Booster-powered valve system

[0002] Portions of this patent application include materials that are subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document itself, or of the patent application, as it appears in the files of the United States Patent and Trademark Office, but otherwise reserves all copyright rights whatsoever in such included copyrighted materials.

[0003] The present invention relates to fluid valves. More specifically, the present invention relates to power circuits for activating and deactivating fluid valves.

[0004] Electrically actuated fluid valves are used in many applications, such as for battery-powered faucet valves, for example. These designs present certain design challenges, however, that make the designs difficult to optimize. In battery-powered faucets that use solenoid-latch valves, the energy required to change the state of the valve is substantial. If such a system is designed to use the whole peak output of the battery, its performance begins to deteriorate soon after the battery strength drains to the point where its peak output diminishes. Alternatively, if the system is designed to use less actuation energy, its performance relative to the supply power is lower from the outset. There is thus a need for higher-performance valve control and power electronics that provide and maintain a high level of performance even after the peak output power of the battery begins to diminish.

[0005] It is one object of the present invention to provide an improved valve power control arrangement. It is another object of the invention to improve the power circuitry for electrically powered valves.

[0006] These objects and others are accomplished by a circuit including a power supply, booster circuitry, and valve control components, where the booster circuit stores energy in one or more capacitors by repeatedly storing energy in an inductor, then discharging the energy through a diode to one or more capacitors. The capacitors are then discharged through the valve control solenoid to change the state of the valve.

[0007] In some variations in this embodiment, the charge stored on the capacitors is monitored, and the cycling of the booster circuit is controlled based on the amount of that charge.

[0008] In other variations of this embodiment, a transistor is switched on and off to store and release the energy from the inductor.

[0009] In still other variations, the capacitors are periodically re-boosted. This compensates for leakage of charge from the capacitor with time, and improves the response time when the valve eventually needs to be actuated.

[0010] FIG. 1 is a block diagram of a valve with its power and control circuitry according to the present invention.

[0011] FIG. 2 is a block diagram of control circuit according to one embodiment of the present invention

[0012] FIG. 3 is a schematic diagram of a booster circuit for use in the present invention.

[0013] FIG. 4 is a flowchart of programming for control circuitry according to one embodiment of the present invention.

[0014] FIG. 5 is a flowchart of a routine for checking and responding to the battery level in one embodiment of the present invention.

[0015] FIG. 6 is a flowchart of a routine for handling the presence of an object in one embodiment of the present invention.

[0016] FIG. 7 is a flowchart of a routine for handling the absence of an object in one embodiment of the present invention.

[0017] FIG. 8 is a flowchart of a routine for determining whether to provide a time-based boost of the capacitor voltage in one embodiment of the present invention.

[0018] FIG. 9 is a flowchart of a routine for controlling a boost process according to one embodiment of the present invention.

[0019] For the purpose of promoting an understanding of the principles of the present invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will, nevertheless, be understood that no limitation of the scope of the invention is thereby intended; any alterations and further modifications of the described or illustrated embodiments, and any further applications of the principles of the invention as illustrated therein are contemplated as would normally occur to one skilled in the art to which the invention relates.

[0020] Generally, the system shown in FIG. 1 provides boosted power from a power supply to an electrically actuated valve through control and booster circuitry. The booster circuitry stores energy from the power supply on one or more capacitors, accumulating more potential than the power supply could provide on its own.

[0021] In particular, in this example embodiment, system 20 comprises power source 22, control circuitry 24, booster circuit 26, and valve 28. In this example, power source 22 comprises four dry cells, such as those of standard sizes AAA, AA, C, or D. Where a plurality of cells are used, they are preferably configured in series to provide a total electrical potential equal to the sum of the potentials provided by each cell.

[0022] Valve 28, in this example, is a solenoid-latched water valve, such as model 612-268, manufactured and distributed by Evolutionary Concepts, Inc. Other valves may be used as desired or necessary given the design parameters of other systems.

[0023] Turning now to FIG. 2, further details regarding control circuitry 24 will be discussed with reference to components in FIG. 1. In this embodiment, control circuitry 24 comprises controller 32, memory 34, one or more optional output devices 36, and one or more optional input devices 38. Power, ground, clock, sensors, and other signals and circuitry are not shown for clarity, but will be understood and easily implemented by those who are skilled in the art.

[0024] Controller 32 is preferably a microcontroller, that reads its program from memory 34. The program operates to generate the booster control signal 41 that is used by booster circuit 26 as discussed below, as well as valve control signal 43 that actuates valve 28. Optional output devices 36 preferably include one or more output devices such as LEDs, LCDs, or audio output devices, or a combination of types, though other output devices and techniques could be used as would occur to one skilled in the art. Likewise, optional input devices 38 may include push-buttons, UARTs, IR and/or RF receivers, decoders, or other devices. In this exemplary embodiment, controller 32 is an Atmega8L-8AC microcontroller made and sold by Atmel Corporation. In alternative embodiments, one or more application-specific integrated circuits (ASICs), general-purpose microprocessors, programmable logic arrays, or other devices may be used as would occur to one skilled in the art.

