Patent Abstract:
An electrical control system may include a sensor unit with an attachment mechanism for mounting the sensor unit to a fluid pipe, a fluid flow sensor, and a signal generator configured to generate a signal indicating at least one of whether the flow sensor detects a fluid flow in the fluid pipe or whether the flow sensor detects no fluid flow in the fluid pipe. The system may also include a control unit having one or more of an electrical plug, an electrical socket, an interruptible circuit between the electrical plug and the electrical socket, a receiving device configured to receive the signal from the sensor unit, and a processor configured to interrupt the circuit between the electrical plug and the electrical socket based on at least one of receipt of the signal or interruption of the signal.

Full Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority under 35 U.S.C. 119 to U.S. Provisional Application Ser. No. 62/100,719 filed Jan. 7, 2015, entitled “POWER CONTROL UNIT WITH REMOTE SENSOR,” the entire contents of which are hereby incorporated by reference for all purposes. 
     
    
     BACKGROUND 
       [0002]    The present invention generally relates to means for controlling the electrical power provided to various appliances and equipment based on readings and/or control signals from remote sensors. 
       SUMMARY 
       [0003]    According to first aspects of the invention, an electrical control system may include a sensor unit with an attachment mechanism for mounting the sensor unit to a fluid pipe, a fluid flow sensor, and a signal generator configured to generate a signal indicating at least one of whether the flow sensor detects a fluid flow in the fluid pipe or whether the flow sensor detects no fluid flow in the fluid pipe. The system may also include a control unit having one or more of an electrical plug, an electrical socket, an interruptible circuit between the electrical plug and the electrical socket, a receiving device configured to receive the signal from the sensor unit, and a processor configured to interrupt the circuit between the electrical plug and the electrical socket based on at least one of receipt of the signal or interruption of the signal. 
         [0004]    In embodiments, the fluid flow sensor may include a plurality of permanent magnets and an induction coil. 
         [0005]    In embodiments, the attachment mechanism may include a flange integrally attached to the sensor unit, a gasket and a plurality of clamps configured to fit around the pipe. 
         [0006]    In embodiments, the sensor unit may be configured to transmit the signal via at least one of a wire connected to the sensor unit or via a wireless communication channel. 
         [0007]    In embodiments, the control unit may be further configured to send a signal to a remote device when the circuit is interrupted by the control unit. 
         [0008]    According to further aspects of the invention, an electrical control system may include a sensor unit with a sensor and a signal generator configured to generate a signal based at least in part on readings of the sensor. Systems may also include a control unit having one or more of an electrical input, an electrical output, an interruptible circuit between the electrical input and the electrical outlet, a receiving device configured to receive the signal from the sensor unit, and a mechanism configured to interrupt the circuit between the electrical input and the electrical outlet based on at least one of receipt of the signal or interruption of the signal. 
         [0009]    In embodiments, the sensor may include at least one of a flow sensor, a current sensor, a pH sensor, a pressure sensor, and/or a vacuum sensor. 
         [0010]    In embodiments, the sensor and the control unit may be configured to communicate via a wireless network. 
         [0011]    In embodiments, the electrical input may include a standard electrical plug, such as a Type A or Type B connector, and the electrical outlet may include a corresponding standard electrical receptacle. 
         [0012]    In embodiments, the control unit may be further configured to send a signal to a remote device when the circuit is interrupted by the control unit. 
         [0013]    According to further aspects of the invention, a control unit may be provided including an electrical plug, an electrical receptacle, an interruptible circuit between the electrical plug and the electrical receptacle, a receiving device configured to receive the signal from a remote sensor unit, and/or a processor configured to interrupt the circuit between the electrical plug and the electrical receptacle based on at least one of receipt of the signal or interruption of the signal. 
         [0014]    In embodiments, the remote sensor may include at least one of a flow sensor, a current sensor, a pH sensor, a pressure sensor, and/or a vacuum sensor. 
         [0015]    In embodiments, the control unit may be configured to communicate with the remote sensor via a wireless network. 
         [0016]    In embodiments, the electrical input may include a standard electrical plug, such as a Type A or Type B connector, and the electrical outlet may include a corresponding standard electrical receptacle. 
