Control method of water softener and water softener

Abstract

The invention discloses a control method of a water softener and the water softener, and belongs to the technical field of water softening treatments.According to the control method, the water injection and salt absorption process is directly metered through a two-way flowmeter, a traditional estimation mode based on fixed time is replaced, the water quantity metering error caused by water pressure fluctuation and pipeline state change is eliminated, and the water softener quality is improved. Therefore, the control precision of the saline water injection amount and the saline water absorption amount is obviously improved. Secondly, due to the introduction of a liquid level sensor and cooperative judgment with flow data, real-time verification and safety monitoring of the state in the water injection and salt absorption process are achieved; monitoring data can be used as effective supplement and verification of flow meter data, a fault-tolerant control basis is provided when a flow meter is abnormal, a switch can be directly triggered to act through a liquid level threshold value, a mechanical safety valve is replaced functionally, overflow prevention and air suction prevention protection is achieved, and the safety of the flow meter is improved. Therefore, the structure of the salt box is simplified while the control reliability is improved.

Description

Technical Field

[0001] This application relates to the field of water softening technology, and in particular to a control method for a water softener and a water softener. Background Technology

[0002] A water softener is a water treatment device that removes calcium and magnesium ions from water using ion exchange resin. Its core working cycle includes two stages: water production and regeneration. In the water production stage, raw water flows through the resin tank, and the hardness ions in the water are adsorbed by the resin. When the resin's adsorption capacity approaches saturation, the regeneration stage is required. Water is injected into the brine tank to form brine, and the brine is drawn into the resin tank to regenerate the resin and restore its softening capacity.

[0003] During the regeneration phase, precise control of the water volume in the brine tank is crucial for both water injection and brine absorption. Traditional methods typically rely on timing and mechanical components, such as estimating the injection volume at fixed intervals and using independent mechanical float-type safety valves to prevent overflow. However, these methods are susceptible to fluctuations in water pressure and pipeline conditions, resulting in limited control accuracy and increased structural complexity. Therefore, improving the accuracy and reliability of brine tank water volume control during regeneration has become a pressing issue. Summary of the Invention

[0004] This application provides a control method and a water softener for a water softener, which improves the accuracy of brine tank water volume control and at least partially solves the above-mentioned technical problems.

[0005] To achieve the above objectives, according to a first aspect of this application, a control method for a water softener is provided. The water softener includes a brine tank, a brine circuit switch, a level sensor disposed within the brine tank, and a bidirectional flow meter disposed in the flow path of the brine tank. The control method includes: Water injection step: Control the salt circuit switch to open to inject water into the salt tank, and obtain the metering data from the bidirectional flow meter and the monitoring data from the liquid level sensor; Salt absorption step: Control the salt circuit switch to open to absorb salt from the salt tank, and obtain metering data from the bidirectional flow meter and monitoring data from the liquid level sensor; In the water injection step and / or the salt absorption step, the salt circuit switch is controlled to close based on the metering data of the bidirectional flow meter and the monitoring data of the liquid level sensor.

[0006] In some embodiments, during the water injection step, when the bidirectional flow meter measures the water flow and the level sensor detects a continuous rise in the liquid level, the salt circuit switch is controlled to close based on the measurement data of the bidirectional flow meter to reach a preset water injection volume.

[0007] In some embodiments, during the water injection step, if the bidirectional flow meter measures water flow but the level sensor detects a continuous drop in the level, a control valve reset operation of the water softener is performed.

[0008] In some embodiments, during the water injection step, if the bidirectional flow meter does not measure water flow but the level sensor detects a continuous rise in the liquid level, the system switches to a control mode based on water injection time to control the closure of the salt circuit switch.

[0009] In some embodiments, during the salt absorption step, when the bidirectional flow meter measures the water flow and the level sensor detects a continuous drop in the liquid level, the salt circuit switch is controlled to close based on the measurement data from the bidirectional flow meter.

[0010] In some embodiments, during the brine extraction step, if the bidirectional flow meter measures water flow but the level sensor detects a continuous rise in the liquid level, a control valve reset operation of the water softener is performed.

[0011] In some embodiments, during the salt absorption step, if the bidirectional flow meter does not measure water flow but the level sensor detects a continuous drop in the liquid level, the system switches to determine the salt absorption endpoint based on the monitoring data from the level sensor and controls the salt circuit switch to close.

[0012] In some embodiments, the water softener further includes a pressure sensor; In the water injection step or the salt absorption step, if neither the bidirectional flow meter nor the liquid level sensor obtains valid monitoring data, the corresponding fault handling procedure is executed based on the pressure detection value of the pressure sensor.

[0013] In some embodiments, executing a corresponding fault handling procedure based on the pressure detection value of the pressure sensor includes: If the pressure detection value is lower than the preset minimum pressure threshold, the system will either wait for the pressure to recover or issue an alarm. If the pressure detection value is not lower than the preset minimum pressure threshold, attempt to control the salt circuit switch and / or control valve to perform a reset operation.

[0014] In some embodiments, during the water injection step, if the bidirectional flow meter measures the water flow and the liquid level sensor detects no change in the liquid level, it is determined that the liquid level sensor is abnormal. And / or, In the salt absorption step, if the bidirectional flow meter measures the water flow and the liquid level sensor detects no change in the liquid level, the liquid level sensor is determined to be abnormal.

[0015] In some embodiments, the control method further includes a backwashing step; During the backwashing step, the real-time flow rate at the inlet is monitored, and the backwashing time is automatically extended when the real-time flow rate is lower than a rated backwash flow rate but higher than a minimum backwash flow rate at the end of the set backwashing time.

[0016] In some embodiments, the control method further includes a forward washing step; During the forward washing step, the real-time flow rate at the inlet is monitored, and the forward washing time is automatically extended when the real-time flow rate is lower than a rated forward washing flow rate but higher than a minimum forward washing flow rate at the end of the set forward washing time.

[0017] In some embodiments, during the backwashing step, when the set backwashing time ends and the real-time flow rate is lower than a minimum backwash flow rate, a judgment is made based on the inlet water pressure value; when the inlet water pressure value is higher than a pressure threshold, the control valve is reset and the system is restarted to the backwashing position.

