CA2098332C - Overflow controller - Google Patents
Overflow controllerInfo
- Publication number
- CA2098332C CA2098332C CA 2098332 CA2098332A CA2098332C CA 2098332 C CA2098332 C CA 2098332C CA 2098332 CA2098332 CA 2098332 CA 2098332 A CA2098332 A CA 2098332A CA 2098332 C CA2098332 C CA 2098332C
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- Prior art keywords
- fluid
- overflow
- receptacle
- flow
- controller
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- Level Indicators Using A Float (AREA)
- Sanitary Device For Flush Toilet (AREA)
Abstract
An overflow controller detects and prevents the introduction of supply fluid into a receptacle beyond a predetermined level. A vertical overflow chamber is in communication with the receptacle and contains a float which is buoyed by fluid entering the overflow chamber when the fluid level in the receptacle increases above the predetermined level. The float preferably interacts with a proximity detector that senses the float when it moves sufficiently close. As the float rises towards the sensor, the sensor is activated to produce an output which is received by a fluid controller. The controller then prevents any supply fluid from being added to the receptacle.
Description
209~332 OVERFLOW CONTROLLER
Technical Field The present invention relates generally to an overflow controller for detecting and preventing the overfilling of a receptacle, more particularly to a method and means for preventing the overflow of a toilet.
Backqround of the Invention Overflow controllers, sometimes called flooding disablers, are used to prevent fluid filled receptacles from overfilling. For example, toilets are supplied with fresh water to carry waste through a drain. If the waste drain is plugged or restricted, it is important to disable the fluid supply stream before the toilet reaches overflow levels. This can particularly be a problem when toilets are used in institutions such as prisons, where inmates may intentionally plug the toilets to create overflow conditions.
Various devices have been used to prevent the accidental or deliberate ~looding of receptacles such as toilets. In Barnum et al., U.S. Patents Nos. 4,538,30 and 4,498,203, for example, a sensor detects flood conditions and prevents further introduction of sunply fluid. The operation of these devices depends on the creation of a partial vacuum in the fluid lines. An orifice communicates with the fluid receptacle and short circuits any partial vacuum communicated to it. When the fluid level in the receptacle reaches sufficient height, it partially seals the orifice thus preventing the '~C
~. -, 20g833~
release or short circuiting of the partial vacuum. The partial vacuum then acts upon a lock-out mechanism to block further flow of the supply fluid into the receptacle. Although this system works well in many situations, it would be advantageous to avoid reliance on the creation of vacuum in the system.
In Albertson, U.S. Patent No. 3,928,874, an overflow prevention device includes a float element pivotably mounted in the toilet bowl. If the water in the toilet bowl rises to a sufficient height, the float is pivoted, activating a switch electrically conn~cted to a solenoid that prevents operation of the handle assembly. Alternatively, the switch is connected to solenoid driven shut off valves located either in the supply line or at the water closet outlet. The primary disadvantage of this system is that it uses a pivoting float mounted within the toilet bowl. The float can easily be manipulated by an individual trying to create fluid overflow. Additionally, such a float is subject to corrosion or accretion of restricting material at its pivot point.
In Gunther, U.S. Patent No. 3,185,789, a fluid overflow switch apparatus is disclosed. The switch is mounted in communication with the drain pipe or fluid exhaust line so, when fluid in the drain pipe backs up, the switch prevents further introduction of supply fluid.
In this apparatus, a float is connected to a float shaft which slides through openings in a casing. When fluid fills the casing, the float rises driving the float sha.t against a switch operator. This action opens the circuit to the washing machine and terminates the operation of the machine. This system is disadvantageous both because the sensor is located on the exhaust line and beca~se the float and float shaft assembly are relatively complicated.
In Meacham et al., U.S. Patent No. 5,028,910, drain overflow alarm for a washing machine is disclosed which sounds an alarm and shuts off the machine when water flow through the drain line is restricted. A float switch is mounted in a vertical drain line attached to a vertical stand pipe or fixed drain line. When the waste water cannot freely drain away, water rises into the float switch causing the float to rise and urge moveable contacts into engagement with fixed contacts. This triggers an alarm and shuts off the washing machine.
Alternatively, the float may include an internal magnet which cooperates with a magnetic reed-type switch to energize the alarm. This apparatus, however, must be used on the drain line side of the receptacle and would not work well with a receptacle such as a toilet where fluid flow to the drain line may be completely blocked.
