Patent Application
20210240209
The disclosure relates to flow control systems, such as for evaporative cooling systems. More particularly, the disclosure relates to an inline flow control system with parallel flow solenoid valves.
An evaporative cooler or cooling system cools air through the evaporation of water. Evaporative cooling systems can be particularly effective for cooling livestock to reduce heat stress and/or production loss. Evaporative cooling is an indirect cooling method that utilizes air entering or within a barn. The barn may be outfitted with evaporative cooling pads that pull air through a media saturated with water. As the water evaporates, it cools and humidifies the air entering the barn. This cool and humidified air then increases convective heat loss from the animals in the barn as compared to utilizing air at ambient conditions.
Thus, evaporative cooling systems include a water supply to provide water to saturate the evaporative cooling pads. A water trough or tank may be employed to store water that is then pumped by a water pump(s) to the evaporative cooling pads for saturation. Proper operation of evaporative cooling systems requires maintaining a minimum water level of the water trough or tank. Some systems to maintain a minimum water level may include sensors and/or processing logic, which may be cost prohibitive in certain applications. Such systems that maintain a minimum water level in the tank or trough may be expensive and/or not easily retrofitted into existing evaporative cooling systems.
No admission is made that any reference cited herein constitutes prior art. Applicant expressly reserves the right to challenge the accuracy and pertinency of any cited documents.
Disclosed is an inline flow control system with parallel flow solenoid valves. In particular, in certain embodiments, the flow control system includes a flow control device with switch ports in electrical communication with a high float switch and a low float switch. The flow control device includes a first solenoid valve to control fluid flow through a first fluid pipe based on a received first electrical signal from the high float switch, and a second solenoid valve to control fluid flow through a second fluid pipe based on a received second electrical signal from the low float switch. The first pipe and second pipe are in parallel flow within the flow control device. In certain embodiments, the flow control system includes a manual bypass valve in parallel flow with the solenoid valves. In certain embodiments, the flow control system is devoid of an electronic controller. Accordingly, the inline flow control system can be retrofitted for existing flow systems (e.g., evaporative cooling systems) with minimal cost and effort. Further, the first solenoid valve and the second solenoid valve can be concurrently activated for parallel flow, such as in extreme circumstances requiring greater flow.
One embodiment is directed to a flow control device, including a flow control housing including a fluid inlet, a fluid outlet, a first switch port, and a second switch port. The flow control device further includes a first fluid pipe positioned in the flow control housing and in fluid communication with the fluid inlet and the fluid outlet. The first fluid pipe includes a first solenoid valve configured to control fluid flow through the first fluid pipe. The flow control device further includes a second fluid pipe positioned in the flow control housing and in fluid communication with the fluid inlet and the fluid outlet. The second fluid pipe includes a second solenoid valve configured to control fluid flow through the second fluid pipe. The second fluid pipe is in parallel flow with the first fluid pipe. The first solenoid valve is further configured to control fluid flow through the first fluid pipe based on a received first electrical signal from a first switch via the first switch port. The second solenoid valve is further configured to control fluid flow through the second fluid pipe based on a received second electrical signal from a second switch via the second switch port.
Another embodiment is directed to a flow control system, including a flow control device. The flow control device includes a flow control housing including a fluid inlet, a fluid outlet, a first switch port, and a second switch port. The flow control device further includes a first fluid pipe positioned in the flow control housing and in fluid communication with the fluid inlet and the fluid outlet. The first fluid pipe includes a first solenoid valve configured to control fluid flow through the first fluid pipe. The flow control device further includes a second fluid pipe positioned in the flow control housing and in fluid communication with the fluid inlet and the fluid outlet. The second fluid pipe includes a second solenoid valve configured to control fluid flow through the second fluid pipe. The second fluid pipe is in parallel flow with the first fluid pipe. The flow control system further includes a high float switch in electrical communication with the first solenoid valve via the first switch port. The flow control system further includes a low float switch in electrical communication with the second solenoid valve via the second switch port. The first solenoid valve is further configured to control fluid flow through the first fluid pipe based on a received first electrical signal from the high float switch. The second solenoid valve is further configured to control fluid flow through the second fluid pipe based on a received second electrical signal from the low float switch.
Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the description serve to explain principles and operation of the various embodiments.
Reference will now be made in detail to the present preferred embodiments, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.
The embodiments set out below represent the information to enable those skilled in the art to practice the embodiments. Upon reading the following description in light of the accompanying drawing figures, those skilled in the art will understand the concepts of the disclosure and will recognize applications of these concepts not particularly addressed herein. It should be understood that these concepts and applications fall within the scope of the disclosure and the accompanying claims.
It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of the present disclosure. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present.
