a. Field
This disclosure relates generally to sensors used in plumbing fixtures to detect the presence of a person or another object. More specifically, this disclosure pertains to a sensing device that enables angular adjustment of the sensor to reduce or eliminate false positives created by reflective surfaces proximate the plumbing fixture.
b. Background Art
Many modern plumbing fixtures including kitchen and bathroom sinks, urinals and toilets include a sensor that indicates the presence of a person or another object in order to start or stop the flow of water. For example, sensors are employed in automatic flushometers (also referred to as hands-free or touchless flushometers) to control delivery of fluid to a toilet bowl or urinal from a fluid supply line. The sensor generates a signal that is used by the flushometer to determine when to flush the toilet. The sensors used in modern plumbing fixtures commonly employ an emitter that emits an electromagnetic wave (e.g., an infrared wave) and a receiver that detects a reflection of the wave to determine whether a person or another object is present and/or the distance to the person or object. Reflective surfaces disposed near the fixture—including, for example, stainless steel stalls or trough sinks and mirrors—will also reflect waves emitted by the emitter of the sensor. Depending on the location of the surfaces and the angle of inclination of the surfaces, waves that are reflected by such surfaces can falsely indicate that a person or another object is present and cause unintended activation of the fixture.
The inventors herein have recognized a need for a sensing device for a plumbing fixture that will overcome one or more of the above-identified deficiencies.
A sensing device for a plumbing fixture is provided. In particular, a sensing device is provided that enables angular adjustment of the sensor to reduce or eliminate false positives created by reflective surfaces proximate the plumbing fixture.
A sensing device for a plumbing fixture in accordance with one embodiment includes an electronics housing including a rear wall. The rear wall includes a tool passage therethrough and a fastener head pocket in communication with the tool passage. The device further includes a fastener including a head carried in the fastener head pocket of the rear wall of the electronics housing and a body extending away from the head and establishing a fastener axis. The device further includes a sensor assembly including a sensor housing having a first portion coupled to the electronics housing and a second portion carried on the body of the fastener and configured for movement relative to the electronics housing along the body of the fastener.
A sensing device for a plumbing fixture in accordance with another embodiment includes an electronics housing including a rear wall and a sidewall extending away from the rear wall and establishing an interior. The rear wall includes a tool passage therethrough and a fastener head pocket in communication with the tool passage. The device further includes a fastener including a head carried in the fastener head pocket of the rear wall of the electronics housing and a threaded body extending away from the head and establishing a fastener axis. The device further includes a sensor assembly carried in the interior of the electronics housing and including a sensor housing having a first portion fixed relative to the electronics housing and a second portion carried on the threaded body of the fastener and configured for movement relative to the electronics housing along the threaded body of the fastener.
A flushometer assembly in accordance with one embodiment includes a valve body, a valve element disposed within the valve body and a solenoid configured to control a position of the valve element. The assembly further includes a sensing device including an electronics housing including a rear wall and a sidewall extending away from the rear wall and establishing an interior. The rear wall includes a tool passage therethrough and a fastener head pocket in communication with the tool passage. The sensing device further includes a fastener including a head carried in the fastener head pocket of the rear wall of the electronics housing and a threaded body extending away from the head and establishing a fastener axis. The sensing device further includes a sensor assembly carried in the interior of the electronics housing and including a sensor housing having a first portion fixed relative to the electronics housing and a second portion carried on the threaded body of the fastener and configured for movement relative to the electronics housing along the threaded body of the fastener. The assembly further includes a controller configured to control the solenoid responsive to an output signal of the sensor assembly.
The foregoing and other aspects, features, details, utilities, and advantages of the disclosed embodiments will be apparent from reading the following description and claims, and from reviewing the accompanying drawings.
Referring now to the drawings wherein like reference numerals are used to identify identical components in the various views,
Flush valve assembly 12 controls delivery of water from the fluid supply line to the sanitary fixture. Referring to
Solenoid cap assembly 14 controls the state of flush valve assembly 12 and, in particular, the position of diaphragm 26 within valve body 18. Assembly 14 is mounted on valve body 18 of flush valve assembly 12 and may include a power source 30, a solenoid 32, and a sensing device 34 in accordance with one embodiment of the present teachings. Although a particular structure for assembly 14 is shown in the illustrated embodiment, it should again be understood that assembly 14 may be configured in a variety of ways.
