Fluid usage monitoring system

Abstract

In a method for monitoring fluid usage in a fluid system, a proportional control valve is provided, comprising a valve element operable to control fluid flow from a fluid source to the fluid system. A first pressure upstream of the valve element and a second pressure downstream of the valve element are measured to identify a pressure differential across the valve element. In response to the identified pressure differential, the valve element is adjusted to one of a plurality of flow positions to adjust the pressure differential across the valve element to substantially match a predetermined pressure differential. The flow rate through the proportional control valve is determined based on the first pressure, the second pressure, and the adjusted flow position of the valve element. The fluid usage in the fluid system is determined based on the flow rate determined over time.

Description

[0001] Cross-reference of related applications

[0002] This application claims priority and all benefits to U.S. Provisional Patent Application Serial No. 62 / 806,458, filed February 15, 2019, entitled FLUID USAGE MONITORING AND CONTROLSYSTEM, the entire disclosure of which is incorporated herein by reference. Background Technology

[0003] Plumbing systems, such as residential plumbing systems, often experience leaks or improper shutdowns in multiple locations, which can be difficult to identify and may lead to increased water bills and / or property damage. Summary of the Invention

[0004] According to an exemplary embodiment of this disclosure, a water monitoring system includes a proportional control valve having: a valve body having an inlet end and an outlet end; a valve element assembled with the valve body and disposed between the inlet end and the outlet end; and an electronically operated actuator assembled with the valve body and operable to adjust the valve element to a plurality of flow positions between a closed position and a fully open position. An upstream pressure sensor in fluid communication with the inlet end and a downstream pressure sensor in fluid communication with the outlet end are provided. A control module is operatively connected to the electronically operated actuator and communicates with the upstream and downstream pressure sensors. The control module is configured to operate the electronically operated actuator in response to pressure indication signals from the upstream and downstream pressure sensors to adjust the valve element to one of the plurality of flow positions to regulate the differential pressure across the valve element to substantially match a predetermined differential pressure.

[0005] According to another exemplary embodiment of this disclosure, a method for monitoring fluid usage in a fluid system is contemplated. In the exemplary method, a proportional control valve is provided, comprising a valve element operable to control fluid flow from a fluid source to the fluid system. A first pressure upstream of the valve element and a second pressure downstream of the valve element are measured to identify a pressure differential across the valve element. In response to the identified pressure differential, the valve element is adjusted to one of a plurality of flow positions to adjust the pressure differential across the valve element to substantially match a predetermined pressure differential. The flow rate through the proportional control valve is determined based on the first pressure, the second pressure, and the adjusted flow position of the valve element. Based on the flow rate determined over time, the fluid usage in the fluid system is determined.

[0006] According to another exemplary embodiment of this disclosure, a method for identifying the use of a water appliance in a piping system including at least first and second water appliances operable to supply water from a water source is envisioned. In the exemplary method, a first flow modulation device is provided with the first water appliance, wherein the first flow modulation device is configured to provide a first identifiable flow characteristic corresponding to the use of the first water appliance. The flow rate from the water source to the piping system is measured. The measured flow rate is compared with the first identifiable flow characteristic to identify whether the first water appliance has been used. Attached Figure Description

[0007] Upon consideration of the following description taken in conjunction with the accompanying drawings and the appended claims, further advantages and benefits will become apparent to those skilled in the art, as illustrated in the drawings:

[0008] Figure 1 is a schematic diagram of an electronically operated proportional valve device for a fluid system according to an exemplary embodiment of the present disclosure;

[0009] Figure 1A This is a schematic diagram of the electrical / electronic components of an electronically operated proportional valve device according to exemplary embodiments of the present disclosure;

[0010] Figure 2 A cross-sectional view of a proportional control valve according to an exemplary embodiment of the present disclosure is shown;

[0011] Figure 3 A perspective view of another proportional control valve according to an exemplary embodiment of the present disclosure is shown;

[0012] Figure 4 It shows Figure 3 A cross-sectional view of a proportional control valve, showing the valve stem in the closed position;

[0013] Figure 5 It shows Figure 3 A partially enlarged cross-sectional view of a proportional control valve, showing the valve stem in the open position;

[0014] Figure 6 The curve showing the relationship between Cv and valve stroke for an exemplary proportional control valve is shown.

[0015] Figure 7 The flow rate versus valve stroke curve of an exemplary proportional control valve is shown;

[0016] Figure 8 Another actuated proportional control valve according to an exemplary embodiment of the present disclosure is shown;

[0017] Figure 9 Another actuated proportional control valve according to an exemplary embodiment of the present disclosure is shown;

[0018] Figure 10This is a schematic diagram of a water monitoring system according to an exemplary embodiment of the present disclosure;

[0019] Figure 11 This is a schematic diagram of a water monitoring system according to an exemplary embodiment of the present disclosure;

[0020] Figure 12A This is a schematic diagram of a water appliance with a pressure and time-dependent flow regulator according to exemplary embodiments of the present disclosure; and

[0021] Figure 12B This is a schematic diagram of another water appliance having a pressure and time-dependent flow regulator according to an exemplary embodiment of the present disclosure. Detailed Implementation

[0022] This detailed description merely illustrates exemplary embodiments of the invention and is not intended to limit the scope of the claims in any way. In fact, the claimed invention is broader than and not limited to the preferred embodiments, and the terms used in the claims have their full ordinary meaning. For example, while the exemplary embodiments described in this disclosure relate to using a fluid usage monitoring system to measure and control water usage in a piping system, it should be understood that one or more features described herein may additionally or alternatively be applied to other water systems or other fluid systems, such as natural gas, air, propane, steam, oil, gas, or other such fluid systems.

