Multi-Mode Rotor Sprinkler Apparatus And Method

A multi-mode sprinkler adjustable for part or full circle operation to irrigate a selected area is provided. The sprinkler includes a nozzle for dispensing fluid, a set of gears for rotating the nozzle and an arc setting mechanism that cooperates with the set of gears. The arc setting mechanism comprises a fixed trip for switching to a first direction for the nozzle and an adjustable trip movable relative to the fixed trip for setting an arc of rotation for the nozzle in the part circle mode. The arc setting mechanism also includes a toggle for engaging the fixed trip and the adjustable to switch between a first direction and a second direction when in the part circle mode. In the full circle mode, the adjustable trip overlaps at least in part the fixed trip, such that the fixed trip deflects the toggle radially inward, allowing continuous rotation of the nozzle.

TECHNICAL FIELD

The technical field relates to irrigation sprinklers and, more specifically, to apparatuses and methods for providing a multi-mode rotor-type sprinkler.

BACKGROUND

Sprinklers are commonly used for irrigating personal and commercial lawns, golf courses, and athletic and agricultural fields. Pop-up irrigation sprinklers are well known in the art, particularly for use in irrigation systems wherein it is necessary or desirable to embed the sprinkler in the ground so that it does not project appreciably above ground level when not in use. In a typical pop-up sprinkler, a tubular riser is mounted within a generally cylindrical upright sprinkler housing or case having an open upper end, with a spray head carrying one or more spray nozzles mounted at an upper end of the riser.

One type of pop-up sprinkler is a sprinkler having a rotary driven spray head mounted at the upper end of a pop-up riser, otherwise known as a rotor sprinkler. Rotor sprinklers generally include a rotating turret that sits on top of the riser. The turret includes at least one nozzle that discharges water from the rotating turret.

Rotor sprinklers commonly include in two forms. One form is a rotor sprinkler where the turret rotates through a full circle or 360-degree arc of rotation. The other form is where the turret reciprocates back and forth in a part circle (e.g., 90 degrees). Part circle type rotor sprinklers typically have a reversing mechanism that allows for setting the watering pattern to a desired angle range.

One concern in landscape irrigation is minimizing water waste and loss. Many communities regulate the use of water for irrigation, and these regulations may limit the amount of water usage, among other restrictions. Part circle rotor sprinklers may be useful in providing watering of a limited area in view of the above concerns. In conventional models, part circle rotor sprinklers operate so that a direction of the water stream from the nozzle oscillates between end limits, avoiding watering of areas that do not need watering, such as sidewalks, driveways, parking lots and the like. On the other hand, while full circle rotor sprinklers may improve water distribution by providing a larger area of irrigation, some full circle rotor sprinklers are not true full circle rotor sprinklers. Instead, they traverse through almost 360 degrees reversing once for every passing. The point where the rotor sprinkler reverses over waters this area radially outward from the sprinkler. In addition, many irrigation terrains require a mixture of the two rotor types, part circle and full circle. This requires two products to be made available, two products to be inventoried, and two products to be installed where incorrect installation could occur. Thus, there is a desire for a single rotor sprinkler that can operate in part circle mode and true full circle mode.

DETAILED DESCRIPTION

As shown generally inFIGS. 1-5, an exemplary pop-up rotor sprinkler100having an improved arc setting mechanism10is illustrated. The sprinkler100enables adjustment between a part circle mode and a true full circle mode. The part circle mode allows one to set arc ranges to water an area less than a full circle. The true full circle mode enables full circle watering in one continuous direction (i.e., without reversing at any point).

The rotor sprinkler100generally comprises a case or housing8having an inlet3for receiving fluid; a riser2including a plurality of components for managing fluid pressure and facilitating a desired spray mode; and a nozzle12(e.g., grid main nozzle) coupled to and disposed within a turret4for discharging pressurized fluid. The turret4is coupled to the riser2at a distal end away from the housing8. The riser2extends from the housing8when water is turned on and retracts in the housing8using a retraction spring16when the water is turned off. Additional examples of rotor sprinklers may be found in U.S. Pat. Nos. 4,787,558; 5,383,600; and 6,732,950, which are incorporated herein by reference in their entirety.