         [0017]    In embodiments, the control unit may be further configured to send a signal to a remote device when the circuit is interrupted by the control unit. 
         [0018]    According to further aspects of the invention, a sensor unit may be provided including one or more of an attachment mechanism, e.g. for mounting the sensor unit to a fluid pipe, a sensor configured to contact fluid in the pipe when the sensor unit is mounted to the pipe, and a signal generator configured to generate a signal based at least in part on readings of the sensor. In some examples, the sensor may include at least one of a flow sensor, a current sensor, a pH sensor, a pressure sensor, and/or a vacuum sensor. 
         [0019]    In embodiments, the sensor may include at least a flow sensor, and the signal may indicate at least one of whether the flow sensor detects a fluid flow in the pipe or whether the flow sensor detects no fluid flow in the pipe. 
         [0020]    In embodiments, the sensor unit may be configured to communicate with a control unit via a wireless network. 
         [0021]    In embodiments, the sensor unit may be configured to mount to the pipe via a circular hole drilled in the pipe. 
         [0022]    In embodiments, the sensor unit may include a charger electrically connected to at least one of a battery or a capacitor. 
         [0023]    In embodiments, the sensor unit may be at least partially user programmable, e.g. to set parameters by which the signal is generated or interrupted. 
         [0024]    Additional features, advantages, and embodiments of the invention may be set forth or apparent from consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that both the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the invention claimed. The detailed description and the specific examples, however, indicate only preferred embodiments of the invention. Various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]    The accompanying drawings, which are included to provide a further understanding of the invention, are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the detailed description serve to explain the principles of the related technology. No attempt is made to show structural details of technology in more detail than may be necessary for a fundamental understanding of the invention and various ways in which it may be practiced. In the drawings: 
           [0026]      FIG. 1  is a schematic diagram of a flow sensor and control arrangement according to aspects of the invention. 
           [0027]      FIG. 2  is a schematic diagram of a flow sensor arrangement according to aspects of the invention. 
           [0028]      FIG. 3  is a schematic diagram of an electrical current sensor arrangement according to aspects of the invention. 
           [0029]      FIG. 4  is a schematic diagram of a pressure/vacuum sensor according to aspects of the invention. 
           [0030]      FIG. 5  is a schematic diagram of a control unit according to aspects of the invention. 
           [0031]      FIGS. 6 and 7  are side views of a control unit according to aspects of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0032]    It is understood that the invention is not limited to the particular methodology, protocols, etc., described herein, as these may vary as the skilled artisan will recognize. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the invention. It also is to be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “a sensor” is a reference to one or more sensors and equivalents thereof known to those skilled in the art. 
         [0033]    Unless defined otherwise, all technical terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which the invention pertains. The embodiments of the invention and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings and detailed in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of one embodiment may be employed with other embodiments as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well-known components and processing techniques may be omitted so as to not unnecessarily obscure the embodiments of the invention. The examples used herein are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those of skill in the art to practice the embodiments of the invention. Accordingly, the examples and embodiments herein should not be construed as limiting the scope of the invention, which is defined solely by the appended claims and applicable law. 
         [0034]      FIG. 1  is a schematic diagram showing an exemplary layout including a sensor and control unit system according to aspects of the invention. In the example shown in  FIG. 1 , a pipe  110  may be, for example, a water pipe connected to a swimming pool. However, it should be appreciated that the example shown in  FIG. 1 , and other examples described herein, is only one implementation, among many, in which aspects of the invention may be used. A sensor  120  is connected to pipe  110  such that flow or other characteristics/conditions inside of the pipe  110  may be monitored. Sensor  120  is also configured to communicate with a control unit  130 . The communication may be performed, for example, using communication wires, power wires, or by various wireless technologies, such as Bluetooth, WiFi, LAN, WAN or other means. In some examples, control unit  130  may be configured to plug into an electrical outlet, and to have power cords from one or more other devices plugged into the control unit. These may include, for example, standard 2 or 3 prong household outlets and plugs, industrial and multiphase outlets and corresponding plugs, hard-wired points, etc. The control unit  130 , in a basic form, acts as a power bridge between a power outlet and a device that is plugged into the control unit. In the example shown in  FIG. 1 , a device  140  is plugged into control unit  130  and relies on control unit  130  to provide electrical power from an outlet to the device. The device  140  may be, for example, a pump connected to chemical tank  150  that adds chemicals to the water supply flowing in pipe  110 , or any other type of device that may be advantageously disabled under certain conditions sensed by sensor  120 . 