[0018] In some embodiments, during the forward washing step, when the set forward washing time ends and the real-time flow rate is lower than a minimum forward washing flow rate, a judgment is made based on the inlet water pressure value; when the inlet water pressure value is higher than a pressure threshold, the control valve is reset and the system is restarted to the forward washing position.

[0019] In some embodiments, after performing the operation of resetting the control valve and running it backwash or forward wash again, if the real-time flow rate is still detected to be lower than the minimum backwash flow rate or the minimum forward wash flow rate and the inlet water pressure value is higher than the pressure threshold, an equipment check reminder is issued and the corresponding backwash or forward wash time is automatically extended again.

[0020] In some embodiments, the control method further includes a pipeline status monitoring step: Control the water softener to switch to the water supply off state; Within a preset pressure holding time, pressure changes in the pipeline network are monitored by a pressure sensor; If the pressure change exceeds a preset threshold, a leak is determined to exist in the pipeline network.

[0021] According to a second aspect of this application, a water softener is provided, including a control module, a brine tank, a brine circuit switch, a liquid level sensor disposed in the brine tank, and a bidirectional flow meter disposed in the flow path of the brine tank; The control module is configured to execute the control method of the water softener as described in any of the above embodiments.

[0022] In the control method of the water softener in this application embodiment, a bidirectional flow meter is used to directly measure the water injection and brine absorption processes, replacing the traditional estimation method based on fixed time. This eliminates water volume measurement errors caused by water pressure fluctuations and pipeline status changes, thereby significantly improving the control accuracy of the injected and absorbed brine volumes. Secondly, the introduction of a liquid level sensor and its collaborative judgment with flow data enables real-time verification and safety monitoring of the water injection and brine absorption processes. Its monitoring data not only serves as an effective supplement and verification of flow meter data, providing fault-tolerant control basis when the flow meter malfunctions, but also directly triggers switching actions through liquid level thresholds. Functionally, it replaces the mechanical safety valve, achieving overflow and cavitation protection, thereby improving control reliability while simplifying the brine tank structure.

[0023] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.

[0026] Figure 1 This is a flowchart illustrating the control method of a water softener provided in one embodiment of this application; Figure 2 This is a control logic flowchart of the water injection step provided in one embodiment of this application; Figure 3 This is a control logic flowchart of the salt absorption step provided in one embodiment of this application; Figure 4 This is a flowchart of the fault handling logic provided in one embodiment of the present application when both the bidirectional flow meter and the liquid level sensor fail. Figure 5 This is a schematic diagram of the structure of a water softener provided in a specific example of this application; Figure 6 yes Figure 5 A schematic diagram of the flow path structure of the water softener in the illustrated embodiment; Figure 7 yes Figure 5 A schematic diagram of the flow path structure of the dual-tank valve in the illustrated embodiment; Figure 8 yes Figure 5A schematic diagram of the flow path of the water softener in the water injection state in the illustrated embodiment; Figure 9 yes Figure 5 The illustrated embodiment shows a flow path diagram of a water softener operating with one tank supplying water and the other tank absorbing brine. Figure 10 yes Figure 5 The illustrated embodiment shows another flow path diagram of the water softener in a state where one tank supplies water and the other tank absorbs brine. Figure 11 yes Figure 5 The illustrated embodiment shows a flow path diagram of a water softener operating under a single tank supply and a single tank backwashing configuration. Figure 12 yes Figure 5 The illustrated embodiment shows a flow path diagram of a water softener operating under a state of one tank supplying water and one tank performing a forward wash. Figure 13 yes Figure 5 The illustrated embodiment shows a schematic diagram of the water softener in the off-water state.

[0027] Explanation of reference numerals in the attached figures: 100 - Dual-tank valve; 113 - Inlet; 114 - Outlet; 120 - First control component; 121 - First grille; 122 - First piston; 130 - First chamber; 131 - First inlet chamber; 132 - First outlet chamber; 133 - First water passage chamber; 134 - First connecting chamber; 135 - Second connecting chamber; 136 - Third connecting chamber; 137 - Fourth connecting chamber; 138 - Third water passage chamber; 139 - Fourth water passage chamber; 140 - Fifth water passage chamber; 150 - Second control component; 151 - Second grille; 152 - Second piston; 160 - Second chamber ; 161-Second inlet chamber; 162-Second outlet chamber; 163-Second flow chamber; 164-Sewage discharge chamber; 165-Brine suction chamber; 166-Bypass chamber; 170-Flow passage; 180-Brine ejector; 190-Bridging passage; 200-Resin tank; 200a-First resin tank; 200b-Second resin tank; 210-Processing chamber; 210a-First processing chamber; 210b-Second processing chamber; 220-Central pipe; 220a-First central pipe; 220b-Second central pipe; 300-Brine tank; 400-Brine circuit switch; 500-Bidirectional flow meter. Detailed Implementation

[0028] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the protection scope of this application.

[0029] This application provides a control method for a water softener, aiming to improve the accuracy and reliability of water volume control in the brine tank 300 during the regeneration process. Please refer to... Figure 1 This illustrates the basic flow of a water softener control method in one embodiment of this application. The control method mainly involves two core steps in the regeneration process: the water injection step and the brine absorption step.

[0030] During the water filling process, the control module of the water softener controls the brine circuit switch 400 to open, thereby filling water into the brine tank 300. Simultaneously, the control module acquires metering data from the bidirectional flow meter 500 located in the flow path of the brine tank 300, as well as monitoring data from the liquid level sensor located within the brine tank 300.

[0031] During the brine extraction step, the control module activates the brine circuit switch 400, thereby drawing brine from the brine tank 300. Similarly, the control module simultaneously acquires metering data from the bidirectional flow meter 500 and monitoring data from the level sensor during this process.

[0032] The core of this control method lies in the fact that, during the water injection and brine absorption steps, the control module does not rely on a single signal, but rather on a collaborative judgment based on both the metering data from the bidirectional flow meter 500 and the monitoring data from the liquid level sensor, ultimately controlling the closing timing of the brine circuit switch 400. This collaborative control strategy enables more precise and reliable management of the water volume in the brine tank 300.