Relative terms such as “below” or “above” or “upper” or “lower” or “horizontal” or “vertical” may be used herein to describe a relationship of one element, layer, or region to another element, layer, or region as illustrated in the Figures. It will be understood that these terms and those discussed above are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. Terms such as “left,” “right,” “top,” “bottom,” “front,” “back,” “horizontal,” “parallel,” “perpendicular,” “vertical,” “lateral,” “coplanar,” and similar terms are used for convenience of describing the attached figures and are not intended to limit this description. For example, terms such as “left side” and “right side” are used with specific reference to the drawings as illustrated and the embodiments may be in other orientations in use. Further, as used herein, terms such as “horizontal,” “parallel,” “perpendicular,” “vertical,” “lateral,” etc., include slight variations that may be present in working examples.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including” when used herein specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Disclosed is an inline flow control system with parallel flow solenoid valves. In particular, in certain embodiments, the flow control system includes a flow control device with switch ports in electrical communication with a high float switch and a low float switch. The flow control device includes a first solenoid valve to control fluid flow through a first fluid pipe based a received first electrical signal from on the high float switch, and a second solenoid valve to control fluid flow through a second fluid pipe based on a received second electrical signal from the low float switch. The first pipe and second pipe are in parallel flow within the flow control device. In certain embodiments, the flow control system includes a manual bypass valve in parallel flow with the solenoid valves. In certain embodiments, the flow control system is devoid of an electronic controller. Accordingly, the inline flow control system can be retrofitted for existing flow systems (e.g., evaporative cooling systems) with minimal cost and effort. Further, the first solenoid valve and the second solenoid valve can be concurrently activated for parallel flow, such as in extreme circumstances requiring greater flow.
The fluid container 106 includes at least a bottom wall 120 and sidewalls 122 defining a container interior 124 to hold and/or direct fluid flow of the fluid 118. In certain embodiments, the fluid container 106 includes a reservoir, tank, barrel, vat, trough, etc. configured to hold stagnant and/or flowing fluid 118 (e.g., water), such as for evaporative cooling systems. The high float switch 110 and low float switch 112 are mounted in the sidewall 122 and extend into the container interior 124. In certain embodiments, the high float switch 110 and/or the low float switch 112 are electromagnetic float switches. As explained in more detail below, the high float switch 110 and/or low float switch 112 are activated or deactivated depending on the height of the fluid 118 within the container interior 124. The high float switch 110 is positioned farther from the bottom wall 120 than the low float switch 112. Accordingly, the high float switch 110 and the low float switch 112 are activated or deactivated at differing fluid heights (e.g., liquid heights).
Based on the signals (or lack thereof) from the low float switch 112 and/or the high float switch 110, the flow control device 102 controls the flow of fluid from the fluid supply 104 through the flow control device 102 to the fluid container 106. In certain embodiments, the flow control device 102 is devoid of an electronic controller to reduce costs while also providing flow control functionality. The flow control device 102 can be retrofitted for existing flow systems (e.g., evaporative cooling systems) with minimal cost and effort. Retrofitting is facilitated by the inline installation of the flow control device 102 and/or minimal mounting requirements of the high float switch 110 and/or the low float switch 112.
The flow control device 102 includes a flow control housing 126 with a base 128 and a cover 130 (may also be referred to as a hinged cover) attached to the base 128 by a hinge 132. The base 128 and the cover 130 of the flow control housing 126 define an interior 134. In certain embodiments, the cover 130 includes a cam latch 133 for selectively locking the cover 130 relative to the base 128.
The flow control housing 126 includes a fluid inlet 136 (may also be referred to as a fluid inlet pipe) in fluid communication with (e.g., coupled to) the fluid supply 104 and configured to receive fluid therefrom (e.g., via external upstream fluid pipes 138) and a fluid outlet 140 (may also be referred to as a fluid outlet pipe) in fluid communication with (e.g., coupled to) the fluid container 106 (e.g., via external downstream fluid pipes 142). The flow control device 102 further includes a first fluid pipe 144A, a second fluid pipe 144B, and a third fluid pipe 144C positioned within the interior 134 of the flow control housing 126 and in fluid communication with (e.g., coupled to) the fluid inlet 136 and the fluid outlet 140. The first fluid pipe 144A, the second fluid pipe 144B, and the third fluid pipe 144C are in parallel flow with one another via an upstream junction 146A and a downstream junction 146B.
The first fluid pipe 144A (may also be referred to herein as a first internal fluid pipe, primary flow pipe, high flow pipe, main flow pipe) includes a first solenoid valve 148A configured to control fluid flow through the first fluid pipe 144A. The first solenoid valve 148A is configured to move between a closed position preventing fluid flow and an open position allowing fluid flow.
