Parsons, Natan E. (Brookline, MA, US)
Guler, Fatih (Winchester, MA, US)
Herbert, Kay (Winthrop, MA, US)
Mo, Xiaoxiong (Lexington, MA, US)
Wu, Haiou (West Roxbury, MA, US)
Zhang, Yue (Nashua, NH, US)

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06/03/2005

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Arichell Technologies Inc (W. Newton, MA, US)

4/623

4/304, 251/129.04

F16K31/02

4/DIG.3, 4/623, 4/304, 4/313, 4/302, 251/129.04

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3034151	Automatic flushing systems	May, 1962	Filliung	4/249
3056143	Apparatus for automatically flushing a toilet bowl or the like	October, 1962	Foster	4/249
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3895645	Fluid level control valve	July, 1975	Johnson	137/403
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4011553	Remote detector to indicate leakage of liquids in toilet tanks	March, 1977	Delgado	4/314
4065095	Fluid level control valve	December, 1977	Johnson	251/118
4097786	Limit control apparatus	June, 1978	Lund	318/282
4105186	Flow control valve	August, 1978	Eby	251/35
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4272052	Flush valves	June, 1981	Gidner	251/39
4280680	Fluid valves	July, 1981	Payne	251/175
4295485	Diaphragm valve	October, 1981	Waterfield	137/74
4295631	Solenoid operated valve	October, 1981	Allen	251/30.03
4295653	Pressure-compensated diaphragm seals for actuators, with self-equalization	October, 1981	Coles	277/320
4304391	Electromagnetically operated valve assembly	December, 1981	Yamaguchi	251/129.05
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4570272	Toilet bowl flushing device	February, 1986	Kawaguchi et al.	4/302
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4609178	Diaphragm type control valve	September, 1986	Baumann	251/229
4611356	Flushing apparatus for urinals	September, 1986	Lin	4/301
4671485	Solenoid-operated pilot valve with adjustable flow control	June, 1987	Saarem	251/60X
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4756031	Automatic toilet flushing system	July, 1988	Barrett	4/407
4787411	Valve controlled by the same medium it handles and activated by a preferably electromagnetic control valve	November, 1988	Moldenhauer	137/244
4793588	Flush valve with an electronic sensor and solenoid valve	December, 1988	Laverty, Jr.	251/30.03
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4894698	Field effect pressure sensor	January, 1990	Hijikigawa et al.	257/254
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4921208	Proportional flow valve	May, 1990	LaMarca	251/30.04
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4932430	Adjustable two-stage fluid pressure regulating valve	June, 1990	Fernstrom	137/85
4941215	Automatic flushing device for a flush toilet	July, 1990	Liu	4/406
4941219	Body heat responsive valve control apparatus	July, 1990	Van Marcke	4/623
4944487	Diaphragm valve	July, 1990	Holtermann	251/129.17
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4988074	Proportional variable force solenoid control valve	January, 1991	Najmolhoda	251/129.08
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5025516	Automatic faucet	June, 1991	Wilson	4/623
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5036553	Fully automatic toilet system	August, 1991	Sanderson	4/313
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5125621	Flush system	June, 1992	Parsons et al.	251/30.03
5127625	Electromagnetically actuated valve	July, 1992	Kleinhappl	251/129.17
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5213303	Solenoid actuated valve with adjustable flow control	May, 1993	Walker	251/30.02
5213305	Bypass orifice filter for flush valve diaphragm	May, 1993	Whiteside et al.	251/40
5224685	Power-saving controller for toilet flushing	July, 1993	Chiang et al.	251/129.04
5232194	Diaphragm assembly	August, 1993	Saadi et al.	251/40
5244179	Diaphragm stop for sensor-operated, battery-powered flush valve	September, 1993	Wilson	251/30.03
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5265594	Apparatus for regulating the flow-through amount of a flowing medium	November, 1993	Olsson et al.	128/204.18
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5548119	Toilet room sensor assembly	August, 1996	Nortier	4/623
5555912	Spout assembly for automatic faucets	September, 1996	Saadi et al.	137/801
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5583434	Method and apparatus for monitoring armature position in direct-current solenoids	December, 1996	Moyers et al.	324/207.16
5584465	Solenoid latching valve	December, 1996	Ochsenreiter	251/65
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5943712	Method for controlling the operation of a water valve	August, 1999	Van Marcke	4/623
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DE29717352	January, 1998
EP0337367	October, 1989			Spray head for automatic actuation.
WO/1985/005648	December, 1985			FLUSH CONTROL APPARATUS

International Search Report issued in PCT Application PCT/US03/41303 on May 4, 2004 (5 pages).
International Search Report issued in PCT Application PCT/US 03/38730 on May 12, 2004 (6 pages).
International Search Report issued in PCT Application PCT/US 03/20117 on Dec. 18, 2003.

Fristoe Jr., John K.

Zitkovsky, Ivan David

This application is a continuation of PCT Application PCT/US03/038730 filed Dec. 4, 2003, entitled “Passive Sensors for Automatic Faucets and Bathroom Flushers” which claims priority from U.S. Provisional Application Ser. No. 60/513,722, filed on Oct. 22, 2003 and entitled “Automatic Faucets with Novel Flow Control Sensors.” The PCT Application PCT/US03/038730 is also continuation-in-part of PCT Application Serial No. PCT/US02/38757, filed on Dec. 4, 2002 and entitled “Electronic Faucets for Long Term Operation,” and continuation-in-part of PCT Application Serial No. PCT/US02/38758, filed on Dec. 4, 2002 and entitled “Automatic Bathroom Flushers,” and a continuation-in-part of PCT Application Serial No. PCT/US02/41576, filed on Dec. 26, 2002 and entitled “Automatic Bathroom Flushers.” This application is also a continuation-in-part of U.S. application Ser. No. 10/421,359, filed on Apr. 23, 2003 now U.S. Pat. No. 6,948,697, entitled “Apparatus and Method for Controlling Fluid Flow.” The above-cited applications are incorporated by reference.

The invention claimed is:

1. A system including optical sensor for controlling a flow valve of an electronic faucet or bathroom flusher, comprising an optical element located at an optical input port and arranged to partially define a detection field having a selected size and orientation that eliminate invalid targets; a light detector optically coupled to said optical element and said input port, said light detector being constructed to detect ambient light; and a control circuit for controlling opening and closing of said flow valve, said control circuit being constructed to receive periodically signal from said light detector corresponding to the detected ambient light and to control said opening and closing by executing a detection algorithm employing detection of increases and decreases of said ambient light due to the presence of a user within said detection field for several time intervals and background levels of said ambient light.

2. The system of claim 1 wherein said control circuit is constructed to execute a calibration routine that accounts for size and orientation of said detection field by said optical element.

3. The system of claim 2 wherein said control circuit is constructed to sample periodically said detector based on the amount of previously detected light.

4. The system of claim 1 wherein said control circuit is constructed to open and close said flow valve based on first detecting arrival of a user and then detecting departure of said user.

5. The system of claim 1 wherein said control circuit is constructed to open and close said flow valve based on detecting presence of a user.

6. The system of claim 1 wherein said optical element includes an array of pinholes.

7. The system of claim 1 wherein said valve controls a bathroom flusher.

8. The system of claim 1 wherein said optical element is further constructed to provide said detection field angled below the horizontal (H).

9. The system of claim 1 wherein said optical element is further constructed to provide said detection field angled below the horizontal and symmetrically with respect to a toilet or urinal.

10. The system of claim 1 wherein said optical element is further constructed to provide said detection field angled below the horizontal and asymmetrically with respect to a toilet or urinal.

11. The system of claim 1 wherein said optical element is further constructed to provide said detection field angled above the horizontal (H).

12. The system of claim 1 wherein said light detector is constructed to detect light in the range of 400 to 1000 nanometers.

13. A method of controlling a flow valve of an electronic faucet or bathroom flusher using an optical sensor, comprising providing an optical element located at an optical input port and arranged to partially define a detection field having a selected size and orientation that eliminate invalid targets; providing a light detector optically coupled to said optical element and said input port, detecting ambient light arriving at said light detector by periodically sampling said light detector; providing a signal corresponding to said detected light from said light detector to a control circuit; and controlling opening and closing of said flow valve using said control circuit and said signal corresponding to the detected ambient light, said controlling including executing a detection algorithm employing detection of increases and decreases of said ambient light due to the presence of a user within said detection field for several time intervals and background levels of said ambient light.

