Abstract:
An integrated actuator coil and decoder module for use in decoder-based irrigation control systems, and related methods of manufacture and installation, are provided herein. In one implementation, an irrigation control device comprises a body, decoder circuitry located within the body, a coil located within the body and coupled to the decoder circuitry, the coil adapted to develop an electromagnetic flux sufficient to cause actuation of a device controlling irrigation equipment in response to signaling from the decoder circuitry. Also included is an electrical connection coupled to the decoder circuitry and adapted to couple to a control wire path of a decoder-based irrigation control system. The decoder circuitry and the coil are integrated into a single device.

Description:
This application is a continuation of U.S. application Ser. No. 13/332,337 filed Dec. 20, 2011, now U.S. Pat. No. 8,793,025, which is a continuation of U.S. application Ser. No. 12/886,471 filed Sep. 20, 2010, now U.S. Pat. No. 8,108,078, which is a continuation of U.S. application Ser. No. 11/228,413, filed Sep. 15, 2005, now U.S. Pat. No. 7,826,931, all of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to irrigation control devices and more specifically to decoder-based irrigation control system including decoder units for coupling to actuator coil-controlled irrigation equipment. 
     2. Discussion of the Related Art 
     In decoder-based irrigation control systems, an irrigation controller sends signaling along a wire path to which one or more decoder devices are attached. Each decoder device monitors transmissions on the wire path and decodes this signaling to determine when to cause irrigation devices coupled thereto to be activated and deactivated. The decoder module typically includes circuitry formed on a printed circuit board located within a housing. Wiring from the decoder module housing must be coupled to the wiring of the wire path as well as coupled to one or more actuator devices each controlling the opening and closing of an irrigation rotor or valve. In one form, the rotor or valve is operated by a solenoid coil as is well known in the art. Likewise, during installation, the operator must provide and electrically connect two separate devices, a decoder module and an actuator coil module, to each other and to the control wire path.  FIG. 1  illustrates a separate decoder module  102  and a coil unit  104  that are conventionally coupled together. For example, as illustrated in  FIG. 2 , for a solenoid activated rotor assembly  200 , the coil module  104  is coupled (in part by a bracket  212  and retainer  214 ) to the parts of a selector valve assembly  202  (including a pressure regulator) attached to a casing assembly  204 . The electrical wire inputs to the coil module  104  are then connected to the electrical wire outputs from the decoder module  102 , while the electrical wire inputs to the decoder module  102  are coupled to the control wire path from the irrigation controller. Thus, a typical installation requires the connection of six wires to install the decoder module  102  and a coil module  104 . 
     As is well known, in operation, a portion of a plunger (not shown) of the selector valve assembly  202  is disposed within the coil unit  104  while another portion is seated against a solenoid plunge port (not shown) within the selector valve assembly  202  in a normally closed position. In this position, high pressure water flow from a main water control valve (not shown) located within a main control valve portion  206  of the device is flowed up high pressure water line  208  into the selector valve assembly  202  and its regulator and is prevented from further movement by the normally closed position of the plunger against the solenoid port in the selector valve assembly  202 . This results in a back pressure that causes the main water control valve to close. In response to signals from the decoder module  102 , the coil module  104  causes the actuation of the plunger to move it off of (or unseat from) the solenoid plunge port allowing the high pressure flow in the high pressure line  208  to flow through the selector valve assembly  202  (and its pressure regulator), which relieves the back pressure and allows water to flow through the main control valve and to a pop-up sprinkler device, i.e., the main water control valve is opened. The pop-up sprinkler device is located within the casing assembly  204  and extends upwardly due to the water pressure through a top portion of the casing assembly  204 . The high pressure flow exits the selector valve assembly  202  down through a discharge flow line  210  which terminates within the casing assembly  204  at a location downstream of the main water control valve. 
     SUMMARY OF THE INVENTION 
     Several embodiments of the invention provide an integrated actuator coil and decoder module for use in decoder-based irrigation control systems. 