The housing8generally has an elongated cylindrical configuration formed typically from a lightweight injection molded plastic. The inlet3may be formed at one end of the housing8and receives pressurized fluid for irrigation. An opposite end8A of the housing8may be configured (e.g., threaded) to accommodate mounting of a cover6. The riser2is generally configured as an elongated hollow tube having a size and shape configured for slide-fit through the cover and reception into the interior of the housing8. The riser2may also be constructed from a lightweight injection molded plastic.

A retraction spring16sits between the inside of a cover6of the housing8and a ratchet ring9at a bottom of the riser2. The ratchet ring9sits above a bottom of a riser flange7, and the retraction spring16sits into the ratchet ring9. The ratchet ring9engages ribs11within the housing8and allows the riser2to slide and/or rotate if the torque exceeds the friction between the riser flange7and the ratchet ring9. In operation, the water pressure overrides the bias of the spring16, compresses the spring16, and extends the riser2for irrigation. When the water is turned off, the spring16expands and urgers the riser2into a retracted position into the interior of the housing8. Further, when the riser2is in a retracted position, a riser cap18at an outboard end of the turret4is substantially seated at least flush with the cover6.

As water passes through the sprinkler100, it also passes through a turbine regulator module14, for effective water use by the sprinkler100. The turbine regulator module14may also include a filter15for eliminating debris. A gear reduction mechanism20is disposed in the riser2downstream of the turbine regulator module14and drives rotation of the turret4for discharging fluid through the nozzle12. The arc setting mechanism10is disposed within the riser2downstream of the gear reduction mechanism20and may be set to enable the part circle mode and the true full circle mode.

As shown inFIGS. 6A and 6B, the arc setting mechanism10includes a gear rack60, a trip lever70operatively coupled to a trip plate50, a trip hood80, a ring gear90, and a trip mount52with two fixed stops52A (right stop),52B (left stop) that limit the movement of the trip lever70to a predetermined arcuate range. The components of the arc setting mechanism10work in cooperation with the gear reduction mechanism20to rotate the turret4to dispense water through the nozzle12for irrigation over a selected target terrain area. Operation of the part circle mode and true full circle mode are described in further detail below with respect toFIGS. 10A-12C.

The gear rack60includes a plurality of gears including: a first drive gear62, an input gear64, an idler gear66and a second drive gear68. The gear rack60is operatively coupled to the arc setting mechanism10to determine the direction of rotation for the turret4. For example, in a part circle mode, the gear rack60pivots back and forth between clockwise rotation of the turret4(when drive gear68is engaged) and counterclockwise rotation of the turret (when drive gear62is engaged). The input gear64directly drives drive gear62and indirectly drives drive gear68through the idler gear66. The input gear64is driven by a drive shaft or shaft13that is driven be the gear reduction mechanism20. (SeeFIGS. 6A and 6B.)

With reference toFIGS. 7A-7C, the trip lever70generally includes a ring71, an arcuate member72and a toggle74. The materials of the components of the trip lever70are designed to cooperate with the mode of operation of the rotor sprinkler100. For example, the arcuate member72may include a coring73that allows radially inward flexibility. This inward flexibility enables the toggle74to move inward and allow tabs or trips82and92to pass by in full circle mode. In some embodiments, the toggle74may be also formed from a thermoplastic material. The arcuate member72may be formed with a stiffer response in a tangential direction. For instance, material at the connection of the arcuate member72to the ring71may be increased relative to that of the acuate member72itself. Further, a web85may extend between the arcuate member72and the ring71. The arcuate member72may be formed with relatively less material to provide reduced stiffness in a radial direction, which facilitates inward radial movement of the toggle74and the arcuate member72to enable the full circle mode.

The ring71, the arcuate member72and the toggle74may be formed of a single piece. An arcuate gap or coring73may be defined between the ring71and the arcuate member72. The trip lever70may also include a boss78that may be configured to aide alignment of the ring71relative to a rack idler40. A second idler gear63, as shown inFIG. 6AandFIG. 16, moves along and between the rack idler40and teeth76defined on an outer surface of the ring71as the toggle74toggles between the stops52A,52B.

