Dishwasher Valve Assembly With Flow Feedback for Precise Filling
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Solution Overview
Problem
Existing dishwasher valve systems inaccurately deliver water due to variations in flow rate and timer accuracy, leading to increased water and energy consumption, and require complex additional wiring for system controllers, with inconsistent water supply throughout wash cycles.
Innovation Solution
A self-regulating valve assembly with a built-in flow sensor and control unit that determines the exact amount of water needed during each fill cycle, independent of the main controller, and includes a temperature sensor to adjust water supply based on cycle type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a mechanical timer controls the valve to deliver water for a predetermined time, then the valve assembly can deliver water without additional complexity, but the delivered water amount becomes inaccurate due to variations in flow rate and timer accuracy
Solution Approach 1:
The patent applies feedback by using a flow sensor to continuously monitor the actual water flow rate through the valve and providing this information to a microprocessor. The microprocessor then adjusts the valve operation based on the measured flow, creating a closed-loop control system that compensates for flow variations and achieves accurate water delivery without requiring complex mechanical timing mechanisms.
Solution Approach 2:
The patent replaces the mechanical timer system with an electronic control system consisting of a microprocessor, flow sensor, and electronic valve control. This substitution eliminates the inaccuracies of mechanical timing while providing precise digital control over water delivery, resolving the contradiction between simplicity and accuracy.
2Measurement precision
If the mechanical timer is configured to activate the valve for a slightly longer duration to account for variations, then water delivery accuracy improves, but water and energy consumption increases due to extra water usage
Solution Approach 1:
The flow sensor provides real-time feedback on actual water delivery, allowing the microprocessor to precisely control the valve closure timing. This eliminates the need to over-deliver water as a safety margin, as the system can accurately stop water flow exactly when the desired amount has been delivered, thereby reducing water and energy consumption while maintaining accuracy.
Solution Approach 2:
The system uses the flow sensor to self-regulate water delivery without requiring external intervention or conservative over-delivery. The microprocessor autonomously adjusts valve operation based on measured flow conditions, delivering precisely the required water amount without waste.
3Measurement precision
If a system controller receives feedback from a flowmeter to control water delivery, then water delivery accuracy improves, but additional wires or lines must be routed from the flowmeter through the cabinet to the system controller, adding complexity
Solution Approach 1:
The patent combines the flow sensor, valve control, and microprocessor into an integrated valve assembly unit. This merging of components eliminates the need for separate wiring to a remote system controller, as all control functions are contained within the assembly itself, thereby reducing wiring complexity while maintaining accurate flow-based control.
Solution Approach 2:
The microprocessor within the valve assembly acts as an intermediary that locally processes flow sensor data and directly controls the valve without requiring external communication infrastructure. This local intelligence eliminates the need for additional wiring through the cabinet to a remote controller.
4Device complexity
If the same fill cycle is performed for all cycles, then the control system operates consistently without additional complexity, but extra water is used during subsequent fill cycles or insufficient water is used during the first fill cycle
Solution Approach 1:
The patent implements dynamic control logic that adapts the fill cycle parameters based on cycle number and measured conditions. The microprocessor modifies water delivery patterns for different cycles (e.g., more water for the first cycle when components are dry, less for subsequent cycles), providing consistent and appropriate water supply without requiring complex external control systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures precise water delivery, reducing water and energy consumption by minimizing extra water usage and optimizing water supply based on cycle type, while integrating seamlessly with existing dishwasher systems without requiring significant redesign or additional complexity.
Implementation Method 1
A control assembly separate from the main controller is configured to control the valve to move between the first position and the second position. The control assembly includes a flow sensor configured to output a signal representing an amount of water flowing through the supply line
Data Source
AI summary
A valve assembly for use with a washing appliance having a main controller includes a valve that is moveable between a first position that prevents water from flowing through a supply line and a second position that allows water to flow through the supply line. A control assembly separate from the main controller is configured to control the valve to move between the first position and the second position. The control assembly includes a flow sensor configured to output a signal representing an amount of water flowing through the supply line and a control unit configured to control the valve assembly based on the output signal of the flow sensor.