14. The method of controlling a valve according to claim 13 including and executing a calibration routine that accounts for size and orientation of said detection field by said optical element.

15. The method of controlling a valve according to claim 14 wherein said control circuit is constructed to constructed to perform said periodic sampling of said detector based on the amount of the amount of light previously detected.

16. The method of controlling a valve according to claim 13 including determining by said control circuit said opening and closing of said flow valve based on a background level of said ambient light and a present level of said ambient light.

17. The method of controlling a valve according to claim 13 wherein said control circuit is constructed to adjust a sample period based on the detected amount of light after determining whether a facility is in use.

18. The method of controlling a valve according to claim 13 wherein said control circuit is constructed to cycle sleep and measurement periods.

19. A sensor-based automatic flusher system, comprising: a flusher body including a water conduit having at least one inlet for receiving water and at least one outlet for providing water to a toilet of a urinal; an optical sensor constructed and arranged to generate sensor output signals corresponding to detected ambient light; a control circuit arranged to control operation of said optical sensor and receive periodically from said optical sensor a signal corresponding to the detected ambient light; and a main valve controlled by an actuator receiving control signals from said control circuit for switching between an open state of said valve and a closed state of said valve; said open state permitting water flow, and a closed state of said valve preventing fluid flow from said outlet, said control circuit being constructed to control said opening and closing by executing a detection algorithm employing increases and decreases of said ambient light due to presence of a user within a detection field of said optical sensor for several time intervals and based on background levels of said ambient light.

20. The sensor-based automatic flusher system of claim 19 wherein said control circuit is constructed to execute a calibration routine that accounts for size and orientation of said detection field by said optical element.

21. The sensor-based automatic flusher system of claim 20 wherein said control circuit is constructed to sample periodically said optical sensor based on the amount of previously detected light.

22. The sensor-based automatic flusher system of claim 19 wherein said control circuit is constructed to open and close said flow valve based on first detecting arrival of a user and then detecting departure of said user.

23. The sensor-based automatic flusher system of claim 19 wherein said control circuit is constructed to open and close said flow valve based on detecting presence of a user.

24. The sensor-based automatic flusher system of claim 19 wherein an optical element is further constructed to provide said detection field angled below the horizontal (H).

25. The sensor-based automatic flusher system of claim 19 wherein an optical element is further constructed to provide said detection field angled below the horizontal and symmetrically with respect to a toilet or urinal.

26. The sensor-based automatic flusher system of claim 19 wherein an optical element is further constructed to provide said detection field angled below the horizontal and asymmetrically with respect to a toilet or urinal.

27. The sensor-based automatic flusher system of claim 19 wherein an optical element is further constructed to provide said detection field angled above the horizontal (H).

28. The sensor-based automatic flusher system of claim 19 wherein said optical sensor is constructed to detect light in the range of 400 to 1000 nanometers.

The present invention is directed to novel optical sensors. The present invention is, more specifically, directed to novel optical sensors for controlling operation of automatic faucets and bathroom flushers, and in particular, to novel flow control sensors for providing control signals to electronics used in such faucets and flushers.

BACKGROUND OF THE INVENTION

Automatic faucets and bathroom flushers have been used for many years. An automatic faucet typically includes an optical or other sensor that detects the presence of an object, and an automatic valve that turns water on and off, based on a signal from the sensor. An automatic faucet may include a mixing valve connected to a source of hot and cold water for providing a proper mixing ratio of the delivered hot and cold water after water actuation. The use of automatic faucets conserves water and promotes hand washing, and thus good hygiene. Similarly, automatic bathroom flushers include a sensor and a flush valve connected to a source of water for flushing a toilet or urinal after actuation. The use of automatic bathroom flushers generally improves cleanliness in public facilities.

In an automatic faucet, an optical or other sensor provides a control signal and a controller that, upon detection of an object located within a target region, provides a signal to open water flow. In an automatic bathroom flusher, an optical or other sensor provides a control signal to a controller after a user leaves the target region. Such systems work best if the object sensor is reasonably discriminating. An automatic faucet should respond to a user's hands, for instance, it should not respond to the sink at which the faucet is mounted, or to a paper towel thrown in the sink. Among the ways of making the system discriminate between the two it has been known to limit the target region in such a manner as to exclude the sink's location. However, a coat or another object can still provide a false trigger to the faucet. Similarly, this could happen to automatic flushers due to a movement of bathroom doors, or something similar.

An optical sensor includes a light source (usually an infra-red emitter) and a light detector sensitive to the IR wavelength of the light source. For faucets, the emitter and the detector (i.e., a receiver) can be mounted on the faucet spout near its outlet, or near the base of the spout. For flushers, the emitter and the detector may be mounted on the flusher body or on a bathroom wall. Alternatively, only optical lenses (instead of the emitter and the receiver) can be mounted on these elements. The lenses are coupled to one or several optical fibers for delivering light from the light source and to the light detector. The optical fiber delivers light to and from the emitter and the receiver mounted below the faucet.

In the optical sensor, the emitter power and/or the receiver sensitivity is limited to restrict the sensor's range to eliminate reflections from the sink, or from the bathroom walls or other installed objects. Specifically, the emitting beam should project on a valid target, normally clothing, or skin of human hands, and then a reflected beam is detected by the receiver. This kind of sensor relies on the reflectivity of a target's surface, and its emitting/receiving capabilities. Frequently, problems arise due to highly reflective doors and walls, mirrors, highly reflective sinks, the shape of different sinks, water in the sink, the colors and rough/shiny surfaces of fabrics, and moving users who are walking by but not using the facility. Mirrors, doors, walls, and sinks are not valid targets, although they may reflect more energy back to the receiver than rough surfaces at the right angle incidence. The reflection of valid targets such as various fabrics varies with their colors and the surface finish. Some kinds of fabrics absorb and scatter too much energy of the incident beam, so that less of a reflection is sent back to the receiver.

A large number of optical or other sensors are powered by a battery. Depending on the design, the emitter (or the receiver) may consume a large amount of power and thus deplete the battery over time (or require large batteries). The cost of battery replacement involves not only the cost of batteries, but more importantly the labor cost, which may be relatively high for skilled personnel.

There is still a need for an optical sensor for use with automatic faucets or automatic bathroom flushers that can operate for a long period of time without replacing the standard batteries. There is still a need for reliable sensors for use with automatic faucets or automatic bathroom flushers.

SUMMARY OF THE INVENTION

The present invention is directed to novel optical sensors and novel methods for sensing optical radiation. The novel optical sensors and the novel optical sensing methods are used, for example, for controlling the operation of automatic faucets and flushers. The novel sensors and flow controllers (including control electronics and valves) require only small amounts of electrical power for sensing users of bathroom facilities, and thus enable battery operation for many years. A passive optical sensor includes a light detector sensitive to ambient (room) light for controlling the operation of automatic faucets or automatic bathroom flushers.

According to one aspect, an optical sensor for controlling a valve of an electronic faucet or bathroom flusher includes an optical element located at an optical input port and arranged to partially define a detection field. Theoptical sensor also includes a ligh detector and a control circuit. The light detector is optically coupled to the optical element and the input port, wherein the light detector is constructed to detect ambient light. The control circuit is constructed for controlling opening and closing of a flow valve. The control circuit is also constructed to receive signal from the light detector corresponding to the detected light.

The control circuit is constructed to sample periodically the detector. The control circuit is constructed to sample periodically the detector based on the amount of previously detected light. The control circuit is constructed to determine the opening and closing of the flow valve based on a background level of the ambient light and a present level of the ambient light. The control circuit is constructed to open and close the flow valve based on first detecting arrival of a user and then detecting departure of the user. Alternatively, the control circuit is constructed to open and close the flow valve based on detecting presence of a user.

The optical element includes an optical fiber, a lens, a pinhole, a slit or an optical filter. The optical input port is located inside an aerator of a faucet or next to an aerator of the faucet.

According to another aspect, an optical sensor for an electronic faucet includes an optical input port, an optical detector, and a control circuit. The optical input port is arranged to receive light. The optical detector is optically coupled to the input port and constructed to detect the received light. The control circuit controls opening and closing of a faucet valve, or a bathroom flusher valve

Preferred embodiments of this aspect includes one or more of the following features: The control circuit is constructed to sample periodically the detector based on the amount of light detected. The control circuit is constructed to adjust a sample period based on the detected amount of light after determining whether a facility is in use. The detector is optically coupled to the input port using an optical fiber. The input port may be located in an aerator of the electronic faucet. The system includes batteries for powering the electronic faucet.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an automatic faucet system including a control circuit, a valve and a passive optical sensor for controlling water flow.

