Wireless position sensor assembly for a rotating actuator

A device for wirelessly transmitting a rotation position of an actuator. The device comprises first and second housings. The housing configured for securing to a body of the actuator. An adaptive sleeve may be used for coupling the second housing to a stem of the actuator. The device includes a sensor and a sensor trigger that are mounted in different ones of the first and second housings. The sensor generates a sensor output signal based on a proximity of the sensor to the sensor trigger. The sensor and sensor trigger are mounted such that relative motion between the first and second housings produces a change in the sensor output signal. A radio transmitter transmits the rotational position of the actuator stem based on the sensor output signal.

TECHNICAL FIELD

The present disclosure relates generally to position sensors, and, more particularly, to wireless position sensors that attach to rotating actuators, such as switches or valves, for retrofitting existing rotating actuators.

BACKGROUND INFORMATION

Many appliances and other devices have manually operated actuators, such as switches and valves, used to control or otherwise operate the appliance. For instance, an actuator on a stove or range controls heating elements. Many stoves have wired actuator position sensors connected to a light that indicates whether a heating element of the stove is on or off. Accordingly, the operational state of the actuator or valve is usually readily apparent to a user observing the light.

DETAILED DESCRIPTION OF EMBODIMENTS

Before beginning a detailed description of the embodiments, mention of the following is in order. When appropriate, like reference materials and characters are used to designate identical, corresponding, or similar components in different figures. The figures associated with this disclosure typically are not drawn with dimensional accuracy to scale, i.e., such drawings have been drafted with a focus on clarity of viewing and understanding rather than dimensional accuracy.

Use of directional terms such as “upper,” “lower,” “above,” “below”, “in front of,” “behind,” etc. are intended to describe the positions or orientations of various components relative to one another as shown in the various figures and are not intended to impose limitations on any position or orientation of any embodiment relative to any reference point external to the reference.

It will, of course, be understood that modifications of the embodiments, in various aspects, will be apparent to skilled persons, some being apparent only after study, others being matters of routine mechanical, chemical and electronic design. No single feature, function or property of the exemplary embodiment(s) is essential. Other embodiments are possible, their specific designs depending upon the particular application. Skilled persons will recognize that numerous modifications and changes may be made to the embodiment(s) without departing from the scope of the claimed invention. As such, the scope of the invention should not be limited by the particular embodiments herein described but should be defined only by the appended claims and equivalents thereof.

Overview

It is often useful to know the operational state of an actuator when there is no one present to observe it. A wireless actuator position indicator allows remote indication of the rotational position of an actuator to a user or a control system remote from the appliance. The rotational position of a stem of the actuator is an amount of angular displacement of the stem about its longitudinal axis, relative to a body of the actuator. The rotational position of the actuator stem controls the operational state of the actuator; thus the operational state of the actuator can be inferred from the rotational position of the actuator stem. Accordingly, the disclosed techniques provide—and may be used to quickly and easily retrofit—an actuator (e.g., on an appliance or other device) with a wireless position sensor that can be readily installed by a typical homeowner lacking specialized knowledge or tools.

Various embodiments of a wireless actuator position sensor assembly are described herein, each configured to wirelessly transmit information regarding the rotational position of a stem of an actuator to a remote station, such as a home computer, a home security system or a mobile phone. The various embodiments of the wireless actuator position sensor assembly may be used either as an Original Equipment Manufacturer (OEM) actuator knob or as a replacement for an OEM actuator knob or handle. The various embodiments of the wireless actuator position sensor assembly may be used, with the appropriate changes made, with any type of actuator having a stem that is rotated, including without limitation, valves and switches, on any type of device or appliance, including without limitation, stoves, ranges, BBQ grills, and washing machines.

The following description includes eight subsections, each of which corresponds to an illustrated embodiment. In general, however, each embodiment includes a rotatable assembly and a stationary component. More specifically, a rotatable assembly refers to a graspable adjustment mechanism such as a knob body, any optional (adaptive and trigger) sleeve devices, and any other optional components that mount to or are otherwise rotatable with an actuator stem of an actuator, whereas a stationary component refers to a faceplate, cover, or housing deployed in fixed relation to a body of the actuator.

First Embodiment

FIGS. 1A, 1B and 1Cshow a first embodiment of a wireless actuator position sensor assembly100. The first embodiment wireless actuator position sensor assembly100is configured for coupling to an actuator with an actuator body122and an actuator stem124. In the first embodiment, the actuator is coupled to an appliance surface126with the actuator body122below the appliance surface126and with the actuator stem124protruding above the appliance surface126. Other embodiments of the wireless actuator position sensor assembly may be configured for use, with the appropriate changes made, for actuators with stems that do not protrude above the appliance surface, or for actuators that are mounted above a surface or elsewhere on an appliance or device. The first embodiment wireless actuator position sensor assembly100comprises a first housing108, a second housing102, electronic circuitry110(including a sensor114), a sensor trigger116, and an adaptive sleeve118.

