Dual function handles for a faucet assembly

A faucet assembly is operable automatically or mechanically to facilitate control in a non-powered or motor failure condition. In the automatic control position, separate and automatic control of fluid flow and temperature is provided by respective actuation of first and second handles. In the manual control position, the first and second handles are moved axially to decouple electric motors from corresponding fluid control valves. Such axial movement of the first and second handles concurrently couples the handles mechanically to the corresponding fluid control valves to provide the desired manual actuation.

BACKGROUND OF THE INVENTION

The present invention relates to a faucet assembly with automatic controls. More specifically, this invention relates to faucet assembly that includes both automatic and manual control of fluid flow and temperature.

Faucets for tubs typically include separate knobs or handles to control the flow of hot and cold water. The separate hot and cold handles are adjusted to provide the desired flow and temperature of water. It is known to provide a faucet with an automated feature for regulating the flow and temperature of water without constant adjustment by a user. In this way temperature fluctuations are compensated for automatically without additional input from a user.

These automated faucets typically utilize electric motors to drive valves that adjust water flow and temperature. During power outages or motor failures, the automated controls for these faucets do not operate.

Accordingly, it is desirable to design and develop an automated fluid delivery device that provides both automatic control and mechanical control of fluid flow and temperature.

SUMMARY OF THE INVENTION

An illustrative faucet assembly is operable both automatically and mechanically to facilitate control in a non-powered or motor failure condition.

The illustrative faucet assembly includes a spout, a first handle and a second handle. The first handle controls a first power module, and the second handle controls a second power module. The first power module includes a first fluid control valve and the second power module includes a second fluid control valve.

In an automatic control position, separate and automatic control of fluid flow and temperature is provided by actuation of the first and second handles. In the illustrative faucet assembly, the first handle provides the input utilized to set a desired fluid flow rate and the second handle provides the input utilized to set a desired fluid temperature. Operation of the first handle to control fluid flow provides an input that results in actuation of electric motors in each of the power modules. Similarly, operation of the second handle to control fluid temperature provides an input that results in selective operation of electric motors in each power module to supply a mixture of hot and cold water that provides the desired temperature of fluid output from the spout.

In a manual control position, the first and second handles are pulled outwardly or upwardly to decouple the electric motors from the respective fluid control valves. A stem gear is then coupled to operate the fluid control valve of each power module to provide manual actuation and adjustment.

Accordingly, in the absence of electrical power or in the event of motor failure, the illustrative electrically controlled faucet remains operable to provide the desired temperature and flow of water.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Referring toFIG. 1, an illustrative faucet assembly10includes a spout12, a first control member, illustratively a knob or handle14, and a second control member, illustratively a knob or handle16. The first handle14controls a first power, or control module18, and the second handle16controls a second power, or control module20. The first power module18includes a first fluid control valve24and the second power module20includes a second fluid control valve26. The first fluid control valve24controls water flow from a hot water inlet28to an outlet34. The second fluid control valve26controls water flow from a cold water inlet30to an outlet36. It should be appreciated that the hot water inlet28and the cold water inlet30may be reversed based on installation and controller programming.

The outlets34and36feed water to a mixing module22. The mixing module22includes a mixing valve32that provides for substantially uniform mixing of hot and cold fluids. The mixing valve32may be similar in functionality to the mixer detailed in U.S. patent application Ser. No. 11/109,283, filed Apr. 19, 2005, which is expressly incorporated by reference herein. A temperature sensor35is illustratively disposed within the mixing module22to obtain information indicative of fluid temperature passing therethrough to the spout12. The mixing module22further illustratively includes a flow triggered diverter valve40, and a solenoid valve42that operates to direct water through an outlet hose38to a hand shower or sprayer device (not shown).

The illustrative faucet assembly10is mounted on a deck46and includes a controller44which may be housed within a cover or escutcheon48. It should be appreciated that the controller44may be positioned at other locations, including below the deck46. Each handle14,16is supported above the deck46by a respective handle support50. Mounting frames60extend downwardly from the deck46and support the power modules18and20. An adjustable clamp59is supported for movement along a threaded post61for coupling each mounting frame60to the deck46. Since the clamp59is adjustable, the mounting frame60may be coupled to decks46having varying thicknesses.

The controller44is programmed to provide instructions to each of the power modules18,20for controlling fluid flow rate and temperature, and to the solenoid valve42for controlling or directing flow between the spout12and the outlet hose38of the hand sprayer device. More particularly, in the automatic control position, the controller44receives inputs from rotation of the handles14and16to establish set fluid flow rate and temperature, respectively.

