MOTOR LEAKAGE CURRENT DETECTOR, DEVICES USING SAME AND RELATED METHODS
20220025894 · 2022-01-27
Inventors
- Philip Anthony Mayleben (Burlington, KY, US)
- Thomas Kent Flippin (Cincinnati, OH, US)
- Cristian Codreanu (Chicago, IL, US)
Cpc classification
F04D13/0693
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02H11/005
ELECTRICITY
F04D15/0088
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
G01R31/52
PHYSICS
G08B21/182
PHYSICS
H02P29/032
ELECTRICITY
F04D15/0263
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D27/001
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F04D27/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
G01R31/52
PHYSICS
G06K7/14
PHYSICS
Abstract
A motor leakage current detector and/or a heat compensating circuit, devices using same and related methods are disclosed herein. Included are a uniquely wired current transformer to allow for polarity agnostic leakage current detection, a leakage current detector using same and having a notifier to alert a user. In other forms, an accessory power cord and power strip are disclosed capable of detecting early motor failure conditions. In still other forms, other machinery failure early warning systems are disclosed as are numerous motor operated devices using same including without limitation pumps.
Claims
1. A method of setting-up a pump comprising: providing a pump system including a pump, the pump system having a computer recognizable code affixed thereto; and scanning, with a user device, the computer recognizable code to setup the pump system.
2. The method of claim 1 wherein the computer recognizable code is a QR code affixed to a portion of the pump system.
3. The method of claim 1 wherein upon scanning the computer recognizable code, a website including installation instructions is provided on the user device.
4. The method of claim 1 wherein scanning the computer recognizable code facilitates associating the pump system with a user account of an application associated with the pump system such that information pertaining the pump system is accessible via the application.
5. A pump system comprising: a pump; a power cord for providing electrical power to the pump, the power cord including an electrical plug for plugging into a wall outlet; a power supply system coupled to at least one of the power cord and the pump for selectively providing electrical power to the pump, the power supply system including a leakage current detector configured to detect a leakage current of the electrical power provided to the pump via the power cord, the power supply system preventing power from being provided to the pump when the detected leakage current exceeds a threshold value.
6. The pump system of claim 5 wherein the power supply system, upon detecting a leakage current exceeding the threshold value, is configured to periodically check the leakage current and permit power to be provided to the pump when the leakage current no longer exceeds the threshold value.
7. The pump system of claim 5 further comprising a notifier configured to notify a user when the detected leakage current exceeds the threshold value.
8. The pump system of claim 5 wherein the threshold value is in the range of about 4 mA to about 6 mA.
9. A motor leakage current detector comprising: a controller connected to a power cord for a motor driven electronic device, the controller having sensors for detecting motor leakage current and alerting a user when a predetermined motor leakage current level has been detected.
10. The motor leakage current detector of claim 9 wherein the controller has an input and a display for displaying data related to detected conditions with respect to the motor driven electronic device.
11. The motor leakage current detector of claim 10 wherein the input serves as a single input that can be used for multiple functions.
12. The motor leakage current detector of claim 9 further comprising a smart home attendant interface that allows a smart home attendant or speaker to provide a user with motor leakage current detector data upon command of the user asking the smart home attendant or speaker to do so.
13. The motor leakage current detector of claim 9 wherein the motor leakage current detector operates like a GFCI, to make the connected motor driven electrical device operate as though it is electrically connected to a conventional GFCI circuit even if that is not the case.
14. The motor leakage current detector of claim 9 wherein the motor leakage current detector operates like a conventional GFCI, but takes action faster than a conventional GFCI would so as not to trigger any conventional GFCI connected into the electrical system the motor leakage current detector is electrically connected to in order to prevent the GFCI from being triggered and causing further problems associated with a triggered GFCI such as a disabling of the motor driven electrical device until the conventional GFCI is manually reset.
15. The motor leakage current detector of claim 9 further including a corresponding software application for interacting with the controller and providing data related to the controller and/or the motor driven electrical device connected thereto.
16. The motor leakage current detector of claim 15 wherein the software application is an App for a mobile device that provides a GUI the user may access to obtain and display data relating to the controller and/or the motor driven electrical device.
17. The motor leakage current detector of claim 16 wherein the controller and App interact to provide a user with real-time data related to the controller and/or the motor driven electrical device and alert the user to urgent issues relating to same.
18. The motor leakage current detector of claim 9 wherein the controller has a housing with a machine detectable or readable code for allowing the mobile device to scan the machine detectable or readable code and automatically launching setup procedures for same.
19. The motor leakage current detector of claim 18 wherein the machine detectable or readable code is at least one of a bar code, RFID sensor, or a machine detectable image or shape.
20. The motor leakage current detector of claim 19 wherein the machine detectable or readable code is a bar code containing information about the controller or the machine-driven electrical device.
21. The motor leakage current detector of claim 20 the bar code is a QR code for photographing with the mobile device to direct the user to a software application for use in connection with the motor leakage current detector and/or motor driven electrical device.
22. The motor leakage current detector of claim 21 wherein the QR code is hydrophobic.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Described herein are embodiments of systems, methods and apparatus for addressing shortcomings of known sump pumps.
[0012] This description includes drawings, wherein:
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[0027] Corresponding reference characters in the attached drawings indicate corresponding components throughout the several views of the drawings. In addition, 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. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted or described in order to facilitate a less obstructed view of the illustrated elements and a more concise disclosure.
DETAILED DESCRIPTION
[0028] This disclosure is directed to various apparatuses, systems, and methods for leakage current detection and applications of same including without limitation an apparatus or device that detects whether leakage current in an electric motor, which may indicate to a motor operator that the motor exhibits conditions indicating the motor is predisposed to or starting to show signs it is going to fail. The devices, systems and methods disclosed herein are for identifying when a failure condition is present in a device, such as an electric motor driven/operated device, and notifying a user of the failure condition. The identified failure conditions may even be further analyzed and categorized as indicating that failure is imminent or that failure conditions are present, but immediate failure is not likely. In preferred forms, the apparatuses, systems and methods disclosed herein can conduct the leakage current detection test while the device is not in operation and provide early warning as to motor failure issues well in advance of a motor failure actually happening.
