Abstract:
An automatic water drain apparatus includes a reservoir, a fluid inlet, and a fluid outlet. A first valve member is moveable between an open position for admitting fluid to the reservoir via the fluid inlet and a closed position for preventing admission of fluid to the reservoir. A second valve member is moveable between an open position for exhausting fluid from the reservoir and a closed position for preventing exhaust of fluid from the reservoir. At least one actuator is operable to move the fluid inlet and the fluid outlet between their respective open and closed positions. A sensor is disposed outside the reservoir and is operable to produce a first sensor output signal in response to detection of the presence of water, wherein the at least one actuator moves the first valve to the open position in response to the first sensor output signal.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application Ser. No. 61/791,382, filed on Mar. 15, 2013, which is incorporated herein in its entirety by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    This disclosure relates to the field of separating water from fuel. 
       BACKGROUND 
       [0003]    In some fuel processing applications, water is mixed into the fuel and needs to be separated from the fuel before the fuel is utilized. One example arises in the context of a diesel fuel processor for a diesel internal combustion engine. The diesel fuel processor may include a housing with a filter media therein for removing particulate contaminants from the diesel fuel. In some previous designs of diesel fuel processors, a reservoir is provided below the area where the diesel fuel passes through the filter media. Because water is heavier than fuel, water will tend to separate from the fuel and collect in the bottom of the reservoir. Occasionally, the reservoir will need to be drained. Some designs utilize manual drains, but this creates a need for ongoing maintenance. Some designs have proposed automatic drains, but need remains for an automatic drain that minimizes the risk that fuel is released from the automatic drain into the environment. 
       SUMMARY 
       [0004]    One aspect of the disclosed embodiments is an automatic water drain apparatus that includes a reservoir, a fluid inlet that is in fluid communication with the reservoir, and a first valve member that is moveable between an open position for admitting fluid to the reservoir via the fluid inlet and a closed position for preventing admission of fluid to the reservoir via the fluid inlet. The apparatus also includes a fluid outlet that is in fluid communication with the reservoir, and a second valve member that is moveable between an open position for exhausting fluid from the reservoir and a closed position for preventing exhaust of fluid from the reservoir. The apparatus includes at least one actuator that is operable to move the fluid inlet and the fluid outlet between their respective open and closed positions. A sensor is disposed outside the reservoir and is operable to produce a first sensor output signal in response to detection of the presence of water. The at least one actuator moves the first valve to the open position in response to the first sensor output signal. 
         [0005]    Another aspect of the disclosed embodiments is an automatic drain assembly that includes a container having water disposed within an interior of the container, a reservoir, a fluid inlet that is in fluid communication with the reservoir and the interior of the container, and a first valve member that is moveable between an open position for admitting water from the container to the reservoir via the fluid inlet and a closed position for preventing admission of water to the reservoir from the container via the fluid inlet. The apparatus also includes a fluid outlet that is in fluid communication with the reservoir, and a second valve member that is moveable between an open position for exhausting fluid from the reservoir and a closed position for preventing exhaust of fluid from the reservoir. The apparatus also includes at least one actuator that is operable to move the fluid inlet and the fluid outlet between their respective open and closed positions. The apparatus further includes a sensor that is disposed in the interior of the container and is operable to generate a first sensor output signal in response to a high water level in the container and a second sensor output signal in response to a low water level in the container. The first sensor output signal causes the at least one actuator to move the first valve member to the open position and the second sensor output signal causes the at least one actuator to move the first valve member to the closed position. 
