GB2439655A

GB2439655A - Valve control

Info

Publication number: GB2439655A
Application number: GB0712712A
Authority: GB
Inventors: David Ronald Boyd
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-06-29
Filing date: 2007-06-29
Publication date: 2008-01-02
Anticipated expiration: 2027-06-29
Also published as: GB2439655B; GB0612865D0; GB0712712D0

Abstract

A valve operating device 200 adapted for insertion between a valve body 201 and the thermostatic head 202 of a thermostatically controlled radiator valve comprises engagement means 220 movable between a first or contact position in which there is operable contact through the device between the valve body 201 and the thermostatic head 202, and a second or non-contact position where there is no operable contact between the valve body and the thermostatic head. Motor-driven gearing 204 moves the engagement 220 means between the first and second positions.

Description

Control System

Field of the invention

This invention relates to a heating control system. It is particularly applicable, but in no way limited, to a heating control system whereby a number of locations in a building can be independently controlled over a period of time from a central control unit, for example the control of individual radiators within a domestic central heating systems.

Background to the Invention

There has recently been a new awareness of the need to reduce energy consumption in buildings and large increases in fuel costs have spurred the need for a more efficient use of space heating.

In most practical situations, even with great determination on the householder's part it is difficult to effectively control individual heating zones to the optimum and desired levels.

Most installations in common use today include a timer which can control hot water and heating but rarely in separate zones. Even if there are separate controls for heating and hot water, the heating is usually a single zone such that heating to the whole dwelling is either on or off. It is apparent that in many dwellings much heat is wasted by heating unoccupied or briefly occupied areas whilst in other cases rooms are left unheated at times when it would be better to heat them. There is a school of thought that a dwelling should be well insulated and the whole kept to a constant temperature.

Whilst this argument may be valid for some small newly built units, for larger or less modern houses, a more sophisticated control system will provide a much greater degree of comfort at a greatly reduced cost.

It is an object of the present invention to provide a heating control system particularly suitable for use with domestic central heating systems and which overcomes or at least mitigates one of more of the problems noted above.

The present invention aims to overcome these problems by providing a control system whereby the heat supply to a number of locations in a building can be independently controlled over a period of time from a central control unit. Also it is suggested that the capital cost of providing such a heating control system would be quite modest and quite likely repay the investment in 12 months due to the savings in reduced waste energy.

The purpose of the invention is to provide a means whereby users of a building or buildings can easily and flexibly control the environment of specifically different areas simultaneously via a time controller which can change the temperature, humidity, ventilation etc over any chosen time periods which can be individually selected for each area to be controlled.

The areas to be controlled can be any number dependent on the design of the control unit.

Summary of the Invention

According to a first aspect of the present invention there is provided a valve-operating device adapted for insertion between the valve body and the thermostatic head of a thermostatically controlled radiator valve, said valve-operating device comprising:- (I) an engagement means adapted to be moved between a first or contact position in which there is operable contact through the device between the valve body and the thermostatic head, and a second or non-contact position where there is no operable contact between the valve body and the thermostatic head; and (ii) drive means adapted to move the engagement means between first and second positions.

This provides a simple, inexpensive after fit control to a radiator heating system which, in combination with a suitable controller, can save substantial amounts on a heating bill.

Preferably the engagement means comprises:-a first engagement means adapted to engage with and operate in use the spindle/plunger on the valve body; a second engagement means adapted to engage with and be operated by in use by the spindle/plunger on the thermostatic head, said first engagement means being moveable between a first, or closed position wherein the first engagement means closes the valve in the valve body and wherein the second engagement means is spaced away from the said spindle/plunger in the thermostatic head by such a distance that movement of the spindle/plunger in the thermostatic head results in no corresponding movement of the spindle/plunger on the valve body, and a second position in which the thermostatic head is in operative contact with the valve body.

This is just one of a number of simple mechanical devices which can be used to decouple the thermostat from the valve, at the same time as closing the valve, when required.

Preferably the second engagement means comprises a threaded spindle constrained within a threaded housing.

Preferably said device further comprises a signal receiving means adapted to receive a signal from a controller. The signals may be conveyed in a variety of means including through a mains supply or by radio waves.

Preferably the device further comprises drive means, the drive means being adapted to move the engagement means between the first closed position and the second position.