The first housing108house the sensor trigger116. In the first embodiment, the first housing108has a shape of a thin annular cylinder, with the sides tapering inward toward a top of the first housing108, but in other embodiments may have another suitable shape, such as a thin annular box. The sensor trigger116is positioned on or within the first housing108and coupled thereto such that when the first housing108is coupled, directly or indirectly, to the actuator body122, the sensor trigger116is fixed laterally and rotationally relative to the actuator body122. In the first embodiment, the sensor trigger116is a magnet, but in other embodiments it may be some other type of sensor trigger such as a Radio Frequency Identification (RFID) tag, a radiation source or a light source. In order to correctly indicate the rotational position of the actuator stem124, the first housing108is configured for coupling to the actuator body122in a manner so that it is in a fixed relation with the actuator body122and cannot move laterally or rotationally relative to the actuator body122. In the first embodiment100, the first housing108is configured for coupling to the actuator body122indirectly, by coupling to the appliance surface126, which in turn is coupled to the actuator body122, typically with an adhesive, or by suction, welding or mechanical fastener such as screws. The first housing108has a first housing cavity (an opening)109configured for accepting insertion of the actuator stem124and the adaptive sleeve118over the actuator stem124. In other embodiments, the first housing cavity109may be configured with a size and shape only large enough for an actuator stem to be inserted, the actuator stem inserting into an adaptive sleeve that does not insert into the first housing cavity109. In the first embodiment, the first housing cavity109is located in the exact center of the first housing108, but in other embodiments may be located off-center. The first housing108is typically made of injection molded plastic, but in some embodiments may be made by other suitable methods with other suitable materials.

The second housing102is typically shaped like a knob, typically similar to the OEM knob which it replaces. In some embodiments the second housing102may have an extending handle to increase leverage. The second housing102comprises a housing top104, and a housing base106. The housing base106has a base cavity130into which the electronic circuitry110is positioned. In the first embodiment, the housing base106and the housing top104are configured for detachably coupling with a mechanical locking mechanism. In other embodiments the housing base106and housing top104are configured for coupling in other ways, such as mechanical fasteners (e.g. screws), clips or adhesive. The housing base106has a base stem128protruding from the bottom of the housing base106with a base stem cavity132therein. The base stem cavity132has a bottom that is open and a top that is closed. The base stem cavity132is configured for the adaptive sleeve118to be inserted therein, so that when the adaptive sleeve118is inserted and the second housing102is rotated, the adaptive sleeve118rotates as well. In the first embodiment, the base stem cavity132has a shape and size similar to that of the adaptive sleeve118. The adaptive sleeve118inserts into the base stem cavity132with a sliding fit or a location fit, but in other embodiments may have a looser or tighter fit. A looser fit will allow some play between the adaptive sleeve118and the second housing102, which may not be desirable. A tighter fit may also be undesirable as it may interfere with height adjustment of the second housing102. In the first embodiment, the base stem cavity132and the exterior of the adaptive sleeve118have hexagonal cross-sections, but may have different cross-sectional shapes in other embodiments. The base stem128is configured for insertion into the first housing cavity109with a fit at least as loose as a sliding fit, permitting the base stem128to rotate freely within the first housing cavity109, though more typically, there is actual clearance between the base stem128and the first housing cavity109. The housing top104and the housing base106are typically made of injection molded plastic, but in some embodiments may be made by other suitable methods with other suitable materials.

The electronic circuitry110includes a battery112, the sensor114and other circuitry such as a radio frequency (RF) transmitter. In the first embodiment, the electronic circuitry110is attached to a circuit board111. In other embodiments, the electronic circuitry110is not attached to a circuit board, but is mounted in some other way, such as directly attaching to the housing base106. In other embodiments, the electronic circuitry110may have a different power source than a battery and the power source may be located off the circuit board111elsewhere in the second housing102. For example, the first embodiment wireless actuator position sensor assembly100may have conductive or inductive contacts leading to an external power source. The circuit board111in the first embodiment comprises rigid materials, but in other embodiments may comprise flexible materials. The sensor114in the first embodiment is a magnetic-field detector, but in other embodiments may be some other type of sensor such as an RFID transmitter, a radiation detector, or a photo detector. The sensor114is configured for generating a signal based on the proximity of the sensor trigger116to the sensor114. The RF transmitter and other components of electronic circuitry110are configured for transmitting information about the rotational position of the actuator stem124based on the signal from the sensor. In some embodiments, the electronic circuitry110also includes an RF receiver. The RF receiver may be configured for receiving commands or for receiving acknowledgements and other communications used to execute the communications protocol.

The adaptive sleeve118has a sleeve center cavity120configured for the actuator stem124of the actuator to be inserted therein. The adaptive sleeve118is configured such that when the actuator stem124is inserted, the actuator stem124rotates when the adaptive sleeve118is rotated. The sleeve center cavity120and the actuator stem124typically have a sliding fit or a location fit. In other embodiments the sleeve center cavity120may have a looser fit with the actuator stem124, though this will allow some play which may not be desirable. The sleeve center cavity120in the first embodiment has a “D” shaped cross-section to match the “D” shape cross-section of the actuator stem124. However, not all actuators will have an actuator stem with a “D” shaped cross-section, but will have actuator stems with other cross-sectional shapes such as square or hexagonal. Thus in other embodiments, the sleeve center cavity120will have a different cross-section, one selected for mating with a specific shape of actuator stem. In some embodiments, the first embodiment wireless position sensor actuator assembly100has multiple adaptive sleeves, each with a sleeve center cavity of a different shape, configured for different types of actuator stems. A user can select the appropriate adaptive sleeve to use, depending on the type of actuator stem on the existing actuator. The adaptive sleeve118is typically made of injection molded plastic, but in some embodiments may be made by other suitable methods with other suitable materials.

