Abstract:
A control system is provided having a flow valve, a control valve for controlling flow through the flow valve, a logic circuit for receiving, processing, and transmitting data signals; a central control unit for receiving, processing, and transmitting data signals; and a flow valve actuator. When the flow valve actuator is actuated, the central control unit informs the logic circuit to permit the control valve to allow flow through the flow valve. However, if during a set time period, the flow valve actuator is actuated too often, subsequent actuation is disallowed for a second time period. Also, if during a shut down, subsequent actuation is disallowed. During the second time period or the shut down, any successive actuation is recorded by the central control unit.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to fluid piping systems, and, in particular, to control systems for use in managing and controlling these fluid flow systems. 
     2. Brief Description of the Prior Art 
     Fluid control systems are used to manage and regulate the flow of fluid through plumbing systems, allowing and preventing fluid flow to and through various plumbing fixtures. For example, control systems are used to regulate flow through toilets and lavatories in a facility, such as a prison. A typical prior art plumbing control system includes a plurality of toilets and lavatories within a facility, each of which are integrated through an associated logic circuit, which, in turn, communicates with a central control unit. Also, each toilet and lavatory typically includes a push button sensor in a solenoid valve to operate the fixture. The control system uses the central control unit to receive requests from any individual fixture, process the request, and communicate an appropriate signal back to the logic circuit associated with each fixture, either allowing or disallowing fluid flow through a flow valve. 
     In certain facilities, such as a prison, these control systems can be used to delay operation of any single fixture, e.g., a toilet, within the facility, and/or to prevent such a fixture from being flushed more than a specified number of times within a predetermined time period, thereby preventing flooding of the toilet. Typically, these systems are classified as “delay” and/or “lockout” systems. For example, U.S. Pat. No. 4,985,944 is directed to a plumbing control system and method for prisons, which uses both a delay and a lockout feature. Specifically, the control mechanism of the &#39;944 patent causes operation of the valve to be delayed for a selected period after the sensor has been operated (the “delay” feature) and limits the number of operations of the valve per unit time (the “lockout” feature). These features prevent a user from utilizing the fixture, e.g., a toilet, in a quick and successive manner, thereby overloading the fluid system. Further, these features block any attempt at operating the fixture too often within a set period of time. Another example of a plumbing control system which uses the delay feature is found in U.S. Pat. No. 5,771,501. 
     While the systems are effective in delaying or locking out fixtures and protecting excessive water use and system overload, there is a need for a system that also tracks such repeated requests for use. Further, there is a need for warning to the system controller, such that the controller can effectively be warned of requests for use and the offending user located. For example, in a prison situation, if an inmate is repeatedly attempting to flush a toilet, it is possible that the inmate is attempting to flush contraband down the toilet. While prior art systems can delay or slow the process down, or, alternatively, halt the ability to activate the fixture for a set period of time, heretofore they have not been effective in tracking and alarming the controller (guard) of such a situation. Therefore, there is a need for a control system that protects against repeated use of a fixture, overload of the fixture, overload of the system, and tracks and warns the controller of these repeated uses. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a control system for a fluid flow system which overcomes the deficiencies of the prior art. It is a further object of the present invention to provide a control system that can prevent excessive and repeated activation of a fixture, thereby preventing a system overload. It is a further object of the present invention to provide a control system that can manage and track the exact location of such repeated usage, such that the controller may immediately investigate the situation. 
     The present invention is directed to a control system for a fluid flow system that includes at least one flow valve with a flow valve fluid inlet and a flow valve fluid outlet. This system also includes a control valve in fluid communication with the flow valve for controlling the flow of fluid from a fluid piping system through the flow valve fluid inlet and out the flow valve fluid outlet. The system also includes a logic circuit in communication with the control valve for receiving, processing, and transmitting data signals through a communication line, and a central control unit for receiving, processing, and transmitting data signals through the communication line. In addition, a flow valve actuator is used to communicate activation to the flow valve via the logic circuit in the control valve. 
