U.S. patent application number 12/288331 was filed with the patent office on 2009-05-14 for automatic bathroom flushers.
Invention is credited to Gregory P. Greene, Fatih Guler, Kay Herbert, Xiaoxiong Mo, Natan E. Parsons.
Application Number | 20090121171 12/288331 |
Document ID | / |
Family ID | 46123998 |
Filed Date | 2009-05-14 |
United States Patent
Application |
20090121171 |
Kind Code |
A1 |
Parsons; Natan E. ; et
al. |
May 14, 2009 |
Automatic bathroom flushers
Abstract
An automatic bathroom flusher includes a body having an inlet in
communication with a supply line and an outlet in communication
with a flush conduit, a valve assembly in the body positioned to
close water flow between the inlet and the outlet upon sealing
action of a moving member at a valve seat thereby controlling flow
from the inlet to the outlet, an actuator for actuating operation
of the moving member, and a controller.
Inventors: |
Parsons; Natan E.;
(Brookline, MA) ; Guler; Fatih; (Winchester,
MA) ; Herbert; Kay; (Winthrop, MA) ; Mo;
Xiaoxiong; (Lexington, MA) ; Greene; Gregory P.;
(Waltham, MA) |
Correspondence
Address: |
IVAN DAVID ZITKOVSKY PH.D PC
5 MILITIA DRIVE
LEXINGTON
MA
02421
US
|
Family ID: |
46123998 |
Appl. No.: |
12/288331 |
Filed: |
October 18, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10859750 |
Jun 3, 2004 |
7437778 |
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12288331 |
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PCT/US02/38758 |
Dec 4, 2002 |
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10859750 |
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10012252 |
Dec 4, 2001 |
6691979 |
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PCT/US02/38758 |
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10012226 |
Dec 4, 2001 |
6619614 |
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10012252 |
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Current U.S.
Class: |
251/129.15 ;
137/511 |
Current CPC
Class: |
E03C 1/05 20130101; E03D
5/105 20130101; E03D 3/02 20130101; Y10T 137/7837 20150401 |
Class at
Publication: |
251/129.15 ;
137/511 |
International
Class: |
F16K 31/02 20060101
F16K031/02; F16K 31/00 20060101 F16K031/00 |
Claims
1-20. (canceled)
21. An electromagnetic actuator system, comprising: an actuator
including a solenoid coil and an armature housing constructed and
arranged to receive in a movable relationship an armature; a
controller coupled to a power driver constructed to provide a drive
signal to said solenoid coil for displacing said armature and
thereby open or close a valve passage for fluid flow; and an
actuator sensor constructed and arranged to sense a position of
said armature and provide a signal to said controller.
22. The actuator system of claim 21 wherein said sensor is
constructed to detect voltage induced by movement of said
armature.
23. The actuator system of claim 22 wherein said sensor is
constructed and arranged to detect changes to said drive signal due
to the movement of said armature.
24. The actuator system of claim 22 wherein said sensor includes a
resistor arranged to receive at least a portion of said drive
signal, and a voltmeter constructed to measure voltage across said
resistor.
25. The actuator system of claim 22 wherein said sensor includes a
coil sensor constructed and arranged to detect said voltage induced
by movement of said armature.
26. The actuator system of claim 25 wherein said coil sensor is
connected in a feedback arrangement to a signal conditioner
providing conditioned signal to said controller.
27. The actuator system of claim 26 wherein said signal conditioner
includes a preamplifier and a low-pass filter.
28. The actuator system of claim 22 wherein said sensor includes
two coil sensors each constructed and arranged to detect said
voltage induced by movement of said armature.
29. The actuator system of claim 28 wherein said coil sensors are
connected in a feedback arrangement to a differential amplifier
constructed to provide a differential signal to said
controller.
30. The actuator system of claim 21 wherein said actuator sensor
includes an optical sensor.
31. The actuator system of claim 21 wherein said actuator sensor
includes a capacitance sensor.
32. The actuator system of claim 21 wherein said actuator sensor
includes a bridge for sensitively detecting a signal change due to
movement of said armature.
33. The actuator system of claim 21 wherein said armature housing
is constructed and arranged for a linear displacement of said
armature upon said solenoid receiving said drive signal.
34. The actuator system of claim 33 wherein said actuator is a
latching actuator constructed to maintain said armature in said
open passage state without any drive signal being delivered to said
solenoid coil.
35. The actuator system of claim 34 wherein said latching actuator
includes a permanent magnet arranged to maintain said armature in
said open passage state.
36. The actuator system of claim 14 wherein said latching actuator
further includes a bias spring positioned and arranged to bias said
armature toward an extended position providing a close passage
state without any drive signal being delivered to said solenoid
coil.
37. The actuator system of claim 21 further including a presence
sensor coupled to said controller.
38. A valve device, comprising: a fluid input port and a fluid
output port; a valve body defining a valve cavity and including a
valve closure surface; and a fram assembly providing two pressure
zones and being movable within said valve cavity with respect a
guiding member; said fram assembly being constructed to move to an
open position enabling fluid flow from said fluid input port to
said fluid output port upon reduction of pressure in a first of
said pressure zones; and being constructed to move to a closed
position, upon increase of pressure in said first pressure zone,
creating a seal at said valve closure surface.
39. The valve device of claim 38, wherein said two pressure zones
include two chambers separated by said fram assembly and wherein
said first pressure zone includes a pilot chamber.
40. The valve device of claim 39 including an operator constructed
and arranged to release pressure in said pilot chamber and thereby
initiate movement of said fram member from said closed position to
said open position.
41. The valve device of claim 40, wherein said operator includes a
latching actuator.
42. The valve device of claim 40, wherein said operator includes a
non-latching actuator.
43. The valve device of claim 40, wherein said operator includes an
actuator having an isolation membrane for containing fluid inside a
plunger cavity of said actuator.
44. The valve device of claim 38 wherein said fram assembly
includes a pliable member and a stiff member, said pliable member
being constructed to come in contact with said valve closure
surface to form said seal in said closed position.
45. The valve device of claim 44, wherein said valve closure
surface includes a lip providing said seal in said closed
position.
46. The valve device of claim 38 including a bias member.
47. The valve device of claim 44 wherein said bias member is
constructed and arranged to assist movement of said fram member
from said open position to said closed position.
48. The valve device of claim 44 wherein said bias member includes
a spring.
49-51. (canceled)
Description
[0001] This application is a divisional of U.S. application Ser.
No. 10/859,750, now U.S. Pat. No. 7,437,778, which is a
continuation of PCT Applicat. PCT/US02/38758, which is a
continuation-in-part of U.S. application Ser. No. 10/012,252,
entitled "Adaptive Object-Sensing System for Automatic Flushers"
filed on Dec. 4, 2001; U.S. application Ser. No. 10/012,226,
entitled "Automatic Flow Controller Employing Energy-Conservation
Mode" filed on Dec. 4, 2001; U.S. application Ser. No. 10/011,390,
entitled "Assembly of Solenoid controlled Pilot-Operated Valve"
filed on Dec. 4, 2001; U.S. application Ser. No. 60/012,252,
entitled "Controlling a Solenoid Based on Current Time Profile"
filed on Mar. 5, 2002; U.S. application Ser. No. 60/391,282,
entitled "High Flow-Rate Diaphragm Valve And Control Method" filed
on Jun. 24, 2002; and U.S. application Ser. No. 60/424,378 entitled
"Automatic Bathroom Flushers for Long-Term Operation" filed on Nov.
6, 2002; all of which are incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is directed to automatic bathroom
flushers and methods for operating and controlling such
flushers.
[0004] 2. Background Information
[0005] Automatic flow-control systems have become increasingly
prevalent, particularly in public rest-room facilities, both
toilets and urinals. Automatic faucets and flushers contribute to
hygiene, facility cleanliness, and water conservation. In such
systems, object sensors detect the user and operate a flow-control
valve in response to user detection. In the case of an automatic
faucet, for instance, presence or motion of a user's hands in the
faucet's vicinity normally results in flow from the faucet. In the
case of an automatic flusher, detection of the fact that a user has
approached the facility and then left is typically what triggers
flushing action.
[0006] Although the concept of such object-sensor-based automatic
flow control is not new, its use has been quite limited until
recently. The usage is becoming more widespread due to the recent
availability of battery-powered conversion kits. These kits make it
possible for manual facilities to be converted into automatic
facilities through simple part replacements that do not require
employing electricians to wire the system to the supply grid. A
consequence of employing such battery-powered systems is that the
batteries eventually need to be replaced.
[0007] There is still a need for automatic flushers that are highly
reliable and can operate for a long time without any service or
just minimal service.
SUMMARY OF THE INVENTION
[0008] The described inventions are directed to automatic bathroom
flushers and methods for operating and controlling such
flushers.
[0009] According to one aspect, the present invention is a bathroom
flusher. The bathroom flusher includes a body, a valve assembly,
and an actuator. The body has an inlet and an outlet, and the valve
assembly is located in the body and positioned to close water flow
between the inlet and the outlet upon sealing action of a moving
member at a valve seat thereby controlling flow from the inlet to
the outlet. The actuator actuates operation of the moving
member.
[0010] The moving member may be a high flow rate fram member, or a
standard diaphragm, or a piston. The bathroom flusher may further
include an infra-red sensor assembly for detecting a urinal or
toilet user. The bathroom flusher may further include different
types of electromechanical, hydraulic, or only mechanical
actuators.
[0011] According to another aspect, the present invention is a
bathroom flusher that includes a cover mounted upon said body and
defining a pressure chamber with the valve assembly. The bathroom
flusher may further include a flexible member fixed relative to the
cover at one end thereof, the other end of the flexible member
being attached to a movable member of the valve assembly, wherein
there is a passage in said flexible member arranged to reduce
pressure in said pressure chamber. The flexible member may be a
hollow tube.
[0012] Preferably, the bathroom flusher may include an automatic
flow-control system. The automatic flow-control system may employ
infrared-light-type object sensors.
[0013] Another important aspect of the present inventions is a
novel design of an infrared-light-type object sensor including an
indicator. In the IR sensor, an IR source (typically an
infrared-light-emitting diode) is positioned behind an
infrared-light-transmitting aperture as to transmit the infrared
light into a target region. The indicator may be a
visible-light-emitting diode included in an LED-combination device
in which it is connected antiparallel to the
infrared-light-emitting diode. When the combination device is
driven in one direction, the infrared source shines normally
through an appropriate aperture. When the device is driven in the
other direction, visible light instead shines through the same
aperture as the infrared light did. This arrangement avoids
separate provisions for the visible light's location or
transmission.
[0014] Yet another important aspect of the present inventions is a
novel algorithm for operating an automatic flusher. The automatic
flusher employs an infrared-light-type object sensor for providing
an output on the basis of which a control circuit decides whether
to flush a toilet. After each pulse of transmitted radiation, the
control circuit determines if the resultant percentage of reflected
radiation differs significantly from the last, and determines
whether the percentage change was positive or negative. From the
determined subsequent data having a given direction and the sums of
the values, the control circuit determines whether a user has
approached the facility and then withdrawn from it. Based on this
determination, the controller operates the flusher's valve. That
is, the control circuit determines the flush criteria based on
whether a period in which the reflection percentage decreased (in
accordance with appropriate withdrawal criteria) has been preceded
by a period in which the reflection percentage increased (in
accordance with appropriate approach criteria). In this embodiment,
the control circuit does not base its determination of whether the
user has approached the toilet on whether the reflection percentage
has exceeded a predetermined threshold, and it does not base a
determination of whether the user has withdrawn from the toilet on
whether the reflection percentage has fallen below a predetermined
threshold.