[0033] This control method can be applied to water softeners that require regeneration functions, such as dual-tank or single-tank water softeners. Whether dual-tank or single-tank, the basic components include a control module, a brine tank 300, a brine circuit switch 400 for connecting or disconnecting the flow path between the brine tank 300 and the main water path, a level sensor installed inside the brine tank 300, and a bidirectional flow meter 500 installed on the water supply or brine suction pipeline of the brine tank 300.

[0034] Specifically, for Figure 5 , Figure 6The dual-tank water softener shown typically includes two resin tanks 200, a dual-tank valve 100, and a brine tank 300. The control module (not shown separately) can be integrated into the dual-tank valve 100 or set up independently. A brine circuit switch 400 is located on the dual-tank valve 100 or on the water injection or brine suction line between the dual-tank valve 100 and the brine tank 300. A level sensor (not shown separately) and a bidirectional flow meter 500 are arranged around the brine tank 300. The level sensor can be located inside the brine tank 300, and the bidirectional flow meter 500 can be located on the water injection or brine suction line to perform the aforementioned water injection and brine suction control. In some embodiments, the dual-tank water softener may not have the aforementioned dual-tank valve 100. Instead, it may use a distributed valve system consisting of multiple valves and pipelines to form the water circuit regulating component. These valves can be single-tank valves, with water circuit regulation achieved through the combination of at least two single-tank valves. They can also be various on / off valves or regulating valves, such as solenoid valves, electric ball valves, etc., or ceramic disc valves. By setting the pipeline connection relationship between these valves and connecting them to the processing chamber 210 and the central pipe 220 of the two resin tanks 200 respectively, a physical flow path with the same function as the dual-tank valve 100 can be constructed.

[0035] For single-tank water softeners, a simplified structure can also be referenced. Figure 5 Understood, but it only includes a resin tank 200 and a corresponding single-tank valve, which also has a brine tank 300 and the aforementioned brine circuit switch 400, level sensor, and bidirectional flow meter 500, etc. Therefore, the control method of this application is also applicable. Correspondingly, a single-tank water softener can also use a distributed valve system to form a water circuit regulating component, as long as it achieves the same physical flow path control function as the single-tank valve.

[0036] In subsequent embodiments, the main focus will be on Figures 5 to 12 Taking the dual-tank water softener shown as an example, and considering its specific flow path structure, the detailed steps and principles of this control method will be further explained. It is understood that this control logic is also applicable to single-tank water softeners; the principle remains the same, only the interface and linkage with the water circuit valves are simplified according to the single-tank structure.

[0037] Please refer to the following: Figure 6 and Figure 7 As shown in the example, the dual-tank water softener mainly includes two resin tanks 200, a dual-tank valve 100, and a brine tank 300. The dual-tank valve 100, as the core water circuit regulating component, connects and controls the water flow direction between the two resin tanks 200 and the inlet, outlet, and sewage pipes.

[0038] The dual-tank valve 100 includes a valve body. The valve body has an inlet 113 and an outlet 114 for connecting to an external water supply network and the user's water supply terminal. The valve body has two valve chambers inside, designated as a first valve chamber and a second valve chamber.

[0039] A first control assembly 120 is provided within the first valve chamber. The first control assembly 120 includes a fixed first grille 121 and a first piston 122 that is axially movable within it. The first grille 121 divides the first valve chamber axially into a series of independent first chambers 130. These first chambers 130 are arranged sequentially along the axial direction, including: a first inlet chamber 131 communicating with an inlet 113; a first outlet chamber 132 communicating with an outlet 114; a first water passage chamber 133; a first connecting chamber 134 for communicating with a first processing chamber 210a of a first resin tank 200a; a second connecting chamber 135 for communicating with a first central tube 220a of the first resin tank 200a; a third connecting chamber 136 for communicating with a second processing chamber 210b of a second resin tank 200b; and a fourth connecting chamber 137 for communicating with a second central tube 220b of the second resin tank 200b. In addition, it also includes a third water passage 138 that is connected to the second connecting cavity 135 through a cross passage 190 provided on the valve body, a fourth water passage 139 that is connected to the third connecting cavity 136 through another cross passage 190 provided on the valve body, and a fifth water passage 140.

[0040] Within the second valve chamber, a second control assembly 150 is correspondingly provided, including a second grille 151 and a second piston 152. The second grille 151 also divides the second valve chamber into multiple second chambers 160. These second chambers 160 mainly include: a second inlet chamber 161 connected to the first inlet chamber 131 via a flow passage 170; a second outlet chamber 162 connected to the first outlet chamber 132; a second flow passage chamber 163 connected to the first flow passage chamber 133; a drain chamber 164 connected to a drain port on the valve body; and a brine suction chamber 165 connected to the fifth flow passage chamber 140. The brine suction chamber 165 is used to connect to the brine suction outlet of a brine suction jet 180, while the second outlet chamber 162 provides a power water source for the brine suction jet 180. In addition, a bypass cavity 166 is provided between the second inlet cavity 161 and the second outlet cavity 162. This bypass cavity 166 can be activated when it is necessary for the water flow to bypass the resin tank 200. The first valve cavity and the second valve cavity are connected by multiple flow channels 170 formed inside the valve body.

[0041] Two resin tanks 200 are connected to the dual-tank valve 100 via corresponding interfaces. Each resin tank 200 has a processing chamber 210 filled with ion exchange resin and a central tube 220. The processing chamber 210 and central tube 220 of one resin tank 200 (i.e., the aforementioned first resin tank 200a) are connected to the first connecting chamber 134 and the second connecting chamber 135 of the dual-tank valve 100, respectively; the processing chamber 210 and central tube 220 of the other resin tank 200 (i.e., the aforementioned second resin tank 200b) are connected to the third connecting chamber 136 and the fourth connecting chamber 137, respectively.

[0042] By precisely driving the first piston 122 and the second piston 152 in their respective valve chambers through the control module, the connection relationship between the above-mentioned chambers can be changed in combination, thereby constructing a variety of working modes and the water circuit states required for backwashing, salt absorption, forward washing, water injection, etc. in the regeneration process.

