FIELD OF THE INVENTION

[0001 ] The present invention relates to pump controllers, and, in particular, to pump controllers for domestic water systems.

BACKGROUND

[0002] Domestic water systems, like home rainwater systems, typically include a water pump to ensure consistent flow and adequate water pressure. To assist with pump operation and flow regulation, pumps are typically fitted with a pump controller that is connected in-line between the pump and the plumbing infrastructure of the water system (see for example, Figure 1 ).

[0003] Pump controllers are usually configured to automatically turn the pump on/off as required, with opening/closure of a plumbing outlet (e.g. tap) of the water system. A cross section of a typical prior art pump controller (200) is shown in figure 2. The pump controller (200) is pressure actuated. It is installed such that, with opening of an in-line water outlet, pressure inside the controller housing decreases. This pressure decrease is detected by a pressure sensing means inside the controller, and, based on input received from the pressure sensing means, an electronic control unit (201 ) turns the pump on.

[0004] In the example prior art device of figure 2, the pressure sensing means is a diaphragm mounted rod (202). As the relevant outlet (e.g. tap) is opened, and the pressure within the housing decreases, the diaphragm (203) is drawn into the housing, moving the rod. A magnet (204) in the rod triggers a magnetic reed switch (205) connected to the electronic control unit (201 ). A spring (21 1 ) operates to later draw the rod back to its neutral position. These diaphragm/rod mechanisms make the controller bulky, and the rod component (202) in particular can impede water flow though the controller (200). Furthermore, the spring component (21 1 ) is prone to spring fatigue, which in turn has an effect on the calibration/performance of the device.

[0005] Water flow through the controller (200) is monitored by a flow sensor valve (206) and prohibited from back flow by a separate non-return valve (207). Both the flow sensor valve (206) and the non-return valve require specific mounting of the pump controller to function effectively. In particular, it is required that the controller (200) be oriented/mounted such that the water flow passage (208) therethrough is vertically aligned. This allows that, due to gravity, the non-return valve (207) can return to the closed position when the plumbing outlet/tap is closed and the pressure at the pump controller inlet and outlet equalise. Similarly, the flow sensor valve, can revert to its default seated position.

[0006] On return to the seated position, a magnet (209) in the flow sensor valve triggers a second magnetic reed switch (210) connected to the electronic control unit (201 ). In typical use, when the flow sensor valve returns to the seated positon, the electronic control unit sends a signal to the pump to turn off. In some situations where there is a malfunction, the flow sensor valve (206) can get stuck in the open position, and no signal is sent to turn the pump off, even though the outlet/tap may have closed. This can result in damage to the pump motor and/or power wastage.

[0007] Prior art pump controllers, like the one shown in figure 2, are typically fitted to any relevant pump assembly and plumbing infrastructure via a screw type engagement. Whilst this may provide secure fitting and adequate sealing, it will be appreciated that the ultimate orientation of the controller is not readily controllable, and, once secured (i.e. after tightening is completed), the controller may end up in a non-desired orientation.

[0008] The present invention seeks to address at least some of the above mentioned disadvantages as well as provide other improvement over conventional pump controllers.

[0009] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application. SUMMARY OF THE INVENTION

[0010] In one broad form, the present invention provides, a pump controller for installation in-line between a pump and a piping infrastructure, the pump controller including: a flow passage extending therethrough between a fluid inlet and a fluid outlet; a valve in the flow passage between the fluid inlet and the fluid outlet; a pressure sensing means configured to detect a pressure change within the flow passage between the valve and the fluid outlet; and a control unit for controlling operation of the pump, wherein the control unit is configured to control the pump based on input received from the pressure sensing means.

[001 1 ] In one form, the control unit is configured to start the pump when input received from the pressure sensing means indicates a pressure decrease in the flow passage.

[0012] In one form, the valve is a non-return valve that is mechanically biased to the closed position. In one form, the valve is spring biased to the closed position. In one form, the valve is configured such that: in the closed position, fluid flow from the outlet side of the valve to the inlet side of the valve is prohibited; and the valve is openable to permit fluid flow from the inlet side of the valve to outlet of the valve.