FIG. 1A is a cross-sectional view of a spout and a sink of the automatic faucet system of FIG. 1 using a fiberoptic coupling to the passive optical sensor.

FIG. 1B is a cross-sectional view of a spout and a sink of the automatic faucet system of FIG. 1 using an electric coupling to the passive optical sensor.

FIG. 1C is a cross-sectional view of an aerator used in the automatic faucet system of FIG. 1.

FIG. 1D is a cross-sectional view of another embodiment of the aerator used in the automatic faucet system of FIG. 1.

FIG. 1E is a perspective view of another embodiment of the aerator used in the automatic faucet system of FIG. 1.

FIG. 1F is a cross-sectional view of the aerator shown in FIG. 1D.

FIGS. 2 and 2A show schematically other embodiments of automatic faucet systems, including another embodiment of a valve and a passive optical sensor for controlling water flow.

FIGS. 3, 3 A, 3 B, 3 C and 3 D show schematically a faucet and a sink relative to different optical detection patterns used by passive optical sensors employed in the automatic faucet systems of FIGS. 1, 1 B, 2 , and 2 A.

FIG. 4 shows schematically a side view of a toilet including an automatic flusher.

FIG. 4A shows schematically a side view of a urinal including an automatic flusher.

FIGS. 5, 5 A, 5 B, 5 C, 5 D, 5 E, 5 F and 5 G show schematically side and top views of different optical detection patterns used by passive optical sensors employed in the automatic toilet flusher of FIG. 4.

FIGS. 5H, 5 I, 5 J, 5 K and 5 L show schematically side and top views of different optical detection patterns used by passive optical sensors employed in the automatic urinal flusher of FIG. 4A.

FIGS. 6, 6 A, 6 B, 6 C, 6 D and 6 E show schematically optical elements used to form the different optical detection patterns shown in FIGS. 3 through 3D and in FIGS. 5 through 5L.

FIG. 7 is a cross-sectional view of an embodiment of an automatic flusher used for flushing toilets or urinals.

FIG. 8 is a perspective exploded view of a valve device used in the automatic faucet system of FIGS. 1, 1 A or 1 B.

FIG. 8A is an enlarged cross-sectional view of the valve device shown in FIG. 8.

FIG. 8B is an enlarged cross-sectional view of the valve device shown in FIG. 8A, but partially disassembled for servicing.

FIG. 8C is a perspective view of the valve device of FIG. 4, including a leak detector for detecting water leaks in an automatic faucet system.

FIG. 9 is an enlarged cross-sectional view of a moving piston-like member used in the valve device shown in FIG. 7 or the valve device shown in FIGS. 8, 8 A, and 8 B.

FIG. 9A is a detailed perspective view of the moving piston-like member shown in FIG. 9.

FIG. 10 is block diagram of a control system for controlling a valve operating the automatic faucet systems of FIGS. 1 through 2A, or bathroom flushers of FIGS. 4 and 4A.

FIG. 10A is block diagram of another control system for controlling a valve operating the automatic faucet systems of FIGS. 1 through 2A, or bathroom flushers of FIGS. 4 and 4A.

FIG. 10B is a schematic diagram of a detection circuit used in passive optical sensor used in the automatic faucet system or the automatic flusher system.

FIG. 11 is a block diagram that illustrates various factors that affect operation and calibration of the passive optical system.

FIGS. 12, 12 A, 12 B, 12 C, 12 D, 12 E, 12 F, 12 G, 12 H and 12 I show a flow diagram of an algorithm for processing optical data detected by the passive sensor operating the automatic flusher system.

FIGS. 13, 13 A and 13 B show a flow diagram of an algorithm for processing optical data detected by the passive sensor operating the automatic faucet system.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

FIG. 1 shows an automatic faucet system 10 controlled by a sensor providing signals to a control circuit constructed and arranged to control operation of an automatic valve. The automatic valve, in turn, controls the flow of hot and cold water before or after mixing.

Automatic faucet system 10 includes a faucet body 12 and an aerator 30 , including a sensor port 34 . Automatic faucet system 10 also includes a faucet base 14 and screws 16 A and 16 B for attaching the faucet to a deck 18 . A cold water pipe 20 A and a hot water pipe 20 B are connected to a mixing valve 22 providing a mixing ratio of hot and cold water (which ratio can be changed depending on the desired water temperature). Water conduit 24 connects mixing valve 22 to a solenoid valve 38 . A flow control valve 38 controls water flow between water conduit 24 and a water conduit 25 . Water conduit 25 connects valve 38 to a water conduit 26 partially located inside faucet body 12 , as shown. Water conduit 26 delivers water to aerator 30 . Automatic faucet system 10 also includes a control module 50 for controlling a faucet sensor and solenoid valve 38 , powered by batteries located in battery compartment 39 .

Referring to FIGS. 1 and 1A, in a first preferred embodiment, automatic faucet system 10 includes an optical sensor located in control module 50 and optically coupled by a fiberoptic cable 52 to sensor port 34 located in aerator 30 . Sensor port 34 receives the distal end of fiberoptic cable 52 , which may be coupled to an optical lens located at sensor port 34 . The optical lens is arranged to have a selected field of view, which is preferably somewhat coaxial within the water stream discharged from aerator 30 , when the faucet is turned on.

Alternatively, the distal end of fiberoptic cable 52 is polished and oriented to emit or to receive light directly (i.e., without the optical lens). Again, the distal end of fiberoptic cable 52 is arranged to have the field of view (for example, field of view A, FIG. 1A) directed toward sink 11 , somewhat coaxial within the water stream discharged from aerator 30 . Alternatively, sensor port 34 includes other optical elements, such as an array of pinholes or an array of slits having a selected size, geometry and orientation. The size, geometry and orientation of the array of pinholes or the array of slits is designed to provide a selected detection pattern (shown in FIGS. 3-3D, for a faucet and FIGS. 5-5L, for a flusher).

Referring still to FIGS. 1 and 1A, a fiberoptic cable 52 is preferably located inside water conduit 26 in contact with water. Alternatively, fiberoptic cable 52 could be located outside of the water conduit 26 , but inside of faucet body 12 . FIGS. 1C, 1 D, and 1 E show alternative ways to provide sensor port 34 inside aerator 30 and alternative ways to arrange an optical fiber 52 coupled to an optical lens 54 . In other embodiments, optical lens 54 is replaced by an array of pinholes or an array of slits.

FIG. 1B illustrates a second preferred embodiment of the automatic faucet system. Automatic faucet system 10 A includes faucet body 12 and an aerator 30 including an optical sensor 37 coupled to a sensor port 35 . Optical sensor 37 is electrically connected by a wire 53 to an electronic control module 50 located inside the body of the faucet. In another embodiment, electronic control module 50 located outside of the faucet body next to control valve 38 (FIG. 1)

In another embodiment, sensor port 35 receives an optical lens, located in from of optical sensor 37 , for defining the detection pattern (or optical field of view). Preferably, the optical lens provides a field of view somewhat coaxial within the water stream discharged from aerator 30 , when the faucet is turned on. In yet other embodiments, sensor port 35 includes other optical elements, such as an array of pinholes or an array of slits having a selected size, geometry and orientation. The size, geometry and orientation of the array of pinholes, or the array of slits are designed to provide a selected detection pattern (shown in FIGS. 3-3D, for a faucet and FIGS. 5-5L, for a flusher).

The optical sensor is a passive optical sensor that includes a visible or infrared light detector optically coupled to sensor port 34 or sensor port 35 . There is no light source (i.e., no light emitter) associated with the optical sensor. The visible or near infrared (NIR) light detector detects light arriving at sensor port 34 or sensor port 35 and provides the corresponding electrical signal to a controller located in control unit 50 or control unit 55 . The light detector (i.e., light receiver) may be a photodiode, or a photoresistor (or some other optical intensity element having an electrical output, whereby the sensory element will have the desired optical sensitivity). The optical sensor using a photo diode also includes an amplification circuitry. Preferably, the light detector detects light in the range from about 400-500 nanometers up to about 950-1000 nanometers. The light detector is primarily sensitive to ambient light and not very sensitive to body heat (e.g., infrared or far infrared light).

