Patent Grant
6860282
The present invention relates to a method and system for converting or retrofitting manually operated, already installed flush valves.
In toilet rooms it is common to use various types of flushing systems for flushing urinals or toilet bowls (also commonly referred to as toilets). A first type of a conventional toilet flush system uses water accumulated in a water storage tank. This system usually includes a float operated intake valve mounted at a water intake pipe for delivering water into the water tank. The intake valve includes a rod connected to a float that acts to close the intake valve when there is a predefined water level in the water tank. At the bottom of the water tank, there is a tank outlet fixture through which water from the tank is discharged into a toilet bowl when a flush handle is activated to flush the toilet. During and after the flushing action, the float drops below a closing position, which in turn opens the intake valve and water flows into the tank until water in the tank reaches the predefined level. At the predefined level, the float floats up to the closing position that in turn closes the intake valve.
A second type of a conventional toilet flush system doesn't use the water storage tank, but uses water for flushing directly from a water supply line. This flush system uses a flush valve (known as a “Flushometer”) that may be a diaphragm-type valve or a piston-type valve. The flush valve can be manually activated by depressing a handle (or can be automatically activated by a sensor) to control flushing a toilet or a urinal. In these systems the flush valve controls a pilot section that is located somewhat above the diaphragm (in the valve diaphragm-type valve) or the piston (in the piston-type valve). The pilot section receives water through one or several control orifices. The valve controls pressure in the pilot section, which in turn activates water flow from the supply line to the toilet or urinal creating the flush action.
In the diaphragm-type valve or the piston-type valve, the pilot section has the control orifices with a quasi-fixed supply rate by virtue of maintaining a hydraulic condition known as “choked flow condition”. The pilot section also includes a drain valve, which is activated by the user handle to lower pressure in the pilot section. Upon activation of the drain valve (which has a flow through rate much higher than the control orifice feed rate), the pilot chamber is depleted, resulting in the opening of the main flow passage that facilitates the main flushing flow. The main passage will remain open as long as it takes for the pilot chamber to refill (after handle release followed by drain valve reseal) through the pilot orifice. The water pressure in the pilot chamber closes the main passage to seal the main water dosage, as described in detail in connection with FIG. 1.
The diaphragm-type flush valves and the piston-type flush valve were described in numerous publications and patents. For example, various diaphragm-type flush valves are described in U.S. Pat. Nos. 5,125,621; 5,456,279; 6,216,730; or PCT publication WO91/17380, and the piston-type flush valve is described in U.S. Pat. No. 5,881,993.
Flush valve 10 includes a pilot chamber 36 formed by the dome 20 and diaphragm 12. Diaphragm 12 includes a control orifice 34, which enables water flow from main chamber 26 to pilot chamber 36 and thus causes pressure equalization between main chamber 26 and pilot chamber 36 separated by diaphragm 12. When the pressure is equalized, there is a net force on diaphragm 12 from pilot chamber 36 downward (on the diaphragm 12) since the diaphragm area in pilot chamber 36 is larger than the opposing diaphragm area in main chamber 26. The downward oriented net force keeps the valve closed by sealing main passage 14. To open flush valve 10, a pilot valve provides a pressure-relief mechanism that lowers the water pressure in pilot chamber 36. The pilot valve includes a pilot valve member 50 with a rod portion 58 displaceable by a plunger 56 connected to a manual flush handle 54. Pilot valve member 50 includes a pilot seat 52 for sealing against in the diaphragm plate 38.
Operation of handle 54 causes displacement of plunger 56 against rod portion 58 of pilot valve member 50. When pilot valve member 50 is displaced, water flows with minimal flow resistance from pilot chamber 36 near pilot seat 52 through the relief opening 49, while control orifice 34 in the diaphragm plate 38 imposes considerable resistance to the compensating flow from main chamber 26 through orifice 34 to pilot chamber 36. Consequently, the pressure in pilot chamber 36 decreases significantly below the pressure in main chamber 26 so that the force exerted by pressure in pilot chamber 36 is lower than that exerted by the pressure in main chamber 26. Thus, the portion of the diaphragm plate 38 located interior to its clamped portion 59 flexes upward, rising off main valve seat 14 (i.e., main passage 14); this opens the valve and water flows from main chamber 26 to water output 32.
