Abstract:
A water treatment system, such as a water softener, is remotely operated and a method of remotely controlling a water treatment system. In a first embodiment, a method of detecting abnormal water usage within a water system associated with a water treatment system is provided. The method includes the steps of monitoring water usage associated with the water treatment system, determining whether the current water usage is above an alarm value, and sending an alarm notice in the event the current water usage is above the alarm value, and automatically taking predetermined action.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. provisional application No. 62/088,636, filed Dec. 7, 2014, the contents of which are incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to water treatment systems in general and, in particular, a water softener which is remotely operated and a method of remotely controlling a water softener. 
       BACKGROUND OF THE INVENTION 
       [0003]    Water softening with ion exchange material, such as resin particles or the like, is well known in the art. During the softening process, typically called the service cycle, the ion exchange resin particles acquire hardness inducing ions from raw water which is being treated, in exchange for soft ions. That is, ions which do not induce hardness to water. After continued contact of the resin particles with hard raw water, the particles ion exchange capacity is considerably diminished and regeneration of the resin particles must be accomplished, conventionally by contacting the resin particles with a brine solution, i.e., an aqueous solution of sodium chloride or potassium chloride or the like, during a regeneration cycle. 
         [0004]    The ion exchange process, which takes place during the regeneration of the ion exchange material, is accomplished in a softener or resin tank of well known construction. A separate brine tank is conventionally used to form brine for use during the regeneration cycle. When regeneration is initiated in the softener system, brine drawn from the brine tank passes through the bed of ion exchange material in the softener tank to reverse the exchange of ions and revitalize the bed by removing hardness inducing ions and replacing them with sodium ions, for example, from the brine. 
         [0005]    As will be appreciated from the above, there is a substantial amount of water flowing into and out of a water softener. In the unlikely event of a leak or rupture within the plumbing in the water softener or in the household system, such as the main water line or the system for distributing the softened water, substantial cost and damage may be incurred if the leakage is not contained. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention provides various embodiments for controlling a water treatment system, such as a water softener. 
         [0007]    In one embodiment, an electronic controller of a water softener is not provided with a web server. The water softener is connected to a remote main server via a LAN, such as the user&#39;s router/modem, or other internet connection. The user&#39;s PC and internet connection, such as a router/modem, may be located at the user softener installation site and, in fact, may be the same internet connection as used by the water softener. However, the user PC and internet connection may be located elsewhere. It will be appreciated that in this embodiment, the user is unable to communicate directly with the water softener via the user&#39;s web browser. Rather, the user&#39;s PC communicates with the remote main server via the user&#39;s web browser, mobile app, etc. to provide the desired user settings for the water softener. In one embodiment, the water softener polls the remote main server for updates from both the main server and from the user. 
         [0008]    The water softener may have a universal serial bus (USB) or other interface to allow a dealer or other individual to connect a PC directly to the water softener for communication with or programming of the water softener, or for downloading of newer software versions. 
         [0009]    Further, the water softener is provided with a valve controller. The valve controller includes a turbine located within a fluid flow path of the water softener, such as the inlet or outlet of the water softener. The turbine turns or rotates proportionally to the rate of fluid flow. An electronic controller such as that provided with the water softener, is capable of monitoring and detecting the rotational speed of the turbine. Thus, it is possible to calculate the flow rate based on monitoring the rotational speed of the turbine. 
         [0010]    The water treatment system of the present invention is also equipped with one or more valves which may be actuated remotely. For example, one or more actuated valves may be located at the water softener inlet or outlet. Alternatively, the actuated valves may be incorporated in a traditional 3-valve type bypass or a traditional push-pull type bypass valve. In addition, or alternatively, one or more actuated valves may be located at the main water line entering the building where the water softener is located. The actuated valves may take various forms. In one embodiment, the actuated valve may be solenoid actuated valve. When a signal is applied to the coil of the solenoid, the valve is actuated to either the closed or open position. When another signal is applied to the solenoid coil, the valve is actuated to the opposite position. U.S. Pat. No. 5,152,321 is an example of a bypass valve and is incorporated herein by reference. 