     In one embodiment, the invention can be characterized as an irrigation control device comprising: a body; decoder circuitry located within the body; a coil located within the body and coupled to the decoder circuitry, the coil adapted to develop an electromagnetic flux sufficient to cause actuation of a device controlling irrigation equipment in response to signaling from the decoder circuitry; and an electrical connection coupled to the decoder circuitry and adapted to couple to a control wire path of a decoder-based irrigation control system. The decoder circuitry and the coil are integrated into a single device. 
     In another embodiment, the invention can be characterized as a method of making an irrigation control device comprising the steps of: providing decoder circuitry; providing a coil unit containing a wire coil adapted to develop an electromagnetic flux sufficient to cause actuation of a device that causes opening and closing of an irrigation valve upon the application of an electrical current to the wire coil; coupling an output of the decoder circuitry to an input of the coil unit; inserting the decoder circuitry into a housing such that an electrical connection to the decoder circuitry can be made from outside of the housing; sealing the decoder circuitry within the housing; sealing at least a portion of the coil unit to the housing, whereby forming an integrated device having both the decoder circuitry and the coil unit. 
     In a further embodiment, the invention can be characterized as a method of electrically connecting an irrigation control device to a decoder based irrigation control system comprising the steps of: electrically coupling a first control wire of the decoder based irrigation control system to a first electrical connection of an integrated coil and decoder module; and electrically coupling a second control wire of the decoder based irrigation control system to a second electrical connection of the integrated coil and decoder module. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects, features and advantages of several embodiments of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings. 
         FIG. 1  illustrates a separate sprinkler coil and decoder module for controlling irrigation equipment in a conventional decoder-based irrigation control system. 
         FIG. 2  illustrates a conventional decoder and electric sprinkler application including a separate coil module and decoder module. 
         FIG. 3  illustrates an integrated coil and decoder module for use in a decoder-based irrigation control system in accordance with one embodiment of the invention. 
         FIG. 4  illustrates a decoder and electric sprinkler application including an integrated coil and decoder module in accordance with several embodiments of the invention. 
         FIG. 5  illustrates decoder circuitry and a coil module of the integrated device of  FIG. 3  shown without the decoder housing in accordance with one embodiment of the invention. 
         FIGS. 6A and 6B  illustrate other views of the integrated coil and decoder module of  FIG. 3  in accordance with other embodiments of the invention. 
         FIG. 7  illustrates the decoder housing of one embodiment of the device of  FIG. 3 . 
         FIG. 8  illustrates a coil housing of one embodiment of the device of  FIG. 3  with a partial cutaway showing a wire coil. 
         FIG. 9  is a diagram of a decoder-based irrigation control system including multiple integrated coil and decoder modules according to several embodiments of the invention. 
     
    
    
     Corresponding reference characters indicate corresponding components throughout the several views of the drawings. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention. 
     DETAILED DESCRIPTION 
     The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of exemplary embodiments. The scope of the invention should be determined with reference to the claims. 
     Referring first to  FIG. 3 , a perspective view is shown of an integrated coil and decoder module  300  for use in a decoder-based irrigation control system in accordance with one embodiment of the invention. The integrated coil and decoder module  300  includes a module body  302  (also referred to simply as body  302 ) including a decoder housing  304  (also referred to as a first housing) and a coil housing  306  (also referred to as a second housing, solenoid housing or coil unit). The module  300  also includes electrical connector wires  308  and  310  (also referred to as electrical connections  308  and  310 ) extending from the decoder housing  304 . The decoder housing  304  includes decoder circuitry (e.g., shown in  FIG. 5 ) and the coil housing  306  includes a wire coil or solenoid (e.g., shown in  FIG. 8 ) formed within. Although the decoder housing  304  and the coil housing  306  are separate functional components, they are integrated together to form a single integrated coil and decoder module  300 . 
     Advantageously, since the module  300  is integrated into a single body  302 , an installer need only connect the two electrical connections  308  and  310  to the control wire path of a decoder-based irrigation control system. It is noted that any electrical connections between the decoder circuitry within the decoder housing  304  and the wire coil within the coil housing  306  are already made and sealingly contained within the body  302 . 