FIGS. 2 and 2A illustrate alternative embodiments of the automatic faucet system. Referring to FIG. 2, automatic faucet system 10 B includes a faucet receiving water from a dual-flow faucet valve 60 and providing water from aerator 31 . Automatic faucet 12 includes a mixing valve 58 controlled by a handle 59 , which may be also coupled to a manual override for valve 60 . Dual-flow valve 60 is connected to cold water pipe 20 A and hot water pipe 20 B, and controls water flow to the respective cold water pipe 21 A and hot water pipe 21 B.

Dual flow valve 60 is constructed and arranged to simultaneously control water flow in both pipes 21 A and 21 B upon actuation by a single actuator 201 (See FIG. 8A). Specifically, valve 60 includes two flow valves arranged for controlling flow of hot and cold water in the respective water lines. The solenoid actuator 201 (FIG. 8A) is coupled to a pilot mechanism for controlling two flow valves. The two flow valves are preferably diaphragm operated valves (but may also be piston valves, or large flow-rate “fram” valves described in connection with FIGS. 9 and 9A). Dual flow valve 60 includes a pressure release mechanism constructed to change pressure in a diaphragm chamber of each diaphragm operated valve and thereby open or close each diaphragm valve for controlling water flow. Dual flow valve 60 is described in detail in PCT Application PCT/US01/43277, filed on Nov. 20, 2001, which is incorporated by reference.

Referring still to FIG. 2, coupled to faucet body 12 there is a sensor port 35 for accommodating a distal end of an optical fiber (e.g., fiberoptic cable 52 ), or for accommodating a light detector. The fiberoptic cable delivers light from sensor port 35 to a light detector. In one preferred embodiment, faucet body 12 includes a control module with the light detector and a controller described in connection with FIGS. 10 and 10A. The controller provides control signals to solenoid actuator 201 via electrical cable 56 . Sensor port 35 has a detection field of view (shown in FIGS. 3A and 3B) located outside of the water stream emitted from aerator 31 .

Referring to FIG. 2A, automatic faucet system 10 C includes faucet body 12 also receiving water from dual-flow faucet valve 60 and providing water from aerator 31 . Automatic faucet 10 C also includes mixing valve 58 controlled by handle 59 . Dual-flow valve 60 is connected to cold water pipe 20 A and hot water pipe 20 B, and controls water flow to the respective cold water pipe 21 A and hot water pipe 21 B.

A sensor port 33 is coupled to faucet body 12 and is designed to have a field of view shown in FIGS. 3C and 3D. Sensor port 33 accommodates the distal end of an optical fiber 56 A. The proximal end of optical fiber 56 A provides light to an optical sensor located in a control module 55 A coupled to dual flow valve 60 . Control module 55 A also includes the control electronics and batteries. The optical sensor detects the presence of an object (e.g., hands), or detects a change in the presence of the object (i.e., movement) in the sink area. Control electronics control the operation of and the readout from the light detector. The control electronics also include a power driver that controls the operation of the solenoid associated with valve 60 . Based on the signal from the light detector, the control electronics direct the power driver to open or close solenoid valve 60 (i.e., to start or stop the water flow). The design and operation of actuator 201 (FIG. 8A) is described in detail in PCT Applications PCT/US02/38757; PCT/US02/38758; and PCT/US02/41576, all of which are incorporated by reference as if fully provided herein.

FIG. 1C shows a vertical cross-section of an aerator 30 A located at the discharge end of the spout of faucet 12 . Aerator 30 A includes a barrel 62 attachable to faucet body 12 using threads 63 . Barrel 62 supports a ring 64 which in turn supports wire mesh screens 65 . Barrel 62 also supports an annular member 70 , a jet-forming member 72 , and an upper washer 74 . Jet forming member 72 includes several elongated slots 76 for providing water passages. Jet forming member 72 and screens 65 include a passage 36 for optical fiber 52 . Water flows through aerator 30 A from top to bottom. In aerator 30 A, a water stream flows from water conduit 26 (FIG. 1A) and is broken up by the vertically elongated slots 76 of the water jet-forming member 72 . Then water flows through to wire mesh screens 65 , which are supported by ring 64 . Ring 64 also enables air intake (suction) through gaps 67 (which it forms between itself and the barrel 62 ) inside a chamber 66 . Just above wire mesh screens 65 , in chamber 66 , air mixes with water so that a mixture of air and water passes through screens 65 . The optical fiber 52 is located in the center of the above described elements inside a tubular member 36 , which holds lens 54 .

FIG. 1D shows a second embodiment of an aerator with a centrally located port for a passive sensor. In this embodiment, the aerator 30 B includes at least two lenticularly arranged wire mesh members 86 A and 86 B, providing a central opening for a passage 88 . Aerator 30 B also includes an insert member 90 including several holes 92 and a central hole 88 for accommodating tubular member 52 . Aerator 30 B is attached to faucet 12 using threads 83 . Water flows from water conduit 26 to an upper chamber 91 and then through holes 92 . Air enters chamber 93 via holes 84 . The mixture of water and air then flows through two screens 86 A and 86 B assembled in a lenticular arrangement. Housing 82 has a surrounding support part oriented inwards, which supports the two screens 86 A and 86 B. Optical fiber 52 extends inside water pipe 26 (FIG. 1A) through aerator 30 B from the top and through the wire mesh screens 86 A and 86 B. As the individual water jets formed by holes 92 enter lower chamber 93 , air is drawn via openings 84 into chamber 93 . Inside chamber 93 , water mixes with air and the mixture is forced through screens 86 A and 86 B.

FIGS. 1E and 1F show alternative ways to provide the optical field aligned with the water stream (i.e., alternative embodiment of an aerator and a sensor port located therein). FIG. 1E is a perspective view of an aerator 30 C and FIG. 1F is a cross-sectional view of aerator 30 C used in the automatic faucet system of FIG. 1. Aerator 30 C is coupled to faucet body 12 and the water conduit 26 using using threads 83 . Optical fiber 52 is located outside the water conduit and introduced via an adapter 97 . Alternatively, adapter 97 can include the light detector coupled to a control module using an electrical cable instead of fiberoptic cable 52 . (For simplicity, the wire mesh members and the air openings are not shown in FIGS. 1E and 1F).

FIG. 3 shows schematically a cross-sectional view of a first preferred detection pattern (A) for the passive optical sensor installed in automatic faucet 12 . The detection pattern A is associated with sensor port 34 and is shaped by a lens, or an element selected from the optical elements shown in FIGS. 6-6E. The detection pattern A is selected to receive reflected ambient light primarily from sink 11 . The pattern's width is controlled, but the range is much less controlled (i.e., FIG. 3 shows pattern A only schematically because detection range is not really limited).

A user standing in front of a faucet will affect the amount of ambient (room) light arriving at the sink and thus will affect the amount of light arriving at the optical detector. On the other hand, a person just moving in the room will not affect significantly the amount of detected light. A user having his hands under the faucet will alter the amount of ambient (room) light being detected by the optical detector even more. Thus, the passive optical sensor can detect the user's hands and provide the corresponding control signal. Here, the detected light doesn't depend significantly on the reflectivity of the target surface (unlike for optical sensors that use both a light emitter and a receiver). After hand washing, the user removing his hands from under the faucet will again alter the amount of ambient light detected by the optical detector. Then, the passive optical sensor provides the corresponding control signal to the controller (explained in connection with FIGS. 10, 10 A and 10 B).

FIGS. 3A and 3B show schematically a second preferred detection pattern (B) for the passive optical sensor installed in automatic faucet 10 B. The detection pattern B is associated with sensor port 35 , and again may be shaped by a lens, or an optical element shown in FIGS. 6-6E. A user having his hands under faucet 10 B alters the amount of ambient (room) light detected by the optical detector. As mentioned above, the detected light doesn't depend significantly on the reflectivity of the user's hands (unlike for optical sensors that use both a light emitter and a receiver). Thus, the passive optical sensor detects the user's hands and provides the corresponding control signal to the controller. FIGS. 13, 13 A, and 13 B illustrate detection algorithms used for the detection patterns A and B.