[0013] In one form, the pump controller further includes a valve sensor configured to monitor operation of the valve. In one form, the control unit is configured to control the pump based on input received from valve sensor. In one form, the control unit is configured to stop the pump when input received from the valve sensor indicates closure of the valve from an open position.

[0014] In one form, the fluid inlet and fluid outlet are substantially aligned and the flow passage provides a substantially linear flow passage therebetween.

[0015] In one form, the valve includes a valve seat formed in the flow passage, and a closure member located / mounted within the passage so as to be movable between a closed position where it is engaged with the seat, and an open position, where it is dis-engaged from the seat. In one form, the flow passage is substantially tubular, and the closure member moves along or parallel to a central axis thereof, between open and closed positions.

[0016] In one form, the valve sensor is configured to detect displacement of the closure member from the valve seat. In one form, the valve sensor is configured detect displacement by detecting a magnet in the closure member.

[0017] In one form, the closure member is located / mounted within the flow passage such that rotation thereof is permitted. In one form, the magnet in the closure member extends substantially around the rotation axis of the closure member. In one form, the closure member is of a spindle form having a stem and head portion, wherein the head portion is configured to engage the valve seat. In one form, the magnet is located at the head portion.

[0018] In one form the pump controller further includes a pump flow detector, the pump flow detector configured to monitor operation of the pump, and in particular, whether or not fluid is being pumped. In one form, the pump flow detector includes a current detector configured to detect load on the pump motor. In one form, the control unit is configured to control the pump based on input from the pump flow detector. In one form, the control unit is configured to stop the pump when input received from the pump flow detector indicates fluid flow through the pump is outside a predetermined operating range.

[0019] In one form, the pressure sensing means is a pressure transducer. In one form, the pressure transducer is located substantially within a wall of the flow passage.

[0020] In one form, the pump controller further includes releasably attachable connector fittings at the fluid inlet and fluid outlet. In one form, the connector fittings are releasably attachable by a substantially tool-less engagement. In one form, the connector fittings are rotatably mounted to the pump controller, so as to permit rotation of the pump controller once installed. [0021 ] In one for the pump controller is configured for use with a liquid pump. In one form the pump controller is configured for use with a water pump.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] A detailed description of a preferred embodiment will follow, by way of example only, with reference to a selection of the accompanying figures, in which:

Figure 1 is one example of typical pump controller placement;

Figure 2 is a cross sectional view of one example of a prior art pump controller;

Figure 3 is a side view of a pump controller according to one example of the invention; Figure 4 is a cross sectional view of the pump controller according to one example of the invention;

Figure 5 is a top view of the pump controller according to one example of the invention; Figure 6 is front view of the pump controller according to one example of the invention; Figure 7 is a rear view of the pump controller according to one example of the invention;

Figure 8 is a bottom view of the pump controller according to one example of the invention;

Figure 9 is a side view (opposite to figure 3) of the pump controller according to one example of the invention;

Figure 10 is an exploded view of the pump controller according to one example of the invention;

Figure 1 1 is a perspective view of a connector fitting and O-ring for use in one example of the invention;

Figure 12 is circuit diagram for an aspect of the control unit for the pump controller according to one example of the invention; and

Figure 13 is a circuit diagram for an aspect of the control unit for the pump controller according to one example of the invention.

DETAILED DESCRIPTION

[0023] Embodiments of the invention provide pump controllers for controlling the operation of pumps and/or regulating fluid flow therefrom. [0024] The pump controllers as described herein are configured to be installed in-line between a pump and a fluid piping/plumbing infrastructure/network. The pump controllers include a flow passage that extends therethrough, providing a pathway for pumped fluid to the piping/plumbing infrastructure. The flow passage includes a fluid inlet, to receive pumped fluid, and a fluid outlet, which connects to the piping/plumbing infrastructure. Typically, the fluid inlet is configured to be connected directly to a relevant pump assembly, however, it will be appreciated that this may not always be the case, and the pump controller may be installed downstream of the pump assembly.