[0043] The brine tank 300 is connected to the brine suction path of the dual-tank valve 100 via a pipeline. A level sensor is installed inside the brine tank 300 to monitor changes in the water level. A bidirectional flow meter 500 is installed on the water supply or brine suction pipeline of the brine tank 300 to accurately measure the amount of water flowing into or out of the brine tank 300. A brine circuit switch 400, which controls the connection between the brine tank 300 and the main water circuit, is also located on this pipeline. In this embodiment, the brine tank 300 does not rely on a traditional mechanical float safety valve to achieve the overflow prevention function.

[0044] The control module is electrically connected to all electronic control components, including the level sensor, the bidirectional flow meter 500, the salt circuit switch 400, and the motor driving the piston, and is configured to execute the control methods described in detail later.

[0045] Please see Figure 2 This document illustrates the detailed control logic of the water injection step in one embodiment of this application. When the water softener needs to inject water into the brine tank 300, the control module controls the brine circuit switch 400 to open, allowing softened water (or raw water) from the main water circuit of the water softener to flow through the pipeline to the brine tank 300. The internal flow path state of the water softener corresponding to this water injection process can be found in [reference needed]. Figure 8 .exist Figure 8 In the state shown, the water softener operates in a mode where the first resin tank 200a and the second resin tank 200b are connected in series to produce water, while simultaneously filling the brine tank 300 with water. A portion of the produced soft water is guided into the brine tank 300 to dissolve salt particles by the brine ejector 180.

[0046] As the salt circuit switch 400 is turned on, the control module begins to acquire and monitor data from two key sensors in real time: one is the water flow data measured by the bidirectional flow meter 500 installed on the water supply pipeline of the salt tank 300, and the other is the liquid level change data monitored by the liquid level sensor installed inside the salt tank 300.

[0047] During a typical, successful water filling process, the bidirectional flow meter 500 continuously measures the water flow signal, indicating that the water supply pipeline is unobstructed. Simultaneously, the level sensor monitors a continuous rise in the liquid level within the brine tank 300 over time, directly confirming that water is being successfully injected into the brine tank 300.

[0048] The control module compares the cumulative flow value measured by the bidirectional flow meter 500 with a preset target water injection volume. This preset water injection volume is pre-set based on factors such as the brine concentration required for the regeneration process. When the control module determines that the cumulative flow data of the bidirectional flow meter 500 has reached the preset water injection volume, it indicates that the amount of water injected into the brine tank 300 has met the requirements. At this point, the control module immediately issues a command to control the brine circuit switch 400 to close, thereby precisely terminating the water injection process.

[0049] This control process achieves precise metering and control of the water injection volume, based on data from a bidirectional flowmeter 500 that directly measures the water flow volume. Simultaneously, a continuously rising liquid level signal from a level sensor serves as a crucial process status verification, corroborating the flow data to jointly ensure the normal execution and accurate termination of the water injection process.

[0050] In some embodiments, during water injection, the control module continuously acquires data from the bidirectional flow meter 500 and the level sensor. One possible anomaly is that the bidirectional flow meter 500 can measure a water flow signal, indicating water flow in the pipeline, but the level in the brine tank 300 monitored by the level sensor does not rise as expected, but instead shows a continuous downward trend. This contradiction between the flow signal and the level change trend indicates that the water injection process may not be proceeding as expected. For example, there may be an inaccurate valve position or other malfunctions, causing water to not be correctly introduced into the brine tank 300, or there may be an unexpected leak in the brine tank 300.

[0051] When the control module detects a signal combination where the bidirectional flow meter 500 is measuring water flow while the liquid level is continuously decreasing, it determines that an anomaly has occurred in the water injection process. Upon this determination, the control module will execute a corrective operation, triggering a reset of the control valve. This reset operation aims to return the internal piston and other moving parts of the control valve to a preset initial position or a known state, eliminating potential water path misalignment caused by inaccurate valve positioning. After the reset, the system can, according to the program settings, attempt to restart the water injection process or enter a further fault diagnosis state. By introducing a mechanism for detecting contradictory signals and an automatic reset mechanism, this control method helps to promptly interrupt the abnormal process and attempt to correct it when sensor data indicates that the water injection behavior is significantly inconsistent with expectations, in order to restore the system to a normal and controllable state.

[0052] In some embodiments, during water injection, the control module continuously monitors data from the bidirectional flow meter 500 and the level sensor. It is possible that the level sensor clearly detects a continuous and stable rise in the liquid level within the brine tank 300, which directly indicates that water is being injected into the brine tank 300 and the fundamental purpose of water injection is being achieved. However, simultaneously, the bidirectional flow meter 500 fails to provide a valid flow metering signal. This combination of sensor data indicates that the water injection action itself is being performed and is effective, but the bidirectional flow meter 500 used to measure the water volume may have experienced a temporary or permanent failure, preventing it from performing its normal metering function.

[0053] When the control module detects a situation where the liquid level is continuously rising but the flow meter has no valid signal, it determines that the bidirectional flow meter 500 is in a malfunctioning state. In this case, the system can no longer rely on the cumulative data from the flow meter to determine whether the water injection volume is up to standard. As a fault-tolerant control strategy, the control module will automatically switch to a control mode based on water injection time.

[0054] In this mode, the control module controls the closing of the salt circuit switch 400 based on a preset water injection duration. This preset duration can be estimated based on the normal water injection flow rate and the required water volume. Switching to time control mode allows the system to maintain its operational capability by using an alternative and predictable method to largely control the water injection process and complete the basic steps required for regeneration, even in the event of a core metering instrument failure. This improves the fault tolerance of the control system in the face of a single sensor failure.

[0055] In a specific example, during the water injection step, the control module acquires the flow rate S from the bidirectional flow meter 500 and the liquid level change Δ from the level sensor. When the bidirectional flow meter 500 detects the flow rate S and the level sensor detects Δ > 0, the water injection process is considered normal; the water injection volume is controlled based on the bidirectional flow meter 500 reaching the preset water injection volume, at which point the salt circuit switch 400 is closed. If the bidirectional flow meter 500 detects the flow rate S, but the level sensor detects Δ < 0, the water injection is considered abnormal, and the control module performs a control valve reset operation and attempts to inject water again. If the bidirectional flow meter 500 does not detect a valid flow signal, but the level sensor detects Δ > 0, the bidirectional flow meter 500 is considered faulty, and the control module switches to a control mode based on a preset water injection time Hs. After the water injection time Hs is reached, the salt circuit switch 400 is closed to complete the water injection.