[0029] The devices, systems and methods of this disclosure may come in many forms. For example, in
[0030] In a preferred form, the notifier will be one of a visual and/or audible device for alerting the user as to an outcome of a test conducted by the smart controller. The alerting may occur only if the leakage current detector 110 indicates early motor failure is detected, but in other preferred instances it may be configured to always provide a response (e.g., providing an alert of a first type if the motor has passed the test conducted by the smart controller 100 and an alert of a second type different than the first if the motor has not passed the test). For example, in a preferred form, the smart controller 100 will include a light or series of lights that provide a green light when the motor has passed the test, a yellow light when early signs of motor failure are detected and a red light when signs of urgent or imminent motor failure are detected. This can be accomplished in one multi-colored LED or it can entail using separate LEDs if desired. In other forms a more comprehensive display, such as a digital display, may be provided that provides additional information (e.g., text, images or symbols, etc.) regarding test results of the smart controller 100.
[0031] As mentioned above, the smart controller 100 may include an audible notifier 120 either in addition to the visual display or instead of the visual display. In a preferred form, the smart controller 100 will include both audible and visual devices for communicating test results of smart controller 100 to the user. In the form show, the audible sound is generated by a buzzer or speaker and may be configured to provide one sound, such as a chirp, to acknowledge the depressing of inputs and another sound, such as a longer and repeated beep or constant sound when either an early motor failure condition is detected, or an imminent motor failure condition is detected by smart controller 100. In one form, the smart controller will chirp when an early motor failure condition is detected but change to a constant audible alert when a more urgent motor failure condition is detected.
[0032] In the form shown in
[0033] In a preferred form, the smart controller 100 is utilized with a software application (App) and is capable of monitoring voltage (V), current (A), current leakage to ground (leakage current) and phase angle. The device 100 via a processor (e.g., either onboard or remote via the cloud, etc.) can process the data to operate like an oscilloscope capturing both waveforms as well as phase angle between them. By knowing and recording the V, A, leakage current and phase angle, the smart controller 100 will be capable of detecting any of the motor driven device's parameters has fallen outside of normal levels. For example, a change in phase angle could indicate an issue with the motor's capacitor meaning the motor capacitor may need to be replaced. Unusual current may indicate the motor bearing is worn or rubbing and needs attention, or that an obstruction is present and needs to be cleared. Leakage current will indicate motor issues like those discussed herein (e.g., insulation breakdown, infiltration of fluid, etc.). Unusual voltage input can also be detected to alert of unstable conditions (e.g., poor power source or power cord, surge, etc.).
[0034] In
[0035] Pump status LED 223 illustrates if the pump is operating correctly and in a preferred form will include a multi-color LED capable of glowing green to indicate the pump is ok, glowing yellow to indicate the pump has some problem with it (e.g., early motor failure conditions have been detected, or any other anomaly with the pump such as an unusual current or voltage draw possibly indicating an obstructed impeller, etc.) and glowing red to indicate the pump is not working correctly (e.g., an urgent motor failure condition has been detected by the testing of smart control 200, or any other anomaly with the pump such as a thermal cut-off (TCO) switch has been triggered, extremely high or low voltages or currents detected, etc.). Wi-Fi status LED 224 illustrates if the smart control 200 is connected to Wi-Fi and/or the strength of that signal. In a preferred form Wi-Fi status LED 224 will be a multi-color LED capable of glowing green when the smart control 200 is connected to Wi-Fi and the signal strength is good, will glow yellow if the smart control 200 is connected to Wi-Fi but the signal is weak, and will glow red if the smart control 200 is not connected to Wi-Fi. It should be understood, that multi-color LEDs may be replaced by multiple single-color LEDs if desired and/or that the smart control 200 could alternatively be setup only to illuminate an LED when an error condition is detected (e.g., only illuminate a fluid level LED to indicate the fluid level is too high, only illuminate a pump status LED when the pump is not working or an imminent motor failure condition has been detected, only illuminate a Wi-Fi status LED to indicate the smart control 200 is not connected to Wi-Fi, etc.).
[0036] As shown in
[0037] In operation, smart controller 200 is capable of performing a leakage current detection test while the motor 250 is not being operated because of the uniquely configured circuitry. As mentioned, this has the added benefit of reducing or minimizing background noise or interference that the operation of the motor would cause. The controller 202 uses triacs 213, 214 to open one triac and thus power line (e.g., hot or neutral) and see if there is leakage to ground and then close that triac and open the other triac and power line (e.g., neutral or hot depending on which was opened via the initial triac) to see if there is any leakage to ground. If leakage to ground is detected, the smart control 200 will determine how critical the condition is and determine how to notify the user of same. In a preferred form, if the leakage detected is 0.05 mA to 0.1 mA, the smart control 200 will send an alert to the user via communication circuit 230 and change the pump status LED 223 to yellow. However, if the leakage detected is greater than 0.1 mA, the smart control 200 will not only send the user an alert via communication circuit 230, but it will also trigger the audible alarm 221 and change the pump status LED 223 to red indicating a more urgent motor failure condition is present. These leakage current thresholds/ranges are exemplary and may be adjusted as desired for a particular motor operated device or application as desired.
