Patent Abstract:
A device and method to implement the device, to automatically adjust a single valve or a plurality of valves including turning the valve(s) on and off. The device includes a motor drive assembly, a mounting method, and a control method. Each component is discrete. The three components can be combined easily. The motor drive and control components can be mounted and connected to a valve that is currently connected to pipes. Thus one application of this invention is to provide a method to convert a manual valve to an automatic valve. 
     The control method can operate as a means to turn the valve on and off using a manually operated switch or can be automatically controlled in response to an external stimulus. 
     The invention has many applications including protecting real property from loss due to water damage, and against vandalism in cases where valves can be controlled by unauthorized people.

Full Description:
(This application claims the benefit of U.S. Provisional Application No. 60/159,583 filed on Oct. 18, 1999.) 
    
    
     FIELD OF THE INVENTION 
     The invention is related to the field of converting a standard manually controlled valve into an electronically controlled automatic valve. One application of the automatic valve is to protect real property against water damage that can occur when a water conduit breaks. Thus the invention is also related to the field of protecting property against water damage. Although not limited to, the invention is particularly useful towards minimizing the damage that can occur if a water supply pipe or other water supply component freezes or breaks, or an appliance, such as a washing machine, dishwasher, ice maker, boiler, and water heater breaks. The invention is also related to the field of protecting real property against damage or excess water usage when outdoor spigots (valves) are left on or hoses break. Among other advantages, when used this way, the invention will serve to conserve water. 
     BACKGROUND OF THE INVENTION 
     Replacing a manually controlled valve with an electronically controlled automatic valve requires installing the valve on to an existing water supply conduit. In most cases, this requires a plumber or other person skilled at making such an installation. The cost to install an electronically controlled valve may exceed the cost of the valve. A method to easily and inexpensively convert a manually controlled valve into an automatic valve would provide a valuable solution to many applications. 
     Real property damage occurs when water supply pipes and other components break. A break can be caused by a variety reasons including freezing. Hoses that supply washing machines, dishwashers, and other appliances are particularly susceptible to breakage. The appliances can also break causing water to leak or gush. Water heaters wear out over time and are prone to leak or break suddenly. 
     A water supply break can cause substantial damage to property, especially if the property is not occupied during the time the break occurs. A device that can be added inexpensively and easily to shut off the water supply to a property or to an appliance located at the property and can be controlled to shut of the water under a variety of conditions would serve to minimize the damage to a property. 
     Another problem faced by property owners is the control of outdoor water supplies. Unauthorized people can turn on outdoor spigots allowing water to run for indefinite periods of time. Hoses can also break allowing large amounts of water to be wasted. A device that can control outdoor water sources from within the property and can be controlled automatically will serve to protect against such losses and provide a convenient means to control water used for outdoor activities. 
     SUMMARY OF THE INVENTION 
     It is therefore an object of the invention to provide a method and apparatus to convert a manually controlled valve into an automatically controlled valve that is responsive to an electronic controller. 
     The invention can be used to easily and inexpensively convert a variety of standard off the shelf valves such as ball valves, gate valves and valves that use washers into electronically controlled automatic valves. The automatic valve can be turned on or off locally or remotely. The automatic valve can be controlled to turn on or off based upon a variety of conditions using sensors. 
     It is also an object of the invention to control a valve assembly comprising two or more valves such as the valve assembly used to supply hot and cold water to an appliance, for example a washing machine. 
     It is also an object of the invention to provide a method and apparatus that will minimize the damage caused if a pipe or other water supply component breaks. 
     It is also the object of the invention to provide a method and apparatus that will control an outdoor water supply to prevent unauthorized use or minimize the water wasted when an outdoor hose breaks. 
     This and other objects are achieved according to the invention by a valve control device that is easily mounted to an existing manually controlled valve. The valve control device includes a motor, a means to increase torque and decrease revolutions per minute of the motor, a means to transfer torque from the motor or any torque/rpm conversion device to a valve without physically relocating the valve, and a means to secure the valve control device to the controlled valve. The valve control device turns the valve on or off based upon a variety of external conditions. The valve control device can be used in a variety of applications including but not limited to 1. Controlling the main water supply valve of a building so that water is shut off when the building is unoccupied and does not require water, 2. Controlling the water supply line that supplies water to an outdoor water supply, and 3. Controlling the hot and cold water valves that supply water to an appliance. 