As illustrated inFIG. 14, an attachment arm77extends radially from the trip lever70. Trip springs42are operatively connected to the trip lever70and the trip mount52to facilitate back and forth rotation of the trip lever70. The attachment arm77defines a stepped notch44defined for attaching one end of the trip spring42in a secure fashion. The stepped notch44prevents the trip spring42from dislodging in the event of air slam or other impact to the sprinkler100. (Note, whileFIG. 16illustrates the placement of the trip springs42, both the trip lever70and the trip mount52have been removed fromFIG. 16for illustration purposes only.)

Embodiments of the toggle74may have a plurality of profile configurations. One example of a toggle is a double columnar profile, as illustrated inFIGS. 7A-7B, 12A-12C. Another example is a stepped profile, as illustrated inFIGS. 6A, 7C, 10A, 10B. The stepped profile of the toggle74has a first wall41a(i.e., upper portion) and a second wall41b(i.e., lower portion). The walls41a,41bextend to different radiuses from the center of the ring71. The second wall41bextends further than the first wall41aso that the second wall41bcan engage the stops52A,52B that limit movement of the ring51when it toggles between different directions of rotation in part circle mode. The first wall41adoes not extend out as far because it is deflected inward by the fixed trip in the full circle mode. This smaller radial extension reduces the amount of inward deflection of the toggle74in the full circle mode. It also ensures that the friction between the fixed trip92over the toggle74in the full circle mode is low enough that it does not trip the trip lever70to change the rotational direction of the sprinkler100.

Both profile configurations of the toggle74may define a notch75. The notch75improves flexibility of the toggle74for inward movement of the toggle74when it engages an angled cam surface95of the fixed trip92in full circle mode. A deflected state of the toggle74is illustrated inFIG. 7B. An undeflected state of the trip lever70is illustrated inFIGS. 7A and 7C. The gap73defined between the arcuate member72and the ring71is smaller in size as the toggle74passes the fixed trip92in the full circle mode. More specifically, the gap73has a first size when the toggle74is spaced from the fixed trip92and a second size when the toggle74is deflected inward by the fixed trip92, the first size being larger than the second size. Additional features of the full circle mode will be described in further detail with respect toFIGS. 12A-12C.

The alignment and positioning of the adjustable trip82relative to the fixed trip92determines the mode of operation of the rotor sprinkler100. When the trips82,92are at least partially overlapped, the sprinkler100is in full circle mode. When the trips82,92are spaced from one another, the sprinkler100is in part circle mode.

Referring toFIGS. 8A and 8B, the trip hood80of the arc setting mechanism10includes the adjustable trip82. The trip hood80and the adjustable trip82may be a single piece. The adjustable trip82includes a right side82A and a left side82B.

With reference toFIG. 9, the ring gear90includes the fixed trip92. The fixed trip92includes a left side94and a right side96. The left side94includes an angled cam surface95that is angled inward. In full circle mode, the adjustable trip82is overlaid at least partially on the fixed trip92, and the angled cam surface95deflects inward the toggle74extending from the arcuate member72. As a result, the aligned trips82,92pass over the toggle74. That is, the toggle74does not engage the trips82,92in a manner that would cause switching the direction of the arc setting mechanism10. Thus, there is continuous rotation of the trips82,92and the turret4in a single direction.

As shown inFIG. 15, there is an arc adjustment stem or stem83that is accessible through the cover18of the turret4to adjust the adjustable trip82relative to the fixed trip92to set the arc pattern in part circle mode. The stem83extends upstream in the turret4and operatively couples to an adjustment ring81. The stem83has an outboard end83aconfigured to be manually turned by a tool, such as a screwdriver, and the inboard end83bincludes teeth79that mesh with inner teeth89on the adjustment ring81. When the stem83is turned, it rotates the adjustment ring81. The adjustment ring81is operatively coupled to the trip hood80so that the trip hood80rotates with the adjustment ring81. In this case, the adjustment ring81is keyed to the trip hood80through notches102on the adjustment ring81that receive projections104extending from the trip hood80.

FIGS. 10A-11illustrate a minimum part circle mode setting for the adjustable trip82and the fixed trip92. The trips82and92are set close to each side of the toggle74and rotate in the same direction until one of them engages the toggle74and moves the toggle74from one of the stops52A,52B to the other of stops52A,52B. Once the toggle is moved, the trips82,92rotate in the other direction until one of them engages the toggle74and moves the toggle to the other stop52A,52B.