The housing base106has a threaded adjustment hole134connecting the base cavity130with the base stem cavity132. The adjustment hole134is threaded to permit a set screw136to engage with it. The set screw136is configured for adjusting the height of the second housing102relative to the adaptive sleeve118. Thus the adaptive sleeve118, the set screw136and the adjustment hole134together comprise a height adjustment mechanism, controlling the distance between the second housing102and the first housing108. This allows sufficient clearance to be established and maintained between the second housing102and the first housing108as well as the appliance surface126, allowing smooth operation of the actuator when turning the second housing102. The height adjustment mechanism may also be used to adjust the sensitivity of the sensor114by changing the distance between the sensor114and the sensor trigger116.

Installing the first embodiment wireless actuator position sensor assembly100typically is done to replace an existing knob of an actuator in an appliance, though it may be installed as original equipment. Once the original knob is removed from the actuator stem124, the first housing108is positioned on the appliance surface126with the actuator stem124passing through the first housing cavity109. The first housing108couples to the appliance surface126or to the actuator with adhesive or some other fastening mechanism. Once installed, the first housing108should not move or rotate relative to the actuator. Next, the adaptive sleeve118is placed over the actuator stem124, with the actuator stem124inserting into the sleeve center cavity120. For some actuators, the actuator stem124changes cross-sectional shape part way down from a top of the actuator stem124, becoming wider and forming a ledge. The adaptive sleeve118is pushed down over the actuator stem124until it contacts the ledge. In other embodiments, the actuator stem124does not change cross-section and in that case, the adaptive sleeve118is pushed down until it contacts the main body of the actuator.

The housing base106is then placed over the actuator, with the base stem128over the actuator stem124and adaptive sleeve118. The base stem128is then pushed down over the adaptive sleeve118with the adaptive sleeve118inserting into the base stem cavity132until the adaptive sleeve118contacts the top of the base stem cavity132. The set screw136is placed into the adjustment hole134and screwed down until it contacts the adaptive sleeve118. The set screw136can then be screwed down further still, pushing against the adaptive sleeve118and increasing the height of the housing base106up above the actuator and the first housing108, stopping when the desired height is reached. The electronic circuitry110is then placed in the base cavity130, if it is not already installed. Installation is done in such a manner so as to result in proper alignment between the actuator, the sensor trigger116and the sensor114. In the first embodiment, the proper alignment is with the sensor114over the sensor trigger116when the actuator is in an off operational state. However, in other embodiments, other alignments are used such as the sensor114over the sensor trigger116when the actuator is in an on operational state or a 50% power operational state.

The electronic circuitry110of the first embodiment wireless actuator position sensor assembly100is configured for transmitting information about the rotational position of the actuator stem124. In some embodiments, the electronic circuitry110is configured for periodically transmitting information regarding the operational state of the actuator. In other embodiments, the electronic circuitry110is configured for transmitting information regarding the rotational position of the actuator stem124when the rotational position of the actuator stem124changes. In other embodiments, the electronic circuitry110is configured for transmitting information regarding the rotational position of the actuator stem124when it receives a request to do so.

In operation, the first embodiment wireless actuator position sensor assembly100typically starts with the actuator in an off operational state, with a rotational position with the sensor114lined up over the sensor trigger116. A user turns the second housing102, which turns the actuator away from the off position and the sensor114from over the sensor trigger116, which remains stationary. The electronic circuitry110, based on a signal from the sensor114determines the sensor114no longer detects the proximity of the sensor trigger116and so transmits information regarding the change of position of the actuator.

Second Embodiment

FIGS. 2A, 2B and 2Cshow a second embodiment of a wireless actuator position sensor assembly140. The second embodiment wireless actuator position sensor assembly140is similar to the first embodiment wireless actuator position sensor assembly100, but with some differences, most notably the location of the electronics, the sensor trigger, and the mechanism for adjusting the distance between the first and second housings. The second embodiment wireless actuator position sensor assembly140is configured for coupling to an actuator with an actuator body160and an actuator stem162. The second embodiment wireless actuator position sensor assembly140comprises a first housing146, a second housing142, electronic circuitry148(including a sensor152), a sensor trigger154, a trigger sleeve156, an adaptive sleeve172, and a pin176. In some embodiments, the second housing142is a pre-existing OEM knob or handle that the adaptive sleeve172is designed to work with, but in other embodiments, the second housing142is a replacement knob specifically designed to work with the adaptive sleeve172.

The first housing146houses the electronic circuitry148. In the second embodiment140, the first housing146has a shape of a thin annular cylinder. In other embodiments the first housing146may have another suitable shape, such as a thin annular box. In order to correctly indicate the rotational position of the actuator stem162, the first housing146is configured for coupling to the actuator body160in a manner so that when coupled, the first housing146is in a fixed relation with the actuator body160and cannot move laterally or rotationally relative to the actuator body160. In the second embodiment140, the first housing146is configured for coupling to the actuator body160indirectly, by coupling to the appliance surface126, which in turn is coupled to the actuator body160, typically with an adhesive, or by suction, welding or mechanical fastener such as screws. The first housing146has a first housing stem166with a first housing stem cavity (opening or bore)168configured for accepting insertion of the actuator stem162and for accepting insertion of the trigger sleeve156sliding over the actuator stem162. In the second embodiment, the first housing stem166is located in the exact center of the first housing146, but in other embodiments may be located off-center. In some embodiments, the first housing stem166is replaced by a hole in the bottom of the first housing146. The first housing146is typically made of injection molded plastic, but in some embodiments may be made by other suitable methods with other suitable materials.

