Ultraviolet light sanitizing assembly with flow switch and keyed lamp

An ultra-violet (UV) assembly for treating a fluid with UV light has a housing. A mounting bracket defines a slot and a hollow. A UV source includes: a tab that twist-locks in the slot; a connector that aligns with the hollow; and an RFID tag. An RFID antenna interacts with the RFID tag to emit a RFID tag position signal. A flow switch sends a flow signal. The flow switch includes: a guide; a shaft slidably mounted to the guide; a disc on the shaft; a magnet coupled to the shaft; and a sensor for generating a magnet position signal. During no flow, a spring biases the shaft so that the magnet is positioned to be detected by the sensor. During flow, the flow applies pressure to move the disc and, in turn, the magnet moves to be positioned to not be detected by the sensor.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

The subject disclosure relates to assemblies and methods for sanitizing water using ultraviolet light (hereafter abbreviated to “UV” or UV light“) and, more particularly to safer and more efficient UV sanitizing assemblies and methods.

2. Background of the Related Art

Treatment of fluids via irradiation with ultraviolet light is known to be an effective method for disinfection without chemicals. The applications are as varied as water, food, swimming pools and the like in both industrial and residential applications. The typical approach is treatment of fluids within an enclosed treatment zone that is irradiated with ultraviolet light as shown inFIG. 1, which is a cross-sectional view of a UV treatment system. The objective of these systems, as for any type of photo-reactor, is to provide a uniform amount of UV energy to each individual element (e.g., contaminant molecule, microorganism) as the contaminant passes through the treatment zone.

Referring toFIG. 1, a typical prior-art UV treatment vessel10is shown. In the vessel10, a UV treatment zone11is contained within a chamber12which is in fluid communication with an inlet port13and an outlet port14. Fluid entering the chamber12is represented by the arrow “a” and fluid exiting the chamber12is represented by the arrow “b”. At least one UV light emitting source assembly15is located within the chamber12to provide radiant UV energy within the UV treatment zone11, the flow of which is indicated by the arrow “c”. Many forms of UV emitting source assemblies are available, including those utilizing mercury vapor lamps or UV light emitting diodes.

The UV source15is housed within a UV transparent sleeve16. The UV source15receives electrical energy via wires17from an electrical power supply not shown designed to suit the specific type of UV source15. A sealing cap18with an o-ring seal19seals the outside of transparent sleeve16to the chamber12, allowing a passageway for the UV source15and wires17while preventing undesirable escape of fluid.

SUMMARY OF THE INVENTION

There are problems associated with UV treatment assemblies. The present technology provides improvements to the current art, by providing enhanced safety features. For example, a keyed lamp assembly that prevents inadvertent operation is disclosed. Also, a very sensitive flow switch for UV assemblies is disclosed.

One embodiment of the subject technology is directed to an ultra-violet (UV) light source assembly for treating a fluid with UV light has a housing. A mounting bracket defines a slot and a hollow. A UV source includes: a tab that twist-locks in the slot; a connector that aligns with the hollow; and an RFID tag. An RFID antenna interacts with the RFID tag to emit a first signal indicating position of the UV source. A flow switch sends a second signal indicating fluid flow. The flow switch includes: a guide; a shaft slidably mounted to the guide; a disc on the shaft; a collar on the shaft; a spring mounted between the collar and the guide to bias the shaft toward a closed position; a magnet coupled to the shaft; and a sensor for generating the second signal based on proximity of the magnet thereto, wherein, during substantially no flow, the spring biases the plunger assembly so that the magnet is positioned to be detected by the sensor, and during flow, the flow applies pressure to move the disc and, in turn, the magnet moves to be positioned to not be detected by the sensor.

The UV light source assembly may also include a ballast controller for receiving and processing the first and second signals, wherein the ballast controller power the UV source based upon the first and second signals. The ballast controller can also receive a signal indicating a flow rate and adjusts an output of the UV source based upon the flow rate. The flow rate signal may come from the flow switch or another sensor. The ballast controller can record operational statistics of the UV source to determine when to replace the UV source. The operational statistics can be stored in the RFID tag to prevent unintended over-use among other things described herein.

