Patent ID: 12252416

DESCRIPTION OF EMBODIMENTS

In the following description, like reference characters designate like or corresponding parts throughout the several figures. It should be understood that the illustrations are for the purpose of describing preferred embodiments of the invention and are not intended to limit the invention thereto. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “left,” “right,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.

In one example, as best seen inFIGS.1-9, a F.O.G. separator assembly10includes a container12. The container12may include sectional covers14a,14b, and14c. In one example, as inFIG.1, the sectional covers are joined by hinges. The cover can be made up of sectional units or a single-unit cover. The sectional covers14a,14band14ccover each of the sections of the F.O.G. and/or solid waste removal assembly and may be one piece, attached or separate. The assembly10has at least one skimmer assembly. In one example, the skimmer assembly includes a rotatable disk16which may be supported, as shown, by the center sectional cover14b.FIG.1shows a gear drive motor20and a trough22which may be attached to the cover14b. The container12also includes an inlet pipe26and an outlet pipe28. The effluent water, with waste materials, enters through the inlet pipe26, and after oil, grease and solid waste have been removed, the grey water exits out of the outlet pipe28. The trough22may include scraper blades24. In this example, the gear drive motor20typically supports and rotates a drive sprocket38which is cooperatively meshed with peripheral holes in the disk16.

Container12may be constructed of rotomolded plastic and may include a basket support34as shown inFIGS.2and3. The basket support34is typically constructed of rotomolded plastic and may be designed to hold a strainer basket (not shown). The basket support34may be immediately downstream of the inlet pipe26and has a cutout36to align with the inlet pipe26. Basket support openings37permits the effluent water with fat, oil and grease to flow downstream of the basket support34after the solid waste material has been trapped in the strainer basket removably positioned in the support34.

As seen inFIG.7A, the cover14bmay also support a heating element50that extends down into the water held in the container12and which is used to maintain a sufficiently warm enough water temperature to melt any grease contained in the grey water, permitting it to flow to and be removed by the rotating disk16. The heating element50is, by way of example, a 450 watt heater.

An oil/grease storage tank (not pictured) may be in communication with the trough22in order to receive the F.O.G. which has been scraped from the disk16by the scraper blades.

In operation, the fat, oil, grease and/or solid removal assembly10is connected to drain from a sink or other device that discharges effluent water with waste materials to be separated. The water containing waste materials flows from the device's drain into the F.O.G. and/or solid removal assembly10through the inlet pipe26. The effluent water flows into the basket support34containing a strainer basket and the solid waste materials are trapped and removed from the effluent water. The effluent water containing fat, oil and grease flows downstream from the basket support34through openings into the center section of container12. In the volume of the container12between the basket support34and an outlet baffle, the effluent has time to reside, permitting fats, oil and grease to rise to the top of the water. The grease is maintained in a liquid state by the heater50. The heating element also turns on when the thermistor detects a temperature approaching freezing (i.e. 0 degrees Celsius).

When the gear drive motor20turns the drive sprocket38, the disk16is rotated in a clockwise direction by the counter clockwise rotation of the drive sprocket38. The disk16is positioned in the center cover14b, so that its lower portion is below the surface of the effluent water having the fat, oil and grease which has floated to the surface. As the disk16rotates through the water, F.O.G. is picked up on the sides of the disk16and the scraper blades24attached to the trough22remove the F.O.G. from the sides of the disk16. The F.O.G. flows down the trough22to a F.O.G. storage container. Once the F.O.G. have been removed from the effluent water, the grey water flows downstream under the baffle outlet and exits the F.O.G. removal assembly10through the outlet pipe28into the sewage system. More examples and details of a F.O.G. removal assembly may be found in U.S. Pat. No. 6,800,195 to Batten et al. and U.S. Pat. No. 7,208,080 to Batten et al. which are both herein incorporated by reference in their entireties. Other types of skimmers can be used in the invention, too, including but not limited to: belt skimmers, examples of which can be seen in U.S. Pat. No. 7,427,356 to Chapin and U.S. Pat. No. 7,296,694 to Weymouth; skimmers that include one or more rotating cylinders that partially or completely submerge, one example as is shown in U.S. Pat. No. 4,051,024 to Lowe et al; skimmers with an absorptive affinity for F.O.G and/or skimmers that include non-cylindrical grease collectors pivoting to come into contact with F.O.G. for removal, one example as seen in U.S. Pat. No. 4,235,726 to Shimko. Another suitable F.O.G. separator is sold by Thermaco, Inc. of Asheboro, NC as its Might Trap brand product.