The electronic circuitry148is positioned within the first housing146and secured thereto. Specifically, the sensor152is secured to the first housing146, either directly or indirectly, in a manner that fixes the location of the sensor152, laterally and rotationally, relative the actuator body160, when the first housing146is coupled to the actuator body160. In the second embodiment, the electronic circuitry148includes a circuit board147, a battery150, the sensor152, a radio frequency (RF) transmitter149. The electronic circuitry148includes a microcontroller (not shown) for controlling and coordinating the activities of the other components of the electronic circuitry148. The circuit board147serves as a mounting platform for the other components of the electronic circuitry148and the circuit board147is coupled to the first housing146. (SeeFIGS. 11A and 11B). In other embodiments, some of the components may be coupled to first housing146in other ways and not mounted on the circuit board147. In the second embodiment, the electronic circuitry148includes an antenna151, coupled to the transmitter149and configured to coil to fit within a first housing cavity (a void space)164. The sensor152in the second embodiment is a magnetic-field detector, specifically a reed switch, but in other embodiments may be some other kind of magnetic-field detector, such as a hall-effect detector, or may be some other type of sensor such as an RFID transmitter, a radiation detector, or a photo detector. The sensor152is configured for generating a signal based on the proximity of the sensor trigger154to the sensor152. The transmitter149and other components of electronic circuitry148are configured for transmitting information about the rotational position of the actuator stem162based on the signal from the sensor152.

In the second embodiment, the electronic circuitry148is a Honeywell 5800Micra Wireless Recessed Transmitter with the external plastic housing removed and the sensor trigger154is a magnet that is provided with the 5800Micra. The reed switch (sensor152) is configured to be in a first state (e.g. open) if the magnet (sensor trigger154) is within one half inch of the reed switch (and the pole of the magnet is in proper alignment with the reed switch), and configured to be in a second state if the magnet is further away than one half inch. The reed switch (sensor152) changing state from open to closed, or from closed to open, constitutes an event. For each event, the transmitter149transmits a message according to the Honeywell 5800 Transmission Protocol. The message is 64 bits in length with 16 bits for CRC and 24 bits for a serial number unique to the transmitter149. For each event, the transmitter149sends the message 10 times, with different spacing between the repeated messages to avoid clashes with other transmitters. The transmitter149transmits in the 345 MHz narrow band frequency range. However, in other embodiments, the electronic circuitry148may have a different set of components than those of the 5800Micra, may transmit in other frequency ranges, according to other communications protocols, such as Bluetooth®, Z-wave®, ZigBee®, Random Phase Multiple Access (RMPA), or LoRaWAN™. In some embodiments, the electronic circuitry148also includes an RF receiver. The RF receiver may be configured for receiving commands or for receiving acknowledgements and other communications used to execute the communications protocol.

The second housing142includes a mating cavity170. The mating cavity170is configured for accepting insertion of the adaptive sleeve172therein, having a shape and size similar to that of the adaptive sleeve172so that when the second housing142is rotated, the adaptive sleeve172rotates as well. In the second embodiment, the adaptive sleeve172inserts into the mating cavity170with a sliding fit or a location fit, but in other embodiments may have a looser or tighter fit. A looser fit will allow some play between the adaptive sleeve172and the mating cavity170, which may not be desirable. A tighter fit may also not be desirable as it may prevent easy removal of the adaptive sleeve172for changing the height adjustment of the second housing142. In the second embodiment, the mating cavity170and the exterior of the adaptive sleeve172have cross-sections that are hexagonal in shape, but may have different cross-sectional shapes in other embodiments. The second housing142is typically made of injection molded plastic, but in some embodiments may be made by other suitable methods with other suitable materials.

The trigger sleeve156has a trigger sleeve cavity157(seeFIGS. 5A and 5B) through its long axis and is configured for accepting insertion of the actuator stem162therein. The trigger sleeve cavity157is configured such that when the actuator stem162is inserted and the actuator stem162rotates, the trigger sleeve156rotates as well. Typically, the trigger sleeve cavity157is configured to have a fit with the actuator stem162that is a sliding fit or a location fit. The trigger sleeve156has a trigger hole158configured for a sensor trigger154to be inserted therein. In the second embodiment140, the trigger hole158and the sensor trigger154each have a cross-sectional shape that is circular, but in other embodiments may be square or some other suitable shape. Typically, the sensor trigger154and trigger hole158are configured for a location fit, but in some embodiments may have a tighter or looser fit. A looser fit may be undesirable as the sensor trigger154could fall out inadvertently. The trigger sleeve156is configured with a size and shape for insertion into the first housing stem cavity168with a sliding fit or looser, permitting the trigger sleeve156to rotate freely with the first housing stem cavity168. In the second embodiment, the exterior of the trigger sleeve156has a hexagonal cross-sectional shape, but may have other cross-sectional shapes in other embodiments. In the second embodiment, the sensor trigger154is a magnet, but in other embodiments, may be some other material or device that triggers the sensor152, such a radioisotope, photoluminescent source, or RFID tag. The trigger sleeve156is typically made of injection molded plastic, but in some embodiments may be made by other suitable methods with other suitable materials.