Another embodiment of the subject technology is directed to an ultra-violet (UV) light source assembly for treating a fluid with UV light including a tubular housing defining: an interior chamber having a treatment zone; an inlet; and an outlet so that the fluid entering the inlet passes through the treatment zone. A mounting bracket couples to the tubular housing and defines at least one slot and a hollow. A UV source mounts in the interior chamber for supplying UV light to the treatment zone. The UV source includes: at least one tab that twist-locks in the slot; a connector that aligns with the hollow when locked for cabling to a ballast controller; and an RFID tag. An RFID antenna couples to the mounting bracket so that in when locked, the RFID antenna interacts with the RFID tag to emit a signal.

One embodiment of the subject technology is directed to a flow switch for an interior chamber of an ultra-violet light assembly. The interior chamber is defined by a housing having an inlet along an axis and a large diameter portion of the housing adjacent the inlet flares outward from the axis. The flow switch includes a guide fixed in the inlet. The guide has a ring shaped body with internal vanes defining a central aperture surrounded by at leat one flowpath. A plunger assembly has a disc and a shaft extending from the disc, wherein the shaft is coupled in the central aperture for sliding motion along the axis and the disc is sized and configured to move within the inlet. A collar couples to a distal end of the shaft for retaining the shaft within the central aperture. A spring mounts between the collar and the guide to bias the plunger assembly toward a closed position. A magnet couples to the plunger assembly for motion therewith and a magnet sensor mounts to the housing for determining proximity of the magnet. In the closed position during little or no flow through the inlet, the spring biases the plunger assembly so that the magnet is positioned to be detected by the sensor. In an open position during flow through the inlet, the flow applies pressure to the disc and, in turn, the disc moves into the large diameter portion of the housing and the magnet moves to be positioned to not be detected by the sensor.

It should be appreciated that the present technology can be implemented and utilized in numerous ways, including without limitation as a process, an apparatus, a system, a device, a method for applications now known and later developed. These and other unique features of the technology disclosed herein will become more readily apparent from the following description and the accompanying drawings.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure overcomes many of the problems associated with prior art UV assemblies. The advantages, and other features of the assemblies and methods disclosed herein, will become more readily apparent to those having ordinary skill in the art from the following detailed description of certain preferred embodiments taken in conjunction with the drawings which set forth representative embodiments of the present invention. All relative descriptions herein such as left, right, up, and down are with reference to the Figures, and not meant in a limiting sense.

UV System with Lamp Key Embodiments

Referring now toFIGS. 2A-2C, various perspective views and a top view of a UV assembly100are shown with a housing102in partial cut-away in accordance with the subject technology. In brief overview, the UV assembly100includes lamp key elements that prevent accidental exposure to UV light. The lamp key elements also provide increased reliability by eliminating the need to manually reset operational parameters related to the UV source when replacing said UV source, and to prevent use of improper UV sources. Further, these advantages and more are accomplished at a relatively low cost.

The UV assembly100includes a ballast controller200and UV source300coupled to the tubular housing102. The ballast controller200is a power source and control center for the UV assembly100. Preferably, the ballast controller200generates a constant current output to drive the UV source300at optimal efficiency and regulate dosage transmitted into the treated fluid. The ballast controller200controls the UV source300through a cable202connected to a bulb connector310(best seen inFIG. 3A). As such, the ballast controller200may be remotely mounted as best seen inFIG. 2C. Alternatively, the ballast controller200is mounted to a mounting bracket150as shown inFIGS. 2A and 2B. The ballast controller200also connects by a cable204to a power source (not shown) such as a 100V-240V/50-60 Hz supply.