Again this drive means can take a wide variety of forms.

Preferably the drive means incorporates a gear train.

Preferably the device further comprises one or more limit switches.

Preferably the valve-operating device is modified in that it is integral with or incorporated in a thermostatically controlled radiator valve, or into a thermostatic head of a thermostatically controlled valve. This makes for a neater and more compact unit.

According to a second aspect of the invention there is provided a control system comprising:- (i) a multi-zone controller; (ii) a plurality of valve-operating devices, said valve-operating devices being adapted to intercede in the normal operation of a control valve to override the normal operation of the control valve; (iii) signal means adapted to convey a signal from the controller to a valve-operating device.

The valve-operating devices may be of the form set out in the claims and as described herein and may preferably be incorporated into a thermostatically controlled radiator valve or a thermostatically controlled radiator valve head.

Preferably the signal means is a mains communication device.

Preferably the control device incorporates a display adapted to display the status of each zone. A simple, clear and easy to read display is an important part of this invention.

Thus according to one aspect of the present invention there is provided a heating control unit for multi-ways programming, capable of providing control of 3 or more circuits over a period of 24 hours. Preferably the heating control unit provides control of 4 or more circuits, and most preferably 5 or more circuits.

According to a further aspect of the present invention the heating control unit comprises a main control unit and a sub control unit located on each heating unit wherein there is communication between these units. The communication may be through conventional wiring, fibre optics, network cables, wireless network, Bluetooth, infrared, or any other

suitable means.

The invention will be further described, by way of example, with reference to the accompanying drawings in which: Figure 1 is a front view of the main control unit; Figure 2 is a schematic diagram of the heating control unit; Figure 3 is a diagram showing how the heating control unit can be integrated into a multi-zone building; Figure 4 is a diagrammatic cross-sectional view of a first embodiment of a valve-operating device according to the present invention; Figures 5 and 6 show diagrammatically the display on a typical control module; and Figure 7 illustrates a diagrammatic cross-sectional view of a second embodiment of a valve-operating device.

The present invention will now be described by way of example only. These examples represent the best ways known to the Applicant of putting the invention into practice, but they are not the only ways this can be done.

This system provides for individual control of any number of zones in a building. A medium sized house might typically need six or eight individually controlled areas or zones. The terms "zone" and "area" are used interchangeably.

There are three main considerations: a) The main central control unit.

b) The control at the remote area/zone to be heated.

c) The communication between a) and b).

It is important that a central master control unit should provide easy access, control and indication of functions. This should be easy to interpret by persons of varying abilities and degrees of familiarity with the system. Many electronic time clocks in this situation have little control apart from basic functions, are difficult to interpret, particularly for someone unfamiliar with them and are not easy to reprogram. Although this invention is intended to cover any mechanical or electronic means of achieving its purpose, it is felt that a well designed electric motor controlled unit would provide one user-friendly solution, as well as providing a unit of well tried, low cost mechanical reliability, having a long life.

The unit needs a reasonably sized timer, displaying each zone, with on and off times easily visible, easy access to a means of changing time programmes and a means of setting and re-setting the clock.

Well designed switches to control each zone individually, where each zone can be: a) left on preset timer settings, b) switched ON to over-ride the timer and c) switched OFF to over-ride the timer.

There would ideally be indicator lights to show the operating state of all zones.

Additionally a "late on" function should be provided to over-ride the ON times to a later time of day. Also, a switch position can be provided designed to take the output from a phone switch or other remote control device, allowing remote control of the system from a distant location. Such "phone-in" technology is well known to those skilled in the art.

In one embodiment the unit is manufactured with its main operating device being a rotating cylinder with adjustable projections on its inner or outer surface which operate switches. However one preferred embodiment, shown in Figure 1, comprises a rotating disc with concentric rings or bands 21 to 28 designated to each switching zone or function. This disc rotates at one revolution per 24 hours with each ring divided into sections of time division (typically 15 or 30 mm). At each time division a movable or adjustable lever or peg is provided for setting ON and OFF times. These project through to the rear of the disc to operate electric switches and thence the remote devices.