The adaptive sleeve172has a sleeve center cavity178(seeFIGS. 6A and 6B) configured for accepting insertion of the actuator stem162therein. The adaptive sleeve172is configured such that when the actuator stem162is inserted and the adaptive sleeve172is rotated, the actuator stem162is rotated as well. Typically, the sleeve center cavity178and the actuator stem162have a sliding fit or a location fit. In other embodiments the sleeve center cavity178may have a tighter or a looser fit with the actuator stem162. A looser fit will allow some play which may not be desirable. The sleeve center cavity178has a flat-sided-circle shaped cross-section to match the flat-sided-circle shape cross-section of the actuator stem162. However, not all actuators will have an actuator stem with a flat-sided-circle shaped cross-section, but may have actuator stems with other cross-sectional shapes such as square or hexagonal. Thus in other embodiments, the sleeve center cavity178will have a different cross-section, one selected for mating with a specific shape of actuator stem. In some embodiments, the second embodiment wireless actuator position sensor assembly140has multiple adaptive sleeves, each with a sleeve center cavity of a different shape, configured for different types of actuator stems. A user can select the appropriate adaptive sleeve to use. The adaptive sleeve172is typically made of injection molded plastic, but in some embodiments may be made by other suitable methods with other suitable materials.

The adaptive sleeve172has a plurality of pin holes174therein, orthogonal to the long axis of the adaptive sleeve172. Each pin hole174is configured for accepting insertion of the pin176therein. The pin176is configured with a size and shape to allow it to insert in a first of the pin holes174, through the sleeve center cavity178and through a second of the pin holes174directly across the sleeve center cavity178. In the second embodiment, the pin176and the pin holes174have a circular cross-sectional shape, but in other embodiments may by square or some other appropriate shape. The pin176has a length sufficient to allow it to insert fully into both the first and second pin holes174at the same time, but not longer than the width of the mating cavity170, so that the pin176will not interfere with the adaptive sleeve172inserting into the mating cavity170while the pin176is inserted into the adaptive sleeve172. The pin176inserted into the pin hole174of the adaptive sleeve172controls the height of the second housing142above the actuator and above the first housing146. With the pin176inserted into one of the pin holes174, and the adaptive sleeve172inserted into the mating cavity170, the pin hole174limits how far down the actuator stem162the second housing142and adaptive sleeve172can be pushed. Thus the adaptive sleeve172and pin176comprise a height adjustment mechanism, controlling the distance between the second housing142and the first housing146. This allows sufficient clearance to be set between the second housing142and the first housing146for smooth operation of the actuator when turning the second housing142. This is a simpler, easier to use, easier and less costly to manufacture height adjustment mechanism than the set screw136of the first embodiment wireless actuator position sensor assembly100since no threaded components need to be made.

Installing the second embodiment wireless actuator position sensor assembly140is typically done replacing an existing knob of an actuator in an appliance, though it may be installed as original equipment. Once the original knob is removed from the actuator stem162of the actuator, the first housing146is positioned over the actuator with the actuator stem162passing through the first housing stem cavity168. The first housing146couples to the appliance surface126or to the actuator with adhesive or some other fastening mechanism. Once installed, the first housing146should not move or rotate relative to the actuator. Next, the sensor trigger154is inserted into the trigger hole158of the trigger sleeve156. The trigger sleeve156is then inserted into the first housing stem cavity168with actuator stem162inserted into the trigger sleeve cavity157. For some actuators, the actuator stem162changes cross-sectional shape part way down from a top of the actuator stem162, becoming wider and forming a ledge. The trigger sleeve156is pushed down over the actuator stem162until it contacts the ledge. In other embodiments, the actuator stem162does not change cross-section and in that case, the trigger sleeve156is pushed down until it contacts the actuator body160. The electronic circuitry148, including the sensor152, is then placed in first housing cavity164and secured thereto, if it is not already installed.

The pin176is inserted into the one of the pin holes174of the adaptive sleeve172. Which pin hole174of the adaptive sleeve172the pin176is inserted into will set the height of the adaptive sleeve172and the second housing142above the actuator body160. Next, the adaptive sleeve172is placed over the actuator stem162, with the actuator stem162inserting into the sleeve center cavity178. The adaptive sleeve172is pushed down over the actuator stem162until the top of the actuator stem162contacts the pin176or the adaptive sleeve172contacts the trigger sleeve156. The second housing142is then placed over the adaptive sleeve172, with adaptive sleeve172inserting into the mating cavity170. The second housing142is pushed down over the adaptive sleeve172until the adaptive sleeve172contacts the top of the mating cavity170. Installation is done in such a manner so as to result in proper alignment between the actuator, the sensor trigger154and the sensor152. In the second embodiment, the proper alignment is with the sensor152positioned with the first housing cavity164so that it is closest to the sensor trigger154when the actuator is in an off position. However, in other embodiments, other alignments are used such as the sensor152is closest to sensor trigger154when the actuator is in an on position or a 50% power position.

