Fluid flow initiated and controlled automatic sequencing cascade system for the recharging of fluid cylinders

Abstract

A system and method for recharging at least one fluid cylinder using a first fluid cylinder. The system uses a flow indicating switch which can comprise an internal magnetic source to detect the flow of fluid. The flow indicating switch is in communication with an electronic sequencing module. The electronic sequencing module controls the order and timing of discharge from the first fluid cylinder into the at least one fluid cylinder.

Claims

1. A system for the automatic recharging of at least one fluid cylinder comprising: a) at least one fluid cylinder; b) at two fluid storage cylinders; c) solenoid valves in communication with each of the at least two fluid storage cylinders; d) a flow indicating switch for detecting a flow of fluid; and e) an electronic sequencing module in electronic communication with the flow indicating switch, wherein the electric sequencing module uses a signal from the flow indicating switch to operate the solenoid valve to control an order and a timing of discharge from the at least two fluid storage cylinders into the at least one fluid cylinder.

2. The system of claim 1, wherein the solenoid valve is electric, electric over pneumatic, or electric over hydraulic.

3. The system of claim 1, wherein the flow indicating switch which emits an electronic signal when the flow of fluid exceeds a predetermined flow quantity.

4. The system of claim 1, wherein the electronic sequencing module maximizes the number of times the at least one fluid cylinder is recharged by the at least two fluid storage cylinders.

5. The system of claim 1, wherein the electronic sequencing module provides a visual or audible reference indicating whether the solenoid valve is open or closed.

6. The system of claim 1, further comprising a back-up power source for providing power in the event of a power failure, wherein the back-up power source is in communication with a means of charging the back-up power source.

7. The system of claim 1, wherein at least a portion of the electronic sequencing module is located remotely to the at least one fluid cylinder.

8. The system of claim 1, wherein a plurality of fluid cylinders are supplied by a single supply line.

9. The system of claim 1, wherein at least a portion of the flow indicating switch is located remotely to the at least one fluid cylinder.

10. The system of claim 1, further comprising a manually operated valve for use in the event of a mechanical or electrical failure.

11. The system of claim 1, further comprising a compressor for providing fluid, wherein the electronic sequencing module directs the fluid into the at least one fluid cylinder until a predetermined fluid level, a fluid volume, or a fluid pressure is reached, at which time the electronic sequencing module then directs the fluid into the at least two fluid storage fluid cylinders.

12. The system of claim 1, further comprising a compressor for providing fluid, wherein the electronic sequencing module directs a portion of the fluid into the at least one fluid cylinder while simultaneously directing a portion of the fluid into the fluid storage cylinder with the lowest pressure of the at least two fluid storage cylinders followed by the next higher pressure cylinder of the at least two fluid storage cylinders.

13. The system of claim 1, further comprising a compressor for providing fluid, wherein the electronic sequencing module directs a portion of the fluid into the at least one fluid cylinder while simultaneously directing a portion of the fluid into the cylinder with the highest pressure of the at least two fluid storage cylinders followed by the next lower pressure cylinder of the at least two fluid storage cylinders.

14. The system of claim 1, wherein at least a portion of the system is attached to a firefighter breathing air replenishment system.

15. A method for automatically recharging at least one fluid cylinder comprising: a) using a at least two fluid storage cylinders to supply a fluid to at least one fluid cylinder; b) using a flow indicating switch to detect a flow of fluid; c) generating an electronic signal with the flow indicating switch; and d) communicating the electronic signal to an electronic sequencing module, wherein the electronic sequencing module operates solenoid valves allowing fluid to flow from the at least two fluid storage cylinders to the at least one fluid cylinder.

16. The method of claim 15, further comprising using a manually operated valve in the event of a mechanical or electrical failure.

17. The method of claim 15, wherein the electronic sequencing module or the flow indicating switch is located remotely from the at least one fluid cylinder.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The detailed description will be better understood in conjunction with the accompanying drawings as follows:

(2) FIG. 1Flow switch triggered auto-cascade tubing and electrical drawing with Back-Fill.

(3) FIG. 2Flow switch triggered auto-cascade tubing and electrical drawing with Priority-Fill.

(4) FIG. 3Valve sub-assembly schematic used to install additional stage(s) in the Back-Fill or Priority-Fill auto-cascade systems.