Power source 30 provides current to electronic components such as solenoid 32 and sensing device 34 and a control circuit that transmits pulses to solenoid 32 responsive to signals from sensor 34. Power source 30 may comprise a battery that is disposed within cover 16. Alternatively, power source 30 may comprise a hardwire connection to, for example, a building power source.
Solenoid 32 opens and closes the pathway between chamber 24 and the fixture. Actuation of solenoid 32 is controlled by a control circuit in response to signals generated by sensing device 34. Sensing device 34 generates signals indicative of the presence of an object and the subsequent departure/absence of the object. Upon departure of the object, sensing device 34 outputs a signal that causes solenoid 32 to open and unseat diaphragm 26 to open flush valve assembly 12 and allow fluid flow to the fixture.
Sensing device 34 is provided to detect the presence of an object (e.g., a person) and to control solenoid 32 in response. Referring to
Electronics housing 36 is provided to protect components of sensing device 34 from foreign objects and elements and to position and orient the components of sensing device 34. Housing 36 may include multiple members 48, 50 that may be coupled together using conventional fasteners such as screws, bolts, pins, welds or adhesives, through interlocking elements formed in members 48, 50 or through an interference fit. Referring to
Sensor assembly 38 is provided to emit electromagnetic (and, in particular, infrared) waves and to receive and collect waves reflected by a person or another object. Assembly 38 is carried in the interior of electronics housing 36. Referring to
Sensor housing 70 is provided to protect emitter 72, receiver 74 and related electronic components from foreign objects and elements and to position and to orient emitter 72, receiver 74 and the electronic components. Housing 70 may be made from a flexible material and may be made from an elastically deformable material for a purpose described below. In some embodiments, housing 70 may be made from polypropylene, acrylonitrile butadiene styrene (ABS) or other plastics. Housing 70 includes a portion that is coupled to electronics housing 36 and may be fixed in position relative to electronic housing 36. In particular, one portion of housing 70 may define a lower end flange 76 that extends from a body 78 of housing 70 and is configured to align with, and be supported on, flat 64 of rear wall 52 of electronics housing 36. Flange 76 defines a fastener passage configured for alignment with fastener passage 62 in rear wall 52 and through which fastener 40 may extend. Housing 70 includes another portion that is carried on a body of fastener 42 and is configured for movement relative to electronics housing 36 along the body of fastener 42. In particular, the portion may define an upper end flange 80 that extends from an opposite side of body 78 relative lower end flange 76 and is configured to align with, and be supported on, flat 66 of rear wall 52 of electronics housing 36. Flange 80 defines a fastener passage 82 through which fastener 42 may extend.
Emitter 72 is provided to generate and direct electromagnetic waves towards objects in the vicinity of flushometer assembly 10. Emitter 72 may comprise a light emitter such as light emitting diode configured to emit infrared light. Receiver 74 is provided to receive and collect electromagnetic waves reflected from objects in the vicinity of assembly 10. Receiver 74 may comprise one or more photodiodes configured to detect infrared light. Receiver 74 detects infrared light reflected by the presence of an object in the path of the emitted light and converts the light into an electrical charge thereby producing a signal indicative of the presence of the object and/or the relative distance of the object. A signal processing circuit converts the electrical charge into a signal corresponding to the presence of the object and/or distance of the object from the sensor assembly 38 and provides that signal to controller 44. Emitter 72 may be disposed proximate upper end flange 80 of sensor housing 70 while receiver 74 is disposed proximate lower end flange 76 of sensor housing 70.
Fastener 40 is provided to couple lower end flange 76 of sensor housing 70 to electronics housing 36. In particular, fastener 40 is provided to fix lower end flange 76 of sensor housing 70 to electronics housing 36 to prevent movement of flange 76 relative to electronics housing 36. Fastener 40 includes a head 84 that is positioned against flange 76 and a body 86 that extends through flange 76 and through rear wall 52 of electronics housing 36. Fastener 40 may comprise a screw. In embodiments including a fastener passage 62 in rear wall 52, passage 62 may be threaded and fastener 40 may be threaded through passage 62. In other embodiments, rear wall 52 may not include passage 62 and fastener 40 may comprise a self-tapping screw.
