HK1191987B - Automatic faucets - Google Patents

Abstract

An automatic faucet includes a housing constructed to receive at least one water inlet conduit and having a spout for delivering water. The automatic faucet includes a valve module, a sensor module, a battery module, a turbine module, and a control module. The valve module includes a valve controlled by an electromagnetic actuator for controlling the water flow from the spout. The sensor module is constructed to provide sensor data influenced by a user. The control module is constructed to control opening and closing of the valve by providing signals to the electromagnetic actuator. The control module is also constructed to receive sensor data from the sensor module and execute a sensing algorithm. The control module is also constructed to execute a power management algorithm for managing electrical power generated by the water turbine and provided to and from the battery.

Description

Automatic water tap

The priority of united states provisional application 61/465,213 entitled "AutomaticFaucets" filed on 3/15/2011 and united states provisional application 61/574,345 entitled "AutomaticFaucets" filed on 7/31/2011, both of which are incorporated by reference.

Technical Field

The present invention relates to automatic faucets and methods for operating and controlling such faucets.

Background

In public or large private facilities, several different types of automatic faucets are used today. There are also metering faucets that are manually turned on by pressing the faucet head to turn on the water and hydraulically timed so that water continues to be discharged for a set period of time after the head is lowered. Some of these faucets have separate heads that allow separate control of hot and cold water. Other metering faucets mix incoming hot and cold water streams and, when turned on, deliver a gentle output flow.

Also known are manually activated metering faucets, the on-time of which is electronically controlled. Other known faucets electronically turn on when a user positions a hand under the faucet. Automatic water dispensing systems offer numerous advantages, including improved sanitation, water conservation, and reduced maintenance costs. Because many infectious diseases are transmitted by contact, public health care facilities encourage the public and mandate food workers to perform appropriate hygiene training, including effective hand washing. Effective hand washing is made easier by an automatic faucet. Automatic faucets typically include an object sensor that detects the presence of an object and an automatic valve that opens and closes the water based on signals from the sensor. People tend to shorten their hand washing time if the water temperature of the automatic faucet is not within the optimal range. To obtain an optimal water temperature, a suitable mixing ratio of hot and cold water and a suitable water actuation must be achieved. Automatic faucets typically use a preset valve that controls the flow of mixed water.

The disadvantages of the hydraulic timing faucet are that: it is difficult to accurately control the on-time of the faucet after a long period of time because of the prevailing pressure variations and impurities accumulated in the faucet that negatively affect the hydraulic control in the faucet. In addition, some faucets do not always recognize a user's hands, other substances, and objects that may be in proximity to the faucet (e.g., reflective objects disposed opposite an infrared transceiver of the faucet, soap set up on a proximity sensor of the faucet, etc.). As a result, those existing faucets may open unintentionally and/or last too long resulting in a waste of water.

There remains a need for a reliable automatic faucet that does not waste water and has efficient energy efficient operation.

Disclosure of Invention

The present invention relates generally to sensor-based automatic faucets and methods of operating such faucets.

According to one aspect, an automatic faucet includes: a housing configured to receive at least one water inlet conduit and having a spout for delivering water; and a valve module including a valve controlled by the electromagnetic actuator for controlling the flow of water out of the spout. This tap still includes: a sensor module configured to provide sensor data affected by a user; and a control module configured to control opening and closing of the valve by providing a signal to the electromagnetic actuator. The control module is configured to receive sensor data from the sensor module and execute a sensing algorithm that keeps track of noise signal levels and dynamically adapts signal thresholds, which tracks signal trends to determine the presence of a user.

According to a preferred embodiment, the control module is configured to execute the sensing algorithm with independent parameters for different power supplies.

The sensor module includes a capacitive sensor. The capacitive sensor includes a touch capacitive sensor, or includes a proximity capacitive sensor. Alternatively, the sensor module comprises an active infrared sensor comprising an infrared emitter and a detector.

The valve module, the sensor module and the control module are located within a housing of the faucet. Alternatively, the valve module and control module are located within a control system unit located below the top surface of the sink. The control system unit may comprise a quick-connect fitting for connecting the water inlet pipe. The control system unit comprises a water filter associated with the actuator.

The control system unit is mounted on the wall using a wall plate. The valve module is designed to close automatically after the actuator is removed.

Automatic faucets include a water turbine for providing power to an electronic control circuit. The water turbine and control module are designed to measure the water flow rate of the faucet. The water turbine and control module are designed to detect a fault condition of the faucet. The control module is configured to execute a power management algorithm.

The automatic faucet includes a photovoltaic cell unit for providing power to an electronic control circuit. The automatic faucet includes an indicator for indicating status to a user. The indicator comprises an LED diode.

According to another aspect, an automatic faucet includes a housing configured to receive at least one water inlet conduit and having a spout for delivering water. The automatic faucet includes a valve module, a sensor module, a battery module, a turbine module, and a control module. The valve module includes a valve controlled by an electromagnetic actuator for controlling the flow of water out of the spout. The sensor module is configured to provide sensor data that is influenced by a user. The control module is configured to control opening and closing of the valve by providing a signal to the electromagnetic actuator. The control module is further configured to receive sensor data from the sensor module and execute a sensing algorithm. The control module is further configured to execute a power management algorithm for managing power generated by the water turbine and provided to or from the battery.

The present invention also relates to a sensor-based flow control system, such as a sensor-based faucet for delivering water to a sink. A sensor-based flow control system comprising: a valve inserted in the pipe and controlled by an electromagnetic actuator; and a sensor for generating a sensor output signal to an electronic control circuit, the electronic control circuit being constructed and arranged to provide a control signal to the electromagnetic actuator to open and close the valve. The sensor-based faucet includes control circuitry located in a faucet body mounted on a sink or includes a control module (control system unit) located below the sink. The faucet may be turned on by a capacitive sensor, an active IR sensor, a passive IR sensor, or an ultrasonic sensor that detects the approach, presence, or departure of a user.