[0023] While various inventive aspects, concepts, and features of the invention may be described and illustrated herein as being embodied in combination in exemplary embodiments, these various aspects, concepts, and features may be used individually or in various combinations and partial combinations thereof in many alternative embodiments. Unless expressly excluded herein, all such combinations and partial combinations are intended to fall within the scope of the invention. Furthermore, while various alternative embodiments of various aspects, concepts, and features of the invention may be described herein—e.g., alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, alternatives in formation, assembly, and functionality, etc.—such description is not intended to be a complete or exhaustive list of available alternative embodiments, whether currently known or developed hereafter. Those skilled in the art will readily incorporate one or more inventive aspects, concepts, or features into additional embodiments and uses within the scope of the invention, even if such embodiments are not expressly disclosed herein. Moreover, even if some features, concepts, or aspects of the invention may be described herein as preferred arrangements or methods, such description is not intended to imply that such features are necessary or essential unless expressly stated otherwise. Furthermore, exemplary or representative values ​​and ranges may be included to aid in understanding this disclosure; however, these values ​​and ranges should not be construed as limiting and are intended to be critical values ​​or ranges only where so explicitly stated. Unless otherwise explicitly stated, parameters identified as “approximate” or “about” specified values ​​are intended to include the specified value and values ​​within 10% of the specified value. Furthermore, it should be understood that the accompanying drawings may, but are not necessarily, drawn to scale and are therefore to be understood as teaching various ratios and proportions apparent in the drawings. Moreover, while aspects, features, and concepts may be explicitly identified herein as part of the inventive step or forming of the invention, such identification is not intended to be exclusive, but rather may exist in aspects, concepts, and features of the invention fully described herein but not explicitly identified as such or as part of a particular invention, which is instead set forth in the appended claims. The description of exemplary methods or processes is not limited to including all steps required in all cases, and the order in which steps are presented is not construed as necessary or required unless explicitly stated otherwise.

[0024] As used herein, “computer,” “controller,” “control module,” or “processor” includes, but is not limited to, any programmed or programmable electronic or collaborative device capable of storing, retrieving, and processing data, and can be a processing unit or a distributed processing configuration. Examples of processors include microprocessors, microcontrollers, graphics processing units (GPUs), floating-point units (FPUs), reduced instruction set computing (RISC) processors, digital signal processors (DSPs), field-programmable gate arrays (FPGAs), and the like. The computer devices described herein can have any of a variety of configurations, such as handheld computers (e.g., so-called smartphones), tablet computers, tablet laptops, desktop computers, and other configurations, and include other form factors. The various computers and processors described herein have logic for performing the various corresponding functions and processes described herein. As used herein, “logic,” synonymous with “circuit,” includes, but is not limited to, hardware, firmware, software, and / or combinations of each to perform one or more functions or actions. For example, depending on the desired application or need, logic can include a software-controlled processor, discrete logic such as an application-specific integrated circuit (ASIC), a programmable logic device, or other processor. Logic can also be entirely embodied in software. As used herein, “software” includes, but is not limited to, one or more computer-readable and / or executable instructions that cause a processor or other electronic device to perform functions, actions, processes, and / or behaviors in a desired manner. Instructions can be embodied in various forms, such as routines, algorithms, modules, or programs, including standalone applications or code from dynamic link libraries (DLLs). Software can also be implemented in various forms, such as standalone programs, network-based programs, function calls, subroutines, servlets, applications, apps, applets (e.g., Java applets), plugins, instructions stored in memory, part of an operating system, or other types of executable instructions or interpreted instructions from which executable instructions are created. Those skilled in the art will understand that the form of software depends on, for example, the requirements of the desired application, the environment in which it operates, and / or the expectations of the designer / programmer, etc. In exemplary embodiments, some or all of the software is stored on memory, which includes one or more non-transitory computer-readable media of one or more local or remote data storage devices. As used herein, “data storage device” refers to a device for non-transitory storage of code or data, such as a device having a non-transitory computer-readable medium. As used herein, “non-transitory computer-readable medium” means any suitable non-transitory computer-readable medium used to store code or data, such as magnetic media, such as fixed disks in external hard drives, fixed disks in internal hard drives, and floppy disks; optical media, such as CDs and DVDs; and other media, such as RAM, ROM, PROM, EPROM, EEPROM, flash PROM, external flash drives, etc.The communication circuitry described herein includes antennas and / or data ports, as well as driver chips for transmitting and receiving communications with other devices. In exemplary embodiments, the communication circuitry may include Wi-Fi antennas and circuitry, LTE antennas and circuitry, GPS antennas and circuitry, CDPD antennas and circuitry, GPRS antennas and circuitry, GSM antennas and circuitry, UMTS antennas and circuitry, Ethernet circuitry and other antennas and circuitry, USB ports and circuitry (e.g., standard, micro, mini, etc.), RS-232 ports and circuitry, proprietary ports and circuitry (e.g., Apple 30-pin and Lightning ports), RFID antennas and circuitry, NFC antennas and circuitry, bump technology antennas and circuitry, Bluetooth (e.g., BLE) antennas and circuitry, DOCSIS circuitry, ONT circuitry, and other antennas, ports, and circuitry.

[0025] As described herein, when one or more components are described as being connected, joined, fixed, coupled, attached, or otherwise interconnected, such interconnection can be a direct interconnection between components or an indirect interconnection, such as through the use of one or more intermediary components. Furthermore, as described herein, references to “component,” “assembly,” or “part” should not be limited to a single structural member, component, or element, but may include assemblies of components, members, or elements.

[0026] According to an exemplary aspect of this disclosure, flow in a piping system (e.g., a residential or commercial piping system) can be measured and controlled by a monitoring system comprising an electronically actuated proportional control valve equipped between a water source (e.g., a utility) and the piping system, having a controller or control module (connected to or remote from the valve) configured to automatically adjust the valve position (and corresponding flow through the valve) to maintain a predetermined pressure differential (e.g., less than about 10 psi, or about 5 psi) between the upstream and downstream sides of the valve, the pressure differential being measured by an upstream pressure sensor and a downstream pressure sensor.

[0027] When no water is being used in the piping system, the valve can automatically close to maintain the predetermined pressure differential between the utility system, which operates at a substantially constant pressure, and the local piping system, which operates at a substantially constant pressure. This closed valve state also prevents backflow from the overpressured local piping system.

[0028] When water flows out of the piping system (e.g., due to intentional use of one or more water appliances, accidental or unintentional use of water appliances, or leakage from appliances, pipes, or connections in the piping system), the downstream pressure sensor detects a decrease in downstream pressure, resulting in an increase in the measured differential pressure. A control module that communicates with upstream and downstream sensors (e.g., wired or wirelessly) can be configured to operate a valve (e.g., by transmitting control signals to an electric actuator in the valve assembly) to open it to a position and for a duration required to restore the differential pressure to a predetermined setting. When the water flow from the piping system decreases or stops, the control module is configured to operate the valve to adjust it in the closing direction to maintain the predetermined differential pressure setting.

