WO2008106784A1

WO2008106784A1 - Batteryless and contactless keyboard control panel and distributed control system

Info

Publication number: WO2008106784A1
Application number: PCT/CA2008/000423
Authority: WO
Inventors: Brian Neil Southon
Original assignee: Argenia Systems Inc.
Priority date: 2007-03-05
Filing date: 2008-03-05
Publication date: 2008-09-12

Abstract

An improved spa, hydrotherapy tub, bathtub and whirlpool control system utilizing a centralized device controller, a batteryless and contactless removable control keyboard which operates without the use of wires, cables, contacts, and an RF exciter/reader energizing unit. All systems components are interconnected by an expandable digital communications bus. Distributed intelligence is used to partition the software so that the software components which drive the peripheral device (drivers) which are static remain in the device controllers under the tub. Control software which defines the key functions, LED operation, displays, and control parameters is placed in the removable keyboard.

Description

BATTERYLESS AND CONTACTLESS KEYBOARD CONTROL PANEL AND DISTRIBUTED CONTROL SYSTEM

Field of Invention

The present invention relates to the field of control systems for spas, hot-tubs, hydrotherapy tubs, bathtubs, saunas, swimming pools and other like vessels.

Background of the Invention

In the past, spa controllers were specifically designed and built for a known spa configuration. These spa controllers had to be replaced with new spa controllers whenever any new feature or component of the spa was added or additional spa controllers had to be added. Some of these tubs were built with timed relays, mechanical switches and various circuit board options. Some systems used expansion cards in the control and added new cards for expanded features. Adding new features involved specialized wiring and installation. This required significant engineering and manufacturing effort to modify the spa and was not cost effective.

With the advent of the microprocessor, control systems began implementing more and more functionality in software, while using the minimum activation hardware necessary. These systems typically used a central microprocessor driven control box with passive control keyboards. A centralized custom configured control program ran the system. Most changes to the feature set involved changing the control software.

Today, it is not unusual to find more than one microprocessor in the spa/tub control system. Many system peripheral devices such as keyboards, LED lighting, water detection circuits have their own separate microprocessors and use a communications network between devices for high speed digital communications.

In a modern world with global competition, spa manufacturers are looking for ways to streamline manufacturing process by using identical components on a wide variety of models. There is a continued need for a spa controller that can control simple devices as well as intelligent spa components, and that has the flexibility to easily add additional spa components to the spa system. It would be desirable if all of the specific programming was located in one module while all other modules under the tub were identical for all spa configurations. It would be ideal if the custom program were easily accessible without going under the tub, and if the final choice of model and configuration were done at installation time. Manufacturers can build generic tubs and test them. Upon installation, the exact set of features could be decided or changed after installation by replacement of a simple component that controls the operational feature set.

Many keyboard options exist, such as wave mode, pulse mode, pre-programmed massage programs, chromatherapy lighting options, etc, keyboard colors, language, optional displays, computer interfaces and monitoring systems. With the proper design, many of these features can be added to the system in the users home because they are primary software controlled, while the device activation hardware under the tub remains static in its configuration.

Traditionally, keypad installation involves cutting holes in the tub and mounting the keypads with mechanical securing brackets under the tub. The keyboard once mounted, could not be changed to other types if the mounting holes were incompatible. These keyboards require sealing gaskets and leaks are common, exposing cables and connectors to corrosion, oxidation and eventual failure. In addition, membrane keyswitches covered with a mylar decal can crack and let in moisture to the keyboard and cause eventual failure. It would be desirable for a system whereby no holes or mounting brackets were needed for the keyboard, and no connectors and wires were used.

RFID tags and Smart Cards are numerous with present day technologies. These devices derive their energy from a RF magnetic field when the tag is in the proximity of the RF base station. Most systems are limited to credit-card sized low profile cards. Still fewer systems exist in the prior art which contain complete microprocessor systems with human readable display and keyboard. This invention further develops this technology to operate in a harsh and wet environment by creating a sealed and waterproof keyboard unit with no mechanical switches and the intelligence to configure or reconfigure and operate the total tub system. No other control systems utilizing these technologies in this industry are known to us.

Summary of the Invention

An improved spa, hydrotherapy tub, bathtub and whirlpool control system is disclosed. The invention describes a spa control system which utilizes a centralized device controller , a batteryless and contactless removable control keyboard which operates without the use of wires, cables, contacts, and an RF exciter/reader energizing unit. All systems components are interconnected by an expandable digital communications bus.