The UV assembly100may includes sensors and devices that connect to the ballast controller200. For example, an antenna housing116contains an antenna and other components that generate an electric field required to operate a RFID tag as described below. The antenna housing116is connected via the cable206to the ballast controller200. The antenna housing116is fixed to the mounting bracket150. The ballast controller200also includes additional output/input connectors208for expansion capabilities.

The ballast controller200has a graphic display210for providing information related to the UV assembly100. Preferably, the graphic display210is 2.1 by 1.5 inches. The display210has a plurality of different screens. The graphic display210is typically a touch screen as is known in the art for allowing user interaction. Each screen may have areas that display various information as icons, graphics, numbs, letters, etc. as necessary to accomplish operation in accordance with the subject technology. In one embodiment, the display210includes a touch screen that can present a keypad and other interactive buttons.

Typically, the graphic display210would provide a boot screen during power up. During the power up, if the ballast controller200detects an error in the UV assembly100such as an invalid lamp, the graphic display210would provide an indication of the error with further instructions. The ballast controller200also includes buttons262for powering on/off, reset, interaction with the graphic display210and the like as needed for the operation described herewith.

By user selection, the graphic display210would also include a home screen that provides information such as lamp life, UV assembly status (e.g., warming up, sensor failure, over-temperature etc.). Additional screens indicate the total system operating time, dealer contact information, replacement lamp information, replacement sleeve information and the like. Each of screens is available from a setup screen via branching menus and the like.

The UV assembly100may be part of an overall system (not shown). The overall system may include scale prevention, water softening, chemical feed(s), reverse osmosis, media filtration and the like to create a complete fluid treatment system. Further, removing dissolved substances such as hardness minerals, iron, manganese, tannins as well as reducing the turbidity and color improves the disinfection performance of the UV assembly100. The UV assembly100is also protected by such additional treatment. As pre-treatment for reverse osmosis, the UV assembly100protects membranes from bio-films or downstream equipment from biological fouling.

Referring now toFIG. 2D, a somewhat schematic block diagram of the ballast controller200implemented in accordance with the subject disclosure is shown. The ballast controller200includes one or more digital data processing devices and other electronics particularly suited to work in various embodiments of the subject disclosure. The ballast controller200preferably includes a printed circuit board with components for receiving, processing, displaying, and/or transmitting digital and/or analog data.

The ballast controller200includes a processor250, which is generally logic circuitry that responds to and processes instructions. The processor250can include, without limitation, a central processing unit, an arithmetic logic unit, an application specific integrated circuit, a task engine, and/or any combinations, arrangements, or multiples thereof. The processor250is in communication with memory252. Typical memory252includes random access memory (RAM), read only memory (ROM), mechanisms and structures for performing 1/0operations, and a storage medium such as a magnetic hard disk drive(s). The memory252includes software254and a plurality of modules as needed to perform the functions of the subject technology. Alternatively, one or more of the modules could be embodied as an all hardware device on one or more printed circuit boards or the like.

For example, the software254may include an operating system for execution on the processor250. Software or code generally refers to computer instructions which, when executed on one or more digital data processing devices, cause interactions with operating parameters, sequence data/parameters, database entries, network connection parameters/data, variables, constants, software libraries, and/or any other elements needed for the proper execution of the instructions, within an execution environment in memory.

The memory252also has plurality of modules. A module is a functional aspect, which may include software and/or hardware. Typically, a module encompasses the necessary components to accomplish a task. It is envisioned that the same hardware (e.g., memory and processor) could implement a plurality of modules and portions of such hardware being available as needed to accomplish the task.

For example, a database module256creates, stores and maintains multiple databases necessary for the proper operation of the subject technology. A program module258stores an instruction set to allow the operator to program operation and otherwise interact with the ballast controller200. An algorithm module260stores an instruction set to allow the processor to apply one or more algorithms to operation of the ballast controller200as well as vary the actual algorithms according to user input.

The ballast controller200also has input and output devices such as buttons262or a keypad and a display210, respectively. The buttons262may have any number of buttons, dials, selector switches and the like as necessary to accomplish operation in accordance with the subject technology.