[0029] Figure 1 An exemplary monitoring system 5 is schematically illustrated, comprising a proportional control valve 10 having an inlet 11 connected to a water source U (utility side) and an outlet 12 connected to a local piping system H (residential side). The valve 10 has upstream and downstream pressure sensors 30, 40, which may be integrated or assembled (directly or indirectly) with the valve 10, located upstream and downstream of a flow regulating valve element 20, to measure fluid pressure upstream and downstream of the valve element (e.g., at the inlet 11 and outlet 12 of the valve 10). The proportional control valve 10 includes an electronically operated actuator 50 operable to regulate the valve element 20 to a series of partially open positions (i.e., providing a series of flow rates or effective flow coefficients) between a closed position that blocks flow between the inlet 11 and outlet 12 and a fully open position (i.e., the position of maximum flow). The control module 60 is operatively connected to pressure sensors 30, 40 (e.g., via wired or wireless electronic communication) to receive and process fluid pressure data, and is operatively connected to actuator 50 to provide an actuation signal for operating the actuator to adjust the valve element to a selected flow position between closed and fully open, for example in response to user input or in response to pressure data sensed from the pressure sensors.

[0030] In one exemplary embodiment, such as Figure 1AAs shown, controller 60 may include multiple electronic components. These components are capable of operating proportional control valve 10 and monitoring the local fluid system. More specifically, these components are capable of enabling, disabling, and controlling valve 10. Controller 60 may be integrated with, assembled with, or remotely connected to proportional control valve 10 (e.g., using wired or wireless communication). Controller 60 may include one or more printed circuit boards (“PCBs”) 61. In the illustrated example, multiple electronic components are mounted on PCB 61, including but not limited to processor 62, memory 63, wireless communication chip 64, timer 65, and power port 66. Processor 62 receives signals from and sends signals to electronically operated actuator 50 to control the operation of valve 10. For example, processor 62 receives signals from sensors 30, 40 (described above and will be described in more detail below) and sends signals to electronically operated actuator 50 to enable, deactivate, and control valve 10. Timer 66 measures the time intervals and instances of these actions, for example for storage or communication with corresponding measurement parameters (e.g., pressure, valve position) or other actions.

[0031] Memory 63 can store information received from sensors 30, 40, and actuator 50. Information can also be stored in remote memory. Exemplary storage locations for remote memory include user input module 70 (e.g., smartphone, tablet, or computer), a central server provided by the valve / control module manufacturer or other service provider, and / or a third-party provider (e.g., [missing information]). and The cloud services provided. In the example shown, examples of remote storage include server 78 and cloud computing network 79.

[0032] In the illustrated example, user input module 70 can provide operation instructions to control module 60. User input module 70 can be any module that allows user input. User input module 70 may include one or more remote input devices 71 and manual input devices 72. Exemplary electronic input devices 71 include enabling sensors, mobile devices, voice control devices, and touchscreen devices, such as smartphones, smart speakers, computers, or tablets. Exemplary manual input devices 72 include buttons, touchpads, and toggle switches connected to valve 10 and / or control module 60. User input module 70 receives input from a user and sends signals to control module 60 to control the operation of valve 10. For example, user input module 70 receives input from a user and sends signals to processor 62 to enable, disable, and control valve 10. In the illustrated embodiment, some components of user input module 70 (e.g., mobile devices or voice control devices) are connected to control module 60 via wireless communication connector 67 (e.g., a Wi-Fi connector with wireless communication chip 64) for wireless signal transmission, while other components of user input module 70 (e.g., local input devices) are connected to control module 60 via hardwired connector 68 for wired signal transmission. In other arrangements, each component of the user input module 70 can be connected to the control module 60 and send signals to and / or receive signals from the processor 62 via any type of connector, including other wireless communication connectors such as Bluetooth, cellular, near field communication (NFC), Zigbee, and Z-Wave, or hardwired connectors. The user input module 70 may include any number of components. Furthermore, each component of the user input module 70 can be located anywhere it can send signals to and / or receive signals from the control module 60 and / or other electronic components of the proportional control valve 10 (e.g., the processor 62), and each component of the user input module 70 can also be integrally formed with or physically connected to the valve 10 and / or the control module 60.

[0033] In the illustrated embodiment, the power module 80 provides power to the electrical / electronic components of the control module 60. In the illustrated embodiment, the power module 80 is connected to the power port 66 of the control module 60 via a hardwired connector 68. The power module 80 may include various power sources, including, for example, AC power, battery power, or AC power with a backup battery.

[0034] During user operation of the electronic valve 10, the user uses one or more components of the user input module 70 to enable, disable, and control the electronic valve 10. For example, the user can operate the user input module 70 by triggering the enable sensor / switch 73 on the valve 10 or control module 60, pressing an appropriate button or touchscreen prompt on the mobile device 74, and / or issuing specific commands (e.g., device-programmed voice prompts such as "open" and "close") to the voice control device 75.

[0035] According to one aspect of this disclosure, the proportional control valve can be automatically adjusted by a control module using control logic to (e.g., in the open or closed direction) adjust the valve to a position where equilibrium is achieved to maintain the differential pressure at a predetermined setting. For example, when valve element 20 is in the closed position, at each time increment (e.g., every 500 milliseconds), control module 60 can analyze pressure measurements from upstream pressure sensor 30 and downstream pressure sensor 40, comparing the corresponding pressure difference with a predetermined differential pressure setting (e.g., less than about 10 psi, or about 5 psi). When a differential pressure greater than the predetermined setting is detected, control module 60 can be configured to adjust the valve in the open direction to supply more water to the piping system, thereby increasing downstream pressure and reducing the differential pressure. Subsequent measurements of the differential pressure can cause the control module to further adjust the flow position of the valve element. When the differential pressure is detected to be greater than a predetermined setting, the valve element is adjusted in the opening direction to supply more water to the pipeline system H (to further increase the downstream pressure and reduce the differential pressure). When the differential pressure is detected to be less than the predetermined setting, the valve is adjusted in the closing direction to supply less water to the pipeline system (to reduce the downstream pressure and increase the differential pressure), until the predetermined differential pressure setting is reached.