Preferred embodiments of this aspect include one or more of the following features:

the control module (control system unit) may include an electromagnetic actuator (solenoid actuator), a battery pack, and a water turbine. The electromagnetic actuator can be automatically shut off so that the water does not need to be shut off in the case of maintenance, valve changes or filter cleaning.

The combination of a filter attached to a removable valve sleeve and an automatic shut-off associated with the electromagnetic actuator allows the filter to be inspected and cleaned without tools and without having to shut off the water supply.

Preferably, the faucet includes a water turbine and a rechargeable battery for providing power to the electronic control circuit. The water turbine and electronic control circuit are designed to measure the water flow rate of the faucet. The faucet may include a water turbine, a photovoltaic cell unit and a rechargeable battery, and the microcontroller may include a power management system for controlling input and output of power and charging the battery.

According to another aspect, a sensor-based faucet includes a water turbine positioned in a water stream flowing from the faucet. The water turbine includes a rotor coupled to rotor blades located within a water passageway having a predetermined flow rate, magnets, a stator, and electrical coils constructed and arranged to generate electrical power.

Preferably, the faucet including the water turbine is further constructed and arranged to detect minute amounts of water exiting the faucet. The faucet including the water turbine is also constructed and arranged to detect the flow rate of water exiting the faucet. The faucet is actuated by an automatic sensor and is further constructed and arranged to detect a malfunction of a component of the faucet based on a signal from the water turbine.

The water turbine includes: a rotor attached to the magnet thereby rotationally displacing the magnet during water flow; and an electrical coil fixed relative to the stator.

Advantageously, the control module is designed to facilitate easy installation and removal of water conduits (e.g., water hoses). Installation requires a simple pull/push to secure the pipe to the control system unit and/or to the faucet. After the water supply is shut off, the quick connect hose fitting allows the hose to be installed before the valve housing (manifold) is installed. In combination with a dedicated wall mounting bracket, the manifold can be easily installed and removed for servicing without tools. The present design uses a special allen wrench, or other key for screw tightening the control module cover against the bracket mounted under the sink.

The control module (control manifold) is designed to cooperate with the wall-mounting bracket. The manifold can be easily mounted to and removed from the wall bracket. The manifold is attached to the wall plate via a simple twisting action and is secured when the manifold cover is placed over the manifold.

The control system unit is rigidly and completely fixed by simple screw tightening. Once the cap screws are secured, the manifold cannot be removed from the wall mounting bracket (wall plate).

The control module manifold also includes a battery housing that holds the battery regardless of the orientation of the housing relative to the manifold. The battery case is mounted in only two ways (180 degree symmetry) and thus prevents wrong polarity mounting. The battery housing allows for "blind" installation, i.e., if the installer cannot see the location under the sink, but can still install the battery. Simply rotating 1/4 the battery cover ring slides the battery out for easy replacement. If the cell housing ring does not lock the cell (cell not secured), the cell housing cannot be mounted to the manifold, which gives the installer an alert. The battery housing is sealed against moisture via an O-ring and the battery housing is secured in the manifold via a snap fit.

The control module manifold also includes a water turbine. The turbine reduces power consumption and also allows accurate metering by reading the AC signal frequency, which is proportional to the flow rate, and is also optimized for different flow rates by the insertable flow nozzle, and is integrated into the manifold and used in fault detection (e.g., leakage and blockage). I.e. the turbine is turned by leakage or stopped by clogging.

The novel faucet allows the crown assembly to be easily installed and removed using one screw. Advantageously, the crown design and function can be easily changed, such as adding photovoltaic cells, display screens (e.g., LCD displays), and user interfaces.

The electromagnetic actuator may be coupled to only one valve inserted in one pipe delivering premixed hot and cold water. The electromagnetic actuator may be coupled to another type of valve to control the flow of hot and cold water in two separate conduits, as described in PCT application PCT/US 01/43277. Alternatively, the control signal may be delivered to two electromechanical actuators constructed and arranged to independently control two valves and thus independently control the water flow in two separate conduits with hot and cold water delivered to the faucet.

According to yet another aspect, the faucet may be an electronic faucet operated by its own batteries, which is capable of operating for more than two, three or more years between battery replacements. The faucet has a minimum number of moving parts and individual parts can be accessed very easily for maintenance. The faucet can be manufactured and maintained at relatively low cost.

According to another aspect, a novel interface for calibrating or programming a sensor-based faucet is provided. The interface interacts with the user via an object sensor coupled to a microprocessor that controls the flow of water in the faucet. The sensor-based faucet includes: a valve inserted in the conduit and controlled by an electromagnetic actuator; and a sensor for generating a sensor output signal to an electronic control circuit, the electronic control circuit being constructed and arranged to provide a control signal for opening and closing the valve. The control circuitry may direct the valve to provide a predetermined number of water bursts at different steps of the various algorithms to communicate with the user. The control circuit may control the valve to provide pulsed water delivery when a different problem is sensed (e.g., a battery low condition in one of the faucet elements, an electrical problem, or a mechanical problem).

According to yet another aspect, the faucet is constructed using a material that prevents or significantly reduces bacterial or other biological growth in the water being conditioned by the faucet. Further, the sensor-based faucet is configured to automatically execute a flush algorithm to flush water contained in the faucet for a predetermined period of time and thus flush bacterial contamination that may have developed inside the faucet. The control circuitry may also provide signals to optical, acoustic, or other indicators when such flushing algorithms are executed.

According to yet another aspect, a faucet has hot and cold water inlets and outlets. The sensor generates a sensor output signal that is provided to an electronic control circuit that is constructed and arranged to provide a control signal to the electromechanical actuator. The control circuit also provides a signal to an optical, acoustic or other indicator that signals when the actuator first opens the valve. The control circuit provides a signal to an indicator that continuously signals for a predetermined period of time to indicate to the user that the time interval specified in accordance with the need for effective hand washing has not expired. When the time interval expires, the user is thereby assured that he has met the relevant duration specification.

Drawings

FIG. 1 is a front perspective view showing a faucet mounted on a sink with a control system unit located below the sink.