In Laverty, Jr., U.S. Patent No. 4,709,427 a water level sensor prevents actuation of a fluid supply valve when the toilet reaches overflow conditions. A
float is connected to a plunger rod which, during overflow conditions, unseats a sealing piston allowing fluid to flow through lines into a drain. This prevents water pressure build-up in a piston actuator assembly so that the valve cannot open to allow fresh supply fluid to flow to the toilet. This device is a mechanically actuated device which is subject to corrosion and clogging that can affect its ability to function.
Other receptacle overflow prevention or warning devices are disclosed in Morris et al., U.S. Patent Nos.
4,195,374 and 4,203,173 and in Applin, U.S. Patent No.
3,849,771.
The present invention overcomes various drawbacks of the prior art devices discussed above.
Summary of the Invention An overflow controller according to the invention detects an overfill condition in an open receptacle receiving fluid from a source and prevents overfill by controlling the flow into the receptacle.
The fluid receiving receptacle has a desired maximum fill level and a fluid inlet port for admitting fluid to that ... .
20g~332 point. A detector assembly is disposed in fluid communication with the interior of the receptacle and includes a vertical-overflow chamber into which fluid may flow from the receptacle. The distal end of the overflow chamber is positioned above the desired maximum fill level. A buoyant float in the overflow chamber is disposed for movement therein in response to any fluid admitted thereto. A proximity detector, located above the float, is adjustably mounted in the overflow chamber and is operable to generate an output when an overfill condition occurs and the f]oat reaches a threshold or set point position. Additionally, the set point position may be changed by adjusting the position of the detector to detect the overfill condition at different levels.
Preferably, the proximity detector is a magnetic sensor, and a permanent magnet is supported by the float, e.g.
embedded in its top section. A controller in the flow line of the source is in operative communication with the detector assembly and halts fluid flow to the inlet port in response to the output from the magnetic sensor.
Brief Description of the Drawinqs The invention will hereafter be described with reference to the accompanying drawing, wherein like numerals denote like elements, and:
Figure 1 is a side view of a plumbing fixture that incorporates the overf 1GW controller of the present invention;
Figure 2 is a partially cut-away perspective view of the detector assembly connected to a receptacle;
and Figure 3 is a cross-sectional view of the detector assembly connected to a receptacle having an annular chamber.
Detailed Description of the Preferred Embodiment Referring to Figure 1, an overflow controller, designated generally as 10, detects an overfill condition in an open receptacle 12 which receives fluid from a source 14. Overflow controller 10 prevents overflow of receptacle 12 by controlling the fluid flow from source 14. Open receptacle 12 may be of a variety of configurations, but it will be shown and described as a toilet for illustrative purposes.
Receptacle 12 is defined overall by a fluid receiving bowl 16, having a fluid exit port 18 and a fluid inlet port 20. Port 18 is located in the lower interior region of bowl 16 and permits fluid in bowl 16 to be flushed from it. The fluid inlet port 20 is preferably located proximate an open top 22 of bowl 16 and permits fresh fluid to flow into bowl 16 from source 14.
Intermediate fluid inlet port 20 and bowl 16 is an annular chamber 24 into which fluid from source 14 is admitted and from which the fluid flows into bowl 16.
Annular chamber 24 is disposed along the perimeter of open top 22 and is fully enclosed except for a series of apertures 26 disposed along the bottom of annular chamber 24 to allow fluid flow into bowl 16. The collective cross-sectional area of apertures 26 must be sufficient to permit flow into bowl 16 under steady-state conditions without appreciable accumulation of fluid in annular chamber 24. Steady-state conditions occur when fluid is flowing into annular chamber 24 through fluid inlet port 20 at the normal maximum flow rate. In other words, the cross-sectional area of apertures 26, whether formed as a single slot through which fluid flows or a plurality of individual apertures, must be large enough so that fluid flows into bowl 16 at a rate substantially comparable to the rate at which fluid flows through fluid inlet port 20 into annular chamber 24.
Overflow controller ~0 also includes a detector assembly 28 disposed in fluid communication with the interior of annular chamber 24. If the fluid level in annular chamber 24 rises above a predetermined level, detector assembly 28 provides an output to a controller ~........................................................ .
30 disposed in a flow line 32 through which fluid flows to fluid inlet port 20. Upon receiving the output from detector assembly 28, controller 30 halts the fluid flow to fluid inlet port 20 preventing receptacle 12 from overfilling beyond that predetermined level. Controller 30 is preferably a solenoid controlled valve such as the Burket Contromatic Corp. Model 281 valve.