(5) FIG. 4Flow switch triggered auto-cascade demonstrated supplying Firefighters Breathing Air Replenishment System (FBARS).

(6) FIG. 5Alternate to FIG. 4.

(7) FIG. 6Single flow indicating switch auto cascade system.

(8) The present embodiments are detailed below with reference to the listed Figures.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(9) Before explaining the present apparatus in detail, it is to be understood that the apparatus is not limited to the particular embodiments and that it can be practiced or carried out in various ways.

(10) Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis of the claims and as a representative basis for teaching persons having ordinary skill in the art to variously employ the present invention.

(11) The present embodiments relate to a system for the automatic recharging of at least one fluid cylinder. While the examples below detail the filling of pressurized gas cylinders as a typical application of the invention, it should be understood that the system described can be used for any fluid, whether liquid, gas, gel, slurry, and the like.

(12) Cylinder is used herein to refer to a container of fluid, and can apply to storage tanks, transportable cylinders, or other such fluid containers.

(13) The invention concerns any fluid in a container, wherein it is desirable for the container to be periodically filled with fluid, or maintained at a desired fluid level, fluid volume, or fluid pressure.

(14) The system can have at least one fluid cylinder to be filled or recharged. The at least one fluid cylinder is the container in which it is desirable to maintain a fluid level or fluid pressure.

(15) One or more storage cylinders, such as a first fluid cylinder and a second fluid cylinder can be in communication with the at least one fluid cylinder for the purpose of supplying the at least one fluid cylinder with fluid.

(16) The fluid cylinders can supplied by a single supply line, providing a distinct advantage over the current state of the art, which requires a separate line for each cylinder supplying fluid. In situations where a pneumatically controlled auto-cascade is used, two lines are actually needed for each storage cylinder, one for fill pressure and one for sensing line pressure.

(17) One or more solenoid valves can be in communication with the first fluid cylinder, the at least one fluid cylinder, or both the first fluid cylinder and the at least one fluid cylinder. While this application refers to a solenoid valve, the intention is to describe any valve that can be controlled with an electrical signal. For example, a pneumatic valve with a control system that receives an electrical input would be considered a solenoid valve for the purposes of this invention.

(18) In embodiments, the solenoid valve can be electric, electric over pneumatic, or electric over hydraulic.

(19) The system can also have a flow indicating switch for detecting a flow of fluid. While many mechanical means exist for measuring or detecting fluid flow, the flow indicating switch can be any means of detecting or measuring a fluid flow within the system and transferring data via electronic communication.

(20) In embodiments the flow indicating switch can be a mechanical switch that has an internal magnetic source which is displaced a predetermined distance when a fluid flow exceeds a minimal flow quantity. In other embodiments, the flow indicating switch can make or break an electrical circuit.

(21) An electronic sequencing module can be in electronic communication with the flow indicating switch, wherein the electric sequencing module uses a signal from the flow indicating switch to operate the solenoid valve to control an order and a timing of discharge from the storage cylinder(s) into the at least one fluid cylinder.

(22) In embodiments, the electronic sequencing module can maximize the number of times the at least one fluid cylinder is recharged by the storage cylinder(s) with a predetermined logic.

(23) In other embodiments, the electronic sequencing module can provide a visual or audible reference indicating whether the solenoid valve is open or closed. For example, such a reference may be an alert tone, light, or signal to a distributed control system for display on a graphical interface.

(24) The electronic sequencing module need not be a single unit. Various electronic portion of it may be distributed and located remotely to the at least one fluid cylinder as long as all components of the electronic sequencing module are in communication with each other, allowing it to operate as a single module or device. In the same manner, a portion of the flow indicating switch can be located remotely to the at least one fluid cylinder.

(25) A back-up power source for providing power in the event of a power failure can be included. In embodiments, the back-up power source can be in communication with a means of charging the back-up power source.

(26) The system can have a manually operated valve for use in the event that the solenoid valve fails. In embodiments, each of the storage cylinders can have their own valve.

(27) In embodiments, the system can have a compressor for providing fluid, wherein the electronic sequencing module sequentially directs fluid. For example, the electronic sequencing module can direct fluid into the at least one fluid cylinder until a predetermined fluid pressure or fluid level is reached, at which time the electronic sequencing module then directs the fluid into a storage cylinder.

