Abstract:
Disclosed embodiments of the invention include methods and systems for upgrading an existing irrigation system to increase its sensing and control capability without requiring extensive rewiring. A controller module is installed between an irrigation controller and a zone valve and physically proximate to the irrigation controller without disturbing most of the existing wiring between the irrigation controller and the zone valve. A field module is installed between the controller module and the zone valve without disturbing most of the existing wiring between the irrigation controller and the zone valve. The controller module and field module are the communicatively coupled primarily using the existing wiring. The controller module may encode commands transmitted to the field module and/or decode encoded data transmitted from the field module. The field module may encode data transmitted to the controller module and/or decode encoded commands transmitted from the controller module.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 61/763,415, filed Feb. 11, 2013. The entire contents of the foregoing application is hereby incorporated by reference. 
     
    
     BRIEF DESCRIPTION OF THE FIGURES 
       [0002]      FIG. 1  is a typical existing irrigation sensing and control system  10 . 
         [0003]      FIG. 2  illustrates an improved irrigation sensing and control system  100  in accordance with one embodiment of the invention. 
         [0004]      FIG. 3  illustrates an exemplary controller module in accordance with one embodiment of the invention. 
         [0005]      FIG. 4  illustrates an exemplary field module in accordance with one embodiment of the invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0006]    The invention is directed to the field of irrigation sensing and control. More particularly, the invention is directed to methods and system for improved irrigation sensing and control without requiring extensive rewiring of an existing irrigation system. 
         [0007]    A typical existing irrigation sensing and control system  10  is illustrated in  FIG. 1 . The system  10  includes an irrigation controller  14 , a zone valve  18 , and wiring  16  that enables controller  14  to communicate with zone valve  18 . A substantial expense in the installation of a typical existing irrigation sensing and control system  10  is the installation of wiring. For example, wiring may be laid underneath pavement. Accordingly, one goal of the methods and systems of the present invention is to avoid the requirement for extensive rewiring of an existing irrigation system when expanding control capabilities and/or sensor inputs. 
         [0008]      FIG. 2  illustrates an improved irrigation sensing and control system  100  in accordance with one embodiment of the invention. System  100  includes existing irrigation controller  14 , existing zone valve  18 , and at least portions of wiring  16 . System  100  further includes new elements to enable collection of additional sensor signals and control based on the additional sensor signals. In  FIG. 2 , exemplary system  100  further includes a controller module  110 , a field module  120 , a master valve  180 , and sensor  140 . 
         [0009]    Controller module  110  is added to an irrigation system between zone valve  18  and irrigation controller  14 , relatively near irrigation controller  14  such that most of the original wiring system need not be disturbed. Controller module  110  may require a power supply, such as the 24 VAC power input illustrated in  FIG. 2 . Controller module  110  is coupled to irrigation controller  14  to enable communication of both information and control signals between module  110  and controller  14 . As illustrated in 
         [0010]      FIG. 2 , the communication between module  110  and controller  14  may require multiple sets of wiring between module  110  and controller  14 . 
         [0011]    Field module  120  is also added between irrigation controller  14  and zone valve  18 , and may be located relatively near irrigation zone valve  18  such that most of the original wiring  16  need not be disturbed. Sensor  140  is added to provide additional sensor information and signals that can be used to provide better control of the irrigation system. Master valve  180  is also added to enable improved control of the irrigation system. Sensor  140 , master valve  180 , and zone valve  18  are each coupled to field module  120  to enable communication of information via field module  120  to controller module  110  and controller  14 . Zone valve  18  may be coupled to field module  120  with the existing pair of zone valve wires. Additional pairs of wires may be added to couple field module  120  with the sensor  140  and the master valve  180 . Field module  120  may also enable communication of control signals to master valve  180  and/or zone valve  18 . 
         [0012]    Additional sensors may also be added to system  100  and coupled to field module  120 . In  FIG. 2 , sensor  140  is a flow sensor, but one of ordinary skill will appreciate that other sensors can be used instead of, or in addition to, sensor  140  and can also provide additional sensor information and signals that can be used to provide better control of the irrigation system. 
         [0013]    Controller module  110  and field module  120  are coupled to each other with wiring  16 . Controller module  110  and field module  120  are configured to enable wiring  16  to expand its signal communication capacity to enable new sensor information, such as from sensor  140  and/or master valve  180 , to be communicated by the field module  120  to controller module  110  and new control information to be communicated by controller module  110  to the field module  120 , which may then be communication to sensor  140 , zone valve  18 , and master valve  180 . For example, controller module  110  and field module  120  can each encode and/or decode information communication via wiring  16  thereby significantly expanding the communication capacity of wiring  16 . In particular, controller module  110  can encode information that it sends to field module  120  and decode information it receives from field module  120  thereby significantly expanding the communication capacity of wiring  16 . Similarly, field module  120  can encode information that it sends to controller module  110  and decode information it receives from controller module  110 . Thus, Thus, existing wiring  16  can be used to accommodate a level of communication well beyond its intended capacity. 
         [0014]    One of skill in the art will appreciate that system  100  may further be expanded with one or more additional field modules  120 . Each additional field module  120  could be coupled to its own associated sensor(s) and/or valve(s). Moreover, each field modules  120  could be configured to expand the communication capacity of wiring  16 —by means similar to that used to communicate between controller module  110  and one field module  120 . 
         [0015]    In the following description, exemplary products consistent with embodiments of the invention are described. An exemplary product generally comprises elements added to an existing irrigation system as described. 
         [0016]    This product will utilize existing irrigation zone valve power and common wires as a signal carrier to add sensor inputs and control outputs to retrofit existing irrigation control systems. Variants of this device may also exploit other installed and unused wiring such as telephone wire pairs, coaxial cables, etc. 
         [0017]    These sensor inputs will be used by the irrigation controller to enhance its control capabilities. The primary control input is a rate of flow sensor installed in the irrigation piping but may include (but not limited to):
       soil moisture sensors   water pressure sensors   tank level sensors   wind speed sensors   temperature sensors   speed sensors   or any other analog or digital sensor       
 