         [0006]    Another aspect of the disclosed embodiments is an automatic drain assembly includes a container having a volume of water and a volume of fuel disposed within an interior of the container, a housing that is connected to the container, a reservoir disposed within the housing, a fluid inlet that is defined by the housing and is positioned adjacent to a top surface of the housing, wherein the fluid inlet is in fluid communication with the reservoir and the interior of the container, and a first valve member that is moveable between an open position for admitting water from the container to the reservoir via the fluid inlet and a closed position for preventing admission of water to the reservoir from the container via the fluid inlet. The apparatus also includes a fluid outlet that is defined by the housing and is positioned adjacent to a bottom surface of the housing, wherein the fluid outlet is in fluid communication with the reservoir, and a second valve member that is moveable between an open position for exhausting fluid from the reservoir and a closed position for preventing exhaust of fluid from the reservoir. The apparatus also includes at least one actuator that is operable to move the fluid inlet and the fluid outlet between their respective open and closed positions, and a sensor that is disposed in the interior of the container and is operable to generate a first sensor output signal in response to a high water level in the container and a second sensor output signal in response to a low water level in the container. The first sensor output signal causes the at least one actuator to move the first valve member to the open position and the second sensor output signal causes the at least one actuator to move the first valve member to the closed position. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The various features, advantages and other uses of the present apparatus will become more apparent by referring to the following detailed description and drawing in which: 
           [0008]      FIG. 1  is a top perspective view showing an automatic water drain apparatus; 
           [0009]      FIG. 2  is a bottom perspective view of the automatic water drain apparatus; 
           [0010]      FIG. 3  is a cross-section view of the automatic water drain apparatus; 
           [0011]      FIG. 4  is a cross-section view of the automatic water drain apparatus showing an air passageway; and 
           [0012]      FIGS. 5A-5C  are cross-section views showing operation of the automatic water drain apparatus. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]    The disclosure herein relates to an automatic water drain apparatus for fuel processors, such as diesel fuel filter assemblies. The automatic water drain apparatus is installed in communication with a container in which water separates from fuel by collecting at the bottom of the container. A sensor is utilized by the automatic water drain apparatus to open a first valve that causes water from the container to flow into a reservoir within the automatic water drain apparatus. The sensor closes the first valve prior to the point at which the water level within the container would become low enough that fuel might enter the reservoir of the automatic water drain apparatus. When the first valve is closed, a second valve is open, and the second valve allows the water within the reservoir to pass out of the automatic water drain apparatus while the reservoir is blocked from fluid communication with the container. A filter can be installed within the reservoir for removing impurities from the water that is removed from the container before it is discharged from the automatic water drain apparatus. 
         [0014]    As shown in  FIGS. 1-2 , an automatic water drain apparatus  100  includes a housing  110  having a fluid inlet  112  positioned adjacent to a top surface  114  thereof and a fluid outlet  116  positioned adjacent to a bottom surface  118  thereof. The fluid inlet  112  and the fluid outlet  116  can, in some implementations, be substantially tubular members that extend outward from the top surface  114  and the bottom surface  118 , respectively. An electrical connector  120  can be provided on the housing for connection to a source of electrical power and/or control signals. The electrical connector  120  can be positioned on the bottom surface  118  of the housing  110 , but other locations would also be suitable for the electrical connector  120 . 
         [0015]    In order to selectively open and close the fluid inlet  112 , a first valve member  122  is provided for selectively opening and closing with respect to the fluid inlet  112 . When the first valve member  122  is in its closed position, fluid is prevented from entering or exiting the fluid inlet  112 . When the first valve member  122  is in its open position, fluid communication is permitted through the fluid inlet  112 . 
         [0016]    In order to selectively establish or prevent fluid communication at the fluid outlet  116 , a second valve member  124  is positioned at the fluid outlet  116 . The second valve member  124  is operable to selectively establish or prevent fluid communication at the fluid outlet  116 . In particular, the second valve member  124  is moveable from a closed position, wherein fluid communication is blocked at the fluid outlet  116  to an open position where fluid communication is permitted at the fluid outlet  116 . 
         [0017]    In order to control opening and closing of the first valve member  122  and the second valve member  124 , the automatic water drain apparatus  100  includes a sensor assembly  126  for detecting the presence of water in fuel. The sensor assembly  126  can be configured to provide at least a first signal when the presence of water is detected and at least a second signal when the presence of water is not detected. In the illustrated example, however, the sensor assembly  126  is a bi-level sensor, which can detect and provide output signals corresponding to the presence or absence of water at two separate locations on the sensor. The two locations for water sensing by the sensor assembly  126  can be located at different elevations along the sensor assembly  126  with respect to the top surface  114  and/or the fluid inlet  112  of the housing  110 . 