FIGS. 3C and 3D show schematically another detection pattern (C) for the passive optical sensor installed in automatic faucet 10 C. The detection pattern C is associated with sensor port 33 , and is shaped a selected optical element. The selected optical element achieves a desired width and orientation of the detection pattern, while the range is more difficult to control. In this embodiment, a user standing in front of faucet 10 C will alter the amount of detected ambient light somewhat more than a user passing by. In this embodiment, light reflections from sink 11 influence the detected light only minimally.

FIG. 4 shows schematically a side view of a toilet including an automatic flusher 100 , and FIG. 4A shows schematically a side view of a urinal including an automatic flusher 100 A. Flusher 100 receives pressurized water from a supply line 112 and employs a passive optical sensor to respond to actions of a target within a target region 103 . After a user leaves the target region, a controller directs opening of a flush valve 102 that permits water flow from supply line 112 to a flush conduit 113 and to a toilet bowl 116 .

FIG. 4A illustrates bathroom flusher 100 A used for automatically flushing a urinal 120 . Flusher 100 A receives pressurized water from supply line 112 . Flush valve 102 is controlled by a passive optical sensor that responds to actions of a target within a target region 103 . After a user leaves the target region, a controller directs opening of a flush valve 102 that permits water flow from supply line 112 to a flush conduit 113 .

Bathroom flushers 100 and 100 A may have a modular design, wherein their cover can be partially opened to replace the batteries or the electronic module. Bathroom flushers with such a modular design are described in U.S. Patent Application 60/448,995, filed on Feb. 20, 2003, which is incorporated by reference for all purposes.

FIGS. 5 and 5A show schematically side and top views of an optical detection pattern used by the passive optical sensor installed in the automatic toilet flusher of FIG. 4. This detection pattern is associated with sensor port 108 and is shaped by a lens, or an element selected from the optical elements shown in FIGS. 6-6E. The pattern is angled below horizontal (H) and directed symmetrically with respect to toilet 116 . The range is somewhat limited not to be influenced by a wall (W); this can be also done by limiting the detection sensitivity.

FIGS. 5B and 5C show schematically side and top views of a second optical detection pattern used by the passive optical sensor installed in the automatic toilet flusher of FIG. 4. This detection pattern is shaped by a lens, or another optical element. The pattern is angled both below horizontal (H) and above horizontal (H). Furthermore, the pattern is directed asymmetrically with respect to toilet 116 , as shown in FIG. 5C.

FIGS. 5D and 5E show schematically side and top views of a third optical detection pattern used by the passive optical sensor installed in the automatic toilet flusher of FIG. 4. This detection pattern is again shaped by a lens, or another optical element. The pattern is angled above horizontal (H). Furthermore, the pattern is directed asymmetrically with respect to toilet 116 , as shown in FIG. 5E.

FIGS. 5F and 5G show schematically side and top views of a fourth optical detection pattern used by the passive optical sensor installed in the automatic toilet flusher of FIG. 4. This detection pattern is angled below horizontal (H) and is directed asymmetrically across toilet 116 , as shown in FIG. 5G. This detection pattern is particularly useful for “toilet side flushers,” described in U.S. application Ser. No. 09/916,468, filed on Jul. 27, 2001, or U.S. application Ser. No. 09/972,496, filed on Oct. 6, 2001, both of which are incorporated by reference.

FIGS. 5H and 5I, show schematically side and top views of an optical detection pattern used by the passive optical sensor installed in the automatic urinal flusher of FIG. 4A. This detection pattern is shaped by a lens, or another optical element. The pattern is angled both below horizontal (H) and above horizontal (H) to target ambient light changes caused by a person standing in front of urinal 120 . This pattern is directed asymmetrically with respect to urinal 120 (as shown in FIG. 5I), for example, to eliminate or at least reduce light changes caused by a person standing at a neighboring urinal.

FIGS. 5J, 5 K and 5 L, show schematically side and top views of another optical detection pattern used by the passive optical sensor installed in the automatic urinal flusher of FIG. 4A. This detection pattern is shaped by a lens, or another optical element, as mentioned above. The pattern is angled below horizontal (H) to eliminate the influence of light caused by a ceiling lamp. This pattern may be directed asymmetrically to the left or to the right with respect to urinal 120 (as shown in FIGS. 5K or 5 L). These detection patterns are particularly useful for “urinal side flushers,” described in U.S. application Ser. No. 09/916,468, filed on Jul. 27, 2001, or U.S. application Ser. No. 09/972,496, filed on Oct. 6, 2001.

In general, the field of view of a passive optical sensor can be formed using optical elements such as beam forming tubes, lenses, light pipes, reflectors, arrays of pinholes and arrays of slots having selected geometries. These optical elements can provide a down-looking field of view that eliminates the invalid targets such as mirrors, doors, and walls. Various ratios of the vertical field of view to horizontal field of view provide different options for target detection. For example, the horizontal field of view may be 1.2 wider than the vertical field of view or vise versa. A properly selected field of view can eliminate unwanted signal from an adjacent faucet or urinal. The detection algorithm includes a calibration routine that accounts for a selected field of view including the field's size and orientation.

FIGS. 6 through 6E illustrate different optical elements for producing desired detection patterns of the passive sensor. FIGS. 6 and 6B illustrate different arrays of pinholes. The thickness of the plate, the size and the orientation of the pinholes (shown in cross-section in FIGS. 6A and 6C) define the properties of the field of view. FIGS. 6D and 6E illustrate an array of slits for producing a detection pattern shown in FIGS. 5B and 5H. This plate may also include a shutter for covering the top or the bottom detection field.

FIG. 7 illustrates in detail an automatic flush valve suitable for use with automatic bathroom flusher 100 or automatic bathroom flusher 100 A. Other flush valves are described in the above-references PCT applications. Yet other suitable flush valves are described in U.S. Pat. Nos. 6,382,586 and 5,244,179, both of which are incorporated by reference. In each case, the flush valve is controlled by a passive optical sensor described herein.

Referring to FIG. 7, automatic flush valve 140 is a high performance, electronically controlled or manually controlled tankless flush valve. Automatic flush valve 140 uses a passive optical sensor 130 (shown in FIG. 7). Passive optical sensor 130 includes a lens 134 for defining the detection field and providing ambient light to a light receiver 132 . Plastic enclosure 135 includes an optical window 136 , which may also include optical elements described in connection with FIGS. 6-6E. The controller is located on a circuit board 138 . Plastic enclosure 135 also houses the batteries for powering the entire flushing system.

Referring still to FIG. 7, flush valve 140 , includes an input union 112 , preferably made of a suitable plastic resin. Union 112 is attached via threads to an input fitting that interacts with the building water supply system. Furthermore, union 112 is designed to rotate on its own axis when no water is present so as to facilitate alignment with the inlet supply line. Union 112 is attached to an inlet pipe 142 by a fastener 144 and a radial seal 146 , which enables union 12 to move in or out along inlet pipe 142 . This movement aligns the inlet to the supply line. However, with fastener 144 secured, there is a water pressure applied by the junction of union 112 to inlet 142 . This forms a unit that is rigid sealed through seal 146 . The water supply travels through union 112 to inlet 142 and thru the inlet valve assembly 150 an inlet screen filter 152 , which resides in a passage formed by member 178 and is in communication with a main valve seat 156 . The operation of the entire main valve can be better understood by also referring to FIGS. 9, and 9 A.

As also described in connection with FIGS. 8, 9 , and 9 A, electro-magnetic actuator 201 controls operation of the main valve, which is a “fram piston valve” 270 . In the opened state, water flows thru a passage 152 and thru passages 158 into passages 159 A and 159 B, into main outlet 114 . In the closed state, the fram element 278 (FIGS. 9 and 9A) seals the valve main seat 156 thereby closing flow through passage 158 . Automatic flusher 140 includes an adjustable input valve 150 controlled by rotation of a valve element 174 threaded together with valve elements 162 and 164 . Valve elements 162 and 164 are sealed from body 170 via one or several o-rings 163 . Furthermore, valve elements 162 and 164 are held down by threaded element 160 , when element 174 is threaded all the way. This force is transferred to element 154 and 178 . The resulting force presses down element 180

When valve element 160 is unthreaded all the way, valve assembly 150 and 151 moves up due to the force of spring 184 located on guide element 186 in this adjustable input valve. The spring force combined with inlet fluid pressure from pipe 142 forces element 151 against the valve seat in contact with O-ring 182 resulting in a sealing action of the O-ring 182 . O-Ring 182 (or another sealing element) blocks the flow of water to inner passage of 152 , which in turn enables servicing of all internal valve element including elements behind shut-off valve 150 without the need to shut off the water supply at the inlet 112 . This is a major advantage of this embodiment.