         [0025]    Control outputs, typically low voltage electrical switch closures, will affect the change initiated by the controller. The primary control output will operate a solenoid actuated master shut off valve but may alternately start or stop other devices. 
         [0026]    As with the inputs above, additional control outputs may include (but not limited to):
       analog output control signals;   digital control signals; and/or   multiple or additional contact closure outputs       
 
         [0030]    Additional features of an embodiment of the invention may include: 
         [0031]    1. Operational status may be indicated by LEDs, simple indicators, or other interfaces on field module  120  and/or the controller module  110 . Status may be indicated continually, intermittently, or by request. For example, the operation status may show:
       the communications network is operational;   the status of the zone valve  18 ;   the status of the flow sensor  140 ; and/or   the status of the master valve  180         
 
         [0036]    2. Diagnostic feedback may be indicated by LEDs, simple indicators, or other interfaces on field module  120  and/or the controller module  110 . Feedback may be indicated continually, intermittently, or by request. The feedback may show for example:
       Condition of the power supply;   Operation of the processors in each module  110  and  120 ;   Condition of the communication path  16 ;   Condition of zone valve  18  output;   Condition of flow sensor  140  input; and/or   Condition of the master valve  180  output       
 
         [0043]    To further explain this product, the example of a flow sensor and a master shut off valve will be used. 
         [0044]    3. This product will reduce the scope of the work involved in adding a flow sensor input and master valve output to an existing irrigation system by using installed field wiring as a data path. Utilizing the wire path to a zone valve close to the intended flow sensor/master valve location may eliminate significant site work and expense. 
         [0045]    4. This product will generally include two separate modules; a “controller module” that will typically be installed at the existing irrigation controller and a “field module” that will typically be installed at the location of an existing zone control valve (or other similarly wired device) near the intended location of a new sensor and/or a new master valve. 
         [0046]    5. The zone valve, whose power wire and common are used as the data path, may remain operational from the irrigation controller exactly as if it were still conventionally wired. 
         [0047]    6. The flow sensor may report flow rate to the irrigation controller as if it were wired conventionally (with network delays). 
         [0048]    7. The master valve controlled by this device may operate as if it were conventionally wired to the controller (with network delays). 
         [0049]    8. An exemplary controller module  110  in accordance with one embodiment of the invention is illustrated in  FIG. 3 . The Controller Module (CM) may be a circuit board, which may be housed in a NEMA 1 enclosure with external terminal strips. Preferably, it will be installed in a protected location near the irrigation controller. Other types of enclosures may be used. Indicators will be visible from the exterior of the enclosure. For example, LED indicators may be visible through the exterior of the enclosure. Connections will be made, for example, via 5 separate two wire terminal strips labeled by function as follows: 
         [0050]    Terminal 1 ( 11010 ): Input Power—nominal 24 VAC (28.5 to 30 VAC irrigation style) 
         [0051]    Terminal 2 ( 11020 ): Flow Sensor—isolated output to controller flow sensor input 
         [0052]    Terminal 3 ( 11030 ): Master Valve—isolated Input from controller master valve output—Controller MV Common and Controller Master Valve Output 