[0015] Yet another important aspect of the present inventions is
novel system and method for storing or shipping the above-described
automatic flushers. The automatic flushers may include an object
sensor (e.g., an IR sensor) and a manual a push button actuator.
When the flusher is operational, the push button is designed for a
user to provide signal to the control circuit to open the flusher's
valve. However, if the button actuator has been pressed continually
for an extended period, the control circuit assumes a sleep mode,
in which its power consumption is negligible. A storage or shipping
container may be designed to activate the button actuator while the
container is closed. As a consequence, the flusher can be packed
with the control circuit's batteries installed without draining
those batteries significantly during shipping and storage.
Alternatively, the storage or shipping container may include an
external magnet cooperatively arranged together with a reed sensor
connected to the control circuit. If the magnet continually
activates the reed sensor for an extended period, the control
circuit assumes the sleep mode, in which its power consumption is
negligible. There are also other "sleep mode inducing" devices that
allow batteries to be installed without draining battery power
significantly during the shipping and storage.
[0016] According to yet another aspect, the present invention is a
novel valve device and the corresponding method for controlling
flow-rate of fluid between the input and output ports of the valve
device. A novel valve device includes a fluid input port and a
fluid output port, a valve body, and a fram assembly. The valve
body defines a valve cavity and includes a valve closure surface.
The fram assembly provides two pressure zones and is movable within
the valve cavity with respect a guiding member. The fram assembly
is constructed to move to an open position enabling fluid flow from
the fluid input port to the fluid output port upon reduction of
pressure in a first of the two pressure zones and is constructed to
move to a closed position, upon increase of pressure in the first
pressure zone, creating a seal at the valve closure surface.
[0017] According to preferred embodiments, the two pressure zones
are formed by two chambers separated by the fram assembly, wherein
the first pressure zone includes a pilot chamber. The guiding
member may be a pin or internal walls of the valve body.
[0018] The fram member (assembly) may include a pliable member and
a stiff member, wherein the pliable member is constructed to come
in contact with a valve closure surface to form seal (e.g., at a
sealing lip located at the valve closure surface) in the closed
position. The valve device may include a bias member. The bias
member is constructed and arranged to assist movement of the fram
member from the open position to the closed position. The bias
member may be a spring.
[0019] The valve is controlled, for example, by an
electromechanical operator constructed and arranged to release
pressure in the pilot chamber and thereby initiate movement of the
fram assembly from the closed position to the open position. The
operator may include a latching actuator (as described in U.S. Pat.
No. 6,293,516, which is incorporated by reference), a non-latching
actuator (as described in U.S. Pat. No. 6,305,662, which is
incorporated by reference), or an isolated operator (as described
in PCT Application PCT/US01/51098, which is incorporated by
reference). The valve may also be controlled may also including a
manual operator constructed and arranged to release pressure in the
pilot chamber and thereby initiate movement of the fram member from
the closed position to the open position.
[0020] The novel valve device including the fram assembly may be
used to regulate water flow in an automatic or manual bathroom
flusher.
[0021] According to yet another aspect, the present invention is a
novel electromagnetic actuator and a method of operating or
controlling such actuator. The electromagnetic actuator includes a
solenoid wound around an armature housing constructed and arranged
to receive an armature including a plunger partially enclosed by a
membrane. The armature provides a fluid passage for displacement of
armature fluid between a distal part and a proximal part of the
armature thereby enabling energetically efficient movement of the
armature between open and closed positions. The membrane is secured
with respect to the armature housing and is arranged to seal
armature fluid within an armature pocket having a fixed volume,
wherein the displacement of the plunger (i.e., distal part or the
armature) displaces the membrane with respect to a valve passage
thereby opening or closing the passage. This enables low energy
battery operation for a long time.
[0022] Preferred embodiments of this aspect include one or more of
the following features: The actuator may be a latching actuator
(including a permanent magnet for holding the armature) of a
non-latching actuator. The distal part of the armature is
cooperatively arranged with different types of diaphragm membranes
designed to act against a valve seat when the armature is disposed
in its extended armature position. The electromagnetic actuator is
connected to a control circuit constructed to apply said coil drive
to said coil in response to an output from an optional armature
sensor.
[0023] The armature sensor can sense the armature reaching an end
position (open or closed position). The control circuit can direct
application of a coil drive signal to the coil in a first drive
direction, and in responsive to an output from the sensor meeting a
predetermined first current-termination criterion to start or stop
applying coil drive to the coil in the first drive direction. The
control circuit can direct or stop application of a coil drive
signal to the coil responsive to an output from the sensor meeting
a predetermined criterion.
[0024] According to yet another aspect, the present invention is a
novel assembly of an electromagnetic actuator and a piloting
button. The piloting button has an important novel function for
achieving consistent long-term piloting of a main valve. The
present invention is also a novel method for assembling a
pilot-valve-operated automatic flow controller that achieves a
consistent long-term performance.
[0025] Method of assembling a pilot-valve-operated automatic flow
controller includes providing a main valve assembly and a
pilot-valve assembly including a stationary actuator and a pilot
body member that includes a pilot-valve inlet, a pilot-valve seat,
and a pilot-valve outlet. The method includes securing the
pilot-valve assembly to the main valve assembly in a way that fluid
flowing from a pressure-relief outlet of the main valve must flow
through the pilot-valve inlet, past the pilot-valve seat, and
through the pilot-valve outlet, whereby the pilot-valve assembly is
positioned to control relief of the pressure in the pressure
chamber (i.e., pilot chamber) of the main valve assembly. The main
valve assembly includes a main valve body with a main-valve inlet,
a main-valve seat, a main-valve outlet, a pressure chamber (i.e., a
pilot chamber), and a pressure-relief outlet through which the
pressure in the pressure chamber (pilot chamber) can be relieved. A
main valve member (e.g., a diaphragm, a piston, or a fram member)
is movable between a closed position, in which it seals against the
main-valve seat thereby preventing flow from the main inlet to the
main outlet, and an open position, in which it permits such flow.
During the operation, the main valve member is exposed to the
pressure in the pressure chamber (i.e., the pilot chamber) so that
the pressurized pilot chamber urges the main valve member to its
closed position, and the unpressurized pilot chamber (when the
pressure is relieved using the pilot valve assembly) permits the
main valve member to assume its open position.
[0026] According to yet another aspect, the present invention is a
novel electromagnetic actuator system. This electromagnetic
actuator system includes an actuator, a controller, and an actuator
sensor. The actuator includes a solenoid coil and an armature
housing constructed and arranged to receive in a movable
relationship an armature. The controller is coupled to a power
driver constructed to provide a drive signal to the solenoid coil
for displacing the armature and thereby open or close a valve
passage for fluid flow. The actuator sensor is constructed and
arranged to sense a position of the armature and provide a signal
to the controller.
[0027] Preferred embodiments of this aspect include one or more of
the following features: The sensor is constructed to detect voltage
induced by movement of the armature. Alternatively, the sensor is
constructed and arranged to detect changes to the drive signal due
to the movement of the armature.
[0028] Alternatively, the sensor includes a resistor arranged to
receive at least a portion of the drive signal, and a voltmeter
constructed to measure voltage across the resistor. Alternatively,
the sensor includes a resistor arranged to receive at least a
portion of the drive signal, and a differentiator receiving current
flowing through the resistor.
[0029] Alternatively, the sensor includes a coil sensor constructed
and arranged to detect the voltage induced by movement of the
armature. The coil sensor may be connected in a feedback
arrangement to a signal conditioner providing conditioned signal to
the controller. The signal conditioner may include a preamplifier
and a low-pass filter.
[0030] Alternatively, the system includes two coil sensors each
constructed and arranged to detect the voltage induced by movement
of the armature. The two coil sensors may be connected in a
feedback arrangement to a differential amplifier constructed to
provide a differential signal to the controller.
[0031] The actuator sensor includes an optical sensor, a
capacitance sensor, an inductance sensor, or a bridge for
sensitively detecting a signal change due to movement of the
armature.
[0032] The actuator may have the armature housing constructed and
arranged for a linear displacement of the armature upon the
solenoid receiving the drive signal. The actuator may be a latching
actuator constructed to maintain the armature in the open passage
state without any drive signal being delivered to the solenoid
coil. The latching actuator may include a permanent magnet arranged
to maintain the armature in the open passage state. The latching
actuator may further include a bias spring positioned and arranged
to bias the armature toward an extended position providing a close
passage state without any drive signal being delivered to the
solenoid coil.
[0033] The controller may be constructed to direct the power driver
to provide the drive signal at various levels depending on the
signal from the actuator sensor. The drive signal may be current.
The system may include a voltage booster providing voltage to the
power driver.
[0034] The controller may be constructed to direct the power driver
to provide the drive signal in a first drive direction and thereby
create force on the armature to achieve a first end position. The
controller is also constructed to determine whether the armature
has moved in a first direction based on signal from the actuator
sensor; and if the armature has not moved within a predetermined
first drive duration, the controller directs application of the
drive signal to the coil in the first direction at an elevated
first-direction drive level that is higher than an initial level of
the drive signal.
[0035] The controller may be constructed to trigger the power
driver to provide the drive signal in a first drive direction and
thereby create force on the armature to achieve a first end
position. The controller is also constructed to determine whether
the armature has moved in a first direction based on signal from
the actuator sensor; and if the armature has moved, the controller
directs application of the drive signal to the coil in the first
direction at a first-direction drive level that is being lower than
an initial level of the drive signal.
[0036] The actuator system may include the controller constructed
to determine a characteristic of the fluid at the passage based on
the signal from the actuator sensor. The characteristic of the
fluid may be pressure, temperature, density, or viscosity. The
actuator system may include a separate a temperature sensor for
determining temperature of the fluid.
[0037] The actuator system may include the controller constructed
to determine a pressure of the fluid at the passage based on the
signal from the actuator sensor. The actuator system may receive
signals from an external motion sensor or a presence sensor coupled
to the controller.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a side elevation of a toilet and an accompanying
automatic flusher.
[0039] FIG. 1A is a side view of a urinal and an accompanying
automatic flusher.
[0040] FIGS. 2A and 2B together form a cross-sectional view of a
first embodiment of the flusher.
[0041] FIGS. 2A and 3B together form a cross-sectional view of a
second embodiment of the flusher.
[0042] FIG. 4 is a cross-sectional view of a third embodiment of
the flusher.
[0043] FIG. 4A is a block diagram of the flusher's control
circuitry.
[0044] FIG. 5 is an enlarged sectional view of a valve for
controlling fluid flow in the flusher shown in FIG. 4.
[0045] FIG. 5A is a perspective exploded view of the valve shown in
FIG. 5.
[0046] FIG. 5B is an enlarged sectional view of another embodiment
of the valve shown in FIG. 5.
[0047] FIG. 5C is an enlarged sectional view of another embodiment
of the valve shown in FIG. 5.
[0048] FIG. 6 is a front elevation of an alternative version's
transmitter and receiver lenses and front circuit-housing part.
[0049] FIG. 6A is a cross-section taken at line 6A-6A of FIG.
6.
[0050] FIG. 6B is an isometric view of a container that can be used
for a subassembly of a flusher conversion kit.