[0036] In the adjusted flow rate position corresponding to a predetermined differential pressure setting at valve element 20, the instantaneous water consumption within the piping system can be identified as the flow rate through valve 10. Therefore, to determine the water consumption, control module 60 can be configured to determine the flow rate through valve 10 based on upstream and downstream pressures and valve element position (corresponding to a known effective flow coefficient Cv), for example, by using a lookup table stored in or otherwise accessible to control module 60, or by flow calculation (e.g., ...). To determine the flow rate.

[0037] When water use in the pipeline system H is stopped, the control module 60 will automatically move the valve element to the closed position in response to the reduced differential pressure measurement value corresponding to the cessation of water use.

[0038] Proportional control valves operated using control modules can offer additional features and advantages. For example, the control module can be configured to keep the valve in the closed position when upstream (utility) pressure exceeds a predetermined threshold, for example, to protect the piping system from overpressure. As another example, communication between the control module and a remote device (e.g., a smartphone) can allow for remote user control of the valve, for example, allowing a user to close the valve while away from home (e.g., in response to notification of unexpected water use or a potential leak). As yet another example, the control module can be configured to control the rate at which the valve opens and closes, for example, to reduce or prevent water hammer effects.

[0039] As another example, the control module can be configured to adjust a differential pressure setting, for example, to increase or decrease water pressure within the piping system. For instance, the differential pressure setting can be increased to reduce water pressure in the piping system during periods of low water usage or no water use (e.g., overnight or vacation mode), to extend appliance life or reduce the likelihood of appliance failure. As another example, during periods of high water demand (e.g., outdoor irrigation, filling a swimming pool or hot tub), the differential pressure setting can be decreased to increase water pressure.

[0040] A series of valve positions can be calibrated to correlate the flow coefficient of each valve position, enabling the control module to calculate the flow rate through the valve based on the upstream pressure, downstream pressure, and valve position (and its corresponding flow coefficient), and accordingly calculate the amount of water flowing out of the local piping system (e.g., due to the use of one or more water appliances or leakage from one or more leak points in the system) and the total water consumption (as the flow rate as an integral of time).

[0041] While many different types of proportional control valves can be used, in this exemplary embodiment, a valve with fine metering capabilities and a wide variety of flow settings can be selected to more accurately measure the flow through the valve with a control ratio (the ratio of maximum capacity to minimum capacity) of at least 100, at least 200, or at least 500. In this exemplary embodiment, an electronically actuated proportional control valve can be configured to be precisely controlled to provide a variety of flow coefficients (Cv) having a minimum Cv of no more than about 0.03 and a maximum (e.g., fully open) Cv of at least about 5.0. The electronically actuated proportional control valve can be configured to be precisely controlled to provide a variety of flow rates, for example, at a differential pressure of about 5 psi, with a minimum flow rate of no more than about 0.05 gpm and a maximum (e.g., fully open) flow rate of at least about 11.3 gpm for a control ratio of about 226. In such an arrangement, the monitoring system may be able to measure water consumption / leakage as low as 0.05 gpm and as high as 11.3 gpm.

[0042] For example, conventional flow meters used by municipal water supply departments typically cannot detect water usage at flow rates below approximately 0.25 gpm. The ability to measure extremely low water usage rates can advantageously allow municipalities or other entities to detect and measure low water usage that conventional volumetric flow meters cannot detect, for example, to properly allocate the costs associated with providing and treating this otherwise free water.

[0043] Figure 2 An exemplary embodiment of a proportional control valve assembly 100 is shown, the proportional control valve assembly 100 including: a valve body 110 having an inlet end 111 and an outlet end 112; a valve element 120 assembled with the valve body and disposed between the inlet end and the outlet end; and an electronically operated actuator 150 assembled with the valve body and operable to adjust the valve element to a plurality of flow positions between a closed position and a fully open position (i.e., the position of maximum flow, which may, but does not have to, be the extreme position of the valve element). The valve body 110 also includes a first pressure port 113 for receiving a first or upstream pressure sensor (schematically shown with reference numeral 130) in fluid communication with the inlet end 111, and a second pressure port 114 for receiving a second or downstream pressure sensor (schematically shown with reference numeral 140) in fluid communication with the outlet end 112.

[0044] While many different types of valve elements can be used, in the illustrated embodiment, valve element 120 includes an axially movable rod 121 having: an annular sealing portion 125 (e.g., an O-ring / gasket seal) that seals against an annular valve seat 115 in the valve body 110 when the valve rod 121 is in the closed position; and a tapered valve rod tip 126 that provides various flow states when the valve rod is adjusted between the closed and fully open positions.

[0045] While many different types of electronic actuators can be used, in the illustrated embodiment, the electronic actuator 150 includes a stepper motor 151, which is operated, for example, by actuating a signal transmitted from a processor, and has an internally threaded rotor 152 that rotates to axially move a rotationally fixed shaft 153 attached (e.g., via a reverse thread connection) to the valve stem 121, so that the valve stem can move axially without rotating the valve stem.

[0046] Many different valve bodies and valve elements can be configured. Figure 2In the valve assembly 100, the upstream port 111 is perpendicular to the axial travel of the valve element 120, while the downstream port 112 is coaxial with the valve element. In other embodiments, the axis of the valve sealing member may be angled relative to the inlet and outlet ends (e.g., between approximately 40° and approximately 50° relative to the inlet end), for example, to allow the valve to be installed on a straight section of the residential water supply main without requiring a separate water tap or conduit to reroute the valve's discharge back to the axis, thereby minimizing valve noise / pressure loss and / or reducing the overall height of the valve by maintaining the straightest possible flow path.