     In the first case, the valve control device is fastened to the main water supply valve of a building. The valve control device turns the water supply off when no occupancy is sensed in the building for a predetermined period of time. Alternatively, the valve control device turns the water on for a predetermined period of time whenever occupancy is sensed. Occupancy sensing can be accomplished using a variety of methods including but not limited to acoustic sensing, infrared sensing, and visual sensing. 
     In the second case, the valve control device is fastened to the valve located inside a building that controls water to an outside water supply. The valve control device turns the water-on for a predetermined period of time based upon the users needs. 
     In the third case, the valve control device is fastened to one or more valves that supply water to an appliance. The valve control device turns the water on only when the water is needed to operate the appliance. 
     The above and other objectives are also achieved according to the invention by a method of controlling a valve that controls liquid flow. 
     In one embodiment, the method comprises the steps of 
     1. Sensing whether a building is occupied, and 
     2. Turning the valve off after a predetermined period of time after occupancy is no longer sensed or alternatively turning the valve on for a predetermined period of time after occupancy is sensed. 
     In a second embodiment, the method comprises the steps of: 
     1. Sensing through a human user interface that the user wants to turn on the valve, and 
     2. Turning on the valve for a period of time selected by the user or as required to serve a purpose such a watering a lawn. 
     In a third embodiment, the method comprises the steps of: 
     1. Sensing through a human interface or electronic interface that the appliance is on and requires water, 
     2. Turning on the valves that supply water to the appliance, and 
     3. Turning off the valves when the appliance no longer requires water either through a human interface, through a timer mechanism, or through sensing that the appliance no longer requires water. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a drawing of a solenoid-controlled valve as used in prior art 
     FIG. 2 is a drawing of a motor driven valve as used in prior art 
     FIG. 3 is a drawing of certain elements of the invention including the motor controller, the motor, a gear drive, the motor mount, and a means to transfer torque from the motor using drive studs. 
     FIG. 4 shows the invention connected to a standard pre-mounted washer valve. 
     FIG. 5 shows the invention mounted to a standard gate valve. The gate is shown open. 
     FIG. 6 shows the invention mounted to a gate or washer valve using a cylindrical coupling device. 
     FIG. 7 shows the invention mounted to a gate or washer valve using a gear drive approach. 
     FIG. 8 shows the invention mounted to a ball valve. FIG. 8 also shows a detail of the drive connecting system. 
     FIG. 9 shows the invention mounted to a ball valve using a cylindrical coupling approach. 
     FIG. 10 shows the invention mounted to a ball valve using a gear drive approach. 
     FIG. 11 shows the invention mounted to a valve using a worm gear drive approach. 
     FIG. 12 is a block diagram of the motor controller including user interfaces. 
     FIG. 13 is a block diagram of the invention to show various elements that can interface to the motor controller to control the motor to turn the main valve that supplies water to a building on and off. 
     FIG. 14 is a block diagram of the invention to show various elements that can interface to the motor controller to control the motor to turn a valve that controls water flow to an outdoor water supply on and off. 
     FIG. 15 illustrates a multiple valve assembly with a single controlling lever such as that used to control hot and cold water to an appliance. 
     FIG. 16 shows the invention mounted to a multiple valve assembly. 
     FIG. 17 shows an alternative means to mount the invention to a multiple valve assembly. 
    
    
     DETAILED DESCRIPTION 
     Figure one and two show the current state of the art for electronically controlled valves. Figure one illustrates a solenoid actuated valve. Moving plunger  150  controls liquid flow from the inlet  110  to the outlet  130 . Current passing through wires  120  actuates solenoid coil  140 . Solenoid coil  140  moves plunger  150  such that plunger  150  either blocks the flow of water or does not block the flow of water. The valve can be constructed so that liquid flows when current passes through wires  120  or does not flow when current passes through wires  120 . 