Referring again to Figure 1 which represents one embodiment of the present invention, it can be seen that there are 8 different zones which are controlled by the main control unit 10. Each zone has a control switch, 11 to 18, whereby that circuit and thus zone can be turned on, off or timed. When the control switch for a particular zone is set to timed, then the time at which the heating will turn on and off in that particular zone is controlled by the timing wheel. In this particular embodiment the pegs are in the places indicated by an x and when a peg is located in a hole, the system will turn the heat on in that zone at that time.

Additionally with the system an electrical output is provided at the appropriate times to control the boiler and the water-circulating pump. In order to facilitate this, the switches operated by the moving disc need to be double pole. Alternatively each zone switch output can be fed via a silicon diode to a relay, or solid state-switching device, to operate the boiler. Secondly if the motorised valves are of the five-wire type -that is with the control motor remaining un-energised during operation, the zone switch needs to be double throw or changeover. This is just one way in which the circuitry may be constructed. However, a person skilled in the art will appreciate that there are many ways in which this can be achieved. A suitable design will be devised by a qualified person using the most up-to-date, practical and reliable components available at that time. Whilst the design is an important factor, it is the functionality which the Applicant is seeking to protect.

A key element however is that a single multi-zone controller controls a multiplicity of zones, and generally more than three zones as found in most prior art controllers.

A schematic diagram of a control unit is shown in Figure 2.

In the control of a heating system with water filled radiators, there are two approaches.

One is to have a number of solenoid or motorised water flow valves near the boiler or source of heat which feed each room by separate pipework. The other is to have the appropriate valves in each room on or near each radiator. These can be connected by electric wiring to the central control unit. This latter type of arrangement is easier to install in both pre-existing systems and in a new building. Alternatively the system can be radio controlled with a coded transmitter in the main control unit sending a signal to a radio receiver attached to and controlling each remote valve. Such remote control systems are known per se and are used, for example, in remote control conservatory blinds. In any event, remote control technology to control multiple zones is well known to the person skilled in the art.

Figure 3 illustrates one possible arrangement in which four radiators are shown. Each radiator 31 to 34 has a valve-operating device 41 to 44 to control when hot water may or may not enter that particular radiator. In this example, each valve-operating device is wired back to the control unit 35. Alternative arrangements which do not necessitate hard wiring between the control unit and the/each valve-operating device are described below.

It is envisaged that there are a number of options for the form and positioning for the valve-operating devices. This valve-operating device could be positioned between the valve body and the thermostatic head of a conventional thermostatically controlled radiator valve. Alternatively the valve-operating device can be incorporated as an integral part of a thermostatically controlled radiator valve or as an integral part of the thermostatic head of such a valve. This would result in a valve of neater and more aesthetically pleasing design.

It is thus envisaged that one option would be to install the valve controller with its own thermostat onto the base of a standard thermostatic radiator valve, or to a non-thermostatic balancing valve, thus providing the possibility of installing the system without any necessity to drain down the system.

There are other means of controlling the remote valves if a mains connection is not available or desired. One is to control the valve and or the receiver by replaceable electric batteries. Another is to operate the radio receiver by batteries and the valve by a clockwork motor. This would need to be manually rewound, perhaps monthly.

A third possibility is to utilise mechanical energy generated by a turbine in the water flow to the radiator (as use in some types of lawn sprinkler).

Although time switches which can turn an item on or off over a 24 hour period are known, it is not known to provide a controller that can turn on and off five or more circuits in this way with the adjustability described above.

Included in the invention are means of sending the control information to the area to be controlled or to the device controlling the environment in the controlled area.

Also included are practical means of using the control information to operate the control devices.

It will be appreciated that the heart of the control system invention is the control unit to be operated by the user. This could be:-A) A mechanical timer controlled by an electric motor.

B) An electronic unit using semiconductor devices.

It is important that the control unit has a display unit which provides readily and easily interpretable information about all the areas under control coupled with means to vary or switch the various functions and time controlled periods.

The control information from the timer unit to the local operating device is transmitted by any practical means but may include:-A) Direct electric wiring.

B) Electromagnetic wave wireless signals.

C) Digital or analogue encoded modulated signals sent via the power supply or other pre-existing cables.

D) Ultra sonic, infrared or other signals.

At the receiving end of the transmitted information a device must be used to control and operate the unit or device controlling the environment.

The transmitted information can also be used to operate a local information display unit in the controlled area.

