Apparatus to implement automatic refilling functionality for a liquid holding tank that is the final tank in a flow-path-interconnected series of tanks
10287153 ยท 2019-05-14
Inventors
Cpc classification
F16K31/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16K5/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B67D3/0003
PERFORMING OPERATIONS; TRANSPORTING
B67D3/0038
PERFORMING OPERATIONS; TRANSPORTING
Y10T137/7404
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B67D3/0061
PERFORMING OPERATIONS; TRANSPORTING
B67D2001/1261
PERFORMING OPERATIONS; TRANSPORTING
B67D1/0014
PERFORMING OPERATIONS; TRANSPORTING
International classification
B67D3/00
PERFORMING OPERATIONS; TRANSPORTING
F16K31/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16K21/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A tank refilling system is configured to keep liquid in a destination tank close to a predetermined destination tank fill line. The tank refilling system has a source tank connected to a destination tank with a flow through secondary process therebetween. Liquid flows between the tanks by gravity fed drainage. A single liquid supply channel to transfer pressurized supply liquid is comprised of a plurality of piping segments and one or more valves, all connected in series. A source tank mounted valve is configured to permit liquid to flow until the height of liquid level in the source tank reaches a predetermined level. A destination tank mounted valve is configured to permit liquid to flow until the height of liquid level in the destination tank reaches a predetermined level. The apparatus of the invention also prevents tank overflow for both the source tank and the destination tank.
Claims
1. A tank refilling system configured to keep a height of liquid level in a destination tank close to a predetermined fill line; said tank refilling system comprising: a) a source tank comprising a source tank liquid entrance opening; b) said destination tank comprising a destination tank liquid entrance opening and, a destination tank liquid discharge valve; c) a secondary process comprising a secondary process liquid inlet and, a secondary process liquid discharge outlet; said secondary process liquid inlet being in liquid communication with said source tank and, said secondary process liquid discharge outlet being in liquid communication with said destination tank; d) said secondary process being positioned above an interior bottom surface of said source tank, such that liquid will flow by gravity fed drainage out of said source tank, and into said secondary process liquid inlet; e) said secondary process being positioned above said destination tank, such that liquid will flow by gravity fed drainage out of said secondary process liquid discharge outlet, and into said destination tank liquid entrance opening; f) a means responsive to liquid level height in said source tank, for increasing and decreasing liquid flow rate into said source tank liquid entrance opening as liquid level height in said source tank falls below and rises to a predetermined height; and g) a means responsive to liquid level height in said destination tank, for increasing and decreasing liquid flow rate into said source tank liquid entrance opening, as liquid level height in said destination tank falls below and rises to a predetermined height.
2. The tank refilling system of claim 1, further comprising: a) a source tank valve comprising an inlet port, an outlet port, a flow rate control input, a ball float and, a float rod; wherein one end of the float rod of said source tank valve is connected to the ball float of said source tank valve and; wherein an other end of the float rod of said source tank valve is connected directly to, and operates, the flow rate control input of said source tank valve; b) a destination tank valve comprising an inlet port, an outlet port, a flow rate control input, a ball float and a float rod; wherein one end of the float rod of said destination tank valve is connected to the ball float of said destination tank valve and; wherein an other end of the float rod of said destination tank valve is connected directly to, and operates, the flow rate control input of said destination tank valve; c) one liquid flow channel comprising a plurality of piping segments, said source tank valve and, said destination tank valve; wherein said plurality of piping segments and, said source tank valve and, said destination tank valve are connected in series; d) a first piping segment, said first piping segment being connected between the outlet port of said destination tank valve and the inlet port of said source tank valve; and e) a second piping segment, said second piping segment being connected between the outlet port of said source tank valve and said source tank liquid entrance opening.