     Figure two illustrates a motor controlled valve. This assembly includes a motor  260 , a motor drive gear  240 , connected to a valve gate drive gear  230 , a valve monitoring switch  220 , a gate  210 , and power wires  250 . The motor  260  gears  230  and  240 , and monitoring switch  220  can be constructed so that liquid flows when current passes through the power wires  250  or does not flow when current passes through the power wires  250 . 
     Valves of the type in Figures one and two are available in many forms from a variety of manufactures. They cannot be used to convert an existing manually controlled valve into an electronic valve. To make such a conversion, the electronically controlled valve must be attached to the pipes servicing the valve. Attaching such a valve usually requires a plumbing expense that exceeds the cost of the valve. A preferred approach would be to have a valve control system that easily mounts to an installed valve. A secondary benefit of separating the motor drive from the valve is to provide a system that converts standard commercial high volume inexpensive valves into electronically controlled valves. 
     The invention described provides such a system. 
     Figure three, one preferred embodiment of the invention, shows a motor, drive, and control assembly that can be mounted to a variety of valve types. Figure three includes motor  304 , drive  303 , drive connector  312 , drive couplers  307  and  311 , controller  306 , mounting bracket  301 , mounting studs  302 ,  309 , motor mount  310 , motor control wires  305 , and power wires  308 . Motor  304  is connected to drive connector  312  through drive  303 . Drive  303  serves to reduce the speed and increase the torque of motor  304 . Drive  303  can be eliminated if the motor is designed to produce relatively high torque at low speeds. Drive connector  312  transfers rotary motion from drive  303  to the controlled valve using drive couplers  307  and  311 . Mounting bracket  301  is mounted behind the controlled valve and connected to motor mount  310  using mounting studs  302  and  309 . Drive connector  312  and drive couplers  307  and  311  transfer rotary motion to a standard valve handle. To prevent damaging the valve under fault conditions, drive couplers  307  and  311  can be designed to break at a stress level that is lower than a level that will break the valve. Thus the entire system can be easily assembled to a valve that is mounted to the pipes servicing the valve without the need to disturb the plumbing. Controller  306  provides power and control to motor  304  through wires  305 . Motor controller  306  receives power from power wires  308 . Motor controller  306  controls the rotational direction of motor  304 . Motor controller  306  controls motor  304  based upon one or more of the following: 
     user programming 
     current demanded by motor  304   
     the volt time product or current time product required to drive motor  304  to turn on or off the controlled valve 
     any other means to turn on and off the controlled valve 
     Figure four shows the assembly described above mounted to a standard washer type valve  405 . In this embodiment, the length of the drive couplers  401  and  402  compensate for the up and down movement of the valve stem  403  and valve handle  404 . 
     Figure five shows the assembly mounted to a standard gate valve  505 . This motor drive assembly is similar to the one shown in Figure four. However, the valve stem  503  and valve handle  504  do not move up and down for this valve type. 
     Figure six shows an alternative embodiment. The torque produced by motor  601  is transferred through drive  602  to valve  605  through a coupling device  603 . The coupling device  603  directly couples drive  602  to valve  605 . Coupler  603  of Figure six replaces the function of drive connector  406  and drive couplers  401  and  402 , of Figure four. To prevent damaging the valve under fault conditions, coupler  603  can be designed to break at a torque that is lower than a torque that will break the valve. 
     Figure seven shows another approach in which the motor drive transfers torque to valve  707  (hidden) through gears  704  and  706 . Motor mount  708  is mounted to the water pipes using mounts  703  and  705 . 