As illustrated in greater detail in Figures 2 and 3, detector assembly 28 is disposed in fluid communication with the interior of receptacle 12, and preferably with the interior of annular chamber 24, through an opening 34 in an outer wall 36 of receptacle 12. Detector assembly 28 includes a vertical overflow chamber 38 into which fluid may flow from annular chamber 24 through opening 34. Vertical overflow chamber 38 includes a lower proximal end 39 and an upper or distal end 40 positioned above the predetermined maximum fill level illustrated as 41 in Figure 3. A buoyant float 42 independently disposed within chamber 38 is freely able to move in response to any fluid admitted into that chamber. Under normal, steady-state flow conditions, when fluid is flowing down into bowl 16 from annular chamber 24 at substantially the same rate as fluid is entering annular chamber 34 from fluid inlet port 20, float 42 is disposed in the lowermost portion of vertical overflow chamber 38.
A proximity detector 46 is adjustably mounted and preferably sealed in overflow chamber 38 above the steady-state location of float 42. However, proximity detector 46 is operable to generate an output when an overfill condition occurs and float 42 rises to a threshold or set point position in vertical overflow chamber 38 at or prior to contact with proximity detector 46. As stated above, controller 30 responds to this output to halt further fluid flow to fluid inlet port 20.
Proximity detector 46 may use different non-contact technologies to detect float 42 when it moves sufficiently close to detector 46. For example, 2Q9833~
proximity detector 46 may use a light sensor which detects the float when a beam of light is interrupted.
Infrared, optoelectronic, magnetic and other types of sensors may also be used to detect the proximity of float 42 preferably prior to contact with detector 46. In the preferred embodiment, proximity detector 46 is a magnetic sensor and float 42 includes a permanent magnet 44 supported in a top portion of the float.
Detector assembly 28 may be constructed in a variety of configurations to achieve the goal of detecting and preventing an overflow condition, but it is preferably constructed from simple non-magnetic components. In the illustrated embodiment, vertical overflow chamber 38 includes a base unit 48 having a horizontally extending nipple 50 which can be press fit into opening 34 and sealed to prevent leakage of fluid from open receptacle 12. A cavity 52 is disposed within base unit 48 and extends through the interior of nipple 50. Cavity 52 fills with fluid when the fluid level in open receptacle 12 rises above opening 34. Vertical overflow chamber 38 also includes a vertical column 54, preferably cylindrical, having an internal vertical passage 56 extending therethrough. Vertical column 54 is press-fit into an upper opening 58 of base unit 48 and sealed with an appropriately sized O-ring 60. Vertical passage 56 communicates with cavity 52 allowing the fluid level in passage 56 to rise coincident with the fluid level in open receptacle 12. Any air trapped in passage 56 by the rising fluid may escape through a pair of pressure relief orifices 62.
Buoyant float 42 is preferably cylindrical in shape and appropriately sized for full vertical movement within vertical passage 56. Magnet 44 is embedded in the top end of buoyant float 42 and is preferably an IG Incor 18 permanent magnet. Float 42 is comprised of a low density plastic which is freely buoyed by fluid filling vertical passage 56. One advantage of using independent buoyant float 42 within vertical overflow chamber 38 is that no linkages are required to hold the float or control its movement. Any time linkages are connected to a float, the potential exists for corrosion to develop on the linkages inhibiting the free movement of the float and debilitating the function of the device.
The magnetic sensor 46 of detector assembly 28 is preferably contained in a plug 64 adjustably mounted in the upper portion of vertical overflow chamber 38 to allow adjustment of the threshold or set point position at which sensor 46 is activated by magnet 44. This, in turn, allows adjustment of the maximum desired fill level 41. As shown in the illustrated embodiment, plug 64 includes external threads 66 that are adjustably engaged with internal threads 68 disposed in vertical passage 56.
Plug 64 further includes a hollow interior region 70 open at the top and sealed at the bottom by a generally horizontal wall 72. Magnetic sensor 46 is positioned in hollow interior region 70 and hermetically sealed by an appropriate potting compound within plug 64 in proximity to wall 72. Horizontal wall 72 may also include a slot for receiving magnetic sensor 46 and holding it in position. Preferably, magnetic sensor 46 is a magnetically operated low gauss digital position sensor such as SS22PE manufactured by MICR0 SWITCH, but other sensors, such as a Hall sensor or Permalloy sensor, could also be used.
As buoyant float 42 and magnet 44 are buoyed vertically, magnetic sensor 46 will provide an output once magnet 44 reaches a threshold level which corresponds to the desired fill level of open receptacle 12. The output is received by a conventional digital control circuit 74 (Figure 1) which appropriately modifies the output to cause controller 30 to halt any further fluid flow to fluid inlet port 20. In the preferred embodiment, electric current to the Burket Model 281 flUsh valve is interrupted so that its spring-loaded solenoid closes the valve preventing any fl~rther fluid flow through the valve.
