U.S. patent application number 17/493768 was filed with the patent office on 2022-08-25 for fluid distribution manifold.
This patent application is currently assigned to Hayward Industries, Inc.. The applicant listed for this patent is Hayward Industries, Inc.. Invention is credited to Kevin Doyle, William Weiss.
Application Number | 20220269294 17/493768 |
Document ID | / |
Family ID | |
Filed Date | 2022-08-25 |
United States Patent
Application |
20220269294 |
Kind Code |
A1 |
Doyle; Kevin ; et
al. |
August 25, 2022 |
FLUID DISTRIBUTION MANIFOLD
Abstract
A manifold includes a housing defining first and second inlets
and outlets. With the housing, a valve retainer defines a first
chamber in fluid communication with the first and second inlets.
The valve retainer may engage a first valve assembly having a first
actuator attached to a first valve member for regulating flow from
the first outlet, and a second valve assembly having a second
actuator attached to a second valve member for regulating flow from
the second outlet port. A sensor assembly is configured to detect
first and second operations of the first and second valve
assemblies. A controller directs independent operations of the
first and second actuators based on first and second flow rates
derived from the first and second operations. The first and second
valve members may be positioned within portions of respective first
and second valve bodies in open fluid communication with the first
chamber.
Inventors: |
Doyle; Kevin; (Pompano
Beach, FL) ; Weiss; William; (Parkland, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hayward Industries, Inc. |
Berkeley Heights |
NJ |
US |
|
|
Assignee: |
Hayward Industries, Inc.
Berkeley Heights
NJ
|
Appl. No.: |
17/493768 |
Filed: |
October 4, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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17185897 |
Feb 25, 2021 |
11137780 |
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17493768 |
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International
Class: |
G05D 7/06 20060101
G05D007/06; F16L 41/03 20060101 F16L041/03; E04H 4/12 20060101
E04H004/12; F16K 27/00 20060101 F16K027/00 |
Claims
1. A fluid distribution manifold comprising: a housing, the housing
defining first and second inlets, and first and second outlets; a
first valve assembly configured to regulate flow from the first
outlet with a first actuator connected to a first valve member; a
second valve assembly configured to regulate flow from the second
outlet with a second actuator connected to a second valve member; a
valve retainer engaged with the housing, the valve retainer
defining a chamber within the housing that is in fluid
communication with the first and second inlets; a sensor assembly
attached to the housing proximate to the first and second outlets,
the sensor assembly configured to detect a first indication of a
first operation of the first valve assembly and a second indication
of a second operation of the second valve assembly; and a
controller configured to direct operations of the first actuator
based on a first flow rate derived from the first indication and
operations of the second actuator based on a second flow rate
derived from the second indication; wherein the first and the
second valve members are positioned within portions of respective
first and second valve housings that are in fluid communication
with the chamber.
2. The fluid distribution manifold of claim 1, wherein the first
and first valve members are disposed in the first valve housing and
the second actuator and second valve member are disposed in the
second valve housing, and wherein the valve retainer is engaged
with the first valve housing and the second valve housing.
3. The fluid distribution manifold of claim 1, further comprising:
a third valve assembly configured to regulate flow from a third
outlet defined by the housing with a third actuator connected to a
third valve member, wherein the third valve member is positioned
within a portion of a third valve housing that are in fluid
communication with the chamber, and wherein the controller is
configured to operate the third actuator based on first and second
required flow rates for the first and second outlets.
4. The fluid distribution manifold of claim 1, wherein the sensor
assembly detects an operation of a first flow sensor of the first
valve assembly for the first operation, and wherein the first flow
sensor is positioned downstream of the first valve member and
upstream of a distal end of the first outlet.
5. The fluid distribution manifold of claim 4, wherein the sensor
assembly detects a movement of the first flow sensor for the first
operation.
6. The fluid distribution manifold of claim 5, wherein the sensor
assembly includes a bus and a Hall effect device attached to the
bus in a location corresponding to the first outlet, wherein the
first flow sensor includes an impeller and magnets positioned
within the impeller, and wherein the Hall effect device detects a
movement of the impeller for the first operation
7. The fluid distribution manifold of claim 5, wherein the first
outlet extends from a lower wall of the housing below the chamber,
and wherein the impeller of the first flow sensor is disposed
within the first outlet outside of the chamber.
8. A fluid distribution manifold comprising: a first housing that
defines first and second inlets, and first and second outlets; a
second housing; a valve retainer positioned between the first
housing and the second housing, the valve retainer and the first
housing defining a first chamber, the valve retainer and the second
housing defining a second chamber; a first valve assembly including
a first actuator configured to adjust a position of a first valve
member within the first chamber to regulate a first flow rate
through the first outlet; a second valve assembly including a
second actuator configured to adjust a position of a second valve
member within the first chamber to regulate a second flow rate
through the second outlet; and a controller configured to instruct:
operations of the first actuator to move the first valve member in
first increments based on the first flow rate, and operations of
the second actuator to move the second member in second increments
based on the second flow rate, wherein the first and the second
valve members are positioned within portions of respective first
and second valve housings in fluid communication with the first
chamber and the first and second inlets.
9. The fluid distribution manifold of claim 8, wherein the first
valve assembly includes a first prime mover engaged with the first
actuator and the first valve member, wherein the second valve
assembly includes a second prime mover engaged with the second
actuator and the second valve member.
10. The fluid distribution manifold of claim 9, wherein the first
increments are at least one of time-based and based on a measure of
displacement of the first prime mover, and wherein the second
increments are at least one of time-based and based on a measure of
displacement of the second prime mover.
11. The fluid distribution manifold of claim 9, wherein first and
second movement paths of the first and second prime movers extend
from the first chamber to the second chamber.
12. The fluid distribution manifold of claim 8, wherein the valve
retainer defines a first slot and a second slot located between the
first and second chambers, wherein the first valve assembly is
engaged with the valve retainer and the first outlet and the second
valve assembly is engaged with a second slot of the valve retainer
and the second outlet, and wherein engagements between the first
and second valve assemblies and the first and second slots seal the
first chamber from the second chamber.
13. The fluid distribution manifold of claim 8, wherein the
controller is configured to control a first stepper motor of the
first actuator until the first fluid flow rate equals a first
required flow rate specified in a control input, and wherein the
controller is configured to control a second stepper motor of the
second actuator to maintain the second fluid flow rate to
compensate for any change to the second flow rate caused by the
first flow rate changing to be equal to the first required flow
rate.
14. The fluid distribution manifold of claim 8, further comprising
a sensor assembly attached to the first housing proximate to the
first outlet and second outlet, the sensor assembly configured to
detect a first indication of a first operation of the first valve
assembly and a second indication of a second operation of the
second valve assembly, wherein the controller is configured to
derive the first flow rate from the first indication and derive the
second flow rate from the second indication.
15. A method for distributing fluid with a fluid distribution
manifold including a plurality of valve assemblies, the method
comprising: continuously monitoring a fluid system including a
plurality of fluid handling devices in fluid communication with the
fluid distribution manifold; receiving a control input, with a
valve operation and coordination ("VOC") controller, including a
first required flow rate for a first fluid handling device;
determining, at the VOC controller, an operating direction for a
first actuator of a first valve assembly of the plurality of valve
assemblies, the VOC controller determining the operating direction
based on a current flow rate of fluid flow to the first fluid
handling device as regulated by the first valve assembly;
controlling operations of the plurality of valve assemblies to
change the flow rate of fluid flow to the first fluid handling
device to the first required flow rate; controlling operations of
the plurality of valve assemblies to maintaining required flow
rates to a remaining group of the plurality of fluid handling
devices; and continuously performing flow rate balancing operations
of the plurality of valve assemblies to deliver required flow rates
based on: current flow rates for all the plurality of valve
assemblies, an input flow rate for the manifold, and a total output
flow rate for the manifold, wherein the current flow rates are
respectively derived from operations of the plurality of valve
assemblies and the fluid distribution manifold includes a sensor
assembly configured to detect indications of the operations of the
plurality valve assemblies; and wherein each of the plurality of
valve assemblies includes an actuator connected to a valve member
disposed in a portion of a respective valve housing that is in open
fluid communication with a first chamber of the manifold that is in
open communication with first and second inlets for the manifold;
and
16. The method for distributing fluid of claim 15, wherein the
sensor assembly detects movements of flow sensors disposed in the
plurality of valve assemblies.
17. The method for distributing fluid of claim 16, wherein the
sensor assembly includes a bus and a Hall effect device attached to
the bus in a location corresponding to each of the valve
assemblies, and wherein each of flow sensors includes an impeller
and magnets positioned within the impeller, and wherein the Hall
effect devices detect respective movements of the impellers for the
operations.
18. The method for distributing fluid of claim 15, wherein each of
the plurality of valve assemblies includes a prime mover engaged
with an actuator and a valve member.
19. The method for distributing fluid of claim 18, wherein movement
paths of the prime movers extend from the first chamber to a second
chamber, and wherein the first chamber and the second chamber are
separated by a valve retainer.
20. The method for distributing fluid of claim 19, valve housings
of the plurality of valve assemblies engage the valve retainer and
a first housing that defines the first chamber with the valve
retainer.
21. each of the plurality of valve assemblies includes a prime
mover engaged with an actuator and a valve member.
22. The method for distributing fluid of claim 15, wherein each of
the plurality of valve assemblies includes a prime mover engaged
with an actuator and a valve member.
23. The method for distributing fluid of claim 15, wherein each of
the plurality of valve assemblies includes a prime mover engaged
with an actuator and a valve member.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority as a continuation of U.S.
patent application Ser. No. 17/185,897, entitled "FLUID
DISTRIBUTION MANIFOLD," filed Feb. 25, 2021, which is herein
incorporated by reference in its entirety for all purposes.
[0002] This application is also related to co-pending U.S. patent
application Ser. Nos. 17/327,488 and 17/327,543, filed on May 21,
2021, each entitled "FLUID DISTRIBUTION MANIFOLD," both of which
are by Kevin Doyle and William Weiss, assigned to the assignee of
the present application, and expressly incorporated by reference
herein, in their entireties, for all purposes.
BACKGROUND
[0003] Fluid distribution systems, such as those employed to manage
pool operations, can include one or more fluid handling
devices--pumps (e.g., single speed, multi-step, variable speed,
etc.), filters, valves, various plumbing components, cleaning
systems, heaters, water features (e.g., fountains, sprays, etc.),
and/or other types. In these fluid distribution systems, multiple
valves may be used to direct flow from, to, and within the various
fluid handling devices. However, incorporation of such valves can
present multiple challenges to highly responsive and precise
operation of fluid distribution systems due to operational
limitations of the valves and the complexities of coordinated
control of large numbers thereof.
[0004] Many fluid distribution systems require multiple valves and
actuators to divert fluid flow to and from fluid handling devices,
as well as different circuits, of those systems. To accomplish
these functions, example valves can be manually actuated, provided
with automatic actuators (e.g., electric motors), capable of being
actuated to operate in multiple positions, or have a combination of
these operational features. However, current valve actuators are
limited in their respective abilities to precisely set flowrates
due to the small ranges of available settings provided by their
respective designs. In the case of a fluid distribution system for
a pool, for example, an installer is very limited in how valves can
be setup because each of the fluid handling devices in the fluid
distribution system may require flow be supplied at predefined
flowrates.
[0005] Some valves may include one or two flow paths, and can be
set to one of two positions by an automation system, for example.
The added flow path and/or flow rate-controlling positions these
valves provide can help to simplify overall system complexity.
However, fluid distribution systems including many and multiple of
the previously mentioned fluid handling devices will still require
a dramatically increased number of these valves relative to simpler
systems. Greater numbers of valves and actuators increase overall
system cost and complexity. Furthermore, larger numbers of valves
increase installation costs for labor and materials because more
time is required for installation due to system complexity, and
more plumbing components (e.g., piping, unions, fittings, etc.) are
required for actual valve installs. In addition, larger physical
space is required for all the valves, actuators, and plumbing
components used to operate such fluid distribution systems.
[0006] Along with increased costs and space requirements needed to
provide and install fluid distribution systems having increased
numbers of fluid handling devices, normal continuous operation and
maintenance can require complex multi-component control systems. In
some examples, each fluid handling device may require its own valve
piped into a fluid circuit serving the component. In other
examples, two components may share a valve connected to the fluid
circuits that serve the two components. Each valve employed may
include its own controller that has to be independently operated to
provide a specific flow rate of fluid to the fluid handling device
it serves. Various schemes may be required to operate valves so
that fluid is directed to different components at specific flow
rates required for proper operation. Controlling each valve in
these fluid distribution systems requires accurate readings for a
flow of fluid to, and more importantly a flow rate from, each
valve.
[0007] Compounding the challenge of controlling multiple valves, is
the variability in operational conditions a fluid distribution
system can experience. Many of these systems may be used daily with
overall flowrates reducing or increasing depending on a state of a
given system that is subject to external conditions that vary in
magnitude/effect and timing.