[0025] A valve is included in the flow passage between the fluid inlet and the fluid outlet, and a pressure sensing means is configured to detect pressure changes within the flow passage between the valve and the fluid outlet. As would be appreciated the pressure sensing means may take a variety of forms. Typically, the pressure sensing means is a pressure transducer, and, is typically located within a wall of the flow passage.

[0026] A control unit is configured to be connected to and to control operation of the pump. In particular, the control unit may be configured, in a first aspect, to control operation of the pump based on input received from the pressure sensing means. For example, the control unit may be configured to turn the pump on when a decrease in pressure is detected by the pressure sensing means. In typical use, such pressure decreases may occur on opening of an in-line connected plumbing outlet (e.g. valve/tap) in the piping infrastructure. For example, in typical use, the pump controller may be installed such that when opening a relevant outlet (e.g. tap) connected in line with the pump controller (e.g. like in Figure 1 , the pressure decreases inside the controller. This pressure decrease is detected by the pump controller, and subsequently, the control unit generates a signal that is transmitted to the pump, to turn it on. A person thus looking draw fluid (e.g. water) from a system incorporating the pump controller, need not separately manually operate the pump, as the pump is rather automatically turned on via operation of the pump controller. It will be appreciated that the control unit may take a variety of forms and may include suitably configured electronic circuity/hardware, electronic processing device/s and/or electronic processing system/s. [0027] Generally, the fluid inlet and fluid outlet are substantially aligned, and the flow passage provides a substantially linear flow path therebetween. This provides that substantial redirection of fluid flowing through the controller is absent/reduced. This minimises turbulence and increases perform ance/efficiency etc.

[0028] The pump controller may also include a secondary chamber in fluid communication with the flow passage that includes a diaphragm to maintain an appropriate level of pressure in the controller/system once the outlet (e.g. tap) is closed and the pump is turned off. This allows that, on opening of the outlet, there is immediate fluid pressure and flow while the pump is starting up/becoming operational (i.e. flow is smooth and continuous). The ‘stored’ pressure as provided by the diaphragm also functions to prevent the pump being unintentionally automatically activated when there is a pressure decrease due to a small leak.

[0029] Generally, to prevent backflow to the pump, the valve is a non-return valve that is mechanically biased into the closed position. Whilst the valve may take a variety of forms, the valve is generally configured such that in the closed position, fluid flow from the outlet side of the valve to the inlet side of the valve is prohibited. With respect to fluid flow in the opposite direction (i.e. from the inlet side of the valve to the outlet of the valve) the valve is openable once the closing bias of the valve is overcome, i.e. by fluid pressure at the inlet side.

[0030] It will be appreciated that mechanical biasing of the valve can be achieved in a variety of ways although typically, a spring or the like is used. Mechanical biasing (as opposed to gravity biasing) provides that the pump controller can be installed/mounted in any orientation and the non-return valve can still function effectively. This is in contrast to prior art devices wherein the non-return valves are typically gravity reliant, and require installation of the pump controller in a particular orientation (i.e. where the flow passage is substantially vertically aligned). [0031 ] The pump controllers as described herein also typically include a valve sensor configured to monitor operation of the valve. By monitoring operation of the valve, separate additional parts, that may have previously been required within the passage for flow or inlet side pressure monitoring, do not need be included. Information indicative of flow or inlet side pressure can rather be determined by monitoring the valve, and in particular openness and/or closure of the valve.

[0032] As would be appreciated the control unit may be configured to control operation of the pump based on input received from the valve sensor in addition to the pressure sensing means. In one typical example, the control unit may be configured to start the pump when input received from the pressure sensing means indicates a pressure decrease in the flow passage (e.g. indicative of opening of an in-line plumbing outlet), but may additionally be configured to stop the pump when input received from the valve sensor indicates closure of the valve from an open state (e.g. indicative of closure of the plumbing/pipe outlet).