[0047] Figure 3-5 An exemplary embodiment of a proportional control valve assembly 200 is shown, comprising: a valve body 210 having an inlet end 211 and an outlet end 212; and a valve element 220 assembled with the valve body between the inlet and outlet ends and oriented at an angle (e.g., approximately 45°) relative to the inlet end. An electronically operated actuator 250 (e.g., a stepper motor device described herein) is assembled with the valve body 210, operatively connected to the valve element 220, and operable to adjust the valve element to a plurality of flow positions between a closed position and a fully open position (i.e., a maximum flow position, which may, but does not necessarily, be the extreme position of the valve element). The valve body 210 also includes: a first or upstream pressure sensor 230 mounted in a first pressure port 213 in the valve body and in fluid communication with the inlet end 211; and a second or downstream pressure sensor 240 mounted in a second pressure port 214 in the valve body and in fluid communication with the outlet end 212.

[0048] Valve element 220 includes an axially movable stem 221 having: an annular sealing portion 225 (e.g., an O-ring / gasket seal) that seals against an annular seat 215 in valve body 210 when the stem 221 is in the closed position; and a tapered stem tip 226 that provides various flow states (e.g., Cv between about 0.02 and about 5.07, or flow rates between about 0.05 gpm and about 11.34 gpm at a differential pressure of about 5 psi) when the stem is adjusted between the closed and fully open positions. Electronically operated actuator 250 includes a stepper motor 251, operated, for example, by actuating a signal transmitted from a processor, and has an internally threaded rotor 252 that rotates to axially move a rotating fixed shaft 253 attached (e.g., via a reverse thread connection) to the stem 221, thereby allowing axial movement of the stem without rotation of the stem.

[0049] In an exemplary embodiment, the electronically operated actuator 250 may be configured to move the valve stem in sufficiently small increments to provide very small valve flow rate differences, allowing the processor to measure and identify correspondingly small water consumption variations. While a wide range of incremental flow rate change resolutions may be suitably selected, in an exemplary embodiment, the electronically operated actuator 250 may be configured to move the valve stem 220 in increments of approximately 0.001”. In an exemplary embodiment, where a full flow or fully open state is achieved with a valve travel of approximately 0.350”, the electronically operated actuator 250 may be configured to move the valve stem 220 in increments of 0.001” over a total travel of approximately 0.375”. Figure 6 The relationship curve between valve Cv and valve stroke for an exemplary proportional control valve of this disclosure is shown. Figure 7 The diagram shows the flow rate versus valve stroke curves for exemplary valves in systems with differential pressure settings of approximately 5 psi and approximately 10 psi.

[0050] In some embodiments, a proportional control valve can be configured to reduce power consumption by decreasing the force required to actuate the valve element, for example by reducing the resistance of the system fluid to the axial movement of the valve element. In one such arrangement, the valve element may include a downstream radial surface exposed to a fluid pressure that applies an upstream bias force (positive pressure), which is configured to counteract or substantially balance a downstream (i.e., back pressure) bias force applied by the fluid pressure acting on the upstream radial surface of the valve element. This counteracting or balancing of the upstream and downstream bias forces can allow the use of a lower-energy (and potentially lower-cost) motor, enabling the possibility of using a backup battery, for example, to significantly reduce cost and power requirements, and / or to allow for extended operating time during power outages. This pressure-balanced valve element design can also reduce or eliminate hysteresis in the valve (e.g., deformation due to prolonged closing forces on the valve sealing elements) and enable repeatable, high-precision actuation of the valve.

[0051] Figure 8 An exemplary proportional control valve assembly 300 is shown, comprising: a valve body 310 having an inlet end 311 and an outlet end 312 (which is in fluid communication with an upstream pressure sensor and a downstream pressure sensor, not shown); and a pressure balancing valve element 320 assembled to the valve body between the inlet and outlet ends (e.g., substantially perpendicular to the inlet and outlet ends, or in any other suitable orientation). An electronically operated actuator (e.g., an exemplary stepper motor device described herein), schematically shown with reference numeral 350, is assembled to the valve body 310, operatively connected to the valve element 320, and operable to adjust the valve element to a plurality of flow positions between a closed position and a fully open position (i.e., the position of maximum flow, which may, but does not have to, be the extreme position of the valve element).

[0052] The pressure balancing valve element 320 includes an axially movable valve stem 321 having: an annular sealing portion 325 (e.g., an O-ring / gasket seal) that seals against an annular valve seat 315 in the valve body 310 when the valve stem 321 is in the closed position; and a tapered stem portion 326 that provides various flow states when the valve stem is adjusted between a closed position and a fully open position. The stem 321 includes an upstream piston portion 322 received in an upper bore 316 of the valve body 310 and sealed by a gasket 302, and a downstream piston portion 327 received in a lower bore 317 of the valve body and sealed by a gasket 303. The radial extensions of the annular sealing portion 325 and the tapered stem portion 326 define an upstream radial surface 323 of the upstream piston portion 322, while the downstream piston portion 327 defines a corresponding downstream radial surface 328. When valve 300 is actuated, the downstream radial surface 328 is exposed to fluid pressure that applies a positive pressure or valve opening bias force, which is configured to counteract or substantially balance the back pressure or valve closing bias force applied by the fluid pressure acting on the upstream radial surface 323 of valve stem 321. This counteracting or balancing of opening and closing bias forces may allow the use of lower-energy (and potentially lower-cost) motors or other such actuation mechanisms to facilitate the use of backup batteries, for example, to significantly reduce cost and power requirements, and / or allow for extended operating time during power outages.

[0053] exist Figure 2-5 and Figure 8 In one embodiment, valve elements 120, 220, 320 provide a closed state at a first limit position and a fully open state at a second limit position (i.e., the position of maximum flow). In other embodiments, the valve elements may be configured to provide a valve closed state at both actuation limits, for example, providing a fail-safe position in the event of overpressure in the piping system or actuator failure (e.g., a spring returning to the closed position upon power failure). Figure 9An exemplary proportional control valve assembly 400 is shown, comprising: a valve body 410 having an inlet end 411 and an outlet end 412 (which can be in fluid communication with an upstream pressure sensor and a downstream pressure sensor, not shown); and a double-seal valve element 420 assembled with the valve body between the inlet end and the outlet end and oriented at an angle (e.g., approximately 45°) relative to the inlet end. An electronically operated actuator 450 (e.g., an exemplary stepper motor device described herein) is assembled with a valve body 410, operatively connected to a valve element 420, and operable to axially adjust the valve element 420 to a plurality of flow positions between a first closed position and a second closed position, wherein in the first closed position, a first annular sealing portion 425 of the valve element (e.g., an O-ring / washer seal) seals against a first annular valve seat 415 in the valve body 410, and in the second closed position, a second annular sealing portion 429 of the valve element (e.g., an O-ring / washer seal) seals against a second annular valve seat 419 in the valve body 410. The tapered rod portion 426 provides various flow states as the valve stem is adjusted between the first and second closed positions.