     In operation, when the flow valve actuator is actuated, an “activate” data signal is communicated to the central control unit, which communicates an “allow” data signal to the logic circuit. This permits the logic circuit to communicate an “allow to activate” data signal to the control valve, which, in turn, allows the control valve to permit fluid flow through the fluid piping system, through the flow valve fluid inlet, and out the flow valve fluid outlet. If, during a first predetermined time period, the flow valve actuator is actuated more than the predetermined allowable activation quantity, the “activate” data signal is communicated to the central control unit, however, the central control unit communicates a “disallow” data signal to the logic circuit. Next, since the logic circuit has received a “disallow” data signal, it does not permit a communication of the “allow to activate” data signal to the control valve. Since the control valve is not activated, fluid flow is not permitted through the flow valve and out of a fixture. This central control unit continues to communicate a “disallow” data signal to the logic circuit for any successive flow valve actuator actuations during a second predetermined time period, thereby locking out the system from activation for a set period of time. Any successive actuation of the flow valve actuator during the second predetermined time period is recorded by the central control unit. The central control unit may also be forced to communicate the “disallow” data signal at any time. During the forced “disallow”, successive actuation of the flow valve actuator is recorded by the central control unit. 
     The present invention, both as to its construction and its method of operation, together with the additional objects and advantages thereof, would best be understood from the following description of specific embodiments when read in connection with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a block diagram of a control system for a fluid piping system according to the present invention; and 
     FIG. 2 is a flow diagram illustrating the operation of a control system according to the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention is a control system  10  for use in connection with a fluid piping system. As seen in FIG. 1, control system  10  includes at least one flow valve  12 , and typically a plurality of flow valves  12 , with each flow valve  12  having a flow valve fluid inlet (not shown) and a flow valve fluid outlet (not shown). In order to control the flow of fluid, typically water, through the flow valve  12 , each flow valve  12  has a control valve  14  associated with it. The control valve  14  is in fluid communication with the flow valve  12  and may be adjacent to or integrated with the flow valve  12 . It is this control valve  14  that serves to either allow or disallow fluid flow through the flow valve  12 , i.e., from the fluid piping system through the flow valve fluid inlet and out the flow valve fluid outlet. 
     Each control valve  14  is in communication with a logic circuit  16 . The logic circuit  16  is used to receive, process, and transmit data signals through one or more communication lines  18 . It is envisioned that the logic circuit  16  can be either associated with or integrated with the control valve  14 . Each respective logic circuit  16  is in communication with a central control unit  20 , which is configured to receive, process, and transmit data signals through the communication line  18 . The central control unit  20  is adapted to control multiple and various types of fixtures  22  through their respective flow valves  12 . 
     In order to activate the fixture  22 , the control system  10  also includes a flow valve actuator  24 , which is in communication with the flow valve  12  via the logic circuit  16  and the control valve  14 . The flow valve actuator  24  may be any actuator capable of transmitting a request for operation of the fixture. For example, the flow valve actuator  24  may be a push button activator, an infrared sensor, or the like. It is also envisioned that the fixture  22  can be a toilet, a sink, a water fountain, a shower, etc. In the case of a sink, a water fountain, or a shower, the fixture  22  may also include a water outlet  26 , e.g., a faucet. 
     The operation of one embodiment of the control system  10  according to the present invention begins when the flow valve actuator  24  is actuated. An “activate” data signal is communicated to the central control unit  20 , typically via the associated logic circuit  16 . A first predetermined time period is tracked by starting a first timer. The central control unit  20  communicates an “allow” data signal to the logic circuit  16 , thereby allowing the logic circuit  16  to communicate an “allow to activate” data signal to the control valve  14 . Next, the control valve  14  permits fluid to flow from the fluid piping system, through the flow valve  12  and into the fixture  22 . 