At the present time, against the background of rising fuel costs and pressure to reduce the carbon footprint' of buildings, it is thought that the most easily installed embodiment of this invention would be an example to operate in a modest domestic environment to provide both a saving by reducing unnecessary heating in unoccupied areas and also by providing heating in other areas exactly when and where it is required so as to produce a more comfortable environment at lower cost.

As an example a timer unit is provided to produce controlling output signals to six or eight separate zones The unit comprises an electronic device, utilising programmable integrated circuits containing a master device, also controlling a display showing the times set for each of the zones to be controlled. An example of such a display unit is illustrated in Figures 5 and 6. These illustrate area control switches 61 to 68. Each switch has three positions, AUTO', in which the zone goes on or off according to the programmed times, CONSTANT ON' in which heat may always reach the radiator if called for, and OFF' in which heat is permanently cut off from the radiator.

Area labels 71 to 78 are provided which may be handwritten or part of the electronic display. The present time is indicated by an indicator bar 79. Interconnecting switching will allow any time slot selected to be altered in length or position in real time. Switching will also allow the on' periods to be individually overridden or to be substituted with constant on' or constant off states for individual zones.

An LCD or LED display 80 shows the status of each zone or area throughout the entire 24-hour period. The various possible combinations are shown in Figure 6 as follows:- 81 -selector switch set to CONSTANT ON'.

82 -selector switch set to OFF'.

83 -No AUTO settings for that zone.

84 -Selector switch set to normal AUTO' run position.

The differently hatched areas of each bar show when the valve-operating device is open or closed. A reset/select button enables each zone to selected in turn in order to set the ON' and OFF' times for each zone using ON' OFF' switches 86.

The electronic device will thus provide at the appropriate times a switch on' signal for the heating boiler or other heat source.

It will also provide a switch on' and a switch off signal at the appropriate times to a mechanical device controlling the heat output of, for example, a hot water radiator.

The electronic device preferably includes means to encrypt the signals into a digital code to be sent via the household power supply cables to any location required in the building. The technology to transmit signals along a llOv/240v cable in a domestic wiring system is well known. Examples such as HOMEPLUGS.CO.UK are available from Flashbyte.Net Limited, 7 Church Road, Shoeburyness, Essex SS3 9ET, Company Number 03877045.

The controlled display device can be configured in a number of different ways using one of the several types of electronic display devices currently available. A ready manufactured liquid crystal display unit could display current time plus a clear graphic display of the on and off time slots for each area selected in turn.

A larger light emitting diode display or liquid crystal display could display all timed zones and their current active state simultaneously. The display device can be optionally constantly displaying or activated to display only when it is needed to check the timing or to make an adjustment.

As an example the electronically controlled device or valve-operating device at the local area to be controlled could be an electric motor operated water controlled valve on a hot water radiator. This would combine the normal air temperature-sensing device with a motor which would provide two alternative mechanical states. One would allow the thermostat to open the radiator valve normally. The other would disable the valve, preventing it from allowing the radiator to operate.

An example of one such valve-operating device is shown in Figure 4. This illustrates a device 100 adapted to be interposed between the valve body 101 and the thermostatic head 102 (not shown) of a conventional thermostatically controlled radiator valve. Its purpose is to interrupt the operative connection between the spindle/plunger on the thermostatic head and the spindle/plunger on the valve body. In this way, the thermostat element continues to operate normally but its actuation of the valve in the valve body may be interrupted. This design of device is most effective when used with a valve body in which the valve is open when the spindle/plunger in the valve body is in the up position.

The valve-operating device 100 consists of a body 103 which contains a motor and gear train 104. The lower part of the device rests on and engages with the spindle/plunger 106 of the valve in the valve body. In this case the spindle is housed within an annular ring or seating. But an indentation in the bottom portion of the device into which the spindle could engage is equally possible.

The drive from the motor is in the form of a threaded spindle 107, housed within a threaded housing 108. Also attached to this threaded housing is a spindle/plunger 120 adapted to engage with of the thermostatic valve. In operation, the housing/spindle combination occupies one of two positions. In a first or contact position where the end of the spindle is substantially in contact with the end of the thermostat's plunger or body (not shown). In this position movement of the thermostat plunger is conveyed directly to the valve spindle and plunger so that the valve operates normally. In a second or non-contact position, as shown, there is a gap between the end of the motor spindle and the thermostat plunger/body. In this case, downward movement of the plunger is not transmitted to the valve so the normal operation is interrupted. In order to control the motion of the motor spindle it will be appreciated that limit switches 109, 110, diodes 111, a power supply 112 and other conventional circuitry is provided.

