Abstract:
A pump system including a motor, a user-interface, and a controller. The user-interface having a single bar graph comprised of light-emitting diodes to provide visual feedback to an operator. The bar graph is used for programming purposes and for providing a motor speed and run duration status to the operator.

Description:
BACKGROUND 
       [0001]    The present invention relates to a user-interface for a pump system. 
       SUMMARY 
       [0002]    Pump systems often include a user-interface for operating a motor of the pump system. Often times the user-interface includes a liquid-crystal display (LCD). However, LCDs are often relatively large and costly. 
         [0003]    In one embodiment, the invention provides a single bar graph comprised of light-emitting diodes to provide visual feedback to an operator. The bar graph is used for programming purposes and for providing a motor speed and run duration status to the operator. 
         [0004]    In another embodiment, the invention provides a pump system comprising a pump housing, a motor connected to the pump housing, a user-interface, and a controller. The user-interface including a plurality of indicators, a speed indicator, a duration indicator, a positive input, a negative input, and a stage input. The controller including a processor and a computer readable memory storing instructions that, when executed by the processor, cause the controller to receive a first input from the stage input, activate the speed indicator, receive a stage speed input from at least one of the positive input and the negative input, the stage speed input representing a selected stage speed, activate at least one of the plurality of indicators indicating the selected stage speed, receive a second input from the stage input, activate the duration indicator, receive a stage duration input from at least one of the positive input and the negative input, the stage duration input representing a selected stage duration, activate at least one of the plurality of lights indicating the selected stage duration, and operate the motor at the selected stage speed for the selected stage duration. 
         [0005]    In another embodiment the invention provides a method of receiving operator instruction for controlling a pump system. The pump system including a pump housing, a motor connected to the pump housing, and a user-interface including a plurality of indicators, a speed indicator, a duration indicator, a positive input, a negative input, and a stage input. The method comprising receiving a first input from the stage input; activating the speed indicator; receiving a stage speed input from at least one of the positive input and the negative input, the stage speed input representing a selected stage speed; activating at least one of the plurality of indicators indicating the selected stage speed; receiving a second input from the stage input; activating the duration indicator; receiving a stage duration input from at least one of the positive input and the negative input, the stage duration input representing a selected stage duration; activating at least one of the plurality of lights indicating the selected stage duration; and operating the motor at the selected stage speed for the selected stage duration. 
         [0006]    Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  illustrates a pool system according to one embodiment of the invention. 
           [0008]      FIG. 2  illustrates a controller of the pool system of  FIG. 1 . 
           [0009]      FIG. 3  illustrates a user-interface of the pool system of  FIG. 1 . 
           [0010]      FIGS. 4   a - 4   c  illustrate an operation of the controller of  FIG. 2 . 
           [0011]      FIG. 5  illustrates an operation of the controller of  FIG. 2 . 
       
    
    
     DETAILED DESCRIPTION 
       [0012]    Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. 
         [0013]      FIG. 1  illustrates a pool or spa system  100  according to a construction. The pool system  100  includes a vessel  105 , a pump system  110 , and a controller  115 . In some constructions, the vessel  105  is a hollow container such as a tub, pool, or vat that holds a fluid. The fluid can be any type of fluid. In some constructions, the fluid is chlorinated water. 
         [0014]    The pump system  110  includes a motor  120 , a fluid pump  125  coupled to the motor  120 , and a fluid agitator  130  located within the fluid pump  135 . In one construction, the motor  120  is a brushless direct-current (BLDC) motor. As is commonly known, BLDC motors include a stator, a permanent magnet rotor, and an electronic commutator. The electronic commutator is electrically connected to a motor controller. The motor controller controls the electronic commutator. The electronic commutator then provides the appropriate electrical energy to the stator in order to rotate the permanent magnet rotor at a desired speed. In other constructions, the motor  120  can be a variety of other types of motors, including but not limited to, a brush direct-current motor, a stepper motor, a synchronous motor, or other DC or AC motors. In some constructions, the motor  120  is a variable speed motor. In other constructions, the motor  120  can be a multi-speed motor or a single speed motor. The fluid agitator  130  is a rotor, such as an impeller or a fan. In operation, the motor  120  rotates the fluid agitator  130  located in the fluid pump  135 . As the fluid agitator  130  rotates, fluid is pumped through the fluid pump  135 . 