This invention uses distributed intelligence to partition the software so that the software components which drive the peripheral device

(drivers) which are static remain in the device controllers under the tub. Every model of spa contains a complete set of device drivers each with a large number of software controlled configurations. The portions of the control software which define the key functions, LED operation, displays, and control parameters are placed in the easily removable keyboard. This partitioning of the overall software separates the high level user commands from the low level device specific drivers.

The keypads send high level commands to the intelligent device controllers which do the actual control of the device. For example, the keyboard may be adjusted by the user to set the water temperature at 100 Deg F. The keyboard sends this request to the device controller system which then executes the command and brings the water temperature up to the desired level.

The specific functions of a particular model are stored in the portable keyboard system which can be factory programmed for a variety of mixed functions as required for each model. For basic tubs, a 4 button control can be used which simply controls say one or two devices in the tub. For an upgraded model, the manufacturer need only remove the keyboard and place a larger 6 or 8 key unit which is programmed with many more options and features. The keyboard selection can be determined at the point of sale since the keyboard simply sits on the tub deck with no holes or cables used.

A magnetic attachment system which holds the keyboard on a fixed surface by fixing adjacent magnets under the tub mounting surface. The keyboard is easily rotated for viewing from within and outside the tub or removed and stored so access to the system is secured. For bathtubs with the automatic fill option, the keyboard can be removed so children cannot activate the automatic fill and possibly drown or scald themselves when hot water fills tub.

For a properly designed system, the safety of the user and the equipment is important, and is typically concerned with the elimination of shock hazard through effective insulation and isolated circuitry, which prevents normal supply voltage from reaching the user. Examples of isolation systems for spa side electronic control panels are described in U.S. Pat. Nos. 4,618,797 and 5,332,944. The present invention further increases the safety by providing a superior barrier between the. wet side of the tub and the AC power under the tub.

OBJECTS OF THE INVENTION

The intent of this invention is to provide a batteryless and contactless keyboard that is totally sealed and uses no batteries or electrical cables or wires to operate. Further more, it contains a microcomputer which can store complex programs and bidirectionally communicate with remote device controllers over a wired network. No holes are needed to be drilled in the tub deck. Servicing is simplified without having to go under the tub to replace the control keyboard. No cables or connectors are needed which may corrode over time and create service issues.

For use in severe wet or corrosive environments, it is desirable to have no mechanical moving parts, in the keyboard. Capacitive proximity detection is useful for detecting human finger proximity, but often fail in the presence of an intense high frequency magnetic filed. This invention overcomes this limitation by sampling techniques and key calibration methods which remove interference signals and provides reliable data entry.

The system is comprised of a device controller which is generic, such that it can control pumps speed and provide features such as wave and pulse mode. The device controller also controls air blowers, heaters and RGB LED chromatherapy system. This device receives its specific commands from the intelligent keyboard which directs the device controller to do a specific function on a specific output port. In this manner, one generic device controller can be used in a multitude of device configurations without modification. This greatly simplifies the installation of the electronics under the tub and reduces costs and servicing as well as stocking and distribution is simplified. The manufacturer and service personnel need only stock a generic device controller for all the different models.

Many keyboard options exist, such as wave mode, pulse mode, pre-programmed massage programs, chromatherapy lighting options, etc, keyboard colors, language, optional displays, computer interfaces and monitoring systems. With the proper design, many of these features can be added to the system in the user's home because they are primary software controlled, while the device activation hardware remains under the tub and static in its configuration.

It is the intention of this invention to:

improve reliability by eliminating the need for a seal under the keyboard;

eliminate the cable and connector assembly on a keyboard;

operate in corrosive environments where electrical connectors would oxidize and create reliability issues;

eliminate the need to drill holes in the tub to mount different keyboard models;

improve shock safety by complete user isolation from AC power;

eliminate membrane switches and mechanical switches so that a completely sealed keyboard can be fabricated; simplify the building of a hot tub spa or bathtub electrically;

provide an easily replaced control keyboard can be removed to disallow children from activating the tub;

provide an attractive ultra-low profile design with user display and touch sensitive keypads;

improve serviceability by having an easily replaced control pad and standardized generic device controller;

provide a rapid incorporation of new features and an easily upgrade path through the use of a digital communication network (bus);

simplify stocking of controllers for different models;

provide modular device controllers can be added to a network to expand system;

provide easy incorporation of temperature and water sensors to the system; provide IR remote and RF wireless remote control add-on to existing systems without modifying tub;

provide a magnetic attachment system which holds the keyboard on a fixed surface by placing additional magnets in the mounting surface;

easily removed and stored so access to the system is secured provide a device controller is on a networked bus communication system which allows multiple device controllers to be added in an unlimited fashion;

provide a keyboard with no batteries or power source self contained, so unit does not need to have battery access panels or be able to be opened to change batteries;

operates wirelessly for several inch range to operate through walls, barriers, bulkheads etc.;

provide an explosion-proof keyboard since no arcing at contacts for use where explosive gas may be present;

operate through a glass barrier without wiring. Great on shower walls with no shock hazard; and provide an operator keyboard using capacitive switch technology.