[0033] The valve within the flow passage can take a variety of forms. Typically though, the valve includes a valve seat formed in the flow passage, and a closure member located/mounted within the passage so as to be movable between a closed position, where it is engaged with the seat, and an open position, where it is dis-engaged from the seat. Generally, the flow passage through the controller is substantially tubular and the closure member moves along or parallel to a central axis thereof, between open and closed positions (i.e. into and out of the valve seat). In such forms, the valve sensor is configured to detect displacement of the closure member from the valve seat. Accordingly, it is clear how the valve may serve two functions, the first being to prevent backflow, and the second, to provide an indication of the inlet side fluid pressure and flow through the controller.

[0034] Generally, the valve sensor is configured detect displacement by detecting a magnet in the closure member. To facilitate fluid flow, the closure member is located/mounted within the flow passage such that it is permitted to rotate (typically about a central axis of the flow passage). To ensure accurate monitoring of the valve in view of any rotation of the closure member, the magnet in the closure member may extend substantially entirely around the rotation axis of the closure member.

[0035] Typically, the closure member is of a spindle form having a stem and a head portion, wherein the head portion is configured to engage the valve seat, and the magnet is located at the head portion. In such forms, to provide closure bias of the valve, a coil spring may be located on the stem. The coil spring typically extending between the head portion of the closure member and a stop in the flow passage such that the expansion force of the coil spring drives the head of the closure member into the valve seat.

[0036] The pump controller may also include a pump flow detector, the pump flow detector configured to monitor operation of the pump, and in particular, whether or not fluid is being pumped. In one example, the pump flow detector includes a current detector configured to detect load on the pump motor. As would be appreciated the control unit may additionally be configured to control operation of the pump based on input from the pump flow detector.

[0037] In one example, the control unit may configured to stop the pump when input received from the pump flow detector indicates fluid flow through the pump is outside a predetermined operating range. This configuration provides that, for example, if the valve gets stuck in the open position (e.g. in the case of a malfunction), and the plumbing outlet is closed or there is no fluid to pump, the pump will be turned off, protecting the pump motor and conserving power.

[0038] The pump controllers as described herein may also include releasably attachable connector fittings at the fluid inlet and fluid outlet of the flow passage. This provides that different connector fittings, for example with different diameters, may be used, and thus, allows an additional layer of flow regulation. For example, by changing the diameter of the connector fittings, fluid flow into the controller can be increased/decreased. Generally, the connector fittings are releasably attachable by a substantially tool-less engagement and may be rotatably mounted to the pump controller. Rotational mounting of the connector fittings permits the pump controller to be rotated on the pump/fluid line during or after installation. This has advantages in relation to orientation of the controller e.g. during maintenance and installation, or in situations with limited space.

[0039] Whilst the pump controllers as described herein may be used with a wide variety of pumps and systems, they are generally configured for use with liquid pumps and especially water pumps such as those used in domestic water systems.

[0040] One particular form of a pump controller according to the invention is shown in figures 3 to 10. The pump controller as shown is for use with a water pump in a domestic water system. The pump controller (1 ) is configured to be connected in-line between a water pump and plumbing/piping infrastructure/network of the water system (e.g. see figure 1 ).

[0041 ] Figure 3 shows a side view of the pump controller (1 ), and figure 4 shows a cross sectional view of the controller (1 ). As shown, the pump controller (1 ) includes a housing (2) with a flow passage (3) that extends therethrough between a water inlet (4) and a water outlet (5). The water inlet side of the housing (2) is configured to be fitted to a pump assembly or directly downstream from a pump assembly whilst the outlet side is configured to be connected to the piping/plumbing infrastructure of the water system (like, for example, the set up shown in figure 1 ). The water inlet (4) and outlet (5) are aligned, and the flow passage provides a substantially linear flow path therebetween. In contrast to prior art devices, there is no substantial redirection of water flowing through the controller, which minimizes turbulence and increases performance/efficiency etc.