[0008] For example, dirty filters can reduce flow and cleaned
filters can increase flow in a circuit of a fluid distribution
system for a pool. The amount of debris that must be filtered by
each filter can depend on a filter's location in the pool, number
of trees or bushes near that location, and/or traffic of pool-goers
around the location. In addition, new fluid handling devices can be
introduced into the pool's fluid distribution system from time to
time, rendering overall performance of the system more
unpredictable and less stable. Any of these exemplary situations
and conditions can cause cascading impacts on fluid flow rates in
other circuits of the pool's fluid distribution system, and impact
operations of other fluid handling devices and the valves that
serve them. Thus, with overall performance being unpredictable and
far from stable, performance of other fluid handling devices, such
as the pool's cleaning systems or water features, can be negatively
impacted.
[0009] As a result, a need exists for a fluid distribution manifold
that can deliver precise specified flow rates from each outlet in
group of outlets, each outlet connected to a different fluid
handling device. In addition, a need exists a manifold that enable
seamless integration of additional fluid handling devices to fluid
system, such as those utilized in pool management systems. Still
further, a need exists a manifold including individual valve
assemblies that can be easily installed, serviced, or replaced
without significantly disrupting the operation of the manifold or
operations of other valve assemblies in the manifold.
SUMMARY
[0010] Examples described herein include systems and methods for
controlling flow rates from a fluid distribution manifold. In one
example, a fluid distribution manifold may include a first housing
that defines first and second inlets, and first and second outlets.
A first valve assembly may be provided in the manifold and
configured to regulate flow from the first outlet with a first
actuator connected and to a first valve member. A second valve
assembly may be provided in the manifold and configured to regulate
flow from the second outlet with a second actuator that is
connected to a second valve member. In other examples, the manifold
may include three or more outlet ports and three or more valve
assemblies, each valve assembly regulating a flow rate through a
respective outlet port.
[0011] The first housing may be engaged to a valve retainer that is
engaged to the first and second valve assemblies. The valve
retainer may secure the valve assemblies in their respective
positions within a chamber defined by the first housing and one
side of the valve retainer. In one example, the chamber is in open
fluid communication with the first and second inlets for the
manifold.
[0012] In some examples, a sensor assembly may be attached to a
first housing proximate to first and second outlets. The sensor
assembly may be configured to detect a first indication (e.g., a
signal representing the occurrence of) of a first operation of the
first valve assembly and a second indication of a second operation
of the second valve assembly. In addition, a controller may be
provided to direct independent operations of the first actuator
based on a first flow rate derived from the first indication and
independent operations of the second actuator based on a second
flow rate derived from the second indication. In other examples,
the first and second valve members may each be positioned within
portions of a first housing and a second valve housing,
respectively, that are in open fluid communication with the
chamber.
[0013] In another example, a fluid distribution manifold may
include a first housing that defines first and second inlets and
first and second outlets, a second housing, and a valve retainer
positioned between the first housing and the second housing. The
valve retainer may define a first chamber with the first housing
and define a second chamber with the second housing. First and
second valve assemblies may be provided, with each including an
actuator configured to adjust a position of a member within the
first chamber to regulate a flow rate through a respective one of
the first and second outlets.
[0014] In one example, a controller may be configured to direct
independent operations of the actuators to move respective valve
members in respective increments based on respective flow rates. In
addition, the valve members for the first and second valve
assemblies may both be positioned within portions of respective
valve housings that are in open fluid communication with the first
chamber and the first and second inlets for the manifold.
[0015] In yet another example, a method for distributing fluid with
a fluid distribution manifold including a plurality of valve
assemblies may include continuously monitoring a fluid system that
includes a plurality of fluid handling devices that are in fluid
communication with the fluid distribution manifold. The method may
further include receiving control inputs with a valve operation and
coordination ("VOC") controller; the control inputs may specify
required flow rates for the fluid handling devices. In one example,
the VOC controller can determine operating directions for actuators
of the valve assemblies of based on current flow rates to the fluid
handling devices as regulated by respective valves assemblies in
the manifold.
[0016] In another example, a method can include controlling
independent operations of valve assemblies to change one or more
flow rates to one or more fluid handling devices, to required flow
rates specified in the control input, while maintaining required
flow rates to the remaining fluid handling devices. In addition,
flow rate balancing operations can be continuously performed and
include operating valve assemblies to deliver required flow rates
to fluid handling devices based on current flow rates for all the
valve assemblies, an input flow rate for the manifold, and a total
output flow rate for the manifold. In one example, each of the
valve assemblies may include an actuator connected to a valve
member that is disposed in a portion of a respective valve housing
that is in open fluid communication with a chamber of a manifold,
which is in open communication with first and second inlets for the
manifold.
[0017] The examples summarized above can each be incorporated into
a non-transitory, computer-readable medium having instructions
that, when executed by a processor associated with a computing
device, cause the processor to perform the stages described.
Additionally, the example methods summarized above can each be
implemented in a system including, for example, a memory storage
and a computing device having a processor that executes
instructions to carry out the stages described.
[0018] Both the foregoing general description and the following
detailed description are exemplary and explanatory only and are not
restrictive of the examples, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 illustrates is a schematic of an example fluid
handling system including an exemplary fluid distribution manifold,
according to an aspect of the present disclosure.
[0020] FIG. 2 is a flowchart for an example method for dynamically
controlling flow rates of outlet ports of a fluid distribution
manifold.
[0021] FIG. 3 is a sequence diagram of an example method for
operating a fluid distribution manifold.
[0022] FIG. 4 illustrates an algorithmic flow chart of an example
method for dynamically controlling valve assemblies of a fluid
distribution manifold.
[0023] FIG. 5 illustrates an algorithmic flow chart for performing
a cycle and control input check.
[0024] FIG. 6 illustrates a schematic view of a manifold control
system and a fluid distribution manifold of a fluid handling
system, according to an aspect of the present disclosure.
[0025] FIGS. 7A and 7B illustrate perspective views of a fluid
distribution manifold, according to an aspect of the present
disclosure.
[0026] FIG. 8 is a sectional view of the fluid distribution
manifold of FIG. 7 taken from a plane indicated by line 8-8.
[0027] FIG. 9 is a sectional view of the fluid distribution
manifold of FIG. 7 taken from a plane indicated by line 9-9.
[0028] FIG. 10 is a sectional view of the fluid distribution
manifold of FIG. 7 taken from a plane indicated by line 10-10.
[0029] FIG. 11 illustrates an exploded view of a fluid distribution
manifold illustrated in FIGS. 7A and 7B.
[0030] FIG. 12A illustrates a sectional view of a housing for a
partially assembled fluid distribution manifold.
[0031] FIGS. 12B and 12C illustrate a sectional view of different
partial assemblies of a fluid distribution manifold and a single
valve housing.
[0032] FIGS. 13A and 13B illustrate perspective views of a single
valve housing.
[0033] FIGS. 13C and 13D illustrate perspective views of a capped
valve housing.
[0034] FIGS. 14A and 14B each illustrate perspective views of a
first side of a valve retainer.
[0035] FIG. 15 illustrates a perspective view of a second side of a
valve retainer.
[0036] FIG. 16 illustrates a perspective view of a first housing
for a fluid distribution manifold.
DESCRIPTION OF THE EXAMPLES
[0037] Reference will now be made in detail to the present
examples, including examples illustrated in the accompanying
drawings. Wherever possible, the same reference numbers will be
used throughout the drawings to refer to the same or like
parts.
[0038] FIG. 1 illustrates a schematic of an example fluid handling
system 100, according to an aspect of the present disclosure. As
illustrated, the fluid handling system 100 includes a pump 102, a
fluid distribution manifold 110 ("manifold 110"), and several fluid
handling devices ("FHD" or "FHDs"). The manifold 110 includes a
communication module 120, a manifold control system ("MCS") 130,
and a chamber 140. The first chamber 140 may include a pair of
inlets 142. Provided within the chamber 140 is N number of valve
assemblies 150--each valve assembly 150 includes an actuator 152
and a flow sensor 154, and is configured to regulate a respective
flow channel 160. In one example, N is equal to six.
[0039] In one example, the MCS may include: a computing device or a
group of computing devices; one or more valve controllers that each
include a respective computing device; a user interface that
includes a display and controls for inputting information and
reviewing information stored by the MCS; various types of inputs
and outputs for power supply and data transfers, for example from
actuators 152 and flow sensors 154 directly or through one or more
valve controllers; and communication devices that implement one or
more communication protocols (e.g., cellular, RS485,
wireless--Wifi, Bluetooth, Zigbee, NFC, etc.) so as to be able to
communicate with computing devices such as servers, personal
computers, laptops, tablets, phones, etc. In another example, any
of the exemplary valve controllers described herein and included in
an exemplary MCS according to the present disclosure, may include a
computing device. As used herein, a computing device may include
any processor-enabled device, such as a laptop, tablet, personal
computer, phone, or hardware-based server.
[0040] Each flow channel 160 can be in fluid communication with a
fluid handling device 170 ("FHD 170"), such as a pump (e.g., a jet
pump), a filter, a valve, a type of plumbing component, a cleaning
system, a heater, or a water feature (e.g., fountain, spray,
bubbler, etc.). Both the chamber 140 of the manifold 110 and the
pump 102 may be provided with a pressure relief valve 104, 144.
[0041] At least one of the flow channels 162 may be in fluid
communication with a fluid reservoir or a recirculation channel
upstream of the inlets 142 or the pump 102. This flow channel 162
may be regulated as part of a process of balancing to all channels
to obtain required flow rates in each of those channels.
[0042] FIG. 2 is a flowchart of an example method for dynamically
controlling fluid flow rates through outlet ports of a fluid
distribution manifold with independently operated valves.
[0043] At stage 210, a fluid system including a plurality of fluid
handling devices ("FHD" or "FHDs") in fluid communication with a
fluid distribution manifold ("manifold") can be continuously
monitored. This can include detecting flow rates, ON/OFF status,
operating states, modes of operations, a show that is being
executed by a pool system, and the like.
[0044] In stage 220, an MCS can receive a control input
corresponding to a required flow rate for a specified FHD. In one
example, the control input can be received through the MCS
executing one or more processes that involve operations of a valve
operation and coordination ("VOC") controller, individual valve
controllers of a VOC controller, and/or different actuators for
respective valve assemblies in the manifold. In another example,
the control input can be received from an external controller, a
pool system control ("PSC") panel, or an FHD served by the
manifold.
[0045] In another example, a control input in stage 220 may include
a flow rate that is required for a modified, initial, or continued
operation of an FHD. In another example, the control input can
correspond to a total flow rate for all the outlet ports of the
manifold. In still another example, the control input may
correspond to an indication for a valve to be opened or closed
according to a current operation of an FHD regulating a fluid
supply to that FHD. In still another example, the control input may
include a flow rate, a magnitude of a valve opening or closing
operation for a bleed valve assembly, or a flow rate for fluid
through a bleed valve assembly.
[0046] In those examples where an initial control input relates to
an operating magnitude, the initial control input may correspond to
a specified distance of travel for a prime mover, number of
rotations for a stepper motor actuator, magnitude of voltage to a
linear motor or solenoid, and the like. In these examples, stage
220 can include converting the operating magnitude into a required
flow rate or flow differential from a current flow rate.
Accordingly, the converted flow rate value can be utilized by the
MCS to monitor and adjust the opening of a valve assembly.
[0047] At stage 230, the MCS can determine an operating direction
for a valve member corresponding to the specified FHD based on a
current flow rate to the FHD. In one example, stage 230 may include
determining that the valve assembly for the specified FHD cannot be
operated to obtain the required flow rate. More specifically, it
may be the case, and determined in stage 230, that a particular
valve assembly is in a fully open position and the current flow
rate is less than a required flow rate specified in the control
input. As a result, the MCS will determine the operating direction
of another valve assembly for the manifold that may result in
increasing a flow rate through the valve assembly of the specified
FHD. In one example in which the manifold employs a bleed valve
assembly which is open, the MCS may determine that operating the
bleed valve assembly in a closing direction will increase a flow
rate through the valve assembly for the specified FHD. As a result,
the MCS may control, or direct the valve controller for the bleed
valve assembly to initiate a closing operation.
[0048] In stage 240, the MCS will control directly, or direct valve
controllers to, execute independent operations of valve assemblies
of the manifold to change a flow rate to specified FHD to required
flow rate, and deliver required flow rates to the remaining FHDs.
Stage 240 may include the MCS continuously polling flow sensors of
all the valve assemblies for the manifold. Based on the readings
from these sensors, actuators for all the valve assemblies will be
operated continuously to maintain or modify flow rates therethrough
in order to deliver the required flow rates through the valve
assembly for the specified FHD.
[0049] In one example, stepper motors may be used as actuators in
each of the valve assemblies installed in the manifold. In this
example, stages 230 and 240 may include several operations specific
to the stepper motors.
[0050] For example, a series of operations may be performed every
millisecond (msec) that includes accessing a step counter for every
actuator/fluid flow channel. For step counts greater than zero, it
may be determined that the stepper motor actuators associated with
those step counts are currently performing stepper movements. As a
result, a flow rate comparison may not be done for each of these
flow channels until stepper movements for a respective stepper
motor actuators is finished being performed.
