fault to the internet enabled device.

### Claim 2 (depends on 1)

The system of claim 1, wherein the pressure switch is mounted to the pump.

### Claim 3 (depends on 1)

The system of claim 1, wherein the pressure switch is configured to receive a signal indicative of a motor current of the pump.

### Claim 4 (depends on 3)

The system of claim 3, wherein execution of the computer readable instructions further cause the microcontroller to:
determine that a first fault occurred based on the motor current; and
determine that a second fault occurred based on the signal output from the pressure sensor.

### Claim 5 (depends on 1)

The system of claim 1, wherein the housing comprises a base and a cover, the cover comprising at least one through-hole and the base comprising at least one recess.

### Claim 6 (depends on 5)

The system of claim 5, wherein the cover is configured to be securely coupled to the base by a coupling element passing through the at least one through hole and into the at least one recess.

### Claim 7 (depends on 1)

The system of claim 1, wherein the pressure switch further comprises a relay electrically connected between the one or more electric power inputs and the water pump, and wherein execution of the computer readable instructions further cause the microcontroller to:
cause the relay to complete a circuit between the one or more electric power inputs and the water pump in response to pressure in at least the portion of the plumbing being less than a cut-in pressure; and
cause the relay to interrupt the circuit between the one or more electric power inputs and the water pump in response to pressure in at least the portion of the plumbing being greater than a cut-out pressure.

### Claim 8 (depends on 1)

The system of claim 1, wherein the pressure sensor is a pressure transducer.

### Claim 9 (depends on 1)

The system of claim 1, wherein the internet enabled device is a mobile computing device.

### Claim 10 (depends on 1)

The system of claim 1, wherein the power supply is a switched-mode power supply.

### Claim 11 (depends on 1)

The system of claim 1, wherein the wireless gateway module is configured to communicate directly with the internet enabled device.

### Claim 12 (depends on 11)

The system of claim 11, wherein the second wireless connection is a Wi-Fi connection, and wherein execution of the computer readable instructions further cause the microcontroller to:
configure the wireless gateway module to function as a discoverable node for a peer-to-peer Wi-Fi connection for a predetermined time in response to the microcontroller transitioning from an off state to an on state;
receive a request to connect to the node from the internet enabled device; and
in response to the request to connect to the node, establish the second wireless connection with the internet enabled device.

### Claim 13 (depends on 12)

The system of claim 12, wherein the first wireless connection is a Wi-Fi connection, and wherein the wireless gateway module is configured to communicate with a wireless access point in a local area network (LAN) to establish the first wireless connection.

### Claim 14 (depends on 13)

The system of claim 13, wherein execution of the computer readable instructions further cause the microcontroller to:
receive the one or more instructions from an application executed by the internet enabled device over the second wireless connection, wherein the one or more instructions includes an instruction indicating a service set identifier (SSID) associated with the wireless access point in the LAN; and
configure the pressure switch to connect to the first wireless network based on the SSID.

### Claim 15 (depends on 1)

The system of claim 1, wherein execution of the computer readable instructions further cause the microcontroller to receive a command corresponding to a selection made via a user interface presented by the internet enabled device.

### Claim 16 (depends on 15)

The system of claim 15, wherein the command includes at least one instruction to cause the pressure switch to change at least one of a plurality of device settings.

### Claim 17 (depends on 16)

The system of claim 16, wherein the wireless gateway module is configured to receive the command over the first wireless connection.

### Claim 18 (depends on 17)

The system of claim 17, wherein execution of the computer readable instructions further causes the microcontroller to change the at least one of the plurality of device settings based on the command.

### Claim 19 (depends on 1)

The system of claim 1, wherein the remote server is a cloud-based server.

### Claim 20 (depends on 1)

The system of claim 1, wherein execution of the computer readable instructions further cause the microcontroller to:
generate a second message, wherein the second message includes information related to a status of the system; and
send the second message to the remote server via the first wireless network.

### Claim 21 (depends on 1)

The system of claim 1, wherein execution of the computer readable instructions further causes the microcontroller to:
generate a second message, wherein the second message includes information related to a change in a status of the system; and
send the second message to the remote server via the first wireless network.

### Claim 22 (depends on 1)

The system of claim 1, wherein execution of the computer readable instructions further causes the microcontroller to:
generate a second message, wherein the second message includes information indicating that the system requires maintenance; and
send the second message to the remote server via the first wireless network.

### Claim 23 (depends on 1)

The system of claim 1, wherein execution of the computer readable instructions further causes the microcontroller to:
generate a second message, wherein the second message includes a request for maintenance; and
send the second message to the remote server via the first wireless network.

### Claim 24 (depends on 23)

The system of claim 23, wherein the remote server is further configured to send a request for maintenance based on the second message to a service provider automatically without user intervention in response to receiving the second message.

### Claim 25 (depends on 1)

The system of claim 1, wherein execution of the computer readable instructions further causes the microcontroller to:
generate a second message, wherein the second message includes a request for replacement parts; and
send the second message to the remote server via the first wireless network.

### Claim 26 (depends on 25)

The system of claim 25, wherein the remote server is further configured to send a request for replacement parts to a parts supplier automatically without user intervention in response to receiving the second message.

### Claim 27 (depends on 25)

The system of claim 25, wherein the remote server is further configured to send payment information with the request for replacement parts.