209~332 If open receptacle 12 is a conventional toilet, detector assembly 28 will also prevent flushing of the toilet if flood conditions already exist. For example, flushing of the toilet would normally be initiated by pressing a plunger type switch 76, such as the solid-state switch No. VX80-Cl manufactured by MICR0 SWITCH, connected to digital control circuit 74. However if open receptacle (toilet) 12 is already filled beyond the desired fill level, magnetic sensor 46 will provide an appropriate output to control circuit 74 to prevent controller 30 from allowing any fluid to flow to inlet port 20.
It will be understood that the foregoing description is of a preferred exemplary embodiment of this invention, and the invention is not limited to the specific form shown. For example, various magnetic sensors and control circuits may be used. The detector assembly may be used in conjunction with receptacles whether or not they have enclosed rims along their top.
In some situations, the detector assembly may be placed directly within the fluid receptacle rather than external to the receptacle. Additionally, the detector assembly is not limited to the use of magnetic fields and magnetic field sensors. It may also be designed to function with infrared, optoelectronic, or other non-contact technologies. These and other modifications may be made in the design and arrangement of the elements without departing from the scope of the invention as expressed in the appended claims.
Technical Field The present invention relates generally to an overflow controller for detecting and preventing the overfilling of a receptacle, more particularly to a method and means for preventing the overflow of a toilet.
Backqround of the Invention Overflow controllers, sometimes called flooding disablers, are used to prevent fluid filled receptacles from overfilling. For example, toilets are supplied with fresh water to carry waste through a drain. If the waste drain is plugged or restricted, it is important to disable the fluid supply stream before the toilet reaches overflow levels. This can particularly be a problem when toilets are used in institutions such as prisons, where inmates may intentionally plug the toilets to create overflow conditions.
Various devices have been used to prevent the accidental or deliberate ~looding of receptacles such as toilets. In Barnum et al., U.S. Patents Nos. 4,538,30 and 4,498,203, for example, a sensor detects flood conditions and prevents further introduction of sunply fluid. The operation of these devices depends on the creation of a partial vacuum in the fluid lines. An orifice communicates with the fluid receptacle and short circuits any partial vacuum communicated to it. When the fluid level in the receptacle reaches sufficient height, it partially seals the orifice thus preventing the '~C
~. -, 20g833~
release or short circuiting of the partial vacuum. The partial vacuum then acts upon a lock-out mechanism to block further flow of the supply fluid into the receptacle. Although this system works well in many situations, it would be advantageous to avoid reliance on the creation of vacuum in the system.
In Albertson, U.S. Patent No. 3,928,874, an overflow prevention device includes a float element pivotably mounted in the toilet bowl. If the water in the toilet bowl rises to a sufficient height, the float is pivoted, activating a switch electrically conn~cted to a solenoid that prevents operation of the handle assembly. Alternatively, the switch is connected to solenoid driven shut off valves located either in the supply line or at the water closet outlet. The primary disadvantage of this system is that it uses a pivoting float mounted within the toilet bowl. The float can easily be manipulated by an individual trying to create fluid overflow. Additionally, such a float is subject to corrosion or accretion of restricting material at its pivot point.
In Gunther, U.S. Patent No. 3,185,789, a fluid overflow switch apparatus is disclosed. The switch is mounted in communication with the drain pipe or fluid exhaust line so, when fluid in the drain pipe backs up, the switch prevents further introduction of supply fluid.
In this apparatus, a float is connected to a float shaft which slides through openings in a casing. When fluid fills the casing, the float rises driving the float sha.t against a switch operator. This action opens the circuit to the washing machine and terminates the operation of the machine. This system is disadvantageous both because the sensor is located on the exhaust line and beca~se the float and float shaft assembly are relatively complicated.
In Meacham et al., U.S. Patent No. 5,028,910, drain overflow alarm for a washing machine is disclosed which sounds an alarm and shuts off the machine when water flow through the drain line is restricted. A float switch is mounted in a vertical drain line attached to a vertical stand pipe or fixed drain line. When the waste water cannot freely drain away, water rises into the float switch causing the float to rise and urge moveable contacts into engagement with fixed contacts. This triggers an alarm and shuts off the washing machine.
Alternatively, the float may include an internal magnet which cooperates with a magnetic reed-type switch to energize the alarm. This apparatus, however, must be used on the drain line side of the receptacle and would not work well with a receptacle such as a toilet where fluid flow to the drain line may be completely blocked.
In Laverty, Jr., U.S. Patent No. 4,709,427 a water level sensor prevents actuation of a fluid supply valve when the toilet reaches overflow conditions. A
float is connected to a plunger rod which, during overflow conditions, unseats a sealing piston allowing fluid to flow through lines into a drain. This prevents water pressure build-up in a piston actuator assembly so that the valve cannot open to allow fresh supply fluid to flow to the toilet. This device is a mechanically actuated device which is subject to corrosion and clogging that can affect its ability to function.