         [0018]    In one implementation, the sensor assembly  126  includes a probe body  128  that extends generally upward with respect to the top surface  114  of the housing  110 . A first sensor  130  is positioned on the probe body  128  at a first elevation with respect to the top surface  114  and/or the fluid inlet  112 . In particular, the first sensor  130  can be positioned at an elevation that is higher than the elevation of the top of the fluid inlet  112 . Thus, the first sensor  130  can function to output a signal that causes the first valve member  122  to be closed before the top surface of the water that is contact with the sensor assembly  126  reaches the fluid inlet  112 . The sensor assembly  126  can also include a second sensor  132  that is positioned at a second elevation with respect to the top surface  114  and/or the fluid inlet  112  of the housing  110 . The second elevation is higher than the first elevation. The second sensor  132  can be utilized to output a signal that causes the first valve member  122  to open when the second sensor  132  detects the presence of water. Thus, the first sensor  130  and the second sensor  132  can, in cooperation, output signals that cause the first valve member  122  to open when a high water level is detected, and cause the first valve member  122  to close when a low water level is detected, where the low water level is higher than the top of the fluid inlet  112 , such that fuel is prevented from entering the fluid inlet  112 . 
         [0019]    Each of the first sensor  130  and the second sensor  132  can include one or more electrical elements that are operable to sense the presence of water. Any suitable type of water sensor can be utilized. In one example, one or more electrodes are provided at each of the first sensor  130  and the second sensor  132 , and an electrical property of the one or more electrodes is monitored to determine whether the electrodes are immersed in water. For example, the first sensor  130  could include two electrodes that are spaced apart and electrically isolated with respect to one another by an insulating body. However, when water contacts both of the electrodes, an electrical property that can be measured across the electrodes changes, such as resistance or capacitance. In response to this change in the electric property, the signals output by the sensor assembly  126  can be interpreted as indicating the presence or absence of water at the first sensor  130 . 
         [0020]    As shown in  FIGS. 3-4 , the fluid inlet  112  defines an inlet passageway  134  that is in fluid communication with a fluid chamber or fluid reservoir  136  for storing water within the housing  110 . The fluid outlet  116  defines an outlet passageway  138  that is in fluid communication with the fluid reservoir  136  for receiving the fluid from the fluid reservoir  136  and passing the fluid out of the fluid outlet  116  when the second valve member  124  is in the open position thereof. In order to remove contaminants from the water that is received within the fluid reservoir  136 , a filter media  140  can be disposed within the fluid reservoir  136 . In one implementation, the filter media  140  is a charcoal filter. 
         [0021]    The first valve member  122  is connected to a first valve stem  142 . The first valve stem  142  extends through the inlet passageway  134  and through an aperture  144  of the housing  110 . The aperture  144  extends from the inlet passageway  134  to an actuator chamber  146  that is located within the housing  110 . The aperture  144  is sized and configured complementarily to the size and shape of the first valve stem  142 , such that the first valve stem  142  occupies substantially all of the aperture  144  to prevent fluid from entering the actuator chamber  146  from the inlet passageway  134 . A first valve end portion  148  is connected to the first valve stem  142  and is engageable with or connected to an actuator member  150 . 
         [0022]    The second valve member  124  is connected to a second valve stem  152 . The second valve stem  152  extends through the outlet passageway  138  and through an aperture  154  of the housing  110 . The aperture  154  extends from the outlet passageway  138  to the actuator chamber  146 . The aperture  154  is sized and configured complementarily to the size and shape of the second valve stem  152 , such that the second valve stem  152  occupies substantially all of the aperture  154  to prevent fluid from entering the actuator chamber  146  from the outlet passageway  138 . A second valve end portion  158  is connected to the second valve stem  152  and is engageable with or connected to the actuator member  150 . 