         [0035]    Some examples of how the system in  FIG. 1  may be employed are in the context of water supply systems that routinely add chemicals, such as chlorine to a pool water supply. In such cases, if the flow of water in pipe  110  stops, there can be health risks associated with continuing to add the chemical(s), e.g. building up a dangerous chemical concentration in a small volume of stagnated water. Therefore, the sensor  120  may be configured to detect the flow of water in pipe  110 , and to send a signal to control unit  130  while the flow is active and/or if the flow stops. The control unit  130  may be configured to interrupt the power to device  140  if the signal indicates that the flow in pipe  110  has stopped, and/or if a signal that indicates positive flow is not received. 
         [0036]    It is envisioned that the present subject matter may find applicability in a wide variety of contexts in which the benefits of constant or near constant industrial monitoring are not available, e.g. in household or small business environments. Therefore, another aspect of the invention may include communication between control unit  130  and a remote device  160 , such as a smartphone, smart watch, a tablet computer, etc. This communication link may be provided using various combinations of communication wires, power wires, or various wireless technologies known in the art, such as Bluetooth, WiFi, LAN, WAN or other means. In some examples, the control unit  130  and/or sensor unit  120  may be programmable via an application running on portable computing device, such as remote device  160 . Such programming may include parameters by which signals are generated and/or interrupted by the sensor unit  120 , and/or parameters by which the control unit interrupts the electrical circuit to device  140 . It should be appreciated that the sensor unit  120  may be configured to set a binary signal (e.g. there is or is not a flow), or it can be programmed to send more detailed information (such as rate of flow, pH, etc.) by which logic onboard the control unit  130  may determine whether certain control parameters are met. In some examples, the sensor unit itself may be programmed to read non-binary sensor data and to generate or interrupt the signal to control unit  130  based on comparing the non-binary sensor readings to programmed parameters. 
         [0037]    In some examples, the system may be configured to send an alert to remote device  160  (via SMS message, Bluetooth signal, or various other addressing methods) if the flow in pipe  110  stops, or other condition(s) are met that interrupt the power being provided to device  140 . In this manner, the user of a household system or small business can be quickly and easily alerted to the problem state and can resolve the problem. 
         [0038]    In some examples, since control unit  130  is plugged in to a power outlet, it has all the power necessary to maintain and/or perform intermittent communication with sensor  120  and/or remote device  160 . Control unit  130  may also be configured to provide low-current power to sensor  120 , e.g. via additional power outlets and/or wires. However, in some cases sensor  120  may be battery powered, self-powered, etc. 
         [0039]    In some examples, control unit  130  may also be configured to report to remote device  160  if device  140  is not drawing power, e.g. if the device  140  has shut down due to a malfunction or other control such as running out of chemical in tank  150 . 
         [0040]    Additional non-limiting examples of sensors and control modules according to aspects of the invention are discussed further below with reference to  FIGS. 2-7 . 
         [0041]      FIG. 2  is a schematic diagram of a flow sensor arrangement according to aspects of the invention. As shown in  FIG. 2 , a sensor assembly  200  including a “paddle wheel” of permanent magnets  202  and an induction coil  204  may be partially inserted through a pipe  214  and clamped to the pipe via hose clamps  212  or other means. A gasket  206  around a flange of the sensor assembly  200  may provide a watertight seal between the sensor assembly and the hole in the pipe  214 . Rotation of the magnets  202  may be caused by water flow in the pipe  214  and may generate a signal from the sensor assembly  200  via the induction coil  204  proximate to the permanent magnets  202 . As shown in  FIG. 2 , the signal may be carried over an electrical line  208  to the control unit, or it may be transmitted wirelessly. It should be noted that the output from the sensor assembly  200  may be configured in various ways. For example, a positive flow condition may result in a constant or intermittent signal, the interruption of which can signal a stop in the flow. In some examples, the steady signal may be fully or partially powered by the induction coil  204 . In some examples, a stop in the flow may initiate an independent signal that alerts the control unit. For example, the sensor assembly  200  may have control logic, and a battery, capacitor or other power source in the housing, that responds to the absence of current from the induction coil  204  by initiating a signal. In some examples, the induction coil  204  may be used to charge a battery or capacitor in the housing that are used to power the alert signal. 