     During the first predetermined time period, subsequent actuations of the flow valve actuator  24  result in the control valve  14  permitting fluid to flow from the fluid piping system, through the flow valve  12 , and into the fixture  22 , until a predetermined allowable activation quantity is reached. 
     During the first predetermined time period, when the flow valve actuator  24  is actuated for a number of times sufficient to reach the predetermined allowable activation quantity, the first timer is stopped and reset, and a second predetermined time period is tracked by starting a second timer. The “allow” data signal is sent to the logic circuit  16 , thereby allowing the logic circuit  16  to communicate an “allow to activate” data signal to the control valve  14 . The control valve  14  permits fluid to flow from the fluid piping system, through the flow valve  12 , and into the fixture  22 . 
     During the second predetermined time period, if the flow valve actuator  24  is actuated, the “activate” data signal is communicated to the central control unit  20 , as discussed above. However, in this situation, the central control unit  20  will communicate a “disallow” data signal to the logic circuit  16 . This “disallow” data signal halts the logic circuit  16  from, permitting communication of the “allow to activate” data signal to the control valve  14 . This, in turn, prevents or disallows the control valve  14  to permit fluid to flow through the flow valve  12 . 
     The central control unit  20  continues to communicate this “disallow” data signal to the logic circuit  16  for any successive flow valve actuator  24  actuations during the second predetermined time period. The central control unit  20  records any unsuccessful (or disallowed) actuations of the flow valve actuator  24  during this second predetermined time period. 
     Once the first predetermined time period has naturally expired, the control system  10  returns to its initial state, thereby allowing activation of the fixture  22  upon receipt of a further actuation request from the flow valve actuator  24  until the predetermined allowable activation quantity is reached again. Upon expiration of the second timer, the control system  10  waits for an actuation of the flow valve actuator  24 . In other words, when the second timer expires, nothing happens with the control system  10 . Alternatively, upon expiration of the second timer, the central control unit  20  sends the “allow to activate” data signal to the logic circuit  16 , thereby allowing the control valve  14  to permit flow through the flow valve  12 . The control system  10  then waits for an actuation of the flow valve actuator  24 . In other words, when the second timer expires, fluid flow automatically occurs based upon a previous actuation of the flow valve actuator  24 . Further alternatively, upon expiration of the second timer, the central control unit  20  sends the “allow to activate” data signal to the logic circuit  16 , thereby allowing the control valve  14  to permit flow through the flow valve  12 . The central control unit  20  records an actuation of the flow valve  12 , and the first timer is started. In other words, when the second timer expires, fluid flow automatically occurs based upon a previous actuation of the flow valve actuator  24 . This activation is again recorded, and the first timer is started. 
     Overall, the central control unit  20  allows a set number of activations of any one fixture  22  within a predetermined time period. However, once the predetermined allowable activation quantity is reached, the central control unit  20  disallows any further request for fluid flow through the remainder of the system for another predetermined time period. It is this operation that provides a “lockout” feature for preventing repeated activations of any one fixture  22 , which would overload the fluid piping system. 
     Examples of typical ranges for the various time periods useful in the present invention include, for the first predetermined time period, from two minutes to ten minutes, for the second predetermined time period from 30 minutes to 90 minutes, and for the predetermined allowable activation quantity, from two to five activations. For example, the central control unit  20  is typically programmed to allow only two flushes of any toilet during any five-minute period. Submission of a single flush request by actuation of the flow valve actuator  24  will send the “activate” data signal to the central control unit  20 , which will then send an “allow” data signal back to the logic circuit  16 , causing the control valve  14  to open the flow valve  12  for a specified period, resulting in flushing of the toilet. Preferably, the “allow” data signal causes the control valve  14  to open the flow valve  12  and operate the fixture  22  without any delay in operation. Upon flushing of the toilet, the central control unit  20  automatically activates, via a first timer, a first predetermined time period, for example, five minutes, within which the central control unit  20  monitors the toilet. If a second flush request is submitted to the central control unit  20  by actuation of the flow valve actuator  24  at any time during that first predetermined time period, for example, within five minutes of the previous flush, the central control unit  20  will again communicate an “allow” data signal to the logic circuit  16 , which, in turn, allows the control valve  14  to permit flow through the flow valve  12 , flushing the toilet a second time, preferably without a delay. 