(28) In alternative embodiments, the system can have a compressor for providing fluid, wherein the electronic sequencing module directs a portion of the fluid into the at least one fluid cylinder while simultaneously directing a portion of the fluid into the first fluid cylinder until a predetermined fluid pressure or fluid level is reached.

(29) In embodiments, a portion of the system is attached to a firefighter breathing air replenishment system or other systems that require a self-contained breathing apparatus (SCBA).

(30) A method of using the system for automatically recharging at least one fluid cylinder is as follows:

(31) Using a first fluid cylinder to supply a fluid to the at least one fluid cylinder. Using a flow indicating switch to detect a flow of fluid. Generating an electronic signal with the flow indicating switch. Communicating the signal to an electronic sequencing module, wherein the electronic sequencing module operates a solenoid valve allowing fluid to flow from a first fluid cylinder to the at least one fluid cylinder.

(32) This method is equally applicable to the various system embodiments described above.

(33) Turning now to the Figures, FIG. 1 is a flow switch triggered auto-cascade tubing and electrical drawing with Back-Fill.

(34) This figure demonstrates the operation of a 3-stage auto-cascade system with Back-Fill which uses the 17FIS (High Pressure Flow Indicating Switch) as the key component which accurately controls the sequential discharge of compressed gas storage cylinders into compressed gas cylinder(s) which are being recharged. While this drawing demonstrates a 3-stage auto-cascade system controlled by the 17FIS and 14ESM (Electronic Sequencing Module) in actuality this configuration can control an infinite number of stages.

(35) 17FIS Operation

(36) The flow of a compressed gas through the 17FIS (Flow Indicating Switch) displaces an internal magnetic source which will activate and/or deactivate an internal or external reed switch. The electric current or signal from the reed switch shall act as a trigger to initiate and control an ESM (Electric Sequencing Module) which in turn controls the automatic sequential discharge from 2 or more compressed gas storage cylinders into 1 or more cylinder(s) which are being recharging.

(37) The 17FIS (Flow Indicating Switch) has two functions in the below described system. Its primary function is to send an electrical signal to the 14ESM when flow is passing though the 17FIS. The secondary function of the 17FIS is to act as a check valve in the event that pressure in the cylinder which is being recharged is higher than that of the compressed gas storage cylinders.

(38) 14ESM Operation

(39) The 14ESM (Electronic Sequencing Model) has two operational states.

(40) The 1st state is the Stand-By mode in which the 14ESM is awaiting the initial signal from the 17FIS which indicates flow is passing through the 17FIS. While the 14ESM is in stand-by mode, the 12 and 13solenoid valves are in the Fail-Safe normally open position.

(41) The 2nd state is the Fill-Sequence mode. This state is achieved when the 14ESM in Stand-By mode receives the initial electrical current or signal from the 17FIS which indicates that a compressed gas flow is passing through the 17FIS. The initially signal from the 17FIS places the 14ESM in the Fill-Sequence mode which immediately closes the 122nd stage and 133rd stage solenoid valves. The 122nd stage and 133rd stage solenoid valves will remain closed until the electrical current or signal from the 17FIS ceases. (This indicates that flow through the 17FIS has stopped.) This will prompt the 14ESM to sequence up to the next stage at which time the 14ESM will open the 122nd stage solenoid valve.

(42) Note: When in the Fill-Sequence mode the 14ESM will be looking for one of two events to take place. The first event would be an electrical current or signal to be sent from the 17FIS which will indicates that flow is present. The second event would be the expiration of the internal timer for the specific stage in the event that a no flow signal is sent by the 17FIS. These two events shall cause the 14ESM to hold the present solenoid valve(s) open or to open the next higher stage solenoid valve.

(43) When the flow of compressed gas has stopped and the 14ESM has sequenced through the last available stage, the 14ESM will reset and return to Stand-By mode. Once in the Stand-By mode the 14ESM will wait for next electrical current or signal from the 17FIS which will re-initiate the Fill-Sequence mode.