Still referring toFIG. 2D, the ballast controller200also includes a WiFi module264and/or wired communication channels to facilitate communication with external sensors, networks, devices, elements and the like. Those of ordinary skill will recognize that the hardware, software, modules, sensors, elements, devices and various processes discussed herein are merely exemplary of the structure and functionality performed by the disclosed technology and thus such hardware and processes (and/or their equivalents) may be implemented in commercial embodiments in various combinations without materially affecting the operation of the disclosed technology. It is also envisioned that the ballast controller200and/or other components may be incorporated into a more comprehensive site controller that controls the operation of additional systems (e.g., heating and air conditioning) along with additional sensors and the like.

Referring again toFIGS. 2A-2C, the housing102, the ballast controller200and UV source300couple to a mounting bracket150. In brief overview, the UV source300is keyed to the mounting bracket150so that an inappropriate UV source does not properly fit in the mounting bracket150. Further, the ballast controller200also recognizes usage of a proper UV source300and prevents operation when an improper UV source is connected and when the UV source300is removed.

Referring now toFIG. 3A, a perspective view of a UV bulb assembly300for the UV source300in accordance with the subject technology is shown. The UV bulb assembly300includes a cap assembly320coupled to a bulb302. When mounted in the UV assembly100, the bulb302is protected by a sleeve304and centrally located in the interior chamber106of the housing102(seeFIG. 2A). The quartz sleeve304allows for transmission of UV light while minimizing the temperature fluctuation effect and protecting the bulb302during use.

The cap assembly320is generally dome-shaped and includes a bulb connector310and knurled manual grip area312. The cap assembly320also includes a rear locking tab324(best seen inFIG. 4A) and a front locking tab322adjacent the bulb connector310. The opposing tabs322,324are designed to provide a turn-to-lock engagement with the mounting bracket150. The cap assembly320also includes an inner flange326for coupling the cap assembly320to the bulb302.

An RFID tag328is mounted inside the cap assembly320for verifying proper lamp installation. The RFID tag328consists of a High Frequency (HF) antenna tuned to transmit and receive at 13.56 MHz (other frequencies may be utilized) and coupled to an integrated circuit (not shown) within the RFID tag328. The integrated circuit (IC) is powered through energy received from a HF antenna when in the presence of an electromagnetic field. When not in the presence of an electromagnetic field, the IC remains passive and does not consume or radiate energy through the HF antenna. The IC contains a unique serial number and digital memory for storing custom user information including, but not limited to, lamp type, lamp serial number, lamp usage, lamp control parameters and the like. Information is written to and read from the IC through the HF antenna by modulating the electromagnetic field in proximity to the tag. As a result, information travels with the UV source300and can be read by the ballast controller200.

Referring now toFIG. 4A, a perspective exploded view of the UV assembly100with the mounting bracket150partially cut-away is shown. The housing102defines an inlet120and an outlet122so that fluid flows through the interior chamber106for treatment. A top124of the housing102is configured to sealingly engage the UV source300so that the bulb302is centrally located within the housing102in a fluid tight manner. The top124preferably threads onto the housing102and contains an inner seal (not shown) for preventing fluid leakage from the housing102. The housing102also couples to the mounting bracket150. In one embodiment, the housing102is glued to the mounting bracket150.

Referring additionally toFIGS. 4B and 4C, perspective views of the UV source300being secured in the housing102are shown. The mounting bracket150couples to an antenna housing116with an RFID antenna110therein. The RFID antenna110is configured to interact with the RFID tag328as described herein. The mounting bracket150is generally formed by bending a flat plate to create a rear portion152upstanding from a central portion154and a front portion156depending from the central portion154. The upward rear portion152defines two keyholes158for easily mounting the bracket150, and thereby the UV assembly100, on fasteners160.