[0051] FIG. 6C is a cross section taken at line 6C-6C of FIG.
6B.
[0052] FIG. 6D is an isometric view of a container that may be
employed for a flusher conversion kit of the type depicted in FIG.
2 or FIG. 3.
[0053] FIG. 6E is a detailed cross section of a button-depression
device included in a container.
[0054] FIG. 7 is a sectional view of a first embodiment of an
electromechanical actuator for controlling any one of the valves
shown in FIGS. 5 through 5B.
[0055] FIG. 7A is a perspective exploded view of the
electromechanical actuator shown in FIG. 7
[0056] FIG. 7B is a sectional view of a second embodiment of an
electromechanical actuator for controlling the valves shown in
FIGS. 5 through 6B.
[0057] FIG. 7C is a sectional view of a third embodiment of an
electromechanical actuator for controlling the valves shown in
FIGS. 5 through 6B.
[0058] FIG. 7D is a sectional view of another embodiment of a
membrane used in the actuator shown in FIGS. 7 through 7C.
[0059] FIGS. 7E is a sectional view of another embodiment of the
membrane and a piloting button used in the actuator shown in FIGS.
7 through 7C.
[0060] FIG. 7F is a sectional view of another embodiment of an
armature bobbin used in the actuator shown in FIGS. 7 through
7C.
[0061] FIG. 8 is a block diagram of another embodiment of a control
system for controlling operation of the electromechanical actuator
shown in FIGS. 7, 7A, 7B or 7C.
[0062] FIG. 8A is a block diagram of yet another embodiment of a
control system for controlling operation of the electromechanical
actuator shown in FIGS. 7, 7A, 7B or 7C.
[0063] FIG. 8B is a block diagram of data flow to a microcontroller
used in the fluid flow control system of FIGS. 8A or 8B.
[0064] FIGS. 9 and 9A show the relationship of current and time for
the valve actuator shown in FIG. 7, 7A, 7B or 7C connected to a
water line at 0 psi and 120 psi reverse flow pressure,
respectively.
[0065] FIG. 9B illustrates a dependence of the latch time on the
water pressure for the actuator shown in FIG. 7, 7A, 7B or 7C.
[0066] FIG. 10 is a flow diagram of a flushing cycle used to
control the flushers shown in FIGS. 2, 3 or 4.
[0067] FIG. 11 is a schematic diagram of the circuitry that the
flusher uses to drive its light-emitting diodes.
[0068] FIGS. 12A, 12B, and 12C together form a simplified
flow-charts a routine that the control circuitry of FIG. 4A
executes.
[0069] FIGS. 13A and 13B together form a more-detailed flow chart
of a step in the routine of FIGS. 12A, 12B, and 12C.
[0070] FIG. 14 illustrates a novel algorithm for controlling
operation of the flushers
[0071] FIG. 15 is a front view of another embodiment of an
automatic flusher and FIG. 15A is a cross-section taken at line
15A-15A in FIG. 15.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0072] In FIG. 1, a flusher 10 receives pressurized water from a
supply line 12 and employs an object sensor, typically of the
infrared variety, to respond to actions of a target within a target
region 14 by selectively opening a valve that permits water from
the supply line 12 to flow through a flush conduit 16 to the bowl
of a toilet 18. FIG. 1A illustrates a flusher 10 for automatically
flushing a urinal 18A. As described above, flusher 10 receives
pressurized water from supply line 12 and employs the object sensor
to respond to actions of a target within a target region 14A by
selectively opening a valve that permits water from the supply line
12 to flow through the flush conduit 16 to the urinal 18A.
[0073] FIGS. 2A and 2B illustrate in detail a first embodiment of
automatic flusher 10. FIG. 2B shows supply line 12, which
communicates with an annular entrance chamber 20 defined by an
entrance-chamber wall 22 formed near the flush conduit 16's upper
end. A pressure cap 24 secured by a retaining ring 25 to the
chamber housing clamps between itself and that housing the outer
edge 26 of a flexible diaphragm 28 seated on a main valve seat 30
formed by the flush conduit 16's mouth.
[0074] The supply pressure that prevails in the entrance chamber 20
tends to unseat the flexible diaphragm 28 and thereby cause it to
allow water from the supply line 12 to flow through the entrance
chamber 20 into the flush conduit 16's interior 32. But the
diaphragm 28 ordinarily remains seated because of pressure
equalization that a bleed hole 34 formed by the diaphragm 28 tends
to permit between the entrance chamber 20 and a main pressure
chamber 36 formed by the pressure cap 24. Specifically, the
pressure that thereby prevails in that upper chamber 36 exerts
greater force on the diaphragm 28 than the same pressure within
entrance chamber 20 does, because the entrance chamber 20's
pressure prevails only outside the flush conduit 16, whereas the
pressure in the main pressure chamber 36 prevails everywhere
outside of a through-diaphragm feed tube 38.
[0075] The flusher also include a solenoid-operated actuator
assembly, that can include any known solenoid or can include an
actuator assembly 40 described in U.S. Pat. Nos. 6,293,516 or
6,305,662 both of which are incorporated by reference.
Alternatively, the solenoid-operated actuator assembly includes an
isolated actuator assembly 40A described in detail in PCT
Application PCT/US01/51098, filed on Oct. 25, 2001, which is
incorporated by reference as if fully reproduced herein. The
isolated actuator assembly 40A is also in this application called a
sealed version of the operator.
[0076] To flush the toilet 18, the solenoid-operated actuator
assembly 40 controlled by circuitry 42 relieves the pressure in the
main pressure chamber 38 by permitting fluid flow, in a manner to
be described in more detail below, between pilot entrance and exit
passages 44 and 46 formed by the pressure cap 24's pilot-housing
portion 48. A detailed description of operation is provided
below.
[0077] FIG. 3 (formed by FIGS. 2A and 3B) illustrates in detail a
second embodiment of automatic flusher 10. This embodiment uses a
novel high flow rate valve 600 (shown in FIG. 3B) utilizing a fram
assembly described in detail in connection with FIG. 5C below.
Referring to FIGS. 2A and 3B, automatic flusher 10 receives water
input from supply line 12, which is in communication with a pliable
member 628 supported by a support member 632 of a fram member 626.
Grooves 638 and 638A provide water passages to a pilot chamber 642.
The actuator relieves pressure in pilot chamber 642 and thus
initiate opening of valve 600. Then water flows from input line 12
by a valve seat 625 to output chamber 32. The entire flushing cycle
is controlled by the solenoid-operated actuator assembly 40
controlled by circuitry 42, shown in FIG. 2A. A detailed
description of operation is provided below.
[0078] FIG. 4 illustrates in detail a third embodiment of automatic
flusher 10. Automatic flusher 10 is a high performance,
electronically controlled or manually controlled tankless flush
system. Water enters thru input union 12, preferably made of a
suitable plastic resin. Union 12 is attached via thread to input
fitting 12A that interacts with the building water supply system.
Furthermore, union 12 is designed to rotate on its own axis when no
water is present so as to facilitate alignment with the inlet
supply line.
[0079] Referring still to FIG. 4, union 12 is attached to an inlet
pipe 64 by a fastener 60 and a radial seal 62, which enables union
12 to move in or out along inlet pipe 64. This movement can align
the inlet to the supply line. However, with fastener 60 secured,
there is pressure applied by the junction of union 12 to inlet 60.
This forms a unit that is rigid and sealed through seal number 62.
The water supply travels through union 12 to inlet 64 and thru the
inlet valve assembly in the direction of elements 76, 78, 70, 72,
and 74. Automatic flusher 10 also includes an inlet screen filter
80, which resides in a passage formed by member 82 and is in
communication with a main valve seat 525, the operation of the
entire main valve is described in connection with FIGS. 5, 5A and
5B.
[0080] As described in connection with FIGS. 5, 5A and 5B, an
electro-magnetic actuator 50 controls operation of the main valve.
In the opened state, water flows thru passage 528 thru passage 528A
thru passage 528B into main outlet 32. In the closed state, the
fram element 528 seals the valve main seat 525.
[0081] Automatic flusher 10 includes an adjustable input valve 72
controlled by rotation of a valve element 54 threaded together with
valve elements 514 and 540, which are sealed from body 54 via
o-ring seals 84 and 54A. Valve elements 514 and 540 of the assembly
are held down by threaded element 52, when element 52 is threaded
all the way. The resulting force presses down element 82 on valve
element 72 therefore creating a path from inlet 78 to passage of
body 82. When valve element 52 is unthreaded all the way, valve
assembly 514 and 540 moves up due to the force of the spring
located in the adjustable valve 70. The spring force combined with
fluid pressure from inlet 78 forces element 72 against seat 72A
resulting in a sealing action. Seal element 74 blocks the flow of
water to inner passage of 82, which in turn enables servicing of
all internal valve elements including elements 82, 50, 514, 50, and
528 without the need to shut off the water supply at the inlet 12.
This is a major advantage of this embodiment.
[0082] According to another function of adjustable valve 70, the
threaded retainer is fastened part way resulting in valve body
elements 514 and 82 to push down valve seat 72 only partly. There
is a partial opening that provides a flow restriction reducing the
flow of input water thru valve 70. This novel function is designed
to meet application specific requirements. In order to provide for
the installer the flow restriction, the inner surface of valve body
54 includes application specific marks such as 1.6 W.C., 1.0 GPF
urinals etc.
[0083] Automatic flusher 10 includes a sensor-based electronic
flush system located in housing 144 and described in connection
with FIG. 2A. Furthermore, the sensor-based electronic flush system
may be replaced by an all mechanical activation button or lever.
Alternatively, the flush valve may be controlled by a hydraulically
timed mechanical actuator that acts upon a hydraulic delay
arrangement. Such hydraulic system can reside in housing 144. The
hydraulic system can be adjusted to a delay period corresponding to
the needed flush volume for a given fixture such a 1.6 GPF W.C etc.
The hydraulic delay mechanism can open the outlet orifice of the
pilot section instead of electromagnetic actuator 50 (shown in FIG.
4) for duration equal to the installer preset value.
[0084] Alternatively, control circuitry 42 can be modified so that
the sensory elements housed in housing 144 are replaced with a
timing control circuit. Upon activation of the flusher by an
electromechanical switch (or a capacitance switch), the control
circuitry initiates a flush cycle by activating electromagnetic
actuator 50 for duration equal to the preset level. This level can
be set at the factory or by the installer in the field. This
arrangement can be combined with the static pressure measurement
scheme described below for compensating the pressure influence upon
the desired volume per each flush.
[0085] The embodiment of FIG. 4 has several advantages. The
hydraulic or the electromechanical control system can be serviced
without the need to shut off the water supply to the unit.
Furthermore, the valve mechanism enables controlling the quantity
of fluid that is passed thru the unit. The main flush valve
includes the design shown in detail in connection with FIGS. 5, 5A,
and 5B. This flush valve arrangement provides for a high flow rate
(for its valve size) when compared to conventional diaphragm type
flush valves, as shown in FIG. 2B.
[0086] The embodiment of FIG. 4 provides fluid control valves in
combination with a low power bi-stable electro magnetic actuator
that combined with the described control circuitry can precisely
control the delivered water volume per each flush. As described
below, the capability of measuring fluid static pressure and in
turn altering the main valve open time controls dynamically the
delivered volume. That is, this system can deliver a selected water
volume regardless of the pressure variation in the water supply
line.
