Sensor-Controlled Plumbing Assembly for Coordinated Fill and Drain

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Solution Overview

Problem

Bathroom plumbing fixtures, such as bathtubs and toilets, often have asynchronous fill and drain features, leading to inefficiencies and potential overflows, as fill volumes are independent of bowl volumes and lack coordinated control.

Innovation Solution

A plumbing assembly with a tank and bowl in fluid communication, featuring a re-fill assembly with valves controlled by a sensor-activated controller that adjusts water flow based on water levels in both the tank and bowl, preventing overflows and leaks, and allowing for precise fill and drain operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If separate operation of fill and drain features is used, then operation simplicity is maintained, but coordination and control efficiency deteriorate

Engineering Contradiction:
Improveoperation simplicityVSAvoidcoordination and control efficiency
Core Design Contradiction:
Ease of operationVSProductivity

Solution Approach 1:

The patent combines separate fill and drain operations into a unified coordinated system. The controller integrates control of the fill valve and drain valve, enabling synchronized operation based on water level sensor feedback. This merging allows the system to maintain operational simplicity while achieving efficient coordination between filling and draining processes.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent implements feedback control through water level sensors that continuously monitor the bowl and tank water levels. The controller receives sensor signals and automatically adjusts valve operations accordingly. This feedback mechanism enables coordinated control without complicating user operation, as the system self-regulates based on real-time conditions.

Inventive Principle:
Principle #23Feedback

2Device complexity

If preset fill volume independent of bowl volume is used, then device complexity is reduced, but overflow risk increases

Engineering Contradiction:
Improvedevice complexityVSAvoidoverflow prevention
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The patent uses water level sensors in both the bowl and tank to provide continuous feedback to the controller. The controller monitors actual water levels and dynamically adjusts the fill volume to match the bowl's capacity. This feedback-based approach prevents overflow while maintaining relatively simple device architecture through automated control.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent transitions from static preset fill volumes to dynamic fill volumes that adapt to actual bowl conditions. The controller adjusts the fill amount based on real-time sensor data, enabling the system to respond to varying bowl volumes and prevent overflow. This dynamic approach improves reliability without significantly increasing device complexity.

Inventive Principle:
Principle #15Dynamics

3Reliability

If coordinated control system with sensors and controllers is implemented, then overflow prevention and control efficiency are improved, but device complexity increases

Engineering Contradiction:
Improveoverflow preventionVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements feedback control using water level sensors that provide real-time information to the controller. The controller uses this feedback to automatically adjust valve operations, preventing overflow through automated monitoring and control. This feedback mechanism achieves high reliability while keeping the control logic relatively simple and the overall device complexity manageable.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent enables the system to self-regulate water levels through automated sensor-controlled valve operation. The controller continuously monitors water levels and automatically opens or closes valves as needed without user intervention. This self-service capability improves overflow prevention reliability while minimizing the need for complex manual control systems.

Inventive Principle:
Principle #25Self-service

4Adaptability or versatility

If asynchronous fill and drain operations are used, then operational flexibility is maintained, but water efficiency deteriorates

Engineering Contradiction:
Improveoperational flexibilityVSAvoidwater efficiency
Core Design Contradiction:
Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The patent uses water level sensors to provide feedback that enables coordinated control of fill and drain operations. The controller monitors both bowl and tank water levels, allowing it to optimize water transfer timing and amounts. This feedback-based coordination improves water efficiency by preventing unnecessary filling or draining while maintaining operational flexibility through automated adaptation to actual conditions.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent implements periodic monitoring and control of water levels through sensor feedback. The system continuously checks water levels and adjusts operations in periodic cycles, enabling efficient coordination of fill and drain actions. This periodic control approach optimizes water usage by acting only when necessary while maintaining the flexibility to respond to varying conditions.

Inventive Principle:
Principle #19Periodic action

Data Source

PatentUS20240318414A1Systems and methods of filling and draining plumbing fixtures
Publication Date: 2024.09.26 KOHLER CO(US)
  • US20240318414A1 patent drawing
  • US20240318414A1 patent drawing
  • US20240318414A1 patent drawing

AI summary

A plumbing assembly includes a tank, a bowl in fluid communication with the tank, and a re-fill assembly fluidly coupled to the tank, the re-fill assembly having at least one re-fill assembly valve and being configured to control a flow of water from the tank to the bowl. The plumbing assembly also includes at least one controller operably coupled to the re-fill assembly, the at least one controller being configured to control the at least one valve within the re-fill assembly. The plumbing assembly further includes a first sensor communicably coupled to the at least one controller, the first sensor being configured to sense a water level within the bowl, wherein the at least one controller is configured to stop the flow of water responsive to the water level within the bowl satisfying a first threshold.