"AUTOMATIC PRESSURE AND FLOW CONTROLLER AND CHA-RGE
CELL FORMING PART OF IT"
The present description refers to a patent of
invention for an automatic pressure and flow controller and charge cell
forming part of it, pertaining to the field of hydraulic installations, and
which have been designed to perform the same functions as similar
conventional equipment, but more efficiently, as well as introduce a, more
simplified construction being sensibly smaller in volume than the mentioned
conventional equipment, and provide further advantages. It is already known in the art, equipment intended
to keep a water pipeline under pressure by driving a water pump every time
the pressure drops below a given value, as well as intended to monitor the
liquid flow in the pipeline in order to secure the pump will not work dry for
a long time. Such conventional device comprises: a casing
through which the water runs; a relief valve; a flow detecting set
comprising: a special piston provided with a magnetic element, and which
moves along with the water flow; and a magnetic sensor suitably arranged
outside the body, and which is sensitized by the magnetic element of the
piston, when such moves, thus detecting the water flow; such device further
comprises: a diaphragm, which separates the inner part from the oxiter part
of the device casing; a spring supporting the diaphragm; a magnetic element
which moves upon the movement of the spring diaphragm set; an external
sensor, which sets the pressure by detecting the movement of the magnetic
element; and an analog circuit that processes the originated flow and
pressure information, upon which it turns the water pipeline pressurization
pump either on or off.
Although such device is useful for the purpose
which it is intended to, it shows the inconvenient of having a relatively
complex construction comprising several sets, and as a result a similarly
complex manufacturing process.
Another drawback consists of the fact such usual
device is extremely bulky, what causes it to require a complicated
installation to receive it for use, and poses a limiting factor to its field of
application. Another drawback consists of the fact such
constructive complexity results in a relatively high cost device.
Therefore, the objective of the invention, object of
the present patent is to provide a pressure and flow controller, which
performs the same functions as the usual device, but overcomes the
drawbacks shown by the conventional device, further to providing other
advantages.
Therefore, having the above-mentioned drawbacks
in mind, with the purpose of overcoming them, and aiming at meeting the
mentioned objectives, the automatic pressure and flow controller designed
according to the present patent of invention, essentially comprises: a piston
featuring a magnetic element associated with an external sensor, and a
casing chamber where the piston works, arranged to perform the functions
of flow detector and relief valve; a pressure sensible charge cell, which
features and subjects a power switch connected to the pipeline pressurization
pump, and either turns the switch on when the pressure in the pipeline drops
below the working pressure, or turns it or keeps it off, when the pressure
either reaches up to or is at the working pressure; said controller of the
present invention further comprises a microprocessed digital circuit
associated with the mentioned sensor and power switch, which controls the
on/off function of the pump and provides other functions. The piston and the chamber where it works are
arranged to perform functions such as flow detection and relief valve, as
provided in the present controller, thus the use of the relief valve provided in
the conventional device is not required, and as a consequence, the present
controller results to be simpler in construction than the conventional one. The charge cell essentially comprises: a cushion-
type elastic diaphragm, whose surface is subject to the pressure to be
monitored; said cell is further formed: by a fixed external tubular body
provided with external means for setting it at the place of use, and at one end
of which the diaphragm is placed; a movable internal tubular body provided
with an end diaphragm path limiting stop; an outer thread screwed in the
inner thread of the fixed body, said movable body can then be turned at the
fixed body either to get closer to or move away from the diaphragm, and so
adjust its path, and consequently the charge cell driving pressure; said
charge cell further comprises a power microswitch placed at the movable
body end opposite to the stop, and whose button is driven by the diaphragm;
and a cover for fastening the microswitch to the movable body.
The charge cell constructed as described above
advantageously replaces the traditional devices which are pressure,
pressostat driven, based upon a membrane and spring, since it has all the
functions as the traditional devices added by the fact it is perfectly
adjustable, occupies a too much smaller space, and does not require the use
of a spring, and all the structure required to support it.