[0025] Likewise, memory 34 can include one or more types of solid-state electronic memory, magnetic memory, or optical memory, just to name a few. By way of non-limiting example, memory 34 can include solid-state electronic Random Access Memory (RAM), Sequentially Accessible Memory (SAM) (such as the First-In, First-Out (FIFO) variety or the Last-In First-Out (LIFO) variety), Programmable Read Only Memory (PROM), Electrically Programmable Read Only Memory (EPROM), or Electrically Erasable Programmable Read Only Memory (EEPROM); an optical disc memory (such as a recordable, rewritable, or read-only DVD or CD-ROM); a magnetically encoded hard disk, floppy disk, tape, or cartridge media; or a combination of any of these memory types. Also, memory 34 can be volatile, nonvolatile, or a hybrid combination of volatile and nonvolatile varieties.

[0026] FIG. 3 illustrates an exemplary boosting circuit for use with the present invention, such as for booster circuit 26 in FIG. 1. Power is supplied to the circuit between terminals B+ and ground, which in this example correspond to the positive and negative terminals of power supply 22. Generally, this power source charges capacitors C₁and C₂, which in turn provide power to valve 28 upon triggering of a change in valve state by control circuitry 24 through booster control signal 41.

[0027] More particularly, the charging cycle begins with raising of booster control signal 41, which turns on transistor Q₁, which in various embodiments is a bipolar transistor, a MOSFET, or (in some small current applications) a transistor internal to microcontroller 32. This provides a low-impedance path from the lower terminal of inductor L₁to ground. Inductor L₁converts the resulting current into a magnetic field. After a short delay, booster control signal 41 is then brought to a low potential, turning off transistor Q₁. Inductor L₁then converts the stored energy (in the form of the magnetic field) into current, which flows through diode D₁to junction 51. A small amount of this current is stored as charge on capacitor C₁, which acts as a filter, while a much larger portion of this current flows through resistor R₃to junction 53 and is stored on capacitor C₂. This cycle is repeated as necessary to sufficiently charge capacitors C₁and C₂for discharging into valve 28 for a particular application. Zener diode Z₁prevents capacitors C₁and C₂from overcharging.

[0028] In some alternative embodiments, booster circuit 26 also provides a monitor/feedback signal 47 (see FIG. 1) to control circuitry 24, which is further programmed to generate pulses on booster control signal 41 at desired times so that valve 28 can be actuated in a timely response to system demand. In some embodiments, signal 47 is an analog or digital signal that reflects the present potential on C1 and/or C2.

[0029] One example of a process that can be followed by control circuitry 24 for controlling system 20 will now be discussed in relation to FIGS. 4-9. FIG. 4 illustrates the overall process 100, beginning with the power-on event 101. (Reference point R will be discussed below in relation to FIG. 5.) The system is initialized at block 103, including tasks such as configuring I/O ports, defining variables and constants, establishing initial values for the system, forcing the valve to an off position, and announcing to the system of electronics that the control system is ready for operation. In this example, this initialization includes the code seen below under the heading “Initialization software associated with the boost feature.”

[0030] The battery status is checked at step 105, which check will be further discussed in relation to FIG. 5 below.

[0031] The system checks for objects being present at decision block 107 using techniques that will be understood by those skilled in the art. If an object is present, that presence is handled at step 109. If no object is present, that situation is handled at step 111. In either event, the processing loop continues with time-based re-boost check routine 113 (see below in relation to FIG. 8), and the processor is put to sleep at step 115. At an appropriate time (such as after the processor has slept for a predetermined period of time, or upon receiving a regular timer-based interrupt, for example), the process 100 returns to step 105 to check the battery status once more.

[0032] Turning now to FIG. 5, the process 120 for checking the battery level will be discussed beginning with start point 121. It is first determined at decision block 123 whether the power supply 22 has been disconnected. If so, the system turns the valve off at step 125, then waits at decision block 127 for the battery to be reconnected. When it is, the process continues at reference point R in FIG. 4. If the battery is not reconnected, the processor will eventually cease to operate, and no decision on reconnection can be made. When the battery is connected again, operation will start at reference point R.

[0033] If the battery is not disconnected (a negative result at decision block 123), the system checks whether its output voltage is less than 4.3 VDC at decision block 129. If so, the system determines at decision block 131 whether this is the first low-voltage iteration. If so, the system handles the low-battery condition at step 133 by, for example, turning the valve off, announcing to the system that the battery is low, and setting the “disable” flag. Then, or after a negative result at decision block 131, the system returns from the battery check routine 120 at return point 139. If the battery output is not less than 4.3 VDC (i.e., a negative result at decision block 129), the system checks at decision block 135 whether the battery output voltage is less than 4.7 VDC. If so, the system sets the “warning” flag at step 137, then returns at return point 139. If not, the system returns immediately.