     Referring next to  FIG. 4 , a perspective view is shown of a decoder and electric sprinkler application including the integrated coil and decoder module  300  of  FIG. 3 . In this embodiment, in a solenoid activated rotor assembly  400 , the coil housing  306  (or solenoid housing) is coupled (in part by the bracket  212  and the retainer  214 ) to the components of the selector valve assembly  202  attached to the casing assembly  204  (which is typically buried underground or located within a valve box above or below ground). In the illustrated embodiment, the casing assembly  204  contains a pop-up and rotary sprinkler device (not shown). Accordingly, an installation in accordance with this embodiment only involves the connection of two wires (e.g., electrical connections  308  and  310 ) to install the decoder module  300 , as opposed to six wires in the separated decoder module and coil module as illustrated in  FIG. 2 . Thus, with the new module according to several embodiments of the invention, the task of installing a decoder module and coil unit is simplified since there are fewer wires to connect. Additionally, this embodiment provides a space-saving design that is more streamlined and easier to install with less clutter due to excess wires. Furthermore, the installer only needs to provide and install a single integrated device rather than purchasing and providing a separate decoder module and a separate coil housing module. 
     In operation, a portion of a plunger (not shown) of the selector valve assembly  202  is disposed within a core tube (not shown) that extends into the opening of the coil housing  306  about which the coil is wound while another portion of the plunger is seated against a solenoid plunge port (not shown) within the selector valve assembly  202  in a normally closed position (e.g., a spring within the core tube holds the plunger against the solenoid plunge port). In this position, high pressure water flow from a main water control valve (not shown) located within a main control valve portion  206  of the device is flowed up high pressure water line  208  into the selector valve assembly  202  and its regulator and is prevented from further movement by the normally closed position of the plunger against the solenoid port in the selector valve assembly  202 . This results in a back pressure that causes the main water control valve to close. In response to signals from the decoder housing  304  portion of the integrated coil and decoder module  300 , the coil module  306  generates a magnetic field that causes the actuation of the plunger within the core tube to move it off of (or unseat from) the solenoid plunge port allowing the high pressure flow in the high pressure line  208  to flow through the selector valve assembly  202  (and its pressure regulator), which relieves the back pressure and allows water to flow through the main control valve and to a pop-up sprinkler device, i.e., the main water control valve is opened. The high pressure flow exits the selector valve assembly  202  down through a discharge flow line  210  which terminates within the casing assembly  204  at a location downstream of the main water control valve. It is noted that the core tube extends through the bracket  212  and the opening of the coil module  306  such that a portion extends through the back opening of the coil module  306  and back side of the bracket  212 . The retainer  214  is preferably a rubber end cap that is positioned over the portion of the core tube extending therethrough to hold the coil module  306  in position against the bracket  212  and the selector valve assembly  202 . 
     Referring next to  FIG. 5 , a view shown of the decoder circuitry and coil module of the integrated device of  FIG. 3  without the decoder housing in accordance with one embodiment of the invention. Illustrated is a printed circuit board  502  including decoder circuitry  504  formed on or otherwise coupled to or attached to the printed circuit board  502 . Also illustrated are the electrical connections  308  and  310  coupled to the decoder circuitry  504  for connection to the control wire path of the decoder-based irrigation control system, as well as electrical connections  506  and  508  extending from the decoder circuitry  504  into the coil housing  306  to electrically couple the decoder circuitry  504  to the wire coil of the coil housing  306 . It is noted that the decoder circuitry  504 , as well as the coil housing  306  including the coil formed within, are well-known in the art. For example, in one embodiment, the decoder circuitry  504  is found within commercial decoder modules available from the Rain Bird Corp., Glendora, Calif., for example, a single channel, single coil decoder (part number FD-101). Likewise, in one embodiment, the coil housing  306  is commercially available from the Rain Bird Corp., Glendora, Calif., as rotor coil, part number 212165. 
