Electronic Fill Valve Dynamic Refill Control
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Solution Overview
Problem
Conventional fill valves in toilets refill at a slower rate than the water drainage rate, leading to inefficiencies and potential issues with water wastage, and lack advanced monitoring capabilities for leaks or irregular flushing patterns.
Innovation Solution
The introduction of an electronic fill valve (EFV) that incorporates low energy digital components and wireless technology, using resistive or capacitive sensing to control the refill process, with features like solenoid and plunger arrangements for precise control, and capacitive or resistive sensing to detect leaks, overflow, and irregular flushing patterns, communicating via Bluetooth or UHF radio waves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional fill valve is used to refill the tank, then the tank can be refilled with water, but the refill rate is much slower than the drainage rate leading to water wastage and inefficiency
Solution Approach 1:
The fill valve system dynamically adjusts the refill rate based on real-time detection of tank water level and flushing patterns. The valve transitions from a static, fixed-rate mechanism to a dynamic system that can accelerate refill operations when appropriate, optimizing the balance between refill speed and water conservation while preventing wastage through intelligent control
Solution Approach 2:
The system incorporates sensors that continuously monitor tank water level, flushing frequency, and refill progress. This feedback mechanism enables the control system to adjust the refill rate in real-time, comparing actual refill performance against drainage rates and optimizing water usage accordingly to eliminate wastage while maintaining efficient refilling
2Reliability
If conventional fill valves are used, then the system is simple and reliable, but they lack advanced monitoring capabilities for leaks or irregular flushing patterns
Solution Approach 1:
The fill valve system is designed to perform multiple functions: basic refilling, leak detection, flushing pattern monitoring, and predictive maintenance alerting. By integrating sensors and a control system that can detect various anomalies (leaks, irregular flushing, potential failures), the system achieves enhanced reliability and diagnostic capability while managing complexity through a unified multi-functional architecture
Solution Approach 2:
The patent replaces purely mechanical fill valve operation with an electronically controlled system that uses sensors, microprocessors, and wireless communication. This substitution enables advanced monitoring capabilities (detecting leaks, analyzing flushing patterns, predicting failures) that would be impossible with mechanical systems alone, while the electronic control integrates multiple functions into a compact unit
3Extent of automation
If digital components and wireless technology are integrated into the fill valve, then monitoring and control capabilities are enhanced, but device complexity increases
Solution Approach 1:
The patent combines digital sensing components, wireless communication modules, control logic, and the fill valve mechanism into a single integrated assembly. By merging these previously separate functions into one unified device, the system achieves high automation for monitoring and control while containing complexity within a compact, integrated structure rather than requiring multiple separate components
Solution Approach 2:
The design nests digital components (sensors, microcontroller, wireless transceiver) within the fill valve housing, creating a compact integrated unit. The electronic control system is embedded within the mechanical valve structure, allowing automated monitoring and wireless communication capabilities to be incorporated without significantly increasing the overall footprint or apparent complexity of the valve assembly
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 EFV ensures efficient refilling, detects leaks and irregularities, and provides remote control options, minimizing water wastage and enhancing operational reliability through smart monitoring and alert systems.
Implementation Method 1
A solenoid and plunger arrangement, or, in another embodiment, a solenoid and pivot arm
Implementation Method 2
The float is located in the float housing which has an inlet opening for allowing water to spill into the float housing so that the float rises upwardly
Implementation Method 3
capacitive or resistive sensing to detect leaks, overflow, and irregular flushing patterns
Implementation Method 4
resistive sensing to control the refill process
Data Source
AI summary
A fill valve for a water storage tank, the fill valve comprising a riser assembly, a valve housing mounted on an upper end of the riser assembly, a pilot orifice in the valve housing, and a sensor adapted to be mounted within the water storage tank. The sensor is responsive to a water level within the water storage tank, and a pilot valve mechanism opens and closes the pilot orifice in response to the sensor determining the water level in the fill tank.