     Figure eight shows the assembly mounted to a ball valve. The drive connector  811  and drive couplers  807  and  808  differ from the prior embodiments illustrated in Figures four and five to accommodate the operation of the ball valve  809 . Figure eight, a preferred embodiment of the invention, includes motor  813 , drive  803 , drive connector  811 , drive couplers  807  and  808 , controller  801 , mounting bracket  810 , mounting studs  806  and  812 , motor mount  805 , motor control wires  802 , and power wires  816 . Motor  813  is connected to drive connector  811  through drive  803 . Drive  803  serves to reduce the speed and increase the torque of motor  813 . This can be done using gear reduction or other known techniques. Drive  803  is not necessary if the motor is designed to produce high torque at low revolutions per minute. Drive connector  811  transfers rotary motion from drive  803  to the controlled valve  809  using the drive couplers  807  and  808 . Mounting bracket  810  is mounted behind the controlled valve  809  and connected to motor mount  805  using mounting studs  806  and  812 . Drive connector  811  and drive couplers  807  and  808  transfer rotary motion to a standard valve handle of the type normally found on a ball valve. To prevent damaging the valve under fault conditions, drive couplers  807  and  808  can be designed to break at a torque that is lower than a torque that will break the valve. Thus the entire system can be easily assembled to a ball valve that is mounted to the pipes servicing the valve without the need to disturb the plumbing. Controller  801  provides power and control to motor  813  through wires  802 . Motor controller  801  receives power from power wires  816 . Motor controller  801  controls the rotational direction of motor  813 . 
     Figure eight also shows a detail of the method used to couple drive connector  811  to ball valve handle  814 . The ball valve handle  814  is secured to the valve stem  815  using standard techniques. Drive connector  811  mounts up against ball valve handle  814 . Drive connector  811  moves gate valve handle  814  in a rotary direction using drive couplers  807  and  808 . Drive couplers  807  and  808  are mounted on opposite sides of ball valve handle  814  such that drive coupler  807  pushes against ball valve handle  814  to move it in a clockwise direction and drive coupler  808  pushes against gate valve handle  814  to move it in a counter-clockwise direction. To prevent damaging the valve under fault conditions, drive couplers  807  and  808  can be designed to break at a stress level that is lower than a level that will break the valve. 
     Figure nine shows an alternative embodiment for the ball valve. The torque produced by motor  903  is transferred through drive  904  to valve  902  through a coupling device  901 . The coupling device  901  directly couples drive  904  to valve  902 . Coupler  901  of figure nine replaces the function of drive connector  811  and drive couplers  807  and  808 , of figure eight. To prevent damaging the valve under fault conditions, coupler  901  can be designed to break at a torque that is lower than a torque that will break the valve. 
     Figure ten shows another approach in which the motor drive transfers torque to a gate valve  1006  (hidden) through gears  1004  and  1005 . Motor mount  1008  is mounted to the water pipes using mounts  1002  and  1003 . 
     Figure eleven illustrates an embodiment for the washer, ball, or gate valves using a worm drive configuration. For this configuration, worm drive gear  1104  is mechanically coupled to gear  1103  to turn valve  1104  (hidden) on and off. Motor  1101  drives worm gear  1104 . Mounting bracket  1102  secures motor  1101  to the pipe. 
     Figure twelve is a block diagram representation of one possible embodiment of the motor control. For this embodiment, motor control  1201  consists of timer circuit  1203 , current sense circuit  1205 , voltage sense circuit  1211 , motor current control switch  1206 , logic driver  1204 , position sensor  1213  and user interface  1210 . Motor control  1201  provides voltage to motor  1208  through wires  1207  and  1212 . Motor  1208  can be of the type such that the motor turns in one direction (clockwise for purposes of this discussion) when wire  1207  is positive with respect to wire  1212  and the opposing direction (counter-clockwise) when wire  1212  is more positive than  1207 . In this example the clockwise direction turns the valve on and the counter-clockwise direction turns the valve off. 