[0042] The pump controller (1 ) includes connector fittings (6, 7) respectively at the water inlet (4) and outlet (5) that facilitate installation/fitting of the pump controller (1 ). The pipe connector fittings (6, 7) are releasably attachable to the housing (2) via a generally tool-less engagement. Once inserted into the inlet and outlet of the flow passage, a U-shaped retainer clip (6a, 7a) locks the fittings (6, 7) in place and prevents their removal. In the first instance, prior to insertion of the U shaped retainer clip, an O-ring (6b, 7b) encircling each fitting (6, 7) provides for secure snug location of the connector fittings (6, 7) within the flow passage (3). The arms of U shaped retainer clip (6a, 7a) are inserted through a wall of the flow passage and received into a groove (6c, 7c) in the connector fittings (6, 7). Abutment of the flanges of the groove (6c, 7c) with the U shaped retainer clip (6a, 7a) prohibits withdrawal of the connecter fittings. To release the connector fittings (6, 7), the U-shaped retainer clip (8) must first be removed.

[0043] Mounting of the connector fittings (6, 7) within the flow passage (3) of the housing (2) is such that they are permitted to rotate therein. This provides that, after and/or during installation, the pump controller may be rotated to be reoriented. The connector fittings (6, 7) are threaded (not shown) at their outer ends (6d, 7d) for screw type engagement with the relevant pump assembly/piping. It will thus be appreciated that the pump controller may be rotated after installation (1 ) which is particularly helpful as it allows the pump controller (1 ) to be reoriented from any un-favourable position after tightening of the connector fittings to the pump assembly/piping infrastructure.

[0044] The flow passage (3) is substantially tubular, and a valve is included therein that, when closed, prohibits water flow from the outlet side back to the inlet side of the controller (i.e. the valve is a non-return valve). The valve is formed of a closure member (9) that moves into and out of engagement with a valve seat (10) to provide the closed and open positions of the valve. As shown, the valve seat (10) is an internally projecting portion/rim/flange that protrudes from the internal wall of the flow passage (3). The closure member (9) is of a spindle-like form including a head portion (9A) and a stem portion (9B). The head (9A) is configured to engage with the valve seat (10) whilst the stem portion (9B) is slidingly received within a tube mount portion (1 1 ) that is centrally located within the flow passage (i.e. along the elongate central axis of the flow passage). The tube mount portion (1 1 ) is centrally supported within the flow passage by three radial arms that extend from the tube mount to meet the internal wall of the flow passage (3). The closure member (9) is able to slide within the tube mount (1 1 ), to move along the central axis of the flow passage (3), into and out of engagement with the valve seat (10). [0045] The valve is mechanically biased into a closed position. This is achieved using a coil spring (12) that is located on the stem (9B) and extends between the tube mount (1 1 ) and the head portion (9A) such that the expansion force thereof drives the head portion (9A) into the valve seat (1 1 ). It will be appreciated that whilst water flow is blocked from returning to the inlet side from the outlet side, it is permitted to travel from inlet side to the outlet side of the housing when the inlet side water pressure on the valve is such that the closing bias of the valve overcome (i.e. the force of the spring is overcome).

[0046] A pressure sensing means in the form of a pressure transducer/sensor (13) is located in a wall of the flow passage to detect pressure changes in the flow passage at the outlet side. As the pressure transducer/sensor is embedded/concealed in the wall (with a small path (13a) leading to the flow passage), it does not impede water flow through the passage (3) and does not require diversion of water flow therearound. As would be appreciated to a skilled person, this contrasts to and is an improvement over prior art systems (e.g. figure 2), in which diaphragm mounted rods (used pressure sensing (e.g. 202)) significantly impede water flow, increasing turbulence and decreasing efficiency/performance.