When a user releases flush handle 54, pilot valve 50 returns to its position on pilot valve seat 52, but the pressure in the pilot chamber 36 does not immediately return to the level in the main chamber 26 because the pressure-equalizing flow from main chamber 26 to pilot chamber 36 is restricted by the small size of control orifice 34. This delay in pressure equalization is desirable because for a predetermined length of time water flows from output 32 to the connected toilet or urinal. Ultimately, however, the water flow via control orifice 34 equalizes the pressure between main chamber 26 and pilot chamber 36 to the point at which the downward force on main diaphragm 12 overcomes the upward force, and the valve closes. This entire flushing cycle is repeated by moving handle 54.
There are several existing design approaches used for converting (i.e., retrofitting) the existing manual flush valves to sensory-activated electronically controlled automatic valves. There is a top cover assembly that replaces upper housing 22 (shown in FIG. 1). The top cover system includes an electronic sensory module, a battery pack, and electronics for controlling a bi-stable solenoid that acts upon a pilot valve. The pilot valve in turn controls the main diaphragm valve. The top cover conversion system usually includes a new main diaphragm assembly that replaces main diaphragm 12 (used in the manual system shown in FIG. 1). These types of conversion systems are described in U.S. Pat. Nos. 5,169,118 and 5,244,179.
Another type of a sensory controlled flushing device (known as a “side mount” conversion device) is described, for example, in U.S. Pat. Nos. 5,431,181, 5,680,879 and 6,056,261. The side mount device includes a sensory module, a battery pack, an electric motor, and an activation plunger that is mounted onto a common housing. Specifically, in the “side mount” device, the activation plunger is mounted on to the flush valve assembly after first removing a manual handle (e.g., flush handle 54 in FIG. 1). Upon receiving a flush command from the sensory module, the electronics activates the movement of the replacement plunger thereby activating the pilot valve, which in turn starts the flush cycle.
The installation of the “side mount” conversion (retrofit) device requires removal and replacement of the manual flush handle. The handle removal frequently requires breaking the existing water seal for installation. Specifically, to install some of these devices, a person may need to turn the water supply off, dismantle portions of the flush valve, install the device, reestablish the water seal, and then turn the water back on. Perhaps, even if the water supply doesn't need to be turned off, the person needs to remove the manual flush handle. Thus, in either case, this installation requires the job to be performed by a qualified professional.
Importantly, some conversion or retrofit devices do not have a truly manual override mechanism (i.e., the ability to override the sensory control to start a flushing cycle if there is no electrical power available). These systems usually have an electrical switch that bypasses the optical sensor to trigger flushing electronically, but this cannot be done during power source failure. That is, such conversion device cannot start a flushing cycle (sensory or “manual” by depressing a switch triggering a solenoid) during power failure.
Therefore, there is still a need for devices for converting or retrofitting manually operated, already installed flush valves used in toilet rooms.
The present invention relates to a method and system for converting or retrofitting manually operated flush valves. A conversion system for converting an installed manually-operated flush valve includes a power module, a control module, and a driver module mechanically coupled to a displacement member arranged to externally activate the converted flush valve.
Preferably, the conversion system may be installed without removing any active flush valve component of the installed manual valve, or without disconnecting the water supply to the already installed flush valve. The use of the conversion system does not prevent fully manual operation (e.g., during complete power failure). That is, after conversion, the manual valve handle may still be activated by a user that triggers manually the flush cycle. This feature allows a truly manual override of the converted automatic, sensor activated flush valve during a total power failure. In the automatic mode, the conversion system uses an automatic sensor to trigger a driver module for activating the flush valve handle.
According to one aspect, the present invention includes a conversion system for converting an installed manually-operated flush valve used with a urinal or toilet. The conversion system includes a power module, a control module, and a driver module arranged for mechanical, hydraulic or other coupling to the manually-operated flush valve.
Preferred embodiments of this aspect may include one or more of the following features: The control module includes a sensor. The sensor may be an optical sensor, an ultrasonic sensor, a capacitive sensor, or any other sensor. The sensor may be constructed to detect motion near the flush valve or to detect presence near the flush valve. The sensor is preferably an infrared sensor.