FIG. 1A is a front perspective view of a faucet with the control system unit shown in an exploded view.

Fig. 2 and 2A are perspective views showing two embodiments of the faucet of fig. 1.

Fig. 3 is a perspective view of the faucet of fig. 1 with the faucet crown removed.

Fig. 3A is a perspective exploded view of a faucet without a faucet crown.

Fig. 3B and 3C are perspective exploded views of a faucet crown and a circuit board module, respectively, with the attachment for the faucet shown in fig. 3 designed for capacitive sensors and IR sensors.

FIG. 4 is a perspective exploded view of the control system unit located under the sink of the apparatus shown in FIG. 1.

Fig. 4A and 4B are perspective exploded views of the control system unit shown in fig. 4, with the various modules shown in greater detail.

Fig. 4C and 4D are perspective side views of the control system unit shown in fig. 4 with the cover removed, showing the actuator module rotated.

Fig. 4E shows a quick connection of the water pipes connected to the control system unit of fig. 4.

Fig. 5 is a perspective view of a wall accessory plate for attaching the control system unit shown in fig. 1 and 1A.

Fig. 6 and 6A are a perspective top view and a perspective bottom view, respectively, of the base holder of the control system unit shown in fig. 4A to 4D without the respective modules.

Fig. 7, 7-I, 7A and 7A-I are top and cross-sectional views of a control system unit with various modules attached.

Fig. 8 shows the cover of the control system unit in various views and detail views, which also show various attachment elements for attaching the cover to the base holder.

Fig. 8A is an exploded perspective view of the battery module shown in fig. 4A.

Fig. 8B is an exploded perspective view of the actuator module shown in fig. 4A.

Fig. 9 is a front perspective view showing another embodiment of the faucet mounted on a sink.

Fig. 9A and 9B are front and side views, respectively, of the faucet shown in fig. 9.

Fig. 10 is a cross-sectional side view of the faucet shown in fig. 9.

Fig. 10A is a cross-sectional, detailed side view of the faucet head of the faucet shown in fig. 10.

Fig. 10B is a cross-sectional side view of the faucet shown in fig. 10, showing the faucet head in an exploded view for better illustration.

Fig. 11 and 11A are top and cross-sectional views of the turbine module located in the faucet head shown in fig. 10A and 10B.

Fig. 11B is a perspective exploded view of the components located inside the faucet head, including the turbine module, the circuit board module and the ventilator.

Fig. 12, 12A, 12B, 12C and 12D are illustrations of turbines that include water flow surfaces that are all located inside the turbine module.

Fig. 13 shows an exploded perspective view of the control manifold inside the faucet shown in fig. 10 with the faucet enclosing structure removed and fig. 13A-13D show the mixing valve in detail.

Fig. 14 is a block diagram of a faucet element and control circuitry for controlling the operation of the faucet shown in fig. 1 or 9.

Fig. 15 is a block diagram of another embodiment of a faucet element and control circuitry for controlling the operation of the faucet shown in fig. 1 or 9.

Fig. 16A to 16G are circuit diagrams of the faucet element shown in the block diagram of fig. 15.

Fig. 17 shows the main operation and control of the tap shown in fig. 1 or 9.

FIG. 18 is a flow chart illustrating power management for the control circuit.

Fig. 19, 19A, 19B, 19C, and 19D show another flow chart illustrating power management for faucet control.

Fig. 20 is a flowchart showing battery contact control for supplying power to the control circuit.

Fig. 21, including fig. 21A, 21B and 21C, shows a flow chart of an algorithm for sensing the presence of a target at the faucet spout shown in fig. 1 or 9.

Fig. 22 is a flowchart illustrating target sensing for opening water in the flowchart of fig. 21.

Fig. 22A is a flowchart illustrating target sensing for turning off water in the flowchart of fig. 21.

Detailed Description

Referring to fig. 1, faucet 10 is shown mounted to sink 14 with faucet base 18 in contact with top sink surface 15. The faucet includes a housing or package body 17 and a faucet crown 16. Faucet 10 is electrically coupled to a control manifold (control system unit) 100 using electronic circuitry 11 and receives water via water line 12. Fig. 1A shows a faucet 10, with a control system unit 100 shown in an exploded view. The water line 12 is coupled to the control center unit 100 using a quick connect device (shown in fig. 4E) and provides mixed hot/cold water. That is, there is a hot-cold mixing unit (not shown in fig. 1 and 1A) located below the water tank 14. The control system unit 100 includes a plastic manifold 120 and a cover 105 attached to the wall attachment plate 106, as also shown in fig. 4 and 4A.

Fig. 2 and 2A show two different mounting embodiments of the faucet 10 to sink 14 shown in fig. 1. This mounting can be achieved using a quick-connect assembly comprising the rod 24 and the coupling elements 25A and 25B. The coupling assembly may include a gasket 22 or a thicker insulating element for electrically insulating the faucet from a sink made of metal. This insulation is important for proper operation of a capacitive sensor (described below) mounted with a metal sink. Fig. 2A shows another mounting embodiment of faucet 10, which uses the assembly of levers 28A and 28B and coupling elements 27A, 27B, 29A and 29B.

The faucet housing is actually constructed of a shell-like structure that forms an upright main body and an upper portion that includes a faucet crown having a spout extending from the main body to the aerator 38. The faucet crown (shown as faucet crown 34 in fig. 2 and 2A) includes a removable cover plate secured to a body. The cover may be replaced by an LCD display or another type of display to communicate with the user or to provide the user with entertainment or advertising related messages.

Fig. 3 and 3A show the faucet with the faucet crown 34 removed. The faucet 10 includes a flexible water conduit 12 having a quick connect 12A, the quick connect 12A being attachable to a faucet crown insert 36 that provides water to a ventilator 38. Fig. 3B is a perspective exploded view of faucet crown 34A, including a circuit board and cover plate designed for capacitive sensing of a user's hand. Fig. 3C is a perspective exploded view of faucet crown 34B, including a circuit board and cover plate designed for IR sensing of a user's hand (or alternatively designed for both capacitive and IR sensing).