The electronic circuitry148of the second embodiment wireless actuator position sensor assembly140is configured for transmitting information about the rotational position of the actuator stem162. In some embodiments, the electronic circuitry148is configured for periodically transmitting information regarding the rotational position of the actuator stem162. In other embodiments, the electronic circuitry148is configured for reporting the rotational position of the actuator stem162when the rotational position of the actuator stem162changes. In other embodiments, the electronic circuitry148is configured for transmitting information regarding the rotational position of the actuator stem162when it receives a request to do so.

In operation, the second embodiment wireless actuator position sensor assembly140typically starts with the actuator in an off position, with the sensor152in proximity to the sensor trigger154. A user turns the second housing142, which turns the actuator away from the off position and rotates the sensor trigger154away from the sensor152, which remains stationary. The electronic circuitry148, based on a signal from the sensor152, determines that sensor152no longer detects the proximity of the sensor trigger154and so transmits information regarding the change of position of the actuator.

Third Embodiment

FIGS. 3A, 3B and 3Cshow a third embodiment of a wireless actuator position sensor assembly190. The third embodiment190is similar to the first embodiment100and second embodiment140, but with some differences, most notably the mechanism for adjustment of the distance between the first and second housings and the location of sensor trigger and the electronics. The third embodiment wireless actuator position sensor assembly190is configured for coupling to an actuator with an actuator body208and an actuator stem210. The third embodiment wireless actuator position sensor assembly190comprises a first housing198, a second housing192, a sensor trigger206, electronic circuitry200(including a sensor204), a pin224, and an adaptive sleeve220.

The first housing198houses the sensor trigger206. In the third embodiment190, the first housing198has a shape of a thin annular cylinder, but in other embodiments may have another suitable shape, such as a thin annular box. The first housing198is configured for coupling to the actuator body208, either indirectly by being coupled to the appliance surface or directly by being coupled to the actuator body208itself, typically with an adhesive, or by suction, welding or mechanical fastener such as screws. In order to correctly indicate the rotational position of the actuator stem210, the first housing198is coupled to the actuator body208in a manner so that it cannot move laterally or rotationally relative to the actuator body208. The first housing198has a first housing stem214with a first housing stem cavity216configured to accept insertion of the actuator stem210into the first housing198. In the third embodiment, the first housing stem214is located in the exact center of the first housing198, but in other embodiments may be located off-center. In the third embodiment wireless actuator position sensor assembly190, the sensor trigger206is positioned with the first housing198and coupled thereto. The first housing198is typically made of injection molded plastic, but in some embodiments may be made by other suitable methods with other suitable materials.

The second housing192comprises a housing top194, a housing base196, and electronic circuitry200. The housing base196has a housing base cavity197into which the electronic circuitry200is positioned. The electronic circuitry200is secured to the second housing192. Specifically, the sensor204is secured to the second housing192. This ensures the location of the sensor204is fixed relative to the actuator stem210when the second housing192is coupled to the actuator stem210. In the third embodiment, the housing base196and the housing top194are configured to detachably couple with a mechanical locking mechanism. In other embodiments the housing base196and housing top194may be configured to couple in other ways, such as mechanical fasteners (e.g. screws), clips or adhesive. The housing base196has a base stem218protruding up into the housing base cavity (internal recess)197from the bottom of the housing base196with a base stem cavity228therein. The base stem cavity228is closed on top and open through the bottom of the housing base196. The base stem cavity228is configured for the adaptive sleeve220to be inserted therein, having a shape and size similar to that of the adaptive sleeve220so that when the second housing192is rotated, the adaptive sleeve220rotates as well. In the third embodiment, the adaptive sleeve220inserts into the base stem cavity228with a sliding fit or a location fit, but in other embodiments may have a looser or tighter fit. A looser fit will allow some play between the adaptive sleeve220and the second housing192, which may not be desirable. A tighter fit may also be undesirable as it may interfere with height adjustment of the second housing192, though the third embodiment is not as sensitive to this as the first embodiment. In the third embodiment, the base stem cavity228and the exterior of the adaptive sleeve220have cross-sections that are hexagonal in shape, but may have different cross-sectional shapes in other embodiments. The housing top194and the housing base196are typically made of injection molded plastic, but in some embodiments may be made by other suitable methods with other suitable materials.

In the third embodiment wireless actuator position sensor assembly190, the electronic circuitry200includes a battery202, a sensor204and other circuitry such as a radio frequency (RF) transmitter. The electronic circuitry200of the third embodiment wireless actuator position sensor assembly190is similar to the electronic circuitry148of the second embodiment wireless actuator position sensor assembly140(SeeFIGS. 11A and 11B). In the third embodiment, the electronic circuitry200includes an antenna205, which is configured to coil to fit within the second housing192. The sensor204in the third embodiment is a magnetic-field detector, but in other embodiments may be some other type of sensor such as a radiation detector or a photo detector. The sensor204and other components of electronic circuitry200are configured to detect the presence or absence of the sensor trigger206in the vicinity of the sensor204. The RF transmitter is configured for transmitting information about the actuator position. In some embodiments, the electronic circuitry200also includes an RF receiver. The RF receiver may be configured for receiving commands or for receiving acknowledgements and other communications used to execute the communications protocol.