The driver module includes a gear mechanism mechanically coupled to a displacement member. The displacement member includes a proximal region coupled to the gear mechanism and a distal end shaped to provide contact with the manual handle. The power module includes a battery and the driver module includes an electromotor powered by the battery and coupled to a displacement member.
According to another aspect, the invention is a conversion system for converting an installed manually-operated flush valve used with a urinal or toilet. The conversion system includes an externally mounted conversion assembly including a power module, a control module including a sensor, and a driver module mechanically coupled to a displacement member arranged to externally activate the manually-operated flush valve using a manual valve handle.
Preferred embodiments of this aspect may include one or more of the following features: The sensor may be an optical sensor or ultrasonic sensor. The sensor may be constructed to detect motion near the flush valve, or to detect presence near the flush valve. The sensor may be an infrared sensor. The displacement member includes a proximal region coupled to the gear mechanism and a distal end shaped to provide contact with the manual handle. The power module includes a battery and the driver module includes an electromotor powered by the battery and coupled to a displacement member.
Preferred embodiments of both of the above aspects may include one or more of the following features: The conversion assembly does not include any part being in direct contact with a water passage of the manually-operated flush valve. The manually-operated flush valve includes a diaphragm-type valve mechanism or a piston-type valve mechanism.
The displacement member is constructed and arranged to rotate or move linearly (or both) when acting on the manual handle. The manually operated flush valve mechanism may include a piston-type mechanism, a diaphragm-type mechanism or another related mechanism.
According to yet another aspect, a method for converting a manually operated flushometer-type valve used with a urinal or toilet, is practiced by manually flushing the valve by displacing a manual valve handle, or another installed manual actuator, to check proper operation of the valve including water flow from a water inlet to a water outlet of the valve, providing a conversion assembly including a sensor constructed to provide a signal to a control module for actuating a drive module and a displacement member, mechanically, hydraulically or otherwise coupling the displacement member to the valve handle, or to another manual actuator, triggering the sensor and thereby actuating the drive module constructed to move the displacement member, and displacing the manual valve handle, or activating the other manual actuator, by action of the displacement member and thereby initiating water flushing.
The method may further include manually displacing the handle. The method may be performed without closing a water supply to the water inlet, or without disassembling any part of the manually operated flush valve. The method may be performed without performed without removing any active part of the existing manually operated flushing system.
According to yet another aspect, a method for converting an existing manually operated flushing system, used with a urinal or toilet, to an automatic flushing system, may be performed by providing a conversion assembly including a sensor constructed to provide a signal to a control module for actuating a drive module, positioning a mechanical actuator coupled to the drive module relative to an existing manually operated handle of the flushing system, triggering the sensor and thereby actuating the drive module constructed to cause displacement of the manual handle, or another manual actuator, of the flushing system causing water flushing, wherein the providing and the coupling is performed without removing any active part of the existing manually operated flushing system.
The method may further include manually displacing the handle. The method may further include manually displacing by hand touching the manually operated handle. The method may be performed without closing a water supply to the water inlet, or without disassembling any part of the manually operated flush valve.
The displacement member may perform a substantially linear motion when displacing the manual handle to actuate the valve mechanism. The displacement member may perform a substantially rotational motion when displacing the manual handle to actuate the valve mechanism. The displacement member may perform both rotational and linear motion when displacing the manual handle to actuate the valve mechanism.
The process of fixedly mounting the conversion assembly relative to the valve body includes attaching the conversion assembly directly onto the valve body, or on a wall near the valve body, or on any suitable stationary surface near the valve body.
The drive module may include a gear mechanism coupled to the displacement member. The displacement member may include a linear structure having a proximal region coupled to the gear mechanism and a distal end shaped to provide contact with the manual handle during the pivotably displacing. The method may include operating a valve mechanism that includes a diaphragm-type valve, or a piston-type valve, or a flush valve for water tanks.
The control module includes one or even several sensors. The sensor may be any suitable sensor such as an optical sensor or an ultrasonic sensor. The sensor may sense presence or motion, or both.
