System and method for automating ancillary devices using a motor controller for a pump

• US 9,880,526 B2
• Filed: 05/07/2014
• Issued: 01/30/2018
• Est. Priority Date: 05/07/2014
• Status: Active Grant

• Current Assignee: Regal Beloit America, Inc. (Regal Rexnord Corp.)
• Original Assignee: Regal Beloit America, Inc. (Regal Rexnord Corp.)
• Inventors: Guzelgunler, Yilcan, Kreidler, Jason Jon, O'Brien, Stephen D.
• Primary Examiner(s): Santana, Eduardo Colon
• Assistant Examiner(s): AGARED, GABRIEL T
• Application Number:
  US14/272,010
• Publication Number:
  US 20150323911A1
• Time in Patent Office: 1,364 Days
• Field of Search: 318478
• CPC Class Codes: G05B 11/32 with inputs from more than one sensing element; with outputs to more than one correcting element
• CPC Class Codes: H02P 1/02 Details of starting control

Abstract

A motor controller coupled to a motor for a pump is described. The motor controller is configured to determine a first mode of operation for the motor, based on at least one of a predefined schedule stored by the motor controller and an input signal received by the motor controller from at least one ancillary device. The motor controller is additionally configured to transmit a first control signal to the motor to operate the motor in the first mode, and to transmit a second control signal to change an operation of the at least one ancillary device, wherein the at least one ancillary device includes one or more of a heater, a chlorine generator, and an ozone generator.

Claims

1. A motor controller integrated in a pump motor configured to drive a pump, said motor controller configured to:

determine a first mode of operation for the pump motor, based on at least one of a predefined schedule stored by the motor controller and an input signal received by the motor controller from at least one ancillary device, the at least one ancillary device pertaining to an environment in which the pump motor and pump operate;

transmit a first control signal to the pump motor to operate the pump motor in the first mode;

determine a mode of operation for the at least one ancillary device based on the input signal received from the at least one ancillary device, wherein the at least one ancillary device includes one or more of a heater, a chlorine generator, and an ozone generator; and

transmit a second control signal wirelessly to the at least one ancillary device to change the mode of operation of the at least one ancillary device.

2. The motor controller of claim 1, further configured to transmit at least one of the first control signal and the second control signal with a voltage of at least 24 volts.

3. The motor controller of claim 1, further configured to transmit at least one of the first control signal and the second control signal with a voltage of at least 120 volts.

4. The motor controller of claim 1, further configured to receive a measurement signal from at least one of a temperature sensor, a pressure sensor, and a flow sensor.

5. The motor controller of claim 1, further configured to communicatively couple to at least one of a user interface, a client computing device, and a building automation system.

6. The motor controller of claim 1, wherein the at least one ancillary device is a plurality of ancillary devices and said motor controller is further configured to communicate with the plurality of ancillary devices using serial communication.

7. The motor controller of claim 1, further configured to communicate wirelessly with the at least one ancillary device.

8. The motor controller of claim 1, further configured to selectively operate the motor in one of at least the first mode associated with a first time setting and a first speed setting, and a second mode associated with a second time setting and a second speed setting, and to operate at least one of an intake valve and a return valve based on at least one of the first mode and the second mode.

9. The motor controller of claim 1, further configured to:

receive the input signal from the at least one ancillary device, wherein the input signal indicates a temperature;

determine that the temperature meets a predefined condition; and

transmit the first control signal to the motor based on the determination.

10. The motor controller of claim 9, wherein the at least one ancillary device includes a heater, and wherein said motor controller is further configured to transmit the second control signal to the heater to activate the heater.

11. The motor controller of claim 1, wherein the at least one ancillary device includes a heater, and wherein said motor controller is further configured to:

receive the input signal from the heater; and

transmit the first control signal to the motor based on the received input signal from the heater.

12. The motor controller of claim 1, wherein the at least one ancillary device includes a heater, and wherein said motor controller is further configured to:

receive the input signal from the heater; and

delay a scheduled deactivation of the motor based on the received input signal from the heater.

13. The motor controller of claim 1, wherein the at least one ancillary device includes a heater, and said motor controller is further configured to:

determine that a water temperature has not met a predefined set point; and

cause the motor and the heater to operate past a predefined deactivation time based on the determination.

14. The motor controller of claim 1, wherein the at least one ancillary device includes a plurality of types of heaters, including a solar heater, and said motor controller is further configured to:

receive a measurement signal indicating a temperature associated with the solar heater; and

select one of the plurality of types of heaters for heating water based at least in part on the temperature associated with the solar heater.

15. The motor controller of claim 1, wherein transmitting the second control signal further comprises transmitting the second control signal to the at least one ancillary device.

16. A system comprising:

a pump;

a pump motor coupled to and configured to drive said pump;

a motor controller integrated in said pump motor; and

at least one ancillary device communicatively coupled to said motor controller, said at least one ancillary device pertaining to an environment in which said pump motor and pump operate, wherein said at least one ancillary device includes at least one of a heater, a chlorine generator, and an ozone generator,

wherein said motor controller is configured to;

determine a first mode of operation for said pump motor, based on at least one of a predefined schedule stored by said motor controller and an input signal received by said motor controller from said at least one ancillary device;

transmit a first control signal to said pump motor to operate said pump motor in the first mode;

determine a mode of operation for said at least one ancillary device based on the input signal received from the at least one ancillary device; and

transmit a second control signal wirelessly to said at least one ancillary device to change the mode of operation of said at least one ancillary device.

17. The system of claim 16, wherein said at least one ancillary device is a plurality of ancillary devices and said motor controller is further configured to communicate with said plurality of ancillary devices using serial communication.

18. The system of claim 17, wherein said motor controller and said plurality of ancillary devices are arranged in a star network and said motor controller is configured to operate as a central hub of said star network.

19. The system of claim 17, wherein said motor controller and said plurality of ancillary devices are arranged in a daisy chain network.

20. A method for automating operations of an ancillary device with a motor controller integrated in a pump motor configured to drive a pump, said method comprising:

determining, by the motor controller, a first mode of operation for the pump motor, based on at least one of a predefined schedule stored by the motor controller and an input signal received by the motor controller from the at least one ancillary device, the at least one ancillary device pertaining to an environment in which the pump motor and pump operate;

transmitting, by the motor controller, a first control signal to the pump motor to operate the pump motor in the first mode;

determining, by the motor controller, a mode of operation for the at least one ancillary device based on the input signal received from the at least one ancillary device, wherein the at least one ancillary device includes one or more of a heater, a chlorine generator, and an ozone generator; and

transmitting, by the motor controller, a second control signal wirelessly to the at least one ancillary device to change the mode of operation of the at least one ancillary device.