Other receptacle overflow prevention or warning devices are disclosed in Morris et al., U.S. Patent Nos.
4,195,374 and 4,203,173 and in Applin, U.S. Patent No.
3,849,771.
The present invention overcomes various drawbacks of the prior art devices discussed above.
Summary of the Invention An overflow controller according to the invention detects an overfill condition in an open receptacle receiving fluid from a source and prevents overfill by controlling the flow into the receptacle.
The fluid receiving receptacle has a desired maximum fill level and a fluid inlet port for admitting fluid to that ... .
20g~332 point. A detector assembly is disposed in fluid communication with the interior of the receptacle and includes a vertical-overflow chamber into which fluid may flow from the receptacle. The distal end of the overflow chamber is positioned above the desired maximum fill level. A buoyant float in the overflow chamber is disposed for movement therein in response to any fluid admitted thereto. A proximity detector, located above the float, is adjustably mounted in the overflow chamber and is operable to generate an output when an overfill condition occurs and the f]oat reaches a threshold or set point position. Additionally, the set point position may be changed by adjusting the position of the detector to detect the overfill condition at different levels.
Preferably, the proximity detector is a magnetic sensor, and a permanent magnet is supported by the float, e.g.
embedded in its top section. A controller in the flow line of the source is in operative communication with the detector assembly and halts fluid flow to the inlet port in response to the output from the magnetic sensor.
Brief Description of the Drawinqs The invention will hereafter be described with reference to the accompanying drawing, wherein like numerals denote like elements, and:
Figure 1 is a side view of a plumbing fixture that incorporates the overf 1GW controller of the present invention;
Figure 2 is a partially cut-away perspective view of the detector assembly connected to a receptacle;
and Figure 3 is a cross-sectional view of the detector assembly connected to a receptacle having an annular chamber.
Detailed Description of the Preferred Embodiment Referring to Figure 1, an overflow controller, designated generally as 10, detects an overfill condition in an open receptacle 12 which receives fluid from a source 14. Overflow controller 10 prevents overflow of receptacle 12 by controlling the fluid flow from source 14. Open receptacle 12 may be of a variety of configurations, but it will be shown and described as a toilet for illustrative purposes.
Receptacle 12 is defined overall by a fluid receiving bowl 16, having a fluid exit port 18 and a fluid inlet port 20. Port 18 is located in the lower interior region of bowl 16 and permits fluid in bowl 16 to be flushed from it. The fluid inlet port 20 is preferably located proximate an open top 22 of bowl 16 and permits fresh fluid to flow into bowl 16 from source 14.
Intermediate fluid inlet port 20 and bowl 16 is an annular chamber 24 into which fluid from source 14 is admitted and from which the fluid flows into bowl 16.
Annular chamber 24 is disposed along the perimeter of open top 22 and is fully enclosed except for a series of apertures 26 disposed along the bottom of annular chamber 24 to allow fluid flow into bowl 16. The collective cross-sectional area of apertures 26 must be sufficient to permit flow into bowl 16 under steady-state conditions without appreciable accumulation of fluid in annular chamber 24. Steady-state conditions occur when fluid is flowing into annular chamber 24 through fluid inlet port 20 at the normal maximum flow rate. In other words, the cross-sectional area of apertures 26, whether formed as a single slot through which fluid flows or a plurality of individual apertures, must be large enough so that fluid flows into bowl 16 at a rate substantially comparable to the rate at which fluid flows through fluid inlet port 20 into annular chamber 24.
Overflow controller ~0 also includes a detector assembly 28 disposed in fluid communication with the interior of annular chamber 24. If the fluid level in annular chamber 24 rises above a predetermined level, detector assembly 28 provides an output to a controller ~........................................................ .
30 disposed in a flow line 32 through which fluid flows to fluid inlet port 20. Upon receiving the output from detector assembly 28, controller 30 halts the fluid flow to fluid inlet port 20 preventing receptacle 12 from overfilling beyond that predetermined level. Controller 30 is preferably a solenoid controlled valve such as the Burket Contromatic Corp. Model 281 valve.