[0087] The system can include a flexible conducting spring contact
arrangement for converting electrical control signals from the
control electronics to the electro magnetic actuator without the
use of a wire/connector arrangement. The system can also enable
actuation of the main flush valve using a direct mechanical lever
or a mechanical level actuating upon a hydraulic delay arrangement
that in turn acts upon the main valve pilot arrangement. The
individual functions are described in detail below.
[0088] FIG. 5 illustrates a preferred embodiment of a valve 500
used in the faucet embodiment shown in FIG. 3 or 4. Valve device
500 includes a valve body 513 providing a cavity for a valve
assembly 514, an input port 518, and an output port 520. Valve
assembly 514 includes a proximal body 522, a distal body 524, and a
fram member 526 (FIG. 5A). Fram member 526 includes a pliable
member 528 and a support member 532. Pliable member 528 may be a
diaphragm-like member with a sliding seal 530. Support member 532
may be plunger-like member or a piston like member, but having a
different structural and functional properties that a conventional
plunger or piston. Valve assembly 514 also includes a guiding
member such as a guide pin 536 or sliding surfaces, and includes a
spring 540.
[0089] Proximal body 522 includes threaded surface 522A
cooperatively sized with threaded surface 524A of distal body 524.
Fram member 526 (and thus pliable member 528 and a plunger-like
member 532) includes an opening 527 constructed and arranged to
accommodate guiding pin 536. Fram member 526 defines a pilot
chamber 542 arranged in fluid communication with actuator cavity
550 via control passages 544A and 544B. Actuator cavity 550 is in
fluid communication with output port 520 via a control passage 546.
Guide pin 536 includes a V-shaped or U-shaped groove 538 shaped and
arranged together with fram opening 527 (FIG. 5A) to provide a
pressure communication passage between input chamber 519 and pilot
chamber 550.
[0090] Referring still to FIG. 5, distal body 524 includes an
annular lip seal 525 arranged, together with pliable member 528, to
provide a seal between input port chamber 529 and output port
chamber 521. Distal body 524 also includes one or several flow
channels 517 providing communication (in open state) between input
chamber 519 and output chamber 521. Pliable member 528 also
includes sealing members 529A and 529B arranged to provide a
sliding seal, with respect to valve body 522, between pilot chamber
542 and output chamber 521. There are various possible embodiments
of seals 529A and 529B (FIG. 5). This seal may be one-sided as seal
530 (shown in FIG. 5A) or two-sided seal 529a and 529b shown in
FIG. 5. Furthermore, there are various additional embodiments of
the sliding seal including O-ring etc.
[0091] The present invention envisions valve device 10 having
various sizes. For example, the "full" size embodiment, shown in
FIG. 5B, has the pin diameter A=0.070'', the spring diameter
B=0.360'', the pliable member diameter C=0.730'', the overall fram
and seal's diameter D=0.812'', the pin length E=0.450'', the body
height F=0.380'', the pilot chamber height G=0.280'', the fram
member size H=0.160'', and the fram excursion I=0.100''. The
overall height of the valve is about 1.39'' and diameter is about
1.178''.
[0092] The "half size" embodiment (of the valve shown in FIG. 5B)
has the following dimensions provided with the same reference
letters (each also including a subscript 1). In the "half size"
valve A.sub.1=0.070'', B.sub.1=0.30, C.sub.1=0.560'',
D.sub.1=0.650'', E.sub.1=0.38'', F.sub.1=0.310'', G.sub.1=0.215'',
H.sub.1=0.125'', and I.sub.1=0.60''. The overall length of the 1/2
embodiment is about 1.350'' and the diameter is about 0.855''.
Similarly, the valve devices of FIG. 5B or 5C may have various
larger or smaller sizes.
[0093] Referring to FIGS. 5 and 5B, valve 500 receives fluid at
input port 518, which exerts pressure onto diaphragm-like members
528 providing a seal together with a lip member 525 in a closed
state. Groove passage 538 provides pressure communication with
pilot chamber 542, which is in communication with actuator cavity
550 via communication passages 544A and 544B. An actuator (shown in
FIGS. 5C, 7) provides a seal at surface 548 thereby sealing
passages 544A and 544B and thus pilot chamber 542. When the plunger
of actuator 142 or 143 moves away from surface 548, fluid flows via
passages 544A and 544B to control passage 546 and to output port
520. This causes pressure reduction in pilot chamber 542.
Therefore, diaphragm-like member 528 and piston-like member 532
move linearly within cavity 542, thereby providing a relatively
large fluid opening at lip seal 525. A large volume of fluid can
flow from input port 518 to output port 520.
[0094] When the plunger of actuator 142 or 143 seals control
passages 544A and 544B, pressure builds up in pilot chamber 542 due
to the fluid flow from input port 518 through groove 538. The
increased pressure in pilot chamber 542 together with the force of
spring 540 displace linearly, in a sliding motion over guide pin
536, fram member 526 toward sealing lip 525. When there is
sufficient pressure in pilot chamber 542, diaphragm-like pliable
member 528 seals input port chamber 519 at lip seal 525.
Preferably, soft member 528 is designed to clean groove 538 of
guide pin 536 during the sliding motion.
[0095] The embodiment of FIG. 5 shows valve 500 having input
chamber 519 (and guide pin 536) symmetrically arranged with respect
to passages 544A, 544B and 546 (and the location of the plunger of
actuator 701. However, valve device 500 may have input chamber 519
(and guide pin 536) non-symmetrically arranged with respect to
passages 544A, 544B (not shown) and passage 546. That is, this
valve has input chamber 519 (and guide pin 536) non-symmetrically
arranged with respect to the location of the plunger of actuator
142 or 143. The symmetrical and non-symmetrical embodiments are
equivalent.
[0096] Referring to FIG. 5C, valve device 600 includes a valve body
613 providing a cavity for a valve assembly 614, an input port 618,
and an output port 620. Valve assembly 614 includes a proximal body
602, a distal body 604, and a fram member or assembly 626. Fram
member 626 includes a pliable member 628 and a support member 632.
Pliable member 628 may be a diaphragm-like member with a sliding
seal 630. Support member 632 may be plunger-like member or a piston
like member, but having a different structural and functional
properties that a conventional plunger or piston. Valve body 602
provides a guide surface 636 located on the inside wall that
includes one or several grooves 638 and 638A. These are novel
grooves constructed to provide fluid passages from input chamber
located peripherally (unlike the central input chamber shown in
FIGS. 5 and 5B).
[0097] Fram member 626 defines a pilot chamber 642 arranged in
fluid communication with actuator cavity 650 via control passages
644A and 644B. Actuator cavity 650 is in fluid communication with
output chamber 621 via a control passage 646. Groove 638 (or
grooves 638 and 638A) provides a communication passage between
input chamber 619 and pilot chamber 642. Distal body 604 includes
an annular lip seal 625 co-operatively arranged with pliable member
628 to provide a seal between input port chamber 619 and output
port chamber 621. Distal body 624 also includes a flow channel 617
providing communication (in the open state) between input chamber
619 and output chamber 621 for a large amount of fluid flow.
Pliable member 628 also includes sealing members 629A and 629B (or
one sided sealing member depending on the pressure conditions)
arranged to provide a sliding seal with respect to valve body 622,
between pilot chamber 642 and input chamber 619. (Of course, groove
638 enables a controlled flow of fluid from input chamber 619 to
pilot chamber 642, as described above.)
[0098] We now turn to the system for controlling the operator.
Regarding the embodiments shown in FIG. 2 and FIG. 3, as FIG. 2A
shows, the operator-control circuitry 42 is contained in a circuit
housing formed of three parts, a front piece 116, a center piece
118, and a rear piece 120. Screws not shown secure the front piece
116 to the center piece 118, to which the rear piece 120 is in turn
secured by screws such as screw 122. That screw threadedly engages
a bushing 124 ultrasonically welded into a recess that the center
housing piece 118 forms for that purpose. A main circuit board 126,
on which are mounted a number of components such as a capacitor 128
and a microprocessor not shown, is mounted in the housing. An
auxiliary circuit board 130 is in turn mounted on the main circuit
board 126. Mounted on the auxiliary board 130 is a light-emitting
diode 132, which a transmitter hood 134 also mounted on that board
partially encloses.
[0099] The front circuit-housing piece 116 forms a transmitter-lens
portion 136, which has front and rear polished surfaces 138 and
140. The transmitter-lens portion focuses infrared light from
light-emitting diode 132 through an infrared-transparent window 144
formed in the flusher housing 146. FIG. 1's pattern 148 represents
the resultant radiation-power distribution. A receiver lens 152
formed by part 116 so focuses received light onto a photodiode 154
mounted on the main circuit board 126 that FIG. 1's pattern 150 of
sensitivity to light reflected from targets results.
[0100] Like the transmitter light-emitting diode 132, the
photodiode 154 is provided with a hood, in this case hood 156. The
hoods 134 and 156 are opaque and tend to reduce noise and
crosstalk. The circuit housing also limits optical noise; its
center and rear parts 118 and 120 are made of opaque material such
as Lexan 141 polycarbonate, while its front piece 116, being made
of transparent material such as Lexan OQ2720 polycarbonate so as to
enable it to form effective lenses 136 and 152, has a roughened
and/or coated exterior in its non-lens regions that reduces
transmission through it. An opaque blinder 158 mounted on front
piece 116 leaves a central aperture 160 for infrared-light
transmission from the light-emitting diode 132 but otherwise blocks
stray transmission that could contribute to crosstalk. Also to
prevent crosstalk, an opaque stop 162 is secured into a slot
provided for that purpose in the circuit housing's front part
116.
[0101] The arrangement of FIG. 2A, in which the transmitter and
receiver lenses are formed integrally with part of the circuit
housing, can afford manufacturing advantages over arrangements in
which the lenses are provided separately from the housing. But it
may be preferable in some embodiments to make the lenses separate,
because doing so affords greater flexibility in material selection
for both the lens and the circuit housing. FIGS. 6 and 6A are
front-elevational and cross-sectional views of an alternative that
uses this approach. That alternative includes a front circuit
housing piece 116' separate from lenses 136' and 152'. The housing
part 116' forms a teardrop-shaped rim 164 that cooperates during
assembly with a similarly shaped flange 166 on lens 136' to orient
that lens properly in its position on a teardrop-shaped shoulder
168 to which it is then welded ultrasonically. Referring to FIG.
6A, the teardrop shape ensures that the lens is oriented properly.
The receiver lens 152 is mounted similarly. Since the front
circuit-housing part 116' and lenses 136' and 152' do not need to
be made of the same material, housing part 116' can be made of an
opaque material so that blinders 170 and a stop 172 can be formed
integrally with it. As was mentioned in connection with FIG. 2A,
the circuit housing contains circuitry that controls the valve
operator as well as other flusher components.
[0102] FIG. 4A is a simplified block diagram of that circuitry. A
microcontroller-based control circuit 180 operates a peripheral
circuit 182 that controls the valve operator. Transmitter circuitry
184, including FIG. 2's light-emitting diode 132, is also operated
by the control circuit 180, and receiver circuitry 186 includes the
photodiode 154 and sends the control circuit its response to
resultant echoes. Although the circuitry of FIG. 4A can be so
implemented as to run on house power, it is more typical for it to
be battery-powered, and FIG. 4A explicitly shows a battery-based
power supply 188 because the control circuit 180, as will be
explained below, not only receives regulated power from the power
supply but also senses its unregulated power for purposes to be
explained below. It also controls application of the supply's power
to various of the FIG. 4A circuit's constituent parts.