[0054] According to another aspect of this disclosure, a water usage monitoring system, for example, utilizing software stored on a control module or provided in a remote software-based or network-based application (e.g., on a smartphone or computer), can analyze water usage data measured by the control module based on, for example, the difference between upstream and downstream pressures and calibrated valve positions, as described above, to identify water usage conditions within a local piping system. The water usage monitoring system can, for example, use a smartphone application or display connected to or remotely connected to the control valve device to communicate water usage data (e.g., flow rate, flow rate changing over time, total water usage) and other system conditions (e.g., upstream or downstream pressure) to the end user.

[0055] Water usage monitoring systems can additionally store water usage characteristic data, which is programmed into or learned by the monitoring system to correlate detected water usage with stored characteristics corresponding to one or more water appliances within the piping system. Water usage characteristic data can identify one or more water usage characteristics, such as instantaneous flow rate, flow rate over time, flow rate relative to pressure, flow duration, and total water usage during a water usage event. By correlating detected water usage with stored water usage characteristics, the monitoring system can identify the occurrence and type of a water usage event to the end user (e.g., indicating a faucet is not turned on or a toilet is stuck) or the total water usage of this event type over time (e.g., suggesting opportunities to reduce water usage). For example, the monitoring system can also identify potential leaks if the water usage data is not correlated with any known characteristics of water appliances within the piping system, or if the water usage data is consistent with a leak condition (e.g., a large, rapid pressure drop consistent with a burst pipe). When water usage data indicates a potential leak or accidental use of a water appliance (e.g., a faucet not running), the control module can be configured to automatically shut off a control valve, for example, to prevent water loss or unnecessary / unintended water usage.

[0056] Figure 10 An exemplary water monitoring system is schematically illustrated, comprising: control logic (phase 1) for controlling valve position based on sensed upstream and downstream pressures and stored valve position calibration data; and machine learning logic (phase 2) for identifying and specifying flow characteristic data for one or more water appliances within the piping system.

[0057] Figure 11 An exemplary water monitoring system 1000 is schematically illustrated, comprising: a proportional control valve 1100 (e.g., any of the exemplary valves described herein) having an inlet 1111 connected to a water source U (utility side) and an outlet 1112 connected to a local plumbing system H (household side); an electronically operated actuator 1150 having an upstream pressure sensor 1130 and a downstream pressure sensor 1140; and an actuator 1150 operable to adjust a valve element 1120 to various partially open positions (i.e., providing various flow rates or effective flow coefficients) between a closed position and a fully open position. A control module 1060 is operably connected to the pressure sensors 1130 and 1140 (e.g., via wired or wireless electronic communication to receive and process fluid pressure data) and communicates with the actuator 1150 to provide an actuation signal, for example, in response to user input or in response to sensed pressure data from the pressure sensors, to operate the actuator to adjust the valve element to a selected flow rate position between closed and fully open.

[0058] The local piping system H includes multiple water appliances 1210, 1220, 1230 (e.g., one or more faucets, showers, toilets, appliances, etc.) connected to the outlet end 1112 of the proportional control valve 1100, and can be normally closed to accommodate pressurized water H within the piping of the local piping system.

[0059] According to another aspect of this disclosure, water appliances 1210, 1220, and 1230 in the piping system H can be configured or adapted to produce different, detectable water flow characteristics during use (i.e., "passively marked" for the water appliance), such that the use of a particular water appliance can be identified by a water usage monitoring system as corresponding to a stored characteristic assigned to that water appliance. Some appliances inherently produce identifiable and unique water usage characteristics, such as toilets, which will produce a predictable flow rate (e.g., 2-3 gpm) for a predictable duration (e.g., 45-90 seconds). For other water appliances affected by variable user operation, such as showers or faucets, flow or pressure changing devices can be assembled with or incorporated into the water appliances to alter the flow or pressure characteristics, thereby producing significantly different water usage characteristics. In some applications, different flow / pressure changing devices can be used with the hot and cold water lines of a shower or faucet to distinguish the use of hot and cold water at the shower / faucet.

[0060] As part of the storage and identification of water usage characteristics, the system may employ an initialization process in which water characteristic data is measured, recorded, and associated with the corresponding water appliances. In such an initialization process, the user may be prompted (e.g., via an application on a smartphone or other mobile device, or an application on the touchscreen of the control module) to turn on the water appliance in the plumbing system and enter an identifiable name for the appliance in use (e.g., “main bathroom sink”, “guest toilet”). When the appliance is turned on, the control module measures and records flow-related data corresponding to the appliance's use (e.g., flow rate, duration, pressure, flow-time curve) to generate a water usage characteristic and associates the appliance name with this characteristic. In the case of water appliances equipped with flow / pressure changing devices, as described in more detail below, the system may additionally or alternatively prompt the user to enter an identification code for a specific flow / pressure changing device (e.g., via barcode scanning, serial number key input, etc.), store a predetermined water usage characteristic corresponding to the flow / pressure changing device, and associate the specified appliance name with the flow / pressure changing device's water usage characteristic. This process can be repeated for each water appliance in the system. After initialization, the monitoring system can use the specified water appliance name in the notification to the user to detect the water usage characteristics corresponding to the named water appliance.

[0061] Many different types of flow / pressure changing devices can be used. As an example, a pressure-compensating aerator (“PCA”) 1215 can be equipped with or installed with at least one water appliance 1210 and configured to generate a substantially constant flow rate across a range of system pressures (e.g., 40-80 psi). As another example, a conventional PCA includes a liquid connector fitted with an O-ring that deforms as fluid pressure increases to increasingly partially obstruct flow passages in the connector, thereby maintaining a substantially constant flow rate across a range of fluid pressures (e.g., a predetermined flow rate value between about 1 gpm and about 4 gpm, such as about 1.5 gpm). The control logic of the monitoring system can be configured to store flow data or water usage characteristics corresponding to the selected PCA 1215 and associate them with the water appliance 1210 to which the selected PCA is assembled, allowing the monitoring system to identify whether the water appliance is in use based on the detected corresponding water usage characteristics.