### Claim 28 (depends on 1)

The system of claim 1, wherein the second wireless connection is a cellular connection, and the wireless gateway module is further configured to communicate with the remote server using the cellular connection.

### Claim 29 (depends on 1)

The system of claim 1, wherein the pressure switch further comprises a temperature sensor, and wherein the message includes information related to an ambient temperature in the vicinity of the pressure switch based on an output of the temperature sensor.

### Claim 30 (depends on 1)

The system of claim 1, wherein the fault corresponds to a low water condition, and wherein execution of the computer readable instructions further causes the microcontroller to interrupt power to the water pump in response to the fault.

### Claim 31 (depends on 1)

The system of claim 1, wherein execution of the computer readable instructions further causes the microcontroller to implement a short cycle protection delay.

### Claim 32 (depends on 1)

The system of claim 1, wherein the fault corresponds to an overcurrent condition, and wherein execution of the computer readable instructions further causes the microcontroller to interrupt power to the water pump in response to the fault.

### Claim 33 (depends on 1)

The system of claim 1, wherein the fault corresponds to an overpressure condition, wherein execution of the computer readable instructions further causes the microcontroller to interrupt power to the water pump in response to the fault.

### Claim 34 (depends on 1)

The system of claim 1, wherein the remote server is further configured to store up to 50 occurrences of fault conditions.

### Claim 35 (depends on 1)

The system of claim 1, wherein the remote server is further configured to store an installation record for the pressure switch, the installation record comprising at least one of a pump size, a pump type, a pump setting, a casing depth, a well depth, a check valve location, a drawdown, and a pressure switch serial number.

### Claim 36 (depends on 1)

The system of claim 1, wherein the microcontroller, the wireless gateway module, the printed circuit board, the power supply, and the pressure sensor are each disposed within the housing,
the housing further comprising an inlet configured to be mechanically coupled to a component of the plumbing such that the pressure sensor is in fluid communication with the plumbing.

### Claim 37

A method for controlling and monitoring a water pump coupled to plumbing, the method comprising:
disconnecting a first pressure switch from the water pump and the plumbing;
connecting a second pressure switch to the water pump and the plumbing, wherein the second pressure switch comprises:
a printed circuit board, the printed circuit board positioned within a housing;
a power supply in electrical communication with one or more components coupled to the printed circuit board;
a wireless gateway module coupled to the printed circuit board, wherein the wireless gateway module is configured to establish a wireless connection to a first wireless network, and transmit a message to a remote server over the first wireless network;
a pressure sensor;
a microcontroller coupled to the wireless gateway module, the printed circuit board, the power supply, and the pressure sensor;
establishing, using an internet enabled device, a second wireless connection to communicate with the second pressure switch over a second wireless network;
causing the internet enabled device to send one or more instructions that cause the second pressure switch to connect to the first wireless network; and
receiving, using the internet enabled device, a message from a remote server, wherein the message includes information related to a fault that occurred in at least one of the second pressure switch or the water pump, and information indicating that further operation of the water pump is inhibited until the fault is addressed.

### Claim 38

A device for monitoring operation of a water pump configured to increase the water pressure in plumbing associated with a structure, and communicating with a remote server that is configured to receive a message from the device, store the message in a file structure associated with a pressure switch, receive a request from a computing device to access information related to the water pump, and send information related to the water pump to the computing device, the device comprising:
a housing configured to be mechanically coupled to a component of the plumbing;
a power supply positioned within the housing, the power supply configured to be electrically coupled to a power source;
a wireless gateway module positioned within the housing, the wireless gateway module configured to establish a first wireless connection to a first wireless network, and transmit messages to the remote server over the first wireless network;
a pressure sensor positioned within the housing; and
a microcontroller coupled to the power supply, the wireless gateway module, and the pressure sensor, the microcontroller configured to execute computer readable instructions, execution of the computer readable instructions cause the microcontroller to:
establish a second wireless connection to communicate with an internet enabled device over a second wireless network;
receive an instruction from the internet enabled device over the second wireless connection;
configure the device to connect to the first wireless network based on the instruction;
determine a pressure in at least a portion of the plumbing based on a signal received from the pressure sensor;
control operation of the water pump based on the pressure;
generate a first message related to operation of the water pump;
establish a connection to the first wireless network; and
send the first message to the remote server via the first wireless network.

### Claim 39 (depends on 38)

The device of claim 38, wherein the power supply comprises:
a first conductor configured to receive power from the power source;
a second conductor configured to provide power to the water pump; and
an electrical switch coupled to the first conductor and the second conductor, the electrical switch configured to receive a signal from the microcontroller to switch between a first state in which the switch provides an electrical connection between the power source and the water pump, and a second state in which the switch inhibits the electrical connection between the power source and the water pump.

### Claim 40 (depends on 39)

The device of claim 39, wherein execution of the computer readable instructions further causes the microcontroller to:
determine that a fault occurred;
in response to determining that the fault occurred, automatically cause the electrical switch to enter the second state;
inhibit the switch from entering the first state until the fault is addressed;
generate a second message related to the fault; and
send the second message to the remote server via the first wireless network.

### Claim 41 (depends on 38)

The device of claim 38, wherein the housing comprises an inlet configured to be mechanically coupled to a component of the plumbing such that the pressure sensor is in fluid communication with the plumbing such that the weight of the device is supported entirely by plumbing.