Bathroom controller

A fluid controller for a fluid supply system such as the plumbing supply system for a bathroom comprises hot and cold fluid temperature sensors and flow sensors which are installed in respective ones of the hot and cold fluid supply pipes upstream of the fluid discharge outlet. Hot and cold fluid flow control valves operated by valve motors are also installed in such pipes. The sensors and motors are connected to a microprocessor including a comparator means which is operative to compare values programmed in a memory means with signals received from the sensors so as to generate control signals for the motors so as to obtain a desired fluid temperature and flow rate at the discharge outlet. The controller can be installed in an existing plumbing system without disturbing the existing faucets and manual control valves. Alternatively, the controller can be used in a new installation with or without manual control valves.

FIELD OF THE INVENTION 
The invention relates to a fluid controller for controlling the temperature 
and flow rate of a fluid such as water to a plumbing fixture, piping, 
appliance or other point of use. The invention also relates to a water 
supply system incorporating such a fluid controller. 
BACKGROUND OF THE INVENTION 
Various different proposals have heretofore been made for providing 
automatic control of water temperature and/or flow rate and the like in 
plumbing systems, such as, for example, at a bathtub faucet. Some of such 
prior proposals are described in the following U.S. Letters Patent namely 
U.S. Pat. Nos.: 4,563,780, 2,991,481, 3,74,195, 3,884,258, 4,189,792, 
4,429,422. 
Many of these earlier proposals are based on the provision of special forms 
of bathroom faucets and control valves which are intended to replace 
existing faucets with their manual control valves. 
There are, however, some general problems with this approach. In the first 
place, it involves complex manufacturing operations, as well as precise 
monitoring and operation of the control valves in use. Furthermore, the 
systems previously proposed are generally speaking suited for use in only 
new construction, since otherwise the existing plumbing fixtures must be 
removed and discarded. Another more fundamental disadvantage is the fact 
that, once such a new faucet and control have been installed, then the 
option for simple manual operation of the faucet in the usual way is lost. 
The automated bathroom system described in U.S. Pat. No. 4,563,780 is a 
typical example of the systems heretofore proposed. 
In addition, many of the devices previously proposed were of limited 
application since they were suitable for use only in bathrooms. 
In another instance, where, for example, a person wishes to fill a bathtub, 
it may be desirable or convenient to have the bathtub automatically filled 
at a predetermined temperature and at a predetermined time. 
Another problem encountered with some of the previously proposed systems is 
that they are dependent on electrical power. Consequently, there is the 
possibility of a power failure or temporary breakdown in the power supply 
while a person is using a facility. In this case, most systems will simply 
shut off immediately, leaving the occupant with the problem of finishing 
bathing and having to remove soap without any water. 
Clearly, it is desirable to have a fluid controller which alleviates these 
various problems, and in particular which provides a user with the option 
of using regular existing manual controls, if desired. 
It is additionally desirable to provide a system which can be installed at 
a location more remote from the actual discharge outlet than is possible 
with the prior art proposals thereby avoiding the need to damage the tiles 
or other finish surrounding a bathtub. 
Accordingly, it is a principal object of the present invention to provide a 
fluid controller for automatically controlling water temperature and flow 
through a water flow discharge outlet or faucet and which can be used, for 
example, in a bathroom installation with the existing plumbing system 
without disturbing the existing discharge outlet or faucet. 
More particularly, it is an object of this invention to provide a fluid 
controller for automatically controlling water temperature and flow 
through a water discharge outlet or faucet and which can also be used in a 
new construction instead of a conventional and separate manually 
controllable faucet. 
It is a further object of this invention to provide a fluid controller 
which is capable of storing information concerning water temperature, time 
on and time off, and even total water flow in some cases and which, in one 
embodiment, may provide for emergency operation of the system for a 
predetermined length of time after a power failure. 
More particularly, it is an object of the invention to provide a fluid 
controller having the foregoing advantages, and which further includes 
auxiliary power means operable in the event of a failure of the main power 
supply, to continue operation of the controller for a predetermined period 
of time. 
Yet another object of the invention to provide a fluid controller having 
the foregoing advantages and including timer means for controlling the 
switching on and off of said valve means, and further timer means for 
controlling the duration of operation. 
Other objects of the invention and the advantages presented thereby will 
become apparent as the description herein proceeds. 