3. The tank refilling system of claim 1, further comprising: a) a source tank valve comprising an inlet port, an outlet port, a flow rate control input, a ball float and a float rod; wherein one end of the float rod of said source tank valve is connected to the ball float of said source tank valve and; wherein an other end of the float rod of said source tank valve is connected directly to, and operates, the flow rate control input of said source tank valve; b) a destination tank ball float and a destination tank alternate float rod wherein one end of said destination tank alternate float rod is connected to said destination tank ball float and wherein an other end of said destination tank alternate float rod extends upward into an interior of said source tank to a vertical distance that is proportional to a height of liquid level in said destination tank; c) and wherein when the height of liquid level in said destination tank rises to a predetermined height, the ball float of said source tank valve, and the float rod of said source tank valve will be held upward by said destination tank alternate float rod to a predetermined height that forces said source tank valve to close; d) said destination tank alternate float rod being positioned horizontally relative to a horizontal position of the ball float of said source tank valve and the float rod of said source tank valve such that said destination tank alternate float rod aligns horizontally with either the ball float of said source tank valve or with the float rod of said source tank valve, or both, such that said destination tank alternate float rod is able to interfere with an angular travel of the ball float of said source tank valve and the float rod of said source tank valve; and e) a first piping segment, said first piping segment being connected between the outlet port of said source tank valve and said source tank liquid entrance opening.
Description
BRIEF DESCRIPTION OF THE FIGURES
(1) The detailed description of some embodiments of the invention is made below with reference to the accompanying figures, wherein like numerals represent corresponding parts of the figures.
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DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS
(12) Numerous advantages are realized by the embodiments disclosed herein. Some of these advantages are described in the list below. 1) Elimination of the need inherent in the prior art systems that they be refilled manually by the user. 2) The ability to self detect when the lower, or destination, tank is becoming empty, and then to automatically begin an autonomous cycle to refill the system in a precise and repeatable manner, while at the same time eliminating any tank overflow occurrences common to the prior art systems. 3) There is no need for electricity or computer functionality for the embodiments to initiate and then sequence correctly through a series of exemplary states in the refill cycle as disclosed. 4) The embodiments make possible the use of tanks that are smaller than the tanks needed in the prior art systems to achieve the same performance characteristics. Because most of the systems being sold today use tanks made of expensive food grade stainless steel, this would result in reductions in the cost of the materials to manufacture the systems. These cost reductions represent a very desirable benefit, both for a manufacturer, and eventually for the consumer. 5) Many of the prior art systems available, such as the popular gravity fed, water purification systems, are comprised of the secondary process elements that are very expensive flow through filter elements having a porous outer surface. The embodiments make possible the use of considerably smaller filter devices than are needed to achieve the same performance characteristics as in the prior art systems. The smaller filter devices result in reductions in the cost of materials to manufacture the systems. This represents a very desirable benefit, both for a manufacturer, and eventually for the consumer.
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(14) TABLE-US-00001 List of elements depicted in the figures Element Number Element Name 100 source tank 102 destination tank 104 ball float of the source tank valve 106 ball float of the destination tank valve 108 source tank valve 110 destination tank valve 112 float rod of the source tank valve 114 float rod of the destination tank valve 116 liquid supply connection 118 manually operated valve 120 third piping segment 122 first piping segment 124 second piping segment 126 secondary process liquid inlet 128 secondary process 130 secondary process liquid discharge outlet 132 destination tank liquid discharge valve 134 the liquid in the system 150 source tank maximum level 152 source tank interior bottom surface 154 destination tank maximum level 156 destination tank transition level 158 destination tank interior bottom surface 900 destination tank alternate float rod
(15) In all of the embodiments here disclosed, a source tank 100 is positioned above a destination tank 102, high enough to allow liquid to drain out of source tank 100, and into destination tank 102, by the force of gravity.
(16) In all of the embodiments here disclosed, a secondary process 128, is comprised of one or more secondary process liquid inlet(s) 126, that are in liquid communication with source tank 100, and one or more secondary process liquid discharge outlet(s) 130, that are in liquid communication with destination tank 102, such that a liquid flow path between the tanks is formed. An example of the secondary process liquid inlet(s) 126 is the porous outer surface of a flow through water filter.