As illustrated in greater detail in Figures 2 and 3, detector assembly 28 is disposed in fluid communication with the interior of receptacle 12, and preferably with the interior of annular chamber 24, through an opening 34 in an outer wall 36 of receptacle 12. Detector assembly 28 includes a vertical overflow chamber 38 into which fluid may flow from annular chamber 24 through opening 34. Vertical overflow chamber 38 includes a lower proximal end 39 and an upper or distal end 40 positioned above the predetermined maximum fill level illustrated as 41 in Figure 3. A buoyant float 42 independently disposed within chamber 38 is freely able to move in response to any fluid admitted into that chamber. Under normal, steady-state flow conditions, when fluid is flowing down into bowl 16 from annular chamber 24 at substantially the same rate as fluid is entering annular chamber 34 from fluid inlet port 20, float 42 is disposed in the lowermost portion of vertical overflow chamber 38.
A proximity detector 46 is adjustably mounted and preferably sealed in overflow chamber 38 above the steady-state location of float 42. However, proximity detector 46 is operable to generate an output when an overfill condition occurs and float 42 rises to a threshold or set point position in vertical overflow chamber 38 at or prior to contact with proximity detector 46. As stated above, controller 30 responds to this output to halt further fluid flow to fluid inlet port 20.
Proximity detector 46 may use different non-contact technologies to detect float 42 when it moves sufficiently close to detector 46. For example, 2Q9833~
proximity detector 46 may use a light sensor which detects the float when a beam of light is interrupted.
Infrared, optoelectronic, magnetic and other types of sensors may also be used to detect the proximity of float 42 preferably prior to contact with detector 46. In the preferred embodiment, proximity detector 46 is a magnetic sensor and float 42 includes a permanent magnet 44 supported in a top portion of the float.
Detector assembly 28 may be constructed in a variety of configurations to achieve the goal of detecting and preventing an overflow condition, but it is preferably constructed from simple non-magnetic components. In the illustrated embodiment, vertical overflow chamber 38 includes a base unit 48 having a horizontally extending nipple 50 which can be press fit into opening 34 and sealed to prevent leakage of fluid from open receptacle 12. A cavity 52 is disposed within base unit 48 and extends through the interior of nipple 50. Cavity 52 fills with fluid when the fluid level in open receptacle 12 rises above opening 34. Vertical overflow chamber 38 also includes a vertical column 54, preferably cylindrical, having an internal vertical passage 56 extending therethrough. Vertical column 54 is press-fit into an upper opening 58 of base unit 48 and sealed with an appropriately sized O-ring 60. Vertical passage 56 communicates with cavity 52 allowing the fluid level in passage 56 to rise coincident with the fluid level in open receptacle 12. Any air trapped in passage 56 by the rising fluid may escape through a pair of pressure relief orifices 62.
Buoyant float 42 is preferably cylindrical in shape and appropriately sized for full vertical movement within vertical passage 56. Magnet 44 is embedded in the top end of buoyant float 42 and is preferably an IG Incor 18 permanent magnet. Float 42 is comprised of a low density plastic which is freely buoyed by fluid filling vertical passage 56. One advantage of using independent buoyant float 42 within vertical overflow chamber 38 is that no linkages are required to hold the float or control its movement. Any time linkages are connected to a float, the potential exists for corrosion to develop on the linkages inhibiting the free movement of the float and debilitating the function of the device.
The magnetic sensor 46 of detector assembly 28 is preferably contained in a plug 64 adjustably mounted in the upper portion of vertical overflow chamber 38 to allow adjustment of the threshold or set point position at which sensor 46 is activated by magnet 44. This, in turn, allows adjustment of the maximum desired fill level 41. As shown in the illustrated embodiment, plug 64 includes external threads 66 that are adjustably engaged with internal threads 68 disposed in vertical passage 56.
Plug 64 further includes a hollow interior region 70 open at the top and sealed at the bottom by a generally horizontal wall 72. Magnetic sensor 46 is positioned in hollow interior region 70 and hermetically sealed by an appropriate potting compound within plug 64 in proximity to wall 72. Horizontal wall 72 may also include a slot for receiving magnetic sensor 46 and holding it in position. Preferably, magnetic sensor 46 is a magnetically operated low gauss digital position sensor such as SS22PE manufactured by MICR0 SWITCH, but other sensors, such as a Hall sensor or Permalloy sensor, could also be used.
As buoyant float 42 and magnet 44 are buoyed vertically, magnetic sensor 46 will provide an output once magnet 44 reaches a threshold level which corresponds to the desired fill level of open receptacle 12. The output is received by a conventional digital control circuit 74 (Figure 1) which appropriately modifies the output to cause controller 30 to halt any further fluid flow to fluid inlet port 20. In the preferred embodiment, electric current to the Burket Model 281 flUsh valve is interrupted so that its spring-loaded solenoid closes the valve preventing any fl~rther fluid flow through the valve.
