Compact Flush Valve Actuator with Belt Drive Linkage
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Solution Overview
Problem
Current automated outlet flush valves in plumbing fixtures, such as toilets, are aesthetically unpleasing, prone to snagging, and require expensive materials due to the lateral projection of motor systems and repetitive hard stop operation, leading to maintenance issues and increased costs.
Innovation Solution
A compact plumbing fixture design with a motor positioned between the bowl and trapway leg, utilizing a belt drive linkage that pivots the flush valve, and a calibration method to set operational positions between high resistance points, reducing wear and maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the motor or actuator system is positioned to project laterally out from the trapway, then the flush valve can be actuated, but it disrupts aesthetics and uses up desirable lateral space
Solution Approach 1:
The motor is repositioned from a lateral projection to a location within the vertical space between the bowl and the upwardly extending trapway leg. This dimensional relocation eliminates the lateral protrusion that compromised aesthetics while maintaining the actuation function through a redesigned linkage system.
Solution Approach 2:
The motor and linkage system are nested within the existing structural space between the bowl and trapway leg. By utilizing this previously underutilized vertical space, the design incorporates the actuator without requiring additional lateral space, thus preserving both aesthetics and functionality.
2Ease of operation
If the motor system is positioned laterally, then the flush valve can be actuated, but it presents surfaces that can snag other items
Solution Approach 1:
The motor is extracted from the lateral position where it created snagging surfaces and relocated to the internal space within the trapway structure. This removal from the external lateral surface eliminates the harmful snagging effect while the actuation function is maintained through the linkage mechanism.
3Productivity
If the pivotable flush valve is repetitively driven between hard stop positions, then the flush function is achieved, but the life of the seal and motor assembly is compromised
Solution Approach 1:
The controller is programmed to operate the flush valve within a limited range of motion that stops short of the extreme hard stop positions. By performing a partial rotation that achieves sufficient sealing and flushing functionality without reaching the mechanical limits, the system reduces wear on the seal and motor assembly while maintaining effective operation.
Solution Approach 2:
The controller preemptively limits the range of motion before the hard stops are reached. This preliminary action prevents the damaging repetitive impact at the extreme positions by establishing operational boundaries that preserve component life while still achieving the necessary flush function.
4Reliability
If expensive materials are used to protect against wear from hard stop operation, then reliability improves, but product cost increases
Solution Approach 1:
Instead of using expensive wear-resistant materials, the solution employs a control strategy that treats the seal and motor as components with limited operational cycles. By limiting the range of motion to avoid hard stops, the system extends component life without requiring costly material upgrades, effectively managing wear through operational constraints rather than material substitution.
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 design enhances aesthetics, reduces snagging risks, conserves space, and minimizes maintenance issues without requiring high-cost materials, resulting in a more efficient and cost-effective automated flush valve system.
Implementation Method 1
A flush valve is positioned between the lower opening and a portion of the trapway for controlling flow from the bowl through the trapway. The plumbing fixture further includes a valve actuator having a motor that is positioned at least in part in said space.
Implementation Method 2
the linkage may be a belt drive
Implementation Method 3
There is also a linkage connected to the motor to be driven thereby.
Implementation Method 4
A flush valve is positioned between the lower opening and a portion of the trapway for controlling flow from the bowl through the trapway.
Data Source
AI summary
Plumbing fixtures with a valve actuator for automatically controlling pivoting of a flush valve, and methods of calibrating movement of the flush valve, are disclosed. The motor of the valve actuator may be positioned between the bowl of the fixture and a leg of a trapway to provide compact assembly. A belt drive laterally extending along the trapway links the motor to the flush valve. The method of calibrating includes establishing stop points which are at positions of less resistance than hard stop positions.