Fig. 4 is a perspective exploded view of the control system manifold 100 positioned under a sink. Fig. 4A is a perspective exploded view of the control system manifold (control system unit) 100 with the cover 105 removed. The control system unit 100 is designed to cooperate with a wall mounting bracket 106 (shown in fig. 4 and 5) to attach to a lavatory wall below the sink.

Referring to fig. 4, 4A, 4B, 4C, and 4D, the control system unit 100 includes a valve module 150, a battery module 200, a turbine module 250, and an electronic control module 400 (shown in fig. 14). The valve module includes a valve housing, a lower valve body, an upper valve body, a filter, and an actuator module. The battery module includes a battery housing and a battery holder for receiving four 1.5V batteries. The turbine module includes a water turbine including a rotor assembly 260 and a stator assembly 270, as shown in detail in fig. 12-12D.

The valve module provides a valve that controls water flow to the faucet 10 using the actuator module and provides a shut-off valve for easy maintenance. When the actuator module is removed from the valve housing, there is no water flow through the control system unit 100. Referring also to fig. 7 and 7A, the actuator module 150 is inserted into a valve housing oriented to mate with the arrows on both elements, as shown in fig. 4D. When the actuator module 150 is rotated, for example, 45 degrees as shown in fig. 4C, water may flow through the valve module with the actuator open. Rotating the actuator module 150 approximately 45 degrees (from the position shown in fig. 4C to the position shown in fig. 4D) closes the valve for maintenance. The actuator module 150 includes an electromechanical actuator (solenoid actuator) described below. FIG. 8B is an exploded perspective view of the actuator module and valve including a water filter, also shown in FIG. 4A. The solenoid actuator controls the flow of water delivered from the ventilator 38 to the user.

The battery module 200 includes four batteries each providing 1.5 VDC. In the control system module 100, the surface or plastic manifold 120 and the cover 105 are cooperatively designed for a tight mechanical secure coupling. Fig. 8A is an exploded perspective view of the battery module. The battery housing located in the control system unit is designed to receive the battery module 200 regardless of the orientation of the housing with respect to the manifold. That is, the battery module 200 is mounted only in two ways (180 degree symmetry), and thus prevents wrong polarity mounting. The battery housing allows for "blind" installation, i.e., if the installer cannot see the location under the sink, but can still install the battery. Simply rotating 1/4 the battery cover ring will slide the battery out for easy replacement. If the cell housing ring does not lock the cell (cell not secured), the cell housing cannot be mounted to the manifold. The battery cell 200 is sealed against moisture via an O-ring and the battery housing is secured in the manifold via a snap fit.

Fig. 5 is a perspective view of a wall attachment plate 106 for attaching the control system unit 100 to a wall or another suitable surface. Plastic manifold 120, plastic cover 105 (shown in fig. 8), and wall attachment plate 106 include cooperating surfaces and are marked to facilitate servicing of control system manifold 100. The entire control system unit is designed to cooperate with the wall mounting bracket 106 for easy installation and attachment to and removal from the wall bracket. The manifold is attached to the wall plate 106 via a simple twisting action and is secured when the plastic cover 105 is placed over the plastic manifold 120. The unit is rigid and is fully secured by simple screw tightening. Once the cover screws (fig. 8) are secured, the manifold cannot be removed from the wall mounting bracket (wall plate) 106. The present design uses a special allen wrench (or other key) for the screws that secure the control module's cover 105. The various modules within faucet 10 and control system unit 100 are removable and easily replaced for quick service.

Fig. 6 and 6A are a perspective top view and a perspective bottom view of a plastic manifold (base holder) 120 for the control system unit 100. Fig. 7, 7-I, 7A, and 7A-I are cross-sectional views of the control system manifold 100. Fig. 10 shows the manifold cover 105 in several views and detail.

The cooperation of the valve module and the actuator module enables automatic shut-off and therefore does not require shut-off of the water in case of maintenance, valve change or filter cleaning. The combination of a filter attached to a removable valve sleeve and an automatic shut-off associated with the solenoid actuator allows the filter to be inspected and cleaned without tools and without having to shut off the water.

The actuator module includes a solenoid actuator (solenoid operator). The solenoid actuator includes a solenoid wound around an armature housing constructed and arranged to receive an armature including a plunger partially enclosed by a membrane. The armature provides a fluid passage for displacement of armature fluid between the distal and proximal portions of the armature, thus enabling rapid and efficient movement of the armature between the open and closed positions. The membrane is fixed with respect to the armature housing and is arranged to seal armature fluid within an armature pocket having a fixed volume, wherein displacement of the plunger (i.e., the distal portion or the armature) displaces the membrane with respect to the valve passage, thereby opening or closing the passage. This enables long-term operation of the low-energy battery.

Preferably, the actuator may be a latching actuator (including a permanent magnet for holding the armature) or a non-latching actuator. The distal part of the armature is arranged cooperatively with a different type of diaphragm designed to act on the valve seat when the armature is placed in its extended armature position. The solenoid actuator is connected to a control circuit configured to apply the coil drive to the coil in response to an output from the optional armature sensor. The armature sensor can sense the armature reaching an end position (open or closed position). The control circuit is capable of applying a coil drive signal directly to the coil in the first drive direction and is responsive to an output from the sensor meeting a predetermined first current termination criterion to start or stop applying coil drive to the coil in the first drive direction. The control circuit can direct or stop applying the coil drive signal to the coil in response to an output from the sensor meeting a predetermined criterion.

The faucet may be controlled, for example, by a solenoid actuator constructed and arranged to release pressure in the pilot chamber and thereby initiate movement of the piston, diaphragm or frame assembly from a closed valve position to an open valve position. The actuator may comprise a latching actuator (as described in US6,293,516, which is incorporated by reference), a non-latching actuator (as described in US6,305,662, which is incorporated by reference), or an isolating operator (as described in PCT application PCT/US/01/51098, which is incorporated by reference). The valve module may also be controlled manually by giving an electrical signal to the actuator driver (instead of the signal from the sensor) or by manually releasing the pressure in the pilot chamber as described in US6,874,535 (incorporated by reference).