[0103] Since the circuitry is most frequently powered by battery,
an important design consideration is that power not be employed
unnecessarily. As a consequence, the microcontroller-based
circuitry is ordinarily in a "sleep" mode, in which it draws only
enough power to keep certain volatile memory refreshed and operate
a timer 190. In the illustrated embodiment, that timer 190
generates an output pulse every 250 msec., and the control circuit
responds to each pulse by performing a short operating routine
before returning to the sleep mode. FIGS. 12A and 12B (together,
"FIG. 12") form a flow chart that illustrates certain of those
operations' aspects in a simplified fashion.
[0104] The automatic flushers shown in FIGS. 2, 3, and 4 may
utilize various embodiments of the isolated actuator, shown in
FIGS. 7, 7B and 7C. Isolated actuator 701 includes an actuator base
716, a ferromagnetic pole piece 725, a ferromagnetic armature 740
slideably mounted in an armature pocket formed inside a bobbin 714.
Ferromagnetic armature 740 includes a distal end 742 (i.e., plunger
742) and an armature cavity 750 having a coil spring 748. Coil
spring 748 includes reduced ends 748a and 748b for machine
handling. Ferromagnetic armature 740 may include one or several
grooves or passages 752 providing communication from the distal end
of armature 740 (outside of actuator base 716) to armature cavity
750 and to the proximal end of armature 740, at the pole piece 725,
for easy movement of fluid during the displacement of the
armature.
[0105] Isolated actuator body 701 also includes a solenoid windings
728 wound about solenoid bobbin 714 and magnet 723 located in a
magnet recess 720. Isolated actuator body 701 also includes a
resiliently deformable O-ring 712 that forms a seal between
solenoid bobbin 714 and actuator base 716, and includes a
resiliently deformable O-ring 730 that forms a seal between
solenoid bobbin 714 and pole piece 725, all of which are held
together by a solenoid housing 718. Solenoid housing 718 (i.e., can
718) is crimped at actuator base 16 to hold magnet 723 and pole
piece 725 against bobbin 714 and thereby secure windings 728 and
actuator base 716 together.
[0106] Isolated actuator 700 also includes a resilient membrane 744
that may have various embodiments shown and described in connection
with FIGS. 7D and 7E. As shown in FIG. 7, resilient membrane 764 is
mounted between actuator base 716 and a piloting button 705 to
enclose armature fluid located a fluid-tight armature chamber in
communication with an armature port 752. Resilient membrane 764
includes a distal end 766, O-ring like portion 767 and a flexible
portion 768. Distal end 766 comes in contact with the sealing
surface in the region 708. Resilient membrane 764 is exposed to the
pressure of regulated fluid provided via conduit 706 in piloting
button 705 and may therefore be subject to considerable external
force. Furthermore, resilient membrane 764 is constructed to have a
relatively low permeability and high durability for thousands of
openings and closings over many years of operation.
[0107] Referring to still to FIG. 7, isolated actuator 701 is
provided, for storage and shipping purposes, with a cap 703 sealed
with respect to the distal part of actuator base 716 and with
respect to piloting button 705 using a resiliently deformable
O-ring 732. Storage and shipping cap 703 includes usually water
that counter-balances fluid contained by resilient membrane 744;
this significantly limits or eliminates diffusion of fluid through
resilient membrane 744.
[0108] Referring still to FIG. 7, actuator base 716 includes a wide
base portion substantially located inside can 718 and a narrowed
base extension threaded on its outer surface to receive cap 703.
The inner surface of the base extension threadedly engages
complementary threads provided on the outer surface of piloting
button 705. Membrane 764 includes a thickened peripheral rim 767
located between the base extension 32's lower face and piloting
button 705. This creates a fluid-tight seal so that the membrane
protects the armature from exposure to external fluid flowing in
the main valve.
[0109] For example, the armature liquid may be water mixed with a
corrosion inhibitor, e.g., a 20% mixture of polypropylene glycol
and potassium phosphate. Alternatively, the armature fluid may
include silicon-based fluid, polypropylene polyethylene glycol or
another fluid having a large molecule. The armature liquid may in
general be any substantially non-compressible liquid having low
viscosity and preferably non-corrosive properties with respect to
the armature. Alternatively, the armature liquid may be Fomblin or
other liquid having low vapor pressure (but preferably high
molecular size to prevent diffusion).
[0110] If there is anticorrosive protection, the armature material
can be a low-carbon steel, iron or any soft magnetic material;
corrosion resistance is not as big a factor as it would otherwise
be. Other embodiments may employ armature materials such as the 420
or 430 series stainless steels. It is only necessary that the
armature consist essentially of a ferromagnetic material, i.e., a
material that the solenoid and magnet can attract. Even so, it may
include parts, such as, say, a flexible or other tip, that is not
ferromagnetic.
[0111] Resilient membrane 764 encloses armature fluid located a
fluid-tight armature chamber in communication with an armature port
752 or 790 formed by the armature body. Furthermore, resilient
membrane 764 is exposed to the pressure of regulated fluid in main
valve and may therefore be subject to considerable external force.
However, armature 740 and spring 750 do not have to overcome this
force, because the conduit's pressure is transmitted through
membrane 764 to the incompressible armature fluid within the
armature chamber. The force that results from the pressure within
the chamber therefore approximately balances the force that the
conduit pressure exerts.
[0112] Referring still to FIGS. 7, 7A, 7B and 7C, armature 740 is
free to move with respect to fluid pressures within the chamber
between the retracted and extended positions. Armature port 752 or
790 enables the force-balancing fluid displaced from the armature
chamber's lower well through the spring cavity 750 to the part of
the armature chamber from which the armature's upper end (i.e.
distal end) has been withdrawn upon actuation. Although armature
fluid can also flow around the armature's sides, arrangements in
which rapid armature motion is required should have a relatively
low-flow-resistance path such as the one that port 752 or 790 helps
form. Similar considerations favor use of an armature-chamber
liquid that has relatively low viscosity. Therefore, the isolated
operator (i.e., actuator 700) requires for operation only low
amounts of electrical energy and is thus uniquely suitable for
battery operation.
[0113] In the latching embodiment shown in FIG. 7, armature 740 is
held in the retracted position by magnet 723 in the absence of a
solenoid current. To drive the armature to the extended position
therefore requires armature current of such a direction and
magnitude that the resultant magnetic force counteracts that of the
magnet by enough to allow the spring force to prevail. When it does
so, the spring force moves armature 740 to its extended position,
in which it causes the membrane's exterior surface to seal against
the valve seat (e.g., the seat of piloting button 705). In this
position, the armature is spaced enough from the magnet that the
spring force can keep the armature extended without the solenoid's
help.
[0114] To return the armature to the illustrated, retracted
position and thereby permit fluid flow, current is driven through
the solenoid in the direction that causes the resultant magnetic
field to reinforce that of the magnet. As was explained above, the
force that the magnet 723 exerts on the armature in the retracted
position is great enough to keep it there against the spring force.
However, in the non-latching embodiment that doesn't include magnet
723, armature 740 remain in the retracted position only so long as
the solenoid conducts enough current for the resultant magnetic
force to exceed the spring force of spring 748.
[0115] Advantageously, diaphragm membrane 764 protects armature 740
and creates a cavity that is filled with a sufficiently
non-corrosive liquid, which in turn enables actuator designers to
make more favorable choices between materials with high corrosion
resistance and high magnetic permeability. Furthermore, membrane
764 provides a barrier to metal ions and other debris that would
tend to migrate into the cavity.
[0116] Diaphragm membrane 764 includes a sealing surface 766, which
is related to the seat opening area, both of which can be increased
or decreased. The sealing surface 766 and the seat surface of
piloting button 705 can be optimized for a pressure range at which
the valve actuator is designed to operate. Reducing the sealing
surface 766 (and the corresponding tip of armature 740) reduces the
plunger area involved in squeezing the membrane, and this in turn
reduces the spring force required for a given upstream
fluid-conduit pressure. On the other hand, making the plunger tip
area too small tends to damage diaphragm membrane 764 during valve
closing over time. Preferable range of tip-contact area to
seat-opening area is between 1.4 and 12.3. The present actuator is
suitable for variety of pressures of the controlled fluid.
including pressures about 150 psi. without any substantial
modification, the valve actuator may be used in the range of about
30 psi to 80 psi, or even water pressures of about 125 psi.
[0117] Referring still to FIGS. 7, 7A, 7B and 7C, piloting button
705 has an important novel function for achieving consistent
long-term piloting of the diaphragm valve shown in FIG. 2B, or the
fram valve shown in FIG. 3B. Solenoid actuator 701 together with
piloting button 705 are installed together as one assembly into the
electronic flusher; this minimizes the pilot-valve-stroke
variability at the pilot seat in region 708 (FIGS. 7, 7B and 7C)
with respect to the closing surface (shown in detail in FIG. 7E),
which variability would otherwise afflict the piloting operation.
This installation is faster and simpler than prior art
installations.
[0118] The assembly of operator 701 and piloting button 705 is
usually put together in a factory and is permanently connected
thereby holding diaphragm membrane 764 and the pressure loaded
armature fluid (at pressures comparable to the pressure of the
controlled fluid). Piloting button 705 is coupled to the narrow end
of actuator base 716 using complementary threads or a sliding
mechanism, both of which assure reproducible fixed distance between
distal end 766 of diaphragm 764 and the sealing surface of piloting
button 705. The coupling of operator 701 and piloting button 705
can be made permanent (or rigid) using glue, a set screw or pin.
Alternatively, one member my include an extending region that is
used to crimp the two members together after screwing or sliding on
piloting button 705.
[0119] It is possible to install solenoid actuator 701 without
piloting button 705, but this process is somewhat more cumbersome.
Without piloting button 705, the installation process requires
first positioning the pilot-valve body with respect to the main
valve and then securing to the actuator assembly onto the main
valve as to hold the pilot-valve body in place. If proper care is
not taken, there is some variability in the position of the pilot
body due to various piece-part tolerances and possible deformation.
This variability creates variability in the pilot-valve member's
stroke. In a low-power pilot valve, even relatively small
variations can affect timing or possibly sealing force adversely
and even prevent the pilot valve from opening or closing at all.
Thus, it is important to reduce this variability during
installation, field maintenance, or replacement. On the other hand,
when assembling solenoid actuator 701 with piloting button 705,
this variability is eliminated or substantially reduced during the
manufacturing process, and thus there is no need to take particular
care during field maintenance or replacement.
[0120] As described above, the main valve assembly includes a main
valve body with a main-valve inlet, a main-valve seat, a main-valve
outlet, a pressure chamber (i.e., a pilot chamber), and a
pressure-relief outlet through which the pressure in the pressure
chamber (pilot chamber) can be relieved, wherein the main valve
member can be diaphragm 28 (FIG. 2B), a piston, or a fram member
(FIG. 3B or FIG. 4), all of which are movable between a closed
position, in which the main valve member seals against the
main-valve seat thereby preventing flow from the main inlet (e.g.,
input 12 in FIGS. 2B, 3B or 4) to the main outlet (e.g., output 34
in FIGS. 2B, 3B or 4).