Brief Description of the Drawings

A detailed description of examples of implementation of the present invention is provided herein with reference to the following drawings, in which:

FIG. 1 shows a spa equipped with a keyboard control panel [18] , exciter/reader[3] , wired keyboard[2Q], device controllers[22], spa devices [24],[25],[26],[27] and communications network[30] in accordance with a first specific example of implementation of the present invention;

FIG. 2 shows an enlarged view of the keyboard control panel and exciter/reader shown in FIG. 1;

Detailed Description of the Invention

With regards to figure 1 , the keyboard control panel is shown just above the tub surface just above where the exciter circuit resides. It is shown with the reader orientation being horizontal, but any orientation deemed suitable may be used. The exciter/read[3] radiates a carrier magnetic field which is coupled by magnetic induction to the keyboard control panel[18]. This magnetic field generates power from which to run the keyboard unit. Data entry from the keypads activates the resident control program in the keyboard control panel[18] which then sends the generated command to the exciter/reader by modulating the carrier. The exciter/reader then receives the magnetic field variations and demodulates and decodes the command sequences which are then passed via the communications network to the device controller[23].

The device control ler[22] is also microcomputer based and contains a communication program for receiving and transmitting command codes to/from the system components. Once a command is received, the device controller will immediately begin execution of the command which executes immediately, or in some cases, takes several minutes to be completed. During the execution of the command in the device controller, the keyboard [18] may repeated request system update information about the status of all devices under control of the device controller. The status information is then displayed on the keyboard LED displays.

The separation of device driver code and high level application code greatly simplifies the operation and organization of the spa system as a whole. The device controller[22] has no knowledge of the overall system functionality: It simply sees a string of commands and uses its standardized device libraries of drivers to execute that command. This part of the control system is dependant on the devices only and is therefore static across all spa models. The keyboard[18] contain all the uniqueness of any models feature set, and can be added or changed simply because it resides above the tub and has no mechanical mounting requirements, or drilled holes or cables to run.

A device controller[23] typically drives up to 4 devices. If additional devices are required, a second device controller can be added onto the same communication buss without changing anything else. This modular concept means that systems can grow and expand as required with the same basic building blocks. Typical configuration may assign all blowers and pumps to one controller and the optional heater system on the optional second controller. Both device controllers are identical reduce servicing and system costs because they are identical. The use of a system digital data bus allows more devices, such as water detection sensors[31], overflow sensors, lighting systems[32], floor or surface heaters etc to be added to the data bus without affecting the base level functions. These additional features can be added at installation time if the customer demands them. The serviceman would swap out the keyboard[18] with an upgraded model in order to activate these new functions.

More detailed operation of the exciter/reader and keyboard control [18] is shown in figure 2. The exciter contains an oscillator which runs at the resonant frequency of the coil[1] and capacitor[33] The input data[6] to the exciter/reader comes from the communication network[30] and originated at the device controller[22], or some other peripheral device, such as the water detector[31].The serial data stream drives the modulatory] which modulates the oscillator frequency and phase in accordance with the data.

The exciter/reader also contains a demodulator[8] which detected carrier frequency perturbations cased by the keyboard modulatory 2] and sends the data to the communications buss.

The keyboard control panel[18] has a resonant coil[9] which resonates with capacitor[10] at or near the resonant frequency of the exciter coil. Time and temperature variation will cause the resonant frequency of each respective tank circuit to vary. Maximum power is generated in the keyboard when both coils resonate at the same frequency. A variable capacitance [11] is controlled by the microprocessor[14] which adjusts the capacitor value to achieve maximum voltage from the power rectifier. This adaptive frequency tuning keeps the system locked in frequency. The control processor receives data from the demodulator[15] and sends back data through the modulator [12] to the exciter.

The control processor[14] drives a display unit[16] and several LED annunciators[20] as required by the application program. Status records from the device controller keep the microcomputer informed so that the microcomputer can update the displays in accordance with the states of the peripheral devices.