The constructive simplicity of the present charge
cell further results in an extremely simple manufacturing process required to
manufacture it in respect of the similar conventional devices. Further, the constructive and manufacturing
simplicity of the present charge cell results in costs dramatically lower than
those required for manufacturing usual similar devices.
The microprocessed digital circuit of the present
controller, besides the pump on/off function, further provides conditions to
perform a number of other operations, such as: to set how many attempts the
circuit will allow to be made prior to entering into the error module; the time
between an attempt and the other; how low the pump must be kept on after a
lack of flow is detected; how long the circuit must wait for prior to turning
the pump on, when a pressure drop in the pipeline is detected, and other
operations according to the programming desired, which are only possible to
be performed and/or implemented by the digital circuit in a way simpler
than that of the analog circuit of the usual device.
Another advantage provided by the present
equipment over the conventional similar is a simpler construction and
manufacturing than those of the usual device and a volume extremely
smaller than that of the conventional device, what expands the choice of
application possibilities available to the present controller.
Such simplicity, and smaller volume result in a
final cost for the present controller that is lower than that for the usual
device. The accompanying drawings show the automatic
pressure and flow controller and the charge cell, object of the present patent,
in which:
Figure 1 shows a lateral section of the controller at
the position where the flow is allowed to pass, and its pressure detected;
Figure 2 shows the same figure as above, but at the
position where it works as a relief valve to prevent the backflow, when lacks
inlet flow;
Figure 3 shows a cross-sectional view of the
controller;
Figure 4 shows an enlarged detail of the charge
cell, which is part to the controller;
Figure 5 shows the charge cell with its parts taken
separately; and
Figure 6 shows it mounted, and the working
indication. According to what is illustrated by the above-
mentioned figures, the purpose of the pressure and flow controller, object of
the present patent of invention is to keep a suitable pressure at a water
pipeline 1, upon monitoring the pressure and driving a pump 10, whenever
the pressure drops below a predetermined pressure value, and secure the
pump 10 will not work dry when flow is lacking, and it is of the type
essentially comprising: a flow detecting device 20, primarily consisting of: a
piston 21 subject to flow "F"; a magnetic element 22 mounted over the
piston; a sensor 23 outside the flow circulation passage, sensible to the
movement of the magnetic element 22, and as a consequence, the movement
of the piston 21; a relief valve 30; a device 40 for setting the pump driving
pressure, essentially consisting of: elastic means 41 subject to pressure "P"
of the flow "F"; and power switch means 42 subject to the elastic means 41;
an electric circuit 80 associated with the sensor 23, and the power switch
means 42, and having the function to turn the pump 10 on/off; and a casing
60, where devices 20, 40; the relief valve 30 and the electric circuit 80 are
properly mounted; such casing being inserted into the water pipeline 1.
According to the present construction, a device 20-
30 with the functions to operate as a flow detector and relief valve is
provided, essentially comprising: a piston 21 being formed by: broader 21'
and narrower 21" sections, the broader section 21 ' being provided with the
magnetic element 22 and an 'O' ring 24 mounted on the face of said section
21 ' turned to the inlet 61 of casing 60, and the narrower piston section 21"
also turned to the inlet 61 having a diameter slightly smaller than the
passage 62 of the casing, and being guided by such casing.
Such device 20-30 with the functions to operate as
a flow detector and relief valve is further formed by: the casing 60 provided
by a chamber 63 broader than the passage 62, and slightly broader than the
broader piston section 21', where it is arranged and ready to move; opposite
lateral recessed stripes extending into said chamber 63 and passage 62 (fig.