[0062] In such an arrangement, the water consumption monitoring system can be configured to control valve operation to perform a "search" across a range of pressure values, thereby using differential pressure and valve position flow coefficients (or, individual flow meters) to determine the flow rate across that range of piping system values ​​(e.g., as...). Figure 6 and 7 (As shown). By comparing this pressure-flow curve with the pressure-flow characteristics stored for water appliances in the piping system, water usage can be identified and attributed to the corresponding appliance. To differentiate multiple appliances from one another, different flow / pressure changing devices can be used for each appliance, resulting in pressure-flow curves with different slopes and / or amplitudes. In cases where the measured pressure-flow curve differs from the stored characteristics, the monitoring system can be configured to identify the corresponding water usage as a potential leak, or as water usage from an appliance that has not yet been identified (e.g., to generate and assign a new characteristic to be stored in the control module). The system may prompt the user (e.g., via SMS text prompts or audible / visual alarms at valves, control modules, or smartphones or other remote devices) to investigate this unidentified source of water usage. In some systems, in response to the immediate detection of an unidentified low water usage event (consistent with a leak or improper shut-off) immediately after the detection of usage at a particular appliance (e.g., due to the identification of a flow rate corresponding to an appliance-specific PCA or some other water characteristic), the system can provide an alarm indicating that the detected leak or improper shut-off may be related to that particular appliance.

[0063] As another example, water appliance 1220 may be equipped with a pressure- and time-dependent flow regulator (e.g., a check valve) 1225, which is configured to, for example, produce a flow rate profile that differs significantly over time due to changes in the internal flow path. For example, as Figure 12A As shown, the flow regulator check valve 1225a may be equipped with a spring 1226a having a selected strength / stiffness to provide a selected delay in the pressurized movement of the check valve seat 1227a, and a corresponding delay in the increase of flow through the water appliance 1220a. As another example, such as Figure 12B As shown, the flow regulator check valve 1225b may be additionally or alternatively equipped with an internal flow path profile 1228b (e.g., conical, stepped, or sinusoidal surface) configured to influence the time-dependent flow rate profile by providing a varying clearance between the flow path and the valve seat 1227b when using an associated water appliance. By measuring the flow rate over time (e.g., using differential pressure and valve position flow coefficients, or optionally a separate flow meter), instantaneous water usage is detected, and this flow rate versus time curve is compared with flow rate versus time characteristics stored for water appliances in the piping system. Water usage can be identified and attributed to the corresponding water appliance. To distinguish multiple water appliances from one another, a different flow regulator can be used for each appliance, resulting in flow rate versus time curves with different slopes and / or amplitudes. If the measured flow-time curve differs from the stored feature, the monitoring system can be configured to identify the corresponding water usage as a potential leak, or as water usage from appliances that have not yet been identified (e.g., to generate and specify a new feature to be stored in the control module).

[0064] Additionally or alternatively, one or more water appliances 1230 may be equipped with an active tag 1235 configured to generate a signal transmitted to the control module 1060 to identify the detected water usage corresponding to the signal appliance 1230. Examples may include one or more sensors (e.g., flow sensors, humidity sensors, vibration sensors) located at the water appliance 1230 and configured to transmit signals to the control module (e.g., wired or wireless transmission, direct or indirect transmission). In some embodiments, some water appliances in the piping system may use active tags, while other water appliances in the piping system may use passive tags for identification.

[0065] While the invention has been described through its embodiments, and these embodiments have been described in considerable detail, the applicant does not intend to limit the scope of the invention or in any way to these details. Further advantages and modifications will readily be apparent to those skilled in the art. Therefore, the inventive concept, in its broader aspects, is not limited to the specific details, representative devices, and illustrative examples shown and described. Thus, deviations from these details may be made without departing from the spirit or scope of the applicant's overall inventive concept.

Claims

1. A water usage monitoring system, comprising: A proportional control valve includes: a valve body having an inlet end and an outlet end; a valve element assembled with the valve body and disposed between the inlet end and the outlet end; and an electronically operated actuator assembled with the valve body and operable to adjust the valve element to a plurality of flow positions between a closed position and a fully open position. An upstream pressure sensor is in fluid communication with the inlet end; A downstream pressure sensor, which is in fluid communication with the outlet end; and A control module, operably connected to and communicating with an electronically operated actuator, wherein the control module is configured to operate the electronically operated actuator in response to pressure indication signals from the upstream and downstream pressure sensors to adjust the valve element to one of the plurality of flow positions to adjust the differential pressure across the valve element to match a predetermined differential pressure. The control module is configured to adjust the valve element to the closed position when no water is used, adjust the valve element in the opening direction when the pressure difference is greater than a predetermined pressure difference, and adjust the valve element in the closing direction when the pressure difference is less than the predetermined pressure difference, so as to adjust the pressure difference across the valve element to match the predetermined pressure difference.

2. The system of claim 1, wherein the predetermined pressure differential is less than 10 psi.

3. The system of claim 1, wherein the plurality of flow locations includes a minimum flow location that provides a flow rate of less than 0.05 gpm at a pressure differential of 5 psi.

4. The system according to any one of claims 1-3, wherein the fully open position provides a flow rate of at least 10 gpm at a pressure differential of 5 psi.

5. The system according to any one of claims 1-3, wherein the proportional control valve has a regulation ratio of at least 200.

6. The system according to any one of claims 1-3, wherein the valve element is arranged at an angle between 40° and 50° relative to the inlet end.

7. The system according to any one of claims 1-3, wherein the valve element includes a rod having a tapered flow regulating rod tip, the tapered flow regulating rod tip being capable of engaging an annular valve seat within the valve body when the valve element is in the closed position.

8. The system according to any one of claims 1-3, wherein the valve element comprises a threaded rod and the electronically operated actuator comprises a motorized rotary actuator.