         [0042]    The sensor assembly  200  in  FIG. 2  may also include a LED, sound, or other indicator  210  used to support visual or manual inspection, e.g. that lights when flow is detected, that sounds when flow is not detected, and/or changes color, illumination, sound, etc. when the sensor detects a change in flow. 
         [0043]      FIG. 3  is a schematic diagram of multi-purpose sensor assembly  300  according to aspects of the invention. As shown in  FIG. 3 , a sensor assembly  300  including one or more sensor probes  302  may be partially inserted through a pipe  314  and clamped to the pipe via hose clamps  312  or other means. It is noted that the interface between the sensor assembly  300  and the pipe  314  may be standardized such that various sensors can be attached using the same dimension hole or other mounting scheme. A gasket  306  around a flange of the sensor assembly  300  may provide a watertight seal between the sensor assembly  300  and the hole in the pipe  314 . The sensor probes  302  inserted into the pipe, or otherwise positioned to detect the desired condition, may be configured, for example, to detect electrical current, temperature, pH, or various other conditions that may be relevant to the operation of another device such as shown in  FIG. 1 . For example, if a heater or other device is malfunctioning, the sensor in  FIG. 3  may be used as an additional safeguard to shut down the device even when the device&#39;s own safeguards are not working. As shown in  FIG. 3 , the signal may be carried over an electrical line  308  to the control unit, or it may be transmitted wirelessly. It should be noted that the output from the sensor assembly  300  may be configured in various ways, depending on the condition(s) that are being sensed. For example, an electrical current, pH, or chemical level, above a certain threshold may initiate an independent signal that alerts the control unit, or the signal may include non-binary information that is constantly, or periodically, transmitted to the control unit. 
         [0044]    The sensor assembly  300  in  FIG. 3  may also include a LED, sound, or other indicator  310  used to support visual or manual inspection, e.g. that lights when current is detected, that sounds when a certain pH level or range is detected, and/or changes color, illumination, sound, etc. when the sensor detects a change in relevant condition. 
         [0045]      FIG. 4  is a schematic diagram of a pressure/vacuum sensor assembly  400  according to aspects of the invention. As shown in  FIG. 4 , a sensor assembly  400  including one or more pressure/vacuum sensors  402  may be partially inserted through a pipe  414  and clamped to the pipe via hose clamps  412  or other means. As previously mentioned, the interface between the sensor assembly  400  and the pipe  414  may be standardized such that various sensors can be attached using the same dimension hole or other mounting scheme. A gasket  406  around a flange of the sensor assembly  400  may provide a watertight seal between the sensor assembly  400  and the hole in the pipe  414 . As shown in  FIG. 4 , the pressure/vacuum signal may be carried over an electrical line  408  to the control unit, or it may be transmitted wirelessly. The sensor assembly  400  may be configured to send the signal when the pressure/vacuum meets certain criteria and/or the signal may include specific pressure/vacuum information that is constantly, or periodically, transmitted to the control unit. 
         [0046]    It is noted that any of the sensor units described above can include programmable logic, e.g. on a storage device, by which a user can set parameters of the sensor such as ranges or thresholds for sending alert signals to the control unit, signal timing, wireless communication address and/or synchronization information, etc. 