209~332 If open receptacle 12 is a conventional toilet, detector assembly 28 will also prevent flushing of the toilet if flood conditions already exist. For example, flushing of the toilet would normally be initiated by pressing a plunger type switch 76, such as the solid-state switch No. VX80-Cl manufactured by MICR0 SWITCH, connected to digital control circuit 74. However if open receptacle (toilet) 12 is already filled beyond the desired fill level, magnetic sensor 46 will provide an appropriate output to control circuit 74 to prevent controller 30 from allowing any fluid to flow to inlet port 20.
It will be understood that the foregoing description is of a preferred exemplary embodiment of this invention, and the invention is not limited to the specific form shown. For example, various magnetic sensors and control circuits may be used. The detector assembly may be used in conjunction with receptacles whether or not they have enclosed rims along their top.
In some situations, the detector assembly may be placed directly within the fluid receptacle rather than external to the receptacle. Additionally, the detector assembly is not limited to the use of magnetic fields and magnetic field sensors. It may also be designed to function with infrared, optoelectronic, or other non-contact technologies. These and other modifications may be made in the design and arrangement of the elements without departing from the scope of the invention as expressed in the appended claims.
Claims (20)
1. An overflow controller for detecting an overfill condition in an open receptacle receiving fluid from a source and for preventing overflow by controlling the flow from said source, comprising:
a receptacle for receiving a fluid, having a desired maximum fill level and a fluid inlet port;
a detector assembly disposed in fluid communication with the interior of said receptacle, said assembly having a vertical overflow chamber into which fluid may flow from said receptacle, the distal end of said overflow chamber being positioned above said fill level, said detector assembly including:
i) a buoyant float in said overflow chamber disposed for movement therein in response to any fluid admitted thereto;
ii) a proximity detector disposed in said overflow chamber above said float and operable to generate an output when an overfill condition occurs and said float reaches a threshold position; and a controller in the flow line of said source and in operative communication with said detector assembly, for receiving said output and for halting fluid flow to said inlet port in response thereto.
a receptacle for receiving a fluid, having a desired maximum fill level and a fluid inlet port;
a detector assembly disposed in fluid communication with the interior of said receptacle, said assembly having a vertical overflow chamber into which fluid may flow from said receptacle, the distal end of said overflow chamber being positioned above said fill level, said detector assembly including:
i) a buoyant float in said overflow chamber disposed for movement therein in response to any fluid admitted thereto;
ii) a proximity detector disposed in said overflow chamber above said float and operable to generate an output when an overfill condition occurs and said float reaches a threshold position; and a controller in the flow line of said source and in operative communication with said detector assembly, for receiving said output and for halting fluid flow to said inlet port in response thereto.
2. The apparatus of claim 1, wherein said float includes a permanent magnet and said proximity detector comprises a magnetic sensor.
3. The apparatus of claim 1, wherein said proximity detector comprises a light sensor which generates a beam of light and provides said output when said float interrupts said beam.
4. The apparatus of claim 1, wherein said proximity detector comprises an infrared sensor.
5. The apparatus of claim 1, wherein said proximity detector comprises an optoelectronic sensor.
6. The apparatus of claim 1, wherein said proximity detector is adjustably mounted in said overflow chamber to allow adjustment of said threshold position.
7. The apparatus of claim 1, wherein the detector assembly is disposed external to said receptacle.
8. The apparatus of claim 1, wherein the detector assembly is disposed in the interior of said receptacle.
9. The apparatus of claim 1, wherein the controller comprises a solenoid valve which responds to said output.
10. The apparatus of claim 1, wherein the receptacle includes a fluid exit port proximate the lower interior region thereof.
11. The apparatus of claim 10, further comprising an annular chamber disposed towards the top of said receptacle into which fluid flows from said fluid inlet port, wherein said annular chamber further includes at least one aperture through which the fluid drains into the receptacle at a rate substantially equivalent to the rate at which fluid flows into said annular chamber from said fluid inlet port.