Solenoid valves provide an advantage over other types of valves in delivering more water faster. For example, mechanical valves (e.g., carrot valves) often deliver water proportional to arm movement. This may create high variability in the exact water level when the water flow turns on and/or off (i.e., turn on and/or off are not consistently accurate). This can be particularly problematic for applications requiring precise and/or shallow water levels (e.g., in certain evaporative cooling systems). In high temperature conditions, mechanical valves may not be able to keep up with the rate of water evaporation due to the proportional flow nature of the mechanical valves. Comparatively, solenoid valves are often binary (not proportional) in their flow, meaning that the solenoid valve is either full on or off. This means that solenoid valves are able to provide higher flow rates to more precisely maintain the desired water level, even in applications requiring precise and/or shallow water levels. This means that in certain applications, less water is required in the trough and/or the trough is able to be filled much faster. Further, the exact water level for when the water flow turns on and/or off is more precise and/or more consistent, with less fluctuation. For example, in an evaporative cooling system, precise water level management prevents flooding evaporative pads while also ensuring a minimum water level to evaporate for cooling purposes.
The first fluid pipe 144A is aligned with the fluid inlet 136 and the fluid outlet 140. Such alignment reduces the length of the fluid path, along with the drag and pressure for improved fluid flow performance (e.g., increased rates). The second fluid pipe 144B (may also be referred to herein as a second internal fluid pipe, secondary flow pipe, low flow pipe, backup flow pipe, etc.) includes a second solenoid valve 148B configured to control fluid flow through the second fluid pipe 144B. The second fluid pipe 144B is offset from the fluid inlet 136 and the fluid outlet 140. The third fluid pipe 144C (may also be referred to herein as a third internal fluid pipe, manual backup flow pipe, etc.) includes a manual bypass valve 148C (e.g., ball valve) configured to control fluid flow through the third fluid pipe 144C. The third fluid pipe 144C is offset from the fluid inlet 136 and the fluid outlet 140. In certain embodiments, the pipes and/or junctions include a plastic material (e.g., polyvinyl chloride (PVC)).
In certain embodiments, the first fluid pipe 144A is positioned between the second fluid pipe 144B and the third fluid pipe 144C and aligned with the fluid inlet 136 and the fluid outlet 140. Alignment with the fluid inlet 136 and fluid outlet 140 and/or positioning between the second fluid pipe 144B and third fluid pipe 144C reduces the length of the secondary fluid paths, along with the drag and pressure for improved fluid flow performance (e.g., increased rates). In other words, for example, a primary flow path positioned between two secondary flow paths is preferred to having a secondary flow path positioned between the primary flow path and another secondary flow path.
The flow control device 102 further includes a device power port 150 (may also be referred to herein as a supply power port), a first switch port 152, and a second switch port 154 mounted in a sidewall 156 of the flow control housing 126. The device power port 150 is in electrical communication with the power supply 108 via external electrical wiring 158. The first switch port 152 (may also be referred to as a high flow switch port, etc.) is in electrical communication with the high float switch 110 via external electrical wire 160. The first solenoid valve 148A is configured to move from the closed position to the open position upon receiving an electrical signal from the first switch port 152. The second switch port 154 (may also be referred to as a low flow switch port, etc.) is in electrical communication with the low float switch 112 via external electrical wires 162. The second solenoid valve 148B is configured to move from the closed position to the open position upon receiving an electrical signal from the second switch port 154.
The flow control device 102 includes a junction box 164 (may also be referred to herein as a control box, power supply box, etc.) positioned within the interior 134 of the flow control housing 126. In certain embodiments, the junction box 164 includes electrical terminals, such as to convert the voltage from the power supply 108 (e.g., from 240V) to a lower voltage (e.g., 12V) and pass the electrical power through the high float switch 110 and/or low float switch 112 to the first solenoid valve 148A and/or the second solenoid valve 148B. In certain embodiments, the high float switch 110 and the low float switch 112 are 12V switches. In certain embodiments, such voltage reduction improves safety of the flow control device 102 (e.g., preventing exposure of a high voltage wire). In this way, the flow control device 102 is controlled by mechanical switches activating electrical components.
In certain embodiments, the junction box 164 includes a watertight junction housing 166 between a base 167A and a cover 167B to protect electrical components within the interior of the junction box 164 from potential contact with fluid or water (e.g., to prevent short circuiting of components or other potential problems). The junction box 164 is in electrical communication with the device power port 150, the first switch port 152, and the second switch port 154 via upstream internal electrical wiring 168. In particular, the junction box 164 includes a junction power port 170 in electrical communication with the device power port 150, and a junction switch port 172 in electrical communication with the first switch port 152 and the second switch port 154. In certain embodiments, the junction box 164 includes multiple junction switch ports (e.g., one for each device switch port).