[0051] On the other hand, for step counts that are equal to zero,
an actual flow rate may be compared to the required flow rate
value. The step counters associated with these flow channels may be
set to a default value of counts (e.g., 100 counts=50 steps), which
will cause a step output pin for those stepper motor actuator to be
toggled. In one example, this toggling may repeat every 1 msec
until a number of steps corresponding to the value set for the step
counters are completed. With a completion of every step (e.g., when
a step output signal is toggled low), a home switch associated may
be checked. If this open limit switch is ON then counts for stepper
counters may be set to 0 since no further steps are needed.
[0052] A user interface may be checked on a predetermined periodic
basis (e.g., every 50 msec) for new control inputs and to update a
display with the most recent flow rate values. These updates may
occur independently of any operation of the stepper motor
actuators.
[0053] At stage 250, the MCS will direct operations of the valve
controllers to continuously perform flow rate balancing operations
of valve assemblies. These operations will continue such that the
manifold delivers FHD-required flow rates within predetermined
tolerances based on individual valve assembly flow rates, manifold
total input, and output flow rates until a new control input is
received.
[0054] FIG. 3 is a sequence diagram of an example method for
operating a fluid distribution manifold.
[0055] At stage 310, a control input is received by the MCS
communication module ("comms module"). The control input may be
received from any of the control input sources shown in FIG. 3.
[0056] In one example a control input may be transmitted from an
external controller implementing a RS485 communication protocol.
The control input may be generated or triggered when the external
controller recognizes a new ON or OFF signal over a communication
channel between an FHD and the external controller. In another
example, the external controller may pick up the signal from a pool
system control (PSC) panel that communicates with the FHD.
[0057] In yet another example, the control input may be
communicated to the MCS comms module directly by the PSC panel. In
this example, the control input may be presented as a message or
according to a particular communication protocol such as RS485. In
another example, a control input originating from the PSC panel
could be defined as an interrupt signal.
[0058] In another example, the control input may be supplied
through a user interface, for example, from a user using an LCD
screen or control buttons provided on a manifold to set a specific
valve opening and associated flow. In yet another example, a
control input can be generated through an internal function of the
MCS, that requires a setting for an actuator, such as a stepper
motor, to change in response to a change in flow rate through a
valve assembly including that actuator.
[0059] In stage 314, the comms module may verify the control input
received in stage 310. In one example, the comms module can include
a universal asynchronous receiver-Transmitter (UART) configured to
generate an interrupt when the comms module receives a control
input such as a byte of data from an interface implementing one or
more communication protocols (e.g., RS485). Each byte from a UART
buffer may be loaded into a register for the comms module to
determine if a full control input (e.g., a message, series of
signals, data string, etc.) has been received.
[0060] In one example, a verification process can include a data
byte being taken from the UART when an interrupt occurs, and the
comms module checking that the control input follows a valid input
protocol. Where a correct protocol is followed, the comms module
can store the data byte it received in the input buffer. In one
example, the buffer may have a 12 byte capacity. Next, a cyclic
redundancy check (CRC) for the comms module may be implemented to
check the input. If the control input is complete and correct, this
may cause a flag to be set with the MCS processor in stage 322
signifying that a verified control input has been received. In
addition, in stage 322, data encompassed by the control input may
then be transmitted to the MCS processor. In turn, a UART received
input buffer may be cleared so that a subsequent control input can
be received.
[0061] Before, or as the verified control input is received by the
MCS processor in stage 322, the comms module can issue a
notification at stage 318, depending on the source of the control
input. This can convey that the control input has been verified, or
include a request that the control input be re-submitted. In one
example, if the control input is incorrect (e.g., not complete,
includes invalid data), the comms module can notify the external
controller or PSC panel, for example, and request a new control
input, more of a control input, or an updated control input in
stage 318. In another example, stage 318 may involve setting an
error flag with the MCS processor and/or a control input source
that indicates a type of error.
[0062] On the other hand, if a control input is correct a
notification may be sent in stage 322 to a source for the control
input like the external controller, in addition to the MCS
processor as previously described. In addition, certain parameters
tacked by the parameter register may be updated with a verifiable
control input (e.g., a Control input Rec Reg Flag may be set to ON,
a six data byte payload representing a channel flow rate value may
be used to update a Channel Received Status Register parameter). In
addition, the MCS processor may call a routine to translate or
otherwise process the control input.
[0063] At stage 330, the MCS processor accesses a parameter
register to set or reference values for parameters in the parameter
registered therein that correspond to operating conditions (e.g.,
flow rate, valve opening degree, flow rate checking frequency,
open/close status) as required based on the translated control
input. In addition, the translated control input may be either
compared directly or by reference to values set for corresponding
required parameters, to values for actual, or current, or most
recently determined parameters in the parameter register (e.g.,
flow rate for a valve assembly regulating flow to given FHD). In
one example the MCS may check a status of a current register value
for an outlet/valve assembly specified (or corresponding to an FHD
specified), in the translated control input, versus a value
included in the control input as a required value for that outlet,
valve assembly, or FHD. These parameters may represent or
correspond to various operating conditions, such as flow rate
(required and/or current).
[0064] In one example, current and required values may correspond
to current and required flow rates through an outlet regulated by
the valve assembly specified, or corresponding to an FHD specified,
in the control input. In another example, the values specified in
the control input and stored in the parameter register may
correspond to an opening degree of an outlet or position of a valve
member. The MCS may do this comparison for every valve assembly as
a matter of sequence; every valve assembly specified in the control
input; or every valve assembly specified in the control input
combined with every outlet for which a new status must be derived
based on a required change for one of those outlets/valve
assemblies that were specified.
[0065] In one example, current values stored in the parameter
register that are compared to values specified in the control
input, may be actual flow rate values (e.g., values in GPMs). The
current actual values may be stored in the parameter register and
derived from most recently processed signals from the flow
monitoring components for the manifold and individual valve
assemblies. In another example, the values stored in the register
may include bytes of data that represent flow rates.
[0066] In yet another example, the values stored in the register
and included in the control input for comparison to the current
values in the parameter register may be representative of an open
or close status of a valve assembly serving a particular FHD
specified in the control input. For example, the control input may
include data that generally indicates that a particular FHD is to
go offline, and therefore does not require a continued supply of
fluid for its operation. Accordingly, the control input may
indicate that the FHD is going offline with the MCS processor as a
valve assembly close status. The MCS processor may therefore
recognize or assign a value corresponding to a closed state of a
corresponding valve assembly, to a required flow rate value.
Subsequently, this value can be compared with a current flow
rate-related value held in the parameter register for the valve
assembly that was specified in the control input (or valve assembly
corresponding to an FHD specified in the control input).
[0067] In stage 334, the VOC controller (via the MCS processor
alone, one or more valve controllers alone, or a combination of the
MCS processor and one or more of the valve controllers) determines
the required flow rates and valve operations (at least initial
operations) required to provide those flow rates based on the
comparison in stage 330. In addition, the VOC controller generates
operating instructions based the comparison. In one example,
operating instructions may include control signals, messages, an
operating sequence, or the like. For any difference determined for
any of the valve assemblies in a manifold managed by the MCS, the
VOC controller may execute, or specify for execution, a specific
series of operations.
[0068] In on example, a specific series of operations specified,
generated, or otherwise caused to be executed, may depend on a
current value in the parameter register associated with valve
assemblies of a manifold. For example, a current flow rate value in
the parameter register for a first valve assembly may correspond to
an open valve status, and a control input may specify a close
value. The MCS processor may set a required flow value parameter
for the first valve assembly to a valve assembly close value
register that is recognized for a communication and control channel
corresponding to the first valve assembly.
[0069] Conversely, it can be the case that a current flow rate
value in the parameter register for the first valve assembly
corresponds to a closed valve status, and a control input may
specify an open value. The MCS processor may set the required flow
value parameter to an open value that is recognized for a specific
communications channel corresponding to the first valve assembly.
In one example, each communication and control channel for each
valve assembly may have its own set of values that are recognized
as open, closed, degrees closed, or degrees of open, and used for
setting corresponding registers of the parameter register.
[0070] At stage 336, the actuators valve assemblies are
continuously operated by the valve controllers based on the
instructions generated in stage 334. In one example, the MCS
processor, or the valve controllers, or a combination thereof, will
operate the valve assemblies for each fluid flow channel for which
a flow rate must be changed based on the control input received in
stage 310. In one example, positions of respective valve members
will be changed until current flow rates are adjusted to match all
the required flow rates specified, or derived from any flow rates
specified, in the control input. In one example, the MCS processor
or valve controllers can access the parameter register that is
continuously updated with current flow rates, and compare these to
the specified required flow rates.
[0071] In stage 338, the valve controllers continuously monitor
actual flow rates from the valve assemblies as detected by a flow
sensor for each valve assembly. The actual flow rates are reported
to the MCS processor in stage 342.
[0072] In one example, Hall Effect devices may be used to measure a
flow rate of fluid supplied to each fluid flow channel by a
manifold of the present disclosure. More specifically, hardware
provided for each Hall Effect device may generate a pulse (positive
or negative) every time a magnet or other piece of hardware
associated with a flow sensor installed in a valve assembly, passes
by the Hall Effect device. In one example, the Hall effect device,
or other type of fluid sensing component, may communicate directly
or indirectly (via a valve controller) with an MCS processor, and
be installed in: a manifold; a sensor assembly attached to a
manifold; or a housing of a valve assembly installed in a manifold.
In this latter example, the valve assembly may include both pieces
of a hardware for sensing flow rates therethrough, and be equipped
with a connector (e.g., terminal, electrical connector), or signal
transmitting device that follows a particular communication
protocol (e.g., a wireless protocol such as Bluetooth, NFC, Zigbee,
WiFi, etc.), to convey signals indicating the flow rate to valve
controllers and/or the MCS processor.
[0073] Regardless of the means of transmission, once the signals
are received by the valve controllers and/or the MCS processor, a
flow rate may be determined. In one example, the valve controllers
may receive the signals from the flow sensors, determine a flow
rate, and transmit this information to the MCS processor. In
another example, the valve controllers may receive the signals
which are then passed on to the MCS processor for flow rate
determinations, which are then pushed back to the valve
controllers. In still another example, the MCS processor may
receive the transmitted signals and calculate the flow rates, which
are then transmitted to the valve controllers.
[0074] In one example, a flow sensor includes magnets that may move
with a flow of fluid through a valve assembly, and a Hall effect
devices that may register the movement of the magnets. In one
particular example, two magnets may be installed in each impeller
positioned immediately downstream of a valve member-regulated
opening in a valve assembly. Accordingly, the Hall effect device
may register two pulses per revolution of the impeller.
[0075] With the arrangement discussed immediately above, the MCS
processor, or a valve controller for a given valve assembly, may
implement a timer interrupt tracking process to calculate a flow
rate from the valve assembly in stage 338. In this process, the MCS
processor or valve controller may include one more timers, and a
counter to count a number of clock pulses between Hall Effect
pulses. An increment for the counts per clock pulses may be set
according to a desired accuracy. In one example, this ratio may be
set at greater than 100 counts per clock pulse for a resulting flow
rate calculation accuracy of better than 1%.
[0076] In one example, a current flow may be transmitted to the MCS
processor in stage 342, may occur as soon as a Hall Effect pulse
occurs. In on example, the parameter registered may be updated with
the new flow rates in stage 343, just after or simultaneously with
the update in stage 342. In one example, the VOC controller,
inclusive of the MCS processor the valve controllers, may be
equipped to determine an RPM based on signals from Hall effect
devices such that: a 3.3 Hz signal corresponds to a low RPM of 100
RPM (i.e., (100 RPM).times.(2 pulses/rev).times.(60 sec/min)); a
33.3 Hz signal corresponds to 1000 RPM; and 133 Hz corresponds to a
4000 RPM maximum.
[0077] A timer function employed by the MCS processor and/or the
valve controllers can be set up for each Hall Effect device and, in
one example, may use a 32 KHz internal clock divided by a factor of
two, and thereby provided 16,000 counts per second. Either the MCS
processor or each of the valve controllers may incorporate a 16 or
more bit counter configured to start counting clock pulses upon a
registering a 0 value for a timer. In one example with this setup,
when a Hall Effect rising edge occurs, an interrupt may be
generated for the valve assembly in which the rising edge occurred.
A flow rate value may be derived from a count and a time that are
recorded or otherwise taken from the counter and the timer when the
interrupt occurs. The counter may be reset at this point and
initialized upon the timer being set to 0.
[0078] In another example, if a flow of fluid to a valve assembly
stops, which may cause an impeller carrying flowing indicating
magnets to stop rotating, a counter for counting clock pulses may
be set to overrun at a preset number of counts (e.g., 65,000
counts) and generate an interrupt. This overrun interrupt may be
processed and recognized by the VOC controller, as a flow channel
with flow rate of 0. In one example, the MCS processor or valve
control can be configured so that an overrun interrupt occur at
0.24 Hz (i.e., 16000 Hz/65K counts), or after 4 seconds of no Hall
Effect device pulses.