         [0011]    In another embodiment, the actuated valve is a motorized ball valve. One embodiment of a motorized ball valve is disclosed in U.S. Patent Application Publication No. 2010/0320152, which is incorporated herein by reference. In one embodiment of a motorized ball valve, the valve may have two positions which are 90 degrees apart from one another. A voltage is applied to the motor which rotates the ball valve from the first position to the second position. Upon reaching the second position, the ball valve will reach a switch state change position, which sends a signal to the controller. The controller then removes the voltage applied the motor. Another signal or voltage may be applied to the motor. The voltage will cause the motor to turn, urging the ball valve from the second position to the first position. Alternatively, another signal or voltage, such as one in opposite polarity from the first voltage, may be applied to the motor. The opposite polarity voltage will cause the motor to turn in an opposite direction, urging the ball valve from the second position to the first position. Upon reaching the first position, the ball valve will reach another switch state change position, associated with the first position, activating a switch which sends a signal to the controller. The controller then removes the voltage applied the motor. 
         [0012]    The ball valve may take various forms. The ball valve may provide a fluid passage in the ball resembling a right angle. The right angle fluid passage may be used to provide a shut-off valve. In another embodiment, the fluid passage may resemble a T-shape. The T-shape flow path may provide the function of a bypass valve. For a bypass valve, depending on the application, it may be also advantageous when setting the ball valve to the bypass position for the electronic controller to move the valve rotor to a position to close the inlet or outlet of the softener controller, as appropriate. 
         [0013]    The actuated valves may be hard wired to the controller of the water softener for control thereof. The controller of the water softener may be controlled via a main server located remotely from the water treatment system but via a local Ethernet or WiFi network. Alternatively, the actuated valves may have WiFi capability, allowing the actuated valve to be controlled directly via a WiFi network at the location of the water treatment system. The WiFi system may be integrated with the water treatment system and/or part of an overall household appliance control network. 
         [0014]    It will be appreciated that the phrase personal computer or PC may include other devices, such as, but not intended to be limited thereto, a smart phone, internet tablet and other mobile devices. Further, such devices typically may include a web browser or similar application or feature. The phrases web browser and web server are intended to include other similar applications, respectively. U.S. Patent Application Publication N. 2003/0038839 discloses an example of a method for a web based service and U.S. Patent Application Publication No. 2005/0215244 discloses an example of a device and method for monitoring a meter, and are both incorporated herein by reference. In addition, it will be appreciated that the web server of the main server or the user PC may include an application programming interface for web services to allow application software, mobile application, or desktop widgets, or similar feature, to access the relevant data. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0015]      FIG. 1  is a schematic representation of an automatic water conditioning system of the general type which embodies the present invention, with one or more actuated valves. 
           [0016]      FIG. 2  is a block diagram of a system including a water treatment system in accordance with one embodiment of the present invention. 
           [0017]      FIG. 3  is a block diagram of the water treatment system of  FIG. 2 . 
           [0018]      FIG. 4  depicts a screen shot during a user interaction with the remote main server. 
           [0019]      FIG. 5  is a perspective view of a housing of a rotary valve controller of the softener and an example of an actuated ball valve at the inlet to the housing. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]    To assist in the understanding of the water softener regeneration control system of this invention, a schematic diagram of a water conditioning system of conventional construction as shown in  FIG. 1  will be described. The system  10  is designed to soften water when it is delivered to a residence or business for use during what is typically called the “service cycle” of the system. Periodically the system  10  must be regenerated to restore its softening capability. The system  10  is regenerated by the use of a brine solution during a “regeneration cycle”. The present invention is concerned with the control of the regeneration cycle. 
         [0021]    During a service cycle, raw or hard water is passed through a supply pipe  12  to a control valve  14 . The control valve  14  supplies the raw water through a pipe  16  to a tank  18  which contains a bed of ion exchange resin particles. The raw water passes through the bed of resin and is withdrawn from the tank  18  through an outlet pipe  20 . The water withdrawn through the outlet pipe  20 , which has been softened by contact with the ion exchange resin again passes through the control valve  14  to a service pipe  22 . 
