Abstract:
A motor driven valve actuator has a manual override that allows operating the valve without causing the motor rotation. The actuator includes a spindle having an axis of rotation, a driving hub rotatable about the axis of rotation, and a connecting plate attached to the spindle to be axially movable and rotatably fixed thereto, the connecting plate rotatably fixed to the driving hub when in a first axial position, thereby rotatably fixing the spindle to the driving hub for conjoined rotation with the driving hub, the connecting plate rotatable relative to the driving hub when in a second axial position.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 62/183,203, filed Jun. 23, 2015, the entirety of which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to valve actuators, and more particularly, relating to an electronically controlled valve actuator having a manual override. 
     BACKGROUND OF THE INVENTION 
     Conventionally, valves have a valve element that is associated with a valve seat. The valve element is moved relative to the valve seat in order to control or regulate flow through the valve. Valve actuators are known and include an electric motor that is coupled to the valve element by a gear mechanism and a spindle. The motor is operated to adjust the position of the valve element relative to the valve seat. In certain instances, it is desirable to manually operate the valve element. However, manual operation of the valve presents several challenges, including having to remove the valve actuator from the valve, causing undesirable manual rotation of the motor, or both. Accordingly, there is a desire for a valve actuator that allows manual operation of a valve to which the actuator is attached without removing the actuator or causing the motor to rotate by manual operation. 
     SUMMARY OF THE INVENTION 
     Embodiments of the present invention provide an electrically operated valve actuator that has a manual override allowing the valve to be manually operated without causing motor rotation and without disassembling the valve actuator. 
     In general, in one aspect, an electronically controlled rotational actuator is provided. The actuator includes a spindle having an axis of rotation, a driving hub rotatable about the axis of rotation, and a connecting plate attached to the spindle to be axially movable and rotatably fixed thereto, the connecting plate rotatably fixed to the driving hub when in a first axial position, thereby rotatably fixing the spindle to the driving hub for conjoined rotation with the driving hub, the connecting plate rotatable relative to the driving hub when in a second axial position. 
     There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated. 
     Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of presently preferred, but nonetheless illustrative, embodiments of the present invention when taken in conjunction with the accompanying drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting. 
     As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated embodiments of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following drawings illustrate by way of example and are included to provide further understanding of the invention for the purpose of illustrative discussion of the embodiments of the invention. No attempt is made to show structural details of the embodiments in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. Identical reference numerals do not necessarily indicate an identical structure. Rather, the same reference numeral may be used to indicate a similar feature of a feature with similar functionality. In the drawings: 
         FIG. 1  is a cross-sectional view of an electronically controlled rotational actuator with manual override constructed in accordance with the principles of an embodiment of the present invention, configured in a manual override mode and in a second position; 
         FIG. 2  is a cross-sectional view of the actuator of  FIG. 1 , taken generally along line  2 - 2 ; 
         FIG. 3  is a cross-sectional view of an electronically controlled rotational actuator with manual override constructed in accordance with the principles of an embodiment of the present invention, configured in a manual override mode and in a first position; 
         FIG. 4  is a cross-sectional view of the actuator of  FIG. 3 , taken generally along line  3 - 3 ; 
         FIG. 5  is a cross-sectional view of an electronically controlled rotational actuator with manual override constructed in accordance with the principles of an embodiment of the present invention, configured in an electrically operated mode and in a second position; 
         FIG. 6  is a cross-sectional view of the actuator of  FIG. 5 , taken generally along line  5 - 5 ; 
         FIG. 7  is a cross-sectional view of an electronically controlled rotational actuator with manual override constructed in accordance with the principles of an embodiment of the present invention, configured in an electrically operated mode and in a first position; 
         FIG. 8  is a cross-sectional view of the actuator of  FIG. 7 , taken generally along line  7 - 7 ; and 
         FIG. 9  is a diagrammatic illustration of an electronic controller. 
     
    
    
     DESCRIPTION OF THE INVENTION 
     The present invention relates to an electronically controlled rotational actuator with manual override, rotating in direction  1  and rotating in direction  2 , with indicator light for each direction, more particularly the present invention relates to rotational electromechanical with manual override valve actuator. 
     In exemplary application, the valve actuator could be used in connection with a motor vehicle to operate a valve on a gas cylinder to deliver gas under pressure from the cylinder to the combustion engine or vehicle components. In such an application, driver would operate an electrical switch located within reach of driver to fully open and fully close the valve via the valve actuator configured to powered mode or manually open and close the valve if the actuator is configured to manual mode. 