         [0015]      FIG. 2  illustrates the controller  115  of the pool system  100 . The controller  115  is electrically and/or communicatively connected to a variety of modules or components of the pool system  100 . For example, the controller  115  is connected to the motor  120  via the motor controller. The controller  115  includes combinations of hardware and software that are operable to, among other things, control the operation of the pool system  100 . 
         [0016]    In some constructions, the controller  115  includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller  115  and pool system  100 . For example, the controller  115  includes, among other things, a processor  150  (e.g., a microprocessor, a microcontroller, or another suitable programmable device) and a memory  155 . In some constructions, the controller  115  is implemented partially or entirely on a semiconductor (e.g., a field-programmable gate array [“FPGA”] semiconductor, microcontroller, or digital signal processor [DSP]) chip. 
         [0017]    The memory  155  includes, for example, a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as read-only memory (“ROM”), random access memory (“RAM”) (e.g., dynamic RAM [“DRAM”], synchronous DRAM [“SDRAM”], etc.), electrically erasable programmable read-only memory (“EEPROM”), flash memory, a hard disk, an SD card, or other suitable magnetic, optical, physical, or electronic memory devices. The processor unit  150  is connected to the memory  155  and executes software instructions that are capable of being stored in a RAM of the memory  155  (e.g., during execution), a ROM of the memory  155  (e.g., on a generally permanent basis), or another non-transitory computer readable medium such as another memory or a disc. Software included in the implementation of the pool system  100  can be stored in the memory  155  of the controller  115 . The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The controller  115  is configured to retrieve from memory and execute, among other things, instructions related to the control processes and methods described herein. In other constructions, the controller  115  includes additional, fewer, or different components. 
         [0018]    The controller  115  receives power from a power supply module  160 . The power supply module  160  supplies a nominal AC or DC voltage to the controller  115  or other components or modules of the pool system  100 . The power supply module  160  is powered by, for example, a power source having nominal line voltages between 110V and 240V AC and frequencies of approximately 50-60 Hz. The power supply module  160  is also configured to supply lower voltages to operate circuits and components within the controller  115  or pool system  100 . In other constructions, the controller  115  or other components and modules within the pool system  100  are powered by one or more batteries or battery packs, or another grid-independent power source (e.g., a generator, a solar panel, etc.). 
         [0019]      FIG. 3  illustrates a construction of a user-interface  200 . The user-interface  200  is electrically coupled to the controller  115 . The user-interface  200  is operable to receive instructions from an operator. The user-interface  200  outputs the instructions to the controller  115 . The controller  115  controls the motor  120  according to the operator instructions. Examples of operator instructions include, but are not limited to, instructing the motor  120  to operate at a selected speed for a selected duration of time (e.g., 1600 RPM for 2 hours). 
         [0020]    The user-interface  200  includes a first stage input  205 , a first stage indicator  210 , a second stage input  215 , a second stage indicator  220 , a third stage input  225 , a third stage indicator  230 , an override input  235 , an override indicator  240 , a positive input  245 , a negative input  250 , a start input  255 , a stop input  260 , a speed indicator  265 , a duration indicator  270 , a plurality of indicators  275 , and an overlay membrane  280 . In some constructions, the first stage input  205 , the second stage input  215 , the third stage input  225 , the override input  235 , the positive input  245 , the negative input  250 , the start input  255 , and the stop input  260  are electrical push-buttons (e.g., pop-switches). In some constructions, the first stage indicator  210 , the second stage indicator  220 , the third stage indicator  230 , the override indicator  240 , a speed indicator  265 , the duration indicator  270 , and the plurality of indicators  275  are lights (e.g., light-emitting diodes [LEDs]). The overlay membrane  280  labels the various indicators and inputs. In some embodiments, the overlay membrane  280  is composed of plastic or a similar material. In other embodiments, the overlay membrane  280  is composed of rubber or a similar material. In the illustrated embodiment, the plurality of indicators  275  is formed into a vertical bar graph. In other embodiments, the plurality of indicators  275  are formed into other visual indication formats, such as, but not limited to, a horizontal bar graph or a circular graph. 
