An electric actuator for a flush valve

Abstract

An electric actuator for a flush valve includes: a housing; a motor disposed within the housing; a transmission mechanism; a push rod connected to the transmission mechanism for reciprocating linear motion; a position detection component; and a control module electrically connected to the motor and the position detection component. The transmission mechanism includes a gear connected to the motor and a rack disposed on the push rod and meshing with the gear. The position detection component includes at least one Hall effect switch and a magnet disposed on the push rod for triggering the Hall effect switch. The control module controls the start, stop, or direction of the motor based on the signal generated by the Hall effect switch. The beneficial effects of this invention are: by controlling the forward and reverse rotation of the gear via the motor, the push rod is directly driven to complete the entire stroke in both the driving and resetting directions, resulting in a significant leap in the overall mechanical reliability and service life of the actuator.

Description

Technical Field

[0001] This utility model relates to the technical field of bathroom equipment, specifically an electric actuator for a flush valve. Background Technology

[0002] With the improvement of living standards and the enhancement of public health awareness, automated bathroom equipment, such as automatic flushing toilets and automatic sensor urinals, has been increasingly widely used in homes and public places. To automate the flushing action, an electric actuator is usually needed to replace the traditional manual pressing or lifting operation to drive the flush valve to open and close.

[0003] Currently, there are various electric actuators available on the market for flush valves. One common technical solution uses a motor as a power source, and a transmission mechanism converts the motor's rotational motion into the linear motion of a push rod. The push rod then simulates the action of a human hand, triggering the flush valve to complete the flushing process.

[0004] In the specific implementation of the above scheme, the design generally adopts a transmission method in which a motor drives a sector gear to rotate, and the sector gear then meshes with a rack. When the motor rotates forward, the sector gear drives the rack to move linearly, pushing the flush valve core; when the sector gear rotates to the end of its teeth and completely disengages from the rack, the drive stroke ends. The rack's reset relies entirely on a pre-compressed or stretched spring, whose elastic force springs the rack back to its initial position, waiting for the next drive.

[0005] However, in practice, the applicant has discovered that the aforementioned prior art has at least the following significant drawbacks:

[0006] 1. In addition to the motor and gear rack mechanism, this structure requires an additional independent spring return mechanism. This not only increases the number of parts and the complexity of the overall structure, but also introduces new potential failure points. Under long-term, high-frequency repeated stretching or compression, the spring is highly susceptible to elastic fatigue, leading to weakened elastic force or even breakage. Ultimately, this causes the push rod to fail to return to its proper position or to completely fail, severely impacting the overall reliability and service life of the product.

[0007] 2. In this structure, the motor can only actively control its unidirectional drive stroke. The reverse reset stroke is a passive process entirely dependent on the spring force, and the control system cannot actively and precisely control it. Therefore, the reset position and speed depend entirely on uncontrollable factors such as the real-time state of the spring and frictional resistance, resulting in poor consistency in each action. When the spring performance deteriorates, incomplete reset often occurs.

[0008] 3. Because the sector gear and rack disengage at the end of their stroke and need to re-engage after resetting, this process is prone to impact and positioning inaccuracies. Furthermore, relying on the rapid spring return causes the push rod to violently impact the mechanical limit point, generating significant noise and vibration, which is undesirable for a quiet home environment. This periodic impact also exacerbates mechanical wear on the gears, rack, and other structural components, further shortening the product's lifespan. Therefore, further improvements are necessary. Utility Model Content

[0009] The purpose of this invention is to overcome the shortcomings of existing technologies and provide an electric actuator for flush valves that is simple in structure, low in manufacturing cost, reliable in operation, precise in control, and has a longer service life.

[0010] The objective of this utility model is achieved in the following way: an electric actuator for a flush valve, comprising:

[0011] A shell;

[0012] An electric motor is housed within the casing;

[0013] A transmission mechanism, connected to the output shaft of the motor, is used to convert the rotational motion of the motor into linear motion;

[0014] A push rod is connected to the transmission mechanism to perform reciprocating linear motion;

[0015] A position detection component is used to detect the stroke position of the push rod;

[0016] A control module is electrically connected to the motor and the position detection component;

[0017] The transmission mechanism includes a gear connected to the motor, and a rack disposed on the push rod and meshing with the gear;

[0018] The position detection component includes at least one Hall switch and a magnet disposed on the push rod for triggering the Hall switch;

[0019] The control module is used to control the start, stop, or direction of the motor based on the signal generated by the Hall switch.

[0020] Furthermore, the position detection component includes two Hall switches, which are used to detect the upper travel limit point and the lower travel limit point of the push rod, respectively.

[0021] Furthermore, the magnet is fixed to one end of the push rod or embedded in the rod body of the push rod.

[0022] Furthermore, the gear in question is a straight gear.

[0023] Furthermore: the housing includes a middle shell and a rear shell that docks with it, the middle shell and the rear shell together form a first accommodating cavity, and the motor is disposed in the first accommodating cavity; it also includes a front shell that docks with the middle shell, the middle shell and the front shell together form a second accommodating cavity, and the transmission mechanism is disposed in the second accommodating cavity.