3), which set the flow passages laterally to the broader section 21' of the
piston; set between said passage 62 and the chamber 63, the downstream
stop 65, and upstream seat 66; said piston 21 moving between two positions:
one corresponding to the existence of flow "F", where the piston 21 is
pushed by the flow and bumps against the downstream stop 65, thus
positioning the magnetic element 22 adjacent to the sensor 23, and arranging
the sensor at the logic position at which the pump 10 can be turned on by
the device 40, in the event the pressure falls below the nominal working
pressure, and another corresponding position when flow "F" is lacking, at
which the piston 21 is pushed by the backflow "F' ", and its 'O' ring 24
closes against the seat 66, thus actuating as a relief valve, and the magnetic
element 22 of the piston simultaneously moves away from the sensor 23,
taking it to a logic position at which the pump 10 is either turned off, or
prevented from being turned on by the device 40.
The device for setting the pump driving pressure
40 has its elastic means 41 and power switch means 42 comprising a charge
cell (figs. 4 a 6) primarily consisting of: a cushion-type elastic diaphragm
43, one of its surfaces being kept subject to a pressure "P" to be monitored;
said cell is further formed by: a fixed external body 44 provided with
external means 45 for setting in the place of use, in the event the casing 60 is
in the housing; an internal passage 46; an end 47, where the diaphragm 43 is
placed, and inner thread 48; an internal movable body 49 provided with an
internal passage 50; an end stop 51, which is adjacent to the diaphragm 43,
and its path limiter; outer thread 52 screwed in an inner thread 48 of the
fixed body 44, and which enables said movable body 49 to be turned and
axially displaced at the fixed body 44 either to get closer to or move away
from the diaphragm 43, and then adjust the diaphragm path, and
consequently the charge cell driving pressure; said charge cell further
comprises a power microswitch 42 placed at the end of the movable body 49
opposite to the stop 51, and whose button 42' is driven by the diaphragm 43;
and a cover 53 for fastening the microswitch 42 to the movable body 49.
The cushion-type diaphragm 43 is ring-shaped and
essentially comprises: an outer frame 54, which is placed at the end 47 of
the fixed body 44; an intermediate, elastic, circular crown-shaped membrane
55 whose periphery is incorporated into the frame, and which bends upon
receiving the monitored pressure "P", and whose bending path is limited by
the stop 51 of the movable body 49, according to the driving pressure
intended for the charge cell; and a rigid, central core 56 with the periphery
incorporated into the membrane 55, which is kept aligned with the button
42' of the microswitch 42, and which presses the button when the membrane
is bent.
Mounting the diaphragm 43 at the end 47 of the
fixed external body 44 provides sealing means 57, which together with the
diaphragm 43 provide further sealing between the room where the
monitored pressure "P" occurs and the environment.
The stop 51 comprises a tapered recess-shaped
surface provided at the end of the movable body 49 adjacent to the
diaphragm 43, and at whose bottom the end of the internal passage 50 of the
body is located, where the button 42' of the microswitch 42 is arranged and
slightly projecting.
The electric circuit 80 is digitally micro-processed
and arranged to receive information from the sensor 23 and/or power switch
42, process such information, and then turn the electric pump 10 either on or
off through the triac 81; said circuit is further arranged to perform other
operations, such as: to set how many attempts the circuit will allow to be
made before entering into the error module; the time between an attempt and
the other; how long the pump must remain turned on after lack of flow is
detected; how long the circuit must wait for prior to turning the pump on,
when a drop in the pipeline pressure is detected, and other operations,
according to the desired programming.
The triac 81 is associated with a cooling system
comprising a heat exchanging plate 82, one end of which keeps a physical
contact with the triac, and the opposite end dips into the water flow "F"
which circulates through the passage 62.
Preferably, the casing 60 is made of thermoplastic
material or similar one, and its diameter is slightly larger than that of the
pipeline 1 where it is set up, said pipeline being essentially formed by a
tubular body 68 and a connection 69.
The body end 68 is opposite to the connection 69,
which forms the water outlet 67, features a male screw, which connects to
the water pipeline 1, and a staggered passage extends along said body and
from said outlet 67, said passage being formed by: a longer, smaller
diameter section forming part of passage 62; radial surface forming the stop
65; an intermediate section, whose diameter is larger than the passage 62,
and forming part of the chamber 63, where laterally recessed passages 64
are provided; a female screwed section; a radial surface forming the sealing
stop, the end section being larger in diameter but having a short axial length,
these three latter elements receiving the connection 69; said body 68 further
features a upper vessel 70, which provides a chamber 71 communicating
with the passage 62, and receiving the charge cell, a means for placing the
electric circuit board 80, and means for fastening a cover 72.