         [0021]    The first stage input  205  and the first stage indicator  210 , along with the positive input  245 , the negative input  250 , the speed indicator  265 , the duration indicator  270 , and the plurality of indicators  275 , are used to set the operating speed and duration of the motor  120  during a first operation stage. The second stage input  215 , and the second stage indicator  220 , along with the positive input  245 , the negative input  250 , the speed indicator  265 , the duration indicator  270 , and the plurality of indicators  275 , are used to set the operating speed and duration of the motor  120  during a second operation stage. The third stage input  225 , and the third stage indicator  230 , along with the positive input  245 , the negative input  250 , the speed indicator  265 , the duration indicator  270 , and the plurality of indicators  275 , are used to set the operating speed and duration of the motor  120  during a third operating stage. 
         [0022]    In operation, an operator begins setting the operating speed and duration of the first stage by activating the first stage input  205 . The first stage indicator  210  will activate indicating to the operator that a first stage is being set. The speed indicator  265  will also activate indicating to the operator that a first stage speed is being set. The operator then uses the positive input  245  and negative input  250  to set the first stage speed. The operator then activates the first stage input  205  a second time. The first stage indicator  210  will remain activated. The speed indicator  265  will deactivate, while the duration indicator  270  will activate indicating to the operator that a first stage duration is being set. The operator then uses the positive input  245  and negative input  250  to set the first stage duration. 
         [0023]    The operator begins setting the operating speed and duration of the second stage by activating the second stage input  215 . The second stage indicator  220  will activate indicating to the operator that a second stage is being set. The speed indicator  265  will also activate indicating to the operator that a second stage speed is being set. The operator then uses the positive input  245  and negative input  250  to set the second stage speed. The operator then activates the second stage input  215  a second time. The second stage indicator  220  will remain activated. The speed indicator  265  will deactivate, while the duration indicator  270  will activate indicating to the operator that a second stage duration is being set. The operator then uses the positive input  245  and negative input  250  to set the second stage duration. 
         [0024]    The operator begins setting the operating speed and duration of the third stage by activating the third stage input  225 . The third stage indicator  230  will activate indicating to the operator that a third stage is being set. The speed indicator  265  will also activate indicating to the operator that a third stage speed is being set. The operator then uses the positive input  245  and negative input  250  to set the third stage speed. The operator then activates the third stage input  225  a second time. The third stage indicator  230  will remain activated. The speed indicator  265  will deactivate, while the duration indicator  270  will activate indicating to the operator that a third stage duration is being set. The operator then uses the positive input  245  and negative input  250  to set the third stage duration. 
         [0025]    In some embodiments, the user-interface  200  includes a single stage input rather than a first stage input  205 , a second stage input  215 , and a third stage input  225 . In such an embodiment, the operator toggles between the various stage setting by activating the single stage input. The controller  115  activates the first stage indicator  210  during setting of the first stage; the second stage indicator  220  during setting of the second stage; and the third stage indicator  230  during setting of the third stage. 
         [0026]    Once the first, second, and third operating stages are set by the operator, the operator activates the start input  255  to begin the operation. Once the operation has begun, the controller  115  operates the motor  120  at the first stage, the second stage, and the third stage in subsequent order. To stop the operation, the operator uses the stop input  260 . In some embodiments, during operation of the motor  120 , the controller  115  will activate the various indicators of the user-interface  200  to display the current operating speed and duration of the motor  120 . 
         [0027]      FIGS. 4   a - 4   d  illustrate an operation  300  for receiving operating instructions for the pump system  110 . The controller  115  receives an input from the first stage input  205  (Step  305 ). The controller activates the first stage indicator  210  and the speed indicator  265  (Step  310 ). The controller  115  receives inputs from at least one of the positive input  245  and negative input  250  (Step  315 ). The controller  115  activates the plurality of indicators  275  indicating the selected first stage speed (Step  320 ). The controller  115  receives an input from the first stage input  205  (Step  325 ). The controller  115  activates the duration indicator  270  (Step  330 ). The controller  115  receives inputs from at least one of the positive input  245  and negative input  250  (Step  335 ). The controller  115  activates the plurality of indicators  275  indicating the selected first stage duration (Step  340 ). 
