Wireless Pump Controller for Fault Detection and Remote Monitoring
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Solution Overview
Problem
Existing pump control systems for well water systems lack effective monitoring and notification capabilities, leading to delayed detection of faults and potential compromise of connected systems like hot water heaters and sprinkler systems, as they are often costly, difficult to install, and incapable of remote alerts or fault diagnosis.
Innovation Solution
A pressure switch system with a printed circuit board, wireless gateway module, and microcontroller that establishes wireless connections to remote servers and internet-enabled devices, allowing for real-time monitoring, fault detection, and automatic notification of issues, enabling remote control and maintenance requests.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a robust pump control system with remote monitoring capabilities is implemented, then fault detection and notification capability is improved, but system cost and installation complexity increases
Solution Approach 1:
The patent introduces a wireless communication module as an intermediary component that enables remote fault notification without requiring complex wired connections. This module receives fault signals from the pressure switch and transmits them via wireless networks (WiFi, cellular, LoRaWAN) to remote servers or mobile devices, thereby improving reliability while avoiding the installation complexity of extensive wiring infrastructure.
Solution Approach 2:
The patent replaces traditional mechanical fault indication methods (such as physical dials, mechanical indicators, or wired alarm systems) with electronic and wireless communication systems. The pressure switch incorporates electronic sensors and microcontrollers that automatically detect faults and transmit digital signals remotely, eliminating the need for complex mechanical monitoring systems while enhancing fault detection capability.
2Reliability
If automatic fault inhibition is implemented, then system reliability is improved, but loss of time for system recovery increases
Solution Approach 1:
The patent implements a feedback mechanism where the wireless communication module continuously monitors system status and provides real-time information to remote users. When a fault occurs, the system automatically inhibits the pump and sends a notification with diagnostic information. The feedback loop allows users to receive detailed fault information and take appropriate actions, reducing the time needed for system recovery while maintaining reliability through automatic protection.
Solution Approach 2:
The patent enables preliminary actions by providing advance notification of faults before they cause severe damage. The system detects early signs of problems, sends alerts to users, and allows them to prepare for maintenance or replacement of components. This preliminary warning system reduces the overall downtime by enabling proactive maintenance scheduling and avoiding catastrophic failures that would require extended repair times.
3Ease of operation
If remote monitoring capabilities are added, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The patent implements multi-functionality by designing the wireless communication module to handle multiple communication protocols and functions through a single integrated component. The module can operate with different network types (WiFi, cellular, LoRaWAN), support various notification methods (SMS, email, push notifications), and provide both monitoring and control functions. This universal approach improves ease of operation while minimizing the increase in device complexity by consolidating multiple functions into one component.
Data Source
AI summary
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.