Retrofit Water Pump Control System with Pulse-Emulated Actuation, Runtime-State Recovery, and Dynamic Sensor Processing.

Abstract

The present invention relates to a retrofit network-connected water pump automation and protection system, configured for industrial, commercial, and residential pump management applications. The invention is designed to integrate with existing magnetic contactor-based pump starter panels, including Direct-On-Line (DOL) and Star-Delta systems, through lowvoltage relay-based integration with existing magnetic contactor starter architectures. The invention incorporates a pulse-based electromechanical actuation architecture configured to emulate manual START and STOP push-button operations through predefined relay pulses, thereby enabling non-invasive retrofit automation of existing industrial control panels. The system further includes a memory-based Power-Interruption State Retention Architectureutilizing Non-Volatile Storage (NVS) memory for preserving operational state, remaining timer duration, and runtime information during electrical power interruptionthrough event-triggered non-volatile memory synchronization and temporary capacitor-assisted energy reserve operation, wherein the controller automatically restores operation from the remaining runtime condition after power recovery. The invention additionally comprises a dynamic hybrid sensor abstraction architecture capable of automatically adapting between resistance-based probe sensing systems and UART-based ultrasonic sensing systems through firmware-controlled operational logic. An edge-processing automation engine performs autonomous local decision-making, emergency fault protection, dry-run prevention, overload monitoring, phase fault detection, and offline automation independently of continuous cloud connectivity