(44) A secondary function of the 14ESM is demonstrated in the 1ASubdrawing which shows the use of optional indicator lights which give the system operating personnel a visual reference of the status of each stage valve of the auto-cascade system. In this example we shall use green lights to signify that the stage valve(s) are open and yellow lights to signify that the stage valve(s) are in the closed position.

(45) When in the 14ESM enters the stand-by mode the 35, 36 and 37 green lights shall be lit indicating the 12 and 13solenoide valves are open. NOTE: Due to the fact that the there is no solenoid valve on the 11st stage and this stage stays in the open position, the 351st stage green light will be connected to a positive wire and remain on at any time that an electrical current is being supplied to the auto-cascade system.

(46) The instant flow begins passing through the 17FIS an electrical current or signal is sent to the 14ESM which initiates the 14ESM. Once initiated the 14ESM enters the Sequence-Fill mode causing the 36 and 37green lights turn off and the 38 and 39yellow lights turn on indicating the 122nd stage and 133rd stage solenoid valves are closed. As each of these solenoid valves are opened by the 14ESM, the 36 and 37green lights will turn on as their respective 38 and 39 yellow lights turn off.

(47) NOTE: The ESM can derive its electrical power supply from any automotive type DC electrical source such as a 12 or 24 volt DC system or structural type AC power source such as 120 or 240 volt AC system. The ESM may also be equipped with an optional built in electrical charging circuit with a backup battery pack system which, in the event of a primary electrical source failure, would energize the FIS base Auto-Cascade system for a predetermined period of time. While this option could be used in any of the FIS controlled Auto-Cascade systems, it would be primarily beneficial when used in conjunction with a stationary or Fixed Mount system such as the FBARS which is discussed in further detail in the FIGS. 4 and 5 detailed descriptions.

(48) Basic Compressed Gas Flow Through the Auto-Cascade System

(49) Compressed gas from the 11st stage (low pressure) compressed gas storage cylinder(s) will flow downstream through 5pipe or tubing into 8pipe or tubing. The 9pressure gauge can be used by personnel operating the cascade system to monitor the pressure in the 11st stage compressed gas storage cylinder(s).

(50) Compressed gas from the 22nd stage (medium pressure) compressed gas storage cylinder(s) will flow downstream through 6pipe or tubing and the normally open 12solenoid valve into 8pipe or tubing. The 10pressure gauge can be used by personnel operating the cascade system to monitor the pressure in the 22nd stage compressed gas storage cylinder(s).

(51) Compressed gas from the 33rd stage (high pressure) compressed gas storage cylinder(s) will flow downstream through 7pipe or tubing and the normally open 13solenoid valve into 8pipe or tubing. The 11pressure gauge can be used by personnel operating the cascade system to monitor the pressure in the 33rd stage compressed gas storage cylinder(s).

(52) The 24check valve on 8pipe or tubing will prevent upstream flow from 8tubing into the 1st stage components 9, 5 and 1. The 25check valve on 8pipe or tubing will prevent upstream flow from 8tubing into the 2nd stage components 12, 10, 6, and 2. The 17FIS check valve function on 8pipe or tubing will prevent upstream flow from 33cylinder which is being recharged into the 3nd stage components 13, 11, 7 and 3.

(53) When the 28block valve is in the closed position, there will be no compressed gas flow through the 17FIS thus making it inactive.

(54) NOTE: Solenoid valves mentioned throughout this document can be either electric, electric over pneumatic or electric over hydraulic. Also the solenoid valve configuration is designed in such a way as to provide a Fail-Safe (normally open) condition when there is no electrical current applied. This Fail-Safe configuration will enable the system to be used as a simple bulk air fill point in the event of a failure of any electrical components.

(55) Auto-Cascade Operation:

(56) An electrical current applied to the 15positive and 16negative wires or electrical connection points will energize the 14ESM. Initially the 14ESM will be in the Stand-By mode and no electrical current will pass through to the 122nd stage and 133rd stage solenoid valves. This places the 122nd stage and 133rd stage solenoid valves in their Fail-Safe normally open position.

(57) One or more compressed gas cylinders which need to be refilled are connected to cascade system 33outlet fitting. The valve(s) on the recharging cylinder(s) are opened completely. As the 28block valve is opened, compressed gas from the 8pipe or tubing will begin to flow through the 17FIS and the 26pressure regulator. The regulated pressure downstream of the 26pressure regulator is monitored by the system operating personnel using 27pressure gauge. Pressure downstream of the 28fill valve (and the cylinder which is being recharged) is monitored by the 31pressure gauge.