     Now with reference to  FIGS. 1 through 8 , there is representatively illustrated a new electronically controlled electromechanical rotational actuator  1  having a manual override that is constructed in accordance with an embodiment of the present invention. The valve actuator  1  is illustrated in connection with a conventional compressed gas cylinder  2 . The gas cylinder  2  is fitted with a conventional valve  3  that is operable to control a flow of compressed gas from the compressed gas cylinder  2 . Valve  3  has a valve stem  5  that is rotated about axis  40  to open and close valve  3 . 
     The rotational actuator  1  includes an adaptor plate  30  that is detachably connected to valve neck  4  of valve  3 , for example, by a slip connection between cooperating surfaces  42  and  43  formed on neck  4  of valve  3  and socket  32  of adaptor plate  30 , respectively. A plurality of set screws  34  may be threaded through the adaptor plate socket  32  for engagement with neck  4  of valve  3  to prevent adaptor plate  30  from rotating or sliding once connected to valve  3 . Other devices could be substituted for set screws to serve the same purpose of preventing adaptor plate  30  from rotating or sliding relative to valve  3  once they are connected together. While adaptor plate  30  is illustrated here being connected to neck  4  of valve  3  by a slip connection and set screws, adaptor plate  30  could be connected to neck  4  of valve  3  by other types of coupling known in the art, serving the same purpose. 
     The rotational actuator  1  includes a hollow-shaft gear-motor  6  attached in this exemplary application to flange  31  of adaptor plate  30  by  4  screws insuring adaptor plate  30  and gear-motor  6  to be centered on valve axis  40 . Other devices known to the art could be substituted to the screws to serve the same purpose of preventing the gear-motor  6  from rotating or translating relative to adaptor plate  30  and valve  3 . 
     Stem  18  of spindle  16  extends through driving hub  22  and gear-motor large gear  8  of gear-motor  6  for rotation about axis  40 . At end  46  of spindle  16  a socket  19  is formed through stem  18  of spindle  16  and is configured to receive the end of valve stem  5  such that when valve stem  5  is inserted into socket  19 , valve stem  5  and spindle  16  are conjoined for rotation about axis  40 . 
     In this exemplary application, a snap-ring  38  is inserted in groove  21  cut into spindle stem  18  preventing spindle  16  from sliding out of gear-motor  6  large gear  8  and driving hub  22  after assembly. Driving hub  22  is conjoined for rotation with large gear  8  of gear-motor  6  by a shock absorbing coupling  9 . Driving hub  22  includes a plurality of radial tabs  23  extending outward. At its mid-section  17 , the spindle  16  includes a plurality of longitudinal grooves  20 . End  44  of the spindle  16  includes a plurality of radial holes housing spring-loaded balls  28 . 
     Housing  11  fits over spindle body  17  rotating about axis  40  independently from spindle  16 . At end  45  of the housing  11  there are two parallel circular grooves  13  and  14 . At end  44  of the housing  11  there is a circular groove  15 . Parallel to groove  15 , in the direction of end  45 , housing  11  includes a plurality of inward facing tabs  14 . The mid-section of housing  11  includes a circular cavity housing connecting plate  24  allowing the connecting plate to rotate about axis  40  independently from housing  11 . 
     Connecting plate  24  includes a plurality of radial inward facing tabs  25  of complementary shape of longitudinal grooves  20  cut in mid-section  17  of spindle  16  in such manner that connecting plate  24  is allowed to move along axis  40  independently from spindle  16  but conjoined for rotation about axis  40  with spindle  16 . Connecting plate  24  includes a plurality of outward facing radial tabs  26  of number, shape and dimensions such that when placed in the same plane as tabs  14  housing  11 , housing  11  and the connecting plate  24  are conjoined for rotation about axis  40 . Connecting plate  24  includes a plurality of axial tabs  27  protruding axially from connecting plate  24  in the direction of valve  3 . Tabs  27  are configured such that when they are in the same plane as tabs  23  of driving hub  22 , the driving hub  22  and connecting plate  24  are conjoined for rotation. Snap ring  37  inserted in groove  15  of knob/housing  11  keeps connecting plate  24  from sliding out of housing  11 . 
     With reference to  FIGS. 1 and 2 , the rotational actuator  1  is depicted in cross sectional and in manual mode configuration in a first position. Housing  11  is located in relation to spindle  16  along axis  40  by spring-loaded balls in groove  13  of the housing. In this position, tabs  14  of housing  11  and tabs  26  of connecting plate  24  are shown disengaged, before rotation of housing  11 , in the process of configuring the unit from electrically powered mode to manual mode. 
     With reference to  FIGS. 3 and 4 , the rotational actuator  1  is depicted in cross sectional and in manual mode configuration in a second position. In this position, tabs  14  of housing  11  and tabs  26  of connecting plate  24  are shown engaged. In this configuration, torque applied to knob  11  is transmitted to spindle  16  via connecting plate  24 . 