         [0047]      FIG. 5  is a front schematic diagram of a control unit according to aspects of the invention. As shown in  FIG. 5 , the control unit  500  may include a standard electrical receptacle  510  that receives, for example, 2 or 3-prong electrical plugs such as Type A and/or Type B connectors. A plurality of visual or other indicators may be included, e.g. an LED power indicator  502  indicating that the control unit is receiving power, an LED sensor indicator  504  indicating that the control unit is coupled to a sensor unit, an LED alarm indicator  506  indicting that the internal circuit has been interrupted, etc. The control unit  500  may be configured to plug into a standard receptacle, similar to the electrical receptacle  510  that is on the face of the control unit. However, in some embodiments, a control unit may be hard-wired to an electrical power line (e.g. as a replacement wall receptacle) and/or to a device (e.g. permanently connected to the power supply line of the device). Screw  508  may be configured to penetrate the control unit  500  for attachment to a corresponding hole in a wall receptacle. 
         [0048]      FIGS. 6 and 7  are side views of a control unit according to aspects of the invention. As shown in both of these figures, the control unit  600  may include standard electrical plugs  612 , e.g. extending from the back surface of the control unit  600 . Inside of the control unit  600 , an interruptible electrical circuit may be provided between the plugs  612  shown in  FIGS. 6 and 7 , and the female receptacles  610  and/or the receptacles  510  shown in  FIG. 5 . The means by which the circuit(s) are interruptible may take various forms including electrically powered switching elements, breakers, etc. In some examples, the control unit  600  may include a manual switch  616  that disposes the control unit in either of a normally open or normally closed configuration. As such, it may also be possible for the control unit  600  to maintain an interrupted (off) state until a signal is received and/or threshold is detected, and then close the circuit to an “on” state based on the signal or threshold. Such modifications may be advantageous, for example, when a device should be turned on only under certain circumstances, such as a sump flood, etc. 
         [0049]    Individual control units may also include multiple sensor inputs and/or channels by which the control unit can communicate with multiple sensor units. For example, as shown in  FIG. 7 , the control unit may include a plurality (in this case 4) sensor input/power connections  718  with a standardized interface for connecting similar or dissimilar sensors units to the control unit. One or more manual switches  716  may also be provided that alter a configuration associated with one or more of the sensor input/power connections  718 . For example, the switch  716  may alter a mode of the I/O such that a signal activates or deactivates a receptacle  610 , it may turn output power to one or more of the sensor input/power connections  718  on or off, etc. 
         [0050]    The control units shown in  FIGS. 5-7  may include various programmable logic, e.g. on a storage device, by which a user can set parameters regarding any of the sensor units coupled to the control unit, ranges or thresholds for interrupting the internal circuit, query timing, wireless communication address and/or synchronization information, etc. 
         [0051]    In some examples, the control unit shown in  FIGS. 5-7  may also include a wireless communication device by which the control unit can communicate with sensor units and/or with a remote device such as  160  shown in  FIG. 1 . The control unit may be configured to transmit an alert to such a remote device when a circuit is interrupted and/or is closed based on sensor information as described herein. 
         [0052]    In some examples, the control unit, sensors, and/or cables may be watertight and/or resistant to chemicals, humidity, and may be configured/constructed to operate in extreme temperatures, e.g. ranging from 0° F. to 140° F., or as otherwise required. 
         [0053]    Although configurations using standard household electrical connections have been described, it should be understood that the invention is not limited to such configurations, and that control units can be, for example, enlarged and/or expanded for new and specialty installations and/or hard wire installs. 
         [0054]    Additional sensors that detect, for example, water, light, sound, UV and/or IR light, radar, Bluetooth, Wi-Fi, etc. can be implemented with a control unit as described herein. The sensor must simply generate an I/O signal and may be powered by the control unit (e.g. 12 or 24 VAC/VDC). Likewise, additional electronics can be installed in the sensor unit to accommodate various control unit designs such as described herein. 
         [0055]    In some examples, the control unit and/or sensor units may be made from ABS or other plastic and may be be designed as not to require additional bonding and/or grounding devices or connections. 
         [0056]    In some examples, sensor cables may be be shielded from external EMP/EMF according to specific requirements. 
         [0057]    While various embodiments have been described above, it is to be understood that the examples and embodiments described above are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art, and are to be included within the spirit and purview of this application and scope of the appended claims. Therefore, the above description should not be understood as limiting the scope of the invention as defined by the claims.

Technology Classification (CPC): 7