[0121] Referring to FIGS. 7D and 7E, as described above, diaphragm
membrane 764 includes an outer ring 767, flex region 768 and tip or
seat region 766. The distal tip of the plunger is enclosed inside a
pocket flange behind the sealing region 766. Preferably, diaphragm
membrane 764 is made of EPDM due to its low durometer and
compression set by NSF part 61 and relatively low diffusion rates.
The low diffusion rate is important to prevent the encapsulated
armature fluid from leaking out during transportation or
installation process. Alternatively, diaphragm member 764 can be
made out of a flouro-elastomer, e.g., VITON, or a soft, low
compression rubber, such as CRI-LINE.RTM. flouro-elastomer made by
CRI-TECH SP-508. Alternatively, diaphragm member 764 can be made
out of a Teflon-type elastomer, or just includes a Teflon coating.
Alternatively, diaphragm member 764 can be made out NBR (natural
rubber) having a hardness of 40-50 durometer as a means of reducing
the influence of molding process variation yielding flow marks that
can form micro leaks of the contained fluid into the surrounding
environment. Alternatively, diaphragm member 764 includes a
metallic coating that slows the diffusion thru the diaphragm member
when the other is dry and exposed to air during storage or shipping
of the assembled actuator.
[0122] Preferably, diaphragm member 764 has high elasticity and low
compression (which is relatively difficult to achieve). Diaphragm
member 764 may have some parts made of a low durometer material
(i.e., parts 767 and 768) and other parts of high durometer
material (front surface 766). The low compression of diaphragm
member 764 is important to minimize changes in the armature stroke
over a long period of operation. Thus, contact part 766 is made of
high durometer material. The high elasticity is needed for easy
flexing diaphragm member 764 in regions 768. Furthermore, diaphragm
part 768 is relatively thin so that the diaphragm can deflect, and
the plunger can move with very little force. This is important for
long-term battery operation.
[0123] Referring to FIG. 7E, another embodiment of diaphragm
membrane 764 can be made to include a forward slug cavity 772 (in
addition to the rear plunger cavity shaped to accommodate the
plunger tip). The forward slug cavity 772 is filled with a plastic
or metal slug 774. The forward surface 770 including the surface of
slug 774 is cooperatively arranged with the sealing surface of
piloting button 705. Specifically, the sealing surface of piloting
button 705 may include a pilot seat 709 made of a different
material with properties designed with respect to slug 774. For
example, high durometer pilot seat 709 can be made of a high
durometer material. Therefore, during the sealing action, resilient
and relatively hard slug 772 comes in contact with a relatively
soft pilot seat 709. This novel arrangement of diaphragm membrane
764 and piloting button 705 provides for a long term, highly
reproducible sealing action.
[0124] Diaphragm member 764 can be made by a two stage molding
process. where by the outer portion is molded of a softer material
and the inner portion that is in contact with the pilot seat is
molded of a harder elastomer or thermo-plastic material using an
over molding process. The forward facing insert 774 can be made of
a hard injection molded plastic, such as acceptable co-polymer or a
formed metal disc of a non-corrosive non-magnetic material such as
300 series stainless steel. In this arrangement, pilot seat 709 is
further modified such that it contains geometry to retain pilot
seat geometry made of a relatively high durometer elastomer such as
EPDM 60 durometer. By employing this design that transfers the
sealing surface compliant member onto the valve seat of piloting
button 705 (rather than diaphragm member 764), several key benefits
are derived. Specifically, diaphragm member 764 a very compliant
material. There are substantial improvements in the process related
concerns of maintaining proper pilot seat geometry having no flow
marks (that is a common phenomena requiring careful process
controls and continual quality control vigilance). This design
enables the use of an elastomeric member with a hardness that is
optimized for the application.
[0125] FIG. 7F is a cross-sectional view of another embodiment of
an armature bobbin used in the actuator shown in FIGS. 7 through
7C. The bobbin's body is constructed to have low permeability to
the armature fluid. For example, bobbin 714 includes metallic
regions 713, which are in contact with the armature fluid, and
plastic regions 713a, which are not in contact with the armature
fluid.
[0126] FIG. 8 schematically illustrates a fluid flow control system
for a latching actuator 801. The flow control system includes again
microcontroller 814, power switch 818, solenoid driver 820. As
shown in FIG. 7, latching actuator 701 includes at least one drive
coil 728 wound on a bobbin and an armature that preferably is made
of a permanent magnet. Microcontroller 814 provides control signals
815A and 815B to current driver 820, which drives solenoid 728 for
moving armature 740. Solenoid driver 820 receives DC power from
battery 824 and voltage regulator 826 regulates the battery power
to provide a substantially constant voltage to current driver 820.
Coil sensors 843A and 843B pickup induced voltage signal due to
movement of armature 740 and provide this signal to a conditioning
feedback loop that includes preamplifiers 845A, 845B and flow-pass
filters 847A, 847B. That is, coil sensors 843A and 843B are used to
monitor the armature position.
[0127] Microcontroller 814 is again designed for efficient power
operation. Between actuations, microcontroller 814 goes
automatically into a low frequency sleep mode and all other
electronic elements (e.g., input element or sensor 818, power
driver 820, voltage regulator or voltage boost 826, signal
conditioner 822) are powered down. Upon receiving an input signal
from, for example, a motion sensor, microcontroller 814 turns on a
power consumption controller 819. Power consumption controller 819
powers up signal conditioner that provides power to microcontroller
814.
[0128] Also referring to FIG. 7, to close the fluid passage 708,
microcontroller 814 provides a "close" control signal 815A to
solenoid driver 820, which applies a drive voltage to the coil
terminals. Provided by microcontroller 814, the "close" control
signal 815A initiates in solenoid driver 820 a drive voltage having
a polarity that the resultant magnetic flux opposes the magnetic
field provided by permanent magnet 723. This breaks the magnet
723's hold on armature 740 and allows the return spring 748 to
displace valve member 740 toward valve seat 708. In the closed
position, spring 748 keeps diaphragm member 764 pressed against the
valve seat of piloting button 705. In the closed position, there is
an increased distance between the distal end of armature 740 and
pole piece 725. Therefore, magnet 723 provides a smaller magnetic
force on the armature 740 than the force provided by return spring
748.
[0129] To open the fluid passage, microcontroller 814 provides an
"open" control signal 815B (i.e., latch signal) to solenoid driver
820. The "open" control signal 815B initiates in solenoid driver
820 a drive voltage having a polarity that the resultant magnetic
flux opposes the force provided by bias spring 748. The resultant
magnetic flux reinforces the flux provided by permanent magnet 723
and overcomes the force of spring 748. Permanent magnet 723
provides a force that is great enough to hold armature 740 in the
open position, against the force of return spring 748, without any
required magnetic force generated by coil 728.
[0130] Referring to FIG. 8, microcontroller 814 discontinues
current flow, by proper control signal 815A or 815B applied to
solenoid driver 820, after armature 740 has reached the desired
open or closed state. Pickup coils 843A and 843B (or any sensor, in
general) monitor the movement (or position) of armature 740 and
determine whether armature 740 has reached its endpoint. Based on
the coil sensor data from pickup coils 843A and 843B (or the
sensor), microcontroller 814 stops applying the coil drive,
increases the coil drive, or reduces the coil drive.
[0131] To open the fluid passage, microcontroller 814 sends OPEN
signal 815B to power driver 820, which provides a drive current to
coil 842 in the direction that will retract armature 740. At the
same time, coils 843A and 843B provide induced signal to the
conditioning feedback loop, which includes a preamplifier and a
low-pass filter. If the output of a differentiator 849 indicates
less than a selected threshold calibrated for armature 740 reaching
a selected position (e.g., half distance between the extended and
retracted position, or fully retracted position, or another
position), microcontroller 814 maintains OPEN signal 815B asserted.
If no movement of armature 740 is detected, microcontroller 814 can
apply a different level of OPEN signal 815B to increase the drive
current (up to several time the normal drive current) provided by
power driver 820. This way, the system can move armature 740, which
is stuck due to mineral deposits or other problems.
[0132] Microcontroller 814 can detect armature displacement (or
even monitor armature movement) using induced signals in coils 843A
and 843B provided to the conditioning feedback loop. As the output
from differentiator 849 changes in response to the displacement of
armature 740, microcontroller 814 can apply a different level of
OPEN signal 815B, or can turn off OPEN signal 815B, which in turn
directs power driver 820 to apply a different level of drive
current. The result usually is that the drive current has been
reduced, or the duration of the drive current has been much shorter
than the time required to open the fluid passage under worst-case
conditions (that has to be used without using an armature sensor).
Therefore, the system of FIG. 8 saves considerable energy and thus
extends life of battery 824.
[0133] Advantageously, the arrangement of coil sensors 843A and
843B can detect latching and unlatching movement of armature 740
with great precision. (However, a single coil sensor, or multiple
coil sensors, or capacitive sensors may also be used to detect
movement of armature 740.) Microcontroller 814 can direct a
selected profile of the drive current applied by power driver 820.
Various profiles may be stored in, microcontroller 814 and may be
actuated based on the fluid type, fluid pressure, fluid
temperature, the time actuator 840 has been in operation since
installation or last maintenance, a battery level, input from an
external sensor (e.g., a movement sensor or a presence sensor), or
other factors.
[0134] Optionally, microcontroller 814 may include a communication
interface for data transfer, for example, a serial port, a parallel
port, a USB port, of a wireless communication interface (e.g., an
RF interface). The communication interface is used for downloading
data to microcontroller 814 (e.g., drive curve profiles,
calibration data) or for reprogramming microcontroller 814 to
control a different type of actuation or calculation.
[0135] Referring to FIG. 7, electromagnetic actuator 701 is
connected in a reverse flow arrangement when the water input is
provided via passage 706 of piloting button 705. Alternatively,
electromagnetic actuator 701 is connected in a forward flow
arrangement when the water input is provided via passage 710 of
piloting button 705 and exits via passage 706. In the forward flow
arrangement, the plunger "faces directly" the pressure of the
controlled fluid delivered by passage 710. That is, the
corresponding fluid force acts against spring 748. In both forward
and reverse flow arrangements, the latch or unlatch times depend on
the fluid pressure, but the actual latch time dependence is
different. In the reverse flow arrangement, the latch time (i.e.,
time it takes to retract plunger 740) increases with the fluid
pressure substantially linearly, as shown in FIG. 9B. On the other
hand, in the forward flow arrangement, the latch time decreases
with the fluid pressure. Based on this latch time dependence,
microcontroller 814 can calculate the actual water pressure and
thus control the water amount delivery.
[0136] FIG. 8A schematically illustrates a fluid flow control
system for another embodiment of the latching actuator. The flow
control system includes again microcontroller 814, power
consumption controller 819, solenoid driver 820 receiving power
from a battery 824 or voltage booster 826, and an indicator 828.
Microcontroller 814 operates in both sleep mode and operation mode,
as described above. Microcontroller 814 receives an input signal
from an input element 818 (or any sensor) and provides control
signals 815A and 815B to current driver 820, which drives the
solenoid of a latching valve actuator 701. Solenoid driver 820
receives DC power from battery 824 and voltage regulator 826
regulates the battery power. A power monitor 872 monitors power
signal delivered to the drive coil of actuator 701 and provides a
power monitoring signal to microcontroller 814 in a feedback
arrangement having operational amplifier 870. Microcontroller 814
and power consumption controller 819 are designed for efficient
power operation, as described above.