[0038] As mentioned above, the inventions disclosed herein may be implemented in numerous different embodiments. As an example, an alternate more simplistic circuit is illustrated in
[0039] In looking at the leakage current detector of the circuit of
[0040] The leakage current detector 310 is capable of detecting small currents, specifically, currents below those which a ground fault circuit interrupter (GFCI) or ground fault interrupter (GFI) will detect and interrupt the circuit. Many GFCI/GFI devices will not allow current to flow to a device when the leakage to ground is greater than 6 mA. The leakage current detector 310 may be designed and configured to detect current flow below that which a GFCI/GFI will interrupt the circuit, to detect the early signs of motor failure, before the leakage current gets above 6 mA. It should be understood that in other regions of the world GFCI/GFI are referred to as residual-current devices (RCD) or residual-current circuit breakers (RCCB).
[0041] The Line and Neutral conductors (or wires) may be connected to the Line and Neutral terminals of an electric outlet, through a power cord. The leakage current detection circuitry 310 further includes a first switch 313 on the first conductor and a second switch 314 on the second conductor. These switches 313, 314 are controlled by the leakage current detection circuitry 310 and allow the leakage current detection circuitry 310 to control whether each conductor is open or closed. These switches 313, 314 may be switched to open or closed independently of each other.
[0042] The leakage current detector 310 may test the condition of the motor 350 at set intervals. The condition of the motor 350 may also be detected by the leakage current detector 310 at any period of time or when prompted to do so (such as by the user requesting such through an App or via actuation of a physical button (like input 204). In one example, the leakage current detector 310 performs its test periodically, for example, once a week, every 24 hours, every hour, every minute, every 30 seconds, every second, etc., although other periods of time are contemplated. In another example, the leakage current detector 310 is configured to test the motor 350 when another system of the motor driven device performs a diagnostic test. The leakage current detector 310 may be configured to automatically perform a test on the motor 350 when the motor (or in the preferred case pump) is connected to a power supply 340, e.g., when plugged into an outlet or power is restored.
[0043] In one embodiment, the leakage current detector 310 is configured to test the motor 350 immediately before the motor 350 is commanded to run. This could be in pump applications, for example, when water rises above a predetermined level. This may be done to ensure the GFCI/GFI will not trip and interrupt the circuit.
[0044] In another embodiment, the motor or pump system includes a push-button like input 204 in the circuit of
[0045] As mentioned, one benefit of the leakage current detector disclosed herein (e.g., 110, 210, 310, etc.) is that the motor does not have to be running to do the test. Another benefit is that it is configured to be polarity agnostic so that it can make-up for situations where the wiring of the electrical socket the motor is connected to was not done correctly. To use such a tool, the motor need only be connected to the power source and then, without needing to operate the motor, the leakage current detector can test the circuit to see if there are signs of motor failure (e.g., motor insulation breakdown, fluid breach into the motor, etc.). For example, in
[0046] After measuring and recording the current flow, the leakage current detection circuitry 310 then opens the first switch 313 and closes the second switch 314. The leakage current detection circuit 310 then measures and, if desired, records the flow of current. If the second switch 314 connects to the Line conductor (instead of Neutral conductor because of improper wiring), then current will flow if the insulation of the motor had degraded such that it has low enough resistance for current to flow to ground. The leakage current detection circuit 310 then determines whether the current flowing in the first or second test was an acceptable amount. Some current may flow when the motor 350 is connected to the Line conductor even if the motor insulation is in good condition. This can be because the motor insulation resistance is not infinite, so some current will flow through the insulation to ground. Small amounts of this leakage current may be acceptable, and not indicate any immediate concern of the condition of the motor 350. If the current flowing was greater than an acceptable amount, the leakage current detection circuitry 310 may communicate this to a notifier circuit (not shown but see 120 and 220). In another example, the leakage current detection circuit 310 communicates the amount of current flow detected to another circuit, such as the notifier circuit, which will then determine if the amount of current flow is not acceptable.
[0047] In a preferred form, the circuit of
[0048] In another example, the notifier includes communication circuitry like 130 discussed above in
[0049] The notifier may be configured to use more than one method of communication to a user. In one embodiment, the wireless communication circuitry is configured to communicate via an internet connection as the primary way of notifying a user of a failure condition, but, if the internet connection is not available, the communication circuitry may be configured to communicate via a direct wireless connection, such as NFC as an example. In another embodiment, the notifier both sounds an alarm through a speaker and sends a notification to a user's smartphone through the internet over Wi-Fi when a failure condition has been detected.
[0050] The notifier may be configured to categorize the degree of the motor failure condition. For example, the notifier may send an alert when it detects the leakage current is within a certain range, for example, less than 0.05 milliamps and configured to send an alarm when the current is detected to be between 0.05 milliamps and 6 milliamps. The alert would notify a user when a motor failure condition exists that does not require immediate attention, and the alarm would notify a user that an imminent motor failure condition exists upon hearing or seeing the notifier alarm. As examples, the alert may be a flashing LED, while the alarm may be an alarm sound playing through a speaker.
[0051] The categorization of the degree of seriousness of the motor failure condition may be determined at least based in part on the amount of leakage current flow. The amount of leakage current can be used to categorize the leakage current to mean either a failure condition is present, or a failure is imminent. In a preferred form, the audible device will be a piezo alarm that goes off when a certain or first leakage current threshold is met or exceeded. For example, if the leakage current detected is below 0.1 mA the piezo buzzer or alarm may chirp at a consistent interval to alert he user to the condition. If the leakage current detected exceeds a second threshold (e.g., over 0.1 mA) the chirp may get louder and/or more frequent or may even become a constant sound to alert the user more urgently. In other forms, the audible device may be configured to actuate only after a period of time has passed since the fault or error condition was first detected and reported. For example, the system may be configured to alert the user via the App initially and then use the audible device to escalate the matter by sounding an alarm after a period of time has expired since the first notice without any corrective action or measures being taken.