The adaptive sleeve220has a sleeve center cavity221configured for the actuator stem210to be inserted therein. The adaptive sleeve220is configured for rotating the actuator stem210when the adaptive sleeve220is rotated. Typically, the sleeve center cavity221and the actuator stem210have a sliding fit or a location fit, but in other embodiments may have a tighter or a looser fit. A looser fit will allow some play which may not be desirable. The sleeve center cavity221has a flat-sided-circle shaped cross-section to match the flat-sided-circle shape cross-section of the actuator stem210. However, not all actuators will have an actuator stem with a flat-sided-circle shaped cross-section, but will have actuator stems with other cross-sectional shapes such as square or hexagonal. Thus in other embodiments, the sleeve center cavity221will have a different cross-section, one selected for mating with a specific shape of actuator stem. In some embodiments, the third embodiment wireless actuator position sensor assembly190has multiple adaptive sleeves, each with a sleeve center cavity of a different shape, configured for different types of actuator stems. A user can select the appropriate adaptive sleeve to use. The adaptive sleeve220is typically made of injection molded plastic, but in some embodiments may be made by other suitable methods with other suitable materials.

The adaptive sleeve220has a plurality of pin holes222therein, orthogonal to the long axis of the adaptive sleeve220. The pin224is configured with a size and shape to allow it to insert in a first of the pin holes222, through the sleeve center cavity221and through a second of the pin holes222directly across the sleeve center cavity221. In the third embodiment, the pin224and the pin holes222have a circular cross-sectional shape, but in other embodiments may be square or some other appropriate shape. The pin224has a length sufficient to allow it to insert fully into both the first and second pin holes222at the same time, but not longer than the width of the base stem cavity228, so that the pin224will not interfere with the adaptive sleeve220inserting into the housing base cavity197while the pin224is inserted into the adaptive sleeve220. The pin224inserted into the pin hole222controls the height of the second housing192above the actuator body208and the first housing198. With the pin224inserted into one of the pin holes222, and the adaptive sleeve220inserted into the base stem cavity228, the pin hole222limits how far down the actuator stem210the second housing192and the adaptive sleeve220can be pushed. Thus the adaptive sleeve220and pin224comprise a height adjustment mechanism, controlling the distance between the second housing192and the first housing198. This allows for setting sufficient clearance between the second housing192and the first housing198for smooth operation of the actuator when turning the second housing192.

Installing the third embodiment wireless actuator position sensor assembly190is typically done to replace an existing knob of an actuator in an appliance, though it may be installed as original equipment. Once the original knob is removed from the actuator stem210, the first housing198is positioned over the actuator body208with the actuator stem210passing through the first housing stem cavity216. The first housing198couples to the appliance surface or to the actuator body208with adhesive or some other fastening mechanism. Once installed, the first housing198should not move or rotate relative to the actuator body208.

Next, the pin224is inserted into the one of the pin holes222of the adaptive sleeve220. Which pin hole222the pin224is inserted into will set the height of the adaptive sleeve220and the second housing192. Next, the adaptive sleeve220is placed over the actuator stem210, with the actuator stem210inserting into the sleeve center cavity221. The adaptive sleeve220is pushed down over the actuator stem210until the top of the actuator stem210contacts the pin224or the adaptive sleeve220contacts and is blocked by some other structure. For the actuator in the third embodiment, the actuator stem210changes cross-sectional shape part way down from a top of the actuator stem210, becoming wider and forming a ledge. The adaptive sleeve220is pushed down over the actuator stem210until it contacts the ledge. In other embodiments, the actuator stem210does not change cross-sectional shape and in that case, the adaptive sleeve220is pushed down until it contacts the actuator body208.

The housing base196is then placed over the actuator body208, with the base stem cavity228over the actuator stem210and the adaptive sleeve220. The housing base196is pushed down over the adaptive sleeve220with the adaptive sleeve220inserting into the base stem cavity228until the adaptive sleeve220contacts the top of the base stem cavity228.

The electronic circuitry200, including the sensor204, is then placed in housing base cavity197, if it is not already installed. Installation is done in such a manner so as to result in proper alignment between the actuator body208, the sensor trigger206and the sensor204. In the third embodiment, the proper alignment is with the sensor204over the sensor trigger206when the actuator is in an off position. However, in other embodiments, other alignments are used such as the sensor204over the sensor trigger206when the actuator is in an on position or a 50% power position.

The electronic circuitry200of the third embodiment wireless actuator position sensor assembly190is configured for transmitting information about the rotational position of the actuator stem210. In some embodiments, the electronic circuitry200is configured for periodically transmitting information regarding the rotational position of the actuator stem210. In other embodiments, the electronic circuitry200is configured for reporting the rotational position of the actuator stem210when the rotational position of the actuator stem210changes. In other embodiments, the electronic circuitry200is configured for transmitting information regarding the rotational position of the actuator stem210when it receives a request to do so.

In operation, the third embodiment wireless actuator position sensor assembly190typically starts with the actuator in an off position, with the sensor204in proximity to the sensor trigger206. A user rotates the second housing192, which rotates the actuator away from the off position and moves the sensor204away from the sensor trigger206, which remains stationary. The electronic circuitry200, based on a signal from the sensor204, determines the sensor204no longer detects the proximity of the sensor trigger206and so transmits information regarding the change of position of the actuator.

