Note: Descriptions are shown in the official language in which they were submitted.
1
AUTOMATIC FAUCETS
This application claims priority from and is a continuation-in-part of PCT
Application PCT/US2012/000150, filed on March 15, 2012, entitled "Automatic
Faucets" and US Provisional Application 61/574,345, filed on July 31, 2011,
entitled 'Automatic Faucets."
This invention relates to automatic faucets and methods for operating
and controlling such faucets.
BACKGROUND OF THE INVENTION
In public facilities or large private facilities, there are several different
types of automatic faucets in use today. There are also metering faucets that
are manually activated to turn on the water by pressing the faucet head and
are hydraulically timed so that the water remains on for a set period of time
after depression of the head. Some of these faucets have separate head
allowing separate control over the hot and cold water. Other metering faucets
mix the incoming hot and cold water streams and, when actuated, deliver a
tempered output stream.
Also known is a manually activated metering faucet whose on-time is
controlled electronically. Still other known faucets are activated
electronically
when the user positions a hand under the faucet. Automatic water dispensing
systems have provided numerous advantages including improved sanitation,
water conservation, and reduced maintenance cost. Since numerous
infectious diseases are transmitted by contact, public-health authorities have
encouraged the public and mandated to food workers the exercise of proper
hygiene including washing hands effectively. Effective hand washing has
been made easier by automatic faucets. Automatic faucets typically include
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an object sensor that detects presence of an object, and an automatic valve
=that turns water on and off based on a signal from the sensor. If the water
temperature in an automatic faucet is not in an optimal range, individuals
tend
to shorten their hand washing time. To obtain an optimal water temperature,
a proper mixing ratio of hot and cold water and proper water actuation has to
be achieved. Automatic faucets usually use a preset valve that controls water
flow after mixing.
The hydraulically timed faucets are disadvantaged in that it is difficult to
accurately control the on-time of the faucet over the long term because of
mains pressure changes and foreign matter build up in the faucet which can
adversely affect the hydraulic controls within the faucet. Furthermore, some
faucets can not always discriminate between a user's hand and other
substances and objects which may be brought into proximity to the faucet,
e.g., a reflective object disposed opposite the faucet's infrared transceiver,
soap build up on the faucet's proximity sensor, etc. Resultantly, those prior
faucets may be turned on inadvertently and/or remain on for too long a time
resulting in wastage of water
There is still a need for reliable automatic faucets that do not waste
water and have energetically efficient operation.
SUMMARY OF THE INVENTION
The present invention generally relates to automatic sensor based
faucets and methods of operating such faucets.
According to one aspect, an automatic faucet includes a housing
forming partially an internal barrel and a faucet head and being constructed
to
include at least one water inlet conduit extending into the barrel and a water
outlet for delivering water from a spout. The automatic faucet also includes a
faucet crown removably mounted on the faucet head. The automatic faucet
also includes inside the barrel a valve module, a sensor module, and a control
module. The valve module includes an electromagnetic actuator for controlling
the water flow from the water outlet. The sensor module is constructed to
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provide sensor data influenced by a user. The control module constructed to
receive the sensor data from the sensor module. The internal barrel and the
faucet head are constructed and arranged to releasably enclose and retain
the valve module, the sensor module and the control module.
Preferred embodiments may include one or more of the following
features: The control module is located on a circuit board removably mounted
inside the faucet head. The circuit board is removable after removing the
faucet crown from the faucet head.
The automatic faucet includes a turbine module constructed to
generate electrical power. The turbine module is located inside the faucet
head and is removable for servicing. The turbine module is constructed to
generate electrical power, and the turbine module is located inside the faucet
head and being removable after removing the faucet crown from the faucet
head.
The valve module includes a housing comprising a mixing valve
module cooperatively arranged with a shut-off cartridge. The shut-off
cartridge is designed for turn shut-off upon removal of the actuator and
associated actuator housing. The automatic faucet may include a mixing
handle for controlling the mixing valve module. The valve module includes a
housing comprising a mixing valve module cooperatively arranged with a
shut-off cartridge and the turbine module is constructed to receive water flow
from the shut-off cartridge.
According to another aspect, an automatic faucet includes a housing
constructed to receive at least one water inlet conduit and having a spout for
delivering water and a valve module including a valve controlled by an
electromagnetic actuator for controlling the water flow from the spout. The
faucet also includes a sensor module constructed to provide sensor data
influenced by a user, and a control module constructed to control opening and
closing of the valve by providing signals to the electromagnetic actuator. The
control module is constructed to receive sensor data from the sensor module
and execute a sensing algorithm that keeps track of a noise signal level and
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dynamically adapts a signal threshold, the sensing algorithm tracking signal
trend to determine a presence of a user.
Preferred embodiments may include one or more of the following
features: The control module is constructed and programmed to execute the
sensing algorithm utilizing separate parameters for different power supply
sources. There may be one or more sensor modules and the sensor module
may include a capacitive sensor. The capacitive sensor includes a touch
capacitive sensor, or the capacitive sensor includes a proximity capacitive
sensor. Alternatively, the sensor module includes an active infra-red (IR)
sensor comprising an infrared emitter and detector, or a passive infra-red
sensor comprising an infrared detector. Alternatively, the sensor module
includes an ultrasonic sensor detecting approach, presence, or departure of a
user.
The valve module, the sensor module and the control module are
located in the housing of the faucet. Alternatively, the valve module and the
control module are located in a control system unit located below a top
surface of a sink. The control system unit may include a quick connect fitting
for connecting the water inlet conduit. The control system unit includes a
water filter associated with the actuator.
The control system unit is mounted on a wall using a wall plate. The valve
module is designed for auto shut off upon removal of the actuator.
The automatic faucet includes a water turbine module for providing
power to the electronic control circuit. The water turbine and the control
module are designed to measure a water flow rate of the faucet. The water
turbine and the control module are designed to detect a fault condition of the
faucet. The control module is constructed to execute a power management
algorithm.
The automatic faucet includes a photovoltaic cell for providing power to
the electronic control circuit. The automatic faucet includes an indicator for
indicating status to a user. The indicator includes an LED diode, an acoustic
indicator, or a display.