[0052] In
[0053] As can best be seen in
[0054] While
[0055] In
[0056] Next, the pump status LED 523 is positioned preferably centered on the housing and with room for graphical information 523a below or above the LED 523 as illustrated in
[0057] The Wi-Fi status LED 524 is located next and preferably centered with room to provide graphical information 524a below or above as well (like illustrated in
[0058]
[0059] While the above embodiments show the smart control having power cords extending from opposite ends, it should be understood that in other embodiments, the smart control could alternatively have a power cord on one end and an electrical socket located elsewhere on the smart control housing that the power cord of an electric motor operated device would simply be plugged into in order to get the benefit of the smart control. In this way, the smart power cord would be more of an accessory for attaching to existing electric motor operated devices.
[0060] In some forms, the smart power cord would have numerous such electrical sockets that electrical devices can be plugged into so that it operates like a smart power strip capable of detecting early motor failure or critical motor failure issues for all devices plugged into the strip. The power strip would be able to detect when one of the electric motor operated devices plugged into it is exhibiting early or imminent motor failure conditions and notify the user of same so that the user can test the devices individually to determine which was exhibiting the motor failure condition detected. Alternatively, LEDs may be provided by each outlet to indicate which device/power cord has exhibited the early or imminent/urgent motor failure concerns.
[0061] As mentioned above, however, in alternate forms the smart control would simply be integrated into OEM products instead of being an accessory for same. As also mentioned above, the smart controller may be used with any type of electric motor operated device. For example, in
[0062] As an example of an original OEM product having a smart control integrated therein (rather than as an accessory capable of being connected and disconnected therefrom),
[0063] In the form shown, the power controller 900 is configured on the circuit of
[0064] As best seen in
[0065] In the form shown in
[0066] While the pump embodiments discussed up to now have been single pump systems, it should be understood that the smart controller disclosed herein may be used in multiple pump systems as well. For example, in
[0067] In the form shown, battery 1174 is a smart battery such as a Lithium Ion battery (Li-ion battery) with a wireless communication circuit capable of communicating with smart control 1100 of AC pump 1160. In a preferred form, the wireless communication technique used is Bluetooth (BT) communication, but in alternate forms it may be any other communication technique like those discussed above (e.g., radio frequency (RF), Bluetooth low energy (BLE), near field communication (NFC), Wi-Fi, cellular, or other communication technique used by Internet of Things (IoT) devices, etc.). In this way, the smart battery 1174 is capable of communicating to smart controller 1100 pertinent information relating to the smart battery to alert the user to any anomaly detected with same and vice versa (smart control 1100 is capable of communicating its data back to smart battery 1174). For example, the smart battery 1160 is capable of communicating to smart control 1100 information regarding the battery's voltage, amperage, state of battery health or state of health (SOH), state of battery charge or state of charge (SOC), etc., so that this information may be conveyed to the user via the app used in connection with the smart control 1100. Thus, during normal operation (e.g., not a power outage or the like) the smart control 1100 can not only relay information to the user regarding smart AC pump 1160, but also relating to the battery back-up system.
[0068] In some forms, the smart control 1100 may have its own internal battery to power itself even during a power outage so that it can continue to provide information relating to the pump system or sump 1161. In such instances, the smart control 1100 could convey the information back to the smart battery 1174 and allow the smart battery 1174 to relay that information to the user via the app due to the ability of the back-up system to run off the battery power of smart battery 1174.
[0069] One benefit to the setup illustrated in
[0070] In the above pump examples, the pumps include a fluid level detector to control the pumping of fluid by the system. The fluid level detector monitors the level of the fluid. When the fluid rises to or beyond a predetermined level, the fluid level detector is configured to detect the rise in fluid and cause the power cord accessory 100 to turn on and/or deliver power to the pump motor. The fluid level detector may be a pneumatic pressure tube or switch. More details of such a switch may be found in Applicant's U.S. Patent Application Publication Nos. 2017/0175746, published Jun. 22, 2017, entitled Integrated Sump Pump Controller With Status Notifications; and 2018/0163730, published Jun. 14, 2018, entitled Pump Communication Module, Pump System Using Same and Methods Relating Thereto, which are hereby incorporated by reference in their entirety. In the forms shown, a tube may be connected to the transducer and pass through the air tube receiver and down into a sump pit. Use of a pneumatic pressure switch reduces (if not eliminates) the number of moving mechanical parts, which can result in an increase in system reliability. The pressure tube has a pressure tube inlet, and is connected to a switch device (e.g., the transducer), which may be contained within the smart controller as shown previously.
[0071] Such systems may evoke additional steps to ensure that the air tube is back to atmospheric pressure. For example, the pneumatic pressure switch system can be configured to flush air after a predetermined period to recalibrate and eliminate problems with condensation build-up or tube leakage. The pneumatic pressure fluid level detection system may alternatively employ sensors that are adapted to operate so that the water level is held below an opening. In this manner the fluid level in the sump pit maintains a certain level with respect to the fluid level in the tube (e.g., the pit and tube fluid levels do not have to be equal or level with one another, but rather simply correlate with one another so that the level in the tube can be used to calculate a corresponding level of fluid within the pit). Further, in some examples, the systems will be configured to turn on after a predetermined time so that the air in the tube returns to atmospheric pressure. In a preferred form, the system will be configured to detect when the pressure reading from the air switch indicates a high fluid level has been reached, will operate the pump to draw fluid down and then will stop the pump once a substantially constant pressure reading has been reached as that will mean the air switch has returned to atmospheric pressure. The reason a particular pressure value is not looked for in determining when to stop the pump but rather a constant pressure is that looking for a particular pressure value would require the pump to be calibrated (possibly often) and would require knowledge of where the pump will be used or in what type of application as the particular pressure value might be different based on elevation or application (e.g., is it used on a regular sump pump application, is it being used in a sealed radon sump system, etc.). By not requiring a specific or particular pressure value to be looked for and rather just a generally or substantially constant pressure value to be seen, the system does not have to worry about these other details/factors and simply knows this means to shut the pump off when this condition is detected.