[0056] Please see Figure 3 The control logic for the salt absorption step is shown below. The control logic for normal sensor signals during the salt absorption process is explained below.

[0057] When the water softener needs to draw brine from the brine tank 300 for resin regeneration, the control module activates the brine circuit switch 400. The internal flow path status of the water softener corresponding to this brine drawing process can be found in [reference needed]. Figure 9 or Figure 10 In these states, the water softener operates in a mode where one resin tank 200 produces water, and the other resin tank 200 uses the produced soft water for brine regeneration. The soft water produced by the production tank serves as the power source, and under the action of the brine jet 180, it draws in the brine from the brine tank 300 and transports it to the resin tank 200 to be regenerated.

[0058] When the salt circuit switch 400 is turned on, the control module acquires and monitors relevant sensor data: namely, the flow rate value S monitored by the bidirectional flow meter 500, and the liquid level change value Δ monitored by the liquid level sensor.

[0059] During a typical and successful brine extraction process, the bidirectional flow meter 500 can monitor an effective flow rate value S, indicating that brine is being extracted and the flow path is unobstructed. Simultaneously, the level sensor detects a continuous decrease in the liquid level within the brine tank 300, i.e., Δ < 0, which directly confirms that brine is being extracted from the brine tank 300.

[0060] The control module compares the accumulated flow rate S from the bidirectional flow meter 500 with a preset target value for brine absorption. This target value is set based on the amount of brine required for regeneration. When the control module determines that the accumulated flow rate S has reached the target value for brine absorption, it considers the required brine absorption to be met. At this point, the control module issues a command to close the brine circuit switch 400, thereby ending the brine absorption process.

[0061] This control process primarily relies on the direct measurement of the brine volume by the bidirectional flowmeter 500, achieving precise control over the brine absorption rate. The continuously decreasing liquid level signal provided by the level sensor serves as real-time verification of the ongoing brine absorption process. Working in conjunction with the flow data, this ensures the accurate execution and termination of the brine absorption process.

[0062] In some embodiments, during the brine extraction process, the control module continuously acquires the flow rate value S monitored by the bidirectional flow meter 500 and the liquid level change value Δ monitored by the liquid level sensor. A possible anomaly is that the bidirectional flow meter 500 detects a valid flow rate value S, indicating liquid flow in the pipeline; however, the liquid level change value Δ in the brine tank 300 fed back by the liquid level sensor is greater than zero, indicating a continuous rise in the liquid level. This signal combination indicates that the flow rate data and the liquid level change trend are contradictory. During normal brine extraction, the liquid level should decrease as brine is extracted. The liquid level rising instead of decreasing may mean that the brine extraction flow path is not correctly established. For example, the internal piston of the control valve may not have moved accurately to the brine extraction working position, resulting in an incorrect water circuit connection, causing water to be accidentally directed to the brine tank 300 for filling instead of extracting brine.

[0063] When the control module detects a situation where the flow rate S is valid but the liquid level change Δ > 0, it determines that an anomaly has occurred in the brine suction process. Based on this determination, the control module will execute a reset operation on the control valve. This operation aims to return the internal piston assembly of the control valve to its reference position to correct any potential valve position deviation. After the reset is complete, the system can, according to the program settings, attempt to run back to the correct brine suction position and restart the brine suction process. By introducing a detection and automatic error correction mechanism for such contradictory signals, this control method helps to intervene in a timely manner when brine suction behavior deviates from expectations, attempting to restore the process to its normal state.

[0064] In some embodiments, during the brine extraction process, the control module continuously acquires the flow rate value S from the bidirectional flow meter 500 and the liquid level change value Δ from the liquid level sensor. A scenario may exist where the liquid level sensor clearly detects a continuous and stable decrease in the liquid level within the brine tank 300, i.e., Δ < 0. This directly indicates that the brine is being effectively extracted, and the core brine extraction action is being performed. However, simultaneously, the bidirectional flow meter 500 installed on the brine extraction flow path fails to report a valid flow rate value S. This combination of sensor data indicates that the brine extraction process itself is underway, but the bidirectional flow meter 500 used to measure the brine extraction volume may have malfunctioned, causing its measurement function to fail.

[0065] When the control module detects a continuous drop in liquid level without a valid signal from the flow meter, it determines that the bidirectional flow meter 500 is in a malfunctioning state. In this case, the system can no longer rely on the cumulative data from the flow meter to determine whether the brine intake is within the acceptable range. As a fault-tolerant control strategy, the control module will automatically switch to a control mode based on liquid level sensor monitoring data.

[0066] In this mode, the system continuously monitors the liquid level change value Δ. The brine absorption process continues until the liquid level sensor detects that the liquid level in the brine tank 300 no longer changes, i.e., the liquid level change value Δ approaches zero. At this point, it can be determined that the brine in the brine tank 300 has reached the end of the brine absorption process. The control module then controls the brine circuit switch 400 to close, completing the brine absorption step. By switching to using liquid level change as the termination criterion, the system can still complete the regeneration process through a valid signal from another sensor even if the core metering instrument fails, thus maintaining the system's basic operational capability in the event of component failure.

[0067] Please see Figure 4 The fault handling logic shown below describes the alternative diagnostic and handling methods when the main monitoring means fail during the water injection or brine absorption process.

[0068] During the water injection or brine extraction process, the control module relies on the metering data from the bidirectional flow meter 500 and the monitoring data from the level sensor for collaborative judgment. However, an extreme situation may exist: the control module fails to obtain a valid flow metering signal from the bidirectional flow meter 500, nor detect a clear trend in liquid level change from the level sensor. In this case, both core process status monitoring sources fail simultaneously, and the system cannot rely on them to determine process progress or detect anomalies. To address this situation, the control method also makes full use of the pressure sensor configured in the water softener. This pressure sensor is used to monitor the pressure status of the piping system. When the control module confirms during the water injection or brine extraction process that neither the bidirectional flow meter 500 nor the level sensor is providing valid monitoring data, it will initiate a backup diagnostic process based on the pressure sensor.