         [0053]    Note: The “Common” connection for the master valve on the controller may be shared with the “Valve Common”. All the zone valve wires on the project, including the one(s) this device may use as a carrier may be electrically connected both inside the irrigation controller and in the underground field wiring. 
         [0054]    Terminal 4 ( 11040 ): Zone Valve—isolated input from controller zone valve output—Controller Zone Valve Common and Controller Valve Output of zone valve wire that may be used as the carrier. 
         [0055]    Terminal 5 ( 11050 ): Network Output—output to field wires that may be used as signal and power carriers to one or more remote valves, sensors, and field modules; typically Zone Valve wire Zone Common. 
         [0056]    Indicators ( 11060 ), such as LEDs, located adjacent to the wire terminals may indicate operating conditions and aid in diagnostic functions. 
       Exemplary Indicator Function 
       [0000]    
       
         
           
             a. When the Controller Module (CM) is connected to 24 VAC power, a green LED may illuminate to indicate “Power is ON”. On start-up, it may blink in a pre-determined pattern to indicate processor and network status, then remain “ON”. Whenever there is a network transmission, it may blink off and then back on. 
             b. When the CM is receiving flow data an LED adjacent to the flow leads may blink at a rate of once per second. When no flow input is present, the LED may be “OFF.” 
             c. When the irrigation controller activates the Master Valve (MV), a corresponding LED on the CM may illuminate to show “Power to the master valve is ON”. This illumination may read back from the Field Module (FM) to confirm that the signal was received and action initiated. 
             d. When the zone valve output is activated, a corresponding LED on the CM may illuminate to show “Power to the zone valve is ON”. This illumination may read back from the FM to confirm the signal was received and action initiated. 
           
         
       
     
         [0061]    9. An exemplary field module  120  in accordance with one embodiment of the invention is illustrated in  FIG. 4 . The Field Module (FM) may be an epoxy encapsulated circuit board. The field module is designed to be installed in the field, typically below grade in valve boxes or underground pits. 
         [0062]    Connections may be made via 4 pair of color-coded wire leads. The device may also feature indicators ( 12060 ), such as LEDs, adjacent to the pairs of leads to indicate operating conditions and aid in diagnostic functions. The field module may be powered from the controller module over the interconnecting wire path. 
         [0063]    Pair 1 ( 12050 ): Network input—input from field wires being used as carriers: a Blue lead may connect to former Zone Valve wire and Blue/White striped lead may connect to former Zone Common. 
         [0064]    Pair 2 ( 12020 ): Flow Sensor—Input from Flow Sensor—Red (+) and Black (−) 
         [0065]    Pair 3 ( 12030 ): Master Valve—Output to Master Valve—White and Orange to Master Valve Solenoid 
         [0066]    Pair 4 ( 12040 ): Zone Valve—Output to Zone Valve Solenoid—White and Brown to valve replacing wires now used as carriers. 
       Exemplary Indicator Function 
       [0000]    
       
         
           
             a. When power is applied to the CM, a green LED on the Field Module (FM) adjacent to the Network Input leads may illuminate to indicate “Power is ON”. On start-up, it may blink in a predetermined pattern to indicate processor and network status, then remain “ON”. Whenever there is a received network transmission, it may blink off and then back on. 
             b. When flow sensor is active an LED on the FM may blink approximately once per second. When no flow input is present, the LED may be “OFF”. 
             c. When the irrigation controller activates the Master Valve (MV), a corresponding LED on the FM may illuminate to show “Power to the master valve is ON” and the connection to the solenoid is complete. 
             d. When the zone valve output is activated, a corresponding LED on the FM may illuminate to show “Power to the zone valve is ON” and the connection to the solenoid is complete.