Compact module with embedded firmware for intelligent monitoring, control, and protection of water pump systems in buildings.

Description

10 Compact module with embedded firmware for intelligent monitoring, control, and protection of water pump systems in buildings. Utility model field

[001] This utility model belongs to the field of automation and electronic control applied to water pumping systems. It relates to the monitoring, protection, automatic activation and deactivation of hydraulic pumps used in residential, commercial and industrial buildings. It also applies to the technical sectors of building sanitation, building automation, water resource management and safety devices for water pumping systems, with emphasis on operational efficiency and the prevention of mechanical or electrical failures in water pumps. Fundamentals of the utility model

[002] Hydraulic pumping systems used in buildings, especially in residential and commercial condominiums, traditionally operate based on manual controls or simple electromechanical automation, such as level floats, timers, or pressure switches. These mechanisms, although functional, have limitations regarding fault diagnosis, operational history recording, and autonomous decision-making capacity.

[003] Some more recent solutions incorporate programmable logic controllers (PLCs) and basic sensors to activate pumps based on pre-established parameters, such as minimum or maximum reservoir levels. However, these systems generally do not offer remote connectivity or continuous supervision with intelligent alert generation, remaining dependent on manual inspection by operators or corrective maintenance after failures occur.

[004] There are also building automation devices that integrate level, flow or pressure sensors, but which are limited to specific functions and do not provide comprehensive system protection or management of anomalies such as overflow, unintended continuous operation or tripped relays. Petition 870260036687, dated 20 / 04 / 2026, page 23 / 33 / 10

[005] Most known solutions do not include automatic pump rotation based on usage time or detected failure criteria, nor do they offer features such as digital hour meter, operating history, offline operation, or native integration with remote monitoring centers.

[006] Thus, although technologies aimed at the automation and operation of hydraulic pumps are already known, there is a lack of integrated, compact and autonomous solutions that bring together multiple sensors, dedicated firmware, diagnostic logic and automatic protection, associated with remote connectivity, characteristics present in the utility model now proposed.

[007] The present invention was motivated by recurring problems encountered in the context of corrective and preventive maintenance of water pumps in buildings, especially in residential condominiums. The applicant, Reinado Alves de Oliveira Bombas ME, has been operating since 1993 in the segment of maintenance of hydraulic pumps, electrical panels and motor rewinding, having accumulated practical experience in more than 300 installations under 24-hour maintenance contracts.

[008] During this trajectory, failures such as air ingress in the pumps, thermal relay tripping, phase failure, motor burnout, improper continuous operation, and lack of water in the lower reservoir were frequently observed. These failures resulted in high maintenance costs, compromised hydraulic infrastructure (especially in installations with PVC piping), and disruptions to the water supply, causing problems for both the company and the residents served.

[009] In response to these difficulties, manual and electromechanical solutions were initially developed, such as the installation of flow switches connected in series to the contactor and local audible alarms. However, these solutions proved ineffective, mainly because they depended on auditory perception in isolated technical environments (such as garages) and because they did not offer any remote notification or fault history.

[010] In the mid-2000s, a prototype system based on a handcrafted electronic board was created, capable of reading electrical faults and triggering signals for the intercom system in condominiums. Although functional, the production cost limited its commercial viability. Subsequently, solutions using PLCs (Programmable Logic Controllers) were tested. Petition 870260036687, dated 20 / 04 / 2026, page 24 / 33 / 10 Programmable Logic Controllers (PLCs) and integration with radio and GSM signals also faced economic and scalability limitations.

[011] Starting in 2023, with the advancement of microcontroller and connectivity technology, the applicant resumed the project in a new format, developing an embedded system with its own firmware, integrated with mobile dashboards and operating in real time. The first prototype of the system was installed in the Spazio Del Mare Building, in Praia Grande / SP, on April 13, 2023. After testing and improvements at more than 40 monitoring points, the system demonstrated high reliability, resulting in the implementation of its own remote monitoring center, currently responsible for supervising 48 devices simultaneously.