The sensing capacitive keypads[19] are pcb foil pads which connect to an 8 channel CMOS multiplexor[17], the channel selected as dictates by the control processor[14]. Each cannel is selectively attached to the oscillator[35] and the effective capacitance loading of the keypads will alter the frequency and amplitude of the oscillators output. The microcontroller[14] keeps track of the baseline unoccupied values from each keypad and compares the occupied values to determine the presence of a finger on the keypad[19].

Although the present specification has described embodiments of the invention having a single keyboard control panel , it will be appreciated that the keyboard control panel may be comprised of two units on the network for facilitating usage thereof from multiple locations. Although various embodiments have been illustrated, this was for the purpose of describing, but not limiting, the invention. Various modifications will become apparent to those skilled in the art and are within the scope of this invention, which is defined more particularly by the attached claims.

Part Number Description

1 coil 2 tub wall

3 exciter/reader

5 modulator

6 input data

8 demodulator

9 resonant coil

10 capacitor

11 variable capacitance

12 keyboard modulator

14 microcontroller

15 demodulator

16 display unit

17 multiplexor

18 keyboard control panel

19 sensing capacitive keypads

20 LED annuciators

22 device controller

23 device controller

24 spa devices

25 spa devices

26 spa devices

27 spa devices

28 wired keyboard 30 communication network

31 water detection sensors

32 lighting systems

33 capacitor 35 oscillator

It will be understood that modifications can be made in the embodiments of the invention described herein.

Claims

CLAIMS:I claim,

1. A control system for a spa, pool, bathtub , hydrotherapy tub, or whirlpool control system, shower unit or any other like vessel , said control system comprised of a device controller interposed between the AC mains power, a plurality of air blowers, pumps, thermistors, heater and other tub devices, a detachable batteryless and contactless keyboard control panel , and an exciter/reader unit, all said components being linked together on a common bus utilizing a high level communications network to transfer information unidirectionally and bidirectionally between all said system components.

2. A keyboard control panel as defined in claim 1 , being removable and re- attacheable to the tub surface without using any tools or mechanical fasteners.

3. A keyboard control panel as defined in claim 1 , containing no fixed or replaceable batteries of any kind, no energy storage devices and containing no external electrical cables, wires, connectors or electrical contacts of any kind for the purpose of providing power to the unit.

4. A keyboard control panel as defined in claim 1 where the human interface is comprised of a display panel for displaying system operating parameters.

5. A keyboard control panel as defined in claim 1 , where the data entry method is effected through mechanical switches or membrane switches.

6. A keyboard control panel as defined in claim 1, where the human interface is a keypad operated by capacitive proximity switch means.

7. A proximity switch as defined in claim 6 being comprised of a high frequency oscillator means influenced by capacitive sensing means which form the essential keypad devices.

8. A proximity switch as defined in claim 6 being in the preferred embodiment a planar printed circuit board copper foil pads in the proximity of each keyboard keypad.

9. A proximity switch as defined in claim 8 said sensing pads on the keyboard control panel keypad artwork legend being connected to the oscillator timing components through a switching CMOS multiplexor circuit so that individual keypads are successively switched onto the oscillator means and create deviation in the oscillator frequency or amplitude dependant upon the effective capacitance of the keypad.

10. A keyboard control panel as defined in claim 1 containing a frequency measurement means which measure the exact frequency for the duration that the each sensing pad is successively and cyclically connected through said multiplexor switch to the oscillator, the deviation of the frequency from the baseline unoccupied value determines the presence of the bathers finger on the keypad.

11. A keyboard control panel as defined in claim 1 containing a voltage measurement means which measures the exact voltage of a rectified AC signal for the duration that the each sensing pads is successively and cyclically connect via said multiplexor switch to the oscillator means, the deviation of the voltage from the baseline unoccupied value determines the presence of the bathers finger on the keypad.

12. An exciter/reader unit as defined in claim 1, placed under the tub deck proximate to the tub surface where the detachable keyboard control panel is mounted, said exciter/reader generating an AC magnetic field in the proximity of the keyboard panel for the purpose of powering the detachable keyboard control panel.

13. An exciter/reader unit as defined in claim 1, whereby adaptive frequency control is utilized to keep the carrier frequency in the optimum range for communications with the keyboard control panel.

14. A communications network where serialized command codes are sent unidirectionally or bidirectionally between the said system components including single or multiple device controllers.

15. A keyboard control panel as defined in claim 1, the keyboard being powered through rectification of an AC magnetic field to derive system power to operate the onboard microprocessor, without the use of batteries or contacts or wires connected from the top side of the tub to the tub interior.