[0079] In one example, one or more settings, flags, or other types
of indicators can be checked on preset intervals, for example 1
millisecond (msec), and used to initiate or stop certain operations
of the manifold. For example, a value for a master setting can be
used to trigger different operations of the manifold, while the
manifold is in the process of performing the various operations
associated with the stages in FIG. 3, and others described herein.
A value of this master setting may be checked concurrently with the
performance of operations associated with stages 334 to 343. The
master setting, in one example, can be set to one of two values to
indicate whether or not a current cycle of operations should
continue or another set of events should be checked for in stage
338. The MCS processor can check a value of the master setting
every 1 msec, which may change upon a recognition that all valve
assemblies have cycled through once or a predefined number of times
since the reception of a most recent control input. In another
example, the main setting may be changed upon the reception of a
new command input.
[0080] In one example, one or more valve assemblies installed in a
manifold may employ a stepper motor as an actuator for changing a
position of a valve member. A setting for the master setting may be
changed upon completing the generation of 500 Hz stepper pulses for
a required flow rate change. If such a stepper control is
completed, a master setting may be changed to cause a current flow
rate to be calculated based on a number of counts from Hall effect
device timer. For a given valve assembly/manifold outlet/flow
channel/FHD corresponding to flow rate being detected, a
corresponding required flow rate set in stage 330 and represented
in the parameter register, may be referenced for comparison in
stage 334. If a required flow rate and actual flow rate are not the
same or differ by more than a preset deviation (e.g., within
.+-.5%), the stepper motor for that valve assembly may be operated
to correct the error.
[0081] At stage 344, the MCS processor can poll the various control
input sources indirectly through MCS comms module. For some
sources, such as the MCS user interface, the MCS processor can
directly check for events that the MCS may respond to by modifying
operations of one or more valve assemblies.
[0082] As noted above, the MCS processor can check certain
settings, flags, or indicators on a preset or dynamically
responsive incremental basis and change current operations based on
the values of these elements which can change with the elapsing of
time, number of operations performed, or reception of a new control
input. In another example, the MCS processor can check a value of a
user interface setting every 50 msec, which changes upon the
reception of a command or instruction by the MCS user interface.
This can include a user operating the MCS user interface to change
a required flow rate, change another operating parameter (e.g.,
temperature, salinity, chlorination, turnover rate for water in a
pool, etc.) that results in a change to a required flow rate, for a
flow channel regulated by the manifold.
[0083] In one example, where the user interface setting is set to
indicate a new command has been received, a display (e.g., an LCD)
can be updated with required actions. An update to the display can
also include displaying current actual flow rate values depending
on a currently active screen on the display. In another example, if
a control input according to certain communication protocol (e.g.,
RS485) has been received, the display may be updated with a new
required flow rate value or any other update specified in the
control input. In one example, MCS processor can perform the check
in stage 344 every 50 msec.
[0084] The MCS processor may periodically transmit the actual flow
rates, flag statuses, counter values, timer values, and other
monitored signals or parameters to the parameter register in stage
346. The parameter register may execute an update function in stage
348 and change tracked parameter values using the information
received in stage 346. Stage 346 may additionally include
transmitting of the actual and required flow rates to the MCS user
interface, which may display these values in stage 350.
[0085] At stage 350, the MCS user interface displays flow rates for
valve assemblies based on various criteria that may be implemented
by the MCS processor.
[0086] Table 1 included herein provides an example of a set of
parameters that a VOC controller may utilize, reference, determine,
update, or report in a process of implementing the example method
of FIG. 3.
TABLE-US-00001 TABLE 1 Parameter Register Parameter Description
Received Input A 12-bytes register which is loaded as bytes are
received from a UART. Channel Status Six 1-byte registers, each
containing a current (actual) status of a channel (e.g., open or
closed) for respective FHDs Channel Received Six 1-byte registers,
each with a value for a channel as received from Status a control
input source. Channel Open Value Six 2-byte registers, each
containing a current flow count value that represents an open flow
channel flow rate value for each channel. (Can be input via MCS
user interface). Channel Close Value Six 2-byte registers, each
containing a current flow count value that represents a closed flow
channel flow rate value for each flow channel. (Can be input via
MCS user interface). Channel Actual Flow Six 2-byte registers, each
containing a 16 bit count captured by a timer measuring a flow rate
for each flow channel regulated by a manifold. Channel Required Six
2-byte registers, each containing a required flow rate for a given
Flow FHD that may specified during setup of a fluid distribution
system, such as a pool, or at any other time. Value may be adjusted
based on system changes that impact flow rate values (e.g.,
addition of new FHDs). Channel Count Six 1-byte counters, each
specifying how many counts for a stepper motor to execute. User
Interface Count 1-byte counter used to count to preset amount of
time that when reached, a user interface setting may be changed and
the counter may be reset to 0. Input Received A 1-bit flag
indicating that a valid 12 bytes message has been received Setting
and loaded in a Received Message Register. Error Message Setting A
1-byte flag for indicating an error is detected (e.g., No error
detected, CRC error detected, byte value error in input) that may
result a request by a routine to update. Master Setting A 1 bit
flag set by a preset timer (e.g., 1 msec timer) and reset when this
flag is processed (e.g., referenced for its status). User Interface
Setting A 1 bit flag set when a timer reaches a preset amount of
time (e.g., 50 msec) has elapsed since last being reset - may cause
a user interface check to be executed.
[0087] FIG. 4 illustrates an algorithmic flow chart of an example
method for dynamically controlling flow rates from valve assemblies
of a manifold.
[0088] At stage 402, a VOC controller can receive a translated
control input. In one example, a cycle timer can be initiated when
the translated control input is received. A valve assembly, or a
flow channel, an outlet number, or an FHD can be identified from
the control input in stage 402, which the VOC controller may
recognize as corresponding to a particular valve assembly for which
a flow rate must be changed or at least checked. As a result of
this identification, an identifier ("R" in FIGS. 4 and 5) used to
select which valve assembly to operate or check, can be set to a
number or value associated with, or otherwise recognized by the VOC
controller as belonging to, the valve assembly identified in the
control input. In another example, this identifier may have a
default value such that a process of checking and operating valve
assemblies always begins with a check of one particular valve
assembly, for example a bleed valve assembly as discussed with
reference to FIG. 10.
[0089] In stage 410, the MCS processor and/or valve controller can
determine if an actuator for a valve assembly regulating flow to
specified FHD is currently performing an operation. In one example,
a value for a flag, setting, or indicator can be set to one of two
(or one of two of three values) when an actuator is operating to
open or close the valve assembly, and the other of the two (or a
third value) with the actuator in an idle or otherwise
non-operational or non-moving state. Accordingly, if a value for
this setting, flag, or indicator corresponds to a non-operational
state, an actual flow rate from the valve assembly can be
determined in stage 412. Otherwise, a continued or next operation
of whatever operation the actuator was performing will be
implemented in stage 426.
[0090] In one example in which the actuator (R) includes a stepper
motor, a step counter may be accessed in stage 410. If the step
count is any number other than zero (0), a of the VOC controller
(e.g., MCS processor, a valve controller (R), combination of the
MCS processor and the valve controller (R)) may determine that the
actuator is currently operating (e.g., causing a valve opening or
closing movement). As a result, the exemplary method may include
preforming an incremental operation of the actuator in stage 426,
which is described in more detail below.
[0091] At stage 412, the VOC controller may determine an actual
flow rate from a specified valve assembly according to any of the
methods described herein. In stage 414, the actual flow rate for
the valve assembly (R) may be compared to a required flow rate
specified in, or otherwise derived from, the information provided
in the control input. In one example, this may include determining
whether or not the detected actual flow rate is within a standard
deviation of a preset magnitude (e.g., 5%) of the required flow
rate for the valve assembly (R). Upon determining that actual flow
rate differs (in absolute terms or by more than a stand deviation)
from the required flow rate, the VOC controller can perform a check
of a position of a valve member (R) in stage 418.
[0092] In stage 418, the VOC controller may determine that the
actuator (R) is in a home position. In one example, a home position
may correspond to a fully open state of a valve assembly. Each
valve assembly may be equipped with a position sensor that
transmits an indication of an actuator or valve member position. A
position may be registered when the actuator or valve member has
been displaced a maximum possible amount in a valve opening
direction.
[0093] In one example, each valve assembly may include a prime
mover component (e.g., a shaft) that is moved by the operation of
an actuator and a switch at the end of a movement path of that
component. The component may contact the switch or cause the switch
to be contact in such a manner as to open the switch if it closed
or close it if it open, when the component reaches a maximum
displacement in a valve opening movement along the component's
movement path. Accordingly, the VOC controller can recognize a
change to the switch as an indication that the valve assembly is in
a fully open state and/or an actuator has reached the end of a
valve opening operation.
[0094] In another example, a position sensor, such as a switch may
be provided at an end of a movement path representing a fully
closed state of the valve. In yet another example, position sensors
(e.g., switches) may be provided at both ends of an actuator or
valve member's movement path. In those configurations in which
fully open and a fully closed home positions are recognized, and
the actuator (R) or valve member (R) is determined to be in one of
those home positions in stage 418, a direction for a next operation
corresponding to the control input may be compared to the home
position (i.e., a direction of movement for a next operation).
[0095] A potential operating direction of the valve member
(R)/actuator (R) may be determined in stage 418 based on a sign of
a differential between the actual and required flow rates. For
example, where the actual flow rate (R) is greater than the
required flow rate (R), a sign of this difference may be negative.
The VOC controller may then recognize that the valve member (R)
must move, or an actuator (R) must be operated, to cause a port
regulated by the valve assembly (R) through which the detected
fluid flows, to be closed (at least to some degree). The opposite
being true for a differential having a positive value, meaning the
valve assembly (R) needs to be opened more to provide the required
flow rate. In the case where the actuator (R)/valve member (R) is
in a fully open home position, and the operating direction is that
of an opening direction, the VOC controller may determine that the
valve assembly (R) cannot be operated in isolation to obtained the
required flow rate (R).
[0096] In one example, a stepper motor may be utilized for at least
one actuator in a manifold. A step count for this actuator may be
set to preset value (e.g., 0) when a valve member is in a home
position, or one of two home positions. In this example, a VOC
controller can recognize this value for the step count as a stop
condition and end the operation of the stepper motor actuator in
stage 446 where the valve is in one of the home positions, and an
operating direction specified in a control input is towards that
home position.
[0097] In stage 422, where the actuator (R), or valve member (R),
or a prime mover connecting them is (A) not in a home position, or
(B) in a home position but an operating direction is not towards
that home position, the VOC controller can determine an operating
range for the actuator (R). Otherwise, where the actuator (R) is
not in a home position, an operating direction and operating range
may be determined in stage 422.
[0098] In one example, for an actuator including a stepper motor,
the operating range may be a number of steps for a step counter of
the actuator to reference. In this example, a step counter for the
actuator (e.g., stepper motor) may be set to a standard (default)
count value to generate a baseline number of steps. This number of
steps for the stepper motor may correspond to a performance in
stage 422 of an increment of stepper motor turns (e.g., 100 counts
may generate 50 steps which result in a 1/4 turn of the stepper
motor). This may be the operation that occurs if the step count is
not currently 0, in which case a step output pin for the stepper
motor actuator may be toggled. In one example, this may cause the
output pin to turn ON and OFF over a short increment of time (e.g.,
1 msec) and create a standard step signal (e.g., a 500 Hz square
wave step signal).
[0099] In stage 426, the VOC controller can perform an incremental
operation of the actuator (R). In one example in which the actuator
was already in operation, the operation in stage 426 is merely a
continuation of a current process, or a predetermined next process,
in the operation of the actuator (R). Otherwise, where a previous
stage included stage 422, an operation of the actuator (R) can be
started in stage 426.
[0100] As noted previously, in some examples an actuator for a
valve assembly may include a stepper motor. In these examples, at
stage 426, a step output pin for a stepper motor for an actuator
may be toggled. In turn this may cause the step output pin to turn
ON and OFF in 1 msec creating a 500 Hz square wave step signal. In
one example, this toggling may be repeated every 1 msec until 50
steps (increment of operation) are completed. Instructions provided
to a valve controller that may operate the actuator/stepper motor
(on its own, or in tandem with a MCS processor, or as a subordinate
to an MCS processor) may include, in stage 426, an enable signal,
an indication of a clockwise or counter-clockwise direction for
motor rotation, and a signal indicating an operating range (e.g., a
step count). Where operations corresponding to stage 422
immediately precede those operations of stage 426, the enable
signal may turn ON motor controller drivers to the stepper motor
actuator. In other examples in which stage 426 is preceded by stage
410 or stage 422, an enable signal may correspond to a stay ON
signal where a stepper motor must remain ON to maintain a current
position. As previously noted, the operating range may include a
number of steps for the stepper motor actuator to take.
[0101] Continuing with the above example, signals for enabling, an
operating direction, and an operating range may be transmitted,
received, and/or processed using general purpose Input/Output
(GPIOs) of, for example, an MCS processor. In one example, a
respective set of three signals may be recognized and associated
with each flow channel and corresponding communication control
channel for an FHD served by the flow channel. Other control inputs
for examples including stepper motor actuators may include inputs
that are hardwired.