The controller44also illustratively receives input from temperature sensor35indicative of the outlet or mixed water temperature, thereby providing control feedback for maintaining the set fluid temperature through control of power modules18,20. The temperature sensor35may also be utilized to provide for scald protection, wherein the first fluid control valve24, and in certain embodiments also the second fluid control valve26, are closed by respective motors66(FIG. 2) when a predetermined temperature is exceeded. A flow sensor (not shown) may also be in communication with the controller44for providing control feedback for maintaining the set fluid flow rate. The power modules18and20are selectively operable in an automatic (or electric) control mode or position, and a manual control mode or position. The illustrative first power module18and the second power module20operate in a similar manner.

Operation of the faucet assembly10in the automatic control position provides for separate and automatic control of fluid flow and temperature. The first handle14provides the input to the controller44utilized to set a desired fluid flow rate. The second handle16provides the input to the controller44utilized to set a desired fluid temperature. It should be appreciated that the first handle14and the second handle16could be reversed, such that the first handle14is utilized to control fluid temperature and the second handle16is utilized to control fluid flow rate. The controller44receives inputs from both the first and second handles14and16and translates those inputs into the appropriate actuation of electric motors66and respective valves24and26(FIGS. 2-4) within each of the power modules18and20. Operation of the first handle14to control fluid flow thereby provides an input to the controller44that results in actuation of the electric motors66in each of the power modules18and20, such that the set or desired flow rate is achieved. Similarly, operation of the second handle16to control fluid temperature provides the input to the controller44that results in selective operation of electric motors66in each power module18and20to supply a mixture of hot and cold water that provides the set or desired temperature of fluid output from the spout12.

Referring toFIGS. 2-4, the operation and features of the illustrative first and second power modules18and20are described with reference to the second power module20. As noted above, the second power module20is substantially identical to the first power module18. The illustrative second power module20includes the second handle16attached to rotate a stem62about an axis25. The stem62extends within front and rear housing portions27A and27B, and is supported for rotational movement within a drive coupling support member58. The stem62supports a stem gear64which is rotatable about the axis25and is also movable axially with the stem62to selectively engage a first valve gear54. More particularly, the stem gear64is engageable with the valve gear54, which is operably coupled to a valve shaft49of the second fluid valve26, when the stem62is moved axially upward or outward (in the direction of arrow77) to the illustrated manual operation position78ofFIG. 3. A valve coupler51receives an upper end53of the valve shaft49, wherein the upper end53of the valve shaft49has a flat defining a “D” cross-section to prevent relative rotation between the valve shaft49and the valve coupler51. A connecting shaft52is coupled to the valve coupler51and the valve gear54through a pin55.

The connecting shaft52is operably coupled to a drive shaft coupler or second valve gear56that is engageable with a motor shaft68of the electric motor66. The coupling support member58mounted to the stem62rotatably supports the drive shaft coupler56. The coupling support member58moves with axial movement of the stem62to selectively engage the drive shaft coupler56with the motor shaft68such that the motor66can drive the fluid control valve26(FIG. 4). The stem gear64(in the manual operation position) and the motor shaft68(in the automatic operation position) are alternatively engageable (i.e., manually coupled or electrically coupled) to drive the valve shaft49and provide control over actuation of the fluid control valve26. An end of travel switch57is configured to provide a signal to the controller44when the valve26reaches a point of maximum rotation. Illustratively, the switch57comprises a snap switch configured to trigger off of grooves63formed in the outer surface of the valve coupler51.

The stem62is held in the manual operation position78(illustratively, axial displacement of approximately 0.5 inches) by a detent assembly72. The detent assembly72holds the stem62in the manual operation position78against the biasing force provided by a return spring70. In the manual operation position, the stem gear64is coupled to the valve gear54, and the motor shaft68is decoupled from the drive shaft coupler56. More particularly, a drive member82is coupled to the motor shaft68. The drive member82illustratively includes an engagement or hex portion83having a hexagonal cross-section, which is free to rotate within an inner chamber84of the drive shaft coupler56. Rotation of the handle16and stem gear64is transmitted to rotation of the first valve gear54that, in turn, rotates the valve coupler51and the valve shaft49to control fluid flow. The control of fluid flow in the manual operation position78provides for the manual control of fluid flow and temperature by controlling the flow of fluid from the inlet30to the outlet36.

When in the manual operation position78, a magnetic encoder or switch74is disengaged such that the controller44does not operate the motors66of respective first or second power modules18or20. More particularly, the magnetic encoder74, illustratively including a plurality of Hall-effect sensors75(FIG. 2), are configured to detect a magnet81supported by the stem gear64only when the stem62is in the automatic operation position.

Referring toFIG. 4, the second power module20is shown in the automatic operation position76. The handle16and the stem62are moved axially downward or inward (in the direction or arrow79) such that in the automatic operation position76, the stem gear64is disengaged from the first valve gear54. The downward movement and position of the stem62includes a corresponding movement of the stem gear64such that the magnet81actuates the magnetic encoder74. Actuation of the magnetic encoder74signals the controller44that the power module20is in the automatic operation position76.