Referring also to
The motorized gear subassembly transfers electrical energy into mechanical motion through the set of gears 74 that increases the torque at the output, as explained below. Cam and spring arrangement 76 converts the torque into a downward motion. Mechanism 76 includes a preload spring (not shown) exhibiting a force slightly less than the force necessary to displace handle 54. The spring counterbalances the existing handle force and thereby reduces the energy needed to supply to driver module 70 to activate handle 54 automatically. After actuation, displacement member 71 pushes on flush handle 54 with a force slightly more than the net force (i.e., the difference of the existing handle force and the counterbalancing spring).
Motor 72 is preferably a DC motor having suitable torque and power consumption. Specifically, motor 72 may be the RF-370CH-13350 motor, or the RF-500TB-12560 motor, both made by Mabuchi. Both motors have a motor constant of about 17 mN m/A. The 370CH motor has a no load speed of about 2800 rpm and a stall torque of about 7.35 mN.m at 6V. The 500TB motor has a no load speed of 2200 and a stall torque of 5.88 mN.m at 6V. Although the 370CH motor is a little stronger, faster and has a slim body, the 500TB motor is shorter and consumes less current.
Referring also to
Preferably, gear arrangement 74 has a relatively large diameter that reduces stress on the shaft gear teeth. The larger shaft gear diameter to transmission gear diameter allows for a thicker shaft. The keyed shaft is designed such that both the molded shaft gear and the cam can simply be slid onto the shaft. Displacement element 71 includes a distal attachment 73 having a shape complementary to the shape of manual handle 54. Upon extension, displacement member 71 provides a typical combined force (including the preload spring) required to push the manual handle (direction of arrow A), which force is about 5 pounds (the required force for ADA compliance). This mechanism is energy efficient in order to extend the battery life to a maximum. The flush can be actuated within a relatively short time of a sensing event and has to be able to repeat every 10 seconds.
As mentioned above, the motorized gear subassembly moves only in one direction. The coupling between the motorized gear subassembly and the actuator mechanism subassembly is such that it enables displacement member 71 to travel downwards and permits said mechanism to be retracted by the forces that exist in the manual handle. The use of a cam in this mode of operation eliminates the need for motor rotation reversal, thereby further reducing energy consumption by simplifying the electronic drive circuitry.
The actuator subassembly includes a section that detects the end of the full stroke on the actuator mechanism and feeds this back to the electronics to stop the rotation of the motorized gear subassembly such that upon stopping of the rotation enough mechanical timing is allowed for the actuator mechanism subassembly to be retracted to its original position. The detection is achieved preferably by sensing the current or voltage changes in the motor driver power. Alternatively, the system can use other sensors measuring position, pressure, timing, etc. For example, the detection is achieved by a secondary sensory mechanism that detects either the position of the actuator mechanism subassembly or the position of the last gear that acts on the actuator mechanism subassembly.
Preferably, power module 80 is battery operated, wherein the batteries are mounted inside the main body of conversion system 60. The overall arrangement of system 60 provides an easy access to the batteries for convenient replacement. Power module 80 can include 4 “C” size batteries, which provide a voltage between 6.3 volts at the beginning of their life down to 4 volts at the end of their life. Alternatively, power module may be powered from an AC supply. The control module 90 includes control electronics, a microprocessor, and a sensor for detecting presence of an object, or for detecting movement. The sensor may be an optical sensor or an ultrasonic sensor. Preferably, the optical sensor is an infra-red sensor operating at a wavelength of about 940 nm.
Referring to
In the embodiment of
Transmitter-lens 110 focuses infrared light from light-emitting diode 106 through infrared-transparent window 114 having a selected radiation-power distribution. Receiver lens 112 focuses received light onto photodiode 108, wherein this arrangement provides a selected pattern of sensitivity to light reflected from different targets. The emitted radiation-power distribution and the sensitivity pattern of photodiode 108 are shown in FIG. 5. Optical sensor 100 also includes an opaque blinder 130 mounted in front of lens 110 to form a central aperture for infra-red light transmission from the light-emitting diode 106, and to block stray transmission that could contribute to crosstalk. To prevent crosstalk, the optical sensor may include opaque stops and other elements.