[0102] In the examples according to the present disclosure that
include actuators that utilize stepper motors, design parameters
for consideration in selecting a particular stepper motor may
include Maximum linear displacement, Linear Displacement per
revolution, and step size. In some examples, a max displacement of
a stepper screw may be 30 mm, one revolution of the stepper may be
produced through 200 steps and moves the stepper screw 2 mm, and
the stepper will move a 1/4 turn, or 50 steps, as an initial
default step size. Further specifications may include each step
signal taking 1 msec to turn ON, and 1 msec to turn OFF so that a
step frequency is 500 Hz or 2 msec per step (50% duty cycle).
[0103] At stage 430, a position tracker for the actuator (R) can be
incremented. In one example this may correspond to incrementing a
step count for an actuator including a stepper motor by one step
count. In this example, the VOC controller may count up to the
operating range (R). In another example, a step count may be
decremented by one where MCS processor on valve controller counts
down from a set range (R).
[0104] In stage 434, the VOC controller determines whether a value
of the position tracker (R) indicates that the actuator (R) has
been operated to the operating range. This is determined according
to whether the position tracker (R) includes a step count that is
incremented up to the operating range (R), or is decrement down to
a minimum valve (e.g., zero (0)).
[0105] In one example in which the actuator (R) includes a stepper
motor, the position tracker (R) may also encompass a status of a
step output pin of the stepper motor. Accordingly, stage 434 can
include, in addition to or as substitute for a comparison with the
operating range, checking the step output pin for a low signal.
This condition may correspond to a prime mover (e.g., a screw
shaft) or a stepper motor of the actuator (R) having been operated
(or moved) a predetermined amount.
[0106] If the operating range (R) criteria is not met, at stage
438, the valve controller or the MCS processor may access a fully
open or closed status indicator (identified as "0/C indicator (R)"
in FIG. 4 and referred to hereafter as "open/close indicator (R)")
for the specified valve assembly to determine whether the valve
member (R) is in a home position in stage 442. Accessing the
open/close indicator (R) can include registering the operation of a
switch position at the end or beginning of a movement path for the
valve member (R) or prime mover (R) moved by the actuator (R).
[0107] In the exemplary method illustrated in FIG. 4, an operation
of the actuator (R) will end where it is determined that an actual
flow rate (R) is equal to the required flow rate (R) in stage 414,
or the home position and operating direction criteria is met in
stage 418, or it is determined that the actuator (R) is in a home
position in stage 442.
[0108] Once the operation of the actuator (R) has been stopped in
stage 446, or it is determined that the actuator is not in a home
position in stage 442, or the operating range (R) criteria is of
stage 434 is met, the MCS processor may perform a cycle check in
stage 500. As will be explained with reference to FIG. 5, the cycle
check may include checking a status of all valve assembly
operations, checking for new control inputs, and, in some examples,
current and required flow rates for each of the FHD served by the
valve assemblies of an exemplary manifold according to the present
disclosure.
[0109] FIG. 5 illustrates an algorithmic flow chart for performing
a cycle and control input check.
[0110] At stage 510, a VOC controller determine may that all the
actuators have not been cycled through and identify a next actuator
in the cycle to be operated in stage 522. An order for a cycle of
operating all the actuators may be preset, or recorded in the
parameter register and updated depending on operating conditions.
In another example, the order can be: consecutive from a valve
assembly requiring operation; specified based on an ordering
criteria that depends on which of the valve assemblies has to be
operated first; based on a difference between actual and required
flow rates; based on a position of a valve assembly for a specified
FHD within the manifold relative to a position of a compensating
valve assembly; or other criteria.
[0111] Alternatively, the VOC controller may determine that all the
valve assemblies have been cycled through and increment a cycle
tracker in stage 514. In one example, the cycle tracker may
correspond to a setting, flag, count, or indicator that the VOC
controller uses as a reference to track operations, or series of
operations that have been performed. In stage 518, the VOC
controller may compare the cycle tracker value to a tracker
threshold value. Where the cycle tracker is less than the tracker
threshold, the VOC controller may identify a next actuator in a
cycle order and set R to an identifier for that actuator. On the
other hand, the cycle tracker will be reset to an initial value in
stage 520 if it is equal to the tracker threshold.
[0112] In one example, the tracker threshold value may correspond
to a total number of valve assemblies in a manifold. Accordingly,
when a cycle tracker reaches the tracker threshold, the VOC
controller can recognize that all of the valve assemblies have been
checked and operated as part of a current cycle since the last time
a cycle tracker was reset. Thus, for a manifold with N number of
valves, the tracker threshold may be set to the value of N. Thus,
when the cycle tracker reaches a value of N after being incremented
in stage 514, the VOC controller will be able to in effect know
that all valve assemblies have been checked and/or operated as part
of current cycle with the evaluation performed in stage 518. In
this situation, the cycle tracker will be reset in stage 520.
[0113] At stage 522, the current value of the cycle tracker can be
used to determine which of the actuators will be the next for
operation. In one example, a reset cycle tracker may cause the VOC
controller to look to the beginning of a cycle order for a next
actuator to operate because a new cycle will be started. On the
other hand, the cycle tracker having a non-reset value will
indicate to the VOC controller that the next actuator to operator
is the next actuator of the cycle order.
[0114] In stage 526, the VOC controller can determine if a cycle
time is equal to or has extended past a threshold time that is used
to trigger a start of a new repetition of operations. In one
example, the preset amount of time set for the threshold time may
be 50 msec. Where the threshold amount of time has not elapsed
since the last instance a cycle time was reset, the VOC controller
may access or reference back to the last control input received. In
addition, operational information (e.g., required flow rate)
specified for an actuator corresponding a current R value may be
pulled from the control input in stage 530 and implemented by the
VOC controller in stage 410.
[0115] On the other hand, where the cycle time is equal to or
greater than the threshold time, the VOC controller can update an
MCS user interface in stage 534. In one example, a value for the
threshold time may be based on or set in accordance with a routine
for checking if any new control inputs have been received from a
user through an MCS user interface. For example, with every
increment of time equal to the threshold amount of time that
elapses (e.g., 50 msec) a user interface flag can be set which
causes a display of the user interface to be updated with the
latest flow rate values.
[0116] At stage 538, the VOC controller may check to see if the
cycle tracker was reset as result of a most recent check of the
cycle tracker in stage 518. If it has not been reset, the VOC
controller can make a check for whether any new control input has
been received in stage 542. Otherwise, if the cycle tracker has not
been reset, or has been reset but a new control input has not been
received, the VOC controller can reset the cycle time in stage 546.
Further, the VOC controller can access the most recent translated
control input for actuator specific operational information in
stage 530. But, where a new control input has been received, the
VOC controller can verify the new control input in stage 550, which
can then be implemented, if verified, starting with the operations
for stage 410.
[0117] FIG. 6 illustrates a schematic view of a manifold control
system 620 ("MCS 620") of a manifold 610 provided in a fluid system
600, according to an aspect of the present disclosure. The manifold
610 includes the MCS 620 and a chamber 680. The MCS 620 includes a
user interface 630 and a valve operation and coordination
controller 650 ("VOC controller 650). The user interface 630 is
provided with a display 634 and a set of controls 638.
[0118] For the display 634, the user interface 630 may include a
liquid crystal display ("LCD") that provides a graphical interface,
and a bus (e.g., I2C or SPI bus) connection to a processor. The
controls 638 may include push-buttons, for example six push
buttons, and associated de-bounce hardware. The user interface 630
may communicate (via, e.g., a processor for the user interface)
with the VOC controller 650 to convey control inputs from the
controls 638 and send and receive information.
[0119] In one example, the VOC controller 650 includes at least one
processor 652, a first comms module 654, a power input 656, and at
least one valve controller 670. It is through the first comms
module 654 that the VOC controller 650 receives control inputs that
the VOC controller 650 processes to determine and implement
operations of valve assemblies 690 installed in a chamber 680 of
the manifold 610. As shown, the power input 656 may be connected to
a power source 602, the chamber 680 may be in fluid communication
with a pump 604, and a second comms module 606 may communicate with
the first comms module 654. The control inputs received through the
first comms module 654 are used by the VOC controller 650 to
dynamically control: (A) flow rate to each of a plurality of flow
channels 608; and (B) a total flow rate of fluid to a combination
of all the flow channels 608.
[0120] In general, the VOC controller 650 will be equipped with
processing power required to control the manifold 610. In a
specific example, the VOC controller 650 may include a microchip
ARM M0+ processor (e.g., an ATSAMC20) that is selected based on a
number of different parameters including memory size (flash/RAM),
timer support capabilities, actuator interface compatibility,
number of general purpose Input/Outputs ("GPIOs"), low voltage
operating capabilities, and other factors.
[0121] The first comms module 654 may be configured to communicate
directly with a PSC panel, (not shown) the fluid handling system
600, or through the second comms module 606. In another example,
either of the first or second comms modules 654, 606 can be
connected to an external control device (not shown), such as an
external controller or a peripheral device (e.g., a phone, laptop,
tablet, personal computer, a controller for an FHD, etc.) that
serves as an intermediary between the MCS 620 and a PSC panel. In
another example, the first comms module 654 can communicate
directly, or through the second comms module 606 with both of a PSC
panel and an external control device.
[0122] As illustrated in FIG. 6, a valve controller 670 is provided
for, and may be included as a part of, each of the valve assemblies
690. In other examples described herein, a single valve controller
670 can be provided, or more generally, less valve controllers than
a number of valve assemblies 690 may be provided. Each of the valve
controllers 670 can include an actuator interface 672 for
communicating and/or directing operations of an actuator 692, a
sensor interface 674 for processing flow information from a flow
sensor 694, a power output 676, and a valve full-open, or full
close, or full-open and full-close indicator 678 (identified as
"O/C IND." in FIG. 6 and hereafter referred to as "open/close
indicator 678").
[0123] Each actuator interface 672 can provide a line of
communication between a respective actuator 692 and either the
processor 652 or a separate control manager (not shown) for a
respective valve controller 670. In one example, the actuator
interface 672 can perform one or more processes to determine an
instruction which it transmits to a respective actuator 692 and
causes the actuator 692 to perform and operation specified in the
instruction. In another example, an instruction can be generated at
the level of the processor 652, and the actuator interface 672
serves merely as a communication channel between the processor 652
and a respective actuator 692. Each actuator 692 may be directly
controlled by a dedicated actuator interface 672 and reduce a
processing burden on the processor 652.
[0124] In one example, stepper motors may be provided for the
actuators 692, actuator interfaces 672 may include an integrated
stepper motor controllers (e.g., a DRV8834, or the like) configured
to issue enable, step, and direction signals to one or more stepper
motors. In this example, the stepper motor controllers may be
equipped with special hardware and have special hardware
requirements for setup such that some operations may hardwired on a
printed circuit board ("PCB"). Such a PCB may be incorporated in
the VOC controller 670.
[0125] A sensor interface 674, in one example, can process
information from a respective flow sensor 694 (e.g., a signal, a
series of signals, a message, flag status, value of a measured
parameter) for: display; translation and display; additional
processing, translation, and display; or verification and display.
In one example, the sensor interface 674 may provide a
communication path between a respective flow sensor 694 and the
processor 652, and the processor 652 may determine a flow rate from
the information provided by the actuator interface 672 which is
based on the information received from the respective flow sensor
694.
[0126] In another example, the sensor interface 674 may primarily,
or additionally, provide a first flow monitoring component, as
incorporated in the exemplary manifold 800 of FIG. 8. Accordingly,
the sensor interface 674 may include a Hall effect device
communicatively attached to a flow measuring device, such as magnet
equipped impeller. In addition, the sensor interface 674 may
include hardware that interfaces these Hall effect signals to a
respective valve controller 670 and/or the processor 654. The flow
measuring device mentioned above may encompass primarily, or in
part, a flow sensor 694, and be provided inside an outlet port of a
manifold. With the outlet port being in fluid communication with a
flow channel, the flow sensor 694 may generate two pulses per
rotation of the impeller of the flow sensor 694 and thereby provide
data that can be used to determine and indicate a flow rate of
fluid passing through the outlet port.
[0127] A power output 676 for each valve controller 670 may be
connected, and supply power to a respective valve assembly 690 and
its actuator 692 and flow sensor 694. Each of the power outputs 676
can draw from a connection to a power supply provided by the power
input 656 for the MCS 620. In one example, the power input 656 may
provide a 24 VAC supply that will be utilized to provide all the
power requirements for the manifold 610. Hardware incorporated in
the manifold 610 and represented by the power outputs 676 may
handle/require/output 5V signals and manage power requirements for
all devices including the valve controllers 670, the actuator
interfaces 672, and the actuators 692.
[0128] Each power output 676 can carry a 5V signal or other voltage
power signal to a respective valve assembly 690. Accordingly, all
valves assemblies 690 provided in the chamber 680 can be powered
through the connection between power input 656 for the MCS 620 and
the power source 606 connected thereto.
[0129] As previously noted, each valve controller 670 includes a
full-open/full-close indicator that may be configured to detect or
otherwise operate as a way of indicating that an actuator 692 (or
valve member) is located in a home position and a respective valve
assembly 690 is in a fully open or fully closed state. For example,
each valve controller 670 may include a home momentary contact
switch that can be used to define, to either a respective valve
controller 670 or the processor 654, a fully open position for a
respective valve assembly 690, and can be considered as a limit
switch for an open flow channel.