         [0022]    When the ion exchange resin losses its capacity to effectively soften the water passing through it, regeneration is necessary. A regeneration cycle typically includes cycles to backwash and rinse the resin. Those cycles are followed by a brine cycle during which a brine solution flows through the ion exchange resin particles. A timer  24  initiates the brine cycle by actuating the control valve  14  to direct water from the supply pipe  12  through a pipe  26  and aspirator valve  28  to pipe  30 . The flow through pipe  30 , which passes through control valve  14 , is directed by the control valve to outlet pipe  20 . The water from pipe  26  passing through the aspirator valve  28  creates a pressure reduction by Venturi effect in a pipe  32  which extends to near the bottom of a brine tank  34 . Due to the pressure reduction, brine is drawn from the brine tank  34  through the pipe  32  and flows with the water through pipe  30 , control valve  14 , and pipe  20  to the bottom of resin tank  18 . The flow of brine through the ion exchange resin particles removes the hardness creating ions and carries them, with the discharge water, through pipe  16 , control valve  14  to a drain  36 . The flow of water through pipe  26  as controlled by timer  24  is continued long enough to withdraw all of the brine available to the pipe  32  in the brine tank  34 . Thereafter the control valve  14 , stops the flow of water to pipe  26  from pipe  12 , and instead directs it to outlet pipe  20  to backwash the ion exchange resin particles. Prior to the next regeneration cycle, water from the supply pipe  12  is directed by the control valve  14  to the brine tank  34  to create brine for the next regeneration cycle. In accordance with this invention, the softening system  10  also includes a microprocessor control  38  and a water meter  40 . 
         [0023]      FIG. 1  also shows a Wi-Fi actuated valve located at an outlet of the water softener. Alternatively, the Wi-Fi actuated valve may be located elsewhere such as at the inlet of the water softener. A Wi-Fi actuated valve is also shown at the main water inlet. In another embodiment, a Wi-Fi actuated valve is incorporated in a push-pull type bypass valve extending across the inlet and outlet of the water softener. U.S. Pat. No. 9,139,986 discloses one example of a Wi-Fi actuated valve and is incorporated herein by reference. In other embodiments, one or more of the actuated valves may be hardwired to the electronic controller for controlling the actuated valve rather than via a WiFi interface. 
         [0024]      FIG. 2  discloses one example of the present invention. The following reference numerals refer to  FIGS. 2 and 3  and not those of  FIG. 1 . The system includes a water softener system  100 , having an Ethernet port  102  coupled to the Ethernet port  14  of a combination router/modem  16 , via an Ethernet cable  18 . A personal computer  20  includes an Ethernet port  22  coupled to an Ethernet port  24  of the router/modem  16 , via an Ethernet cable  26 . However, this embodiment does not require that the PC  20  couple to the internet via the same LAN or internet interface as the water softener system  100 . The PC  20  includes web browser software capable of retrieving, presenting, and traversing information resources on the World Wide Web. It will be appreciated that the router/modem  16  may be coupled to the water softener system  100  or PC  20  via other interface devices, such as a USB or wireless connection, provided that the water softener system  100  or PC  20  are provided the appropriate corresponding interface, as is known in the art, such as a Wi-Fi adapter  125  ( FIG. 3 ). The modem portion of the router/modem  16  may be a DSL modem or cable modem, or similar device. The combination router/modem  16  is shown as being coupled via a cable  30  to the internet  32 , in a manner as known in the art. The combination router/modem  16  may also be comprised of separate components, rather than the combined system as shown, as is known in the art. 