Fourth Embodiment

FIGS. 4A, 4B and 4Cshow a combined sleeve280. The combined sleeve280is used in combination with the second embodiment wireless actuator position sensor assembly140, replacing the adaptive sleeve172and the trigger sleeve156, thereby constituting a fourth embodiment of a wireless actuator position sensor. The combined sleeve280has one or more pin holes288penetrating through orthogonal to a long axis of the combined sleeve280and a sleeve cavity290in the combined sleeve280. The combined sleeve280also has one or more trigger holes286penetrating through orthogonal to the long axis of the combined sleeve280and orthogonal to the one or more pin holes288. A sensor trigger282may be placed in one of the trigger holes286and a pin284may be placed in one of the pin holes288.

The combined sleeve280is a simpler, but less robust arrangement than the separated trigger sleeve156and adaptive sleeve172. In situations where a less robust sleeve will do, it may be preferable.

The combined sleeve280or adaptive sleeve172may be useful in other instances than with all the components of the second embodiment wireless actuator position sensor assembly140. For instance, the combined sleeve280or adaptive sleeve172could be used with the second housing142to replace an existing knob that does not have correct clearances.

Fifth Embodiment

FIG. 7shows a fifth embodiment wireless actuator position sensor assembly700. The fifth embodiment700is similar to the third embodiment190, with the following noted differences. The base stem218extends below the housing base196. The base stem218includes a stem trigger hole292configured for accepting insertion of the sensor trigger206. The adaptive sleeve280with trigger holes286as shown inFIGS. 4A-4Cused instead of the adaptive sleeve220as shown inFIG. 3C. To install the fifth embodiment assembly700, the electronic circuitry200is installed in the first housing198, if it is not installed already. The first housing198, the adaptive sleeve280and pin284are installed as in the third embodiment190. The sensor trigger206is inserted into the stem trigger hole292and into one of the trigger holes286of the adaptive sleeve280. The second housing192is positioned over the adaptive sleeve280(already mated to the actuator stem210) and then pushed down over the adaptive sleeve280, the base stem218inserting into the first housing stem cavity216and the base stem cavity219accepting insertion of the adaptive sleeve280. In operation, the fifth embodiment wireless actuator position sensor assembly700typically starts with the actuator in an off position, with the sensor204in proximity to the sensor trigger206. A user rotates the second housing192, which rotates the actuator away from the off position and moves the sensor204away from the sensor trigger206, which remains stationary. The electronic circuitry200, based on a signal from the sensor204, determines the sensor204no longer detects the proximity of the sensor trigger206and so transmits information regarding the change of position of the actuator.

Sixth Embodiment

FIGS. 8A, 8B, and 8Cshows a sixth embodiment wireless actuator position sensor assembly800. The sixth embodiment800is similar the second embodiment140, with the following noted differences. The sixth embodiment does not have a second housing142nor an adaptive sleeve172. The second housing142can be omitted for actuators that have a sufficiently long actuator stem162that the OEM knob (not shown) can used with sufficient clearance between the first housing146and the OEM knob. In such instances the first housing146, trigger sleeve156, sensor trigger154, and electronic circuitry148are installed as for the second embodiment140. The OEM knob is placed over the first housing146and pushed down on the actuator stem162. Operation of sixth embodiment800is similar to operation of the second embodiment140.

Seventh Embodiment

FIG. 9shows a seventh embodiment wireless actuator position sensor assembly900. The seventh embodiment900is similar to the second embodiment140, with the following noted differences. The seventh embodiment900has a second housing902that is configured for accepting insertion of the actuator stem162of a particular actuator. The second housing902has a stem that is sufficiently long such that it will create sufficient clearance between the first housing146and second housing902. The second housing902has a stem that includes a trigger hole904configured for accepting insertion of sensor trigger154. To install the seventh embodiment900, the first housing146and electronic circuitry148are installed as for the second embodiment140. The sensor trigger154is placed into the trigger hole904. The second housing902is placed over the first housing146and pushed down on the actuator stem162, the stem of the second housing902and the sensor trigger154inserting into first housing stem cavity168. Operation of seventh embodiment900is similar to operation of the second embodiment140.

Eighth Embodiment

FIG. 10shows an eighth embodiment wireless actuator position sensor assembly1000. The eighth embodiment1000is similar the second embodiment140, with the following noted differences. In the eighth embodiment1000, the second housing142is replaced with a handle1002that is specially designed to mate with the actuator stem162of a particular actuator. The handle1002may be provided with the eighth embodiment wireless actuator position sensor assembly1000or it may be a pre-existing part, provided with the actuator when it was installed. The actuator has a sufficiently long actuator stem162such that the handle1002can used with sufficient clearance between the first housing146and the handle1002. The eighth embodiment1000has a skirt1006that fits over the first housing146that functions as a splash guard to protect the electronic circuitry148in situations where the actuator is used in a wet environment, such as the control valve of a shower. To install the eighth embodiment1000, the first housing146, trigger sleeve156, sensor trigger154, and electronic circuitry148are installed as for the second embodiment140. The handle1002is placed over the first housing146and pushed down on the actuator stem162. Operation of eighth embodiment1000is similar to operation of the second embodiment140.