The central portion154of the mounting bracket150defines a central opening162for retaining the housing102. In one embodiment, the housing102is inserted into the central opening162without the top124so that screwing the top124to the housing102securely couples the mounting bracket150and housing102together. The central opening162also includes a rear slot164(best seen inFIG. 4A) and a front slot166. The rear slot164is configured so that when the UV source300is positioned as shown inFIGS. 4B and 4C, the rear tab324passes there through. In other words, a shape of the rear slot164matches the rear tab324of the cap assembly320.

Similarly, a shape of the front slot166matches the front tab322and bulb connector310so that, when positioned as shown inFIGS. 4B and 4C, the front tab322and bulb connector310pass there through. Once in position as shown inFIG. 4C, clockwise rotation of the UV source300captures the tabs322,324under the mounting bracket150so that the UV source300is fixed longitudinally with the bulb302centered in the housing102. Additionally, the bulb connector310aligns with a hollow portion168of the front portion156. This hollow portion168allows coupling and decoupling the cable202to the bulb connector310only when the UV source300is properly positioned.

With the UV source300fully installed, it is not possible to remove the UV source300unless the cable202is disconnected because the tabs322,324lock the UV source300in longitudinally and the cable202in the bulb connector310prevents rotation by virtue of orientation within the hollow portion168cut into the front portion156of the mounting bracket150. Also, when the UV source300is in the fully installed position, the RFID tag328is aligned with the antenna housing116, so as these two items are in close enough proximity to operate. Based upon a signal received from the antenna110, the ballast controller200is able to control power to the UV source300, determine if the UV source300is proper, determine a number of hours used for the particular UV source300and the like as described below.

To change the UV source300, the cable202must be removed from the bulb connector310. Then, the UV source300is rotated counterclockwise to release engagement of the tabs322,324so that the UV source300can be pulled out of the housing102in an axial direction. Displacement of the UV source300from a fully installed position causes an increase in the distance between the antenna110and the RFID tag328. Thus, requiring the cable202to be disconnected and reading the antenna signal act as duplicative safety measures to prevent inadvertent UV exposure when the UV source300is not properly positioned. For additional safety, as shown inFIG. 4D, if the cable202is inserted in the bulb connector310with the UV source300outside of the housing, the cable202prevents the UV source300from being coupled to the mounting bracket150for safety because the bulb connector310will not pass through the front slot166. Additionally, the antenna signal, as read by the ballast controller200, will prevent the UV source300from being powered on when the RFID tag326is not adjacent the antenna housing116even if the cable202is connected.

UV Assembly with Flow Switch

Another embodiment of the subject technology includes a flow switch for providing a signal to the ballast controller200to indicate whether or not fluid is flowing through the housing102. As a result, the UV source300may be dimmed or even turned off to conserve energy when fluid is not flowing or flowing slowly. In still another embodiment, the UV assembly100is part of a fluid network that includes a flow sensor (not shown). The flow sensor may be part of the UV assembly100. The flow sensor provides a flow rate to the ballast controller200, which adjusts the output of the UV source300based upon the flow rate.

Referring now toFIGS. 5A and 5B, a flow switch400in accordance with the subject technology is shown in cross-sectional view in a closed position (e.g., no fluid flow). The housing102has an increasing diameter portion128adjacent the inlet120. The flow switch400mounts in the increasing diameter portion128of the interior chamber106by, for example, coupling to the inlet120.FIGS. 6A and 6Bare cross-sectional views of the flow switch400in the open position (e.g., fluid flow).

Referring now toFIG. 7, an exploded view of the flow switch400is shown. The flow switch400includes a shaft guide402that is fixes in the inlet120. The shaft guide402may be glued, welded, snap fit or otherwise secured in place. The shaft guide402has a ring shaped body404with internal vanes406defining a central aperture408. Thus, the shaft guide402provides a plurality of flowpaths through the inlet120.