According to another function of adjustable valve 140 , the threaded retainer is fastened part way resulting in valve body elements 162 and 162 to push down the valve seat only partially. There is a partial opening that provides a flow restriction reducing the flow of input water thru valve 150 . This novel function is designed to meet application specific requirements. In order to provide for the installer the flow restriction, the inner surface of the valve body includes application specific marks such as 1.6 W.C 1.0 GPF urinals etc. for calibrating the input water flow.

Automatic flush valve 140 is equipped with the above-described sensor-based electronic system located in housing 135 . Alternatively, the sensor-based electronic flush system may be replaced by an all mechanical activation button or lever. Alternatively, the flush valve may be controlled by a hydraulically timed mechanical actuator that acts upon a hydraulic delay arrangement, as described in PCT Application PCT/US01/43273, which is incorporated by reference. The hydraulic system can be adjusted to a delay period corresponding to the needed flush volume for a given fixture such a 1.6 GPF W.C etc. The hydraulic delay mechanism can open the outlet orifice of the pilot section instead of electromagnetic actuator 201 for duration equal to the installer preset value.

Referring again to FIG. 7, depending on the passive optical sensor signal, the microcontroller executes a control algorithm and provides ON and OFF signals to valve actuator 201 , which, in turn, opens or closes water delivery. The microcontroller can also execute a half flush or delayed flush depending on the mode of use (e.g., a toilet, a urinal, a frequently used urinal as in a ball park). The microcontroller can also execute a timed flush (one flush per day or per week in facilities such as ski resorts in summer) to prevent drying of the water trap.

FIGS. 8, 8 A and 8 B illustrate an automatic valve 38 constructed and arranged for controlling water flow in automatic faucet 10 . Specifically, automatic valve 38 receives water at a valve input port 202 and provides water from a valve output port 204 , in the open state. Automatic valve 38 includes a body 206 made of a durable plastic or metal. Preferably, valve body 206 is made of a plastic material but includes a metallic input coupler 210 and a metallic output coupler 230 . Input and output couplers 210 and 230 are made of metal (such as brass, copper or steel) so that they can provide gripping surfaces for a wrench used to connect them to water lines 24 and 25 , respectively. Valve body 206 includes a valve input port 240 , and a valve output port 244 , and a cavity 207 for receiving the individual valve elements shown in FIG. 8.

Metallic input coupler 210 is rotatably attached to input port 240 using a metal C-clamp 212 that slides into a slit 214 inside input coupler 210 and also a slit 242 inside the body of input port 240 (FIG. 8). Metallic output coupler 230 is rotatably attached to output port 244 using a metal C-clamp 232 that slides into a slit 234 inside output coupler 230 and also a slit 246 inside the body of output port 244 . When servicing the faucet 12 , this rotatable arrangement prevents tightening the water line connection to any of the two valve couplers unless attaching the wrench to the designated surfaces of couplers 210 and 230 . (That is, a service person cannot tighten the water input and output lines by gripping on valve body 206 .) This protects the relatively softer plastic body 206 of automatic valve 38 . However, body 206 can be made of a metal in which case the above-described rotatable coupling is not needed. A sealing O-ring 216 seals input coupler 210 to input port 240 , and a sealing O-ring 238 seals output coupler 230 to input port 244 .

Referring to FIGS. 8, 8 A, and 8 B, metallic input coupler 210 includes an inlet flow adjuster 220 cooperatively arranged with a flow control mechanism 310 (FIG. 8). Inlet flow adjuster 220 includes an adjuster piston 222 , a closing spring 224 arranged around an adjuster pin 226 and pressing against a pin retainer 218 . Input flow adjuster 220 also includes an adjuster rod 228 coupled to and displacing adjuster piston 222 . Flow control mechanism 310 includes a spin cap 312 coupled by screw 314 to an adjustment cap 316 in communication with a flow control cam 320 . Flow control cam 320 slides linearly inside body 206 upon turning adjustment cap 316 . Flow control cam 320 includes inlet flow openings 321 , a locking mechanism 323 and a chamfered surface 324 . Chamfered surface 324 is cooperatively arranged with a distal end 229 of adjuster rod 228 . The linear movement of flow control cam 320 , within valve body 206 , displaces chamfered surface 324 and thus displaces adjuster rod 228 . Adjuster piston 222 also includes an inner surface 223 cooperatively arranged with an inlet seat 211 of input coupler 210 . The linear movement of adjuster rod 228 displaces adjuster piston 222 between a closed position and an open position. In the closed position, sealing surface 223 seals inner seat 211 by the force of closing spring 224 . In the opened position, adjuster rod 228 displaces adjuster pin 222 against closing spring 224 thereby providing a selectively sized opening between inlet seat 211 and sealing surface 223 . Thus, by turning adjustment cap 316 , adjuster rod 228 opens and closes inlet adjuster 220 . Inlet adjuster 220 controls or closes completely the water flow from water line 24 . The above-described manual adjustment can be replaced by an automatic motorized adjustment mechanism controlled by a microcontroller.

Referring still to FIGS. 8, 8 A and 8 B, automatic valve 38 also includes a removable inlet filter 330 removably located over an inlet filter holder 332 , which is part of the lower valve housing. Inlet filter holder 332 also includes an O-ring and a set of outlet holes 267 shown in FIG. 8. The “fram piston” 270 is shown in detail in FIGS. 9 and 9A. Referring again to FIG. 8A, water flows from input port 202 of input coupler 210 through inlet flow adjuster 220 and then through inlet flow openings 321 , and through inlet filter 330 inside inlet filter holder 332 . Water then arrives at an input chamber 268 inside a cylindrical input element 276 providing pressure against a pliable member 278 (FIG. 9).

Automatic valve 38 also includes a service loop 340 (or a service rod) designed to pull the entire valve assembly, including attached actuator 200 , out of body 206 , after removing of plug 316 . The removal of the entire valve assembly also removes the attached actuator 200 (or actuator 201 ) and the piloting button described in PCT Application PCT/US02/38757 and in PCT Application PCT/US02/38757, both of which are incorporated by reference. To enable easy installation and servicing, there are rotational electrical contacts located on a PCB at the distal end of actuator 200 . Specifically, actuator 200 includes, on its distal end, two annular contact regions that provide a contact surface for the corresponding pins, all of which can be gold plated for achieving high quality contacts. Alternatively, a stationary PCB can include the two annular contact regions and the actuator may be connected to movable contact pins. Such distal, actuator contact assembly achieves easy rotational contacts by just sliding actuator 200 located inside valve body 206 .

FIG. 8C illustrates automatic valve 38 including a leak detector for indicating a water leak or water flow across valve device 38 . The leak detector includes an electronic measurement circuit 350 and at least two electrodes 348 and 349 coupled respectively to input coupler 210 and output coupler 230 . (The leak detector may also include four electrodes for a four-point resistivity measurement). Valve body 206 is made of plastic or another non-conductive material. In the closed state, when there is no water flow between input coupler 210 and output coupler 230 , electronic circuit 350 measures a very high resistance value between the two electrodes. In the open state, the resistance value between input coupler 210 and output coupler 230 drops dramatically because the flowing water provides a conductive path.

There are various embodiments of electronics 350 , which can provide a DC measurement, an AC measurement including eliminating noise using a lock-in amplifier (as known in the art). Alternatively, electronics 350 may include a bridge or another measurement circuit for a precise measurement of the resistivity. Electronic circuit 350 provides the resistivity value to a microcontroller and thus indicates when valve 38 is in the open state. Furthermore, the leak detector indicates when there is an undesired water leak between input coupler 210 and output coupler 230 . The entire valve 38 is located in an isolating enclosure to prevent any undesired ground paths that would affect the conductivity measurement. Furthermore, the leak detector can indicate some other valve failures when water leaks into the enclosure from valve 38 . Thus, the leak detector can sense undesired water leaks that would be otherwise difficult to observe. The leak detector is constructed to detect the open state of the automatic faucet system to confirm proper operation of actuator 200 .