[0024] The beneficial effects of this utility model are: 1. Simple structure, low manufacturing cost, and improved market competitiveness. 2. By controlling the forward and reverse rotation of the gears via a motor, the push rod is directly driven to complete the entire stroke in both the driving and resetting directions. This design completely eliminates the complex and unreliable spring resetting mechanism of existing technologies. As a result, not only is the number of parts reduced, but the internal structure is also simplified and compact. Furthermore, it fundamentally eliminates the risk of resetting failure caused by elastic fatigue, performance degradation, or even breakage of the spring due to long-term use, leading to a qualitative leap in the overall mechanical reliability and service life of the actuator.

[0025] 3. This utility model adopts a closed-loop control scheme of motor-gear rack-Hall switch. The motor always actively controls the position of the push rod, and the magnet set on the push rod cooperates with the fixed Hall switch to provide the control module with accurate and real-time position feedback signals.

[0026] 4. The control module can precisely control the start, stop, direction, and end position of the push rod's up and down strokes based on signals triggered by, for example, two Hall switches. This ensures that the stroke of each flush drive and reset is accurate and consistent, completely solving the problems of insufficient stroke and inconsistent action caused by the reliance on passive spring force reset in existing technologies.

[0027] 5. Since the gear and rack remain meshed throughout the entire working process, the movement and reversal of the push rod are under the smooth control of the motor, avoiding the mechanical impact during the disengagement and re-meshing process of the sector gear in the existing technology. Attached Figure Description

[0028] Figure 1 This is a rendering of the final assembly of this utility model.

[0029] Figure 2 , 3 This is an exploded view of the structure of this utility model. Detailed Implementation

[0030] The present invention will be further described below with reference to the accompanying drawings. An electric actuator for a flush valve includes:

[0031] One shell 1;

[0032] A motor 2 is installed inside the housing 1;

[0033] A transmission mechanism is connected to the output shaft of the motor 2 and is used to convert the rotational motion of the motor 2 into linear motion;

[0034] A push rod 3 is connected to the transmission mechanism to perform reciprocating linear motion;

[0035] A position detection component is used to detect the stroke position of the push rod 3;

[0036] A control module is electrically connected to the motor 2 and the position detection component;

[0037] The transmission mechanism includes a gear 4 connected to the motor 2, and a rack 5 disposed on the push rod 3 and meshing with the gear 4;

[0038] The position detection component includes at least one Hall switch 6 and a magnet 7 disposed on the push rod 3 for triggering the Hall switch 6;

[0039] The control module is used to control the start, stop, or direction of the motor 2 according to the signal generated by the Hall switch 6.

[0040] In this embodiment: the control module, acting as the control core, drives motor 2 to rotate upon receiving a flushing command. The rotational motion of motor 2 is transmitted to gear 4 connected to it via its output shaft. Since gear 4 is always engaged with rack 5 mounted on push rod 3, the rotational motion of gear 4 is precisely converted into linear motion of push rod 3. During the linear motion of push rod 3, magnet 7 fixed to it also moves synchronously. When magnet 7 moves into the effective sensing range of preset Hall switch 6, Hall switch 6 is triggered and generates an electrical signal. This signal is sent back to the control module, which can accurately determine that push rod 3 has reached the predetermined stroke position based on this signal. At this time, the control module immediately issues a command to stop motor 2 from rotating or change its rotation direction, thereby achieving precise closed-loop control of the push rod 3's movement.

[0041] In this embodiment, the stable meshing of gear 4 and rack 5 enables the motor 2 to actively control the movement and reset of push rod 3 throughout its entire process, completely replacing the unreliable spring reset mechanism. The non-contact positioning using Hall effect switch 6 and magnet 7 avoids the wear and environmental influences of traditional mechanical switches, ensuring a stable and reliable positioning signal.

[0042] In one embodiment, the position detection component includes two Hall switches 6, used to detect the upper and lower travel limit points of the push rod 3, respectively. Two independent Hall switches 6 are spaced apart along the movement path of the push rod 3. One Hall switch 6 is used to calibrate the position where the push rod 3 extends to its furthest point, i.e., the position where the flushing action is performed; the other Hall switch 6 is used to calibrate the position where the push rod 3 is fully retracted, i.e., the position where standby or reset is complete.

[0043] Compared to traditional technologies, by monitoring both the start and end points of the stroke, the effective working range of the push rod 3 can be defined with extreme precision. This ensures that each drive stroke of the push rod is just right, fully driving the flush valve without causing mechanical shock due to overtravel; at the same time, it ensures that the reset is fully in place, ready for the next action.

[0044] In one embodiment, the magnet 7 is fixed to one end of the push rod 3 or embedded within the rod body of the push rod 3. Securely fixing or embedding the magnet 7 within the push rod 3 ensures that the magnet 7 and the push rod 3 form a rigid whole, with their relative position remaining constant. This fixing method ensures that the magnet 7 will not shift, loosen, or fall off during the movement of the push rod 3. This guarantees that the magnetic field signal detected by the Hall switch 6 can accurately and stably reflect the precise position of the push rod 3, which is the fundamental guarantee for the reliability of the entire closed-loop control system.