SUMMARY OF THE INVENTION 
With a view to overcoming all of the various problems and disadvantages 
noted above, the present invention provides a fluid controller for 
controlling fluid temperature and flow through a fluid flow discharge 
outlet supplied with hot and cold fluid from hot and cold fluid sources 
respectively via respective hot and cold fluid supply pipes and which 
controller comprises hot fluid flow-controlling valve means adapted to be 
installed in said hot fluid supply pipe upstream of said fluid flow 
discharge outlet and having hot fluid motor means operatively associated 
therewith to operate same and to control the flow of hot fluid 
therethrough; cold fluid flow-controlling valve means adapted to be 
installed in said cold fluid supply pipe upstream of said fluid flow 
discharge outlet and having cold fluid motor means operatively associated 
therewith to operate same and to control the flow of cold fluid 
therethrough; hot fluid temperature-sensing means adapted to be attached 
to said hot fluid supply pipe upstream of said fluid flow discharge outlet 
sand operative to sense the temperature of hot fluid flowing through said 
hot fluid supply pipe; cold fluid temperature-sensing means adapted to be 
attached to said cold fluid supply pipe upstream of said fluid flow 
discharge outlet and operative to sense the temperature of cold fluid 
flowing through said cold water fluid supply pipe; hot fluid flow-sensing 
means adapted to be attached to said hot fluid supply pipe upstream of 
said fluid flow discharge outlet and operative to sense the rate of flow 
of hot fluid therethrough; cold fluid flow-sensing means adapted to be 
attached to said cold fluid supply pipe upstream of said fluid flow 
discharge outlet and operative to sense the rate of flow of cold fluid 
therethrough; a signal processor including comparator means connectable to 
a principal electrical power supply and connected to said hot and cold 
fluid motor means, to said hot and cold fluid temperature-sensing means 
and to said hot and cold fluid flow-sensing means, and a memory means 
operatively associated with said signal processor and adapted to store 
predetermined parameters concerning desired hot and cold fluid 
temperatures and flow values, and said comparator means being adapted to 
process information from said hot and cold fluid temperature-sensing means 
and said hot and cold fluid flow-sensing means and, in response thereto to 
calculate the temperature of the fluid at the discharge outlet and to 
compare said calculated temperature with a desired temperature in said 
memory means and to generate control signals for said hot and cold fluid 
motor means thereby to operate said hot and cold fluid flow-controlling 
valve means as needed to regulate the flow of hot and cold fluid in 
respective said hot and cold fluid supply pipes to procure the desired 
temperature at said discharge outlet. 
In addition to providing a fluid controller as hereinbefore defined, this 
invention also embraces a fluid supply system comprising hot and cold 
fluid sources; a fluid flow discharge outlet; hot and cold fluid supply 
pipes extending from respective ones of said hot and cold fluid sources to 
said fluid flow discharge outlet for the supply of hot and cold fluid 
respectively thereto; hot fluid flow-controlling valve means in said hot 
fluid supply pipe upstream of said fluid flow discharge outlet and having 
hot fluid motor means operatively associated therewith to operate same and 
to control the flow of hot fluid therethrough; cold fluid flow-controlling 
valve means in said cold fluid supply pipe upstream of said fluid flow 
discharge outlet and having cold fluid motor means operatively associated 
therewith to operate same and to control the flow of cold fluid 
therethrough; hot fluid temperature-sensing means attached to said hot 
fluid supply pipe upstream of said fluid flow discharge outlet and 
operative to sense the temperature of hot fluid flowing through said hot 
fluid supply pipe; cold fluid temperature-sensing means attached to said 
cold fluid supply pipe upstream of said fluid flow discharge outlet and 
operative to sense the temperature of cold fluid flowing through said cold 
fluid supply pipe; hot fluid flow-sensing means attached to said hot fluid 
supply pipe upstream of said fluid flow discharge outlet and operative to 
sense the rate of flow of hot fluid therethrough; cold fluid flow-sensing 
means attached to said cold fluid supply pipe upstream of said fluid flow 
discharge outlet and operative to sense the rate of flow of cold fluid 
therethrough; and a signal processor including comparator means, 
connectable to a principal electrical power supply and connected to said 
hot and cold fluid motor means, to said hot and cold fluid 
temperature-sensing means and to said hot and cold fluid flow-sensing 
means, and said comparator means being adapted to process information from 
said hot and cold fluid temperature-sensing means and said hot and cold 
fluid flow-sensing means and, in response thereto, to calculate the 
temperature of the fluid at said discharge outlet and to compare said 
calculated temperature with a desired temperature and to generate control 
signals for said hot and cold fluid motor means thereby to operate said 
hot and cold fluid flow-controlling valve means as needed to regulate the 
flow of hot and cold fluid in respective said hot and cold fluid supply 
pipes to procure the desired temperature at said discharge outlet. 