     With reference to  FIGS. 5 and 6 , the rotational actuator  1  is depicted in a front cross-sectional view, in electrically operated mode in a first position. In this position, tabs  23  of driving hub  22  and tabs  27  of connecting plate  24  are shown disengaged, in the process of configuring the unit from manual mode to electrically powered mode. 
     To configure the rotational actuator  1  from manual mode to electrically powered mode, housing  11  is manually pushed along axis  40  in the direction of valve  3  until, by engaging groove  12  of housing  11 , spring loaded balls  28  locate housing  11  and spindle  16  in electrically powered mode configuration. During this proceeding, under pressure exerted on connecting plate  24  by spring loaded plungers  29 , connecting plate  24  moves in the direction of valve  3 , tabs  27  of connecting plate  24  come in contact with tabs  23  of driving hub  22 , tabs  14  of housing  11  disengage from tabs  26  of connecting plate  24 . 
     With reference to  FIGS. 7 and 8 , the rotational actuator  1  is depicted in a front cross-sectional view, in electrically operated mode in a second position. In this position, tabs  23  of driving hub  22  and tabs  27  of connecting plate  24  are shown engaged. In this configuration, torque from gear-motor  6  is transmitted to spindle  16  via driving hub  22  and connecting plate  24 . 
     As gear-motor motor  35  is electrically energized, driving hub  22  rotates, under pressure from plungers  29  applied to connecting plate  22 , tabs  27  of connecting plate  24  engage tabs  23  of driving hub  22  when proper angular relation is achieved, driving hub  22  and connecting plate  24  becoming conjoined in rotation about axis  40 . 
     To configure the actuator from electrically powered mode to manual mode, housing  11  is manually pulled along axis  40  in opposite direction of valve  3  until, by engaging in groove  13  of housing  11 , spring loaded balls  28  locate housing  11  and spindle  16  in manual mode configuration. During this proceeding, tabs  14  of housing  11  come in contact with tabs  26  of connecting plate  24 , moving connecting plate  24  away from driving hub  22 , causing tabs  27  of connecting plate  24  to disengage with tabs  23  of driving hub. 
     As housing  11  is manually rotated, under pressure from spring loaded plungers  29  on connecting plate  24 , tabs  26  of connecting plate  24  engage tabs  14  of housing  11  when proper angular relation is achieved, connecting plate  24  and housing  11  conjoining in rotation about axis  40 . Snap-ring  37  keeps connecting plate  24  from sliding out of knob/housing  11 . 
     With reference to  FIG. 9 , an electronic controller  50  is diagrammatically illustrated. In this exemplary application, the electronic controller  50  is connected to a permanent  12 V source  53  protected by a fuse, ground  55 , and a temporary  12 V source  56  from the ignition switch of the vehicle. Connected to the module are motor leads L 1  and L 2 , indicator lights  58  and  59 , and a single pole single throw OFF (ON) switch  57 . 
     Depressing switch  57  will cause the electronic controller  50  to allocate electricity from power source  53  to motor leads L 1  and L 2 , initiating rotation of motor  35  in a first direction. Reaching the physical end of rotation cycle, spindle  16  will stop rotating and rubber coupling  9  will be compressed. Through motor leads L 1  and L 2 , electronic controller  50  will sense the increase in current delivered to motor  35  and shut off motor  35  when reaching a pre-determined current level and energizing indicator light  48 . 
     Depressing switch  57  again will cause the electronic controller to allocate electricity from power source  53  to motor leads L 1  and L 2 , initiating rotation of motor  35  in a second direction, opposite of the first direction. At the end of the physical rotation, the spindle  16  will stop rotating and rubber coupling  9  will be compressed. Through motor leads L 1  and L 2 , electronic controller  50  will sense the increase in current delivered to motor  35  and shut off motor  35  when reaching a pre-determined current level and energizing indicator light  49 . 
     Each consecutive depression of switch  57  will initiate rotation of motor  35  in the opposite direction of the last direction in which it has rotated. Also, the indicator lights will be lit alternatively. 
     After turning ignition OFF electronic controller  50  will memorize the last direction in which the motor has rotated and corresponding indicator light will be reenergized after turning ignition ON again. In case rotation of motor  35  does not stop in the normal time taken to achieve a normal cycle, the controller will shut off the supply to the motor after a preset time expires and both lights will be lit, indicating malfunction. In case last motorized rotation was in first direction and the valve has been rotated manually in the second direction, next motorized rotation will be in second direction. 
     A number of embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.