Fastener 42 is provided to couple upper end flange 80 of sensor housing 70 to electronics housing 36. In particular, fastener 42 couples flange 80 of sensor housing 70 to electronics housing 36 in such a way that flange 80 is capable of movement relative to the electronics housing 36 along fastener 42 to allow positional adjustment of sensor assembly 38. Fastener 42 includes a head 88 that is carried in fastener head pocket 68 in rear wall 52 of electronics housing 36. Head 88 defines a tool recess 90 that is accessible through tool passage 56 from the exterior side 60 of rear wall 52. Tool recess 90 may have a shape that is complementary to the shape of a tool used to rotate fastener 42. In some embodiments, recess 90 may have a shape that defines one or more flats that engage corresponding flats on the tool. For example, recess 90 may have a polygonal shape such as a hexagonal shape configured to receive a hex key (Allen wrench). Recess 90 may alternatively be shaped to receive a screwdriver. Because fastener 42 is accessed and rotated through tool passage 56 in rear wall 52 of electronics housing 36, the position and orientation of sensor assembly 38 can be adjusted without affecting the environmental packaging of sensor device 34. Fastener 42 further includes a body 92 that extends away from head 88 and extends in a direction opposite the direction in which body 86 of fastener 40 extends away from head 84 of fastener 40. Body 92 is disposed about, and may be centered about, a fastener axis 94. Body 92 may be threaded and configured to engage mating internal threads formed in fastener passage 82 of upper end flange 80 in sensor housing 70. The threads may be formed directly in upper end flange 80 or in another fastener (e.g., a nut) supported within fastener passage 82 of upper end flange 80. During assembly, fastener 42 may be inserted into fastener passage 82 from one side of sensor assembly 38 and the combination of the sensor assembly 38 and fastener 42 inserted into electronics housing 36 such that the head 88 of fastener 42 is disposed within fastener head pocket 68. Thereafter, fastener 40 may be inserted into lower end flange 76 from an opposite side of sensor assembly 38 and into electronics housing 36 to secure flange 76 to housing 36. Rotation of fastener 42 about fastener axis 94 translates flange 80 of sensor housing 70 along body 92 of fastener 42 and fastener axis 94 to move flange 80 towards or away from rear wall 52 of electronics housing 36. Because sensor housing 70 is made from a material that has some level of flexibility, upper end flange 80 is able to move along body 92 of fastener 42 and fastener axis 94 despite the fixed position of lower end flange 76. Alternatively, or in addition, sensor housing 70 could be formed with a living hinge at the intersection of lower end flange 76 and body 78 of sensor housing 70 by removing or thinning the material between the lower end flange 76 and the body 78. Referring to
Referring again to
Potting material 46 is provided to limit or prevent movement of controller 44 within electronics housing 36 due to vibration and other forces (movement of controller 44 (and the printed circuit board supporting controller 44) is also limited by sensor assembly 38 through fastener 40). Material 44 may also prevent damage to controller 44 from fluids and corrosive elements. Material 46 is disposed within the interior of housing 36 and may be made from a silicon rubber gel or a thermosetting plastic or a self-healing potting gel. Material 44 may have a spring like or elastic characteristic such that material 44 biases sensor assembly 38 towards an original or default position proximate rear wall 52 of electronics housing 36 and thereby assists in returning sensor housing 70 to this position when fastener 42 is rotated in a direction that causes sensor assembly 38 to move towards rear wall 52 (tension in the bend of sensor housing 70 may also bias housing 70 to its original or default position).
Referring again to
A sensing device 34 in accordance with the present teachings is advantageous relative to conventional sensing devices because it enables fine adjustment of the position and/or orientation of sensor assembly 38. As a result, the sensor assembly 38 can be positioned and/or orientated to eliminate false positives resulting from reflection of emitted electromagnetic waves by reflective surfaces in the vicinity of the sensing device. Further, the adjustment can be done through a relatively simple process of rotating a fastener 42 that is easily accessible to an installer thereby promoting ease of installation and testing. Because the fastener 42 is accessed through a tool passage 56 in a rear wall 52 of electronics housing 36, the adjustment can also be made without disrupting the environmental packaging of housing 36.
While the invention has been shown and described with reference to one or more particular embodiments thereof, it will be understood by those of skill in the art that various changes and modifications can be made without departing from the spirit and scope of the invention.
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