(17) In all of the embodiments here disclosed, the descriptions are written assuming that manually operated valve 118 is used.
(18) The valves in embodiments one and two for destination tank valve 110 and source tank valve 108 are float valves of the common bulkhead mounting style with an integral float rod connected between a ball float and a flow rate control input. This design of float valve, when bulkhead mounted through the sidewall of a tank, has its outlet port on the same end of the valve that will be inside the tank, and its inlet port on the same end of the valve that will be outside the tank. For example, in these two embodiments, the outlet port of destination tank valve 110 will be inside destination tank 102, and the inlet port of destination tank valve 110 will be outside destination tank 102. The outlet port of source tank valve 108 will be inside source tank 100, and the inlet port of source tank valve 108 will be outside source tank 100. Source tank valve 108 is mounted in the sidewall of source tank 100 with its ball float 104 and its float rod 112 being inside of source tank 100. Destination tank valve 110 is mounted in the sidewall of destination tank 102 with its ball float 106 and its float rod 114 being inside of destination tank 102.
(19) The valves in embodiment three for destination tank valve 110 and source tank valve 108 are float valves of the common pipe mounting style. This design of float valve, when mounted has both its inlet port and its outlet port outside of a tank in which it is being used.
(20) Other embodiments are possible that use one each of the two different valve styles used in embodiments one, two, and three.
(21) A first embodiment is depicted in
(22) Second, third and fourth embodiments are described in the paragraphs below.
(23) A second embodiment, depicted in
(24) A third embodiment, not depicted in the figures, is identical to the second embodiment, except that the float valves used in this embodiment are of the pipe mount style, and the float valves used in embodiment two are of the bulkhead mount style.
(25) A fourth embodiment is depicted in
(26) The new flow control behavior of the configuration in this embodiment will be equivalent to the flow control behavior of a system that has two separate float valves connected in series with each other in a common flow channel. The two separate valves used in the first, second and third embodiments, are indeed physically connected in series by the piping segments.
(27) The flow control behavior of the series connection pair, is different from the flow control behavior of either of the valves individually, and different to flow control behavior that would result from a pair float valves connected in parallel.
(28) The flow control behavior of the series connected pair is an essential feature of the embodiments disclosed herein. Briefly, the flow control behavior of the series connected pair will be such that valve that is a state of a more restricted flow will be dominant over the other valve. For example if one of the valves is fully open and the other valve is fully closed, the combined result will be a complete restriction of to the flow. The elimination of destination tank valve 110, by this embodiment would result in significant cost savings, both to a manufacturer, and to the consumer.
(29) The components and their interconnection disclosed for all of the embodiments disclosed herein, realize an autonomous refill cycle that is automatically started when the level of liquid in destination tank 102, falls below a preselected minimum level.
(30) The steps of the refilling cycle will sequence the system through four exemplary states. These exemplary states are depicted in
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(33) Exemplary states in a refill cycle.
(34) TABLE-US-00002 Exemplary Liquid Level in Liquid Level in Source Tank Destination Tank Flow rate of the State Source Tank 100 Destination Tank 102 Valve 108 Valve 110 supply liquid First Empty Empty Fully open Fully open Maximum Second Maximum and Still very close to Nearly closed and Fully open Reduced to a flow being regulated being empty but regulating the liquid rate consistent with by the Source increasing very level in the Source the liquid level in the Tank Valve 108 slowly Tank 100 Source Tank 100, being regulated by Source Tank Valve 108 Third Mid level Mid level and being Nearly closed and Nearly closed and Nearly fully restricted regulated by the regulating the liquid limiting the liquid Destination Tank level in the Source flow into the Source 110 Tank 100 Tank 100 Fourth Empty At maximum (full) Fully open Fully closed No liquid flow level
(35) The refill cycle is complete when the system enters the fourth exemplary state. The system will remain in this fourth exemplary state until the user draws enough of the liquid from the destination tank 102, by using the destination tank liquid discharge valve 132, so that the liquid level in the destination tank 102 falls to a level that will allow the destination tank valve 110, to again begin to open and allow the pressurized liquid to flow to source tank 100. The liquid now flowing in the system indicates that a new refill cycle is occurring. This sequence of steps will automatically repeat anytime the liquid level in destination tank 102 falls below the level that causes destination tank valve 110 to transition from fully closed to partially open. The liquid level decreasing through this level automatically initiates another refill cycle.