The junction box 164 is also in electrical communication with the first solenoid valve 148A and the second solenoid valve 148B via downstream internal electrical wiring 174. In particular, the junction box 164 includes a first valve port 176 in electrical communication with the first solenoid valve 148A and a second valve port 178 in electrical communication with the second solenoid valve 148B. Accordingly, the high float switch 110 is in electrical communication with the first solenoid valve 148A via the first switch port 152 and the electrical junction box 164, and the low float switch 112 is in electrical communication with the second solenoid valve 148B via the second switch port 154 and the electrical junction box 164. In other words, the junction box 164 provides electrical communication between the first switch port 152 and the first solenoid valve 148A and between the second switch port 154 and the second solenoid valve 148B.
The first solenoid valve 148A is configured to control fluid flow through the first fluid pipe 144A based on a received first electrical signal from the high float switch 110 (first switch) via the first switch port 152. The second solenoid valve 148B is configured to control fluid flow through the second fluid pipe 144B based on a received second electrical signal from the low float switch 112 (second switch) via the second switch port 154. Thus, the orientation of the first solenoid valve 148A and the second solenoid valve 148B (and the water flow therethrough) is based on the electrical signals (or lack thereof) from the high float switch 110 and the low float switch 112.
In certain embodiments, the flow control device 102 has dimensions in a range of about 5-30 inches by 5-40 inches (including the fluid inlet 136 and fluid outlet 140) by 2-30 inches. In certain embodiments, the flow control device 102 has dimensions of about 14.60 inches by 21.79 inches (including the fluid inlet 136 and fluid outlet 140) by 6.25 inches. In certain embodiments, the flow control device 102 is sold with the high float switch 110 and/or low float switch 112 within the flow control housing 126 for more compact packaging. In this way, a user can remove the high float switch 110 and/or low float switch 112 from the flow control housing 126 for mounting in a fluid container 106.
In certain embodiments, the first solenoid valve 148A and/or second solenoid valve 148B are ASCO RedHat solenoids. In certain embodiments, the high float switch 110 and/or the low float switch 112 are Dwyer float switches. It is noted that should one or more of the first solenoid valve 148A and/or second solenoid valve 148B fail, they may be easily replaced.
Similarly, the manual bypass valve 148C may be used as a manual backup. In this way, the manual bypass valve 148C may be changed from a closed orientation to an open orientation, such as, for example, in case of an operational failure of the first solenoid valve 148A and/or the second solenoid valve 148B, and/or in case the fluid flow through the first fluid pipe 144A and/or the second fluid pipe 144B is insufficient.
In certain embodiments, the high float switch 110 and the low float switch 112 are mounted laterally offset from one another so that the high float switch 110 does not interfere with the float portion of the low float switch 112 (e.g., because the float portion moves vertically). Because the high float switch 110 and the low float switch 112 are merely measuring the fluid height, their lateral location is generally flexible. In certain embodiments, the high float switch 110 is laterally offset from the low float switch 112 by a range of 0.5 to 10 inches (e.g., 2 inches).
The flow control endcap assembly 300 further includes an outlet hole 310 for mounting a bulkhead fitting 312. In certain embodiments, the diameter of the outlet hole 310 is in a range of about 0.5 to 20 inches. The outlet hole 310 has a center positioned beneath a center of the low float hole 308 so that fluid does not interfere with the low float switch 112. In certain embodiments, the bulkhead fitting 312 is mounted through the flow control endcap 302 and in fluid communication with the fluid outlet of the flow control device 102.
In certain embodiments, the flow control endcap assembly 300 includes an external coupler 316 for coupling the bulkhead fitting 312 to external downstream fluid pipes 142 (see
As similarly noted above, the high float switch 110 and the low float switch 112 are mounted vertically offset from one another. Further, in certain embodiments, the high float switch 110 and the low float switch 112 are mounted laterally offset from one another so that the high float switch 110 does not interfere with the float portion of the low float switch 112.
The trough 402 further includes an outlet hole 412 for mounting a bulkhead fitting 414. In certain embodiments, the diameter of the outlet hole 412 is in a range of about 0.5 to 20 inches. The outlet hole 412 has a center positioned beneath a center of the low float hole 410 so that fluid does not interfere with the low float switch 112. Dimensions for holes sizes and offsets are discussed above.
In certain embodiments, the flow control trough assembly 400 includes an external coupler 416 for coupling the bulkhead fitting 414 to external downstream fluid pipes 142 (see
It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the invention.
Many modifications and other embodiments of the embodiments set forth herein will come to mind to one skilled in the art to which the embodiments pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the description and claims are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. It is intended that the embodiments cover the modifications and variations of the embodiments provided they come within the scope of the appended claims and their equivalents. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