In this example a low voltage power supply is provided using a transformer and signalling device plunged in to a mains socket local to the radiator being controlled. It is envisaged that the control signals are provided through the mains as described above, or by radio waves.

In certain typical known thermostatically controlled radiator valves, when the control pin or spindle/plunger on the valve body is UP, the valve is OPEN and when it is DOWN, it is closed. This means that when the inside cell or threaded motor spindle extension of the controller is at its longer length, the radiator is in the OFF mode and vice versa. A valve-operating device more suited to this arrangement is shown in Figure 7. However, it will be appreciated that the opposite mode of operation, which may exist in some valves of this type, is equally possible.

Figure 7 illustrates a device 200 adapted to be interposed between a valve body 201 and the thermostatic head 202 of a conventional thermostatically controlled radiator valve. As with the device illustrated in Figure 4 and described above, its purpose is to interrupt the operative connection between the spindle/plunger or moveable body of the thermostatic head and the spindle/plunger on the valve body, whilst in the process substantially closing the valve in the valve body to prevent hot water reaching the radiator. The device in Figure 7 is shown in the first or contact position.

The device consists of a body 203 which contains a motor 223 and a gear train 204.

The motor is fixed within the body and is provided with electric current as and when required through input socket 212. The drive from the motor is in the form of a threaded spindle or worm drive 207. This engages within an internally threaded housing 208.

This threaded housing is constrained to move up or down, depending on the direction of rotation of the worm drive 207. The degree of movement of housing 208 is constrained by limit switches 209 and 210. When moving in a downward direction the housing 208 bears down on operating lever 221 causing it to move downwards and to eventually substantially close the valve in the valve body 201 by depressing the spindle/plunger 206 to its maximum extent.

In this so-called first' position the valve in the valve body is closed and the spindle 220 is drawn away from the thermostatic valve head to make the head inoperative as far as controlling the valve in the valve body is concerned. When the work gear rotates in the opposite direction the housing 208 lifts away from operating level 221, allowing the thermostatic valve head free to operate the valve-operating shaft 206 as normal, albeit through a now intervening shaft 220. Shaft 220 is constrained to operate along a pre-determined longitudinal axis by mountings 230 and 231. Thus in this so-called first position the head is in operative contact with the valve body.

It will be appreciated that the top and bottom of shaft 220 act as engagement means to engage with the thermostatic valve head and the spindle/plunger of the valve body as required. When the shaft is positioned in a certain position it provides operative contact between the two.

Components, control devices and a power supply will be required as described above in relation to the embodiment shown in Figure 4.

It will therefore be appreciated that a special valve can be manufactured which replaces an existing conventional radiator valve entirely. Alternatively a device has been designed which is installed between an existing water valve (or the lower part of a conventional radiator valve) and the air temperature sensitive upper part. It is envisaged that this type of device could be installed without draining down a central heating system.

The valve is controlled via a low voltage signal supplied from a receiver unit installed or plugged into a suitable nearby mains supply.

The receiver unit consists of a low voltage power supply coupled to a decoder to interpret the mains born digital signals sent from the main control unit.

A further possible variation of the radiator controller is to contain an electrical switching thermostat in the receiver unit to be plugged into the power socket and feed via electrical wiring the controlling electrical signal to a unit containing an electro-mechanical operating device to open or close the valve. This unit will simply replace the normal thermostat part of the thermostatic radiator valve.

A further variation of the system is to leave the existing thermostaticradiator valve in place, working as installed and for the receiver unit to send a signal to a motorised controller which would be attached to the existing lock shield' valve on the radiator or alternatively to a newly installed electric valve at any other part of the pipework controlling the radiator.

The devices controlling the valves can be an electro-mechanical means including any type of electric motor, solenoid etc. In any event, it will be appreciated that an extra level of control is provided, over and above the normal on/off control of the heating system and the normal thermostatic control of the radiator valve. This extra level of control is provided by a multi-zone, radiator-by-radiator controller and a special valve-operating device on one of the radiator valves.