(36) In order to make the discussion of the description of the embodiments more understandable in this specification, a set of liquid levels and liquid volumes have been predefined and given both text labels and abbreviations. These terms are only for the purpose of making this discussion more clear and understandable.
(37) A volume of liquid is associated with each of the three aforementioned liquid levels. The liquid volumes associated with each of the liquid levels, are labeled and the abbreviations used herein to refer to them are described in the following table.
(38) TABLE-US-00003 Corresponding Liquid Liquid Level/Abbreviation Volume/Abbreviation Source Tank Maximum Source Tank Maximum Level Level/STML Volume/STMLV Destination Tank Transition Destination Tank Transition Level Level/DTTL Volume/DTTLV Destination Tank Maximum Destination Tank Maximum Level Level/DTML Volume/DTMLV
(39) Another purpose for defining these liquid volumes and associating them with the defined liquid levels is that if the tanks have a different length and/or width from each other, it cannot be assumed that the volume of liquid corresponding to any liquid level in one of the tanks is necessarily equivalent to the volume of liquid corresponding to an identical value for the level of liquid in the other tank. The reason for defining the volumes will become evident in the discussion below.
(40) For source tank 100, a liquid level labeled source tank maximum level is defined and referred to using the abbreviation STML and the number 150, and extends upwards from the source tank interior bottom surface 152. STML refers to the maximum height of liquid level that will ever exist in source tank 100. For destination tank 102, two liquid levels are defined. A liquid level labeled destination tank transition level is defined and referred to using the abbreviation DTTL, and the number 156. DTTL refers to the height of liquid level in the destination tank 102 at which the destination tank valve 110 will transition between opened and closed. Another liquid level labeled destination tank maximum level is defined and referred to using the abbreviation DTML, and the number 154. DTML refers to the maximum height of liquid level that will ever exist in destination tank 102. The DTML liquid level also indicates the height of liquid level in destination tank 102 that is considered tank full level. The liquid level STML extends upwards from the source tank interior bottom surface 152. The liquid levels DTTL and DTML extend upwards from the destination tank interior bottom surface 158.
(41) To further describe how the components of the embodiments work together to implement the automatic refilling functionality the discussion below describes a full refill cycle, starting with the apparatus being in an exemplary first state as depicted in
(42) The complete refill cycle is comprised of the following steps:
(43) A cycle starts with the apparatus being in an exemplary first state with both tanks being completely empty. Manually operated valve 118 is opened by the user so that liquid can flow from the pressurized liquid supply source into the system through by way of the third piping segment 120. Because both tanks are empty at the start of this cycle, both the source tank valve 108 and the destination tank valve 110 will be fully open and allowing the unrestricted flow of liquid from the source pressurized liquid into the supply portion of the system.
(44) As the pressurized fill liquid starts to flow, source tank 100 will begin to fill at a rate determined by the pressure level of the pressurized liquid supply from liquid supply connection 116, the size of the liquid channels in the valves, and the size of the piping segments. Note that because of the configuration of the piping and valves, destination tank 102 never receives any liquid from the pressurized supply source directly, but instead will eventually get liquid indirectly from source tank 100, after it passes through secondary process 128 that is situated between the two tanks. It is assumed that the liquid flow rate through any secondary process 128 and into destination tank 102 will be at a far slower flow rate than the liquid flowing into source tank 100 because the liquid flowing into source tank 100 is under pressure, and the flow out of source tank 100, then through the secondary process 128, and finally into destination tank 102 is by the process of gravity fed drainage alone.