     At this point, the central control unit  20  will automatically activate, via a second timer, a second predetermined time period, for example, one hour, and prevent the toilet from any further flushing during this second predetermined time period. Thus, the toilet is effectively prevented or “locked out” from flushing until after expiration of the second predetermined time period. Submission of any flush requests by actuation of the flow valve actuator  24  during this lockout period will be tracked and recorded by the central control unit  20 . 
     In another embodiment of the control system  10 , the second time period is not “predetermined”, but “dynamic” in that it is based on a remaining time of the first predetermined time period. Thus, only a certain number of activations are permitted during a specific time period. In operation, once the predetermined allowable activation quantity is reached, the central control unit  20  disallows any further request for fluid flow through the remainder of the system for the time remaining in the first dynamic time period, that is, the second time period is set to equal the remaining time in the first predetermined time period. 
     For example, if it is desired that only two flushes work in any one hour time period, the first flush would start the first predetermined time period running. Whenever the second flush is executed, for example, thirty-five minutes after the first flush, the second dynamic time period is set to be the remaining time of the first predetermined time period, in this situation, twenty-five minutes. For the next twenty-five minutes, no further flushes are permitted. Submission of any flush request by actuation of the flow valve actuator  24  during this second dynamic time period will be tracked and recorded by the central control unit  20 . 
     After the second time period expires, whether the time period is a predetermined or a dynamic time period, the control system  10  is reset. Preferably, the toilet will not flush after expiration of the second time period until a subsequent flush request is submitted after expiration of the second time period, even if a flush request is submitted during the second time period. Submission of a flush request by actuation of the flow valve, actuator  24  after expiration of the second time period will send the “activate” data signal to the logic circuit  16 , which will instruct the control valve  14  to permit the flow valve  12  to again operate, flushing the toilet. At this point, the central control unit  20  will again automatically activate the first predetermined time period within which the central control unit  20  monitors the toilet. 
     In another embodiment of the control system  10 , it may be desirable to disallow any activation of the fixture  22  at any time, for example, during a search procedure of the prison. Whenever desired, a “shut down” is created by forcing the central control unit  20  to communicate the “disallow” data signal to the logic circuit  16 . If the first predetermined time period or the second predetermined time period have previously been activated, that is, the first timer or the second timer are running, the predetermined time periods (and the timers) are reset. Alternatively, the predetermined time periods may be allowed to expire naturally. The “disallow” data signal is communicated to the logic circuit  16  until the central control unit  20  communicates the “allow” data signal, such as when an operator turns the system back on, or until a predetermined “shut down” time period expires. The central control unit  20  records any request for actuation of the flow valve actuator  24  during the “shut down”. Thus, during the “shut down”, a request for actuation of the flow valve actuator  24  at any time will not result in an activation of the control valve  14  under any circumstance, but will result in the request for actuation being transmitted to the central control unit and the disallowed request being recorded. In this manner, the central control unit  20  can track and record whether operation of a specific fixture is requested during the “shut down”, which may indicate, for example, that an inmate is attempting to flush contraband down a toilet during a search being conducted during the “shut down”. 