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According to yet another aspect, 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.
5 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.
Preferred embodiments may include one or more of the following
features:
The control module (control system unit) may include the valve module
including the electromechanical actuator (a solenoid actuator) and an optional
filter. The actuator housing is constructed to enables an auto shut-off by
turning the actuator housing (i.e., turn shut-off) and thus there is no need
to
shut the water off in case of maintenance, valve changing, or filter cleaning.
The combination of filter attached to removable valve module (i.e., valve
cartridge) and the turn shut-off associated with the electromagnetic actuator
allows for inspecting and cleaning of the filter without tools and without
having
to shutoff the water supply.
According to yet another aspect, a sensor based faucet includes a
water turbine module located in the water flow discharged from the faucet.
The water turbine includes a rotor coupled to rotor blades located within the
water path having a predetermined flow rate, a magnet, a stator and an
electrical coil constructed and arranged to generate electrical power.
Preferably, the faucet includes the water turbine for providing power to
the electronic control circuit and a rechargeable battery. The water turbine
and the electronic control circuit are designed to measure a water flow rate
of
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the faucet. The faucet may include a water turbine, a photovoltaic cell and a
rechargeable battery, and the microcontroller may includes a power
management system for controlling input and output of electrical power and
charging of the battery.
Preferably, the faucet including the water turbine are further
constructed and arranged to detect a minute amount of water leaving the
faucet. The faucet including the water turbine are further constructed and
arranged to detect a flow rate of water leaving the faucet. The faucet is
activated by an automatic sensor and is further constructed and arranged to
detect a malfunction of a faucet element based on a signal from the water
turbine.
Advantageously, the control system unit is designed for easy
installation and removal of water conduits (e.g., water hoses) using a quick
connect design. The installation requires a simple pull / push to secure the
conduits to the control system unit and/or to the faucet. After shutting off
the
water supply, the quick connect hose fittings allow installation of hoses
prior to
installing the valve housing (manifold). In combination with the special wall-
mounting bracket, the manifold can be easily installed and removed for
repairs without tools. The present design uses a special Allen wrench, or
other key for a screw securing the cover of the control module with respect to
a bracket mounted below the sink.
The control module (control manifold) is designed cooperatively with a
wall-mounting bracket. The manifold provides for easy installation and
removal onto the wall bracket. The manifold attaches to the wall plate via a
simple twist action and is secured as soon as the manifold cover is put over
the manifold.
The control system unit is rigidly and totally secured by a simple screw
tightening to a wall plate. Once the cover screw is secured, the manifold
cannot be removed from the wall mounting bracket (wall plate).
The control system unit also includes a battery module that connects
batteries inside a battery case regardless of orientation of the case with
respect to the holder. The battery case can only be installed two ways (180
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degree symmetry) and therefore prevents wrong polarity installation. The
battery case allows for "blind" installation, i.e., if installer cannot see
the
location under the sink but still can install the batteries. A simple quarter
turn
of the battery cover ring will make the batteries slide out for easy
replacement.
If the battery cover ring is not locking the batteries (batteries not secured)
the
battery case cannot be installed onto the manifold, which alerts the
installer.
The battery case is sealed via an o-ring from humidity and the battery case is
secured in the manifold via snaps.
The control module manifold also includes a water turbine. The turbine
reduces power consumption and also allows for precise metering by reading
the AC signal frequency which is proportional to the flow rate and also
optimized for different flow rates with an insertable flow nozzle and
integrated
in the manifold and fault detection such as leaks and clogs. That is, the
turbine turns for leaks or stops for clogs.
The novel faucet provides for easy installation and removing the crown
assembly using one screw. Advantageously, the crown design and function
can be easily changed such as adding photovoltaic cells, display screens
(e.g., LCD display) and user interfaces.
The electromechanical actuator may be coupled to only one valve
interposed in one conduit delivering premixed hot and cold water. The
electromechanical actuator may coupled to another type of a valve for
controlling flow of hot and cold water in two separate conduits, as described
in
PCT application PCT/US01/43277. Alternatively, the control signals may be
delivered to two electromechanical actuators constructed and arranged to
control separately two valves and thereby control separately water flow in two
separate conduits with hot and cold water delivered to a faucet.
According to yet another aspect, the faucet may be self-contained
battery operated, electronic faucet which can operate for over two, three or
more years between battery replacements. The faucet which has a minimum
number of moving parts, and the individual parts may be accessed quite
easily for maintenance purposes. The faucets can be manufactured and
maintained at relatively low cost.
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According to yet another aspect, there is a novel interface for
calibrating or programming a sensor-based faucet. The interface interacts
with a user via an object sensor coupled to a microprocessor for controlling
the water flow in the faucet. The sensor-based faucet includes a valve
interposed in a conduit and controlled by an electromechanical actuator, and
a sensor for generating sensor output signals to an electronic control circuit
constructed and arranged to provide the control signals for opening and
closing the valve. The control circuit may direct the valve to provide a
predetermined number of water bursts or light flashes at different steps of
various algorithms to communicate with a user when sensing different
problems such as a battery low state, an electrical problem or a mechanical
problem in one of the faucet's elements.
According to yet another aspect, the faucet has a hot and cold-water
inlet and an outlet. A sensor generates sensor output signals provided to an
electronic control circuit constructed and arranged to provide control signals
to
an electromechanical actuator. The control circuit provides also signal to an
optical, acoustic or other indicator starts signaling when the actuator first
opens the valve. The control circuit provides signals to the indicator that
continues signaling for a predetermined duration to indicate to a user that a
time interval prescribed as necessary for effective hand washing has not yet
expired. When the interval does expire, the user is thereby assured that he
has complied with the relevant duration regulation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view showing a faucet installed on a sink
with a control system unit located below the sink.
FIG. 1A is the front perspective view of the faucet with the control
system unit shown in an exploded view.
FIGs. 2 and 2A are perspective views showing two embodiments of the
faucet of FIG. 1.
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FIG. 3 is perspective view of the faucet of FIG. 1 with a faucet crown
removed.
FIG. 3A is a perspective exploded view of the faucet without the faucet
crown.
FIGs. 3B and 3C are perspective exploded views of the faucet crown
and a circuit board module with an attachment for the faucet shown in FIG. 3
designed for capacitive sensing and IR sensing, respectively.
FIG. 4 is a perspective, exploded view of the control system unit
located below the sink of the installation shown in FIG. 1.
FIGs. 4A and 4B are perspective exploded views of the control system
unit shown in FIG. 4 with individual modules shown in more detail.
FIGs. 4C and 4D are perspective side views of the control system unit
shown in FIG. 4 with the cover removed illustrating a valve module with a turn
shut-off when removing.
FIG. 4E illustrates a quick connect for a water conduit connecting to the
control system unit of Fig. 4.
FIG. 5 is a perspective view of a wall attachment plate for attaching the
control system unit shown in FIG. 1 and in FIG. 1A.
FIGs. 6 and 6A are a perspective top view and a perspective bottom
view, respectively, of a base holder for the control system unit shown in
FIGs.
4A through 40 without the individual modules.
FIGs. 7, 7-1, 7A, and 7A-I, are top and cross-sectional views of the
control system unit with the individual modules attached.
FIG. 8 shows a cover for the control system unit in several perspective
and detailed views also illustrating individual attachments elements for
attaching the cover to a base.
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.
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FIG. 9 is a front perspective view showing another embodiment of a
faucet installed on a sink with a control system unit located inside the
faucet
body.
FIGs. 9A and c,'B are a front view and a side view of the faucet shown
5 in FIG. 9, respectively.
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
10 showing the faucet head in an exploded view for better illustration.
FIGs. 11 and 11A are top and cross-sectional views of a turbine
module located in the faucet head shown in FIGs. 10A and 10B.
FIG.11B is a perspective exploded view of the elements located inside
the faucet head including the turbine module, the circuit board module and the
aerator.
FIGs. 12, 12A, 12B, 12C and 12D show several views of the turbine
including water flow surfaces all located inside the turbine module
FIG. 13 shows an exploded perspective view of the control system
located inside the faucet shown in FIG. 10, having the faucet enclosure
removed.
FIGs. 13A, 13B, 13C, 13D and 13E show several views of a mixing and
shut-off valve located inside the faucet shown in FIG. 10.
FIG. 14 is a block diagram of the faucet elements and control circuitry
for controlling operation of the faucet shown in FIG. 1 or FIG. 9.
FIG. 15 is a block diagram of another embodiment of the faucet
elements and control circuitry for controlling operation of the faucet shown
in
FIG. 1 or FIG. 9.
FIGs. 16A through 16G are circuit diagrams of the faucet elements
shown in the block diagram in FIG. 15.
FIG. 17 illustrates the main operation and control of the faucet shown
in FIG. 1 or FIG. 9.
=
=
11
FIG. 18 is a flow chart that illustrates power management for the
turbine module executed by a controller.
FIGs. 19, 19A, 19B, 19C, and 19D show another flow chart that
illustrates power management for the faucet executed by a controller.
5 FIG. 20 is a flow chart that illustrates a battery contact algorithm
for
powering up the control circuitry.
FIG. 21 includes FIGs 21A, 21B and 21C illustrating a flow chart of the
algorithm for sensing a target present at the faucet spout shown in FIG. 1 or
FIG. 9.
10 FIG. 22 is a flow chart that illustrates target sensing for turning
water
on in the flow chart of FIG. 21.
FIG. 22A is a flow chart that illustrates target sensing for turning water
off in the flow chart of FIG. 21.
15 DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a water faucet 10 is shown mounted to a sink 14,
wherein a faucet base 18 is in contact with a top sink surface 15. The faucet
includes a housing or encasement body 17 and a faucet head 16. Faucet 10
20 is electrically coupled to a control manifold (control system unit) 100
using
electrical line 11 and receives water via a water line 12. FIG. 1A illustrates
faucet 10 with control system unit 100 shown in an exploded view. Water line
12 is coupled to control center unit 100 using a quick connect arrangement
(shown in FIG.4E) and provides mixed hot/cold water. That is, there is a hot
25 cold mixing unit (not shown in FIGs 1 and 1A) located below sink 14.
Control
system unit 100 includes a plastic manifold 12, i.e., a base designed to
accept
the individual modules, and a cover 105.
FIGs. 2 and 2A show two different mounting embodiments of faucet
10, shown in FIG. 1, to sink 14. These mounting embodiments are also
30 applicable to faucet 10A, shown in FIG. 9. The mounting can be done
using a
quick connect assembly including a rod 24 and coupling elements 25A and
25B. The coupling assembly may include a gasket 22 or a thicker insulation
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element for electrically insulating the faucet from a sink made of metal. This
insulation is
important for proper operation of the capacitance sensor (described below) in
installation with
a metal sink. FIG. 2A shows another mounting embodiment of faucet 10 using the
assembly of
rods 28A and 28B and coupling elements 27A, 276, 29A and 29B.
The faucet housing actually consists of a shell-like structure that forms an
upright main
body and the upper portion including the faucet crown having a spout extending
out from the
main body portion to an aerator 38. Aerator 38 includes a removable aerator
body 38A and a
wrench 38B. The faucet head 16 comprises a faucet head body 32. The faucet
crown (Shown
as faucet crown 34 in Figs. 2 and 2A) includes a removable cover plate secured
to the body.
The cover plate may be replaced by an LCD display or another type of display
for
communicating with a user or providing a message to the user for entertainment
or
advertising.
FIGs. 3 and 3A illustrate the faucet having a faucet crown 34 removed. Faucet
10
includes a flexible water conduit 12 having a quick connect 12A attachable to
faucet crown
insert 36 providing water to aerator 38. FIG. 3B is a perspective exploded
views of a faucet
crown 34A, including a circuit board and a cover plate, designed for
capacitive sensing of the
user's hands. FIG. 3C is perspective exploded view of a faucet crown 34B,
including a circuit
board and a cover plate, designed for IR sensing of the user's hands (or
alternatively designed
for both capacitive sensing and IR sensing).
FIG. 4 is a perspective, exploded view of a control system unit 100 located
below the
sink. FIG. 4A is a perspective exploded view of control system manifold
(control system unit)
100 having a cover 105 removed. Control system unit 100 is designed co-
operatively with a
wall-mounting bracket 106 (shown in FIGs. 4 and 5) for attachment to the
bathroom wall below
the sink.
Referring to FIGs. 4, 4A, 4B, 40 and 40, 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 150 includes a valve housing 160, a
lower valve
body 156, an upper valve body 152, a filter 158 (or a strainer 158), and an
actuator 153.
Actuator
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housing 152 includes an alignment mark 154A and valve housing 160
includes an alignment mark 154B used for the turn shut-off by turning the
actuator housing (i.e., turn shut-off operates as a bayonet connection) and
thus there is no need to shut the water off in case of maintenance, valve
changing, or filter cleaning. This is enabled by the combination of a turn
shut-
off cartridge 170 (shown in FIGs. 13C and 13 D) located inside a turn shut-off
base structure 180 and enclosed within turn shut-off housing 160.
The valve module 150 provides a valve for controlling water flow to
faucet 10 using actuator 153 and provides a shut-off valve for easy
maintenance. When valve module 150 is removed from the turn shut-off
housing 160 there is no water flow across control system unit 100. Also
referring to FIGs. 7 and 7A, actuator module 150 is inserted into the valve
housing oriented to match the arrows 154A and 154B on both elements, as
shown in FIG. 4D. When actuator module 150 is turned, for example, 45
degrees as shown in Fig. 4C, water can flow across the valve module if the
actuator is open. Rotating actuator module 150 about 45 degrees (from the
position shown in FIG. 4C to the position shown in FIG. 4D) closes the valve
for maintenance. Actuator module 150 includes an electromechanical actuator
(a solenoid actuator) described below. FIG. 8B is an exploded perspective
view of the actuator module and the valve including the water filter, also
shown in FIG. 4A. The solenoid actuator controls the water flow delivered to
the user from aerator 38. The entire faucet system includes numerous 0-
rings and water seals to prevent water leakage and improve water flow, as is
known to a person of ordinary skill in the art.
Referring to FIGs. 4A and 4B, water turbine module 250 includes a
rotor assembly 260 (shown in detail in FIG. 12C) and a stator assembly 270
(shown in detail in FIG. 12D). Rotor assembly 260 includes a ceramic magnet
262 (or another corrosion resistant magnet) and a propeller 264 secured with
a plastic pin. Stator assembly 270 includes a coil 271 located between two
stator pieces 272 and 273 made from non-magnetic material.
Water turbine module 250 is located in the water path wherein the rotor
is fixed integrally using the rotary shaft to couple turbine blades 264, and
rotor
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magnet 262. The rotor magnet is opposed to stator pole elements. The
stator coil is provided to be interlinked with a magnetic flux passing through
the stator poles. When, the water turbine rotates by receiving the water flow,
magnet 262 rotates relatively with respect to the stator pole. The flow of the
magnetic flux flowing to the rotor and the stator pole is changed. As a
result,
an induced current flows in the stator coil in such a direction as to prevent
the
change in the flow of the magnetic flux. The stator ¨ rotor arrangement has
preferably 12 poles (but can also have a smaller or a larger number of poles
to optimize energy output). The generator is also used as a tachometer to
measure effectively the flow rate thru the faucet. This arrangement also
enables fault monitoriag and detection of a clogged line or a clogged filter.
After the current is rectified, it is stored, for example, in the rechargeable
battery using the power management algorithm described below. The
corresponding signal is provided to the microcontroller, as shown in FIGs. 14
and 15.
Referring still to Fig 4B and FIGs. 12A and12B, water turbine module
250 has a single fluid path designed to enable a range of flow rates. Turbine
rotor 260 is cooperatively designed with a turbine base 282 having a specially
designed focusing inlet 284, and an optional nozzle 283 located in a focusing
inlet 284. For flow rates of over 0.7 GPM (gallons per minute) to 1.8 GPM, a
larger cross sectional flow path is provided to reduce the internal flow
resistance (that is, a pressure loss). On the other hand, for low flow rates
as
low as 0.35 GPM, focusing inlet 284 includes nozzle 283 that boosts the
power output of the turbine generator. The nozzle may held in place by a
small tab and groove molded to the nozzle. This design requires relatively
small amount of space.
As shown in FIG. 4B, turn shut-off cartridge 170 includes an exit port
174 (see also FIGs. 13C and 13 D), which receives water flow from the valve,
which flow is confined by turn shut-off cartridge 170 and exits port 174 and
has a laminar flow between turn shut-off base 180 and housing 160 flowing
into focusing inlet 284. Advantageously, valve housing 160 and turbine
housing 280 are made of a single piece to improve the laminar water flow.
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The water turbine module reduces power consumption and also allows
for precise water metering by reading the AC signal frequency, which is
proportional to the flow rate and also is optimized for different flow rates
with
the insertable or permanent flow nozzle 283.
5 As described above, the magnetic flux flows between the rotor and the
stator pole in the generator. The magnetic flux acts as a resistance when the
water turbine is to be rotated by the force of the flowing water. That is, a
magnetic flux generated between the rotor and the stator pole acts as a
detent torque to brake the operation of the water turbine during the starting
10 and rotation of the water turbine. The turbine module of the present
invention
is designed to start and detect a small amount of water flow to detect the
water leak in the faucet. The turbine module may be replaced by another
rechargeable power source module, such as one or several photovoltaic cells.
The photovoltaic cells may be installed at the top of the crown assembly.
15 Battery module 200 includes four batteries each providing 1.5V DC.
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 orientation of battery case 204 with respect to
holder 210 in the manifold. That is, battery case 210 can only be installed
two
ways (180 degree symmetry) by clipping attachment clips 208 onto
attachment elements 212 of holder 210. This prevents wrong polarity
installation of the batteries. In other words, battery case 204 allows for
"blind"
installation when installer cannot see the location under the sink, but still
can
install the batteries. During the installation, a simple quarter turn of the
battery cover ring will make the batteries slide out for easy replacement. If
the
battery case ring is not locking (i.e., the batteries not secured), the
battery
case cannot be installed onto holder 210. Battery module 200 is sealed via
an or-ring from humidity and battery case is secured in the manifold via
snaps.
Control system module 100 includes plastic manifold 120, which
attaches to a wall plate 106. FIG. 5 illustrates wall attachment plate 106
having attachment elements 113, 114 and 115 cooperatively designed with
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the attachment elements located on plastic manifold 120, which are
cooperatively designed for tight, mechanically robust coupling. Specifically,
plastic manifold 120 includes an opening 122 and a barrier 123 designed with
element 115 of plate 106. These cooperating surfaces provide mechanically
robust coupling and are marked for easy servicing of control system unit 100.
The entire control system unit is designed cooperatively with the wall-
mounting bracket 106 for easy installation and attachment to, and removal
from the wall bracket.
The manifold attaches to the wall plate 106 via a simple twist action
and is secured as soon as the plastic cover 105 is put over the plastic
manifold 120. The unit is rigidly and totally secured by a simple screw
tightening using a screw 118. Once the cover screw (FIG. 8) is secured, the
manifold cannot be removed from the wall mounting bracket (wall plate) 106.
The present design uses special Allen wrench (or other key) for a screw
securing a cover 105 of the control module. The individual modules within
faucet 10 and control system unit 100 are removable and easily replaceable
for quick servicing.
FIGs. 6 and 6A are perspective top view and perspective bottom view
of plastic manifold (base holder) 120 for control system unit 100. FIGs. 7, 7-
1,
7A, and 7A-I, are cross-sectional views of control system manifold 100. FIG.
10 shows manifold cover 105 in several perspective and detailed views.
The cooperative action of the valve module and the actuator module
enables auto shut off and thus there is no need to shut the water off in case
of
maintenance, valve changing or filter cleaning. The combination of filter
attached to removable valve cartridge and auto shutoff associated with the
electromagnetic actuator allows for inspecting and cleaning of the filter
without
tools and without having to shutoff the water.
The actuator module includes an electromagnetic actuator
(electromagnetic operator). The electromagnetic 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
17
a distal part and a proximal part of the armature thereby enabling
energetically efficient movement of the armature between open and closed
positions. The membrane is secured with respect to the armature housing
and is arranged to seal armature fluid within an armature pocket having a
fixed volume, wherein the displacement of the plunger (i.e., distal part or
the
armature) displaces the membrane with respect to a valve passage thereby
opening or closing the passage. This enables low energy battery operation
for a long time.
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 cooperatively arranged with different types
of diaphragm membranes designed to act against a valve seat when the
armature is disposed in its extended armature position. The electromagnetic
actuator is connected to a control circuit constructed to apply said coil
drive to
said coil in response to an output from an optional armature sensor.
The armature sensor can sense the armature reaching an end position (open
or closed position). The control circuit can direct application of a coil
drive
signal to the coil in a first drive direction, and in 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 application of a coil drive signal to the coil
responsive
to an output from the sensor meeting a predetermined criterion.
The faucet may be controlled, for example, by an electromagnetic
actuator constructed and arranged to release pressure in the pilot chamber
and thereby initiate movement of a piston, diaphragm, or a fram assembly,
from the closed valve position to the open valve position. The actuator may
include a latching actuator (as described in U.S Patent 6,293,516
), a non-latching actuator (as described in U.S
Patent 6,305,662 ), or an
isolated operator
(as described in PCT Application PCT/US01/51098
). The valve module may also be controlled manually, initialing an
electrical signal to the actuator driver (instead of a signal initialed by a
sensor)
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or by manually releasing pressure in the pilot chamber as described in US
Patent 6,874,535 .
Referring to FIG. 4 E, the control system unit is designed for easy
installation and removal of the water conduit using a quick connect for
providing water to faucet 10. The installation requires a simple pull-push to
secure the conduit (e.g., a hose) from the mixing valve or from the faucet
into
an opening 128. After placement of the water conduit a sliding plate 124 is
placed within a slot assembly 132 (FIG. 4A). In combination with the special
wall-mounting bracket 106, control system unit 100 can be easily installed and
removed for repairs basically without tools.
FIG. 9 is a front perspective view showing another embodiment of a
faucet installed on a sink with a control system unit located inside the
faucet
body. FIGs. 9A and 9B are a front view and a side view of the faucet shown in
FIG. 9, respectively. 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. and 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. 13 shows an exploded perspective view of the interior of faucet
10A. In this embodiment the control system unit is arranged differently than
in
FIGs 4¨ 4D, but provides similar advantages and modular design for all
modules now located inside the faucet as shown in FIG. 10. Still referring to
FIG. 13, the control system unit includes a valve module 150A, a battery
module 200A, and a turbine module 250A. Valve module 150A includes a
water mixing handle 20 cooperatively designed with a mixing valve module
180A (shown in FIGs 13A, 13B and 13E) and turn shut-off cartridge 170A
(shown in FIGs 13C and 13D) all enclosed in turn shut-off housing 160A.
The valve module 150A includes a lower valve body 156A, an upper
valve body 152A, a filter 158A (or a strainer 158A), and an actuator 153
located inside upper valve body 152A The actuator housing 152 may also
include an alignment mark cooperatively designed with an alignment mark
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located on valve housing 160A used for the turn shut-off by turning the
actuator housing as described in connection with FIGs. 4C and 40. The water
output from valve module 150A flows into turbine module 250A shown in
detail in FIGs. 11 through 12B.
FIGs. 11 and 11A are top and cross-sectional views of turbine module
250A located in the faucet head shown in FIGs. 10A and 10B, and FIG.11B is
a perspective exploded view of the elements located inside faucet head 16A.
Turbine module 250A includes rotor 260 and stator 270 both cooperatively
designed to fit into turbine base 275A, which in turn fits into a hydraulic
crown
assembly 280A. Turbine module 250A includes a rotor assembly 260 (shown
in detail in FIG. 12C) and a stator assembly 270 (shown in detail in FIG.
12D).
Rotor assembly 260 includes rotor magnet 262 (made of ceramic or another
corrosion resistant magnet) and propeller 264 secured with a plastic pin.
Stator assembly 270 includes coil 271 located between two stator pieces 272
and 273 made from non-magnetic material.
Faucet head 16A includes a circuit board located above hydraulic
crown assembly 280A. The circuit board includes electronics described in
connection with FIGs. 14 and 15.
Similarly as described above in connection with faucet 10, water
turbine module 250A has a single fluid path extending from a seal 252A into a
focusing inlet 276A and exiting the turbine at port 277A. Turbine module
250A is designed to enable a range of flow rates. Turbine rotor 260 is
cooperatively designed with a turbine base 282 having a specially designed
focusing inlet 276A and the optional nozzle located in focusing inlet 276A.
FIG. 14 is a block diagram of control electronics 400 for controlling
operation of faucet 10. The control electronics preferably uses a capacitance
sensor 50, or alternatively an active IR sensor or a passive IR sensor. The
active IR sensor includes an IR transmitter 420 for emitting an IR beam and
an IR receiver 424 for detecting the reflected IR light. The passive IR sensor
uses passive optical detector for detecting presence of a user as described as
20
described in PCT Applications PCT/US03/38730 and PCT/US03/41303.
Referring to FIG. 14, control electronics 400 includes a controller 402
powered by a battery 200. Controller 402 is preferably a microcontroller
MC9S08GT16A made by Freescale . The microcontroller executes various
detection and processing algorithms, which are preferably downloaded.
However, the controller and algorithms may also be implemented in the form
of dedicated logic circuitry, ASIC, or other. The 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 a solenoid 150 monitored
by a solenoid feedback amplifier 412, and a signal conditioner 414. Controller
402 communicates with an indicator driver 434 for driving a visible diode 436
(e.g., a blue diode or a red diode) for communications with the user.
As shown in FIG. 14, the active optical sensor includes an IR diode
driver 422 providing power to an IR transmitter 420, and an IR sensor
amplifier 426 receiving a signal from an IR receiver 424. The entire operation
is controlled by controller 402.
The IR diode driver 422 may be designed to progressively increase
and decrease the optical power output according to target and environment
conditions. The same applies to the IR receiver using IR sensor amplifier 426.
Usually only one of the modes is used both since one is enough to achieve
the purpose. The following are examples of the conditions: If the environment
is too IR bright, the system boosts the optical emission signal. If the target
is
too close, such as in the closet, the system reduces the IR signal to save
power. If the target is not sufficiently IR reflective, the system boosts the
IR
signal either from the IR transmitter 520 or using IR sensor amplifier 526.
The system 402 uses an optional voice synthesizer 440 connected to a
speaker 442 for providing a user interface. An optional flow sensor
conditioner 444 connected to a flow sensor 446 is used for detecting water
flow through the faucet. Alternatively, a sensor may be used to detect
overflow of water in the sink and provide signal to controller 402 for
shutting
down the automatic faucet.
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The system may include an optional RF transceiver 450 connected to
an antenna 452 for wireless communication with a remotely located central
controller 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 gathering of information
concerning the faucets and appliances. The communication between the
faucets and appliances uses preferably low frequency RF signals, and the
communication to the remotely located network node uses preferably a high
frequency RF signals.
In general, wired or wireless data communication is used for
transmitting information as it relates to the well being of the bathroom
faucets
and sanitary appliances. The transmitted information (together with the ID of
the device) may include the battery voltage, number of flushes, the unit is on
run-on condition (cannot turn off), no water condition (cannot turn on), etc.
Using an RF transceiver 450 and antenna 452, the system can receive
information such as command remotely initiated from somewhere else. The
fixtures may talk to each other in a networked fashion. The fixtures may talk
to a proximal central unit and this unit may transmit data (wired or wireless)
to
a wider network such as internet. In a preferred embodiment, the user
initiates a location wide diagnostic mission by requesting each fixture to
turn
on and then off. In turn, each fixture reports successful/unsuccessful
operation. The fixture may also report other variables such as battery
voltage,
number of flushes, etc. The user then gathers the information and schedules
a maintenance routing according to results. This is particularly useful in
establishments such as convention centers, etc. where the maintenance
personnel currently send crews to monitor the well being of the fixtures and
take notes manually prior to an event.
Another embodiment of the control electronics is described in PCT
Publications W02005/056938 and W02004/061343.
According to another embodiment, the control electronics includes a
microcontroller that is an 8-bit CMOS microcontroller IMP86P807M made by
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Toshiba. The microcontroller has a program memory of B Kbytes and a data
memory of 256 bytes. Programming is done using a Toshiba*adapter socket
with a general-purpose PROM programmer. The microcontroller operates at
3 frequencies (fc = 16MHz, fc = 8MHz and fs = 332.768kHz), wherein the first
two clock frequencies are used in a normal mode and the third frequency is
used in a low power mode (i.e., a sleep mode). The microcontroller operates
in the sleep mode between various actuations. To save battery power,
microcontroller periodically samples optical sensor unit for an input signal,
and
then triggers power consumption controller. Power consumption controller
powers up signal conditioner and other elements. Otherwise, the optical
sensor unit, the voltage regulator (or the voltage boost) and the signal
conditioner are not powered to save battery power. During operation, the
microcontroller also provides indication data to an indicator, e.g., a visible
diode or a speaker. Control electronics may receive a signal from the passive
optical sensor or the active optical sensor described above. A Low battery
detection unit may be the low battery detector model no. TC54VN4202EMB,
available from Microchip Technology. The voltage regulator may be the
voltage regulator part no. TC55RP3502EMB, also available from Microchip
Technology (http://www.microchip.com). Microcontroller may alternatively be
a microcontroller part no. MCU COP8SAB728M9, available from National
Semiconductor.
The faucet may include one or several photovoltaic cells alone or in
combination with the water turbine for producing voltage that is proportional
to
the amount of light that it receives. When system 500 powers up and starts
operation, the system registers this voltage and continuously monitors the
voltage thereafter. At first time power up, if there is no voltage from the
photovoltaic cell, this means dark environment and therefore the unit marks
the time and count for a predetermined amount of time. If the time is long
enough, such as hours and days, and there is no target detected within the
same period of time then the faucet system is powered up but nobody is using
the bathroom (i.e., the lights are turned off) and therefore the system goes
into a power saving mode. In this mode, the system scans for target at a
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much slower frequency to conserve battery power. The system may also shut
down or slow down other functions such as scanning the override buttons,
battery voltage, etc. The use of the photovoltaic cells is described in the
PCT
Application PCT/US2008/008242, filed on July 3, 2008.
FIG. 15 is a block diagram of another embodiment of the control
circuitry for controlling operation of the faucet shown in FIG. 1.
FIGs. 16A ¨ 16G are circuit diagrams of the control circuitry shown in
the block diagram in FIG. 15.
Fig. 17 the faucet operation using a state diagram 500. The processor
executes the algorithm by first performing all initialization, enabling the
interrupts set to power up (state 501). Next, the power for all sources is
checked in the All Power Source Check state (state 506). If there is a battery
A/D error or the microcontroller is running out of external power the
algorithm
enters again state 501 (transition 504). Otherwise, for normal power level and
if there is no solenoid activation, the algorithm enters (by transition 512)
the
Big Capacitor Charge Control (state 518).
In state 506, if there is normal power level and if there is solenoid
activation, the algorithm enters (508) Solenoid Open Timer Control (state
510). After the target is no longer detected or after a pre-selected time
period
(520) the algorithm enters the Close Solenoid state (state 524). Thereafter,
the algorithm transitions (over transition 526) to Big Capacitor Charge
Control
(state 518). From Big Capacitor Charge Control (state 518) the algorithm
transitions (over transition 528) to Capacitor Sensor Control (state 530).
In Capacitor Sensor Control (state 530) the system executes target
detection and when the target is not detected and solenoid activated, the
system transitions (transition 534) to Red LED Flash Control (state 550).
Alternatively, when the target is detected (FIGs. 22 and 22A), the system
transitions (transition 536) to the Open Solenoid state (state 540), where the
solenoid is opened. Alternatively, when the target is out of detection zone
when solenoid is opened, the system transitions (transition 532) back to the
Close Solenoid state (state 524), where the solenoid is closed. Otherwise,
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when there is no sensing activity, and there is no LED Flash and second
battery check needed, the system transitions from state 530 (over transition
538) to the Sleep state (state 570).
From the Red LED Flash Control state (state 550), the system
transitions (transition 552) to the Sleep state (state 570) after there is LED
Flash and 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). Also, after the Open Solenoid state
(state 540) is there is second battery check required the system transitions
(transition 546) to the Second Battery Check Control state (state 560), and
then after the battery checking is completed, the system transitions
(transition
554) to the Sleep state (state 570).
Upon each wakeup, the system transitions (transition 574) from the
Sleep state (state 570) to the All Power Source Check state (state 506). If
there is no turbine power, or no battery power (or low battery power for 10
min
les than 3.7 V), or no solar power, the system transitions (transition 572)
back
to the Sleep state (state 570).
FIG. 18 is a flow chart that illustrates power management for the
control circuitry. The system periodically checks battery power, power from
the turbine and optionally power provided by a photovoltaic cell. FIGs. 19,
19A, 19B, 19C, and 19D illustrate power management for the control circuitry.
FIG. 20 is a flow chart that illustrates battery contact control for
powering the control circuitry.
FIG. 21 is a flow chart that illustrates the algorithm for sensing a target
present at the faucet spout shown in FIG. 1 or FIG. 9.
The system performs the capacitive sensing operation in order to
control the faucet operation. Starting from power-up or any kind of reset,
system performs self calibration and initialization first, and then it acts as
a
state machine. Upon waking up from its sleep, the system scans the
capacitance sensor to get the current raw data, to update the baseline, and
then the system performs associated tasks based on its current status. The
processor will go to sleep again after the completion of current task.
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The calibration process includes several processes: "Normalize raw
data", "Environment Check", and "Determine Water Effect". The Normalize
Raw Data adjusts raw data in dynamic range (a range near 11500). The
Environment Check makes sure the noise level is in predefined range, if not,
5 the system blinks LED and keeps monitoring noise level until it falls in
the
predefined range. If the system keeps in this stage, it is the indication that
the
system is not suitable for this environment, as shown in Fig. 21A. The
Determine Water Effect turns on water to determine water effect and
determines if this is a 1.5/0.5 GPM spout / head. It is only an initial value,
10 .. system will automatically update this during its regular operation. When
the
calibration is completed, the system turns on water second times to indicate
system is ready to use.
The system uses the total of 8 statuses: TARGETCLEAR, INVERIFY,
TOUCHED, TARGETSET, OUTVERIFY, PROHIBITION, PAUSE, and
15 .. CLEAN. The system will be in one and only one of these statuses at any
given time.
In the TARGETCLEAR status, target signal is always cleared. The
system updates the signal threshold, monitoring the noise level and
determines signal threshold and the number of a signal to be verified as a
20 target. If the difference of current data and baseline is greater than
the signal
threshold, and the data continuously increased more than certain value, the
system enters INVERFY status and speedup the scan. In the INVERIFY
status, the target signal will be set if the data is verified in this status.
The
system determines when it needs to set target signal. If the signal data is
over
25 Signal Threshold and continuously for predetermined times, than the
system
turns on target signal and enters TARGETSET status, and stores current raw
data as part of reference used to determine when the target removing. If this
is triggered 5 times in 30 seconds, the system enters the PAUSE status.
In the TOUCHED status, target signal will be cleared after it is been
touched for 5 seconds. The system determines to clear target signal and
clear target signal if it is touched for more than 5 seconds. The system
determines what to do from touch to untouched. If touched more than 5
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seconds, system enters in the CLEAN status. If touched less than 5 seconds,
system goes back to the TARGETSET status.