(58) As gas flow through the 17FIS reaches a predetermined minimum quantity the 17FIS activates and electrical contacts of the 17FIS close which send a signal to the 14ESM via 18electrical or fiber optic wires. This electrical signal will cause the 14ESM to exit the stand-by mode and initiate the fill sequencing mode.

(59) Once in the sequencing mode the 14ESM will transmit an electrical current through the 19, 20, 21 and 22electrical wires which will close the 122nd stage solenoid valve and the 133rd stage solenoid valve and, as illustrated in the 1Asubdrawing, activate the 38 and 39LEDs and simultaneously deactivate their respective 39 and 39LEDs. This initial electrical signal to the 14ESM will also initiate an internal timing sequence with a predetermined expiration point.

(60) If the flow of compressed gas from the 11st stage storage cylinder(s) through 8pipe or tubing and through the 17FIS is above the predetermined quantity, the 14ECM will continue to hold the 122nd stage solenoid valve and the 133rd stage solenoid valve in the closed position thus permitting only compressed gas from the 11st stage storage cylinder(s) to flow into the 33cylinder(s) which are being recharged.

(61) If the flow of compressed gas from the 11st stage storage cylinder(s) through 8pipe or tubing and through the 17FIS is below the predetermined quantity and the predetermined no-flow time expires, the 14ESM will open the 122nd stage solenoid valve, deactivate 38LED, activate 36LED and reset its internal timer. The 122nd stage solenoid valve shall remain open through the remainder of the fill sequence.

(62) If flow is reestablished through the 17FIS the 14ESM will hold the 122nd stage solenoid valve open which will permit the compressed gas from the 22nd stage storage cylinder(s) to flow downstream and into the 33cylinder(s) which are being recharged.

(63) If the flow of compressed gas from the 22nd stage storage cylinder(s) through 8pipe or tubing and through the 17FIS is below the predetermined quantity and the predetermined no-flow time expires, the 14ESM will open the 133rd stage solenoid valve, deactivate 39LED, activate 37LED and reset its internal timer. The 133rd stage solenoid valve shall remain open through the remainder of the fill sequence.

(64) If flow is reestablished through the 17FIS the 14ESM will hold the 133rd stage solenoid valve open which will permit the compressed gas from the 33rd stage storage cylinder(s) to flow downstream and into the 33cylinder(s) which are being recharged.

(65) The above listed sequence shall continue until either, 1the cylinder(s) which is being recharged has reached the desired pressure, 2the cylinder(s) which is being recharged pressure equalizes with that of the highest pressure storage cylinder stage or 3the system operating personnel manually stops the fill sequence. (Closes the 28block valve)

(66) Once the 14ESM has sequenced through all available stages it shall automatically reset and go back into standby mode. At this point the 14ESM will be ready to cycle through the fill sequence again once it receives the next initiating signal from the 17FIS.

(67) When the 33cylinder(s) which are being recharged reach the desired pressure, the 33cylinder valve and the 28block valve are both closed. The 30bleed valve is opened allowing the pressure which is captured between the 28block valve and the 33cylinder which is being recharged exit through the 29bleed valve outlet. Once all pressure has been vented the 33cylinder which is being recharged can be removed and replaced with the next cylinder which needs to be recharged.

(68) 1BSubdrawing is an expanded view of the 17FIS which shows an alternate placement of the 17FIS. Due to the fact that the 17FIS is responsible for the electrical current or signal which initiates and controls the 14ESM, it may be placed at any single or multiple point(s) in the system downstream where the compressed gas flow from all compressed gas storage cylinders converge into a single pipe or tube.

(69) 1CSubdrawing demonstrates an alternate valve assembly location. NOTE: The alternate location of the 17FIS shown in 1BSubdrawing can be used in the alternate valve assembly locations. The purpose of relocation of the entire valve assembly shown in the 1CSubdrawing would be primarily for operations where the compressed gas storage cylinders and main auto-cascade valve assembly would be remote from the area(s) where the 33cylinder(s) which are being recharged. An example of this would be a FBARS (Firefighter Breathing air Replenishment System) which will be discussed in further detail in FIG. 4.