More specifically, with reference toFIGS. 10A and 10B, the left side82B of the adjustable trip82on the trip hood80is illustrated as it is about to contact the right side74A of the toggle74on the trip lever70, when rotating in the clockwise direction. This contact will initiate moving the toggle74from one stop52A to the other stop52B. Once the toggle74contacts the other stop52B, counterclockwise rotation will begin. The fixed trip92will soon contact the left side74B of the toggle74and initiate moving the toggle74back to stop52A. Once the trip lever70contacts the stop52A, clockwise rotation will start. Thus, in this configuration, the arc of coverage matches the arcuate distance between the stops52A,52B. The trip spring42maintains the toggle74at one of the stops52A,52B until contacted to move to the other of the stops52A,52B.

FIG. 11illustrates a maximum arc of coverage. In this configuration, the adjustable trip82and the fixed trip92are close to one another but to one side of the toggle74. During clockwise rotation, the left side82B of the adjustable tab82engages the right side74A of the toggle74. This contact initiates the toggle74to move from stop52A to stop52B. Once the toggle74engages stop52B, counterclockwise rotation will begin. In a counterclockwise rotation, the fixed tab surface96ultimately engages a left side74B of the toggle74. When that contact occurs, the toggle74will move from stop52B back to stop52A, and the rotation will be reversed back to clockwise. This switching back and forth in rotation continues until the watering cycle is complete.

With reference toFIGS. 12A-12C and 13A-13B, the user engages the full circle mode of the rotor sprinkler100by using the stem83to move the adjustable trip82on the trip hood80so that it at least partially overlaps with the fixed trip92on the ring gear90. The preferred overlap configuration has the adjustable trip82substantially overlapped with the fixed trip92. To achieve this overlap, one turns the stem83counterclockwise until this movement is stopped by engagement of the right side82A of the adjustable trip82with the fixed trip92on the ring gear90. Thus, the rotor sprinkler100uses the same arc adjustment stem83to operate the part circle mode and to set the rotor sprinkler100to full circle mode.

In this position, the trips82,92pass by the toggle74in the clockwise direction because the angled cam surface95engages and deflects the toggle74inward. This inward deflection of the toggle74occurs once during each revolution of the trips82,92. If the sprinkler100is set to counterclockwise rotation when the user activates the full circle mode, the trips82,92will move into contact with the left side74B of the toggle74, which causes it to move from stop52B to stop52A. This will switch the direction of the rotor sprinkler100to clockwise rotation. The rotor sprinkler100will then remain in clockwise rotation until a user switches it to part circle mode.

The above embodiments provide several benefits, advantages, and improvements over existing sprinkler technologies. For example, the full circle mode of these embodiments provides a true full circle mode. That is, the sprinkler provides continuous full circle motion in one direction, as opposed to reversing. This provides improved water distribution, allowing every portion of an irrigated terrain area to receive a uniform water distribution, rather than permitting additional watering at the edges of the arc in full circle reversing rotors.

Further combining the part-circle and true full circle functionality in a single sprinkler eliminates the need for separate rotors to achieve both these functionalities. This helps optimize distribution, stocking, ease of installation and service. It also minimizes line change overs during manufacturing.

Further, the switch from one mode to the other may be made manually by an installer or end user, who may be able to adjust a mode of one or more of a plurality of sprinklers within an irrigation system. In some embodiments, adjustment of the arc setting mechanism may be made by engaging the appropriate components through a cap of the riser, without opening up, taking out, or exchanging components within the rotor sprinkler.

It will be understood that various changes in the details, materials, and arrangements of parts and components which have been described and illustrated above to explain the nature of the sprinkler may be made by those skilled in the art within the principle and scope of the sprinkler as expressed in the following claims. Furthermore, while various features have been described with regard to a particular embodiment or a particular approach, the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. Further, while embodiments have been shown and described, it will be apparent to those skilled in the art that modifications may be made to them without departing from the broader aspects of the technological contribution. The actual scope of the protection sought is defined in the following claims.