[012] The invention now proposed as a utility model consists of a robust, low-cost, and highly efficient solution for the intelligent monitoring of water pump operation, with immediate fault detection and notification, prevention of damage to hydraulic infrastructure, optimization of technical response, and significant reduction in the risk of water shortages in buildings. Its development seeks to fill a relevant technological gap in the sector, promoting operational safety and continuity in building water supply. Brief description of the drawings Figure 1 shows the schematic diagram of the PLC V1.1 board, with power supply, control and drive circuits. Figure 2 shows the relay circuit diagram for the PLC V1.1 board, with its respective protection and activation components. Figure 3 shows the drive circuit of the PLC V1.1 board, with ULN2003A drivers connected to the relays and the microcontroller. Figure 4 shows the silkscreen of the PLC V1.1 board, identifying the components, connectors, and interfaces. Figure 5 shows the soldering face of the PLC V1.1 board, with the layout of the tracks and conductive paths. Figure 6 shows a top view of the assembled PLC V1.1 board, with the components soldered and the ESP32-S3 microcontroller installed. Petition 870260036687, dated 20 / 04 / 2026, page 25 / 33 / 10 Figure 7 shows the bottom view of the PLC V1.1 board, with the printed circuit board traces and solder points visible. Figure 8 shows the silkscreen used for applying solder paste to the PLC V1.1 board. Figure 9 shows the outer casing of the device. Figure 10 shows the interior of the device, with the PLC V1.1 board, the power supply, and the relay responsible for activating and protecting the system. Figures 11 through 19 depict various images of how the invention will function, detailing the ways in which faults in the water pumping system will be detected. Figure 20 shows the invention device already in operation, and how it will be operated. Figure 21 shows the utility model installed on the wall of a property. Figure 22 shows a spreadsheet detailing all aspects of the utility model, such as its technical criteria, how alerts are issued, intelligent thermal protection, and other functionalities. Description of the utility model

[013] The present invention relates to a utility model, consisting of an embedded electronic module for supervision, autonomous protection and operational control of hydraulic pumping systems in building structures, with main application in residential and commercial condominiums and industrial facilities that require continuous and safe operation of water pumps.

[014] The model was developed to correct operational and maintenance deficiencies in conventional systems, preventing critical failures, motor burnouts and flooding, eliminating manual inspections and enabling preventive automation with autonomous response. It is a single technical-functional and physical unit, as determined by art. 23 of the LPI, materialized by a compact module that integrates dedicated hardware, embedded firmware and cloud connectivity, mounted in a single hermetic enclosure.

[015] With regard to the Physical Structure and Body Unit, it is worth noting that the device is housed in a hermetically sealed black ABS polycarbonate casing with standardized dimensions of 32 cm x 17 cm x 8 cm, resistant to dust, moisture and splashes, allowing Petition 870260036687, dated 04 / 20 / 2026, page 26 / 33 / 10 installation in hostile environments such as pump houses, basements, garages and pumping stations.

[016] Inside the enclosure is the PLC V1.1 electronic board, built on a multilayer printed circuit board with an optimized layout, integrating all the elements necessary for the system's operation. The main components include:

[017] ESP32-S3 Microcontroller (44 pins, standard Lolin package, connected by two 22-pin headers, modularly replaceable);

[018] 6 electromechanical relays G5LE-1 SPDT 24VDC, driven by ULN2003 driver (SOIC-16) for switching the pumps;

[019] 9 PC817 (SOP-4) optocouplers for electrical isolation and reading signals from sensors (level, flow, electrical fault, overflow);

[020] LM2596S-5 regulator associated with SS310 diodes, Low ESR capacitors (100 pF and 470 pF), 100 μH inductors, resistors and ceramic decoupling capacitors (100nF / 24V package 0805);

[021] Indicator LEDs (15 green SMD 0805 and 6 green 3 mm LEDs) and 5V piezoelectric buzzer (12 x 9.5 mm) for visual and audible alerts;

[022] SPST tactile key for manual reset;

[023] 75W (24VDC / 3A) dual-voltage switched-mode power supply for system power supply;

[024] Sonoff relay or Wi-Fi circuit breaker for remote shutdown, reset and lockout of operation in critical faults.