[0034] An exemplary routine 140 for handling the presence of an object (see above at step 109 in FIG. 4) is illustrated in FIG. 6, beginning at start point 141. The system checks at decision block 143 whether the valve is in an “on” state. If so, the system checks at decision block 145 whether the maximum allowable running time has been reached. If it has not, the routine 140 returns at return point 169.

[0035] If the maximum running time has been reached (i.e., a positive result at decision block 145), the system initiates a boost cycle (routine 210, below, in relation to FIG. 9) at step 147, then turns the valve off at step 149, and sets the “time-out” flag at step 151. Routine 141 then returns at return point 169.

[0036] If, on the other hand, the system determines at decision block 143 that the valve is not on, the system tests at decision block 153 whether the “disable” flag is set. If so, the system disables the faucet at step 155 by turning the valve off and announcing the low battery condition, then return point 169. If not (i.e., the system has not been disabled), the system checks at decision block 157 whether the “time-out” flag has been set. If the “time-out” flag has been set, the system returns at return point 169. If the time-out flag has not been set, the system initiates a boost cycle at step 159, then turns the valve on at step 161 and returns at return point 169.

[0037] Routine 170, illustrated in FIG. 7, handles the absence of an object beginning at start point 171. At decision block 173, it is determined whether the valve is on. If not, routine 170 returns at return point 189. If so, the system updates an “OffDelay” timer at step 175. The system then checks at decision block 177 whether a threshold (four seconds, for example) for the “OffDelay” timer has been exceeded. If it has not, the system returns at return point 189. If the “OffDelay” threshold has been exceeded (i.e., a positive result at decision block 177), the system calls the boost routine at step 179, then turns the valve off at step 181.

[0038] The system then checks at decision block 183 whether the “warning” flag has been set. If not, the system returns at return point 189. If so, the system announces the low-battery condition at step 185, then returns at return point 189.

[0039] A routine 190 for determining whether a time-based boost is appropriate will now be discussed in relation to FIG. 8, starting at start point 191. The present example embodiment of the inventive boost technique boosts the capacitor power and actuates the valve only on demand, which introduces a delay in the operation of the valve. The magnitude of the delay is therefore a function of the difference between the battery voltage B+ and the desired output potential. Although C₂is re-boosted after each operation of the valve, the level of voltage at V_outwill eventually decrease due to leakage to a level equal to B+. In order to minimize this delay, a time-triggered boost function is periodically performed. The system checks at decision block 193 whether it is time for a periodic boost. If not, the routine 190 returns at return point 203. If so, the system resets the boost timer (to five minutes, for example) at step 195, then checks the capacitor voltage V_outat step 197. Then, at decision block 199, it is determined whether the capacitor voltage is below a minimum threshold. If not, the system returns at return point 203. If so, the system calls the boost routine at step 201, then returns at return point 203. A software implementation of routine 190 in the example embodiment follows this description under the heading “Boost Control Subroutines.” FIG. 9 illustrates routine 210 for processing a capacitor boost, beginning at start point 211. The system determines at decision block 213 whether the “disable” flag has been set. If so, the routine 210 returns immediately at return point 230.

[0040] If not, a watchdog timer is started at step 215, then cycling of the boost circuit is enabled at step 217. The booster circuit raises and lowers booster control signal 41 as discussed above in relation to FIGS. 1-3, with high and low voltages, duty cycle, and frequency as appropriate in the particular system.

[0041] Then the system checks at decision block 221 whether the capacitor voltage is at or above the desired potential. If so, cycling of the boost circuit is disabled at step 223, and the routine 210 returns at return point 230. The check at decision block 221 is performed in the example embodiment by the code sample below under the heading “Subroutine to monitor boosted capacitor's voltage level.”

[0042] If the capacitor is not yet charged to the desired voltage (i.e., negative result at decision block 221), the system determines at decision block 225 whether the watchdog timer has timed out. If not, routine 210 returns to decision block 221. If so, cycling of the boost circuit is disabled at step 227, the “disable” flag is set at step 229, and routine 210 returns at return point 230.

[0043] One exemplary set of software routines is presented below for use with the microprocessor and other design parameters discussed above. Again, this disclosure is not the only way to implement this invention, and therefore is not limiting.

[0044] All publications, prior applications, and other documents cited herein are hereby incorporated by reference in their entirety as if each had been individually incorporated by reference and fully set forth herein.

[0045] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that would occur to one skilled in the relevant art are desired to be protected.