Modular Wireless Pump Motor Control With Split Control Boards

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Solution Overview

Problem

Existing pool and spa pump systems lack efficient wireless communication and control capabilities, limiting user interaction and flexibility in operation, with electronic controllers often requiring physical proximity and lacking modular upgrade options.

Innovation Solution

A control system is divided into a first control board outside the pump motor housing for wireless communication and a second board inside for motor control, enabling wireless user input processing and system-level command translation, allowing modular replacement of the external board without affecting the internal safety and certified components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If electronic controllers are located adjacent the electric motors (mounted within a wall box), then the control system can regulate pump operation and control motor speed, but user interaction requires physical proximity and the system lacks wireless communication capabilities

Engineering Contradiction:

Improveuser interactionVSAvoidcontrol system structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The control system is divided into two separate modules: a first control board with wireless communication capabilities located outside the motor housing, and a second control board inside the housing that interfaces with the motor. This segmentation allows users to interact with the system wirelessly from a distance while maintaining the existing motor control functionality.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If the control system is integrated within the pump motor housing, then the system is compact and certified for safety, but the controller cannot be easily upgraded or replaced

Engineering Contradiction:

Improvemodular upgrade capabilityVSAvoidsafety certification

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

By separating the control system into an external first control board and an internal second control board, the patent enables independent replacement and upgrading of the external board without affecting the certified internal components. The internal second control board remains within the housing maintaining safety certifications, while the external board can be upgraded independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wireless communication and user interface functions are extracted from the motor housing into a separate external control board. This allows the external board to be removed, replaced, or upgraded without impacting the internal motor control system that maintains safety certifications.

Inventive Principle:

Principle #2Taking out (Extraction)

3Device complexity

If a single integrated control board is used, then the system structure is simple, but wireless communication and motor control cannot be physically separated

Engineering Contradiction:

Improvecontrol board configurationVSAvoidwireless control capability

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The control system is divided into two separate control boards: the first control board handles wireless communication and user input externally, while the second control board manages motor control internally. This segmentation enables both wireless control capability and simplified motor control architecture to coexist.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second control board inside the housing acts as an intermediary between the external first control board and the motor. It receives control signals from the external board via wired connection and executes motor control, thereby enabling wireless control capability while maintaining a simple internal control structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Adaptability or versatility

If the control system requires physical proximity for operation, then wireless communication infrastructure is not needed, but user flexibility and remote operation are limited

Engineering Contradiction:

Improveremote operation capabilityVSAvoidwireless communication energy consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The control system separates wireless communication functions (first control board) from motor control functions (second control board). The external first control board handles wireless communication only when needed for user interaction, while the internal second control board manages continuous motor control, thereby enabling remote operation while minimizing unnecessary energy consumption from wireless communication.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12523218B2Systems and methods for wireless control of a pump motor

Publication Date: 2026.01.13 REGAL BELOIT AMERICA INC

AI summary

A control system for a pump motor includes a first portion disposed outside a housing of the pump motor. The first portion may include a wireless communication interface and a processor. In some embodiments, the processor of the first portion is configured to control the wireless communication interface to receive a user input from a user device, and generate a control signal in response to receiving the user input. The control system also includes a second portion physically separate from the first portion and communicatively coupled to the first portion. The second portion may include a processor configured to receive the control signal from the first portion, and control the pump motor in response to receiving the control signal.