[025] Regarding Firmware and Operational Functionalities, the firmware, written in C++ and embedded in the ESP32-S3 microcontroller, is responsible for autonomously and continuously executing the supervision and control routines, which include:

[026] Reading of level sensors (upper and lower tank), flow, overflow, electrical fault (missing phase or tripped circuit breaker) and thermal fault;

[027] Automatic activation and deactivation of pumps according to pre-programmed parameters;

[028] Automatic switching between pumps based on accumulated operating time or fault detection;

[029] Digital hour meter with daily and total operating log; Petition 870260036687, dated 20 / 04 / 2026, page 27 / 33 / 10

[030] Detection of air ingress by analysis of interrupted or anomalous flow;

[031] Local storage of events and operational data in non-volatile memory, ensuring offline operation;

[032] Issuance of local alerts (LEDs, buzzer) and remote alerts (via internet);

[033] Communication with monitoring platforms (Blynk) and remote control (eWeLink), via MQTT or HTTPS protocol, for viewing on dashboards and triggering commands via application or browser.

[034] Furthermore, Integration with Platforms and Remote Monitoring is structured as follows:

[035] Blynk Platform: monitors water level, flow, hour meter, relay status, event history, alerts and offline mode in real time, allowing manual activation or remote reversal of pumps.

[036] eWeLink platform: remotely manages the Sonoff relay or Wi-Fi circuit breaker for emergency shutdown, reset, or operation lockout.

[037] The system is cryptographically secure and allows intervention from any location with internet access, eliminating the need for immediate physical travel in case of failures.

[038] No less important, regarding applications and usage scenarios, the device is designed for simple installation and integration into existing hydraulic systems, without structural modifications. It is applicable to:

[039] Vertical and horizontal condominiums;

[040] Pumping and drainage stations;

[041] Supply systems requiring redundancy;

[042] Buildings with a history of recurring hydraulic failures;

[043] Sewage pumping and water treatment stations.

[044] Regarding Technical Advantages and Benefits, the invention provides:

[045] Preventive automation with autonomous response;

[046] Reducing the risk of pump burnouts and flooding;

[047] Elimination of routine manual inspections;

[048] Continuous technical control and real-time monitoring;

[049] Low replication cost and simplified installation; Petition 870260036687, dated 20 / 04 / 2026, page 28 / 33 / 10

[050] Greater water security and reduced operating costs.

[051] Furthermore, the Technical-Functional Unit and Descriptive Sufficiency can be described as follows: the model is characterized by constituting a single technical-functional body, composed of a single three-dimensional structure (PLC V1.1 board with all components integrated into a single enclosure), whose operation is coordinated by embedded firmware, exclusively performing the function of supervision, control and protection of water pumps.

[052] All the essential information for a technician in the field (in the areas of electronics, building automation or hydraulic systems maintenance) to reproduce the invention has been described here in a complete and sufficient manner, as required by art. 24 of the LPI, enabling its execution without additional inventive effort. Examples of implementations of the utility model

[053] The preferred embodiment of the utility model object of the present invention consists in the assembly of an embedded electronic module, structured from the PLC V1.1 controller board, developed specifically for the supervision, protection and automation of water pumps in building systems.

[054] This configuration is practically applied in environments such as pump rooms in residential, commercial and industrial buildings, featuring simplified installation and immediate operation after initial parameterization.

