Patent Publication Number: US-6993415-B2

Title: Distributed control system for a whirlpool tub

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not Applicable 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to plumbing fixtures, such as spas and whirlpool tubs; and more particularly to control systems for operating the components of the spa or whirlpool tub. 
     2. Description of the Related Art 
     Hydro-massage spas and whirlpool tubs provide a therapeutic massaging action by delivering water through several nozzles in the tub walls to create a circulating flow of turbulent water. The tub water is drawn through a drain to a pump and then is forced outward through the nozzles to create jets of water in the tub. Air can be added to the circulating water at a controlled rate at each nozzle to increase the turbulence and massaging action of the water exiting the nozzles. Often each nozzle can be pivoted to direct its jet of water toward a desired area of the bather&#39;s body. Some nozzles even allow adjustment of the amount of water flow or the amount of air that is mixed with the water. 
     Valves are operated to create a pulsating water flow that provides a massaging effect replicating the rhythmic manipulation of tissue performed by a masseur or masseuse. The water flow can be fed sequentially through a series of jets to provide a progressive stimulation along the bather&#39;s spine which is particularly soothing to the back and neck of an individual. 
     To enhance the bathing experience underwater lamps can be controlled to produce light of varying intensity and color. 
     The typical manufacturer of whirlpool tubs produces a product line comprising a number of models starting with one having very basic functions and continuing to the top of the line model with the full range of functions. The top of the line model enables the bather to activate selected jets and define the flow pattern for different groups of jets. 
     Each whirlpool tub model has a controller to operate the various components, i.e. valves, pumps, heater, lights, etc., in response to signals from an operator control panel usually mounted on the rim of the tub. Because the different models have different combinations of components the controller and operator control panel must be unique to a particular model. This requires that a series of matched controllers and operator control panels be developed for the line of whirlpools. It is desirable to use common components as much as possible on the different whirlpool models as that reduces the number of different components which have to be designed and manufactured. 
     SUMMARY OF THE INVENTION 
     A control system for a plumbing fixture, such as a whirlpool tub, that has a plurality of components which are electrically operated, comprises a main controller and an input controller. The main controller includes a first microprocessor, a first memory connected to the first microprocessor, and a plurality of outputs coupling the first microprocessor to the plurality of components on the plumbing fixture. The input controller comprises an input device by which a plumbing fixture user is able to enter commands for selectively operating the plurality of components. The input device is connected to an input controller that includes a second microprocessor which is connected to a second memory. The second memory stores a first software program for execution by the second microprocessor to process the commands from the input device, and also stores a second software program for execution by the first microprocessor to control the plurality of components. A transfer mechanism is provided to convey the second software program from the first memory to the second memory upon activation of the control system. 
     This configuration of the control system enables only the input controller of the control circuit to be unique for a particular whirlpool model. Only that subassembly contains the devices and software which are customized to a particular whirlpool model. The circuitry of the main controller and the software permanently stored therein are generic and suitable for controlling any of the plurality of whirlpool models. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an isometric view of a whirlpool that incorporates the present invention; and 
         FIG. 2  is a schematic block diagram of a control circuit in the whirlpool. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to  FIG. 1 , a hydro-massage whirlpool  10  includes a tub  12  having a plurality of conventional whirlpool nozzles  14  projecting through an interior side wall  16 . The tub floor has a standard drain opening  18 . One end of the tub has an end wall  20  with a plurality of nozzles  21 ,  22 ,  23 ,  24  and  25  that are positioned in pairs. Four of the nozzles pairs  21 ,  22 ,  23  and  24  are arranged above one another and the fifth pair of nozzles  25  is located horizontally on either side of the fourth pair of nozzles  24 . As will be described, the flow of water through each pair of nozzles  21 – 25  is controlled by a separate valve so that its flow may regulated independently of the other nozzle pairs. 
     A soft cushion  30  is attached to the rim of the tub end wall  20 . The cushion  30  is formed of a outer covering of a vinyl material with a soft filler inside. The cushion  30  has a central cut out section in which a separate removable pillow  32  is located. The pillow  32  has a U-shaped inner pad of resilient material that conforms to the bather&#39;s neck. The pad is covered by a porous fabric membrane to form a rectangular shaped pillow that permits streams of water to pass there through from jets located beneath the pillow. Additional valves independently control the flow of water through the pillow in a pulsating or continuous manner to massage the bather&#39;s neck. 
     A control panel  34  is mounted on the rim of tub  12  and is part of a control circuit  40  shown in  FIG. 2 . Alternatively for whirlpools that mount in an aperture in a bathing deck, the control panel  34  can be located on that deck adjacent the whirlpool. The control panel  34  more particularly is part of an input controller  35  which is electrically coupled to a main controller  42  located remote from the control panel  34  in a separate housing  43  underneath the tub adjacent the valves, pump, and other electrically operated whirlpool components. The control panel  34  is used by the bather to select various functions and components of the whirlpool  10  to activate and that selection is communicated to the main controller  42  which controls operation of those components. 
