Flush Valve Motor Bracket for Precise Gear Alignment
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Solution Overview
Problem
Automated flush valves require manual positioning and adjustment of gears during assembly to align the drive and valve gears properly, which is inefficient and prone to user error.
Innovation Solution
A bracket is designed to be removably coupled to the manifold, featuring specific apertures and a groove to align the drive gear and valve gear in a predetermined position, eliminating the need for manual alignment by securing the motor, valve cartridge, and sensor assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual positioning and adjustment of gears is performed during assembly, then the drive gear and valve gear can be aligned, but the assembly process is inefficient and prone to user error
Solution Approach 1:
The patent introduces a positioning bracket as an intermediary tool during assembly. The bracket includes positioning features such as ribs and recesses that automatically align the drive gear and valve gear when the components are assembled. This intermediary device eliminates the need for manual positioning and adjustment, providing precise gear alignment while significantly improving assembly efficiency and reducing user error.
2Reliability
If manual positioning and adjustment of gears is performed during assembly, then the gears can be aligned, but the process is prone to user error
Solution Approach 1:
The positioning bracket serves as a mediator that guides the assembly process. The bracket's positioning features (ribs and recesses) automatically ensure correct gear alignment, making the assembly process more reliable and less prone to user error. The bracket essentially performs the alignment function that would otherwise require skilled manual operation.
Solution Approach 2:
The positioning bracket is designed with pre-formed positioning features (ribs and recesses) that are created during bracket manufacturing. These features perform the alignment action automatically when assembly occurs, eliminating the need for manual positioning and adjustment during the assembly process itself.
3Manufacturing precision
If a bracket with apertures and groove is used to align gears, then gear alignment precision is improved, but the device complexity increases
Solution Approach 1:
The positioning bracket is designed to perform multiple functions: it provides structural support for the motor assembly, positions the drive gear, positions the valve gear, and guides the assembly process. By consolidating these multiple functions into a single component, the patent achieves precise gear alignment without proportionally increasing device complexity.
Solution Approach 2:
The bracket is designed with distinct functional segments: apertures for motor mounting, ribs for drive gear positioning, recesses for valve gear positioning, and grooves for alignment. This segmentation of functions into distinct structural features makes the bracket's complexity manageable and justifies the added precision through functional specialization.
Data Source
AI summary
A flush valve assembly including a manifold including an inlet, an outlet, and a fluid passageway positioned between the inlet and the outlet, a motor coupled to the manifold and including a drive gear, a valve cartridge coupled to the manifold, and a shaft extending from the valve cartridge. The shaft includes a valve gear configured to mesh with the drive gear. Rotational motion from the motor is transferred through the drive gear, the valve gear, and the valve shaft to rotate the valve cartridge between a first position and a second position. The flush valve assembly additionally includes a bracket removably coupled to the manifold. The bracket is configured to align the drive gear and the valve gear in a predetermined position.