In practice the power supply, electronic control boards and associated display device will be contained in one self-contained unit which can be placed in any convenient place in the building. As the mains power supply into the unit and the output control signals both travel via the connecting cable to a power socket, the only installation required is to plug the unit into a wall socket.

The scope of this invention also covers the possibility of providing two or more different preset levels of temperature at various times rather than simple ON or OFF periods.

This would need a more complex timer unit with extra timed channels -possibly more suited to installations in other than domestic situations.

Claims

Claims: 1. A valve-operating device adapted for insertion between the

valve body and the thermostatic head of a thermostatically controlled radiator valve, said valve-operating device comprising:- (i) an engagement means adapted to be moved between a first or contact position in which there is operable contact through the device between the valve body and the thermostatic head, and a second or non-contact position where there is no operable contact between the valve body and the thermostatic head; and (ii) drive means adapted to move the engagement means between first and second positions.

2. A valve-operating device as claimed in Claim 1 wherein the engagement means comprises:-a first engagement means adapted to engage with and operate in use the spindle/plunger on the valve body; a second engagement means adapted to engage with and be operated by in use by the spindle/plunger on the thermostatic head, said second engagement means being moveable between a first, contact position wherein the engagement means is in contact with the said spindle/plunger, and a second, non-contact position wherein the engagement means is spaced away from the said spindle/plunger by such a distance that movement of the spindle/plunger in the thermostatic head results in no corresponding movement of the spindle/plunger on the valve body.

3. A vaive-operating device as claimed in Claim 2 wherein the second engagement means comprises a threaded spindle constrained within a threaded housing.

4. A valve-operating device as claimed in any preceding claim wherein said device further comprises a signal receiving means adapted to receive a signal from a controller.

5. A valve-operating device as claimed in any preceding claim wherein the device further comprises drive means, the drive means being adapted to move the engagement means between the contact position and the non-contact position.

6. A valve-operating device as claimed in Claim 5 wherein the drive means incorporates a gear train.

7. A valve-operating device as claimed in any preceding claim wherein the device further comprises one or more limit switches.

8. A valve-operating device as claimed in any of Claims I to 7 modified in that it is integral with or incorporated in a thermostatically controlled radiator valve, or into a thermostatic head of a thermostatically controlled valve.

9. A valve-operating device as claimed in Claim 1 wherein when the engagement means is in the second position the valve in the valve body is constrained into a substantially closed position.

10. A valve-operating device as claimed in Claim 1 or Claim 9 wherein the engagement means comprises a spindle disposed between the thermostatic head and the spindle/plunger on the valve body, said spindle being attached to an operating lever.

11. A valve-operating device as claimed in C'aim 10 wherein said device further comprises a motorised worm drive constrained within a threaded housing, operation of the worm drive in one direction causing the lever to move in such a way that the valve in the valve body is closed and the thermostatic head is disassociated from the valve body.

12. A valve-operating device as claimed in Claim 1 and any of Claims 9 to 11 inclusive further comprising a signal receiving means adapted to receive a signal from a controller.

13. A valve-operating device as claimed in Claim I and any of Claims 9 to 12 inclusive further comprising one or more limit switches.

14. A valve-operating device as claimed in Claim 1 or any of Claims 9 to 13 inclusive modified in that it is integral with a thermostatically controlled radiator valve, or integral with a thermostatically controlled head.

15. A control system comprising:- (i) a multi-zone controller; (ii) a plurality of valve-operating devices, said valve-operating devices being adapted to intercede in the normal operation of a control valve to override the normal operation of the control valve; (iii) signal means adapted to convey a signal from the controller to a valve-operating device.

16. A control device as claimed in Claim 15 wherein the valve-operating device is of the type as claimed in any of Claims 1 to 14 inclusive.

17. A control device as claimed in Claim 15 or Claim 16 wherein the signal means is a mains communication device.

18. A control device as claimed in any of Claims 15 to 17 inclusive wherein the control device incorporates a display adapted to display the status of each zone.

19. A control device substantially as herein described with reference to and as illustrated in any combination of the accompanying drawings.

20. A valve-operating device substantially as herein described with reference to and as illustrated in any of the accompanying drawings.