     In accordance with one embodiment, a commercially available coil housing, such as coil housing  306 , is electrically coupled to commercially available decoder circuitry, such as decoder circuitry  504 , via electrical connections  506  and  508 . Such decoder circuitry includes electrical input connections, such as electrical connections  308  and  310  to be coupled to the control wire path of a decoder-based irrigation control system. The decoder circuitry  504  and coil housing  306  are then inserted into a volume (see volume  706  of  FIG. 7 ) formed within a housing, such as the decoder housing  304 , such that the electrical connections  308  and  310  extend through at least one opening formed in the decoder housing  304 . Generally, a portion of the coil housing  306  extends into the volume formed within the housing  304 , while the portion of the coil housing  306  that is adapted to mate to the selector valve assembly  202  extends out of this volume. Next, a sealant material is filled into the remaining volume within the housing  304  in order to hermetically seal the electronic components within the housing as well as to hermetically and rigidly seal the coil housing  306  to the decoder housing  304 . The sealant material may comprise any suitable potting material, such as an epoxy, that is initially in a liquid or fluid state and filled within the volume, and which hardens or cures with time. In other embodiments, other suitable sealants may be applied to the interface between the decoder housing  304  and the coil housing  306  without filling the volume of the decoder housing. Advantageously, the resulting module  300  is an integrated single device in which the decoder circuitry and the coil housing are rigidly fixed to each other and form a single integrated body  302 . This embodiment is easy to construct from commercially available components. However, it is noted that in other embodiments, the coil housing  306  and the decoder housing  304  comprise a single housing that is not required to be coupled or otherwise hermetically sealed to each other. One of ordinary skill in the art could certainly design such a housing. Thus, in such embodiments, the wire coil may be directly electrically coupled to the printed circuit board  502  and the decoder circuitry  504  within the same housing. 
       FIG. 6A  illustrates a perspective view of the integrated coil and decoder module  300  illustrating one embodiment of connection openings  602  and  604  formed in a bottom wall  704  of the decoder housing  304 . In this embodiment, the electrical connections  308  and  310  extend through the openings  602  and  604  as the decoder circuitry  504  is positioned within the housing  304 .  FIG. 6B  illustrates another perspective view of the integrated coil and decoder module  300  illustrating a sealant or potting material  606  filling the interior volume of housing and preventing moisture or other contaminants from entering the housing  304  at the interface between the decoder housing  304  and the coil housing  306  and at the openings  602  and  604 . It is noted that in other embodiments, a single opening (as opposed to the two openings  602  and  604 ), is formed in the decoder housing  304  that any electrical connections extend through, while a suitable sealant or potting material seals the opening. 
     Referring next to  FIG. 7 , a perspective view is shown of the decoder housing  304  of the device of  FIG. 3 . As illustrated, in preferred form the decoder housing  304  has an elongated rectangular parallelepiped geometry formed by side walls  702  and a bottom wall  704 . A top end of the housing  304  is open illustrating a volume  706  formed within and for receiving the decoder circuitry and in some embodiments, at least a portion of the coil housing  306 . It is noted that the shape of the decoder housing  304  may take many forms other than that illustrated. 
     Referring next to  FIG. 8 , a perspective view is shown of the coil housing  306  of the device of  FIG. 3  with a partial cutaway view to show the wire coil. The coil housing  306  includes a coil portion  802  (or solenoid portion) and a neck portion  804 . In preferred form, a portion of the neck portion  804  extends into the volume  706  formed in the decoder housing  304 . However, in other embodiments, coil housing  306  does not extend into the volume but nevertheless is rigidly and sealingly coupled to the decoder housing  306 . The coil portion  802  is preferably cylindrically shaped and formed about an opening  806 . Thus, the coil portion  802  has an outer cylindrical periphery and an inner concentric cylindrical periphery. The coil portion  802  contains a wire coil  808  or solenoid (shown in the partial cutaway view of  FIG. 8 ) wrapping about the inner periphery and sealingly contained within the walls of the coil portion  802 . As is well known in the art, the wire coil  808  wraps about the inner periphery in a coil shape. Upon the application of an electrical current through the wire coil  808 , an electromagnetic flux is formed in the opening  806  of the coil portion  802  about a central axis  810  extending through the opening  806 . This flux is used to actuate a component  812  or device (such as a plunger) typically moveable along the central axis  810  (e.g., along the path of arrow  814 ) within the opening  806  of the coil portion  802  in order to cause the opening or closing of a solenoid actuated irrigation valve (e.g., in one embodiment, by opening a valve of a selector valve assembly  202  controlling the solenoid actuate irrigation valve). In preferred form, the component  812  does not contact the inner surfaces of the coil portion  802  in the opening  806  and is metallic and/or magnetic in order to respond to the generated electromagnetic flux. In one example, the component  812  is a plunger contained within a core tube (not shown) that extends through the opening  806  and is coupled to a selector valve assembly (such as selector valve assembly  202  of  FIG. 4 ). The plunger is held in a normally closed position within the core tube by a spring also within the core tube. Upon the application of current to the wire coil  808 , the plunger is caused to move within the core tube relative to the coil housing  306  (and wire coil  808 ) and the core tube to open the selector valve assembly as described above. One end of the core tube extends through the opening  806  to allow a retainer (such as retainer  214 ) to help hold the coil module or housing  306  in position about the core tube and the selector valve assembly. Such coil housings  306  including the wire coil  806 , as well as core tube and plunger assemblies are well-known in the art. 