In accordance with a preferred feature of this invention, the memory means 
provided in a fluid controller is advantageously adapted to store 
individual predetermined parameters concerning hot and cold fluid 
temperatures and flow values for individual users whereby, on input to 
said signal processor of an individual user identification signal, said 
signal processor is operative automatically to control said hot and cold 
fluid flow-controlling valve means to supply fluid to said discharge 
outlet in accordance with said individual predetermined parameters. 
Such a fluid controller usefully additionally comprises timer means 
operatively associated with said signal processor and adapted to control 
operation of said hot and cold fluid flow-controlling valve means in 
accordance with a predetermined timed sequence. 
Furthermore, such a fluid controller additionally comprises input means for 
inputting information to said signal processor. Such input means can also 
include modem means whereby information may be inputted to said signal 
processor by telephonic communication therewith. 
Display means operatively associated with said signal processor are 
usefully provided for displaying information therefrom. 
In accordance with another preferred feature of this invention, a fluid 
controller additionally comprises an auxiliary electrical power supply 
means operable automatically to power said signal processor and said hot 
and cold fluid motor means in the event of a failure of said principal 
electrical power supply, thereby to permit continued operation of said 
fluid controller at least for a short time after such failure. 
A fluid supply system as provided by this invention may comprise an 
existing water plumbing system with one or more manually controllable 
faucets and in which a fluid controller as previously defined has been 
incorporated. 
Alternatively, a fluid controller as provided by this invention may be 
installed as such in a new plumbing system without any separate manually 
operable hot and cold water flow control valves. 
The various features of novelty which characterize the invention are 
pointed out with more particularity in the claims annexed to and forming a 
part of this disclosure. For a better understanding of the invention, its 
operating advantages and specific objects attained by its use, reference 
should be had to the accompanying drawings and descriptive matter in which 
there are illustrated and described preferred embodiments of the invention 
.

DESCRIPTION OF SPECIFIC EMBODIMENTS 
Referring first to FIG. 1, it will be seen that this preferred embodiment 
of a fluid controller according to the invention is illustrated in 
connection with a plumbing facility, in this case, a conventional bathtub 
T, provided with a conventional manually controlled faucet valve 10. 
Faucet valve 10 is connected so as to supply either the tub supply outlet 
12 or the shower outlet or head 14. Typically, the valve 10 and the pipes 
connecting to the outlets 12 and 14, will be built into the wall. 
Typically the wall will then have been tiled, so that access to the faucet 
or the pipes supplying the two outlets is possible only at very 
considerable expense and inconvenience. 
As will become apparent from the following description, however, by the use 
of the invention, the controller can be installed and connected generally 
speaking without tampering with the wall or tub surround and with less 
disruption than would be necessary if the entire valve 10 and outlets 12 
and 14 were to be replaced. 
Typically the faucet valve 10 will have either one or two manual control 
knobs 16 for controlling the flow of hot and cold water. It will of course 
be appreciated that the hot and cold water flow becomes mixed usually 
within the valve 10 itself, depending upon the particular design, and then 
flows as a mixture to either of the outlets 12 and 14. 
By operation of one or two control knobs 16, the temperature and flow rate 
of the water mixture can be controlled in an entirely conventional manner. 
Again in a typical installation, the tub outlet 12 will normally have a 
manual diverter knob 18, by means of which flow through outlet 12 can be 
stopped, thereby causing the flow to go upwardly to shower head 14. 
As noted above, all of this is entirely conventional and is described here 
only to illustrate that a fluid controller according to the present 
invention can be incorporated in a plumbing system without in any way 
altering or tampering with the existing faucet valve and water outlets of 
the facility. 
It will of course also be appreciated that the description and illustration 
of a conventional bathroom facility is merely by way of illustration. The 
fluid controller itself may have many other applications other than in a 
conventional existing bathroom. For the purpose of this explanation, 
therefore, any reference to faucet, tub outlet, shower head or the like is 
to be understood as merely being illustrative of the application of the 
fluid controller. Such a tub outlet or shower head may in fact be any 
plumbing facility from which or through which water may flow, and at which 
it is desired to control water temperature and flow rate. Such a facility 
may include other fixtures connected to other equipment such as 
dishwashers, washing machines, and the like, and in domestic, commercial 
and institutional situations. 