[0130] During an initial setup, an actuator 694 may operate a valve
assembly 690 to open a respective fluid flow channel until a
respective open/close indicator 678 registers a position of a valve
member and, in this example, an open state of a flow channel. In a
particular example where a stepper motor is provided as an actuator
694, a stepper motor controller may open a respective flow channel
until a home switch provided as an open/close indicator 678 closes,
and thereby indicates a maximum open travel of a valve member has
been hit. This method of open (or closed) detection can be utilized
to cause a valve assembly to be in a fully open state during setup.
During normal manifold operations, this functionality may be used
as a diagnostic tool to indicate a possible error in a position of
a valve member.
[0131] As described herein, a home position may correspond to a
position of an actuator and valve member that corresponding a fully
open or a fully closed state for a valve assembly 690. In one
example, each open/close indicator 678 may be monitored by a
respective valve controller 670, and/or by the processor 654.
Recognition of these operational conditions (fully open or fully
closed) can be used as a way to determine that: (1) other valve
assemblies may have to be operated to achieve a desired flow rate
through a particular valve assembly that is fully open; or (2)
other valve assemblies may have to be operated to achieve a desire
flow rate through a select valve assembly since the fully closed
valve assembly cannot further having an increasing affect to the
flow rate of fluid entering another valve assembly in a
manifold.
[0132] FIGS. 7A and 7B illustrate perspective views of a fluid
distribution manifold 700 ("manifold 700"), according to an aspect
of the present disclosure. The manifold 700 includes a first
housing 710, a valve retainer 730, and a second housing 740.
Together the first housing 710 and the valve retainer 730 define a
first chamber 750, and the second housing 740 and the valve
retainer 730 define a second chamber 760, both of which are
identified in FIG. 8. In one example, the first housing 710
includes a body that defines at least two inlets 712, at least one
pressure relief outlet 714, and a plurality of outlets 720.
[0133] Each of the outlets 720 may extend from a portion of an
external surface 717 of a lower wall 716 of the first housing 710
that surrounds an aperture (not visible) formed in the lower wall
716. The apertures defining outlet ports extend through an inner
surface of the lower wall 716 to be able to receive valve
assemblies 800. As shown in FIGS. 7A and 7B, each outlet 720 may
include a stepped profile with a distal end 724 having a smaller
diameter than a proximal end 722 that extends from the lower wall
716. An inner surface of the proximal end 722 may correspond to an
outer surface of a valve housing so that portion of the valve
housing of a valve assembly 800 can extend through the lower wall
716 and be received in the proximal end 722 of the outlet 720. In
one example, the first housing 710 may include at least six (6)
outlets 720, with a valve assembly 800 respectively received in a
proximal end 722 of each outlet 720 to control a flow of fluid
through a corresponding distal end 724 of the outlet 720.
[0134] In other examples, a slot corresponding to each outlet 720
may extend into the first housing 710 from an internal surface of
the lower wall 716. The first housing 710 may include at least six
(6) slot and outlet 720 combinations, with a valve assembly 800
received in each slot to control a flow of fluid through a
corresponding outlet 720.
[0135] The second housing 740 may house components of a manifold
control system 770 ("MCS 770") and a valve cover 860 for each of
the valve assemblies 800. Various components of the MCS 770 may be
integrated into or otherwise be attached the second housing 740.
Exemplary manifold control systems are described herein, but
generally are configured to operate or otherwise include a user
interface 772. As shown the user interface 772 of the MCS 770 can
include a display 774 and controls 776 such as an exemplary display
634 and user interface 638 illustrated in FIG. 6.
[0136] In one example, the second housing 740 is sealed from the
first housing 710 by the valve retainer 730 and valve covers 860
and housings of the valve assemblies 800. Thus, within the second
housing 740, components of the MCS 770 are not exposed to fluid
flowing through the first housing 710 from the inlets 712. In
particular, an MCS processor 778, or a component serving as a VOC
controller that includes the MCS processor and valve controllers
(both installed in the valves housings and/or in the second housing
740), are exposed to the fluid flowing through the first housing
710.
[0137] Such an MCS, as previously described, may be configured to
operate the display 774 and receive various input commands that are
received by the controls 776 of the user interface 772. The display
774 and the controls 776 may be installed in the second housing
740. In various examples, the user interface 772 includes physical
buttons, or is provided by a touch screen defined or otherwise
provided by the display 774, or is comprised of a combination of
physical buttons and touch screen functionality.
[0138] A sensor assembly 780 for determining flow rates of fluid
through the outlets 720 may be attached to the first housing 710
proximate to the outlets 720. Each valve assembly 800 may be
equipped with a second flow monitoring component 840 (see FIGS. 8
and 9) that is paired with a first flow monitoring component 880
(see FIGS. 8 and 9) provided by the sensor assembly 780. According
to aspects of the present disclosure, operational control of each
valve assembly 800 in the manifold 700 will depend from: (1) an
input fluid flow rate to the inlets 712 of the manifold 700; (2) a
flow rate through a flow channel required by an FHD served by that
flow channel and regulated by a respective valve assembly 800; and
(3) a total output flow rate required by all flow channels
regulated by the manifold 700. The first flow monitoring components
880, and in some examples the second flow monitoring components
840, may communicate with the MCS 770 to enable independent
operational control of each valve assembly 800 for achieving
required channel output flow rates and a required total output flow
rate as previously described herein.
[0139] FIG. 8 is a sectional view of the fluid distribution
manifold taken from a plane indicated by line 8-8 as illustrated in
FIG. 7.
[0140] As shown, the first housing 710 includes a first rim 890
provided with a groove 892 configured to receive a protruding edge
894 of the valve retainer 730. As shown, the protruding edge 894
extends downward from a flanged lip 897, which extends outwardly
from a side wall 891 of the valve retainer 730. As also shown in
FIG. 8, the sidewall 891 extends downward from a retention plate
893 that is defined by a first surface 895 and a second surface 896
of the valve retainer 730. In one example, the protruding edge 894
can be friction fitted to the groove 892. In another example, a
snap fit can be provided with corresponding engagement features
provided on the outer and inner surfaces that respectively define
the protruding edge 894 and the groove 892. In still another
example, the protruding edge 894 or the groove 892 may be formed
with a recessed groove for receiving an O-ring configured to secure
the protruding edge 894 in the groove 892 of the rim 890. As
assembled, the first surface 895 of the valve retainer 730 and an
inner surface 872 of the first housing 710 define the first chamber
750 in which the valve assemblies 800 are primarily positioned.
[0141] Referring back to FIGS. 7A and 7B, the first housing 710
includes the two inlets 712, the pressure relief outlet 714, and
the plurality of outlets 720. As shown in FIG. 8, surrounding wall
870 defines inlet ports 874 and a pressure relief port 876 within
the first housing 710, and from which the inlet ports 874 and the
pressure relief port 876 extend respectively. The inlet ports 874
are provided on opposite ends of the first housing 710 so that a
flow rate of fluid flowing in the first chamber 750 and around the
valve assemblies 800 is substantially uniform. Although the inlets
and corresponding inlet ports 874 could be provided in multiple
numbers and locations, the configuration illustrated provides
advantages over configurations that include one inlet on just one
end, or in a middle portion of the first housing. In these
configurations, an incoming flow rate may be lower for fluid
flowing to valve assemblies 800 located within the manifold 700
further from the inlet than flow rates for assemblies located
closer to the inlets. The duel inlet ports 874 of the exemplary
manifold 700 illustrated in FIGS. 7B and 8, convey fluid into to
the first chamber 750 from opposite ends of the first housing 710
to reduce the opportunity for non-uniform flow rates.
[0142] In one example, each valve assembly 800 can include a valve
housing 810 having a first mating structure 812 extending from two
or more wall segments 820 that extend from a second mating
structure 822. In the example illustrated in FIG. 8, the valve
housing 810 has an overall cylindrical shape, but one of ordinary
skill in the art will recognize that other configurations can be
used.
[0143] The first mating structure 812 includes a first end 814 that
is sized so as to fit within a proximal end 722 of an outlet 720
provided by the first housing 710. The first end 814 of the first
mating structure 812 may define a first end face 815 that is shown
in a closeup of FIG. 8. The first end face 815 may engage an end
piece 848 of the valve assembly 800 that secures an impeller 830
within the first end 814. The first end 814 and first end face 815
may be sized to directly or indirectly engage, rest on, or
otherwise be prevented from moving beyond a ridge 878 formed on an
inner surface of the outlet 720 at a step defined by a transition
from the proximal end 722 to the distal end 724 of the outlet
720.
[0144] An impeller 830 is positioned within the first end 814 of
the first mating structure 812 and carries one or more magnets 840
within individual blades 832 of the impeller 830. Each blade
includes a base portion 834, and at least two or more base portions
may be formed with bores 836 configured to receive magnets 840. In
one example, the magnets 840 are positioned within base portions
832 that are diametrically opposed relative to a longitudinal axis
of the impeller 830.
[0145] The magnets 840 provide a second flow monitoring component
configured to be paired with a corresponding first monitoring
component 880 provided in the sensor assembly 780 as shown in the
close up of FIG. 8. In one example, the first flow monitoring
component 880 includes a Hall effect device that is fixed to a
strip or elongated terminal 882 configured to operate as a bus
(hereafter referred to as "bus 882"). The bus 882 is configured to
transmit signals generated by the first flow monitoring components
880 to the MCS 770, or any type of MCS described herein. As fluid
flows through the first end 814 of the valve assembly 800, the
impeller 830 is caused to rotate at a speed that may be
proportional to a flow rate of the fluid flow through the first
mating structure 812 and out of the outlet 720. As will be
explained with reference to FIG. 9, rotation of the impeller 830
may be detected by the first flow monitoring component 880 as it
registers the rotational movement of the magnets 840.
[0146] A second end 818 of the first mating structure 812 is
separated from the first end 814 by a partition 816 as shown in
FIG. 8. An outer circumference of the first mating structure 812
may be formed with a recessed groove 817 as shown in the close-up
of FIG. 8, and used to receive an O-ring that helps secure the
valve housing 810 within the proximal end 722 of the outlet 720. In
another example, instead of, or in addition to the O-ring, the
first end 814 of the first mating structure 812 can be sized to be
press-fit to an inner surface of the proximal end of the outlet
720.
[0147] Above the partition 816 and the recessed groove 817, the
second end 818 of the first mating structure 812 defines a bore or
other shaped area that may receive a valve member 850 of the valve
assembly 800. The second end 818 of the first mating structure 812
defines a second end face 819 configured to provide a valve seat
(hereafter "second end face 819" or "valve seat 819") for engaging
valve members 850 (e.g., a plunger) of the valve assemblies 800.
During a valve closing operation, an actuator 852 of the valve
assembly may be operated to bring a surface of the valve member 850
into abutment with the second end face 819 and provide a tight
seal. As a result of this operation, fluid flowing within the first
chamber will not enter the second end 818, and therefore not flow
through the partition 816, past the impeller 830, and out of the
distal end of the outlet 720.
[0148] Turning to the second mating structure 822 of the valve
housing 810, this portion of the valve assembly 800 is configured
to slide in and be locked to a slot 1130 (see FIGS. 11-12C, 14A,
and 14B) of the valve retainer 730. An outer surface 824 of the
second mating structure 822 may be provided with engagement members
1110 (see FIGS. 11 and 13A-D) to facilitate an interlocking
engagement with the slot 1130 that is described in more detail with
reference to FIGS. 12A to 15. An inner surface 823 of the second
mating structure 822, on the other hand, may be specifically
configured to receive and secure an actuator housing 854 of an
actuator sub-assembly of the valve assembly 800.
[0149] The actuator sub-assembly includes the actuator housing 854
that is configured to receive an actuator 852, which is operatively
coupled to a prime mover 856 configured to engage the valve member
850. In one example, the actuator 852 may include a stepper motor
having a stator and rotor, and the prime mover 856 may include a
threaded main shaft 857 that is caused to move in a linear manner
by rotation of the rotor of the stepper motor. The prime mover 856,
as shown, may include a threaded end 858 that can be used to
securely attach the valve member 850 to the prime mover 856. The
actuator housing 854 may include a bearing 855 to assist the linear
movement of the prime mover 856.
[0150] Upward movement of the prime mover 856 will likewise cause
an upward movement of the valve member 850 away from the valve seat
819 defined by the first mating structure 812. However, as with the
valve assembly 800 illustrated in FIG. 8, the valve member 850 may
be shaped so that moving away from the valve seat 819 gradually
lessens by how much a fluid port defined by the second end 818 is
obstructed by a body of the valve member 850. A flow rate of fluid
entering the second end 818 of the first mating structure 812, and
thus exiting through the outlet 720, increases or decreases in
proportion to a degree to which the valve member 850 obstructs an
opening to the fluid chamber 811 defined by the second end 818. In
the exemplary case shown, with the actuator 852 provided by a
stepper motor, the actuator can controllably move the prime mover
856, and thus the valve member 850, in extremely small and precise
increments. As a result, a degree to which the second end is
obstructed by the valve member 850, and flow rate of fluid through
the outlet 720, can be controlled to a very precise degree by the
MCS 770, which may include all the capabilities of any exemplary
MCS described herein, such as the MCS 600 shown in FIG. 6.