In the TARGETSET status the target signal is always set. The system
calibrates the water effect during first 2 seconds, and determines the water
effect value, and then sets following parameters:
= signal threshold for the water on time; and
.= reference value for the water on to be used to determine if the target
has been moved out. The system determine if it needs to enter the
OUTVERIFY status.
The system enters OUTVERIFY status if any of the following occurs:
= Run time out
= Raw data does not change over a predefined range
= Signal data is less than signal threshold
= Raw data is fall below than the reference predefined just
before the water is turned on.
In the OUTVERIFY status, the target signal will be cleared if the signal
has been verified. The system tracks water run time and clears target signal
if
water time run out, and system enters in the PAUSE status. The system
determines if the data is stable and clears the target signal when data is in
predefined range continuously for 1.5 seconds, and then enters in status
PROHIBITION. The system determines if the data falls below a reference
value, clears target signal when data is in predefined range continuously for
1.5 seconds, and then enters in status PROHIBITION. The system
determines if the data is below signal threshold, clear target signal when
data
is in predefined range continuously for 1 second, and then enters in status
PROHIBITION.
In the PROHIBITION status, the target signal is always cleared. The
system determines when to go out of this status. The system will enter in
TARGETCLEARED status if it has been in this status for predefined minimum
off time.
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In the PAUSE status, target signal is always cleared. The system
determines when to go out of this status. The system will enter in
TARGETCLEARED status if it has been in this status for predefined time. In
the CLEAN status, the target signal is always cleared. The system
determines when to go out of this status. The system will enter in
TARGETCLEARED status if it has been in this status for predefined time.
Referring to FIG. 14, the capacitance detector processor 465
communicates with microcontroller processor 402 using the Heart Beep pulse
from high to low every 5 seconds to indicate it is in good condition. In the
Hold down, the system stops scanning when port 2.5 is low to save the
power. In the request LED power, the system sets port 1.5 low to indicate it
may need power to turn on LED.
FIG. 22 is a flow chart that illustrates target sensing for turning water
on and FIG. 22A is a flow chart that illustrates target sensing for turning
water
off in the flow chart in FIG. 21C. This algorithm is described for the
proximity
and touch capacitive sensor (such as made by Cypress Semiconductor).
However, this algorithm is also applicable for the active IR sensor using a
light
source and a light detector detecting a reflected signal from a user. The
target detection algorithm (and any algorithm described herein) may be
imbedded in a designated chip or may be downloaded to the corresponding
processor.
Referring to FIG. 22, the target detection algorithm for turning "water
on" starts in the target clear status (water is off).
= Scan sensor at 8 Hz to read sensor data
= Signal = Current raw data ¨ baseline
= If signal > Threshold, Go to verify status
= In verify status, Threshold increase by 5
= In verify status, Threshold increase by 5
= If signal > Threshold consecutively more than "Verify" times,
turn on water.
= Threshold and "Verify" times are dynamically updated as below:
For the past 5 seconds:
Noise level = Maximum raw data - minimum raw data
If noise level is low,
threshold = High sensitive level
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Verify = 3
If noise level is Medium,
threshold = medium sensitive level
Verify = 4
If noise level is HIGH,
threshold = low sensitive level
Verify = 5
= In "Verify" < Verify Threshold than scan sensor to read sensor data.
Referring to FIG. 22A and 22A-I, the target detection algorithm for
turning "water off' starts after water was turned on.
= Once water is turned on, it will stay on for at least one second even
target left right away.
= Target threshold will be set as:
Threshold = Target signal at the time of trigger + water effect ¨ 15
= Three counters are used for determining the target leaving,
Counter1 is to count the number of signal less than threshold
Counter2 is to count the number of signal not change
Counter3 is to count the number of signal decrease
= If current signal is less than threshold, Counter1 increases by1,
otherwise Counter2 reset to 0.
= Stable reference initialized to the first signal data. If the difference
between current signal and stable reference is less than predefined range,
Counter2 increases by 1, otherwise Counter2 reset to 0, and the stable
reference reset to current signal.
= If current signal is less than previous signal, Counter3 increase by 1,
and the decreased value add to total signal decreased, otherwise, ccounter3
reset to 0, and total decreased reset to 0.
= If Counter1 greater than 8, or counter2 greater than 16, or counter3 is
greater than 8 and total signal decreased is greater than 45, or counter3 is
greater than 12. Turn off water, as shown in FIG. 22A-I
= Threshold reset to 15 after water turning off.
The above-described sensing algorithm overcomes several problems
associated with the capacitive proximity sensing. In the capacitance signal,
the sensing area is uncertain, especially when water is flowing and the human
hands are only part of capacitance source. The signal/ noise ratio is not
29
sufficiently big, and noise may cause false detections. The signal strength
varies for different power supply sources (e.g., battery or power adaptor). To
overcome these problems, the sensing algorithm automatically calibrates the
baseline based on real application environments. The sensing algorithm
keeps track of the noise signal level and adapts signal threshold accordingly.
The sensing algorithm tracks signal trend not only strength to determine the
presence of human hands. Furthermore, the sensing algorithm uses separate
parameters for different power supply sources.
The faucet may use an alternative optical transceiver is described in
U.S. Patent 5,979,500 or U.S. Patent 5,984,262, and is also described in co-
pending US Applications 10/012,252 and 10/012,226.
The microcontroller may be microcontroller
COP8SAB and COP8SAC made by National Semiconductor, or
microcontroller IMP86c807M made by Toshiba. To save power and
significantly extend battery operation, the wake-up period is much shorted
than the sleep period. Depending on the controller's mode, the sleep time
may be 100 msec, 300 msec, or 1 sec.
The electronic faucet also communicate with a user by a novel "burst
interface" that provides signals to a user in form of water bursts emitted
from
the faucet. Alternatively, the electronic faucet may include novel an optical
or
acoustic interface. The electronic faucet is designed to prevent wasting of
water when for example an object permanently located in a sink.
What is claimed is:
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