     Motor control  1201  directs current flow based upon one or more of the following: 
     The current flowing through motor  1208   
     The last direction of rotation of the motor 
     The time required to turn on or off the controlled valve 
     The volt time product to turn the valve on or off 
     The current time product to turn the valve on or off 
     The position of position sensor  1213   
     User interface  1210   
     Figure thirteen shows one potential application of the invention. In this embodiment, the motor controlled valve  1301  (hidden) is the main shut off to a building. Motor control  1306  includes an occupancy sensor  1307 . Motor control  1306  turns valve  1301  on when building occupancy is sensed and off when building occupancy is not sensed. A delay can be added so that valve  1301  (hidden) is turned off after a pre-selected period after no occupancy is sensed in the building. Alternatively, a delay can be added that keeps the valve on for a pre-selected time after occupancy is sensed in the building. The motor drive can also contain circuitry that turns the valve on for short periods of time at specific intervals. This feature is useful under certain circumstances where equipment in the residence such as boilers, ice-cube makers, humidifiers, etc must be refurbished with water. The motor drive circuit can also include an override function to turn on the valve as required to operate other types of appliances such as lawn sprinklers. The valve would shut of concurrently with the equipment to minimize any damage done if a break had occurred in the water distribution system. The motor controller can also respond to a moisture detector  1308 , or other sensing mechanism  1309 . The motor controller can be set to turn on the valve using wires  1304  during periods when water is needed such as when a sprinkler system or outdoor spigot is turned on. 
     Figure fourteen illustrates a second application of the invention. In this embodiment, the motor controlled valve  1401  (hidden) is used to turn on and off water supply to an outdoor water spigot. Motor control  1406  turns valve  1401  on based upon a user interface. The user interface can be as simple as a switch  1402  or a more complicated timer  1403  or water supply measuring device  1404 . 
     Figure fifteen shows a multiple valve assembly, in this case two valves, in which both valves are controlled by a single user interface, in this case a lever  1570 . Pipe  1540  provides liquid to valve  1520  and pipe  1530  provides liquid to valve  1510 . Coupler  1580  connects valve  1510  to valve  1520 . Valve control lever  1570  is connected to coupler  1580  to turn valve  1510  and valve  1520  on and off. One implementation of this type of valve assembly is to turn the hot and cold water to a washing machine for cloths on and off. For this case hoses  1550  and  1560  connect the hot and cold water to the washing machine. However, this arrangement could be used to supply liquid to any machine or appliance. 
     Figure sixteen shows one method to couple a motor to the multiple valve assembly shown in figure fifteen. Motor  1620  is mounted to motor bracket  1610 . Motor bracket  11610  is either an integral part of valve brace  1640  or is mounted to valve brace  1640  using any suitable fastening system. Valve brace  1640  is a box like structure that has a top and four sides. One of the sides is cut to accommodate hoses  1550  and  1560 . The top has a slot that allows valve control lever  1570  to pass through and move freely. Valve brace  1640  is placed over the valve assembly such that hoses  1550  and  1560  pass through one of the sides and lever  1570  passes through the top. The valve brace braces the motor bracket to the valve assembly. 
     Lever  1630  is fastened to the motor shaft on one end and to coupler  1640  on the second end. One method to fasten lever  1630  to coupler  1640  is to use a pin such that the angle between lever  1630  and coupler  1640  can change as the motor rotates. The second end of coupler  1640  is fastened to valve control lever  1570  such that coupler  1640  transfers the rotary torque from lever  1630  to valve control lever  1570  in such a way as to turn the multiple valve assembly on and off. 
     Figure seventeen shows a second means to control valves  1520  and  1510  using the current invention. Motor  1720  is mounted to motor mount  1750 . Motor mount  1750  is either an integral part of valve brace  1640  or is mounted to valve brace  1640  using any suitable mounting method. Motor  1720  is mounted to motor mount  1750  such that its shaft runs parallel and above the front of valve brace  1640 . Lever  1730  is connected to motor  1720 &#39;s shaft at one end so that it rotates with the shaft. The second end of lever  1730  is connected to one end of connecting rod  1740  using a pin or similar connecting device. The second end of connecting rod  1740  is fastened to valve control lever  1570  such that connecting rod  1740  transfers the rotary torque from lever  1730  to valve control lever  1570  in such a way as to turn the multiple valve assembly on and off. 
     The invention is not limited in any way to the applications discussed. The invention can be used to automatically control the flow of liquid or gas in any application. In particular, the methods described earlier to control an individual valve including sensing current, voltage, occupancy, position, and instructions from a user interface apply to the control of a multiple valve assembly.

Technology Classification (CPC): 3