[0069] In this control method, two key pressure thresholds are preset for auxiliary diagnosis: one is the minimum pressure threshold PY, which is mainly used for the water injection step; the other is the second pressure threshold P2, which is mainly used for the brine absorption step.

[0070] The control module acquires the real-time pressure value P detected by the pressure sensor and selects the appropriate pressure threshold for comparison based on whether the current step is water injection or salt absorption.

[0071] During the water injection process, the control module compares the real-time pressure value P with the preset minimum pressure threshold PY. If the pressure value P is lower than the threshold PY, it indicates that the current water supply pressure is insufficient. At this time, the control module temporarily closes the brine circuit switch 400 and enters a loop waiting state. In this state, the pressure value P is periodically monitored until it recovers to a level not lower than PY, after which water injection can be attempted again. If the pressure value P is not lower than the threshold PY, the brine circuit switch 400 is reopened, followed by a control valve reset operation, and then water injection is attempted again.

[0072] During the brine extraction process, the control module compares the real-time pressure value P with a preset second pressure threshold P2. If the pressure value P is lower than the threshold P2, it is determined that the water supply pressure is abnormal. At this time, the control module temporarily shuts off the brine circuit switch 400 and enters a loop waiting state, in which it periodically monitors the pressure value P until it recovers to a level not lower than P2. If the pressure value P is not lower than the threshold P2, it then attempts to reopen the brine circuit switch 400, performs a control valve reset operation, and then attempts to extract brine again.

[0073] By introducing pressure sensors and matching corresponding pressure thresholds (PY or P2) for different operating conditions of water injection and salt absorption, this control method can provide an accurate backup diagnostic tool when the main sensor system fails. It can effectively distinguish between the two main types of faults: insufficient water supply pressure and abnormal internal valve circuits, and guide the system to implement targeted countermeasures.

[0074] Please refer to it again. Figure 2 and Figure 3 During the water injection or brine absorption steps, the control module comprehensively monitors the data from the bidirectional flow meter 500 and the level sensor to evaluate the working status of each sensor. One possible diagnostic scenario is that during the water injection step, the bidirectional flow meter 500 continuously measures the water flow, but the level signal from the level sensor in the brine tank 300 remains unchanged, i.e., the level change Δ is always zero; or during the brine absorption step, the bidirectional flow meter 500 continuously measures the water flow, but the level signal from the level sensor also shows no change.

[0075] When the bidirectional flow meter 500 shows a water flow signal but the level sensor signal remains unchanged, it indicates that the level sensor may not be responding to actual level changes. During water injection, water flowing into the brine tank 300 should cause the level to rise; during brine extraction, the extraction of brine should cause the level to drop. The continuous change in the level signal contradicts the actual water flow events.

[0076] Upon recognizing this specific combination of signals, the control module will determine that the level sensor is malfunctioning. This determination helps the system identify sensor failures and provides a basis for further fault logging, alarm prompts, or masking the data from the failed sensor in subsequent control logic, thereby maintaining the overall reliability of the control system's assessment of the process status.

[0077] In some embodiments, the regeneration process of the water softener includes, in addition to the water injection and brine absorption steps, a step of cleaning the resin tank 200, specifically divided into a backwash step and a forward wash step. These cleaning steps are carried out in a one-in-one-out operating mode, that is, one resin tank 200 maintains a water production state, while the other standby tank performs the cleaning steps of the regeneration process.

[0078] The implementation of the backwashing step can be combined with Figure 11 The water flow pattern shown is explained below. In this state, the raw water, after passing through the first treatment chamber 210a and the first central pipe 220a of the first resin tank 200a, produces soft water. A portion of this soft water flows through the internal pipe of the dual-tank valve 100 and into the second treatment chamber 210b of the second resin tank 200b via the second central pipe 220b, where it is flushed from bottom to top against the resin inside. The flushed wastewater is then discharged through the drain pipe. This process removes impurities.

[0079] The implementation of the forward washing step can be combined with Figure 12 Understand the water circuit state shown. In this state, the raw water from the inlet 113 flows partly through the first resin tank 200a to produce soft water, and the other part flows through a specific internal pipeline of the dual-tank valve 100 to enter the second treatment chamber 210b of the second resin tank 200b, where the resin inside is flushed from top to bottom to remove residual regeneration liquid and impurities. The wastewater is also discharged through the drain pipe.

[0080] During the backwash or forward wash cycle, the control module continuously monitors the real-time flow rate Q through the water inlet 113 of the water softener via a flow meter. Simultaneously, the program presets the rated time H1 required to complete one effective backwash and the rated time H2 required to complete one effective forward wash, and sets corresponding rated flow rates for different cleaning effects. These include: the rated backwash flow rate QF2 required to achieve a standard backwash effect, and the rated forward wash flow rate QZ2 required to achieve a standard forward wash effect. It also includes minimum flow rates necessary to ensure the cleaning process, including: the minimum backwash flow rate QF1 required to achieve the backwash function, and the minimum forward wash flow rate QZ1 required to achieve the forward wash function.

[0081] In this embodiment, when the preset rated cleaning time H1 or H2 is reached, the control module will evaluate the average real-time flow rate Q at this moment. If the monitored average flow rate Q is lower than the corresponding rated flow rate value QF2 or QZ2, but higher than the corresponding minimum flow rate value QF1 or QZ1, it indicates that the current water flow can maintain a basic cleaning effect, but has not reached the optimal cleaning intensity or flow rate.

[0082] In this situation, the control module does not immediately end the cleaning step, but automatically triggers an extension operation. The system will extend the current backwash time or forward wash time by a specific duration according to preset rules. For example, it may extend the backwash time J1 or the forward wash time J2. In this way, when the flow rate is not at the optimal standard but still meets the minimum requirements, the system compensates for insufficient water flow intensity by supplementing the cleaning time, aiming to achieve a more thorough cleaning effect before proceeding to the next stage of the regeneration process.