         [0023]    The actuator member  150  is operable to move the first valve member  122  and the second valve member  124  between their respective open and closed positions. For example, the actuator member  150  can be engageable with or connected to the first valve end portion  148  and the second valve end portion  158 . The actuator member  150  is part of or connected to an actuator such as an electrically-operated solenoid actuator  160  that is operable to move with respect to a support member  162  between a first position and a second position in response to energization and de-energization of the solenoid actuator  160 . For example, when the solenoid actuator  160  is in the first position, the first valve member  122  can be in its closed position, and the second valve member  124  can be in its open position. When the solenoid actuator  160  is in the second position, the first valve member  122  can be in the open position, and the second valve member  124  can be in the closed position. 
         [0024]    The solenoid actuator  160  is controlled by signals received from a control unit  164 , which can be a programmable controller that is operable to execute program instructions that, when executed, cause movement of the solenoid actuator  160  in response to control signals that are received from the sensor assembly  126 . In other implementations, the control unit  164  can be special purpose hardware that causes appropriate movement of the solenoid actuator  160  in response to the control signals that are received from the sensor assembly  126 . The control unit  164  can receive power from the electrical connector  120  and can be in electrical communication with the sensor assembly  126  and the solenoid actuator  160  for receiving signals from the sensor assembly  126  and for outputting control signals to the solenoid actuator  160  for causing movement of the solenoid actuator  160 . 
         [0025]    Operation of the automatic water drain apparatus  100  will now be explained with reference to  FIGS. 5A-5C . The automatic water drain apparatus  100  is installed with respect to a container  200  having a volume of water  210  and a volume of fuel  220  disposed therein. The automatic water drain apparatus  100  is installed with respect to the container such that the fluid inlet  112  and the sensor assembly  126  are in communication with the interior of the container. 
         [0026]    In  FIG. 5A , the water level in the container  200  is above the first sensor  130  of the sensor assembly  126  but is below the second sensor  132  of the sensor assembly  126 . Because the second sensor  132  is not submerged in the water  210 , the control unit  164 , based on the signals received from the sensor assembly  126 , maintains the first valve member  122  in the closed position and maintains the second valve member  124  in the open position. 
         [0027]    In  FIG. 5B , the fluid level of the water  210  has risen such that the second sensor  132  is submerged in the water  210 . Upon receiving a sensor output signal from the sensor assembly  126  indicating that the second sensor  132  is submerged in the water  210 , the control unit  164  energizes the solenoid actuator  160  to move the first valve member  122  to the open position. The second valve member  124  is simultaneously moved to the closed position in response to movement of the solenoid actuator  160 . With the first valve member  122  in the open position, a portion of the water enters the fluid inlet  112  and begins to fill the fluid reservoir  136  of the automatic water drain apparatus  100 . Because the second valve member  124  is in the closed position, the water that enters the automatic water drain apparatus  100  is maintained within the fluid reservoir  136  while the first valve member  122  is open. 
         [0028]    When the fluid level of the water  210  within the container  200  drops below the first sensor  130  of the sensor assembly  126 , the control unit  164  receives a sensor output signal from the sensor assembly  126  indicating an absence of water at the second sensor  132 , and in response to this sensor output signal, the control unit  164  de-energizes the solenoid actuator  160 . In response to de-energization of the solenoid actuator  160 , the first valve member  122  moves to the closed position, and the second valve member  124  moves to the open position, as shown in  FIG. 5C . At this time, the fluid reservoir  136 , which is filled with the water  210  received from the container  200 , is now in fluid communication with the fluid outlet  116 , and the water that is present in the fluid reservoir  136  exits the fluid reservoir  136  through the fluid outlet  116 . As the water passes through the fluid reservoir  136 , it is filtered by the filter media  140 , thereby reducing the incidence of contaminants present in the water that exits the automatic water drain apparatus  100  at the fluid outlet  116 . 
         [0029]    While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.