(70) A second example of 1B and 1Csubdrawing would be a mobile cascade system which is brought in when needed to supply the above listed FBARS with compressed gas.

(71) A third example of the 1B and 1Csubdrawing would be where the auto-cascades storage cylinders and the auto-cascade valve assembly are located in areas of a structure or vehicle such as a trailer or Fire Truck which is remote to the SCBA fill station.

(72) NOTE: When auto-cascade is used in conjunction with a Fire Fighters SCBA RIT (Rapid Intervention Team) or RIC (Rapid Intervention Crew) connection, the 30bleed valve and/or the 28block valve may be eliminated.

(73) Back-Fill Operation:

(74) Recharging of the 1, 2, and 3compressed gas storage cylinders is accomplished by use of the patented Back-Fill system in which a compressor or alternate compress gas source is attached to the 32Back-Fill inlet. As the outlet pressure of the compressor or alternate air source becomes equal to, or greater than, that of the pressure of the 11st stage storage cylinder(s) the compressed gas shall begin to flow through the 23check valve and into the 11st stage storage cylinder(s).

(75) When the outlet pressure of the compressor or alternate air source and the 11st stage storage cylinder(s) becomes equal to, or greater than that of the pressure of the 22nd stage storage cylinder(s), the compressed gas shall begin to flow through the 24check valve and, due to its design, the 122nd stage solenoid valve and then into the 22nd stage storage cylinder(s). At this point the gas flow from the compressor or alternate air source shall be recharging the 11st and 22nd stage storage cylinders simultaneously at an equal rate of flow.

(76) When the outlet pressure of the compressor or alternate air source and the 11st stage storage cylinder(s) and 22nd stage storage cylinder(s) becomes equal to or greater than that of the pressure of the 33rd stage storage cylinder(s), the compressed gas shall begin to flow through the 25check valve and, due to its design, the 133rd stage solenoid valve and then into the 33rd stage storage cylinder(s). At this point the gas flow from the compressor or alternate air source shall be recharging the 11st, 22nd and 33rd stage storage cylinders simultaneously at an equal rate of flow. The compressed gas storage cylinders can be recharged with the Back-Fill system either during auto-cascade fill operations or after they are completed.

(77) While this demonstrates the Back-Fill system used to recharge the storage cylinders of a 3-stage cascade system in actuality, the Back-Fill systems can be used to recharge the storage cylinders of a cascade system with an infinite number of stages and compressed gas storage cylinders.

(78) FIG. 2 is a flow switch triggered auto-cascade tubing and electrical drawing with Priority-Fill.

(79) This figure demonstrates the operation 3-stage auto-cascade system with Priority-Fill which uses the 66FIS (High Pressure Flow Indicating Switch) as the key component that controls the sequential discharge of compressed gas storage cylinders into the compressed gas cylinder(s) which are being recharged. While this drawing demonstrates a 3-stage auto-cascade system controlled by the 66FIS and 59ESM (Electronic Sequencing Module) in actuality this configuration can control an infinite number of stages.

(80) 66FIS Operation

(81) The flow of a compressed gas through the 66FIS (Flow Indicating Switch) displaces an internal magnetic source which will activate and/or deactivate an internal or external reed switch. The electric current or signal from the reed switch shall act as a trigger to initiate and control an ESM (Electric Sequencing Module) which in turn controls the automatic sequential discharge from 2 or more compressed gas storage cylinders into 1 or more cylinder(s) which are being recharging.

(82) The 66FIS (Flow Indicating Switch) has two functions in the below described system. Its primary function is to send an electrical signal to the 59ESM when flow is passing though the 66FIS. The secondary function of the 66FIS is to act as a check valve in the event that pressure in the cylinder which is being recharged is higher than that of the compressed gas storage cylinders.

(83) 59ESM Operation

(84) The 59ESM (Electronic Sequencing Model) has two operational states.

(85) The 1st state is the Stand-By mode in which the 59ESM is awaiting the initial signal from the 66FIS which indicates that flow is passing through the 66FIS. While in the standby mode the 50, 53 and 56solenoid valves are in the Fail-Safe normally open position.