     The main controller  42  contains a first microcomputer  45  that has a first microprocessor  44  which executes software programs stored within a non-volatile first memory  48 . The first memory  48  also stores data used by those programs. First input/output (I/O) circuits  50  interface sensors, such as a water level sensor  36  mounted in the tub side wall  16  in  FIG. 1 , and other input devices to first microprocessor  44 . The execution of the software program by the first microprocessor  44  produces output signals which are processed by a set of output circuits  52 – 55  to drive components of the whirlpool  10 . One of those output signals is processed by a pump output circuit  52  to control the pump  56  of the whirlpool. A group of other output signals is applied to a set of circuits  53  which operate the valves  57  that control the flow of water through the whirlpool jets. Another output signal from the first microprocessor  44  is applied to a heater control circuit  54 , which controls the heater for the whirlpool tub. Other types of output circuits can be provided, such as light control circuit  55  which receives output signals to govern the operation of the lights  38  within the whirlpool. 
     The main controller  42  processes control commands from the input controller  35  via a communication line  60 . The input controller  35  comprises a user interface  62  on the input panel  34  by which the bather selects different functions to be activated and the intensity or other parameters of the selected function. The user interface  62  provides input commands to a second microcomputer  63  which has a second microprocessor  64 , which executes a program stored within a non-volatile second memory  66  that governs the operation of the input controller  35 . The second microcomputer  63  includes second I/O circuits  68  which interface the second microprocessor  64  to the user interface  62  and the communication line  60 . The second microprocessor  64  responds to the input commands from the user interface  62  by generating control commands which are sent via the communication line  60  to the main controller  42 . The control commands are relayed to the first microprocessor  44 . 
     The main controller  42  also receives operator provided input signals directly from a wireless remote control  70  that is similar to such devices commonly used with consumer electronic equipment. The wireless remote control  70  has a plurality of switches  72  for the various whirlpool functions. The switches  72  are connected to an encoder  74  that produces a control command indicating which of the switches has been activated by the bather. That control command is modulated onto a radio frequency (RF) carrier by a transmitter  76  which produces and transmits a remote control signal  78 . The remote control signal  78  is detected by an RF receiver  80  in the main controller  42  which recovers and applies the control command to an input of the first microprocessor  44 . 
     The main controller  42  is generic to a plurality of different whirlpool models having various combinations of features, functions and components  38 ,  56 – 58 . The first memory  48  on the main controller  42  permanently stores routines for driving and operating all the different components that are used on any of those various whirlpool models. Specifically, the first memory contains software drivers for the different types of pumps, valves, heaters, lights and other devices. Thus, regardless of into which specific whirlpool model the generic main controller  42  is incorporated, it has all of the software routines for driving the specific output devices employed in that model. Similarly, the first memory  48  permanently stores the software routines for processing the input signals received by the first I/O circuits  50  from the sensors, input controller  35 , and the RF receiver  80 . The various input, output and communication routines stored within the memory are generic, being used in a number of different models of whirlpools in which the main controller  42  can be incorporated. 
     In contrast to the generic main controller  42 , the input controller  35  is unique to a specific whirlpool model. In other words, the user interface  62  and other components of the input controller  35  are configured for only the functions utilized in one particular model. The second memory  66  contains the software for processing the signals from the user interface  62  into specific control commands for the available whirlpool functions. Therefore a separate version of the input controller  35  is created for each different whirlpool model. 
     The second memory  66  of the input controller  35  also contains the software program for execution by the first microprocessor  44  on the main controller  42 . This control program also is unique to the particular model of whirlpool tub, as it must be specifically configured to operate the functions and components that are provided in that particular model. Upon the activation of the control circuit  40 , the main controller software program stored within the second memory  66  is transferred from the input controller  35  to the first memory  48  on the main controller  42 . That transfer is carried out by the second microprocessor  64 , sequentially accessing each storage location within the second memory  66  and reading out the corresponding program instruction. Those program instructions are transmitted via communication line  60  to the first microprocessor  44  which sequentially stores the instructions a section of the first memory  48  in the main controller  42 . The activation of the control circuit  40 , which triggers the transfer of the software program, may be the application of electrical power from the building circuits to the whirlpool  10 , activation of a main power button on the input panel  34  by a bather, or some other event which occurs at the commencement of whirlpool use. 
     This transfer of the software stored within the second memory  66  configures the main controller  42  for the particular whirlpool model. As a consequence, only the input controller  35  of the control circuit  40  has to be unique for a particular whirlpool model. The circuitry of the main controller  42  and the software permanently stored therein are generic and suitable for controlling any of the plurality of whirlpool models. However, it will be understood that if a particular whirlpool model does not have a specific component, such as the heater  58 , the corresponding output line from the output control circuits  52 – 55  will be unconnected. This greatly simplifies fabrication of the whirlpool control circuit and reduces the number of different parts which must be manufactured and maintained in inventory. 
     The foregoing description was primarily directed to a preferred embodiment of the invention. Although some attention was given to various alternatives within the scope of the invention, it is anticipated that one skilled in the art will likely realize additional alternatives that are now apparent from disclosure of embodiments of the invention. Accordingly, the scope of the invention should be determined from the following claims and not limited by the above disclosure.