Automatic valve 38 may include a standard diaphragm valve, a standard piston valve, or a novel “fram piston” valve 270 explained in detail in connection with FIGS. 9 and 9A. Referring to FIG. 9, valve 270 includes a distal body 276 , which includes an annular lip seal 275 arranged, together with pliable member 278 , to provide a seal between input port chamber 268 and output port chamber 269 . The distal body 276 also includes one or several flow channels 267 (also shown in FIG. 8) providing communication (in the open state) between input chamber 268 and output chamber 269 . Pliable member 278 also includes sealing members 279 A and 279 B arranged to provide a sliding seal, with respect to valve body 272 , between pilot chamber 292 and output chamber 271 . There are various possible embodiments of seals 279 A and 279 B (FIG. 9). This seal may be a one-sided seal or a two-sided seal as 279 A and 279 B shown in FIG. 9. Furthermore, there are various additional embodiments of the sliding seal including O-rings, etc.

The present invention envisions valve device 270 having various sizes. For example, the “full” size embodiment has the pin diameter A=0.070″, the spring diameter B=0.310″, the pliable member diameter C=0.730″, the overall fram and seal's diameter D=0.412″, the pin length E=0.450″, the body height F=0.2701″, the pilot chamber height G=0.220″, the fram member size H=0.160″, and the fram excursion I=0.100″. The overall height of the valve is about 1.35″ and diameter is about 1.174″.

The “half size” embodiment of the “fram piston” valve has the following dimensions provided with the same reference letters. In the “half size” valve A=0.070″, B=0.30, C=0.560″, D=0.650″, E=0.34″, F=0.310″, G=0.215″, H=0.125″, and I=0.60″. The overall length of the ½ embodiment is about 1.350″ and the diameter is about 0.455″. Different embodiments of the “fram piston” valve device may have various larger or smaller sizes.

Referring to FIGS. 9 and 9A, the fram piston valve 270 receives fluid at input port 268 , which exerts pressure onto diaphragm-like member 278 providing a seal together with a lip member 275 in a closed state. Groove passage 288 inside pin 286 provides pressure communication with pilot chamber 292 , which is in communication with actuator cavity 300 via communication passages 294 A and 294 B. An actuator (described in PCT Application PCT/US02/38757) provides a seal at surface 298 thereby sealing passages 294 A and 294 B and thus pilot chamber 300 . When the plunger of actuator 200 moves away from surface 298 , fluid flows via passages 294 A and 294 B to control passage 296 and to output port 269 . This causes pressure reduction in pilot chamber 292 . Therefore, diaphragm-like member 278 and piston-like member 288 move linearly within cavity 292 , thereby providing a relatively large fluid opening at lip seal 275 . A large volume of fluid can flow from input port 268 to output port 269 .

When the plunger of actuator 200 seals control passages 294 A and 294 B, pressure builds up in pilot chamber 292 due to the fluid flow from input port 268 through “bleed” groove 288 inside guide pin 286 . The increased pressure in pilot chamber 292 together with the force of spring 290 displace linearly, in a sliding motion over guide pin 286 , from member 270 toward sealing lip 275 . When there is sufficient pressure in pilot chamber 292 , diaphragm-like pliable member 278 seals input port chamber 268 at lip seal 275 . The soft member 278 includes an inner opening that is designed with guiding pin 286 to clean groove 288 during the sliding motion. That is, groove 288 of guiding pin 286 is periodically cleaned.

The embodiment of FIG. 9 shows the valve having a central input chamber 268 (and guide pin 286 ) symmetrically arranged with respect to vent passages 294 A and 294 B (and the location of the plunger of actuator 200 ). However, the valve device may have input chamber 268 (and guide pin 286 ) non-symmetrically arranged with respect to passages 294 A, 294 B and output vent passage 296 . That is, in such a design, this valve has input chamber 268 and guide pin 286 non-symmetrically arranged with respect to the location of the plunger of actuator 200 . The symmetrical and non-symmetrical embodiments are equivalent.

Automatic valve 38 has numerous advantages related to its long term operation and easy serviceability. Automatic valve 38 includes inlet adjusted 220 , which enable servicing of the valve without shutting of the water supply at another location. The construction of valve 38 including the inner dimensions of cavity 207 and actuator 200 enable easy replacement of the internal parts. A service person can remove screw 314 and spin cap 312 , and then remove adjustment cap 316 to open valve 38 . Valve 38 includes service loop 340 (or a service rod) designed to pull the entire valve assembly, including attached actuator 200 , out of body 206 . The service person can then replace any defective part, including actuator 200 , or the entire assembly and insert the repaired assembly back inside valve body 206 . Due to the valve design, such repair would take only few minutes and there is no need to disconnect valve 38 from the water line or close the water supply. Advantageously, the “fram piston” design 270 provides a large stroke and thus a large water flow rate relative to its size.

Another embodiment of the “fram piston” valve device is described in PCT applications PCT/US02/34757, filed Dec. 4, 2002, and PCT/US03/20117, filed Jun. 24, 2003, both of which are incorporated by reference as if fully reproduced herein. Again, the entire operation of this valve device is controlled by a single solenoid actuator that may be a latching solenoid actuator or an isolated actuator described in PCT application PCT/US01/51054, filed on Oct. 25, 2001, which is incorporated by reference as if fully reproduced herein.

FIG. 10 schematically illustrates control electronics 400 , powered by a battery 420 . Control electronics 400 includes battery regulation unit 422 , no or low battery detection unit 425 , passive sensor and signal processing unit 402 , and the microcontroller 405 . Battery regulation unit 422 provides power for the whole controller system. It provides 6.0 V power through 6.0V power 1 to “no battery” Detector; it provides 6.0 V power to low battery detector; it also provides 6.0 V to power driver 408 . It provides a regulated 3.0 V power to microcontroller 405 .

“No battery” detector generates pulses to microcontroller 405 in form of “Not Battery” signals to notify microcontroller 405 . Low Battery detector is coupled to the battery/power regulation through the 6.0V power. When power drops below 4.2V, the detector generates a pulse to the microcontroller (i.e., low battery signal). When the “low battery” signal is received, microcontroller will flash indicator 430 (e.g., an LED) with a frequency of 1 Hz, or may provide a sound alarm. After flushing 2000 times under low battery conditions, microcontroller will stop flushing, but still flash the LED.

As described in connection with FIG. 10B, passive sensor and signal processing module 402 converts the resistance of a photoresistor to a pulse, which is sent to microcontroller through the charge pulse signal. The pulse width changes represent the resistance changes, which in turn correspond to the illumination changes. The control circuit also includes a clock/reset unit that provides clock pulse generation, and it resets pulse generation. It generates a reset pulse with 4 Hz frequency, which according to the clock pulse, is the same frequency. The reset signal is sent to microcontroller 405 through “reset” signal to reset the microcontroller or wake up the microcontroller from sleep mode.

A manual button switch may be formed by a reed switch, and a magnet. When the button is pushed down by a user, the circuitry sends out a signal to the clock/reset unit through manual signal IRQ, then forces the clock/reset unit to generate a reset signal. At the same time, the level of the manual signal level is changed to acknowledge to microcontroller 405 that it is a valid manual flush signal.

Referring still to FIG. 10, control electronics 400 receives signals from optical sensor unit 402 and controls an actuator 412 , a controller or microcontroller 405 , an input element (e.g., the optical sensor), a solenoid driver 408 (power driver) receiving power from a battery 420 regulated by a voltage regulator 422 . Microcontroller 405 is designed for efficient power operation. To save power, microcontroller 405 is initially in a low frequency sleep mode and periodically addresses the optical sensor to see if it was triggered. After triggering, the microcontroller provides a control signal to a power consumption controller 418 , which is a switch that powers up voltage regulator 422 (or a voltage boost 422 ), optical sensor unit 402 , and a signal conditioner 416 . (To simplify the block diagram, connections from power consumption controller 418 to optical sensor unit 402 and to signal conditioner 416 are not shown.)

Microcontroller 405 can receives an input signal from an external input element (e.g., a push button) that is designed for manual actuation or control input for actuator 410 . Specifically, microcontroller 405 provides control signals 406 A and 406 B to power driver 408 , which drives the solenoid of actuator 410 . Power driver 408 receives DC power from battery and voltage regulator 422 regulates the battery power to provide a substantially constant voltage to power driver 408 . An actuator sensor 412 registers or monitors the armature position of actuator 410 and provides a control signal 415 to signal conditioner 416 . A low battery detection unit 425 detects battery power and can provide an interrupt signal to microcontroller 405 .