(45) Due to the continuous flow of pressurized liquid into it, the liquid level in source tank 100 will eventually reach the level defined previously as the liquid level, source tank maximum level, STML 150. When the liquid reaches this level, source tank valve 108 will partially close and create a restriction in the flow that will cause the level to be held at or very close to the level STML. In this state, source tank valve 108 will be allowing only enough liquid to enter source tank 100 sufficient to replace the liquid that is being slowly removed from that tank by way of drainage into secondary process. This liquid flowing out of source tank 100, into and through secondary process 128, and into destination tank 102, causes destination tank 102 to begin filling. Because this liquid is being gravity fed, it will be at a slower flow rate than the rate of the liquid flowing into source tank 100, which is pressurized.
(46) The liquid level in source tank 100 will be held at the source tank maximum level, STML 150 while the liquid level in destination tank 102 will be increasing from empty towards the destination tank transition level, DTTL 156.
(47) When the liquid level in destination tank 102 increases to the destination tank transition level, DTTL 156, destination tank valve 110 will close, thus causing the liquid from the pressurized liquid supply, source, via liquid supply connection 116, into the system to stop flowing. When the system enters this exemplary third state, the liquid level in source tank 100 will be at the source tank maximum level, STML 150. In this exemplary third state, liquid will still be flowing by the gravity fed drainage out of the source tank 100, into and through the secondary process 128, and into the destination tank 102 also by the process of gravity fed drainage. The result of the apparatus being in this state is that the liquid level in destination tank 102 will continue to raise slowly, above the destination tank transition, DTTL 156 while the liquid level in source tank 100 will continue to fall slowly. The effect of the liquid level in destination tank 102 increasing is that destination tank valve 110 will be held harder and harder in the closed position. With this liquid level in destination tank 102 being even higher than the destination tank transition level, DTTL 156; destination tank valve 110 will be prevented from opening again until a sufficient volume of liquid is removed from destination tank 102 by the user using destination tank liquid discharge valve 132.
(48) After a period, 100% of the liquid that was in source tank 100 will have drained into destination tank 102. When this condition is reached, the fill cycle that started with both tanks being empty, and finishing with destination tank 102 being full, and source tank 100 being empty, is complete.
(49) The system will remain in this state, with destination tank 102 being at the destination tank maximum level, DTML 154 and source tank 100 being empty, indefinitely until enough liquid is removed from destination tank 102 by the user so that the liquid level in destination tank 102 again falls below the destination tank transition level, DTTL 156. This can only occur when the user draws liquid out of the destination tank 102 by using the destination tank liquid discharge valve 132.
(50) When the liquid level in destination tank 102 drops below the destination tank transition level, DTTL 156, destination tank valve 110 will again open, and another refill cycle will be started automatically.
(51) The above described refill cycle will repeat automatically every time enough liquid is removed from destination tank 102, such that the liquid level in that tank falls below the destination tank transition level, DTTL 156.
(52) In addition to the automatic refill cycle disclosed, all of the embodiments also implement tank overflow prevention by strategic mounting positions of the float valves in the tanks, and by the serial plumbing connection of, source tank valve 108, and destination tank valve 110. Both source tank valve 108, and destination tank actuated flow-rate control valve 110 are mounted in their respective tanks at strategically preselected heights above each tank's interior bottom surface, to cause the apparatus to implement the novel features of automatic tank refilling and tank overflow prevention. These heights are chosen in coordination with each other.