When a person using toilet 5 leaves the irradiated area, optical sensor 100 triggers driver module 70, which in turn moves displacement member 71 to activate manual handle 54. Upon activation of manual handle 54, valve 10 enables water flow from input pipe 24 to output pipe 33. The user can also manually flush toilet 5 by depressing flush handle 54, as done prior to retrofitting valve 10. The ability to operate manually flush handle 54 is a useful feature of the conversion system that still enables manual use of Flushometer in case of electronic failure or complete power loss.
Referring to
According to other embodiments, conversion system 60 is also suitable for actuating manual flushing systems described in U.S. Pat. No. 6,263,519; and U.S. patent applications Ser. Nos. 09/716,870; 09/761,533; and 09/761,408 all of which are incorporated by reference for all purposes. In these embodiments, the displacement member actuates the manual actuator of the installed flush system (described in the above patent documents) to start the flush cycle.
The flush toilet system 135 includes a flush water tank 136 closed by cover 137, a float operated intake valve 138 connected to a float 140, and a ball valve 142 connected to a manual flush handle 144. Water from water tank 136 is discharged into toilet bowl 5 covered by a cover 6. Flush toilet system 135 also includes intake valve 138 mounted at the upper end of a water intake pipe 139 and has an outlet 141 into tank 136. Intake valve 138 is connected by a rod to float 140. Float 140 acts to close intake valve 138 when there is a certain water level in tank 136. To flush manually toilet 5, a user presses on a manual handle 144, which opens ball valve 142. Water is then discharged through a tank outlet fixture 147 into toilet 5.
Conversion system 60 is preferably mounted externally onto a flush water tank 136, on cover 137. Conversion system 60 may also be incorporated into a replacement cover that is installed instead of cover 137. This embodiment may be implemented by providing a coupling between flush handle 144 and displacement member 71, or by another coupling between displacement member 71 and valve 142 (which doesn't have to be a ball valve). In the embodiment of
In the embodiments of
Upon valid target detection through the sensory electronics located on circuit board 104, motor 74 is activated and gear assembly pushes on the pre-existing flush handle by one of several means such as a cam preferably in a downward motion. The downward direction further permits the actual handle (which may protrude beyond the device) to be operated manually thereby letting the Flushometer to be used as a manual Flushometer, in case of electronic failure or power loss.
The housing of conversion system 60 is designed with respect of the type of attachment used with respect to the manual Flushometer. The housing may be anchored to the main body of the Flushometer at the manual handle mount structure prior to the handle or retaining nut. (See
An alternative mechanism for the manual operation of the Flushometer may include a mechanical push button mounted on the top of the structure that surrounds the existing manual handle. The button is designed to directly push on handle 54 to provide a downward motion. Furthermore, the button is preferably loaded with a return spring mechanism to bring it back to its original position.
Referring to
The person then couples displacement member 71 to manual flush handle 54 (step 168). Next, the driver module is triggered by a test switch or by triggering optical sensor module 100 (step 170). After triggering driver module 70, the displacement member 71 activates manual handle 54 (step 170). If displacement member 71 does not activate manual handle 54, the person has to adjust the mechanical coupling between displacement member 71 and manual handle 54. (step 174). If manual handle 54 is displaced, but it does not cause water flow, displacement member 71 and driver module 70 may need to be adjusted. These adjustments are possible, but do not need to be performed in most cases. That is, in conversion system 60, the housing and the attachments are constructed so that after mounting the housing and coupling displacement member 71 to manual flush handle 54, no mechanical adjustments are needed in most cases. If there is water flow, the person can install or adjust position of optical sensor 100 to obtain desired transmission and detection fields. (step 178). The person then completes the installation of conversion system 60, and again tests automatic operation of the flush valve (step 182).
Having described various embodiments and implementations of the present invention, it should be apparent to those skilled in the relevant art that the foregoing is illustrative only and not limiting, having been presented by way of example only. There are other embodiments or elements suitable for the above-described embodiments, described in the above-listed publications, all of which are incorporated by reference as if fully reproduced herein. The functions of any one element may be carried out in various ways in alternative embodiments. Also, the functions of several elements may, in alternative embodiments, be carried out by fewer elements, or a single, element.
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