(86) The 2nd state is the Fill-Sequence mode. This state is achieved when the 59ESM in Stand-By mode receives the electrical current or signal from the 66FIS which indicates that a compressed gas flow is passing through the 66FIS. The initial signal from the 66FIS places the 59ESM in the Sequence-Fill mode which immediately closes the 501st stage, 532nd stage and 563rd stage solenoid valves. The 501st stage, 532nd stage and 563rd stage solenoid valves will remain closed until the electrical current or signal from the 66FIS ceases. (This indicates that flow through the 66FIS has stopped.) This will prompt the 59ESM to sequence up to the next step at which time the 59ESM will open the 501st stage solenoid valve.

(87) Note: When in the Fill-Sequence mode the 59ESM will be looking for one of two events to take place. The first event would be an electrical current or signal to be sent from the 66FIS which will indicates that flow is present. The second event would be the expiration of the internal timer for the specific stage in the event that there is a No Flow signal from the 66FIS. These two events shall cause the 59ESM to hold the present solenoid valve open or to sequence up and open the next higher stage solenoid valve at which point the 59ESM will close the preceding solenoid valve.

(88) When the flow of compressed gas has stopped and the 59ESM has sequenced through the last available stage, the 59ESM will reset and return to Stand-By mode. Once in the Stand-By mode the 59ESM will wait for next electrical current or signal from the 66FIS which will re-initiate the Fill-Sequence mode.

(89) A secondary function of the 59ESM is demonstrated in the 2ASubdrawing which shows the use of optional indicator lights which give the system operating personnel a visual reference of the status of each stage valve of the auto-cascade system. In the following example a green light will indicate that an individual solenoid valve is open while yellow light indicates that this solenoid valve is closed.

(90) When in the 59ESM enters the stand-by mode the 75, 76 and 77 green lights shall be lit. The instant that the 59ESM enters the Sequence-Fill mode the 75, 76 and 77green lights turn off and the 78, 79 and 80yellow lights turn on indicating that the 501st stage, 532nd stage and 563rd stage solenoid valves are closed. As each of these solenoid valves are opened by the 59ESM, the 75, 76 and 77green lights will turn on as their respective 78, 79 and 80 yellow lights turn off.

(91) NOTE: The ESM can derive its electrical power supply from any automotive type DC electrical source such as a 12 or 24 volt DC system or structural type AC power source such as 120 or 240 volt AC system. The ESM may also be equipped with an optional built in electrical charging circuit with a backup battery pack system which, in the event of a primary electrical source failure, would energize the FIS base Auto-Cascade system for a predetermined period of time. While this option could be used in any of the FIS controlled Auto-Cascade systems, it would be primarily beneficial when used in conjunction with a stationary or Fixed Mount system such as the FBARS which is discussed in further detail in the FIGS. 4 and 5 detailed descriptions.

(92) Basic Compressed Gas Flow Through the Auto-Cascade System

(93) Compressed gas from the 401st stage (low pressure) compressed gas storage cylinder(s) will flow downstream through 43pipe or tubing and the normally open 50solenoid valve then into 46pipe or tubing. The 47pressure gauge can be used by personnel operating the cascade system to monitor the pressure in the 401st stage storage compressed gas cylinder(s).

(94) Compressed gas from the 412nd stage (medium pressure) compressed gas storage cylinder(s) will flow downstream through 44pipe or tubing and the normally open 53solenoid valve then into 46pipe or tubing. The 48pressure gauge can be used by personnel operating the cascade system to monitor the pressure in the 412nd stage compressed gas storage cylinder(s).

(95) Compressed gas from the 423rd stage (high pressure) compressed gas storage cylinder(s) will flow downstream through 45pipe or tubing and the normally open 56solenoid valve then into 46pipe or tubing. The 49pressure gauge can be used by personnel operating the cascade system to monitor the pressure in the 423rd stage compressed gas storage cylinder(s).

(96) The 64check valve on 46pipe or tubing will prevent upstream flow from 46tubing into the 1st stage components 40, 43, 47 and 50. The 65check valve on 46pipe or tubing will prevent upstream flow from 46tubing into the 2nd stage components 41, 44, 48 and 53. The 66FIS check valve function on 46pipe or tubing will prevent upstream flow from 73cylinder which is being recharged into the 3rd stage components 42, 45, 49 and 56.