Referring now in greater detail to the description of the present 
invention, it will be noted that the faucet valve 10 is supplied with hot 
water via hot water pipe 20 and with cold water via cold water pipe 22. 
The hot water source will typically be a hot water tank 24. The cold water 
source will typically be the incoming household water main, which is 
represented simply by a continuation of the pipe 22. 
Pipes 20 and 22 will typically be located inside walls or floors and, in 
most cases, access can be obtained to those pipes simply by removing a 
portion of the dry wall or other wall panelling, or by removing a floor 
board. It will be understood that such access can often be more readily 
obtained at a location somewhat remote from the bathroom thereby avoiding 
the need for disturbing the bathroom wall tiles or tub surround. In some 
cases, access may conveniently be obtained to such pipes at locations, for 
example, in basements, where such pipes are exposed so avoiding the need 
for any wall removal or the like. 
In accordance with this invention, the pipes 20 and 22 are provided with 
hot and cold water control valves 30 and 32 respectively. Valves 30 and 32 
are operated by respective electrical drive motors 34 and 36, which are 
powered and controlled in a manner yet to be described. 
Pipes 30 and 32 are further provided with hot and cold water temperature 
sensors 38 and 40. Sensors 38 and 40 are operable to continuously monitor 
the temperature of water flowing in their respective pipes and to deliver 
temperature signals in a manner described below. 
In accordance with this invention, pipes 20 and 22 are further provided 
with water flow sensors 42 and 44. Sensors 42 and 44 continuously monitor 
the rates of flow of water through the pipes 20 and 22 respectively and 
deliver flow signals in a manner to be described below. 
In order to process the information from the sensors 38, 40, 42 and 44 and 
to deliver control signals to motors 34 and 36, a signal processor 50 is 
provided. Processor 50 is connected via suitable electrical means to the 
motors 34 and 36 and to the sensors 38, 40, 42 and 44. 
The processor 50 is usefully connected to a visual display and input key 
pad unit 52 which can be installed at any appropriate location, either 
adjacent to or removed from the plumbing facility. 
Referring now to FIG. 2, the processor 50 will be seen to comprise a 
central processing unit (CPU) 54 which will typically be a 
micro-processor. The CPU 54 is supplied with power at an appropriate 
voltage by a principal power supply or converter 56, which in turn is 
typically supplied by the mains electrical supply 57. 
In accordance with a particularly useful and preferred feature of this 
invention, an auxiliary battery power supply 58 is also connected to the 
CPU 54. Auxiliary power supply 58 is normally off and is adapted to 
receive a signal from CPU 54 if and when the power supply from the 
converter 56 fails for any reason. 
CPU 54 is connected to a series of separate memories indicated as 60a, 60b, 
60c, etc., for storing information as will be explained in greater detail 
as the description herein proceeds. 
CPU 54 is further connected to watch dog timer 62, a duration timer 64, an 
invocation timer 66, and a clock timer 68. The watch dog timer 62 serves 
to monitor the operation of the system. The clock timer 68 functions 
simply to provide a signal regarding real time. The real time signal may 
also be displayed on the key pad display 52 for added convenience. 
The duration timer 64 serves to time the duration of water flow. 
The invocation timer 66 functions to provide a time signal to start water 
flow. 
Cold water flow is controlled in response to temperature sensor 40 and flow 
sensor 44 by flow valve motor 36. 
Hot water flow is similarly controlled in response to temperature sensor 38 
and flow sensor 42 by flow valve motor 34. 
In operation, the faucet valve 10 will normally be left fully open with 
both hot and cold water flow control knobs 16 also set for maximum flow. 
It will be understood that the tub shut-off or diverter 18 for the tub 
outlet 12 will normally be in the open position. This will mean that any 
water flow that takes place without the shut-off 18 being operated, will 
flow through outlet 12 into the tub. 
This is in fact desirable from the viewpoint of the operation of the 
invention. Normally, where a person is taking a shower, it will not be 
required for the shower to be switched on at a predetermined time. In most 
cases a person taking a shower will simply want the shower to operate as 
soon as he switches on the control. 
On the other hand, a person may well wish to program the system so as to 
fill a bath tub at a predetermined temperature commencing at a 
predetermined time in the future. 
The operation of the shower will make use of the fact that the tub outlet 
12 is normally open and can only be closed by manual operation of the 
shut-off 18. 