Referring to fig. 4E, the control system unit is designed so that a water pipe supplying water to the faucet 10 is easily installed and removed. Installation requires a simple push-pull to fix the conduit (e.g., hose) relative to the mixing valve or relative to the faucet. In conjunction with a dedicated wall mounting bracket 106, the control system unit 100 can be easily installed and removed for repair without tools.

Referring to fig. 4A and 4B, the turbine module 250 is also shown in fig. 12-12D, the water turbine module 250A including a rotor assembly 260 and a stator assembly 270 that form a francis turbine disposed in the water passageway within the control system unit. The rotor is integrally fixed to the rotating shaft turbine blade and the magnet 262. The rotor magnets are opposed to the stator poles through the wall of the non-magnetic member. The stator assembly 270 includes stator coils 271. Each stator coil is arranged to interconnect with magnetic flux passing through the stator poles 272 and 273. When the water turbine rotates by receiving the water flow, the magnet rotates relative to the stator pole. The flow of magnetic flux to the rotor and stator poles changes. As a result, current flows to the stator coil in such a direction to prevent the flow of magnetic flux from being distorted. After the current is rectified, it is stored, for example, in a rechargeable battery using the power management algorithm described below.

In the turbine module 250, a claw-pole stator uses multi-stage magnets as generators, and a rotor is rigidly attached to the propeller 264 and submerged in water on a rotating shaft. The magnet slides over the pusher in a novel arrangement and is secured by a plastic pin (fig. 12C). The stator-rotor arrangement preferably has 12 poles (but may also have a smaller or greater number of poles to optimize energy output). The generator also acts as a tachometer to effectively measure the flow rate through the faucet. This arrangement also enables fault monitoring and detection of a plugged line or a plugged filter. The corresponding signals are provided to the microcontroller as shown in fig. 14 and 15.

Still referring to fig. 12-12D, the francis turbine has a single fluid passageway that is designed to enable a larger cross-sectional flow passageway for more than 0.7GPM (gallons per minute) to 0.8GPM to reduce internal flow resistance (i.e., pressure loss). On the other hand, for low flow rates as low as 0.35GPM, the turbine module uses factory installed nozzles that increase the power output of the generator. The nozzle is held in place by a small tab and groove molded into the manifold nozzle shown in fig. 12. This design requires a relatively small amount of space.

The water turbine module 250 reduces power consumption and also allows accurate water metering by reading the AC signal frequency, which is proportional to the flow rate and is also optimized for different flow rates by the insertable flow nozzle. The insertable flow nozzle is integrated in the manifold.

As described above, magnetic flux flows between the rotor and the stator poles in the generator. The magnetic flux acts as a resistance when the water turbine is rotated by the force of the flowing water. That is, the magnetic flux generated between the rotor and the stator poles is used as a detent torque to brake the operation of the water turbine during startup and rotation of the water turbine. The turbine of the present invention is designed to start and detect small water flows.

The turbine module may be replaced by another rechargeable power module (e.g., one or several photovoltaic cells). The photovoltaic cell unit may be mounted on top of the crown assembly.

Fig. 9 is a front perspective view showing another embodiment of the faucet mounted on a sink with the control system unit located inside the faucet body. Fig. 9A and 9B are front and side views, respectively, of the faucet shown in fig. 9.

Fig. 10 is a cross-sectional side view of the faucet shown in fig. 9.

Fig. 10A is a cross-sectional, detailed side view of the faucet head of the faucet shown in fig. 10.

Fig. 10B is a cross-sectional side view of the faucet shown in fig. 10, showing the faucet head in an exploded view for better illustration.

Fig. 11 and 11A are top and cross-sectional views of the turbine module located in the faucet head shown in fig. 10A and 10B.

Fig. 11B is a perspective exploded view of the components located inside the faucet head, including the turbine module, the circuit board module and the ventilator. Fig. 12, 12A, 12B, 12C and 12D are several views of a turbine including water flow surfaces all located inside the turbine module.

Fig. 13 shows an exploded perspective view of the control manifold located inside the faucet shown in fig. 10 with the faucet enclosure removed. The faucet includes a valve module including an actuator module 150, a housing 155, a lower valve module 165, and an upper valve module 170, as shown in fig. 13A-13E. The faucet also includes a mixing valve 140, a battery module 250, and a turbine module 350.

Fig. 14 is a block diagram of control electronics 400 for controlling the operation of the faucet 10. The control electronics preferably use a capacitive sensor 50, or alternatively an active IR sensor or a passive IR sensor. The active IR sensor includes an IR emitter 420 for emitting an IR light beam and an IR receiver 424 for detecting reflected IR light. Passive IR sensors use passive optical detectors for detecting the presence of a user as described in PCT applications PCT/CN03/38730 and PCT/US03/41303, both of which are incorporated by reference.

Referring to fig. 14, the control electronics 400 include a controller 402 powered by the battery 200. The controller 402 is preferably composed ofThe manufactured microcontroller MC9S08GT 16A. The microcontroller executes various detection and processing algorithms that are preferably downloaded. However, the controller and algorithms may also be implemented in the form of dedicated logic circuits, ASICs, or the like. Control electronics 400 includes a power switch 405, a DC-DC converter 406, and a solenoid driver 408. Solenoid driver 408 provides a drive signal to solenoid 150 that is monitored by solenoid feedback amplifier 412 and signal conditioner 414. The controller 402 communicates with an indicator driver 434 that drives a visible diode 436 (e.g., a blue diode or a red diode, also shown in fig. 3C), the visible diode 436 being used to communicate with the user.

As shown in FIG. 14, the active optical sensor includes an IR diode driver 422 that provides power to the IR emitter 420 and an IR sensor amplifier 426 that receives a signal from an IR receiver 424. The entire operation is controlled by the controller 402.