[0151] The MCS 770 dynamically controls the flow rate of fluid
through the outlets 720 by operating the valve assemblies 800.
Further, the MCS 770 is positioned, at least in part, within a
second chamber 760 defined by the valve retainer 730 and the second
housing 740. The second housing 740 includes a second rim 898 that
corresponds to the flanged lip 897 that extends outwardly from the
sidewall 891, which itself extends downwardly from the retention
plate 893 of the valve retainer 730. In one example, the second rim
898 can be configured to be snap fit to the flanged lip 897. More
specifically, one of the valve retainer 730 or the second housing
740 can be formed with prongs that can releasably snap into slots
or recesses formed in the other of these two components.
[0152] As assembled, the second surface 896 of the retention plate
893 of the valve retainer 730 and an inner surface 899 of the
second housing 740 define the second chamber 760 as previously
mentioned. The second chamber 760 houses many of the components
that make up the MCS 770 and a valve cover 860 of each valve
assembly 800. In one example, a shape of the second housing 740 may
be formed in such a way to accommodate one or more components of
the MCS 770 or the valve assemblies 800. In one example, the second
housing 740 may be provided in a shape having a sufficient height
to accommodate a full range of motion of a prime mover 856 of an
actuator 852.
[0153] FIG. 9 is a sectional view of the fluid distribution
manifold 700 taken from a plane indicated by line 9-9 in FIG. 7A
More specifically, FIG. 9 shows an elevation view of a bottom side
of the pressure relief outlet 714, the inlets 812, and an outer
surface of the lower wall 716 of the first housing 710, as well as
a cross-sectional view of the sensor assembly 780, each outlet 720,
and a base portion 834 of each impeller 830.
[0154] The sensor assembly 780 includes a sensor housing 910 that
is fastened to the first housing 710 with fasteners 902 (e.g.,
screws, removable pins, etc.). These fasteners 902 may be received
in first bores 916 formed in protrusions 914 that extend from a
first side 912 of the sensor housing 910. The first bores 916 may
correspond to second bores (not shown) formed in the lower wall 716
of the first housing 710. The sensor housing 910 is sized such that
a width between the first side 912 and a second side 918 of the
sensor housing 910 corresponds to a space between outer surfaces of
the proximal ends 722 of the outlets 720 and guide prongs 904 that
extend from the outer surface 717 of the lower wall 716. With the
guide prongs 904, installation and removal of the sensor assembly
780 can easily be accomplished by, for example, field personnel
servicing the manifold 700 and other components of a fluid
distribution system, such as a pool system.
[0155] The sensor assembly 780 includes the sensor housing 910, the
bus 882 that extends over a length of the sensor housing 910, and
second flow monitoring components 840 attached to the bus 882 for
each outlet 720. In one example, each first flow monitoring
component 880 can includes a Hall effect device (e.g., a Hall
sensor) that detects the movement of magnets 840 in a base portion
834 of an impeller 830 positioned in an outlet 720 adjacently
located to the that first flow monitoring component 880. In
addition, a terminal 882 extends from the sensor housing 910 and
provides a power supply and a data communication channel, such as a
wire, cable, or other data carrying component, that connect to the
bus 882.
[0156] During operation, a flow rate of fluid flowing through each
outlet 720 can be detected and independently adjusted through an
operation of a respective valve assembly 800. A current actual flow
rate can be determined from information generated as an impeller
830 rotates within a first end 814 of a respective valve assembly
800. As these actual flow rates are monitored, feedback including
these readings is conveyed to the MCS 770. In turn, the valve
assemblies 800 may be individually adjusted by the MCS 770 to
compensate for increases or decreases in flow rates outside of a
predetermined tolerance. Accordingly, the manifold 700 of the
present disclosure can provide a closed loop system on each outlet
720 and fluid flow channels connected to that outlet 720.
[0157] More specifically with the exemplary manifold of FIG. 9,
first flow monitoring components 880 of the sensor assembly 780 may
include Hall effect devices, and the second flow monitoring
components 840 installed in the impellers 830 may include magnets
as previously described. In one example, two magnets on opposite
side of an impeller 830 balance the impeller 830 and may generate
two pulses per revolution. With this exemplary configuration, the
Hall effect devices may generate pulses (positive or negative)
every time a magnet passes that Hall effect device as a result of
the rotation under a force of the fluid flowing through a first end
814, of an impeller 830 carrying that magnet. The pulses can then
be transmitted to the MCS 770 via the bus 882 and connector 930 of
the sensor assembly 780. A VOC controller, via a valve controller
for a respective valve assembly 800 that transmitted the pulses or
a processor of the MCS 770, can process these pulses in the form of
signals and derive an actual flow rate and generate a GPM
value.
[0158] FIG. 10 illustrates a sectional view of the fluid
distribution manifold 700 taken from a plane indicated by line
10-10 in in FIG. 7A With a common source of fluid, for example the
pump 102 of the fluid system 100 of FIG. 1, connected to the inlet
ports 874 of the manifold 700. Fluid will enter and fill the first
chamber 750. Any one, or more than one, of the valve assemblies 800
illustrated in FIG. 10 may regulate fluid flow to a flow channel in
fluid communication with a reservoir or recirculation line.
[0159] As shown, each of the valve assemblies in FIG. 10 include
valve housings 810 that include wall segments 820 which define open
chambers 821 surrounding respective valve members 850 upstream of
respective valve seats 819. During operation, a valve member 850
for any of the valve assemblies 800 may be moved within an open
chamber 821 defined by respective wall segments 820 toward or away
from a valve seat 819 defined by a second end 818 of a respective
first mating structure 812. Movement away from the valve seat 819
will allow or increase fluid communication between the open chamber
821 a fluid chamber 811 defined by the second end 818 downstream of
the valve set 819. Each of the valve assemblies 800 being
configured such that the first chamber 750 surrounding the wall
segments 820, and thus the open chambers 821, provides a supply of
fluid for which each valve assembly 800 regulates a flow of through
a respective outlet 720.
[0160] For the purposes of explaining total flow balancing
operation of the manifold 700, the first valve assembly on the left
side of FIG. 10 has been designated with the reference numeral
800-R to indicate it regulates a flow of fluid to reservoir or a
recirculation line and will be referred to as "bleed valve assembly
800-R." In addition, the remaining valve assemblies are labeled
with and "-F" and number corresponding to a number of a fluid
handling device it regulates flow to.
[0161] Together with the bleed valve assembly 800-R, the channel
connected to a reservoir or recirculation line can be utilized as
bleed passage to compensate for changes to required flow rates, or
an input flow rate from a common fluid source. In the latter case,
there could be an instance where an object or debris is stuck in a
channel between a pump and tee connected to the inlet ports, or
even a branch of the tee. In such a situation, were the bleed
passage previously in an open or semi-open state, the reduced input
flow rate would be detected through one or all the valve assemblies
800-F1 to F5 and the bleed valve assembly 800-R may be closed to
increase fluid flow rate to all the other valve assemblies.
[0162] The manifold 700 of the present disclosure is configured to
deliver precise specified flow rates from each of the outlets 720
illustrated in in FIG. 10, as described above. From a practical
standpoint, the methods and systems described herein enable
independent control of each of the valve assemblies 800-R, 800-F1
to F5 such that a first valve assembly 800-F1 can be adjusted in
isolation, or in combination with a second valve assembly 800-F2 to
obtain a desired flow rate through the first valve assembly 800-F1.
In this second situation, an MCS can operate the valve assemblies
800-R, 800-F1 to F5 independently of one another, meaning their
respective operations do not have to be simultaneous (although they
can be achieved substantially simultaneously with the manifold 700
of the present disclosure).
[0163] Furthermore, especially in the case where three or more
valve assemblies are provided, operation of the second valve
assembly 800-F2 to compensate for a required flow rate increase or
decrease for first valve assembly 800-F1, does not mandate that a
required flow rate or a change in a required flow rate for the
second valve assembly 800-F2 be ignored or addressed at a later
time. Rather, the bleed valve assembly 800-R can be used to
compensate for a change in required flow from any one or more of
the valve assemblies 800-F1 to F5. In addition, where tolerances
are used as discuss below, a third valve assembly 800-F3 could be
operated to allow for adjustments to the flow rates through both of
the first and second valve assemblies 800-F1, 800-F2.
[0164] In one example, an MCS can operate the valve assemblies 800
to obtain required flow rates within a standard range of deviation,
.+-.5% of required flow rate for example. Accordingly, the MCS may
operate several of valve assemblies, or several combinations of
several valve assemblies, so that a flow rate through one
particular valve assembly comes within that tolerance, while flow
rates through other operated valve assemblies stay within the
tolerance. Thus, the MCS may adjust one or more other valve
assemblies 800 to deviate more from a current required flow rate
than at the present moment, but still within the predefine standard
range of deviation, to obtain this result.
[0165] FIG. 11 illustrates an exploded view of a fluid distribution
manifold illustrated in FIGS. 7A and 7B. As illustrated, the
manifold 700 includes the first housing 710, the sensor assembly
780, the valve retainer 730, a valve assembly 800 for each slot
1400 in the valve retainer 730, and the second housing 740. The MCS
770, including the display 774, user interface controls 776, and
the VOC controller 778, is integrated into the second housing 740.
As shown in FIG. 11, the first housing 710 includes apertures 1100
formed in the lower wall 716, and a baffle 1150 within or otherwise
a part of the surrounding wall 870. The baffle 1150 includes a
planar surface 1152 and flanks 1154, with the pressure relief port
876 being defined in the planar surface 1152.
[0166] The exemplary manifold 700 of FIG. 11 includes six valve
assemblies 800, however more or less valve assemblies can be
provided in other example manifolds according to the present
disclosure having different numbers of outlet ports (and
corresponding numbers of slots in respective valve retainers. In
other examples, the number of complete valve assemblies 800 can be
less than the number of slots 1400 and outlets 720, where slots
1400 that do not receive complete valve assemblies are capped with
covers.
[0167] The VOC controller 778 may be any type of computing device
that includes one or more memory stores, one or more storage
locations, and one or more processors configured to execute
instructions. In one example, the VOC controller 778 may include a
printed circuit board. In other examples, the VOC controller 778
may include information processing components that include, are
integrated with, or otherwise define a processor or a group of
processors, and are coupled with some type of memory and storage
that may be provided by a physical hard drive or a solid-state
drive.
[0168] Each of the valve assemblies 800 includes a cover 860, and a
valve housing 810 including a first mating structure 812 connected
to a second mating structure 822 by two or more wall sections 820.
The wall sections 820 are spaced apart about a shape corresponding
to cross-sections of the first and second mating structures 810,
822. During assembly of the manifold 700, the valve retainer 730
will be secured to the first housing 710. Further, each valve
assembly 800 can be inserted into a first chamber 750 defined
between the valve retainer 730 and the inner surfaces 817, 872 of
lower and surrounding walls 716, 870 of the first housing 710,
through a slot 1400 in the retention plate 893 of the valve
retainer 730. The first mating structure 812 can pass through the
slot 1400 formed in the retention plate 893 and be received by an
aperture 1100 in the lower wall 716 of the first housing 710 that
corresponds to the slot 1400.
[0169] FIG. 12A illustrates a sectional view of a partially
assembled version of the manifold 700 which provides a perspective
view of the pressure relief port 876 that is in fluid communication
with the pressure relief outlet 714. As shown, the pressure relief
outlet 714 is: (A) in fluid communication with an aperture which
defines the pressure relief port 876 and is formed in the baffle
1150 that extends inwardly into the first chamber 750 from the
surrounding wall 870 of the first housing 710; (B) extends from the
baffle 1150 through the surrounding wall 870; and (C) is configured
to receive, or have integrally provided therein, a check valve or
other type of pressure sensitive one-way valve (not shown). As
shown the baffle 1150 includes a planar surface 1152 and two flanks
1154 that extend on opposite sides of the planar surface 1152 to
the surrounding wall 872 of the first housing 710.
[0170] In one example, the baffle 1150 is shaped such that a
cross-sectional area of the first chamber 750, along a plane
parallel to the plane indicated by line 10-10 in FIG. 7A, is
reduced around third and fourth outlets 720 (i.e., middle two
outlet ports in the exemplary six outlet manifold 700 illustrated
in FIGS. 7-11). Of the plurality of outlets 720, the third and
fourth outlets 720 are the farthest from the inlet ports 874.
Accordingly, the pathways for fluid to reach the valve assemblies
800 installed in these ports are longer, and more torturous as the
fluid crosses over more flow rate affecting obstacles than fluid
flowing to the valve assemblies 800 located closer to the inlet
ports 874. The baffle 1150 reduces an area of the first chamber 750
proximate to the valve assemblies provided in the third and fourth
outlet ports.