When starting up operation for the first time, a person will normally key 
in using the key pad 52 an individual identification code and values for 
the desired temperature and water flow rate. This information will then be 
stored in an appropriate one of the memories 60a, 60b or 60c. 
The user would then, through key pad 52, provide an immediate "on" signal 
to signal processor 50, which will, in turn, deliver appropriate signals 
to motors 34 and 36 to set them to appropriate positions for the desired 
temperatures and flow rates. 
Water will then flow through the pipes 20 and 22 to the faucet valve 10 and 
initially out through the tub outlet 12. The individual will then operate 
the diverter 18 causing water then to flow to the shower outlet 14. At 
this stage, the hot water may be somewhat under temperature and will only 
gradually come up to full temperature. Conversely, the cold water may be 
slightly above the normal cold water temperature and may gradually drop to 
the temperature of the incoming main. 
Differences in temperature will be sensed by sensors 38 and 40, sending 
appropriate signals to signal processor 50 which will, in turn, 
continuously signal motors 34 and 36 to adopt different positions. This 
will continuously vary the flow rate of hot or cold water, or both, as 
needed, to maintain a pre-set temperature. 
As the position of the valves 30 and 32 is altered, the relative flow 
between hot and cold water is altered and this will be sensed via flow 
sensors 42 and 44 which will in turn provide information to signal 
processor 50. 
The processor 50 includes comparator means adapted to compare the two 
temperatures and the two flow rates and, in response thereto, to calculate 
the temperature of the water at the discharge outlet and then to compare 
said calculated discharge temperature with a desired discharge 
temperature, the value of which is programmed into a predetermined one of 
the memories 60a, 60b and 60c. The processor 50 also generates control 
signals operative to continuously adjust the motors 34 and 36 so as to 
regulate the flow of hot and cold water in the hot and cold water supply 
pipes to procure the desired discharge temperature and a desired flow rate 
at the showerhead 14, or other discharge outlet. 
In the case of filling the tub with water, where, for example, it may be 
desired to cause the tub to be filled at a predetermined time, then the 
individual will also key in the appropriate time duration and start up 
time information. In this case, when the appointed time is reached, as 
sensed by clock timer 68, the time invocation control 66 will issue a 
start-up signal, and information from the appropriate memory 60a, 60b or 
60c will be supplied to the CPU 54 as to temperature and flow rate. After 
a predetermined elapsed time, duration timer 64 will then issue a shut off 
signal, causing the two valves 30 and 32 to be shut off. 
In the event that, for any reason, it is desired, such as if such fluid 
controllers are used in institutions, hotels or the like, signal processor 
50 may optionally be connected to a memory 82 for collecting information 
concerning flow rates and times. Such information may also be supplied 
directly to a central location in a hotel where information for all flow 
volumes in all rooms may be continuosly monitored and recorded, for 
billing or other purposes. 
In the event of any interruption of the main power supply, the signal 
processor 50 will instruct the auxilliary power supply 58 to supply power 
for a predetermined length of time, allowing for continued operation of 
the device, for example, for a predetermined period of time. At the same 
time, an audible warning device such as the buzzer 84 may give an audible 
warning that the water flow will shortly shut off. 
In addition, the key pad 52 can incorporate an override control whereby the 
signal processor 50 be simply rendered inoperative, leaving both valves 30 
and 32 wide open. This may be desirable if, for example, a member of the 
household wishes to use the manual faucet valve 10 without using the fluid 
controller according to the invention. 
While the invention has hereinbefore been particularly described with 
reference to its installation in an existing plumbing facility, it should 
be understood that it can also be used in a new plumbing installation. In 
such a situation, the conventional faucet valve 10 and control knobs 16 
can be dispensed with completely, if desired. In such a case, operation of 
the system would be controlled solely by means of the CPU 54 under the 
control of the key pad 52 and the other components of the processor 50 as 
already described. Additionally, if desired, the tub shut-off control 18 
in such a new installation could be replaced by a solenoid operated 
diverter valve indicated schematically at 86 under the control of the 
processor 50. In such a new installation, an additional discharge water 
temperature sensor 88 can be provided at the actual discharge outlet. 
Yet another possibility within the scope of this invention is to provide an 
auxiliary input in the form of a modem 90 whereby programming and/or 
operating signals can be fed to CPU 54 from a telephone line (not shown). 
Other remote input systems are also possible. 
The foregoing is a description of preferred embodiments of the invention 
which is given here by way of example only. The invention is not to be 
taken as limited to any of the specific features as described, but 
comprehends all such variations thereof as come within the scope of the 
appended claims.