A plunger assembly410is slidably mounted in the central aperture408for up and down motion depending upon the status of fluid flow. The plunger assembly410has a disc412mounted on a shaft414. In particular, it is the shaft414captured in the central aperture408. The disc412is sized and configured to move within the inlet120. A collar416couples to a distal end418of the shaft414for retaining the shaft414within the central aperture408. A spring420surround the shaft414adjacent the collar416. By pushing against the guide402, the spring420biases the disc412toward a closed position. The plunger assembly410also includes a cylinder422holding a magnet424. A spacer426in the cylinder422positions the magnet424radially outward. When flow against the disc412moves the shaft414up, the magnet424moves with the shaft414.

Referring again toFIGS. 5A, 5B, 6A and 6B, in order to sense the position of the magnet424, and thereby whether or not fluid is flowing, a sensor430is mounted to the housing102. The sensor430provides a signal to the ballast controller200via cable432. In the closed position, during little or no flow through the inlet120, the spring420biases the plunger assembly400so that the disc412is in the inlet120and the magnet424is aligned for detection by the sensor430. In the open position during flow through the inlet120, the flow applies pressure to move the disc412into the increased diameter portion128of the housing102and, in turn, the magnet424moves out of proximity so as not to be detected by the sensor430. In short, starting and stopping flow causes the sensor430to change state. As could be appreciated by those of ordinary skill in the art, the flow switch400provides an indication of very low flow because minimal flow is required to push the disc412upward.

Operation

The subject technology provides features that facilitate safe operation and maintenance of the UV assembly100. In operation, the ballast controller200has will first check for a valid RFID tag328being adjacent the antenna110before attempting to send power to UV source300. If a valid RFID tag328is not detected, then the ballast controller200will not attempt to send power to the UV source300. Therefore, if the UV source300is connected via cable202slightly outside of the interior chamber106, the RFID tag328will not be detected due to distance from the antenna housing116and the UV source300will not produce UV light.

In order to install a new UV source300, the tabs322,324must pass through the respective slot164,166, which is prevented if the cable202is connected. Only once the UV source300has been inserted and rotated into a locked position with the connector310oriented in the hollow168can the cable202be connected. Thus, in addition to the ballast controller200requiring a proper signal from the RFID antenna110by virtue of proper installation, there is a mechanical structure to further insure proper installation. Additionally, the flow switch400provides a signal to the ballast controller200indicating whether or not fluid flow is present. As a result, when there is no fluid flow, the ballast controller200can dim or power down the lamp to conserve energy.

Further, the ballast controller200can record the operational statistics of the UV source such as run time, run time at full power, run time dimmed and the like to provide particular indication that replacement is needed. These parameters can also be stored in the RFID tag328so that removal and replacement of a UV source300cannot circumvent periodic replacement. The ballast controller200may provide reminders to replace the UV source300after a certain amount of usage in time or power output. The ballast controller200can even power down the UV source300after a predetermined threshold of usage is reached.

In order to subsequently remove the UV source300for replacement, it is necessary to disconnect the cable202from the connector310(which prevents the UV light from being produced). Then, the UV source300can be rotated counter-clockwise and lifted out of the housing102. Further, the UV source300moving away from the housing102takes the RFID tag328away from the antenna110so that the signal generated thereby, as processed by the ballast controller200, prevents power to the UV source300as well. This combination of RFID tag to prevent generation of UV light coupled with mechanical locking is safer and more reliable than using the RFID tag alone, as it prevents the possibility of ballast controller malfunctioning and timing issues. Once the UV source has been disconnected from the ballast controller via the cable, the ballast controller can be reset. For example, ballast controller power can be cycled or a manual reset button can be pressed in order to ready the ballast controller to attempt to restart a UV source.

As would be appreciated by those of ordinary skill in the art the subject technology is applicable to agriculture, aquaculture, breweries, bottling plants, cooling towers, dairies, the electronics industry, food, beverages, hospitals, laboratories, pharmaceuticals, potable drinking water, swimming pools, and the like.

While the invention has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the invention without departing from the spirit or scope of the invention. For example, each claim may depend from any or all claims, even in a multiple dependent manner, even though such has not been originally claimed.