[0072] In still other forms, a solid state fluid level switch may be used such as those disclosed in Applicant's U.S. Pat. No. 8,380,355, U.S. Patent Application Publication No. 2013/0156605, published Jun. 20, 2013, entitled Capacitive Sensor and Method and Apparatus for Controlling a Pump Using Same, and U.S. application Ser. No. 13/768,899 (Mayleben et. al.), which are hereby incorporated by reference in their entirety.
[0073] While various example pump embodiments have been disclosed, it should be understood that the disclosed subject matter may be broadly applied to other forms of pumps, for example, single flow or discharge utility pumps, well pumps, lawn pumps, sewage pumps, pool pumps, etc. For example, pumps such as Applicant's utility pumps illustrated in U.S. Patent Application Publication Nos. 2017/0030371, published Feb. 2, 2017, entitled Multi-Outlet Utility Pump, and 2019/0048875, published Feb. 14, 2019, entitled Thermally Controlled Utility Pump and Methods Relating to Same, which are incorporated herein by reference in their entirety.
[0074] Again, while a pump has been primarily used as an example application for the disclosed invention, it should not be assumed that the disclosure is limited to submersible pump applications, but rather can be broadly applied to any motor driven device. The above principles may be used to detect when motor driven machinery will fail or that it exhibits signs indicating a failure will occur in the near future or that failure is imminent. The machinery may be plugged into a power cord accessory which is plugged into the wall outlet or a power strip with such technology. Alternatively, the machinery may be built to include a leakage current detector and notifier discussed in this disclosure within the machinery. In either example, the leakage current detector tests the machinery's motor before the motor is run. The leakage current detector determines if any leakage current exists and to what extent. If the leakage current falls within the range that indicates any type of failure condition is present, then the notifier of the machinery or the power cord accessory will alert the machinery operator of this failure condition, so they may be aware that the machinery may fail, allowing the operator to take appropriate action. The machinery may include a warning system that the notifier circuit communicates with to alert or notify the operator or machinery supervisor that a machinery failure condition has been detected.
[0075] In an alternative embodiment, a smart control including circuitry as illustrated in
[0076] In situations where the pump 1260 needs to run for a longer period of time, the triac 1252 may generate too much heat to be adequately dissipated between run cycles. Instead of using a large and/or expensive heat sink to aid in heat dissipation for these situations, the smart control 1200 of this embodiment includes a relay 1254 in parallel with the triac 1252. The controller 1202 may be in communication with a temperature sensor 1256 that monitors the temperature of the triac 1252. When the temperature of the triac 1252 is above a threshold temperature (e.g., 60 degrees Celsius) and/or the triac 1252 is powered on by the controller 1202 for a certain period of time, the controller 1202 may turn off the triac 1252 and close the normally open relay 1254. Power is then supplied to the pump 1260 via the relay 1254 while the triac 1252 is off, thus allowing the triac 1252 to cool.
[0077] In some forms, rather than turning off the triac 1252, the controller 1202 simply closes the relay 1254 with the triac 1252 still on. This reduces the heat generated by the triac 1252 while allowing the triac 1252 to serve as the main conduit for powering the pump 1260. This reduces the burden on the relay 1254 as power (e.g., 120 VAC) is provided to the pump 1260 via the both the relay 1254 and the triac 1252. This aids in increasing the life of the relay 1254. In still other forms, however, the relay provides a path of least resistance and, thus, the current passes through the relay rather than the triac 1252 because of the resistance associated with the triac 1252. This still offers significant benefits, however, in that the relay 1254 is not exposed to direct line voltage at start-up, but rather a reduced start-up voltage associated with the internal resistance of the triac 1252. Thus, the relay 1254 is turned-on or activated much more gradually than if it was exposed to direct alternating current (“AC”) line voltage at start-up. This protects the relay and prolongs the life by not exposing it to the higher start-up line voltage it would otherwise be exposed to but for the triac. For example, the more gradual or manageable start-up prevents damage to the relay such as pitting that can cause relays to die earlier than their desired life expectancy.
[0078] In another form, the controller 1202 turns on the triac 1252 to power the pump 1260 and then shortly after, closes the relay 1254 to provide power to the pump 1260. For instance, where the triac 1252 is above a certain temperature (e.g., 60 degrees Celsius) and the controller 1202 determines that the pump 1260 must be powered, the controller 1202 may first turn on the triac 1252 to provide power to the motor of the pump 1260 and after a certain period of time (e.g., 20 ms) close the relay 1254. Under this approach, the triac 1252 bears the brunt of the 120 VAC power that is used to turn on the motor 1250 of the pump 1260. Then the relay 1254 may be closed, which, being connected in parallel to the triac 1252, aids in providing the power to the pump 1260 and reduces the amount of heat generated by the triac 1252. Turning the relay 1254 on after the triac 1252 initially powers the pump 1260 aids in reducing the wear placed on the relay 1254 (e.g., pitting of the relay contact, extreme relay parameter operation, etc.) that would occur under the high current draw associated with initially powering the pump 1260 and specifically motor 1250.
[0079] Providing a relay 1254 in parallel with the triac 1252 also adds redundancy into the smart control 1200. For instance, if the triac 1252 should fail, the controller 1202 may use the relay 1254 to deliver power to the pump 1260. Thus, even if the triac 1252 fails, the pump 1260 may be operated via the relay 1254. The smart control 1200 may be configured to provide an error signal or notification indicating that the triac 1252 of the smart control 1200 has failed and that the smart control 1200 is in need of maintenance or replacement while still allowing the unit to operate in the meantime (e.g., if not a full redundant operation, at least a limp-home feature that provides for some operability). The opposite is true as well in that the triac 1252 provides redundancy for the relay 1254. Thus, if the relay fails, the triac will continue to allow the system to operate, however, it may have to shutdown from time to time if heat build-up becomes a problem since the relay is no longer available to help address that issue. In practice, the relay 1254 will not be needed until the pump has been running for an excessive period of time. In some forms this may be greater than ten seconds (10 s), however, in other forms it may be a lower threshold such as six seconds (6 s).