[0171] Reducing an area of the first chamber 750 around the valve
assemblies 800 provided in the third and fourth outlet ports, can
increase flow rate of fluid in and around those valve assemblies
800. Furthermore, the angle flanks 1154 may generate a jet effect
in the areas of the first chamber 750 immediately surrounding open
chambers 821 within which the valve members 850 for these valve
assemblies 800 operation. As a result, the baffle 1150 may
compensate for any reductions in flow rate because of the longer
and more tortuous flow paths to these valve assemblies.
[0172] FIG. 12A provides a sectional view from the forth outlet 720
to provide contrasting views of a third and a fourth outlet 720
relative to an inlet port 874 corresponding to one of the inlets
712. More specifically, a sectional view of the fourth outlet 720,
absent a valve assembly 800, and a perspective view of the third
outlet 720 in which a valve assembly 800 is installed, are shown.
FIGS. 12B and 12C illustrate a sectional view of different partial
assemblies of the manifold 700 taken from the third outlet 720 from
the inlet port 874. FIG. 12B provides a sectional view of the
manifold 700 including all housing components, and a sectional view
of only a valve housing 810 installed in the third outlet 720.
Whereas FIG. 12C provides a sectional view of the manifold 700 with
just the first housing 710 and valve retainer 730, and the
sectional view of the valve housing 810 as in FIG. 12B. With FIGS.
12A, 12B, and 12C, and the following description, it will become
apparent how the various components of the first housing 710 and
the valve retainer 730 facilitate easy installation and removal of
entire, or even portions of, valve assemblies 800 from the manifold
700.
[0173] With reference to FIG. 12A, an inner surface 1210 of the
proximal end 722 of the fourth outlet 720 defines an open
unobstructed space 1212. Further, there exists no components in a
space between an aperture 1100 of the fourth outlet 720, and a
bottom end face 1406 of a slot 1400 provided by the valve retainer
730. Accordingly, a valve assembly 800 can be easily inserted, in
its entirety through the slot 1400 and into the proximal end 722 of
the fourth outlet 720. This is especially the case because the
second housing 740 can be removed from the valve retainer 730 as
shown in FIG. 12C, without disturbing the positioning of the
manifold 700, and without disturbing any positioning or operations
of the valve assemblies 800.
[0174] FIGS. 12B and 12C also illustrate that a partial valve
assembly 800 can be installed within the manifold 700. This means
that for maintenance, capped versions of the valve housing 810 can
be installed in outlet 720/slot 1400 combinations in place of valve
assemblies that require maintenance or replacement. In addition,
for systems having less fluid handing devices than the manifold 700
has outlet ports 720 (minus an outlet port connected to a reservoir
or recirculation line), such capped valve housings 810-C (see FIGS.
13C and 13D) can be installed in those outlet 720/slot 1400
combinations that will not be connected to a fluid handling device.
This also enables simple and convenient installations of additional
fluid handling devices, or replacements of existing fluid handling
devices. This is because piping downstream of the manifold for any
one outlet port can be cut off from a supply of fluid simply by
installing a capped valve housing 810-C in a respective outlet
port/slot combination corresponding to that line of piping.
[0175] Thus, exemplary manifolds of the present disclosure enable
simple and convenient physical installments of additional fluid
handling devices. In addition, exemplary MCSs described herein
enable seamless integration of the operations of those additional
FHDs, into the coordinated operations of all the FHDs serviced by a
manifold of the present disclosure.
[0176] FIGS. 13A and 13B illustrate perspective views of a single
valve housing, according to an aspect of the present
disclosure.
[0177] As previously discussed, the valve housing 810 may including
the first mating structure 812 extending from two or more wall
segments 820, which extend from the second mating structure 822.
The first mating structure 812 includes the first end 814 that is
sized so as to fit within a proximal end of an outlet port of a
manifold as described herein. The first end 814 may define the
first end face 815 configured to engage an end piece 848 (not
shown) that secures an impeller 830 (not shown) within the first
end 814, or a first end cap 1350 as shown in FIG. 13C.
[0178] The second end 818 of the first mating structure 812 may be
separated from the first end 814 by the partition 816. An outer
circumference of the first mating structure 812 may be formed with
a recessed groove 817 to receive an O-ring. Above the partition 816
and the recessed groove 817, the second end 818 of the first mating
structure 812 defines a bore or other shaped area that may receive
a valve member (or portion thereof). The second end 818 of the
first mating structure 812 defines a second end face 819 configured
to provide a valve seat 819 for engaging valve members 850 (e.g., a
plunger) of the valve assemblies 800.
[0179] Turning to the second mating structure 822, an inner surface
823 may be specifically configured to receive and secure an
actuator housing 854 of an actuator sub-assembly. An outer surface
824 on the other hand, may be provided with engagement members 1300
as shown, to facilitate an interlocking engagement with a slot 1400
of a valve retainer 730 as shown in FIGS. 14A and 14B.
[0180] In one example, the engagement members 1300 may include a
horizontal body 1310, and legs 1320 extending from opposite ends of
the horizontal body 1310 towards the first end 814 of the valve
housing 810. An outer perimeter of the engagement member 1300
therefore defines a rectangular shape that may correspond to a
recess provided in a valve retainer for receiving a valve assembly.
Together with the horizontal body 1310, the legs 1320 can define a
height of the engagement member 1300 substantially corresponding to
height of a track of a slot of a valve retainer. Thus, the second
mating structure 822 of the valve housing 810 is configured to
slide in and be locked or otherwise secured to/within a slot. In
another example, a recess 1322 defined between the legs 1322 can
engage a protrusion formed within a slot.
[0181] The valve housing 810 can tightly fit into a proximal end of
an outlet port, be interlocked into a position through and
engagement with a slot of a retention plate of a valve retainer,
and securely, but removably, retain an actuator of a valve
assembly. As a result of the combined flexibility provided by how
the valve housing 810 engages all these components, a substantial
number of components provided in exemplary manifolds of the present
disclosure can be serviced or replaced in isolation. Servicing or
replacement may be accomplished, with little or no down time. In
addition, additional sensors, such as temperature, salinity,
chlorine, and other types of sensors can be added to one or more
valve assemblies since the valve assemblies can easily be accessed
by removing a second housing of a manifold. As previously noted,
manifolds according to the present disclosure can continue to fully
operate even with a second housing removed from a valve
retainer.
[0182] Sensor swaps and additions can be made with a simple swap of
a given valve assembly for a capped valve housing 810-C, as shown
in FIGS. 13C and 13D. As applied to the manifold 700 of FIG. 7,
while a removed valve assembly 800 is retrofitted with a new
sensor, or provided with a new actuator, valve member, or impeller,
the FHD it served may be put offline and flow stopped thereto by a
capped housing 810-C. The capped housing 810-C may include the
valve housing 810 as shown in FIGS. 13A and 13B with a first end
cap 1352 fitted on to the first end face 815 of the first mating
structure 812, and a second end-cap 1354 fitted to an end face
defined by the second mating structure 822. While the capped
housing 810-C blocks fluid flow into the second chamber 760 of the
manifold 700 and to an FHD the swapped valve assembly previously
served, remaining FHDs connected to the manifold 700 may continue
to operate fully.
[0183] FIGS. 14A and 14B illustrate a perspective view of the
second surface 896 of the valve retainer 730, according to an
aspect of the present disclosure. As shown in FIG. 14A, the second
surface 896, which defines one side of the retention plate 893, is
configured to receive valve assemblies. More specifically, each
slot 1400 extending through the retention plate 893 of the valve
retainer 730 is of a shape corresponding to a second mating
structure 822 of a valve housing 810. In addition, each slot 1400
includes at least one track 1410 configured to interlock with an
engagement member 1300 of the valve housing 810. In the example
shown, each slot 1400 includes two tracks 1410. Each track 1410 is
formed within or otherwise defined by a slot wall 1402 that extends
from the first surface 895 of the valve retainer 730. As shown in
FIGS. 14A, 14B, and 15, each slot wall 1402 defines the slot 1400
within the retention plate 893 between the second surface 896 and
the first surface 895, and extends from the first surface 895 to a
respective inwardly extending lip 1404. A first end 1412 of each
track 1410 includes a recess 1420 formed in the second surface 896.
A second end 1414 of the track 1410 may be defined in the slot wall
1402 at the end of an arc length relative to the first end 1412
having a central angle of 15.degree. to 20.degree.. It will be
understood that the track can be longer or shorter such that it is
of an appropriate length to ensure the valve assembly 800 is
securely mounted to the retention plate 893 and thus the valve
retainer 730.
[0184] As shown in FIG. 14A, the recess 1420 at the first end 1412
of each track 1410 may have a depth from a plane coinciding with
the slot wall 1402 that substantially corresponds with a thickness
of the engagement member 1300 extending from the valve housing 810.
In addition, a dimension of the recess 1420 along the slot wall
1402 moving downward from the second surface 896 (referred to
hereafter as a height of the recess), may be substantially equal to
two times the combined height of the legs 1320 and the horizontal
body 1310 of the engagement member 1300 shown in FIGS. 13A-13D. In
this example, the height of the remaining length of the track 1410
may be at least that of the legs 1320 plus the horizontal body
1310. This is so the engagement member 1300 can slide from the
first end of the track 1410 to, and be stopped at, the second end
1414 as shown in FIG. 14B, with a turn of the valve housing 810 in
a first direction A
[0185] In practice, the valve assembly 800 shown in FIGS. 14A and
14B, will be passed through the retention plate 893 of the valve
retainer 730. With the engagement members 1300 aligned with the
recesses 1420 in the first side as shown in FIG. 14A, the valve
assembly 800 can continue moving through the retention plate 893 of
the valve retainer 730 until the bottoms of the legs 1320 contact
the bottom surfaces of the recesses 1420. From this position, the
valve assembly 800 can be rotated in a first direction A until a
lead edge of each engagement member 1300 comes into abutment with
second ends 1414 of respective tracks 1410 as shown in FIG. 14B.
Removing the valve assembly 800 will involve rotating the valve
assembly 800 in a second direction B opposite of the first
direction A until leading edges of the engagement members 1300 for
that rotational movement, abut the first ends 1412 of the tracks
1410. From this position, the valve assembly 800 can be pulled
upward, out, and away from the valve retainer 730.
[0186] FIG. 15 illustrates a perspective view of the first surface
895 of the valve retainer 730. As shown, each of the tracks 1410
may be formed in or otherwise defined by an interior surface 1402A
of a respective slot wall 1402, and can protrude outwardly from an
exterior surface 1402B of the same slot wall 1402. In one example,
each slot 1400 may include the inwardly extending lip 1404, which
is shown and identified in FIGS. 12A, 14A, and 14B. The inwardly
extending lip 1404 is configured to engage an end face of a second
mating structure 822 of a valve housing 810 as shown in FIG. 8. A
side of the inwardly extending lip 1404 opposite this engaging
surface defines an end face 1406 of the slot 1400 which faces the
lower wall 716 of the first housing 710 when attached thereto. All
the slots 1400 are surrounded by the protruding edge 894, which
includes a baffle section 1550 with a planar surface 1552 and
flanks 1554 which correspond to the planar surface 1152 and flanks
1154 of the baffle 1150 of the first housing 710.
[0187] FIG. 16 illustrates a perspective view of a first housing
1610 for a manifold, according to an aspect of the present
disclosure. In the example shown, each of two inlets 1612 are
provided with impellers 1622 within collars 1620 that are fitted to
ends of each inlet 1612. The impellers 1622 may be similar to the
impellers of the valve assemblies described herein, and include
magnets. Hall effect devices may be installed within the collars
1600. As fluid flows into the first housing 1610 through the inlet
ports 874, impellers 1622 may rotate and the Hall effect devices
may generate pulses as magnets in the impellers 1622 pass by. As a
result, a flow rate of fluid in each branch of a tee, such as the
tee illustrated in FIG. 1, can be known at all times.
[0188] FIG. 16 also provides another view of a baffle 1650 that
defines a portion of a surrounding wall 1670 of the first housing
1610. As in other examples previously discussed, the baffle 1650
can be shaped such that a cross-sectional area of a first chamber
is reduced around outlets that are furthest from the inlets.
Reducing an area of the first chamber around valve assemblies
provided in these outlet ports can increase flow rate of fluid in
and around those valve assemblies. Angled flanks 1654 may generate
a jet effect in areas immediately surrounding spaces within which
valve members for these valve assemblies operate. As a result, the
baffle 1650 may compensate for any reductions in flow rate
resulting from the longer and more tortuous flow paths to those
valve assemblies.
[0189] Other examples of the disclosure will be apparent to those
skilled in the art from consideration of the specification and
practice of the examples disclosed herein. Though some of the
described methods have been presented as a series of steps, it
should be appreciated that one or more steps can occur
simultaneously, in an overlapping fashion, or in a different order.
The order of steps presented are only illustrative of the
possibilities and those steps can be executed or performed in any
suitable fashion. Moreover, the various features of the examples
described here are not mutually exclusive. Rather any feature of
any example described here can be incorporated into any other
suitable example. It is intended that the specification and
examples be considered as exemplary only, with a true scope and
spirit of the disclosure being indicated by the following
claims.
* * * * *