     Turning to FIG. 2, the preferred operation of the control system  10  begins with the flow valve actuator  24  being actuated. The actuation is recorded by the central control unit  20 . Next, the “activate” data signal is sent to the central control unit  20 , which checks whether the first timer, i.e., the timer associated with the first predetermined time period, is running. If the first timer is running, the actuation count is checked to see whether it is equal to the predetermined allowable activation quantity. If the actuation count is below the predetermined allowable activation quantity, the central control unit  20  sends the “allow to activate” data signal to the logic circuit  16 , which allows the control valve  14  to permit flow through the flow valve  12 . However, if the actuation count equals the predetermined allowable activation quantity, the first timer is stopped and reset, but not restarted, and the second timer, i.e., the timer tracking the second predetermined time period, is started. This means that further actuation will encounter a stopped first timer and a running second timer. At this point, since the second predetermined time period defines a lockout period, the “disallow” data signal is sent from the central control unit  20  to the logic circuit  16 , and flow is halted or prevented through flow valve  12 . Each disallowed actuation of the flow valve actuator  24  is recorded by the central control unit  20 . 
     By recording each disallowed actuation of the flow valve actuator  24  during the “lockout” or “shut down” at the central control unit  20 , a record can be maintained of any requests for actuation that are made for any particular unit. As such, a guard or other individual monitoring the central control unit  20  can observe the behavior during the “lockout” or “shut down” and will be alerted if a particular inmate is attempting to operate a fixture during such a “lockout” or “shut down”, which may suggest, for example, that the inmate is attempting to flush contraband. 
     It is also envisioned that if the number of disallowed flow valve actuator  24  actuations during the second predetermined time period or during the “shut down” exceeds a predetermined alarm quantity, the central control unit  20  produces an “alarm” data signal. For example, the central control  20  unit may record each actuation during the second predetermined time period or during the “shut down”, but may only signal an alarm after a predetermined number of actuations have been requested during the second predetermined time period (i.e., the “lockout”) or the “shut down”. Further, the control system  10  may include an audible alarm module  30 , such that if the audible alarm module  30  receives the “alarm” data signal from the central control unit  20 , the audible alarm module  30  produces an audible alarm. This would allow the controller, or in the case of a prison, the guard, to be notified of the possibility that a prisoner is attempting to flush contraband down a toilet. 
     The flow valve actuator  24  may require mechanical actuation, such as a knob or switch. When such mechanical actuation is required, the logic circuit  16  may also include an analog/digital signal converter  28 . Since the flow valve actuator  24  requires mechanical actuation, the “activate” data signal is an analog signal. When this analog signal is transmitted to the logic circuit  16 , the analog/digital signal converter  28  converts the analog “activate” data signal to a digital “activate” data signal, which is then transmitted to the central control unit  20  via the communication line  18 . 
     While the flow valve actuator  24  may be mechanical, it may also be a sensor. In particular, the flow valve actuator  24  may be a touch sensor, such that, when contacted, the touch sensor communicates the “activate” signal to the central control unit  20 , typically via the logic circuit  16 . In addition, the flow valve actuator  24  may be adjacent the fixture  22 , so long as the fixture  22  is in fluid communication with the flow valve  12 . It is also envisioned that the flow valve actuator  24  is integrated with the fixture  22 . 
     The control system  10  may also include a control module  32 , which allows a user to set the first predetermined time period or the first timer, the second predetermined time period or the second timer, and the predetermined allowable activation quantity. Additionally, the control module  32  allows the user to force the “shut down” at the central control unit  20  or to set the predetermined “shut down” time period. Also, this control module  32  may be a separate unit or integrated with the central control unit  20 . 
     The present invention provides a control system  10  that effectively monitors and locks out the fluid piping system and flow of fluid to a fixture  22  after repeated actuations of the flow valve actuator  24 . This ensures that the fluid piping system will not be overloaded or misused. Further, the present invention provides a control system  10  that tracks and manages successive actuations of the flow valve actuator  24  during the “lockout” or “shut down”. This is particularly useful in situations where the controller needs to monitor certain user behaviors in the overall quantity of actuations during any set period. In the area of prison plumbing systems, this recordation is particularly useful when used together with the alarm feature, thereby notifying a guard that an inmate may possibly be attempting to flush contraband down a toilet or other water drain. 
     This invention has been described with reference to the preferred embodiments. Other modifications and alterations will be apparent to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations.