Flush Valve Gear Position Sensing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The unpredictability of the opening in the relief valve of flush valves, due to variations in pressure and actuation methods, leads to control and precision issues in fluid flow and flush cycle timing, making it difficult to manage the amount of fluid flowing through and the timing of the flush cycle.

Innovation Solution

A flush valve assembly with a motor-driven gear system and optical sensor that precisely controls the rotational position of a valve cartridge between open and closed positions, using a flag to indicate the position to the sensor, allowing for controlled fluid flow and improved durability by removing components from the fluid outlet flow path.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a manual lever arm or automated actuation mechanism is used to actuate the relief valve, then the flush valve can be operated, but the opening of the relief valve becomes unpredictable due to variations in pressure and actuation force, leading to control and precision issues

Engineering Contradiction:

Improveoperation of flush valveVSAvoidcontrol of relief valve opening

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical actuation system (manual lever arm or automated actuation mechanism) with an electrical motor-driven system. The motor provides controlled rotational motion to the valve stem through a gear reduction mechanism, eliminating the unpredictability associated with manual or simple automated actuation. This substitution enables precise control of the relief valve opening while maintaining ease of operation through automated control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent incorporates a sensor that detects the position of the valve stem and provides feedback to the control system. This feedback mechanism allows the controller to monitor and adjust the motor's rotational position to achieve the desired relief valve opening, ensuring precise control despite variations in system pressure or other operating conditions.

Inventive Principle:

Principle #23Feedback

2Productivity

If the valve stem is laterally displaced to open the relief valve, then fluid communication is established, but the amount of fluid flowing through and the timing of the flush cycle become difficult to control

Engineering Contradiction:

Improvefluid flow through flush valveVSAvoidtiming of flush cycle

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent transitions from a static lateral displacement mechanism to a dynamic rotational control system. The motor-driven valve stem can rotate to precisely control the opening degree of the relief valve, allowing dynamic adjustment of fluid flow rate and duration. This enables accurate control of both the amount of fluid flowing through the flush valve and the timing of the flush cycle.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the control parameter from lateral displacement distance to rotational angle. By controlling the rotational position of the valve stem through the motor and gear system, the relief valve opening can be precisely regulated. This parameter change enables better control over fluid flow characteristics and flush cycle timing.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If components remain in the fluid outlet flow path, then the valve structure is complete, but durability is reduced due to exposure to high-velocity fluid flow and potential cavitation

Engineering Contradiction:

Improvestructural completeness of valveVSAvoiddurability of components

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent extracts certain components from the high-velocity fluid outlet flow path and positions them in protected locations. Specifically, the motor and gear reduction mechanism are housed in a protected chamber separate from the direct fluid flow path. This extraction protects these components from cavitation and high-velocity fluid damage while maintaining the structural completeness and functionality of the valve.

Inventive Principle:

Principle #2Taking out (Extraction)

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

This solution provides precise control over the opening of the relief valve, enhancing the reliability and consistency of fluid flow and flush cycle timing, thereby improving the overall performance and durability of the flush valve system.

Implementation Method 1

A sensor is positioned to receive at least a portion of the flag in a gap of the sensor

Methodology Applied

Scientific EffectOptical detection: Light

Data Source

PatentUS10578228B2Sensing mechanism for valve operation

Publication Date: 2020.03.03 ZURN WATER LLC

AI summary

A flush valve assembly has a pilot valve and a drive train for selective driving the pilot valve between an open position and a closed position. The drive train has a drive gear coupled to a motor for rotating the drive gear and a valve gear coupled to the pilot valve and intermeshing with the drive gear. At least one of the drive gear and the valve gear have a flag extending outwardly therefrom. A sensor positioned to detect the flag and establish a rotational position of the drive gear and the valve gear to thereby establish an opened or closed position of the pilot valve.