Downward axial movement of the stem62disengages the stem gear64from the valve gear54, and concurrently moves the coupling support member58and the drive shaft coupler56into an engaged position. More particularly, the drive or hex portion83of the drive member82operably couples with a cooperating hex portion or lip85of the drive shaft coupler56. The illustrative connecting shaft52and drive shaft coupler56include cooperating engagement portions86and87, respectively, that provide for transmission of motor shaft rotation to the valve shaft52while at the same time providing for axial sliding movement of the drive shaft coupler56between coupled and decoupled positions. The engagement portions86and87may comprise of cooperating hex portions or splines.

An alignment pin88may extend between the connecting shaft52and the drive member82to facilitate axial alignment therebetween but without transmitting rotational movement. The return spring70provides a downward bias on the coupling support member58such that if the drive portion83of the drive member82and the lip85of the drive shaft coupler56are not aligned, initial rotation of the electric motor66relative to the drive shaft coupler56will operate to engage once in a proper position. Further, the return spring70maintains the stem62and the handle16in the automatic position78until the detent assembly72is engaged.

The magnetic encoder74mounted relative to the stem62generates a signal indicative of rotation of the stem62that is provided to the controller44. More particularly, the encoder74provides an indication of the relative angular positions of the poles of the magnet81supported by the stem gear64. While a single ring magnet81is illustrated inFIG. 2, it should be appreciated that multiple angularly spaced magnets could be substituted therefor. Detected rotation of the stem62is thereby translated into a corresponding rotation of the electric motors66within each of the power modules18and20. The rotation of the electric motors66responsive to rotation of the stem62provides for actuation of the fluid control valves24and26to provide the desired fluid flow output necessary to accomplish the desired fluid flow and temperature from the spout12.

In the absence of electric power to the faucet assembly10, or in the event of motor failure, operation can be changed from automatic to manual. The first and second knobs14and16would be pulled axially upwardly, or away from the deck46, to engage the corresponding detent assemblies72. With the axial upward movement, the electric motor66is decoupled from the valve shaft52by disengaging the hex portion83of the drive member82from the drive shaft coupler56. Further, the magnetic encoder or switch74is disengaged to signal manual operation to the controller66that, in turn, discontinues operation of the motors66. The disengaged magnetic encoder or switch74provides for manual operation even with available electric power, if desired. The stem gear64is then coupled to the valve gear54and provides for manual actuation and adjustment of the first and second valves24and26(FIG. 1). Operation is thereby provided without power to the faucet assembly10or activation of the motors66.

Referring toFIGS. 5-7, another example faucet assembly90includes selection levers92and94disposed at a base of a first knob or handle96and a second knob or handle98, respectively. Movement of the selection levers92and94moves the handle stem62axially between the automatic and mechanical positions76and78(FIGS. 3 and 4). Movement of the levers92and94provides for indication of an operating mode within first and second displays100A and102A supported by handle supports104. The first and second displays100A and102A are shown in a manual operating position where the first and second handles96and98(FIG. 5) control hot and cold water flow (FIGS. 6 and 7). Selection of an automatic operating position would change the displays to indicate that the first handle96controls flow100B, and that the second handle98controls temperature102B. The first and second knobs96and98may illustratively be illuminated by way of a power source separate from the main power supply. In the illustrative faucet assembly90, the displays100A and102A are illuminated in response to a power failure, thereby illuminating faucet knobs96and98to aid in the use and selection of the manual operation mode.

Referring toFIG. 8, another illustrative faucet assembly108includes a handle stem110that extends from a handle112. A bevel gear120is mounted at the end of the handle stem110. In manual mode, a manual gear122is moved axially to engage the bevel gear120. The manual gear120includes a collar128that includes splines to transfer rotational movement to the valve shaft124while still providing for axial movement of the manual gear120. Axial movement of the collar128causes a decoupling of the collar128with the motor shaft116. The motor shaft includes corresponding splines that engage the splines of the collar128. An alignment pin118may be provided between the motor shaft116and the valve shaft124to facilitate alignment therebetween.

An automatic mode is provided by moving the manual gear122out of engagement with the bevel gear120. The axial movement of the manual gear122causes the collar128to span a gap between the motor shaft116and the valve shaft122. This coupling of the motor shaft116to the valve shaft124provides for the transmission of rotational movement of the motor114to the valve126. The collar128can only couple the motor shaft116with the valve shaft124when the manual gear120is spaced apart from the bevel gear120.

Rotation of the handle stem110is sensed by magnetic encoders130to provide the desired input utilized to control the electric motor114, and thereby the valve126.