         [0025]    In the embodiment of  FIG. 2 , the water softener system  100  and router/modem  16  are located at the customer softener installation site. As suggested above, the PC  20  may or may not be located at the customer softener installation site. If the PC  20  is not located at the customer softener installation site, then the router function of the router/modem  16  may not be required. Further, another internet interface, such as a modem, will be required at the location of the PC  20  for coupling the PC  20  to the internet. In addition, a server  40  is shown and is at a location remote from the customer softener installation site. It is not likely, but not necessarily prohibited, that the server  40  and PC  20  would be at the same location. The server  40  is capable of communicating over the internet  32  via a connection  42  which may comprise any one of various methods as known in the art. Further, the server  40  includes web server software capable of delivering content, such as web pages, to a client, such as the PC  20 . The content may be delivery of HTML documents. The server  40  further maintains records  44  of customers with various fields related to the customer data, equipment, and services. In addition, the server  40  may maintain other data  46 , such as data on water hardness in specific locations, data regarding water containments identified in specific locations, and water usage by region or customer. In addition, preferably, the server  40  is associated with one or more URLs which are associated in name with the water treatment system and service provider, to provide a URL more readily recalled by the customer. 
         [0026]      FIG. 3  is a block diagram of one example of the water treatment system  100  of  FIG. 2 . The water softener system  100  is shown to include a water softener  108  coupled to a control system  110 . The control system  110  and water softener  108  may be a unitary system. Alternatively, the control system  110  may be separate from the water softener  108 . In fact, it will be appreciated that the control system  110  might take the form of a personal computer, with the appropriate software installed. The control system  110  includes a controller  112  and communications interface device  114 . The communications interface device  114  may optionally include a WiFi adapter  125 . The controller  110  does not require web server software. 
         [0027]    The controller system  110  includes a port  118  coupled to a port  120  of the water softener  108  via data and control lines  122 . The controller  112  is capable of requesting and storing a local network IP address  124 . The controller  112  or communications interface device  114  includes the MAC address, or similar unique identifier. A label with the unique identifier may be provided on the water treatment system  100 . In any event, the unique identifier is provided with the system to associate the system with the customer. The communication interface device  114  also includes the Ethernet port  102 . 
         [0028]      FIG. 4  depicts a screen shot  200  during a user interaction with the remote main server  40 . The screen shot  200  is shown to include a dashboard user interface  202 . The user interface  202  presents status information  204 , as well as a user preferences interface  206  whereby the user may set various preferences for either of the remote main server  40  or softener controller, some of which may be action to take in the event of detecting certain events. In addition, user interface  202  includes a user commands interface  208  wherein, for example, the user may select or enter commands to be executed promptly. 
         [0029]      FIG. 5  is a perspective view of a housing  250  of a rotary valve controller of the softener. The housing  250  includes an inlet  252  and an outlet  254 . Coupled across the inlet and outlet is a bypass valve  256 . The bypass valve includes an inlet  258  for coupling to untreated water and an outlet  260  for coupling to the treated water service line. The bypass valve  256  includes an example of an actuated ball valve  262  at the inlet  252  to the housing  250 . The ball valve  262  may include a ball (not shown) having a T-shaped fluid passage. The ball valve  262  includes an electric motor  264  and a mechanical and electrical controller  266  for moving the ball to the desired position. It will be appreciated that in the service position, a right angled portion of the T-shaped fluid passage couples the inlet  258  to the inlet  252  and blocks the inlet  258  from the outlet  260 . In a bypass position, the ball is arranged so that the straight portion of the T-shaped fluid passage couples the inlet  258  to the outlet  260  and blocks the inlet  252 . 
         [0030]    The actuated ball valve  262  may be hard wired to the electronic controller of the water softener for control thereof based on predetermined events. The controller of the water softener may be controlled via a main server located remotely from the water treatment system but via a local Ethernet or WiFi network. Alternatively, the actuated ball valve  262  may have WiFi capability, allowing the actuated ball valve  262  to be controlled directly via a WiFi network at the location of the water treatment system. The WiFi system may be integrated with the water treatment system and/or part of an overall household appliance control network. 
         [0031]    The ball valve  262  is also shown to include a handle  268  for manual control of the position of the ball. To operate the handle  268  the ball valve  262  may include a means to disengage the ball from control of the motor  264  and controller  266 . 
         [0032]    It should be apparent to those skilled in the art that what has been described is considered at present to be a preferred embodiment of the system and method. However, in accordance with the patent statutes, changes may be made in the system and method without actually departing from the true spirit and scope of this invention. The appended claims are intended to cover all such changes and modifications which fall within the true spirit and scope of this invention.