[055] The PLC V1.1 board is internally mounted in a hermetically sealed polycarbonate enclosure with IP65 protection rating, containing all integrated electronic elements, including:

[056] ESP32-S3 microcontroller;

[057] ULN2003 Driver;

[058] G5LE-1 SPDT 24VDC Relays;

[059] LM2596S-5 regulator;

[060] 24V switched-mode power supply;

[061] Pluggable connectors;

[062] 5V piezoelectric buzzer;

[063] Indicator LEDs;

[064] Optocoupler sensors; Petition 870260036687, dated 20 / 04 / 2026, page 29 / 33 / 10

[065] Resistors, capacitors and protection diodes;

[066] 22-way double pin headers;

[067] Other components specified in the Bill of Materials (BoM).

[068] All embedded logic is operated by firmware developed in C++ language, with its own communication protocols and support for Wi-Fi connectivity.

[069] The system is powered by an internal 75W switched-mode power supply, which stabilizes the 24V voltage for the power and logic circuits. Protection and remote control are performed by a Sonoff smart relay or compatible Wi-Fi circuit breaker, integrated into the eWeLink platform, allowing emergency shutdowns and remote restarts with full compatibility with a mobile app.

[070] Operational supervision is complemented by a remote interface on the Blynk platform, which enables:

[071] Real-time visualization of sensors (level, flow, thermal fault, etc.);

[072] Access to historical failure records;

[073] Digital hour meter;

[074] Automatic and manual drives;

[075] Sending test commands;

[076] Receiving alert notifications.

[077] The system operates in both online and offline modes, maintaining a queue of events for later transmission, ensuring continuous operation even in environments with unstable connectivity.

[078] The present invention has already been implemented in the field in different scenarios, such as:

[079] Spazio Del Mare Building (Praia Grande / SP) - installation for monitoring two main pumps and one reserve pump, with level sensors installed in the upper and lower reservoirs.

[080] Horizontal condominiums - application with variations in hydraulic topology, using only part of the system's relay and sensor capacity, while preserving the complete embedded logic. Petition 870260036687, dated 20 / 04 / 2026, page 30 / 33 / 10

[081] Integration with existing electrical panels - coupling without the need for structural changes, made possible by pluggable connectors and parameterization system via application.

[082] Respecting the technical-functional unity of the model, the following constructive variations are permitted:

[083] Replacing the Sonoff relay with a Wi-Fi circuit breaker from another brand, provided it is compatible with MQTT or similar protocols;

[084] Addition of I / O expansion modules via I2C or GPIO bus for reading additional sensors, while maintaining embedded integration;

[085] Altering the enclosure to a horizontal or vertical format, without modifying the internal functional assembly;

[086] Inclusion of an LCD display integrated into the housing cover for local reading of operating states.

[087] All these variations preserve the bodily and functional unity of the model, being mere constructive adaptations that do not detract from the central function of the invention: embedded control and protection of water pumps in building environments.

[088] As required by article 32 of Law No. 9,279 / 1996 (LPI) and INPI Resolution No. 93 / 2013, it is declared that all technical, structural and functional information considered essential to the understanding and patentability of this utility model has been fully described in this descriptive report, prior to the formal request for examination using service codes 204 or 285.

[089] This document was prepared in full compliance with the principles of clarity, precision and descriptive sufficiency, with the aim of enabling a person skilled in the art as defined in Article 24 of the LPI to understand and reproduce the invention in its entirety, using the technical resources normally available in the sector. The following were included:

[090] A comprehensive description of the proposed technical object, with functional and structural details of the system;

[091] Identification of all electronic and logic components, including microcontroller, relays, sensors, drivers, LEDs, buzzer, connectors, power supply, safety devices and PLC V1.1 board; Petition 870260036687, dated 20 / 04 / 2026, page 31 / 33 / 10

[092] A description of the embedded firmware, its language (C++), the main routines and the operating logic;

[093] The processes of connecting, disconnecting, protecting, monitoring and remote communication (via Blynk and eWeLink);

[094] Preferred implementation methods, construction variations, integration with monitoring centers and practical applications;

[095] And also, the technical and functional comparison with the state of the art, demonstrating the advantages of the proposed model.