Actuator sensor 412 provides data to microcontroller 405 (via signal conditioner 416 ) about the motion or position of the actuator's armature and this data is used for controlling power driver 408 . The actuator sensor 412 may be an electromagnetic sensor (e.g., a pick up coil) a capacitive sensor, a Hall effect sensor, an optical sensor, a pressure transducer, or any other type of a sensor.

Preferably, microcontroller 405 is an 8-bit CMOS microcontroller TMP86P807M made by Toshiba. The microcontroller has a program memory of an 8 Kbytes and a data memory of 256 bytes. Programming is done using a Toshiba adapter socket with a general-purpose PROM programmer. The microcontroller operates at 3 frequencies (f _c =16 MHz, f _c =8 MHz and f _s =332.768 kHz), wherein the first two clock frequencies are used in a normal mode and the third frequency is used in a low power mode (i.e., a sleep mode). Microcontroller 405 operates in the sleep mode between various actuations. To save battery power, microcontroller 405 periodically samples optical sensor 402 for an input signal, and then triggers power consumption controller 418 . Power consumption controller 418 powers up signal conditioner 416 and other elements. Otherwise, optical sensor 402 , voltage regulator 422 (or voltage boost 422 ) and a signal conditioner 416 are not powered to save battery power. During operation, microcontroller 405 also provides indication data to an indicator 430 . Control electronics 400 may receive a signal from the passive optical sensor or the active optical sensor described above. The passive optical sensor includes only a light detector providing a detection signal to microcontroller 405 .

Low battery detection unit 425 may be the low battery detector model no. TC54VN4202EMB, available from Microchip Technology. Voltage regulator 422 may be the voltage regulator part no. TC55RP3502EMB, also available from Microchip Technology (http://www.microchip.com). Microcontroller 405 may alternatively be a microcontroller part no. MCU COP8SAB728M9, available from National Semiconductor.

FIG. 10A schematically illustrates another embodiment of control electronics 400 . Control electronics 400 receives signals from optical sensor unit 402 and controls actuator 412 . As described above, the control electronics also includes microcontroller 405 , solenoid driver 408 (i.e., power driver), voltage regulator 422 , and a battery 420 . Solenoid actuator 411 includes two coil sensors 411 A and 411 B. Coil sensors 411 A and 411 B provide a signal to the respective preamplifiers 416 A and 416 B and low pass filters 417 A and 417 B. A differentiator 419 provides the differential signal to microcontroller 405 in a feedback loop arrangement.

To open a fluid passage, microcontroller 405 sends OPEN signal 406 B to power driver 408 , which provides a drive current to the drive coil of actuator 410 in the direction that will retract the armature. At the same time, coils 411 A and 411 B provide induced signal to the conditioning feedback loop, which includes the preamplifier and the low-pass filter. If the output of a differentiator 419 indicates less than a selected threshold calibrated for the retracted armature (i.e., the armature didn't reach a selected position), microcontroller 405 maintains OPEN signal 406 B asserted. If no movement of the solenoid armature is detected, microcontroller 405 can apply a different (higher) level of OPEN signal 406 B to increase the drive current (up to several time the normal drive current) provided by power driver 408 . This way, the system can move the armature, which is stuck due to mineral deposits or other problems.

Microcontroller 405 can detect the armature displacement (or even monitor armature movement) using induced signals in coils 411 A and 411 B provided to the conditioning feedback loop. As the output from differentiator 419 changes in response to the armature displacement, microcontroller 405 can apply a different (lower) level of OPEN signal 406 B, or can turn off OPEN signal 406 B, which in turn directs power driver 408 to apply a different level of drive current. The result usually is that the drive current has been reduced, or the duration of the drive current has been much shorter than the time required to open the fluid passage under worst-case conditions (that has to be used without using an armature sensor). Therefore, the control system saves considerable energy and thus extends the life of battery 420 .

Advantageously, the arrangement of coil sensors 411 A and 411 B can detect latching and unlatching movement of the actuator armature with great precision. (However, a single coil sensor, or multiple coil sensors, or capacitive sensors may also be used to detect movement of the armature.) Microcontroller 405 can direct a selected profile of the drive current applied by power driver 408 . Various profiles may be stored in, microcontroller 405 and may be actuated based on the fluid type, the fluid pressure (water pressure), the fluid temperature (water temperature), the time actuator 410 has been in operation since installation or last maintenance, a battery level, input from an external sensor (e.g., a movement sensor or a presence sensor), or other factors. Based on the water pressure and the known sizes of the orifices, the automatic flush valve can deliver a known amount of flush water.

FIG. 10B provides a schematic diagram of a detection circuit used for the passive optical sensor 50 . The passive optical sensor does not include a light source (no light emission occurs) and only includes a light detector that detects arriving light. As compared to the active optical sensor, the passive sensor enables reduced power consumption since all power consumption related to the IR emitter is eliminated. The light detector may be a photodiode, a photo-resistor or some other optical element providing electrical output depending on the intensity or the wavelength of the received light. The light receiver is selected to be active in the range or 350 to 1,500 nanometers and preferably 400 to 1,000 nanometers, and even more preferably, 500 to 950 nanometers. Thus, the light detector is not sensitive to body heat emitted by the user of faucet 10 , 10 A, 10 B or 10 C, or body heat emitted by the user located in front of flushers 100 or 100 A.

FIG. 10B shows a schematic diagram of the detection circuit used by the passive sensor, which enables a significant reduction in energy consumption. The detection circuit includes a detection element D (e.g., a photodiode or a photo-resistor), two comparators (U 1 A, and U 1 B) connected to provide a read-out from the detection element upon receipt of a high pulse. Preferably, the detection element is a photo-resistor. The voltage V _CC is +5 V (or +3V) received from the power source. Resistors R _{2 and} R ₃ are voltage dividers between V _CC and the ground. Diode D ₁ is connected between the pulse input and output line to enable the readout of the capacitance at capacitor C ₁ charged during the light detection.

Preferably, the photo-resistor is designed to receive light of intensity in the range of 1 lux to 1000 lux, by appropriate design of optical lens 54 or the optical elements shown in FIGS. 6 through 6E. For example, optical lens 54 may include a photochomatic material or a variable size aperture. In general, the photo-resistor can receive light of intensity in the range of 0.1 lux to 500 lux for suitable detection. The resistance of the photodiode is very large for low light intensity, and decreases (usually exponentially) with the increasing intensity.

Referring still to FIG. 10B, upon receiving a “high” pulse at the input connection, comparator U _1A receives the “high” pulse and provides the “high” pulse to node A. At this point, the corresponding capacitor charge is read out through comparator U _1B to the output 7 . The output pulse is a square wave having a duration that depends on the photocurrent (that charged capacitor C ₁ during the light detection time period. Thus, microcontroller 34 receives a signal that depends on the detected light.

In the absence of the high signal, comparator U _1A provides no signal to node A, and therefore capacitor C ₁ is being charged by the photocurrent excited at the photo resistor D between V _CC and the ground. The charging and reading out (discharging) process is being repeated in a controlled manner by providing a high pulse at the control input. The output receives a high output, i.e., the square wave having duration proportional to the photocurrent excited at the photo resistor. The detection signal is in a detection algorithm executed by microcontroller 405 .

By virtue of the elimination of the need to employ an energy consuming IR light source used in the active optical sensor, the system can be configured so as to achieve a longer battery life (usually many years or operation without changing the batteries). Furthermore, the passive sensor enables a more accurate means of determining presence of a user, the user motion, and the direction of user's motion.

The preferred embodiment as it relates to which type of optical sensing element is to be used is dependent upon the following factors: The response time of a photo-resistor is on the order or 20-50 milliseconds, whereby a photo-diode is on the order of several microseconds, therefore the use of a photo-resistor will require a significantly longer time form which impacts overall energy use.

Furthermore, the passive optical sensor can be used to determine light or dark in a facility and in turn alter the sensing frequency (as implemented in the faucet detection algorithm). That is, in a dark facility the sensing rate is reduced under the presumption that in such a modality the faucet or flusher will not be used. The reduction of sensing frequency further reduces the overall energy consumption, and thus this extends the battery life.

FIG. 11 illustrates various factors that affect operation and calibration of the passive optical system. The sensor environment is important since the detection depends on the ambient light conditions. If there the ambient light in the facility changes from normal to bright, the detection algorithm has to recalculate the background and the detection scale. T