(53) The designer of any particular implementation of an embodiment has design flexibility in selecting the mounting heights of the valves to meet any certain design optimization goal the designer might have. A possible design procedure is as follows. The height above the interior bottom surface 158, of destination tank 102, at which destination tank valve 110 is to be mounted is chosen as an independent variable. This level is referred to here as the destination tank transition level, DTTL 156. When the liquid level inside destination tank 102 reaches this level during a refill cycle, destination tank valve 110 will change from being partially open to being fully closed. When destination tank valve 110 is closed, pressurized supply liquid flowing in the system will cease. Assuming for example that the valve is placed so that the liquid level associated with it is near the mid level of the tank, there will a volume of unused liquid holding capacity above the top surface of the liquid, and below a predetermined desirable maximum full level. This unused liquid holding capacity represents the additional volume of liquid that can be added to destination tank 102 to bring the liquid level up to the level labeled destination tank maximum level, DTML 154. Source tank valve 108 is then installed in the source tank 100, at a distance above the source tank interior bottom surface 152 of source tank 100 that will limit the maximum volume of liquid in source tank 100 to an amount equal or less than the unused liquid holding volume remaining in destination tank 102. When all of the liquid has flowed out of source tank 100, then through the secondary process and into destination tank 102, the height of liquid level in destination tank 102 will be at the level labeled destination tank maximum level, DTML 154 which is near the top of the tank, but still well below a level that would cause an overflow. Shown in mathematical algebraic equation format, the valves are placed such that the relationship of the volumes of liquid in the tanks meets the following constraint.
(54) Using the abbreviations for the liquid volumes previously defined in the table.
(STMLV+DTTLV)DTMLV
(55) The reason for placing the float valves in positions that will result in this relationship between the volumes stated above is to ensure that the destination tank 102 will never contain a volume of liquid great enough to cause it to overflow. Any particular design of the apparatus can use different choices for where the critical liquid levels are set by setting the placement of the liquid level sensing components, depending on what parameter in the particular implementation is to be optimized. For example, one application may be optimum having a lower liquid level in destination tank 102, along with a corresponding higher liquid level in the source tank 100 or vice versa.
(56) Two specific examples are presented below to illustrate the design choices made available to a system designer.
Example 1
(57) The position of destination tank valve 110 is preselected by the designer such that the liquid volume DTTLV is 75% of the liquid volume DTMLV, and the position of source tank valve 108 is set by the designer so that the liquid volume STMLV is 25% of the liquid volume DTMLV. With the valve mounted at the heights of the above positions, when the liquid level in destination tank 102 rises to the level DTTL, there will still be an unused liquid holding volume above the DTTL level more than large enough to hold the liquid still in source tank 100, without destination tank 102 overflowing.
Example 2
(58) The mounting position of destination tank valve 110 is preselected by the designer such that the liquid volume DTTLV is 25% of the liquid volume DTMLV, and the mounting position of source tank valve 108 is set by the designer so that the liquid volume STMLV is 75% of the liquid volume DTMLV. With the valve mounting positions set to the above positions, when the liquid level in destination tank 102 rises to the level DTTL, there will still be an unused liquid holding volume above the DTTL, more than large enough to hold the liquid still in source tank 100, without destination tank 102 overflowing.
(59) As used in this application, the term a or an means at least one or one or more.
(60) As used in this application the terms single, a single, or the single each mean one and only one.
(61) As used in this application, the term about or approximately refers to a range of values within plus or minus 10% of the specified number.
(62) As used in this application, the term substantially means that the actual value is within about 10% of the actual desired value, particularly within about 5% of the actual desired value and especially within about 1% of the actual desired value of any variable, element or limit set fourth herein.
(63) All references throughout this application, for example patent documents including issued or granted patents or equivalents, patent application publications, and non patent literature documents or other source material, are hereby incorporated by reference herein in their entireties, as though individually incorporated by reference, to the extent each reference is at least partially not inconsistent with the disclosure in the present application (for example, a reference that is partially inconsistent is incorporated by reference except for the partially inconsistent portion of the reference).
(64) A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
(65) Any element in a claim that does not explicitly state means for performing a specified function, or step for performing a specified function, is not to be interpreted as a means or step clause as specified in 35 U.S.C. 112, 6. In particular, any use of step of in the claims is not intended to invoke the provision of 35 U.S.C. 112, 6.
(66) Persons of ordinary skill in the art may appreciate that numerous design configurations may be possible to enjoy the functional benefits of the inventive systems. Thus, given the wide variety of configurations and arrangements of embodiments of the present invention the scope of the invention is reflected by the breadth of the claims below rather than narrowed by the embodiments described above.