The IR diode driver 422 may be designed to gradually increase or decrease the optical power output depending on the target and environmental conditions. The same applies to IR receivers using IR sensor amplifier 426. Typically, only one of the two approaches is used, as one approach is sufficient to achieve this. The following are examples of conditions: if the environment is too bright for IR, the system enhances the optical emission signal. If the targets are too close, such as in a private room, the system reduces the IR signal to save power. If the target is not sufficient to cause IR reflection, the system enhances the IR signal from the IR emitter 520 or for the IR sensor amplifier 526.

The system 402 uses an optional speech synthesizer 440 connected to a speaker 442 to provide a user interface. An optional flow sensor regulator 444 connected to a flow sensor 446 is used to detect water flow through the faucet. Alternatively, a sensor may be used to detect an overflow of water in the sink and provide a signal to the controller 402 to turn off the automatic faucet.

The system may include an optional RF transceiver 450 connected to an antenna 452 for wireless communication with a remotely located central processor or network. The present design may be deployed with a network of wirelessly connected bathroom faucets and sanitary appliances. The remotely located network enables monitoring and collection of information about the faucet and the appliance. Communication between the faucet and the appliance preferably uses low frequency RF signals, while communication with a remotely located network node preferably uses high frequency RF signals.

Typically, wired or wireless data communication is used to transmit information as it relates to the operational status of the bathroom faucet and the sanitary fixture. The information transmitted (along with the device ID) may include battery voltage, number of flushes, the unit is running (cannot be shut down), no water (cannot be turned on), etc. Using RF transceiver 450 and antenna 452, the system can receive information, such as commands initiated from a remote location. The fixed devices may communicate with each other in a network fashion. The stationary device may communicate with a near-end central unit, and the unit may transmit data (wired or wireless) to a wider network, such as the internet. In a preferred embodiment, the user initiates a wide location (locationwide) diagnostic task by requesting that each fixed location be turned on and then off. Each fixture, in turn, reports successful/unsuccessful operation. The fixture may also report other variables such as battery voltage, number of flushes, etc. The user then collects the information and schedules maintenance based on the results. This is particularly beneficial in situations where maintenance personnel are currently dispatching staff in an establishment (such as a convention center, baseball stadium, etc.) to monitor the operating status of the fixtures and manually do the recording before the event occurs.

According to another embodiment, the control electronics include a microprocessor, which is a microcontroller of an 8-bit CMOS microcontroller TMP86P807M manufactured by Toshiba. The microcontroller has a program memory of 8 kbytes and a data memory of 256 bytes. Programming is accomplished using a Toshiba adapter socket with a generic PROM programmer. The microcontroller operates at three frequencies (f)_c=16MHz，f_c=8MHz and f_s=332.768 kHz) where the first and second clock frequencies are used for normal mode and the third frequency is used for low power mode (i.e. sleep mode). The microcontroller operates in a sleep mode between various actions. To conserve battery power, the microcontroller periodically samples the optical sensor for an input signal and then triggers the power consumption controller. The power consumption controller energizes the signal conditioner and other components. Differently, the optical sensor unit, the voltage regulator (or booster), and the signal regulator are not powered to save battery power. During operation, the microcontroller also provides indicating data to an indicator, such as a visual diode or speaker. The control electronics may receive signals from the passive optical sensor or the active optical sensor described above. The low battery detection unit may be a low battery detector model No. TC54VN4202EMB available from microchip technology. The voltage regulator may be a voltage regulator that is also available from Microchiptechnology (http:// www.microchip.com)The resulting voltage regulator was model number TC55RP3502 EMB. The microcontroller may alternatively be a microcontroller available from national semiconductor under part number MCUCOP8SAB728M 9.

The faucet may include one or several photovoltaic cells 435, alone or in combination with a water turbine, to produce a voltage proportional to the amount of light received. When the system 400 is powered on and begins operating, the system registers the voltage and then continues to monitor the voltage. On first power-up, if the photovoltaic cell unit has no output voltage, this means a dark environment and therefore the unit marks time and counts for a predetermined amount of time. If the time is long enough, e.g., hours and days, and no target is detected within the same time period, the faucet system is powered on, but no one is using the toilet (i.e., the lights are off), so the system goes into a power saving mode. In this mode, the system scans the target at a much lower frequency to conserve battery power. The system may also stop or slow other functions such as scanning an override button, battery voltage, etc. The use of photovoltaic cells is described in PCT application PCT/US2008/008242 filed on 3.7.2008, which is incorporated by reference.

FIG. 15 is a block diagram of another embodiment of a control circuit for controlling the operation of the faucet shown in FIG. 1.

Fig. 16A to 16G are circuit diagrams of the control circuit shown in the block diagram of fig. 15.

Fig. 17 illustrates faucet operation using state diagram 200. The processor executes the algorithm by first performing all initialization, setting the interrupt to power on (state 501). Next, the power of all power supplies is checked in the all power supply check state (state 506). If there is a battery A/D error or the microcontroller runs out of external power, the algorithm again enters state 501 (transition 504). Additionally, for normal power levels and if there is no solenoid activation, the algorithm enters (via transition 512) large capacitance charge control (state 518).

At state 506, if a normal power level is present and if there is solenoid activation, the algorithm proceeds 508 to solenoid on timer control (state 510). After the target is no longer detected or after a preselected period of time (520), the algorithm enters a close solenoid state (state 524). Thereafter, the algorithm transitions (via transition 526) to the large capacitance charge control (state 518). Since the large capacitance charge control (state 518), the algorithm transitions (via transition 528) to the capacitance sensor control (state 530).