[0083] In some embodiments, during the backwashing step, when the preset backwashing rated time H1 is reached, the control module judges the average real-time flow rate Q monitored by the inlet flow meter 113. If the average flow rate Q is lower than the preset minimum backwash flow rate QF1, it indicates that the backwash water flow is severely insufficient, which may affect the cleaning effect. At this time, the control module further acquires the inlet water pressure value P detected by the pressure sensor. If the inlet water pressure value P is higher than the preset second pressure threshold P2, it indicates that the external water supply pressure is normal, and the insufficient backwash water flow is not caused by low pressure. In this case, the cause of the fault may point to the piston inside the control valve not accurately running to the backwash working position, or there is a partial blockage in the backwash flow path.

[0084] Based on this determination, the control module executes a reset operation on the control valve. This operation drives the control valve ( Figure 11 and Figure 12 The first piston 122 and the second piston 152 inside the dual-tank valve 100 move to a preset reference position. After the reset is complete, the control module controls the pistons to move to the backwash position again in order to re-establish the correct backwash water path, such as... Figure 11 The system attempts to eliminate flow path abnormalities caused by valve position deviation through reset and repositioning, thereby restoring normal backwashing function.

[0085] In some embodiments, during the forward washing step, when the preset forward washing rated time H2 is reached, the control module judges the average real-time flow rate Q monitored by the inlet flow meter 113. If the average flow rate Q is lower than the preset minimum forward washing flow rate QZ1, it indicates that the forward washing water flow is severely insufficient. At this time, the control module further acquires the inlet water pressure value P detected by the pressure sensor. If the inlet water pressure value P is higher than the preset second pressure threshold P2, it indicates that the external water supply pressure is normal, and the reason for insufficient water flow may be that the control valve is not in the correct forward washing working position.

[0086] Based on this determination, the control module executes a reset operation on the control valve. After the reset is complete, the control module again controls the piston to move to the positive wash position to establish... Figure 12 The correct forward flush water path is shown, thus attempting to restore sufficient forward flush flow.

[0087] In some embodiments, during the backwash or forward wash steps, after the control valve is reset and restarted to the cleaning position due to insufficient flow and normal pressure, the control module continues to monitor the real-time flow rate Q and inlet pressure P of the inlet 113.

[0088] If, after this attempt, the control module still detects that the real-time flow rate Q is lower than the corresponding minimum backwash flow rate QF1 or minimum forward wash flow rate QZ1, and simultaneously detects that the inlet water pressure P is higher than the second pressure threshold P2, then the problem persists. This situation usually points to a more complex possibility of failure, such as sticking of internal components of the control valve, persistent blockage in the cleaning flow path, or other mechanical problems requiring manual intervention.

[0089] Based on this secondary judgment, the control module will perform two operations: First, it will issue an equipment inspection reminder to the user, for example, through indicator lights or network information prompts, to indicate that the water softener needs maintenance and inspection; second, under the premise of ensuring basic safety, the system will automatically extend the current backwash time or forward wash time by a preset duration, for example, extending the backwash time R1 or the forward wash time R2. By extending the time again, an additional buffer period is provided for potentially unstable water flow, while clear prompts are conveyed to the user to convey fault information and guide necessary maintenance, thus balancing the need for automatic processing and manual intervention.

[0090] In some embodiments, the control method may also include a separate pipeline status monitoring step for detecting potential leaks in the user pipeline network downstream of the water softener.

[0091] In this step, the control module first controls the control valve of the water softener to switch to a position such as... Figure 13 The water supply is shut off as shown, meaning the water softener's supply to the downstream household water network is cut off. At this time, a closed pressure-maintaining system is formed, consisting of the control valve, outlet 114, and the downstream water network.

[0092] Subsequently, the control module initiates a preset pressure-holding time period HA, and during this period, continuously monitors the pressure change ΔP in the closed system's pipeline network using pressure sensors installed at outlet 114 or on the corresponding pipeline. The program presets a pressure drop threshold ΔPA as a benchmark for determining whether a significant leak exists.

[0093] At the end of the pressure holding time HA, the control module compares the monitored pressure change ΔP with the critical value ΔPA. If ΔP is greater than ΔPA, it is determined that there is a leak in the downstream pipeline network, and the system can record this event or issue a leak warning to the user.

[0094] Specifically, during the pressure monitoring period HA, if the pressure sensor detects a sudden and sharp drop in the pipeline pressure, for example, a sudden drop to near atmospheric pressure, this characteristic signal usually indicates that a user has turned on a water supply point during this period. Once this water supply signal is detected, the control module will drive the control valve to switch back to the operating mode before performing this pressure monitoring within a very short time. For example, for Figures 5 to 13 The dual-tank valve 100 shown can operate in series, parallel, or one-in-use-one-backup mode, thereby immediately restoring normal water supply to the pipeline network and achieving rapid response to users' water usage behavior. Afterwards, leak detection can be carried out again at an opportune time.

[0095] This application also provides a water softener, which includes a control module, a brine tank 300, a brine circuit switch 400, a liquid level sensor, and a bidirectional flow meter 500.

[0096] The brine tank 300 stores salt particles and is connected to the main water circuit of the water softener. A brine circuit switch 400 is installed on the water supply or brine suction line of the brine tank 300, or on a control valve, to controllably connect or disconnect the flow path between the brine tank 300 and the main water circuit. A level sensor is located inside the brine tank 300 to monitor water level changes in real time. A bidirectional flow meter 500 is installed in the water supply or brine suction flow path of the brine tank 300 to accurately measure the flow rate of water entering or leaving the brine tank 300.

[0097] The control module, as the core processing unit of the water softener, is electrically connected to the aforementioned brine switch 400, level sensor, bidirectional flow meter 500, and motor driving the control valve, among other electrical control components. This control module is configured to execute the control method described in any of the preceding embodiments through its internally stored program instructions. For example, during regeneration, the control module coordinates the opening and closing of the brine switch 400 based on the acquired data from the bidirectional flow meter 500 and level sensor; or, when sensor data is abnormal, it executes corresponding fault handling procedures based on pressure sensor information; furthermore, it can also perform functions such as backwash and forward wash flow monitoring and duration adjustment, as well as leak detection of the pipeline network.