[0047] Information from the pressure transducer/sensor (13) is received by a control unit which, in use, is connected to the pump. The control unit is configured to turn the pump on when a pressure decrease occurs that is indicative of opening of an in-line plumbing outlet (e.g. tap) of the water system. In this way, the pump controller (1 ) automatically turns on the pump when water is required, i.e. when a person opens the plumbing outlet. For example, referring to the example set up shown in Figure 1 , when the tap is opened, there would be a pressure decrease at the outlet side of the controller, triggering the controller to turn any connected pump on.

[0048] The controller (1 ) also includes a secondary chamber (20) in fluid communication with the outlet side of the flow passage (3). The secondary chamber (20) includes a spring biased diaphragm (21 ) therein which allows for‘storage’ of water pressure so that water pressure and flow are provided immediately on opening of the in-line outlet whilst the pump is starting up. This ensures water flow from the outlet/tap is smooth and continuous. The‘stored’ or‘buffer’ water pressure provided by the diaphragm also functions to prevent the pump being unintentionally automatically activated when there is a minor pressure decrease due to a small leak. It will be appreciated that on installation, the controller may be initially charged with water to extend the diaphragm to an operational position.

[0049] The control unit also receives input from a valve sensor (15) which monitors operation of the valve. The valve sensor (15) is configured to detect displacement of the closure member (9) from the valve seat (10). In particular, the valve sensor (15) is configured to detect a magnet (14) in the head portion (9A) of the closure member (9). By monitoring displacement of the closure member the valve sensor is able to provide information related to water flow and inlet side pressure. This negates the need for a separate flow sensor valve to obtain such information.

[0050] The control unit is also configured to control the pump based on information received from the valve sensor (15). In particular, the control unit is configured to stop operation of the pump when the closure member (9) returns from an open position to the closed position, which is typically indicative of closure of an open in-line plumbing outlet (i.e. with closure of an open outlet, the pressure difference between the inlet side and the outlet side equalizes, and the force of the spring is sufficient to close the valve). Thus, the pump is automatically turned on by the pump controller with opening of an in-line plumbing outlet and subsequently automatically turned off when the plumbing outlet is later closed. A person does not need to manually operate the pump in addition to opening/closing a relevant plumbing outlet/tap/valve

[0051 ] To facilitate water flow through the flow passage (3), the closure member (9) is permitted to rotate within the tube mount (1 1 ) (i.e. about the central axis of the flow passage). Such that the valve sensor (15) is able to effectively detect the magnet (14) in the head portion (9A) after any rotation, the magnet extends entirely around the rotation axis of the closure member (i.e. is substantially toroidal or ring shaped). [0052] The control unit is also additionally configured to receive input from a pump flow detector which is a current detector that, in use, is connected to the pump motor. The current detector monitors load on the pump motor. When the load on the pump motor is out of a predetermined operating range the control unit will stop the pump. For example, if the valve fails and is stuck in the open position load may reduce below the minimum operating threshold if there is no water to pump or may increase above maximum threshold if the plumbing outlet is closed. The pump flow detector thus provide a protection mechanism for the water pump.

[0053] It will be appreciated that the control unit may take a variety of forms and may include suitably configured electronic circuity/hardware, electronic processing device/s and/or electronic processing system/s. typically, the control unit includes a microcontroller or microcomputer. The control unit is located in an auxiliary portion of the housing (2a) adjacent to the flow passage (3). A shown in figure 6, a control interface (17) is provided on the outside of the housing for inputting information into the control unit (e.g. for calibrating the controller etc.). It will also be appreciated that that the housing (2) is typically formed of a polymer/plastic material (e.g. in one form, it is formed of PA66 GF30).

[0054] It is clear how the presently described pump controller provide several advantages over prior art controllers. In particular, the presently described pump controller can be installed in any orientation, and further, can be readily rotated to be reoriented after installation without having to be disconnected. The presently described pump controller is also less bulky than prior art controllers and is of a simpler internal construction which means less interference with fluid flow through the controller. It also allows for interchangeable connector fittings, e.g. with different diameters, and provides a protection mechanism for any pump motor used therewith.