In capacitive sensor control (state 530), the system performs object detection, and when an object is not detected and the solenoid is activated, the system transitions (transition 534) to red LED flashing control (state 550). Alternatively, when a target is detected (fig. 22 and 22A), the system transitions (transition 536) to an open solenoid state (state 540), in which the solenoid is open. Alternatively, when the target is outside the detection zone when the solenoid is open, the system transitions (transition 532) back to the close solenoid state (state 524) where the solenoid is closed. Additionally, when there is no sensing activity, and there is no LED flashing and a second battery check is not needed, the system transitions from state 530 (via transition 538) to the sleep state (state 570). From the red LED blink control state (state 550), the system transitions (transition 552) to the sleep state (state 570) after there is an LED blink and a second battery check is needed. However, if the flag is set to the second battery check, the system transitions (transition 556) to the second battery check control state (state 560). Further, after the solenoid on state (state 540), a second battery check is required, the system transitions (transition 546) to a second battery check control state (state 560), and then after the battery check is complete, the system transitions (transition 554) to a sleep state (state 570).

After each wake-up, the system transitions (transition 574) from the sleep state (state 570) to the all power check state (state 506). If there is no turbine power, or no battery power (or low battery power less than 3.7V10 minutes), or no solar energy, the system transitions (transition 572) back to the sleep state (state 570).

Fig. 18 is a flowchart showing power management of the control circuit. The system periodically checks the battery power, the power from the turbine and optionally the power provided by the photovoltaic cell. Fig. 19, 19A, 19B, 19C, and 19D illustrate power management of the control circuit.

Fig. 20 is a flowchart showing battery contact control for supplying power to the control circuit.

Fig. 21 is a flow chart illustrating an algorithm for sensing the presence of a target at the faucet spout shown in fig. 1 or 9.

To control faucet operation, the system performs a capacitive sensing operation. Starting from power-on or any type of reset, the system first performs self-calibration and initialization and then acts as a state machine. After waking up from its sleep, the system scans the capacitive sensor for current raw data, updates the baseline, and then performs the relevant tasks based on its current state. After the current task is completed, the processor will go to sleep again.

The calibration process includes several processes: "normalized raw data", "environmental check", and "determine water effects". Normalizing the raw data adjusts the raw data over a dynamic range (a range approaching 11500). The environmental check determines that the noise level is within a predetermined range, and if not, the system blinks the LED and keeps monitoring the noise level until it falls within the predetermined range. If the system remains at this stage, it indicates that the system is not suitable for the environment, as shown in FIG. 21A. Determining water effect opens water to determine water effect and determine if this is 1.5/0.5GPM spout/head. It is simply an initial value that the system will automatically update during its normal operation. When the calibration is complete, the system turns on water a second time to indicate that the system is ready for use.

The system uses a total of 8 states: TARGETCLEAR, INVERIFY, TOUCHED, TARGETSET, OUTVERIFY, PROHIBITION, PAUSE and CLEAN. The system will be in one and only one of these states at any given time.

At state TARGETCLEAR, the target signal is always cleared. The system updates the signal threshold, monitors the noise level and determines the signal threshold and the number of signals to be validated as targets. If the difference between the current data and the baseline is greater than the signal threshold and the data continues to increase beyond a certain value, the system enters the invert state and the scan is accelerated. In the invert state, the target signal will be set if the data verification is in that state. The system determines when the target signal needs to be set. If the signal data exceeds the signal threshold for a predetermined time, the system turns on the target signal and enters TARGETSET a state and stores the current raw data as part of a reference for determining when the target was removed. If this is triggered 5 times in 30 seconds, the system enters the PAUSE state.

In the touchhed state, the target signal is cleared after the target has been contacted for 5 seconds. The system determines to clear the target signal and clears the target signal if the target is contacted for more than 5 seconds. The system determines what to do from contact to no contact. If the contact is for more than 5 seconds, the system enters the CLEAN state. If the contact is less than 5 seconds, the system returns to TARGETSET.

In the TARGETSET state, the target signal is always set. The system calibrates for water effect during the first 2 seconds and determines the water effect value, after which the following parameters are set:

signal threshold for water out time; and

a reference value for effluent to be used to determine whether the target has been removed. The system determines whether the OUTVIFY state needs to be entered.

The system enters the OUTLIFY state if either of the following occurs:

end of run time

Raw data unchanged above a predetermined range

The signal data is less than the signal threshold

Raw data is below a reference that was predetermined just before water was turned on.

In the OUTVIFY state, the target signal will be cleared if the signal is verified. The system tracks the water run time and clears the target signal if the water run time is over, and the system enters the PAUSE state. The system determines whether the data is stable and clears the target signal when the data is within a predetermined range for 1.5 seconds, and then enters a state progress. The system determines whether the data falls below the reference value, clears the target signal when the data is within a predetermined range for 1.5 seconds, and then enters a state progress. The system determines whether the data is below a signal threshold, clears the target signal when the data is within a predetermined range for 1 second, and then enters a state progress.

In the inhibit state, the target signal is always cleared. The system determines when to go out of the state. If the system has been in this state for a predetermined minimum off time, the system will enter TARGETCLEARED state.

In the PAUSE state, the target signal is always cleared. The system determines when to exit the state. If the system has been in this state for a predetermined time, the system will enter TARGETCLEARED state. In the CLEAN state, the target signal is always cleared. The system determines when to exit the state. If the system has been in this state for a predetermined time, the system will enter TARGETCLEARED state.

Referring to fig. 14 and 15, capacitance detector processor 465 communicates with microcontroller processor 402 using a high-to-low heartstop pulse every 5 seconds to indicate that it is in good condition. In the pressed state, the system stops scanning when port 2.5 is low to save power. When LED power is requested, the system sets port 1.5 low to indicate that it needs power to turn on the LED.

Fig. 22 is a flowchart illustrating target sensing for turning on water, and fig. 22A is a flowchart illustrating target sensing for turning off water in the flowchart of fig. 21C. The algorithm is described for proximity and contact capacitive sensors (e.g., manufactured by cypress semiconductor). However, the algorithm is also applicable to active IR sensors using light sources and light detectors that detect reflected signals from the user. The target detection algorithm (and any algorithm described herein) may be embedded in the design chip or may be downloaded to a corresponding processor.

Referring to FIG. 22, the target detection algorithm for "open water" begins with a target purge state (water off).