[0080] In view of the above, it should be understood that numerous apparatus, systems and methods are disclosed herein. For example, in some forms, apparatus, systems and methods are disclosed for detecting motor leakage current indicative of a failing motor so that early warning of this situation may be provided without a pump owner or user experiencing failure that might otherwise lead to further damage (e.g., flooding of an area, the cessation of a motor driven device during a critical time of operations, etc.). In a preferred form, the apparatus, systems and methods disclosed herein will alert the user to the problem with sufficient time to address same before it becomes a bigger problem. In this regard, one form of the apparatus, systems and methods disclosed herein involves monitoring leakage current to ground without needing the motor to be operated (or turned on) so that the line and neutral wires can be checked for leaking to ground and alerting the user to that situation when it is detected well in advance of motor failure. In some forms, the apparatus, system and methods can alert the user when the polarity of the outlet the motor is connected to is wired incorrectly (or the polarity the motor is exposed to is incorrect). In some forms the apparatus, system and method will alert the user to the improper polarity, such as by way of an audible alert and/or a visual alert (e.g., a buzzer, an illuminated light, etc.). In a preferred form, the alert will be provided via a message sent to the user's mobile device alerting him/her to the early failure detection prior to it becoming a more serious issue.
[0081] In other forms, the apparatus, systems and methods disclosed herein address heat issues circuitry may be exposed to due to operation of the motor driven device. For example, in one form, an AC switch is used to allow the motor driven device to operate off conventional AC line voltage or power. Such switches can be exposed to excessive heat generation that can cause protective components or circuitry like thermal cutoffs (TCOs) to kick in to prevent the circuitry or motor driven device from overheating. For example, in the sump pump embodiment disclosed above, a triac is used to serve as the AC switch. The triac is capable of operating the pump for a reasonable period of time without generating excessive heat (e.g., six seconds, ten seconds, etc.). When excessive heat is generated, the apparatus, system and method disclosed herein could simply use a thermal cutoff or TSO switch to shutdown the motor driven device, however, in a preferred form, the circuit will include a relay in parallel to the AC switch to allow the relay to close such that it diverts (or largely diverts) the current and power from the triac to the relay to allow the triac to cool. This configuration allows the heat generation issue associated with the triac to be addressed while also allowing the relay to be powered-up or started more gently by not exposing it to the brunt of the AC line voltage at start-up and instead subjecting it only to the much lower start-up voltage associated with the resistive drop over the triac. This protects and prolongs the life of the relay by preventing it from the damage or wear and tear that a relay normally sees when exposed directly to AC line voltage (e.g., pitting, relay contact and/or terminal damage, etc.). Thus, the circuit has a first switch in combination with a second switch wired generally in parallel with the first switch so that the second switch may be used to address heat issues associate with the first switch when necessary and doing so in a way that protects or prolongs the life of the second switch during its operation. The terms first and second switch may be used generically to refer to either the triac or relay. In some forms discussed herein, the triac is simply called-out as the triac with the relay being referred to as the first switch wired in parallel with the triac to take over operation of the powering of the motor driven device when the triac needs a break due to heat build-up.
[0082] While the above embodiments have primarily described the current leakage detector (110, 210, 310, etc.) detecting current below which a GFCI outlet will trip to preemptively detect failure of the pump, in some embodiments, the current leakage detector (110, 210, 310, etc.) may serve as and/or be used in place of a GFCI outlet. For instance, the outlet to which the pump is plugged into may not include a GFCI. Instead, the current leakage detector monitors the amount of current leaking to ground and prevents power from being provided to the pump when the amount of leakage current rises to a level at which a GFCI outlet would typically trip or interrupt the circuit (e.g., 4-6 mA). This enables a pump with a smart controller (100, 200, 300, etc.) to be used with either a GFCI outlet and non-GFCI outlets with the pump being shut off and prevented from running when an electrical fault is detected. Use of the leakage current detector provides the safety benefits of a GFCI outlet even where the pump is plugged into a non-GFCI outlet. It also makes it possible to give electronic motor driven devices the benefits of a GFCI when the surrounding environment (e.g., building wiring (e.g., residential, commercial or industrial), surrounding area, etc.) does not lend itself to such features. While a pump is discussed herein, it should be understood this motor leakage current detector could be used with any electric motor driven device and this disclosure is intended to cover same.
[0083] One problem with the use of GFCI outlets for sump pumps is that once the GFCI trips, the sump pump will not be able to run unless reset which may result in a homeowner's basement being flooded. Many electrical codes require sump pumps to be plugged into a GFCI outlet so that power provided to the pump is cut when the leakage current exceeds a threshold to prevent a potential hazardous situation from arising. While the GFCI outlet may trip due to an actual electrical fault with the pump, occasional nuisance trips may occur, for example, during a brief power interruption, where the GFCI outlet opens preventing the pump to run even when there is nothing wrong with the pump. As a result, a homeowner's basement may be flooded even when their pump is in a good condition due to the GFCI cutting power to the pump. The current leakage detector solves this problem, because the current leakage detector cuts the power to the pump when an electrical fault is detected (e.g., high leakage current) preventing a potentially hazardous condition, but further may periodically test the leakage current after the electrical fault has been detected to check if the electrical fault is still present or was only a temporary situation (e.g., due to a power interruption) and not a problem with the pump. For example, with reference to the smart controller 300 of
[0084] Furthermore, because the power outlet has not tripped, the smart controller may remain powered even when a problem is detected with the pump. The smart controller may notify the user as described above when an actual electrical fault has occurred and alert the user that the sump pump will not run. This alerts the homeowner of the problem with their pump and may provide the homeowner with the opportunity to remedy the situation and/or minimize the damage to their home.