9. The system according to any one of claims 1-3, wherein the closed position includes a first closed position at a first actuation limit of the valve element, and the valve element has a second closed position at a second actuation limit of the valve element.

10. The system according to any one of claims 1-3, wherein the electronic actuator is configured to automatically move the valve element to the closed position in response to a power outage of the electronic actuator.

11. A method for monitoring fluid usage in a fluid system, the method comprising: A proportional control valve is provided, which includes a valve element that can be operated to control fluid flow from a fluid source to a fluid system. A first pressure upstream of the valve element and a second pressure downstream of the valve element are measured to identify the pressure difference across the valve element; In response to the identified differential pressure, the proportional control valve is adjusted to one of a plurality of flow positions to adjust the differential pressure across the valve element to match a predetermined differential pressure, wherein the plurality of flow positions include a closed position and a fully open position; The flow rate through the proportional control valve is determined based on the first pressure, the second pressure, and the adjusted flow position of the valve element. and Based on the flow rate that is determined over time, the fluid usage in the fluid system is determined. Specifically, the valve element is adjusted to the closed position when no water is used, the valve element is adjusted in the opening direction when the pressure difference is greater than a predetermined pressure difference, and the valve element is adjusted in the closing direction when the pressure difference is less than the predetermined pressure difference, so as to adjust the pressure difference across the valve element to match the predetermined pressure difference.

12. The method of claim 11, wherein measuring the first pressure and the second pressure comprises transmitting an upstream pressure signal and a downstream pressure signal, which are in fluid communication with the inlet and outlet of the proportional control valve, to a control module.

13. The method of claim 12, wherein the proportional control valve includes an electronically operated actuator operable to adjust the valve element, wherein adjusting the proportional control valve includes transmitting a control signal from the control module to the electronically operated actuator.

14. The method according to any one of claims 11-13, wherein the predetermined pressure differential is less than 10 psi.

15. The method according to any one of claims 11-13, wherein the plurality of flow locations includes a minimum flow location that provides a flow rate of less than 0.05 gpm at a pressure differential of 5 psi.

16. The method according to any one of claims 11-13, wherein the fully open position provides a flow rate of at least 10 gpm at a pressure differential of 5 psi.

17. The method according to any one of claims 11-13, wherein the proportional control valve has a regulation ratio of at least 200.

18. The method according to any one of claims 11-13, further comprising comparing the determined flow rate with flow characteristics stored for a plurality of devices in a fluid system to identify whether one of the plurality of devices has been used.

19. The method of claim 18, wherein when a fluid usage consistent with a leak is measured after one of the plurality of appliances has been identified as being in use, a user communication indicating that a leak has occurred at said one of the plurality of appliances is generated.

20. The method of any one of claims 11-13, further comprising comparing a flow rate determined over time with one or more thresholds corresponding to improper fluid usage, and generating a user communication indicating improper fluid usage in response to the flow rate determined over time exceeding one of the one or more thresholds.

21. The method according to any one of claims 11-13, further comprising comparing a flow rate determined over time with one or more thresholds corresponding to an improper fluid usage, and automatically moving the proportional control valve to a closed position in response to the flow rate determined over time exceeding one of the one or more thresholds.

22. A method for identifying water appliances used in a piping system, the piping system including at least a first water appliance and a second water appliance operable to supply water from a water source, the method comprising: A first flow modulation device is provided having a first water appliance, wherein the first flow modulation device is configured to provide a first identifiable flow characteristic corresponding to the use of the first water appliance; Measure the flow rate from the water source to the pipeline system; and The measured flow rate is compared with the first identifiable flow rate feature to identify whether the first water appliance was used. The measurement of flow rate from the water source to the pipeline system includes: A proportional control valve is provided, which includes a valve element that can be operated to control the flow of fluid from a water source to a piping system. A first pressure upstream of the valve element and a second pressure downstream of the valve element are measured to identify the pressure difference across the valve element; In response to the identified differential pressure, the proportional control valve is adjusted to one of a plurality of flow positions to regulate the differential pressure across the valve element to match a predetermined differential pressure; and The flow rate through the proportional control valve is determined based on the first pressure, the second pressure, and the adjusted flow position of the valve element. Specifically, the valve element is adjusted to the closed position when no water is used, the valve element is adjusted in the opening direction when the pressure difference is greater than a predetermined pressure difference, and the valve element is adjusted in the closing direction when the pressure difference is less than the predetermined pressure difference, so as to adjust the pressure difference across the valve element to match the predetermined pressure difference.

23. The method of claim 22, wherein measuring the first and second pressures comprises transmitting upstream and downstream pressure signals from an upstream pressure sensor and a downstream pressure sensor in fluid communication with the inlet and outlet of the proportional control valve to a control module.

24. The method of claim 23, wherein the proportional control valve includes an electronically operated actuator operable to adjust the valve element, wherein adjusting the proportional control valve includes transmitting a control signal from the control module to the electronically operated actuator.

25. The method of claim 22, further comprising altering the water supply from the water source to the piping system to apply water pressure to the piping system across a predetermined series of pressure values, wherein the first flow modulation device is configured to provide a first identifiable flow characteristic across the predetermined series of pressure values.

26. The method according to any one of claims 22-25, wherein the first flow modulation device comprises a pressure-compensated inflator.

27. The method according to any one of claims 22-25, wherein the first flow modulation device comprises a pressure and time-dependent flow regulator.

28. The method of claim 27, wherein the pressure and time-dependent flow regulator includes a check valve, and the first identifiable flow characteristic includes an identifiable flow curve corresponding to the movement of the check valve from a closed position to an open position.

29. The method according to any one of claims 22-25, further comprising providing a second flow modulation device for the second water appliance, wherein the second flow modulation device is configured to provide a second identifiable flow characteristic corresponding to the use of the second water appliance, and to compare the measured flow rate with the second identifiable flow characteristic to identify whether the second water appliance has been used.

30. The method according to any one of claims 22-25, further comprising providing a sensor for the second water appliance to identify whether the second water appliance has been used.

31. The method of claim 30, wherein the sensor comprises at least one of a flow sensor, a pressure sensor, a humidity sensor, and a vibration sensor.

Images