     Referring next to  FIG. 9 , one embodiment is shown of a decoder-based irrigation control system  900  including several integrated coil and decoder modules  300  according to several embodiments of the invention. An irrigation controller  902  provides a control wire path  901  extending from the controller  902  into a geographic region where irrigation is desired. The control wire path  901  is typically buried underground. It is understood that multiple separate control wire paths may be output from the controller  902 ; however, for purposes of illustration, only a single control wire path  901  is shown. Typically, the control wire path  901  includes two wires, a power wire  904  and a common wire  906 . A power signal, e.g., 24 volts AC, from the controller  902  is sent on the power line  904  to any connected devices while the common line provides a return to complete the circuit. Generally, the power signal is of sufficient voltage to cause a magnetic flux in the coil housing to open a solenoid activated valve  908 . In other words, the electromagnetic flux is sufficient to control irrigation equipment. In a decoder-based system, the power signal is modulated or encoded with data that is readable by the decoder circuitry as is known in the art so that the controller  902  can control multiple irrigation valves using the single control wire path  901 . 
     At various locations in the field, an integrated coil and decoder module  300  according to several embodiments of the invention is directly coupled to the control wire path  901 . For example, at various locations in the field, the electrical connections  308  and  310  are coupled to the power line  904  and the common line  906 . In one embodiment, the lines and connections are respectively coupled together using twist-on wire connectors and silicon grease to provide water resistant electrical connections. The decoder portion of the integrated coil and decoder module  300  decodes the modulated or encoded power signal on the power line  904  and determines whether or not to provide the power signal (electrical current) to the wire coil of the integrated coil and decoder module  300  (e.g., via electrical connections  506  and  508 ). 
     As described above, the wire coil generates a magnetic flux sufficient to cause device of an actuator or solenoid assembly  912  (e.g., in one embodiment, to actuate a plunger of a selector valve assembly  202 ) to open a normally closed solenoid operated valve  908  (e.g., in one embodiment, a main control valve of a main control valve portion  206 ), which is coupled to a water supply line on one end and to one or more sprinkler devices on the other end. It is noted that in embodiments implemented in a solenoid activated rotor assembly for a pop-up sprinkler device, that a given integrated coil and decoder module couples to a solenoid operated valve  908  that couples to a single sprinkler device; however, that in other embodiments, the solenoid activate valve  908  may be coupled to multiple sprinkler devices. It is further noted that generally, a sprinkler device may be any rotor device, stationary device, drip device, etc. As is known, there may be multiple integrated coil and decoder modules  300  coupled to the control wire path  901  at various locations. Advantageously, according to several embodiments of the invention, by providing integrated coil and decoder modules  300  instead of separate decoder modules and coil units that must be coupled to each other and to the control wire path, the installation process has been simplified by reducing the number of wires than an installer must connect and by providing a more streamlined design at the casing assembly  204 . Additionally, the decoder circuitry and the coil housing form a single rigid and integrated body. 
     While the invention herein disclosed has been described by means of specific embodiments, examples and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.