[0085] In
[0086] The graphical overlay 1322 similarly may include a hole or transparent portion aligned with the pump status LED 1323 and WiFi status LED 1324 for viewing the pump status LED 1323 and WiFi status LED 1524 through the graphical overlay 1322a. The graphical overlay 1322a further includes graphical information 1123a below or above the pump status LED 523 as illustrated in
[0087] The graphical overlay 1322a may further include a computer recognizable code 1325 for use during setup of the pump or for use in troubleshooting the pump. As one example, the code 1325 is a scannable QR code that a user may use or scan for use in setting up their pump. When scanned by a user device (e.g., a smartphone, computer tablet, etc.), the QR code may provide the user with a link or automatically direct a user to instructions for setting up or troubleshooting their pump. For instance, by scanning the QR code the user may be able to access a webpage, download an owner's manual/troubleshooting manual, and/or open instructions on a smartphone application associated with the pump, such as that shown in
[0088] In some forms, a user may link the pump 1360 to their user account on their smartphone application by scanning the QR code. For example, a user may create a user account in the smartphone application associated with the pump 1360. To link their particular pump with their user account to view diagnostic data and receive updates associated with the health of the pump 1360, the user may scan the QR code 1325 within the application. The smartphone application may then automatically configure or register the scanned pump 1360 with their user account. In a preferred form, the scanning of the QR code 1325 by a user's mobile device (e.g., smart phone, tablet, laptop, etc.) automatically launches on the user's mobile device the setup and registration for the electric motor driven device (e.g., taking the user to an application provider to download the required app, stepping the user through the setup of the app and/or the electric motor driven device (e.g., the pump), stepping the user through warranty registration or even simply completing the warranty registration process for the user based on the data already collected through setup). Setup may include obtaining the necessary software app, determining geographically where the user and electronic device is located, the user's contact info, the particulars with respect to the actual electronic device the user has (e.g., what part number, model number, batch number, etc.), usage information for the electronic device (e.g., is it a utility pump, sump pump, effluent pump, lawn pump, pool cover pump, pool pump, well pump, battery backup system, etc.), setting-up push notifications (e.g., one way or two way notifications such as texts, etc.), allowing the user to setup additional features they can sign onto if they want (e.g., tracking, notifications, alerts, additional contacts to be reached out to, product milestone reminders to remind the user about such as number of cycles, battery condition, motor condition, efficiency of unit, etc.). Again, in the main form disclosed herein a pump is discussed, but it should be understood that the electric motor driven device could be numerous other electric or electronic devices.
[0089] As mentioned above, and with reference again to
[0090] In some forms, the smart controller 900 processes the collected data to determine the pump health status and/or whether any monitored conditions are present. The smart controller 900 may communicate the determined pump health status and associated collected data to the remote server computer. The remote server computer may be a server computer of a smartphone application associated with the smart controller 900 and/or pump 960. The pump health status, detected condition, and/or associated data may be displayed or viewed within the smartphone application. In some forms, the remote server computer processes all or a portion of the data to determine the health of the pump and/or detect the presence of a monitored condition based on the data collected by and received from the smart controller 900. The remote server may determine the health of the pump 960 and/or whether any monitored conditions are present and communicate a signal to the smart controller 900 causing the smart controller 900 to illuminate the pump health status LED 923 a color to indicate the determined status.
[0091] As described above, a user may view the pump health status LED 923 to receive a simple indication of the overall health of the pump 960. In some forms, the user may also use the associated smartphone application to view the pump health status. The smartphone application may also be used to access further details regarding the status of the pump 960. For example, a user may use the smartphone application to determine a specific reason the pump health status LED 923 is yellow or red. The smartphone application may include a field indicating the overall health of the pump 960 similar to the pump health status LED 923 to provide a simple, concise indication of the health of the pump based on a plurality of monitored factors within the application. The smartphone application may permit the user to further access, or display to the user, a status for various monitored conditions or states of the pump 960. The smartphone application may indicate which conditions are determined to be present that may be impacting the overall pump health status determination. Where a monitored condition is determined to be present (e.g., an abnormal condition), the smartphone application may provide instructions for how to troubleshoot, fix, and/or remedy the detected condition. For example, if the input voltage is too low, the smartphone application may present a message instructing the user to consult an electrician. As another example, where a high leakage current is detected, the smartphone application may indicate to the user to replace the pump 960 immediately.
[0092] The following table provides a list of example conditions that may be monitored by the smart controller 900, along with the color that may be displayed by the pump health status LED 923 as a result of the presence of the condition, and an example of a message that may be displayed in the application when the condition is determined to be present.