The connection 69 is formed by a staggered
passage consisting of: an end, larger diameter section, which forms another
part of the chamber 63, and arranged as a continuation of part of body 68; a
radial surface forming the seat 66, and the end, opposite, smaller diameter
section, which constitutes part of the passage 62, forming the inlet 61, and
provided with a male screw connecting to the water pipeline 1, and at the
end of said part of the passage 62 next to the seat 66 a retaining rod 73 is
placed, where a longitudinal rip 74 is guided and made along the piston
section having a smaller width 21"; externally, said connection provides an
intermediate flange 75, which fits inside the end section of the body 68,
whose section is larger in diameter and has a small axial length, and an 'O'
ring 76 is arranged around said connection and adjacent to said flange 75,
and seals against the body sealing stop 68, the end of said connection
connecting to the body 68 further features a male screw.
Thus, the automatic pressure and flow controller of
the present invention works as follows: when there is a flow "F" at a
nominal pressure level "P", the diaphragm 43 of the charge cell bends, and
presses the button 42' of the normally closed switch 42 towards reaching the
open position at which the water pump 10 is not turned on. Simultaneously,
flow "F" pushes the piston 21 against the stop 65, and its magnetic element
22 is adjacent to the sensor 23, and thus the sensor is arranged at the logic
position at which the pump is allowed to be turned on, in case of pressure
drop. When there is a flow "F", but the pressure drops below the nominal
value, the diaphragm 43 takes over the non-bent position, releasing the
button 42' of the normally closed switch 42, which is automatically
switched to the position that turns on the pump 10, and then the nominal
pressure conditions are restored in the pipeline 1 (fig. 1).
When flow "F" is disrupted, the backflow "F"'
pushes the piston 21 towards a position at which the 'O' ring 24 of said
piston seals against the seat 66, thus acting as a relief valve. Simultaneously,
the magnetic element 22 moves away from the sensor 23, and the sensor
takes over another logic position at which the pump 10 is either turned off,
in case it is on, or the pump 10 is prevented from being turned on, in case it
is off, in order to avoid the pump from working dry (fig. 2).
The charge cell is used with any equipment, such
as for instance, the present flow and pressure controller, whose internal
pressure "P" is to be monitored, so that when a predetermined limit is
reached, some procedure will be started. The pressure limit value is
determined and the monitoring and driving are carried out by the charge
cell. Therefore, said charge cell is mounted at the equipment so the outer
face of its diaphragm 43 will be subject to pressure "P", and previously, by
means of a suitable screw to the fixed external body 44, the movable internal
body 49 is arranged at a desired distance in respect of the diaphragm 43,
which sets the diaphragm bending path, and as a result, the cell driving
pressure. This way, when the monitored pressure "P" reaches the pre¬
programmed limit by means of the positioning of the movable body 49, and
its stop 51 inside the fixed body 44, the diaphragm 43 bends along the preset
path and turns on the microswitch 42, which starts some procedure
associated therewith, as for instance, driving the controller pump, or relief
valve, or other operations.
Under this condition, the movable body 49 and its
stop 51 can be arranged at several positions in respect of the diaphragm 43,
causing the microswitch 42 to be turned on at a number of corresponding
pressure levels, in order to meet the application to which the cell is intended.
In addition to such function, once adjusted in respect of the diaphragm 43,
the movable body 49 and its stop 51 also act in order to keep a constant
distance between the diaphragm core 56 and the button 42' in order to avoid
pressure overload over the button.
According to the above described primary
construction, the controller and charge cell object of the present patent of
invention can have changes relating to materials, dimensions, constructive
details and/or functional and/or ornamental configuration, without departing
from the scope of the protection required.