As seen inFIG.9the preferred embodiment provides a F.O.G. separator (that may have a control system) that senses a F.O.G. layer using thermocouples. Two rods that are suspended from the ceiling. As used in this application, “skimming” includes other ways of taking the F.O.G. off the top, including opening spouts that drain the F.O.G. (see U.S. Pat. No. 7,186,346 for examples), pumping the F.O.G. (see U.S. Pat. No. 6,517,715 for an example), or other active methods.

In one example, rods112,114are of differing length, and each has at its end a thermocouple and heater. Each thermocouple and heater has wires that travel inside the respective rods to a control box with communications module130in the embodiment ofFIG.9in the roof of the unit. The control box130is configured to periodically input current to the heating element. A volt meter may be included in the box130on the output lines of the thermocouple to measure the output voltage of the thermocouple. Alternatively, the box130can digitize and communicate the reading from the thermocouple for evaluation at a remote server, as will be discussed below.

The thermocouple output voltage varies with its temperature, and its temperature response to the applied voltage varies with the dissipation of heat from the heater into the surrounding liquid. If the liquid is water, the heat dissipation from the heater is at a faster rate than if the heater is located in F.O.G. so if the thermocouple is in F.O.G. its temperature will rise faster than if it is in water. If the heater is in air, the temperature rise is much faster yet. Thus, the temperature rise of the thermocouple and, hence its output voltage, will vary depending on whether the thermocouple is immersed in air, water or F.O.G. This difference is sufficient to enable control or output box18to identify whether one or more of the thermocouple probes is located in air, F.O.G. or water.

The thermocouples are useful on the active F.O.G. removal units, such as the Big Dipper. As seen inFIG.9, such active units include a container12that receives effluent from an inlet26and allows the flow rate to slow sufficiently that a F.O.G. mat38can collect on top of the grey water40.

Numerous advantages can result when the active separator is used with sensors that measure when a sufficient F.O.G. mat38is present in the container12to warrant operation of the active separator, and that avoid or terminate operation when not needed. The sensed data can be communicated to a remote server for decision-making, and decisions can be downloaded to the separator, using the communications module, as discussed in more detail below.

This type of control of the operation avoids wasted operation and it avoids operation for periods when operation is not needed. In some instances, a particularly heavy load of F.O.G. needs removal, and if the skimmer operates for a pre-set removal period, inadequate removal may be the result.

Also, by halting the removal of F.O.G. early enough, so as to always leave a slight layer of F.O.G. on the top of the water, the escape of foul odors from the water that would be exposed by complete removal of the F.O.G. can be avoided. As seen inFIG.9, detector112is slightly below the static water line46. By terminating operation as soon as the detector112senses water, rather than F.O.G., a slight F.O.G. mat remains above the grey water40. This also avoids the release of humidity that can challenge the longevity of electronics and other gear of the separator.

A logic circuit can be provided to indicate a malfunction has occurred requiring service if the lower most sensor114continues to detect F.O.G. after separator operation for enough time that F.O.G. removal should be complete.

The logic of determining whether a sensor is in F.O.G., water, or air is explained in more detail in U.S. Pat. No. 7,828,960 to Batten et al., the entire disclosure of which is incorporated herein by reference.

When a sufficiently thick level of F.O.G. is determined to exist, the heater49which is immersed in the water (as is conventional) can be actuated to raise the temperature of the liquids so as to assure that the F.O.G. will be in a liquefied form. This can be followed by operation of the active skimmer32, which continues until such time as the upper level thermocouple112begins output data that it is immersed in water, rather than F.O.G., at which time the active skimmer is stopped. The signals to operate the skimmer can be comparable to those conventionally received from a timer for timer-operated skimmers.