TABLE-US-00001 TABLE 1 Monitored Conditions and Associated Output Pump Health Status Message Provided by Smartphone Monitored Condition LED Displayed Color Application No Pump Health Green Faults Detected Abnormal Run Time Yellow Your pump is running longer than usual. Please check your system to ensure no debris is blocking your pump inlet or pump discharge Too High Supply Yellow Incompatible voltage detected. Please have Voltage (pump off) an electrician correct outlet to extend the (e.g., >128 V @ 0 A) life of your pump Too Low Supply Yellow Incompatible voltage detected. Please have Voltage (pump off) an electrician correct outlet to extend the (e.g., <104 V @ 0 A) life of your pump High Leakage Current Red We have detected a critical issue with your (e.g., >0.1 mA) pump. Replace your pump immediately! High Current Yellow Your motor is showing signs of aging. (e.g., >7.2 A @ 127 V; Consider replacing your pump soon to stay >7.2 A @ 115 V; protected. >7.8 A @ 104 V) Exceed High Current Red We have detected a critical issue with your Limit pump. Replace your pump immediately! (e.g., >7.7 A @ 127 V; >7.7 A @ 115 V; >8.3 A @ 104 V) Locked Rotor Red We have detected a critical issue with your (e.g., >15 A) pump. Replace your pump immediately! Too Low Current Yellow Your motor is showing signs of aging. Consider replacing your pump soon to stay protected. Exceed Low Current Red We have detected a critical issue with your Limit pump. Replace your pump immediately! Water Level not Yellow Water level is not dropping! Incoming dropping while pump flowrate exceeds pumping capability. running; Normal Immediate attention is required. Current Water Level not Yellow Water level is not dropping! Please verify dropping while pump there are no obstructions in your system running; Low Current discharge piping or damaged/incorrectly installed check valve. Low Power Supply Red We have detected a critical issue with your Power Factor pump. Replace your pump immediately! (e.g., <0.93 PF) Non-functioning Air Red Non-functioning air switch detected! Please Switch check the following: Verify air hose is properly connected to controller and air switch. Verify air hose is not damaged, bent or twisted. Verify air switch is not damaged. Contact customer service for further troubleshooting. Outlet Wired Yellow Outlet wired incorrectly. Please have an Incorrectly (reverse electrician correct outlet to allow full polarity) functionality of your device. Relay exceeds cycle Red We have detected a critical issue with your limit pump. Replace your pump immediately! Continuous Run Yellow Warning! Your pump is running continuously. Immediate attention is required. Thermal Protector Yellow Warning! The thermal protector of your Trip pump has tripped. Immediate attention is required. Abnormal Duty Cycle Collect [This is an experimental data point that data will be collected on for possible use in future warnings/alerts.] High Inrush Current Collect [This is an experimental data point that data will be collected on for possible use in future warnings/alerts.]
[0093] The smart controller 900 and/or remote server computer may determine that a condition is present based on one or more categories of the collected data. For instance, by monitoring the current draw of the pump and the water level within the sump pit, a determination may be made that the pump 960 is clogged and that debris may need to be removed. As another example, the determination of whether a monitored condition is present may be based on whether the pump is operating and a current or voltage level. A locked rotor may be detected based on a very high current draw by the pump 960, for example, greater than 15A. While examples of monitored data (e.g., voltages, currents, etc.) are provided as indicative of the presence of the exemplary monitored conditions listed above, those having skill in the art will appreciate that these limits and ranges indicative of various conditions may vary based on the specifications (e.g., size, recommended input voltage level, etc.) and application of the pump 960.
[0094] The smart controller 900 may also monitor the number of pump cycles the pump 960 has performed. Pumps are often expected to perform a certain threshold number of pump cycles before breaking down or needing to be replaced. Thus, as the number of pump cycles are monitored, the estimated number of pump cycles remaining and/or the life expectancy of the pump 960 can be predicted and presented to the user via the smartphone application. The smartphone application may notify or alert the user when the pump is nearing the end of its life expectancy and recommend the user replace the pump. The smartphone application may provide the user with a link to one or more pumps for the user to consider purchasing. After exceeding a certain number of pump cycles, the owner may be notified via the application that their pump has exceeded a threshold number of cycles and/or reached the end of its life expectancy and should be replaced. Similarly, for smart controller 1200 including a relay 1254, the number or relay cycles may be monitored, and the user alerted when the number of relay cycles nears or exceeds a threshold number of cycles that the relay 1254 is expected to perform in a lifetime before needing replacement. The smart controller 900 and/or associated server computer may monitor the warranty of the pump 960 and alert or notify the user when the warranty of their pump is nearing expiration or has expired. The user may be notified via the smartphone application and provided with a recommendation to replace their pump to stay protected by warranty.
[0095] In some embodiments, when a monitored condition is determined to be present and/or a health status of the pump 960 is determined to change, the smartphone application may present or push a notification to the user. The notification may present the user with a message alerting them of the problem and/or a message of the recommended action to address any problems detected by the smart controller 900.
[0096] An example of a graphical user interface (GUI) 1400 displayed by such a smartphone application described above for use in remotely monitoring a pump (or other motor driven devices) is shown in
[0097] The GUI may include a health status indicator 1404 indicating the overall health of the pump that provides the user with a simple indication of the overall health of the pump similar to the pump health LED of the smart controller described above. With reference to
[0098] The application may include a system test button 1406 that the user may select or press to cause the system to perform a test on the pump, similar to the tests performed on the pump system in response to receiving user input via the user input 204 of smart controller embodiments described above. The application may also display pump data 1412 to the user including the pumps activity that day, that week, that month, and/or that year including the number of pump cycles and the runtime. With respect to
[0099] In addition to the above, in some forms, the electronic device the leakage current detection technology is paired with may be equipped to work as an Internet of Things (IoT) device and utilize other smart home technology. For example, in one form, the pump illustrated herein may be used to pair with a smart home attendant (e.g., Amazon's ALEXA brand items, Apple's SIRI brand items, Google Assistant brand items, etc.) so that the user may ask the smart home attendant to report on the status of the electronic device. In instances where the device is a pump, for example, the user may ask their smart home attendant what is the status of the pump. In response, the smart home attendant will provide data on the pump. In some forms the data provided will be a rundown of the main software app dashboard, e.g., it may provide current status or state of pump, any detected malfunctions, number of cycles (e.g., during a specific period like 24 hours, or this week, or this month or over the product's lifetime), run time data (e.g., again over a specific period or over the lifetime, whichever the user desires or sets-up), etc. In addition to the above exemplary embodiments, it should be understood that numerous methods are disclosed and contemplated herein as well. For example, a method of providing GFCI benefits to a non-GFCI component or a non-GFCI environment is disclosed herein. In addition, a method of triggering an electronic device before triggering a GFCI so as to prevent a tripped GFCI from causing further damage before being reset is also disclosed. While GFCI is reference herein, it should be understood that includes a GFI device, a Residual Current Device (RCD), or any such interrupter regardless of name. Further to the above, a method of protecting electronic devices is also disclosed herein including a method of protecting electronic devices without the use or triggering of a GFCI.