12. The apparatus of claim 2, wherein said magnetic sensor is a magnetically operated digital position sensor.
13. The apparatus of claim 12, wherein said magnetic sensor is hermetically sealed in said overflow chamber.
14. An overflow controller for detecting an overfill condition in an open receptacle receiving fluid from a source and for preventing overflow by controlling the flow from said source, comprising:
a) an open receptacle for receiving a fluid, defined by a fluid-receiving bowl having a desired maximum fill level, a fluid exit port proximate the lower interior region thereof, and a fluid inlet port proximate the open top thereof;
b) an annular chamber intermediate said fluid entry port and said bowl, into which fluid from said source is admitted and from which said fluid flows into said bowl;
c) a plurality of apertures in said annular chamber for fluid flow therefrom into said bowl, the collective cross-sectional area of said apertures being sufficient to permit flow into said bowl under steady-state conditions without an appreciable accumulation of fluid in said annular chamber;
d) a detector assembly disposed in fluid communication with the interior of said annular chamber, said assembly having a vertical overflow chamber into which fluid may flow from said annular chamber, the distal end of said overflow chamber being positioned above said fill level, said detector assembly including:
i) a buoyant float in said overflow chamber disposed for movement therein in response to any fluid admitted thereto;
ii) a magnet supported by said float;
iii) a magnetic sensor sealed in said overflow chamber at a location above the steady-state location of said magnet and operable to generate an output when an overfill condition occurs and said magnet reaches a threshold position; and, e) a controller in the flow line of said source and in operative communication with said detector assembly, for receiving said output and for halting fluid flow to said inlet port in response thereto.
a) an open receptacle for receiving a fluid, defined by a fluid-receiving bowl having a desired maximum fill level, a fluid exit port proximate the lower interior region thereof, and a fluid inlet port proximate the open top thereof;
b) an annular chamber intermediate said fluid entry port and said bowl, into which fluid from said source is admitted and from which said fluid flows into said bowl;
c) a plurality of apertures in said annular chamber for fluid flow therefrom into said bowl, the collective cross-sectional area of said apertures being sufficient to permit flow into said bowl under steady-state conditions without an appreciable accumulation of fluid in said annular chamber;
d) a detector assembly disposed in fluid communication with the interior of said annular chamber, said assembly having a vertical overflow chamber into which fluid may flow from said annular chamber, the distal end of said overflow chamber being positioned above said fill level, said detector assembly including:
i) a buoyant float in said overflow chamber disposed for movement therein in response to any fluid admitted thereto;
ii) a magnet supported by said float;
iii) a magnetic sensor sealed in said overflow chamber at a location above the steady-state location of said magnet and operable to generate an output when an overfill condition occurs and said magnet reaches a threshold position; and, e) a controller in the flow line of said source and in operative communication with said detector assembly, for receiving said output and for halting fluid flow to said inlet port in response thereto.
15. The overflow controller of claim 14, wherein said magnetic sensor is a magnetically operated digital position sensor.
16. The overflow controller of claim 14, wherein said magnetic sensor is a magnetically operated Hall sensor.
17. The overflow controller of claim 14, wherein said magnetic sensor is a magnetically operated Permalloy sensor.
18. An overflow controller for detecting an overfill condition in an open receptacle receiving fluid from a source and for preventing overflow by controlling the flow from said source, comprising:
a) an open receptacle for receiving a fluid, defined by a fluid-receiving bowl having a desired maximum fill level and including a fluid exit port proximate the lower interior region thereof and a fluid inlet port proximate the open top thereof;
b) flow isolation means intermediate said bowl and said fluid source, including a chamber through which fluid may flow without appreciable accumulation during steady-state but in which fluid may accumulate at the onset of an overflow condition in said bowl;
c) detector means in fluid communication with said flow isolation means, including a fluid-borne switch element for indicating the onset of overflow conditions and initiating a signal representative thereof; and d) flow controller means responsive to said signal for controlling said flow from said source during overflow conditions.
a) an open receptacle for receiving a fluid, defined by a fluid-receiving bowl having a desired maximum fill level and including a fluid exit port proximate the lower interior region thereof and a fluid inlet port proximate the open top thereof;
b) flow isolation means intermediate said bowl and said fluid source, including a chamber through which fluid may flow without appreciable accumulation during steady-state but in which fluid may accumulate at the onset of an overflow condition in said bowl;
c) detector means in fluid communication with said flow isolation means, including a fluid-borne switch element for indicating the onset of overflow conditions and initiating a signal representative thereof; and d) flow controller means responsive to said signal for controlling said flow from said source during overflow conditions.
19. The overflow controller of claim 18, wherein said flow isolation means includes an annular chamber having a plurality of apertures through which fluid flows into said bowl during steady-state conditions.
20. The overflow controller of claim 18, wherein said detector means comprises a magnetically activated sensor.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US97989892A | 1992-11-23 | 1992-11-23 | |
| US07/979,898 | 1992-11-23 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2098332A1 CA2098332A1 (en) | 1994-05-24 |
| CA2098332C true CA2098332C (en) | 1997-02-25 |
Family
ID=25527208
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2098332 Expired - Fee Related CA2098332C (en) | 1992-11-23 | 1993-06-14 | Overflow controller |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2098332C (en) |
-
1993
- 1993-06-14 CA CA 2098332 patent/CA2098332C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2098332A1 (en) | 1994-05-24 |
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