[0137] Also referring to FIG. 8A, to close the fluid passage,
microcontroller 814 provides a "close" control signal 815A to
solenoid driver 820, which applies a drive voltage to the actuator
terminals and thus drives current through coil 728. Power monitor
872 may be a resistor connected for applied drive current to flow
through (or a portion of the drive current) Power monitor 872 may
alternatively be a coil or another element. The output from power
monitor 872 is provided to the differentiator of signal conditioner
870. The differentiator is used to determine a latch point, as
shown in FIG. 9A.
[0138] Similarly as described in connection with FIG. 8, to open
the fluid passage, microcontroller 814 sends CLOSE signal 815A or
OPEN signal 815B to valve driver 820, which provides a drive
current to coil 728 in the direction that will extent or retract
armature 740 (and close or open passage 708). At the same time,
power monitor 872 provides a signal to opamp 870. Microcontroller
814 determines if armature 740 reached the desired state using the
power monitor signal. For example, if the output of opamp 870
initially indicates no latch state for armature 740,
microcontroller 814 maintains OPEN signal 815B, or applies a higher
level of OPEN signal, as described above, to apply a higher drive
current. On the other hand, if armature 740 reached the desired
state (e.g., latch state shown in FIG. 9A), microcontroller 814
applies a lower level of OPEN signal 815B, or turns off OPEN signal
815B. This usually reduces the duration of drive current or the
level of the drive current as compared to the time or current level
required to open the fluid passage under worst case conditions.
Therefore, the system of FIG. 8A saves considerable energy and thus
extends life of battery 824.
[0139] Referring to FIG. 10, flow diagram 900 illustrates the
operation of microcontroller 814 during a flushing cycle.
Microcontroller 814 is in a sleep mode, as described above. Upon an
input signal from the input element or external sensor,
microcontroller 814 is initialed and the timer is set to zero (step
902). In step 904, if the valve actuator performs a full flush, the
time T.sub.bas equals T.sub.full (step 906). If there is no full
flush, the timer is set in step 910 to T.sub.bas equals T.sub.half.
In step 912, microcontroller samples the battery voltage prior to
activating the actuator in step 914. After the solenoid of the
actuator is activated, microcontroller 814 searches for the
latching point (see FIG. 9 or 9A). When the timer reaches the
latching point (step 918), microcontroller 814 deactivates the
solenoid (step 920). In step 922, based on the latch time,
microcontroller 814 calculates the corresponding water pressure,
using stored calibration data. Based on the water pressure and the
known amount of water discharged by the tank flusher, the
microcontroller decides on the unlatch time, (i.e., closing time)
of the actuator (step 926). After the latching time is reached,
microcontroller 14 provides the "close" signal to current driver
820 (step 928). After this point the entire cycle shown in flow
diagram 900 is repeated.
[0140] Referring to FIGS. 12A and 12B, blocks 200 and 202 represent
the fact that the controller remains in its sleep mode until timer
190 generates a pulse. When the pulse occurs, the processor begins
executing stored programming at a predetermined entry point
represented by block 204. It proceeds to perform certain
initialization operations exemplified by block 206's step of
setting the states of its various ports and block 208's step of
detecting the state of FIG. 2's push button 210. That push button,
which is mounted on the flusher housing 146 for ready accessibility
by a user, contains a magnet 210a whose proximity to the main
circuit board 126 increases when the button is depressed. The
circuit board includes a reed switch 211 that, as FIG. 6 suggests,
generates an input to the control circuit in response to the
resultant increased magnetic field on circuit board 126.
[0141] Push button 210's main purpose is to enable a user to
operate the flusher manually. As FIG. 12's blocks 212, 214, 216,
217, and 218 indicate, the control circuit 180 ordinarily responds
to that button's being depressed by initiating a flush operation if
one is not already in progress, and if the button has not been
depressed continuously for the previous thirty seconds.
[0142] This thirty-second condition is imposed in order to allow
batteries to be installed during manufacture without causing
significant energy drain between the times when the batteries are
installed in the unit and when the unit is installed in a toilet
system. Specifically, packaging for the flusher can be so designed
that, when it is closed, it depresses the push button 210 and keeps
it depressed so long as the packaging remains closed. It will
typically have remained closed in this situation for more than
thirty seconds, so, as FIG. 12's block 220 shows, the controller
returns to its sleep mode without having caused any power drain
greater than just enough to enable the controller to carry out a
few instructions. That is, the controller has not caused power to
be applied to the several circuits used for transmitting infrared
radiation or driving current through the flush-valve operator.
[0143] Among the ways in which the sleep mode conserves power is
that the microprocessor circuitry is not clocked, but some power is
still applied to that circuitry in order to maintain certain
minimal register state, including predetermined fixed values in
several selected register bits. When batteries are first installed
in the flusher unit, though, not all of those register bits will
have the predetermined values. Block 222 represents determining
whether those values are present. If not, then the controller
concludes that batteries have just been installed, and it enters a
power-up mode, as block 224 indicates.
[0144] The power-up mode deals with the fact that the proportion of
sensor radiation reflected back to the sensor receiver in the
absence of a user differs in different environments. The power-up
mode's purpose is to enable an installer to tell the system what
that proportion is in the environment is which the flusher has been
installed. This enables the system thereafter to ignore background
reflections. During the power-up mode, the object sensor operates
without opening the valve in response to target detection. Instead,
it operates a visible LED whenever it detects a target, and the
installer adjusts, say, a potentiometer to set the transmitter's
power to a level just below that at which, in the absence of a
valid target, the visible LED's illumination nonetheless indicates
that a target has been detected. This tells the system what level
will be considered the maximum radiation level permissible for this
installation.
[0145] Among the steps involved in entering this power-up mode is
to apply power to certain subsystems that must remain on
continually if they are to operate. Among these, for instance, is
the sensor's receiver circuit. Whereas the infrared transmitter
needs only to be pulsed, and power need not be applied to it
between pulses, the receiver must remain powered between pulses so
that it can detect the pulse echoes.
[0146] Another subsystem that requires continuous power application
in the illustrated embodiment is a low-battery detector. As was
mentioned above, the control circuitry receives an unregulated
output from the power supply, and it infers from that output's
voltage whether the battery is running low, as block 226 indicates.
If it is low, then a visible-light-emitting diode or some other
annunciator, represented in FIG. 4A by block 228, is operated to
give the user an indication of the low-battery state.
[0147] Now, the battery-check operation that block 226 represents
can be reached without the system's having performed block 224's
operation in the same cycle, so block 226's battery-check operation
is followed by the step, represented by block 230, of determining
whether the system currently is in the power-up mode.
[0148] In the illustrated embodiment, the system is arranged to
operate in this power-up mode for ten minutes, after which the
installation process has presumably been completed and a visible
target-detection indicator is no longer needed. If, as determined
in the block-230 operation, the system is indeed in the power-up
mode, it performs block 232's step of determining whether it has
been in that mode for more than ten minutes, the intended length of
the calibration interval. If so, it resets the system so that it
will not consider itself to be in the power-up mode the next time
it awakens.
[0149] For the current cycle, though, it is still in its power-up
mode, and it performs certain power-up-mode operations. One of
those, represented by block 234, is to determine from the
unregulated power-supply output whether any of the batteries have
been installed in the wrong direction. If any have, the system
simply goes back to sleep, as block 236 indicates. Otherwise, as
block 238 indicates, the system checks its memory to determine
whether it has commanded the valve operator five times in a row to
close the flush valve, as the illustrated embodiment requires in
the power-up mode. We have found that thus ordering the valve to
close when the system is first installed tends to prevent
inadvertent flushing during initial installation.
[0150] As block 242 indicates, the system then determines whether a
target has been detected. If is has, the system sets a flag, as
block 244 indicates, to indicate that the visible LED should be
turned on and thereby notify the installer of this fact. This
completes the power-up-mode-specific operations.
[0151] The system then proceeds with operations not specific to
that mode. In the illustrated embodiment, those further operations
actually are intended to be performed only once every second,
whereas the timer wakes the system every 250 msec. As block 246
indicates, therefore, the system determines whether a full second
has elapsed since the last time it performed the operations that
are to follow. If not, the system simply goes back to sleep, as
block 248 indicates.
[0152] If a full second has elapsed, on the other hand, the system
turns on a visible LED if it had previously set some flag to
indicate that this should be that LED's state. This operation,
represented by blocks 250 and 252, is followed by block 254's step
of determining whether the valve is already open. If it is, the
routine calls a further routine, represented by block 256, in which
it consults timers, etc. to determine whether the valve should be
closed. If it should, the routine closes the valve. The system then
returns to the sleep mode.
[0153] If the valve is not already open, the system applies power,
as block 258 indicates, to the above-mentioned subsystems that need
to have power applied continuously. Although that power will
already have been applied if this step is reached from the power-up
mode, it will not yet have been applied in the normal operating
mode.
[0154] That power application is required at this point because the
subsystem that checks battery power needs it. That subsystem's
output is then tested, as blocks 260 and 262 indicate. If the
result is a conclusion that battery power is inadequate, then the
system performs block 264's and block 266's steps of going back to
sleep after setting a flag to indicate that it has assumed the
power-up mode. Setting the flag causes any subsequent wake cycle to
include closing the valve and thereby prevents uncontrolled flow
that might otherwise result from a power loss.
Now, it is desirable from a maintenance standpoint for the system
not to go too long without flushing. If twenty-four hours have
elapsed without the system's responding to a target by flushing,
the routine therefore causes a flush to occur and then goes to
sleep, as blocks 268, 270, and 272 indicate. Otherwise, the system
transmits infrared radiation into the target region and senses any
resultant echoes, as block 274 indicates. It also determines
whether the resultant sensed echo meets certain criteria for a
valid target, as block 276 indicates.
[0155] The result of this determination is then fed to a series of
tests, represented by block 278, for determining whether flushing
should occur. A typical test is to determine whether a user has
been present for at least a predetermined minimum time and then has
left, but several other situations may also give rise to a
determination that the valve should be opened. If any of these
situations occurs, the system opens the valve, as block 280
indicates. If the visible LED and analog power are on at this
point, they are turned off, as block 282 indicates. As block 284
indicates, the system then goes to sleep.
[0156] Block 276's operation of determining whether a valid target
is present includes a routine that FIGS. 13A and 13B together,
("FIG. 13") depict. If, as determined in the step represented by
that drawing's block 288, the system is in its power-up mode, then
a background gain is established in the manner explained above.
Block 290 represents determining that level.
[0157] The power-up mode's purpose is to set a background level,
not to operate the flush valve, so the background-determining step
290 is followed by the block-292 operation of resetting a flag
that, if set, would cause other routines to open the flush valve.
The FIG. 13 routine then returns, as block 294 indicates.
[0158] If the step of block 288 instead indicates that the system
is not in the power-up mode, the system turns to obtaining an
indication of what percentage of the transmitted radiation is
reflected back to the sensor. Although any way of obtaining such an
indication is suitable for use with the present invention, a way
that tends to conserve power is to vary the transmitted power in
such a way as to find the transmitted-power level that results in a
predetermined set value of received power. The transmitted-power
level thereby identified is an (inverse) indication of the
reflection percentage. By employing this approach, the system can
so operate as to limit its transmission power to the level needed
to obtain a detectable echo.