[096] Therefore, it will not be necessary to subsequently insert additional information to ensure the sufficiency of the application, under penalty of direct affront to the provisions of article 32 of the LPI, which prohibits the expansion of the technical scope after the examination request, and any subsequent supplementation of the content that serves as a basis for evaluating the novelty, inventive activity or industrial application of the claimed subject matter is prohibited.

[097] Thus, it is recorded that the present application was drafted in such a way as to unequivocally and completely cover all the elements necessary for the legal protection of the utility model, with no omissions that compromise its understanding, execution or legal assessment. Petition 870260036687, dated 20 / 04 / 2026, pp. 32 / 33

Claims

1 / 3 CLAIMS 1. EMBEDDED ELECTRONIC MODULE FOR SUPERVISION AND PROTECTION OF WATER PUMPS IN BUILDING PUMPING SYSTEMS, characterized by being developed to operate in conjunction with an intelligent dashboard composed of multiple configurable templates, allowing remote interaction through analog commands integrated into a real-time monitoring center, intended for supervision, detection and protection against operational anomalies during the operation of water pumps, including failures due to air intake detected by flow sensors coupled to the piping, overflow from the upper reservoir, absence of water in the lower reservoir, improper continuous operation, leaks, wear due to inadequate flow, tripping of overcurrent relay and phase failure, having a modular architecture compatible with pre-existing hydraulic systems without the need for structural replacements,comprising automatic pump switching with each activation via the control panel, precise accounting of operating time by onboard hour meter, real-time alert issuance, operation independent of internet connection with maintenance of local control and offline mode signaling on the dashboard, integration of physical sensors with embedded logic in firmware that allows autonomous identification of said anomalies and remote replacement of the defective pump by reversing the activation via the dashboard, activating a reserve pump, notifying the maintenance team and ensuring continuity of supply, also equipped with safety shutdown features, issuance of instant alerts to the 24-hour monitoring center, compatibility with mobile systems and a customized dashboard for remote viewing, control and intervention. Petition 870260036687, dated 04 / 20 / 2026, page 19 / 33 2 / 3, 2. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by having a modular architecture compatible with pre-existing hydraulic systems, eliminating the need for structural replacements and reducing implementation costs.

3. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by comprising automatic switching between pumps so that a different pump operates with each activation, ensuring balance in usage time.

4. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by operating independently of an internet connection, maintaining control of the pumps in offline mode and indicating this condition on the dashboard.

5. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by being integrated with firmware developed in C++ language for executing supervision and protection routines, sensor analysis, and autonomous actuation on relays.

6. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by having an automatic shutdown function in case of thermal failure, lack of water or detection of improper continuous operation.

7. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by recording operational events in memory and organizing alerts in a queue for later sending when the internet connection is restored.

8. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by emitting local and remote alerts in real time, including via mobile devices, without the need for constant human intervention. Petition 870260036687, dated 04 / 20 / 2026, page 20 / 33 3 / 3 9. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by comprising a customized dashboard for remote viewing, control and intervention via mobile devices.

10. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by integrating physical sensors for level, flow, electric current, temperature, drainage and presence of air, connected to embedded firmware for autonomous decision making.

11. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by being equipped with an embedded hour meter for precise accounting of the operating time of the pumps.

12. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by comprising a dedicated system for monitoring drainage in buildings with basements and high water tables, including overflow alarms.

13. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by including a buzzer for acoustic signaling and LEDs for visual signaling of critical events.

14. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by having a ULN2003 driver for relay actuation and PC817 optocouplers for electrical isolation and circuit protection.

15. EMBEDDED ELECTRONIC MODULE, according to claim 1, characterized by being powered by a circuit based on an LM2596S5 regulator, with capacitors, inductors and protection diodes, ensuring voltage stability. Petition 870260036687, dated 04 / 20 / 2026, page 21 / 33

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