         [0028]    The controller  115  receives an input from the second stage input  215  (Step  345 ). The controller activates the second stage indicator  220  and the speed indicator  265  (Step  350 ). The controller  115  receives inputs from at least one of the positive input  245  and negative input  250  (Step  355 ). The controller  115  activates the plurality of indicators  275  indicating the selected second stage speed (Step  360 ). The controller  115  receives an input from the second stage input  215  (Step  365 ). The controller  115  activates the duration indicator  270  (Step  370 ). The controller  115  receives inputs from at least one of the positive input  245  and negative input  250  (Step  375 ). The controller  115  activates the plurality of indicators  275  indicating the selected second stage duration (Step  380 ). 
         [0029]    The controller  115  receives an input from the third stage input  225  (Step  385 ). The controller activates the third stage indicator  230  and the speed indicator  265  (Step  390 ). The controller  115  receives inputs from at least one of the positive input  245  and negative input  250  (Step  395 ). The controller  115  activates the plurality of indicators  275  indicating the selected third stage speed (Step  400 ). The controller  115  receives an input from the third stage input  225  (Step  405 ). The controller  115  activates the duration indicator  270  (Step  410 ). The controller  115  receives inputs from at least one of the positive input  245  and negative input  250  (Step  415 ). The controller  115  activates the plurality of indicators  275  indicating the selected third stage duration (Step  420 ). 
         [0030]      FIG. 5  illustrates an operation  500  for operating the pump system  110  based on received operating instructions. The controller  115  receives a start signal from the start input  225  (Step  505 ). The controller  115  operates the motor  120  based on the first stage operating instructions (Step  510 ). The controller  115  determines if a stop signal has been received from the stop input  230  (Step  515 ). If a stop signal has been received, the controller  115  stops operation of the motor  120  (Step  520 ). If a stop signal has not been received, the controller  115  operates the motor  120  based on the second stage operating instructions (Step  525 ). The controller  115  determines if a stop signal has been received from the stop input  230  (Step  530 ). If a stop signal has been received, the operation reverts to Step  520  to stop operation of the motor  120 . If a stop signal has not been received, the controller  115  operates the motor  120  based on the third stage operating instructions (Step  535 ). The controller  115  determines if a stop signal has been received from the stop input  230  (Step  540 ). If a stop signal has been received, the operation reverts to Step  520  to stop operation of the motor  120 . If a stop signal has not been received, the operation reverts to Step  510 . 
         [0031]    In some embodiments, the controller  115  is operable to receive a stop signal at any time and stop operation of the motor  120  once the stop signal has been received. In some embodiments, when the motor operation is stopped after receiving a stop signal, the controller  115  will restart operation of the motor  120  upon receiving a start signal. 
         [0032]    In some embodiments, the user-interface  200  is operable to receive an override operation. The override operation is a one-time operation that interrupts the normal operation. Once the override operation is complete, the controller  115  automatically returns to operating the motor  120  based on the normal operation. The operator sets an override operation by activating the override input  240 . The override indicator  240  will activate indicating to the operator that the override operation is being set. The speed indicator  265  will also activate indicating to the operator that override speed is being set. The operator then uses the positive input  245  and negative input  250  to set the override speed. The operator then activates the override input  235  a second time. The override indicator  240  will remain activated. The speed indicator  265  will deactivate, while the duration indicator  270  will activate indicating to the operator that the override duration is being set. The operator then uses the positive input  245  and negative input  250  to set the override duration. If the motor  120  is currently operating according to the first stage, the second stage, or the third stage, the controller  115  will suspend the operation and operate the motor  120  according the override operation. Once the override operation is complete, the controller  115  will resume operating the motor  120  according to the suspended operation. If the motor  120  is not currently in operation, the controller  115  will operate the motor  120  according to the override operation. 
         [0033]    Thus, the invention provides, among other things, a thin, low-cost user-interface for operating a pump system. Various features and advantages of the invention are set forth in the following claims.