[0159] In principle, the illustrated embodiment follows this
approach. In practice, the system is arranged to transmit only at
certain discrete power levels, so it in effect identifies the pair
of discrete transmitted-power levels in response to which the
reflected-power levels bracket the predetermined set value of
received power. Specifically, it proceeds to block 296's and block
298's steps of determining whether the intensity of the reflected
infrared light exceeds a predetermined threshold and, if it does,
reducing the system's sensitivity--typically by reducing the
transmitted infrared-light intensity--until the reflected-light
intensity falls below the threshold. The result is the highest gain
value that yields no target indication.
[0160] In some cases, though, the reflected-light intensity falls
below the threshold even when, if the sensitivity were to be
increased any further, the system would (undesirably) detect
background objects, such as stall doors, whose presence should not
cause flushing. The purpose of block 290's step was to determine
what this sensitivity was, and the steps represented by blocks 300
and 302 set a no-target flag if the infrared echo is less than the
threshold even with the gain at this maximum, background level. As
the drawing shows, this situation also results in the flush flag's
being reset and the routine's immediately returning.
[0161] If the block-300 step instead results in an indication that
the echo intensity can be made lower than the threshold return only
if the sensitivity is below the background level, then there is a
target that is not just background, and the routine proceeds to
steps that impose criteria intended to detect when a user has left
the facility after having used it. To impose those criteria, the
routine maintains a push-down stack onto which it pushes entries
from time to time. Each entry has a gain field, a timer field, and
an in/out field.
[0162] Block 304 represents determining whether the absolute value
of the difference between the current gain and the gain listed in
the top stack entry exceeds a threshold gain change. If it does
not, the current call of this routine results in no new entry's
being pushed onto the stack, but the contents of the existing top
entry's timer field are incremented, as block 306 indicates. If the
block-304 step's result is instead that the gain change's absolute
value was indeed greater than the threshold, then the routine
pushes a new entry on to the stack, placing the current gain in
that entry's gain field and giving the timer field the value of
zero. In short, a new entry is added whenever the target's distance
changes by a predetermined step size, and it keeps track of how
long the user has stayed in roughly the same place without making a
movement as great as that step size.
[0163] As blocks 310, 312, and 314 indicate, the routine also gives
the entry's in/out field an "out" value, indicating that the target
is moving away from the flusher, if the current gain exceeds the
previous entry's gain, and it gives that field an "in" value if the
current gain is less than the previous entry's gain. In either
case, the routine then performs the block-306 step of incrementing
the timer (to a value of "1") and moves from the stack-maintenance
part of the routine to the part in which the valve-opening criteria
are actually applied.
[0164] Block 316 represents applying the first criterion, namely,
whether the top entry's in/out field indicates that the target is
moving away. If the target does not meet this criterion, the
routine performs the block-292 step of setting the flush flag to
the value that will cause subsequent routines not to open the flush
valve, and the routine returns, as block 294 indicates. If that
criterion is met, on the other hand, the routine performs block
318's step of determining whether the top entry and any immediately
preceding entries indicating that the target is moving away are
preceded by a sequence of a predetermined minimum number of entries
that indicated that the target was moving in. If they were not,
then it is unlikely that a user had actually approached the
facility, used it, and then moved away, so the routine again
returns after resetting the flush flag. Note that the criterion
that the block-318 step applies is independent of absolute
reflection percentage; it is based only on reflection-percentage
changes, requiring that the reflection percentage traverse a
minimum range as it increases.
[0165] If the step of block 318 instead determines that the
requisite number of inward-indicating entries did precede the
outward-indicating entries, then the routine imposes the block-320
criterion of determining whether the last
inward-movement-indicating entry has a timer value representing at
least, say, 5 seconds. This criterion is imposed to prevent a flush
from being triggered when the facility was not actually used.
Again, the routine returns after resetting the flush flag if this
criterion is not met.
[0166] If it is met, on the other hand, then the routine imposes
the criteria of blocks 322, 324, and 326, which are intended to
determine whether a user has moved away adequately. If the target
appears to have moved away by more then a threshold amount, as
determined by block 322, or has moved away slightly less but has
appeared to remain at that distance for greater then a
predetermined duration, as determined in blocks 324 and 326, then,
as block 328 indicates, the routine sets the flush flag before
returning. Otherwise, it resets the flush flag.
[0167] The test of FIG. 13 is typically only one of the various
tests that FIG. 12B's operation 276 includes. But it gives an
example of how the illustrated system reduces problems that
variations in user-clothing colors would otherwise make more
prevalent. As a perusal of FIG. 13 reveals, a determination of
whether a user has arrived and/or left is based not on absolute
gain values but rather on relative values, which result from
comparing successive measurements. This reduces the problem, which
afflicts other detection strategies more severely, of greater
sensitivity to light-colored clothing than to dark-colored
clothing.
[0168] It was mentioned above that the illustrated system employs a
visible-light-emitting diode ("visible LED"). In most cases, the
visible LED's location is not crucial, so long as a user can really
see its light. One location, for instance, could be immediately
adjacent to the photodiode; FIG. 4A shows a non-roughened region
330 in the flange of receiver-lens part 152', and the visible LED
could be disposed in registration with this region. In the
embodiment of FIG. 2, though, no such separate visible LED is
apparent. The reason why is that the visible LED in that embodiment
is provided as a part of a combination-LED device 132, which also
includes the transmitter's infrared source.
[0169] To operate the two-color LED, transmitter and annunciator
circuits 184 and 228 (FIG. 4A) together take the form shown in FIG.
11. That circuitry is connected to the two-color LED's terminals
332 and 334. The control circuit separately operates the two-color
LED's infrared-light-emitting diode D1 and the
visible-light-emitting diode D2 by driving control lines 336, 338,
and 340 selectively. Specifically, driving line 340 high turns on
transistors Q1 and Q2 and thereby drives the visible-light-emitting
diode D2, at least if line 338 is held high to keep transistor Q3
turned off. If line 340 is driven low, on the other hand, and line
338 is also driven low, then infrared-light-emitting diode D1 is
allowed to conduct, with a power that is determined by the voltage
applied to a line 336 that controls transistor Q4.
[0170] It was stated above in connection with FIG. 12's blocks 214,
217, and 220 that the system goes to sleep if the push button has
remained depressed for over 30 seconds. FIG. 6 illustrates
packaging that takes advantage of this feature to keep power use
negligible before the kit is installed, even if the kit includes
installed batteries while it is in inventory or being transported.
To adapt a previously manual system to automatic operation, a
prospective user may acquire a flow controller that, for example,
contains all of the elements depicted in FIG. 2A except the
through-diaphragm feed tube 38. This flow controller, identified by
reference numeral 348 in FIG. 6D, is delivered in a container
comprising a generally rectangular cardboard box 350. The box's top
includes an inner flap 352, which is closed first, and an outer
flap 354, which is closed over the inner flap. Tabs 356 that fit
into slots 358 provided in the box body keep the box closed. To
keep the button depressed while the box is closed, the box is
provided with a button activator 360 so mounted on the inner flap
352 that it registers with the push button 310 when that flap is
closed. The package may be provided with inserts, not shown, to
ensure that the flow controller's push button registers correctly
with the activator.
[0171] FIG. 6E is a detailed cross-sectional view of the button
activator 360 showing it mounted on the inner flap 352 with the
outer flap 354 closed over it. The illustrated activator 360 is
typically a generally circular plastic part. It forms an annular
stop ring 362, which engages the top of the flow controller's
housing 146 (FIG. 2A) to ensure that a central protuberance 364
depresses the push button by only the correct amount. To mount the
activator 360 in the inner flap, it is provided with a barbed post
366. Post 366 forms a central slot 368 that enables it to deform so
that its barbs can fit through a hole 370 in the inner flap 352.
The outer flap 354 forms another hole 372 to accommodate the barbed
post 366.
[0172] Other arrangements may place the button actuator elsewhere
in the container. It may be placed on the container's bottom wall,
for example, and the force of the top flaps against the flow
controller.
[0173] Now, it sometimes occurs that the batteries are placed into
the circuit even before it is assembled into the housing, and the
circuit with the batteries installed may need to be shipped to a
remote location for that assembly operation. Since there is as yet
no housing, the circuitry cannot be kept asleep by keeping the
housing's button depressed. For such situations, an approach that
FIGS. 6B and 6C depict can be employed.
[0174] FIG. 6B is a view similar to FIG. 6D, but the contents 376
of FIG. 6B's package 350' are only a subset of the kit 348 that the
package 350 contains. They may, for instance, exclude FIG. 2's
housing 146 as well as the pressure cap 24 and the solenoid and
pilot-valve members mounted on it. So the package 350' in the FIG.
6B embodiment does not include a button activator like the one that
the box 350 includes. Instead, as FIG. 6C shows, a magnet 380 is
glued to the inner surface of the package 350's bottom wall 382,
and a hole 384 in an insert board 386 that rests on the bottom wall
382 receives the magnet.
[0175] The circuit assembly 376, which FIG. 6C omits for the sake
of simplicity, is so placed into the package that the circuits reed
switch is disposed adjacent to the magnet. That switch is therefore
closed just as it is when the push button is operated, and the
circuit therefore remains asleep.
[0176] FIGS. 15 and 15A illustrate another embodiment of an
automatic flusher including a flexible tube that eliminates dynamic
seal 38 used in the flusher described in connection with FIG. 2.
The automatic controller shown schematically in FIG. 15 transmitter
and receiver lenses and front circuit-housing part (see FIG. 6)
described above. The automatic flusher includes the isolated
operator 701 in a side (perpendicular) position.
[0177] The flush valve body is indicated at 10 and may have an
inlet opening 12 and a bottom directed outlet opening 14. The area
between the underside of the inner cover 1030 and the upper side of
the diaphragm 1032 forms a pressure chamber 1038. The pressure of
the water within this chamber holds the diaphragm 1032 upon a seat
1040 formed at the upper end of barrel which forms a conduit
between the inlet 12 and the outlet 14.
[0178] Details of this operation are disclosed in U.S. Pat. No.
5,244,179, as well as in U.S. Pat. Nos. 4,309,781 and 4,793,588.
Water flow through the inlet 12 reaches the pressure chamber 38
through a filter and bypass ring, the details of which are
disclosed in U.S. Pat. No. 5,967,182. Thus, water from the flush
valve inlet reaches the pressure chamber, to maintain the diaphragm
in a closed position, and the pressure chamber will be vented by
the operation of the solenoid as water will flow upwardly through
passage 44 (FIG. 2A), then into chamber 46 and then through the
passage in the flex tube as described in U.S. Pat. No. 6,382,586,
which is incorporated by reference.
[0179] The flex tube 1050 is hollow and in the form of a flexible
sleeve. The sleeve includes a coiled spring 1052, which prevents
the tube from collapsing due to water pressure flowing downwardly
through the disc of the assembly. At its upper end, the flex tube
1050 is attached to an inner cover adaptor or another element.
[0180] Seated on top of the upper end of the guide is a refill head
with the diaphragm 1032 being captured between the upper surface of
the refill head and a lower surface of a radially outwardly
extending portion of the disc. The diaphragm, the disc and the
guide, will all move together when pressure is relieved in chamber
1038 and the diaphragm moves upwardly to provide a direct
connection between flush valve inlet 12 and flush valve outlet 14.
When this takes place, the disc will move up and will carry with it
the lower end of the flex tube 1050. Thus, the flex tube must bend
as its upper end is fixed within the passage of the inner cover
1030. However, the flex tube always provides a reliable vent
passage for operation of the valve assembly.
* * * * *