[0098] This water softener can be implemented as follows: Figures 5 to 12 The dual-tank water softener shown has two resin tanks 200 and corresponding dual-tank valves 100; it can also be implemented as a single-tank water softener, having one resin tank 200 and corresponding single-tank valve. Regardless of the specific form, it is acceptable as long as it includes the aforementioned key components and the control module is configured to execute the control logic of this application.

[0099] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0100] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0101] The embodiments, implementation methods, and related technical features of this application can be combined and substituted for each other without conflict.

[0102] The above are merely preferred embodiments of this application and are not intended to limit this application in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of this application without departing from the scope of the technical solution of this application shall still fall within the scope of the technical solution of this application.

Claims

1. A control method of a water softener, characterized by, The softener comprises a salt tank, a salt path switch, a liquid level sensor arranged in the salt tank, and a bidirectional flow meter arranged in a flow path of the salt tank; the control method comprises: a water injection step of controlling the salt path switch to be opened to inject water into the salt tank and obtaining metering data from the bidirectional flow meter and monitoring data from the liquid level sensor; a salt suction step of controlling the salt path switch to be opened to suck salt from the salt tank and obtaining metering data from the bidirectional flow meter and monitoring data from the liquid level sensor; wherein in the water injection step and / or the salt suction step, the salt path switch is controlled to be closed according to the metering data of the bidirectional flow meter and the monitoring data of the liquid level sensor.

2. The control method of the water softener according to claim 1, characterized by, In the water injection step, when the bidirectional flow meter measures water flow and the liquid level sensor monitors continuous rise of the liquid level, the salt path switch is controlled to be closed according to the metering data of the bidirectional flow meter reaching a preset water injection amount.

3. The control method of the water softener according to claim 2, characterized by, In the water injection step, when the bidirectional flow meter measures water flow but the liquid level sensor monitors continuous drop of the liquid level, a control valve reset operation of the softener is performed.

4. The control method of the water softener according to claim 2, characterized by, In the water injection step, when the bidirectional flow meter does not measure water flow but the liquid level sensor monitors continuous rise of the liquid level, a control mode based on water injection time is switched to control the salt path switch to be closed.

5. The control method of the water softener according to claim 1, characterized by, In the salt suction step, when the bidirectional flow meter measures water flow and the liquid level sensor monitors continuous drop of the liquid level, the salt path switch is controlled to be closed according to the metering data of the bidirectional flow meter.

6. The control method of the water softener according to claim 5, characterized by, In the salt suction step, when the bidirectional flow meter measures water flow but the liquid level sensor monitors continuous rise of the liquid level, a control valve reset operation of the softener is performed.

7. The control method of the water softener according to claim 5, characterized by, In the salt suction step, when the bidirectional flow meter does not measure water flow but the liquid level sensor monitors continuous drop of the liquid level, a control mode based on the monitoring data of the liquid level sensor is switched to determine a salt suction end point, and the salt path switch is controlled to be closed.

8. The control method of the water softener according to any one of claims 1 to 7, characterized by, The softener further comprises a pressure sensor; In the water injection step or the salt suction step, when neither the bidirectional flow meter nor the liquid level sensor obtains valid monitoring data, a corresponding fault handling procedure is performed according to a pressure detection value of the pressure sensor.

9. The control method of the water softener according to claim 8, characterized by, Performing a corresponding fault handling procedure according to the pressure detection value of the pressure sensor comprises: when the pressure detection value is lower than a preset minimum pressure threshold, performing an operation of waiting for pressure recovery or issuing an alarm; when the pressure detection value is not lower than the preset minimum pressure threshold, attempting to control the salt path switch and / or a control valve to perform a reset operation.

10. The control method of the water softener according to claim 1, characterized by, In the water injection step, when the bidirectional flow meter measures water flow and the liquid level sensor monitors no change of the liquid level, it is determined that the liquid level sensor is abnormal; and / or, In the salt suction step, when the bidirectional flow meter measures water flow and the liquid level sensor monitors no change of the liquid level, it is determined that the liquid level sensor is abnormal.

11. The control method of the water softener according to claim 1, characterized by, The control method further comprises a backwashing step; In the backwash step, the real-time flow rate of the water inlet is monitored, and when the set backwash time ends, if the real-time flow rate is lower than a backwash rated flow rate but higher than a minimum backwash flow rate, the backwash time is automatically extended.

12. The control method of the water softener according to claim 1, characterized by, The control method further comprises a forward wash step; In the forward wash step, the real-time flow rate of the water inlet is monitored, and when the set forward wash time ends, if the real-time flow rate is lower than a forward wash rated flow rate but higher than a minimum forward wash flow rate, the forward wash time is automatically extended.

13. The control method of the water softener according to claim 11, wherein In the backwash step, when the set backwash time ends, if the real-time flow rate is lower than a minimum backwash flow rate, the water inlet pressure value is determined; if the water inlet pressure value is higher than a pressure threshold value, the control valve is reset and the operation of running to the backwash position is performed again.

14. The control method of the water softener according to claim 12, wherein In the forward wash step, when the set forward wash time ends, if the real-time flow rate is lower than a minimum forward wash flow rate, the water inlet pressure value is determined; if the water inlet pressure value is higher than a pressure threshold value, the control valve is reset and the operation of running to the forward wash position is performed again.

15. The control method of the water softener according to claim 13 or 14, characterized by, After the operation of resetting the control valve and running to the backwash position or the forward wash position is performed, if the real-time flow rate is still detected to be lower than the minimum backwash flow rate or the minimum forward wash flow rate, and the water inlet pressure value is higher than the pressure threshold value, a device inspection reminder is issued and the corresponding backwash time or forward wash time is automatically extended again.

16. The control method of the water softener according to claim 1, wherein The control method further comprises a pipe network state monitoring step: The control module controls the water softener to switch to a closed water supply state; Within a preset pressure maintaining time, the pressure sensor monitors the change of the pipe network pressure; If the pressure change exceeds a preset change threshold value, it is determined that the pipe network has a leak.

17. A water softener comprising: The control module is configured to perform the control method of the water softener according to any one of claims 1 to 16. The control module is configured to perform the control method of the water softener according to any one of claims 1 to 16.

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