16. A keyboard control panel as defined in claim 1 whereby magnetic holding devices are used to secure the keyboard to the tub surface where the tub surface has similar magnetic holding means.

17. A keyboard control panel as defined in claim 1 whereby non slip re- useable adhesive or adhesive-like material secures the keyboard control panel to the tub surface without any mechanical fasteners.

18. A communications system of claim 1, whereby a 16 bit CRC is used to provide data integrity.

19. A keyboard control panel as defined in claim 1 having an envelope and phase detector means to extract information from the modulated magnetic field.

20. A keyboard control panel as defined in claim 1 containing a modulation means to create magnetic disturbances in said incident carrier magnetic field, called backscattering, such that the exciter /reader can sense and decode these intelligent modulations.

21. An exciter/reader unit as defined in claim 1 containing a demodulator which extracts reflected data from the control panel and forward the data on to the device controller.

22. An keyboard control panel as defined in claim 1 , whereby an InfraRed sensing detector is mounted such that InfraRed (heat) energy from the various InfraRED sources (IR) can be measured.

23. An keyboard control panel as defined in claim 1 , whereby an InfraRed sensing detector is mounted such that IR communications may be received from various control devices.

24. An InfraRed source of claim 18, being ambient room temperature.

25. An InfraRed source of claim 18, being ambient water temperature.

26. An InfraRed source of claim 19 being a remote control handheld device with IR sourcing with modulation means which sends commands encoded to the IR sensing device.

27. An InfraRed source of claim 19 a stationary RF to IR converter in direct line of sight to the keypad IR sensing device such that communications is enacted between the stationary RF to IR converter and the IR sensing device of the keyboard control panel.

28. A wall mounted RF to IR converter of claim 23 whereby remote control RF wireless devices can transmit RF commands to the wall mounted RF to IR converter which then relays these commands to the keyboard control panel.

29. A device controller as defined in claim 1 capable of powering and controlling industry known devices such as water pumps, variable speed air blowers, multi-colored LED lighting, silver ion generator, temperature sensing devices, electrical heater, IR heat lamps, and other similar devices.

30. A communication network as defined in claim 1 being a send and receive conductor in a shared buss configuration where all devices can communicate in a controlled access multiplexed arrangement.

31. A communication network as defined in claim 31 whereby each said system component is assigned a unique address so that data and command packets are addressed to each specific device.

32. A communications network of claim 1, whereby a 16 bit CRC is used to provide data integrity.

33. A communications network of claim 1 , whereby additional future devices can be attached to the network to provide additional functionality while preserving the present implementations.

34. A keyboard control panel as defined in claim 1 whereby the separation distance between the devices is in excess of 1 inch and operates through any non-magnetic and non conductive insulation and isolation material.

35. A non-magnetic and non conductive insulation and isolation material as defined in claim 24 said insulation material providing an insulation and isolation capability to enhance operator safety and mitigate electrical eliminate shock hazard by protecting the user from the high voltage AC power wiring.

36. A keyboard control panel as defined in claim 1 whereby all control programs reside in the removable and replaceable control panel thusly, all uniqueness of a particular tub model control features is contained in the control panel programmable intelligence.

37. A keyboard control panel as defined in claim 1 whereby a preprogrammed sequence of blower/pump speed and cycle rate produces a massage action for the user, these preprogrammed massage programs operate by synchronization of multiple blowers, air control valves, water pumps and multi-coloured LED lighting.

38. A device controller as defined in claim 1 capable of powering and controlling industry known devices such as water pumps, variable speed air blowers, multi-colored LED lighting, silver ion generator, temperature sensing devices, electrical heater, IR heat lamps, and other similar devices.

39. A device controller as defined in claim 1 capable of executing all of the command codes received from the keyboard control panel utilizing an operating system composed of a command decoder and all the specific device drivers needed for controlling and execution of the entire command set.

40. A device controller as defined in claim 40 where identical hardware and software resides in each device controller, unique system attributes are achieved through unique sequences of command codes sent from the keyboard control panel.

41. A keyboard control panel as defined in claim 1, being totally sealed and waterproof and contain no mechanical or moving parts, hence is immune to water, chemical vapors and oxidation and may reliably operate in corrosive environments where electrical connectors would oxidize.

42. A keyboard control panel as defined in claim 1 , in a second embodiment, is a capacitively operated proximity switch, but is interfaced through direct connection to the communications bus and operates in an identical fashion otherwise as the magnetically coupled keyboard control panel describe herein.