[0045] In one embodiment, gear 4 is a spur gear. The use of a spur gear in conjunction with rack 5 is a classic and efficient transmission method. The rotational torque of motor 2 is transmitted to rack 5 through the spur gear, providing direct and efficient driving force. Furthermore, spur gear transmission has advantages such as simple structure, easy manufacturing, low cost, and high transmission efficiency, making it ideal for use in space-constrained actuators requiring cost-effectiveness, achieving an optimal balance between performance and cost.

[0046] In one embodiment, the housing 1 includes a middle shell 11 and a rear shell 12 that docks with it, the middle shell 11 and the rear shell 12 together form a first accommodating cavity, and the motor 2 is disposed in the first accommodating cavity; it also includes a front shell 13 that docks with the middle shell 11, the middle shell 11 and the front shell 13 together form a second accommodating cavity, and the transmission mechanism is disposed in the second accommodating cavity.

[0047] In this embodiment, the housing 1 is defined by a cleverly modular structure. The entire actuator is ingeniously divided into two functional areas: a first accommodating cavity at the rear and a second accommodating cavity at the front. The motor 2, serving as both a power source and a heat source, is located in the rear power area; while the precision transmission mechanism, consisting of gears 4 and racks 5, is located in the front transmission area. The modular chamber design allows for a clear and non-interfering layout of the internal components, greatly simplifying the assembly process and improving production efficiency. Simultaneously, physically isolating the motor 2 from the transmission mechanism enhances overall stability and durability.

[0048] In summary, in this case, the standby state is as follows: the actuator is powered on, the push rod 3 is at the fully retracted upper travel limit position, and the magnet 7 on it is directly facing the Hall switch 6 above. After the control module receives this signal, it confirms that the system is in standby state and the motor 2 does not work.

[0049] Receiving and executing commands: When an external sensor, such as an infrared sensor, detects the user and issues a flushing command, the command is sent to the control module. The control module immediately drives the motor 2, which is located in the first accommodating cavity formed by the rear shell 12 and the middle shell 11, to rotate forward.

[0050] Transmission and flushing: The motor 2 drives the spur gear 4, which is located in the second accommodating cavity formed by the front shell 13 and the middle shell 11, to rotate. The spur gear then pushes the rack 5 that meshes with it, causing the push rod 3 to extend outward smoothly. Its end then drives the valve of the external flushing valve to perform the flushing action.

[0051] Lower stroke positioning and reversing: When push rod 3 extends to the preset "lower stroke limit point", the magnet 7 on it triggers the Hall switch 6 at the bottom. After receiving this signal, the control module immediately controls motor 2 to stop and rotate in the opposite direction.

[0052] Reset and Standby: Under the reverse drive of motor 2, gear 4 drives rack 5 and push rod 3 to retract smoothly inward. When push rod 3 is fully retracted to the "upper travel limit point" and triggers the upper Hall switch 6 again, the control module controls motor 2 to stop rotating.

[0053] At this point, a complete, precise, and reliable automatic flushing and reset cycle is finished, and the system returns to its initial standby state, awaiting the next command. The entire process achieves fully closed-loop active control, operates smoothly, is highly accurate in positioning, has no mechanical shock, and is highly reliable, thus it can be widely used.

[0054] In the description of this utility model, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. 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.

[0055] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model.

Claims

1. An electric actuator for a flush valve, comprising: A shell (1); A motor (2) is disposed inside the housing (1); A transmission mechanism is connected to the output shaft of the motor (2) and is used to convert the rotational motion of the motor (2) into linear motion; A push rod (3) is connected to the transmission mechanism to perform reciprocating linear motion; A position detection component is used to detect the stroke position of the push rod (3); A control module is electrically connected to the motor (2) and the position detection component; The characteristic feature is that the transmission mechanism includes a gear (4) connected to the motor (2) and a rack (5) disposed on the push rod (3) and meshing with the gear (4); The position detection component includes at least one Hall switch (6) and a magnet (7) disposed on the push rod (3) for triggering the Hall switch (6). The control module is used to control the start, stop or direction of the motor (2) according to the signal generated by the Hall switch (6).

2. An electric actuator for a flush valve according to claim 1, characterized in that: The position detection component includes two Hall switches (6), which are used to detect the upper travel limit point and the lower travel limit point of the push rod (3), respectively.

3. An electric actuator for a flush valve as defined in claim 1, wherein The magnet (7) is fixed to one end of the push rod (3) or embedded in the rod body of the push rod (3).

4. An electric actuator for a flush valve as defined in claim 1, wherein The gear (4) is a straight gear (4).

5. An electric actuator for a flush valve as defined in claim 1, wherein The housing (1) includes a middle shell (11) and a rear shell (12) that docks with it. The middle shell (11) and the rear shell (12) together form a first accommodating cavity, and the motor (2) is disposed in the first accommodating cavity. It also includes a front shell (13) that docks with the middle shell (11). The middle shell (11) and the front shell (13) together form a second accommodating cavity, and the transmission mechanism is disposed in the second accommodating cavity.

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