If the rate of rise of temperature for either thermocouple is extraordinarily fast, logic can sense that the thermocouple is in air, rather than in F.O.G. or water. Suitable logic can be provided to deal with that circumstance. In particular, for a F.O.G. removal separator that is provided with an automatic solids transfer unit (such as is shown in U.S. Pat. Nos. 6,491,830 or 5,360,555) the fact that the sensor is in air indicates that the automatic solids transfer unit should not operate.

The provision of the sensors enables the elimination of the conventional electromechanical timer as the control of when to turn on the skimmer. If desired, a timer can be used to determine when to send sensing voltage to the probes. Also, in some instances the collection canister for removed F.O.G. is of a limited capacity, so that allowing F.O.G. to be directed to the canister from the skimmer for an unspecified period of time risks overflowing the canister. In such cases it may be preferable to use a timer to terminate skimming after a predefined time interval, although skimming starts when a thermocouple senses F.O.G. In such installations, only the one thermocouple is needed.

Additional F.O.G. removal devices with which the invention can be used include the Trapzilla line of grease interceptors sold by Thermaco, Inc. of Asheboro, NC, discussed in U.S. Pat. No. 7,367,459 to Batten et al. entitled Passive Grease Trap Using Separator Technology and U.S. Pat. No. 7,641,805 to Batten et al. entitled Passive Grease Trap With Pre-Stage For Solids Separation. The disclosures of these patents are hereby incorporated herein by reference in their entireties. It can also be used on other F.O.G. separators that have electrical components. U.S. Pat. No. 7,367,459 describes a F.O.G. trap for separating F.O.G. and solid waste from waste water. An example is seen inFIGS.10and11of this application. The F.O.G. trap includes a tank60, in this example, having a conically shaped bottom62. A divider63divides the tank into an upper chamber and a lower chamber. A hole (not shown in theFIG.10or11) near an upper part of the divider63allows F.O.G. to rise into the upper chamber. An inlet invert64in the tank receives incoming waste water, while an outlet invert66removes water from the tank. A lid68covers the tank. A pipe70extends through the lid, upper chamber, and the divider for pumping solid waste out of the lower chamber, as well as the F.O.G.s, most grey water having passed through the outlet invert66.

Two vertical rods112and114supported by lid68have the heater/thermocouple assemblies in their lower portion, by way of example the lower 1 to 2 inches. The remainder of the column lengths of the rods is made up of conduit for carrying the wires to the top and for supporting the heater/thermocouple at the correct depth within the tank. The longer rod14preferably terminates at the level where the tank is considered to be about 75% full of F.O.G., and the shorter one is at about the 50% level. Other locations can be used. The power and thermocouple wires come from the top of the rods and connect through connector17to control box130and to allow for periodic connection through connector17to an “output box” (not shown). The output box, described below, is in the possession of a sewer official or other person assessing the condition of the unit. The wiring from the rods to the connector17is preferably sufficiently long to allow the lid68, to be removed and for the addition of expansion collars. The preferred thermocouple is available from Watlow Electric Manufacturing Company, 12001 Lackland Road, St. Louis, Missouri, USA 63146 as their Firerod Internal thermocouple, Style A.

In one example in the process, the voltages of the two thermocouples are measured at a first stage A and again at a later stage B, with power being supplied to the heaters between A and B. The changes in the voltages of the thermocouples are computed at stage C (either within the control box or remotely, as with the embodiment ofFIGS.1-9). If the voltage change exceeds a threshold (i.e. >x.xx mV), then an indication that the rate of rise was fast can be generated. A voltage change below the threshold indicates that the thermocouple is in water. If the voltage is over a higher threshold, similar logic can indicate that the thermocouple is in air. The threshold, of course, is determined for each separator design based upon geometry and the length of time the heaters stay on and the time between voltage readings. Applicants have used heaters of 50 and 200 watts and time intervals of ten seconds, but a wide range of other values would be suitable. Time intervals measured on the order of milliseconds can be used.

In both embodiments, if the temperature rise indicates that a thermocouple is in air, pumping or skimming is inappropriate. If both are in air, a repair may be needed.