Scanning the sensor at 8Hz to read out sensor data

Signal = current raw data-baseline

If the signal > threshold, proceed to verify state

In the verify state, the threshold is increased by 5

In the verify state, the threshold is increased by 5

If the signal > threshold value continuously exceeds the "verify" times, the water is turned on

The threshold and "verify" times are dynamically updated as follows:

for the past 5 seconds:

noise level = maximum raw data-minimum raw data

If the noise level is low

Threshold = high sensitivity level

Verification =3

If the noise level is middle

Threshold = medium sensitivity level

Verification =4

If the noise level is high

Threshold = low sensitivity level

Verification =5

Under "verify" < verify threshold, the sensor is scanned to read out the sensor data.

Referring to fig. 22A and 22A-I, the target detection algorithm for "turn off water" begins after the water is turned on.

Once the water is turned on, it will remain on for at least one second, even if the target leaves immediately.

The target threshold will be set to:

threshold = target signal at trigger + water effect-15

Three counters are used to determine target departure.

The counter 1 will count the number of signals less than the threshold

The counter 2 will count the number of unchanged signals

The counter 3 will count the number of signal reductions

If the current signal is less than the threshold, the counter 1 is incremented by 1, otherwise the counter 2 is reset to 0.

The stable reference is initialized to the first signal data. If the difference between the current signal and the stable reference is less than the predetermined range, the counter 2 is incremented by 1, otherwise the counter 2 is reset to 0 and the stable reference is reset to the current signal.

If the current signal is less than the previous signal, the counter 3 is incremented by 1 and the decremented value is incremented to the decremented total signal, otherwise the counter 3 is reset to 0 and the decremented total is reset to 0.

If counter 1 is greater than 8, or counter 2 is greater than 16, or counter 3 is greater than 8, the reduced total signal is greater than 45, or counter 3 is greater than 12. The water is turned off as shown in fig. 22A-I.

After the water is shut off, the threshold is reset to 15.

The above-described sensing algorithm overcomes several problems associated with capacitive proximity sensing. In a capacitive signal, the sensing area is uncertain, especially when water is flowing and the human hand is only part of the capacitance source. The signal/noise ratio is not sufficiently large and noise may cause false detections. The signal strength varies for different power supplies (e.g., batteries or power adapters). To overcome these problems, sensing algorithms automatically calibrate the baseline based on the real application environment. The sensing algorithm keeps track of the noise signal level and therefore the applicable signal threshold. The sensing algorithm tracks signal trends (not just intensities) to determine the presence of a human hand. Furthermore, the sensing algorithm uses independent parameters for different power supplies.

The faucet may use an alternative optical transceiver, described in US patent US5,979,500 or US patent US5,984,262, and also in co-pending US applications 10/012,252 and 10/012,226, all of which are incorporated by reference. Microcontroller COP8SAB and COP8SAC made by national semiconductor, or microcontroller TMP86c807M made by Toshiba. To conserve power and significantly extend battery operation, the wake-up period is much shorter than the sleep period. The sleep time may be 100 milliseconds, 300 milliseconds, or 1 second depending on the controller mode.

The electronic faucet is also in communication with the user through a novel "burst interface" that provides a signal to the user in the form of a water bundle emanating from the faucet. Alternatively, the electronic faucet may include a novel optical or acoustic interface. Electronic faucets are designed to prevent wasting water when, for example, an object is permanently located in a sink.

Claims (16)

1. An automatic faucet comprising:

a housing configured to receive at least one water inlet conduit and having a spout for delivering water;

a valve module comprising a valve controlled by an electromagnetic actuator for controlling the flow of water out of the spout;

a sensor module configured to provide sensor data affected by a user;

a control module configured to control opening and closing of the valve by providing a signal to the electromagnetic actuator, an

The control module configured to receive sensor data from the sensor module and execute a sensing algorithm that keeps track of noise signal levels and dynamically adapts signal thresholds, the sensing algorithm tracks signal trends to determine the presence of a user,

wherein the control module is configured to execute the sensing algorithm with independent parameters for different power supplies.

2. The automatic faucet of claim 1 wherein said sensor module includes a capacitive sensor.

3. The automatic faucet of claim 2, wherein said capacitive sensor comprises a touch capacitive sensor.

4. The automatic faucet of claim 2 wherein said capacitive sensor comprises a proximity capacitive sensor.

5. The automatic faucet of claim 1 wherein said sensor module includes an active infrared sensor including an infrared emitter and detector.

6. The automatic faucet of claim 1 including an indicator for indicating status to a user.

7. The automatic faucet of claim 1 wherein said valve module and said control module are located within a control system unit located below a top surface of a sink.

8. The automatic faucet of claim 7 wherein said control system unit includes a quick connect fitting for connecting said water inlet conduit.

9. The automatic faucet of claim 1 further comprising a water filter associated with said actuator.

10. The automatic faucet of claim 7 wherein said control system unit is mounted to a wall using a wall plate.

11. The automatic faucet of claim 1 wherein said valve module is designed to automatically close after removal of said actuator.

12. The automatic faucet of claim 1 including a water turbine for providing electrical power to said electronic control circuit.

13. The automatic faucet of claim 12 wherein said water turbine and said control module are designed to measure the water flow rate of said faucet.

14. The automatic faucet of claim 12 wherein said water turbine and said control module are designed to detect a fault condition of said faucet.

15. The automatic faucet of claim 12 wherein said control module is configured to execute a power management algorithm.

16. A method of controlling water flow in an automatic faucet, comprising:

providing an automatic faucet comprising:

a housing configured to receive at least one water inlet conduit and having a spout for delivering water;

a valve module comprising a valve controlled by an electromagnetic actuator for controlling the flow of water out of the spout;

a sensor module configured to provide sensor data affected by a user;

a control module configured to control opening and closing of the valve by providing a signal to the electromagnetic actuator;

executing a sensing algorithm that keeps track of noise signal levels and dynamically adapts signal thresholds, the sensing algorithm tracking signal trends to determine the presence of a user; and

the opening and closing of the valve is controlled by providing a signal to the electromagnetic actuator,

the method also includes executing the sensing algorithm with independent parameters for different power supplies.