As seen inFIG.13, the communications module130has communications capabilities such as a cellphone or Wi-Fi connection and can relay messages from the sensors112,114and switches. Sensors can sense temperature, solids levels, water levels, F.O.G. levels or other variables. The switches can be used to turn on a skimmer in a skimming type F.O.G. separator or signal lights or other devices. If desired, an inteimediate controller electrically situated between the module130and the sensors or switches can be included. A suitable module130may be available from Zytron Control Products, Inc., of Trenton, New Jersey. The module130can include a printed circuit board with a processor140, transmitter142, antenna143, modem144, and memory146. The module130can operate with the Apple iOS, Google Android, or other suitable operating system. The memory may store an App to carry out the functions described herein. Information about the geographic location of the F.O.G. separator can be ascertained by the GPS module132for use by the controller130.

In one embodiment the controller may permit cellphone or other communications operation to report a malfunction and/or need for a service call. In addition, the GPS receiver or the like can help a service technician locate where the F.O.G. separator is. Also, a central office can be informed of the selected mode or skimming frequency, so the central office can recommend or implement changes if it does not think a mode setting is appropriate for the specific establishment. The communications capability can report cumulative operating time to allow recommendations for replacement parts for preventative maintenance.

Referring toFIG.13, the module130can be configured to send or relay information to restaurant owners or managers160, or sewer system officials180, grease pumpers or maintenance personnel170, or to the F.O.G. separator system vendor190, or more than one of them. The module130is given unique identifier, so as it sends or relays information, that identifier can be included in message protocols, enabling the recipient to know with which separator it is communicating. The module is preferably password protected.

The monitoring of the F.O.G. separator can include uploading data to a database for recordation in that database. The app in the module's memory is preferably programed to upload data in a consistent format to allow standardization in the database among all of the reporting separators. The database can be maintained by restaurant owners or managers, or sewer system officials, grease pumpers or maintenance personnel, or to the F.O.G. separator system vendor, or more than one of them.

The uploading of data can take place on a regular schedule, reporting whatever has or has not happened at a particular F.O.G. separator. Or, the uploading can be intermittent, only occurring when a reportable event occurs or to report a problem. A particularly useful message for grease traps requiring periodic pumping is a signal that such pumping is needed.

Data can also be downloaded to the module130in a particular separator, to provide updated software, or instructions for particular actions. For example, a vendor may download an override to reset control of the remote device.

In addition, the module130can be configured to allow for operation of the separator based upon logic and data stored “in the cloud,” that is, on a remote server200. The server includes the database and decision-making logic and downloads instructions to the module130in the separator. One such instruction to a skimming separator would be to tell the skimmer to be active. Locating the logic devices in the remote server allows the electronics at the separator to be reduced in complexity, essentially only the sensors needed to collect data and relays to open and close switches as instructed by the cloud server200.

Also disclosed is a method of controlling removal of grease, oil and solid waste material from effluent water including: installing an oil, grease and solid waste removal assembly at a facility site; connecting an inlet pipe of the oil, grease and solid waste removal assembly to a source discharging effluent water with waste materials to be removed; connecting an outlet pipe of the oil, grease assembly to a sewage system; installing a communications module to allow the oil, grease and solid waste removal assembly at the facility site to communicate over cellular or WiFi signals to a remote station. The remote station can record data from the oil, grease and solid waste removal assembly at a facility site. In another embodiment the remote station can download instructions to the oil, grease and solid waste removal assembly at a facility site.

Numerous characteristics and advantages have been set forth in the foregoing description, together with details of structure and function. Many of the novel features are pointed out in the appended claims. The disclosure, however, is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts, within the principle of the disclosure, to the full extent indicated by the broad general meaning of the terms in which the general claims are expressed. It is further noted that, as used in this application, the singular forms “a,” “an,” and “the” include plural referents unless expressly and unequivocally limited to one referent. Certain modifications and improvements will occur to those skilled in the art upon reading the foregoing description. It should be understood that all such modifications and improvements have been omitted for the sake of conciseness and readability, but are properly within the scope of the following claims.