(97) When the 69block valve is in the closed position, there will be no compressed gas flow through the 66FIS thus making it inactive.

(98) NOTE: Solenoid valves mentioned throughout this document can be either electric, electric over pneumatic or electric over hydraulic. Also the solenoid valve configuration is designed in such a way as to provide a Fail-Safe (normally open) condition when there is no electrical current applied. This Fail-Safe configuration will enable the system to be used as a simple bulk air fill point in the event of a failure of any electrical components.

(99) Auto-Cascade Operation:

(100) NOTE: The operating principle of FIG. 2 closely mimics that of FIG. 1 with the exception of three items. These changes were necessary for the use of the Hybrid Priority-Fill system and method that FIG. 2 uses for recharging of its compressed gas storage cylinders. The three obvious changes are: 1When closed the 50, 53 and 56solenoid valves prevent pressure and/or gas from flowing either upstream or downstream. 2When in Sequence-Fill mode only one solenoid valve at a time is open. 3The 50solenoid valve has been added in 43pipe or tubing so that flow from the 401st stage compressed gas cylinder can be stopped from entering 46pipe or tubing.

(101) An electrical current applied to the 60positive and 61negative wires or electrical connection points will energize the 59ESM. Initially the 59ESM is in the Stand-By mode and no electrical current is passing through to the 501st stage, 532nd stage and 563rd stage solenoid valves. This places the 501st stage, 532nd stage and 563rd stage solenoid valves in their Fail-Safe normally open position.

(102) One or more compressed gas cylinders which need to be refilled are connected to cascade system 73outlet fitting. The valve(s) on the recharging cylinder(s) are opened completely. As the 69block valve is opened, compressed gas from the 46pipe or tubing will begin to flow through the 66FIS and the 67pressure regulator. The regulated pressure downstream of the 67pressure regulator is monitored by the system operating personnel using 68pressure gauge. Pressure downstream of the 69fill valve (and the cylinder which is being recharged) is monitored by the 72pressure gauge.

(103) As gas flow through the 66FIS reaches a predetermined minimum quantity, the 66FIS activates and its electrical contacts close which send an electrical current or signal to the 59ESM via 62electrical or fiber optic wires. This electrical signal will cause the 59ESM to exit the standby mode and initiate the sequence-fill mode.

(104) Once in the sequence-fill mode the 59ESM will transmit an electrical current through the 51, 52, 54, 55, 57 and 58electrical wires which will close their respective 501st stage solenoid valve, 532nd stage solenoid valve and the 563rd stage solenoid valve and as illustrated in the 2ASubdrawing, activate the 78, 79 and 80LEDs. This electrical signal to the 59ESM will also initiate an internal timing sequence with a predetermined expiration point.

(105) NOTE: Obviously there will be no flow through the 66FIS and into the 73cylinder(s) which are being recharged since the 501st stage solenoid valve, 532nd stage solenoid valve and the 563rd stage solenoid valves are now in the closed position. At this point the closing of the 501st stage solenoid valve may seem to have no effect on the auto-cascade systems operation however; the importance of this step will be obvious as the Hybrid Priority-Fill operation is described at the end of the FIG. 2 detailed description.

(106) Since the 50, 53 and 54solenoid valves are closed and no flow of compressed gas will be passing through 46pipe or tubing and through the 66FIS, the back pressure will flow upstream from the 73cylinder which is being recharged and be stopped by the check valve function of the 66FIS. This back pressure will help in assuring that the 66FIS will remain closed so the 59ESM will then be able to rely solely on the internal timer for opening of the 501st stage solenoid valve.

(107) When the 501st stage timer expires the 59ESM will open the 501st stage solenoid valve. When this happens the 75LED will activate and, in the same instant, the 78LED will deactivate indicating that the 501st stage solenoid valve is open.

(108) If flow is reestablished through the 66FIS the 59ESM will hold the 501st stage solenoid valve open which will permit the compressed gas from the 401st stage storage cylinder(s) to flow downstream into the 73cylinder(s) which are being recharged.

(109) If the flow of compressed gas from the 401st stage storage cylinder(s) through 46pipe or tubing and through the 66FIS is below the predetermined quantity and the predetermined no-flow time expires, the 59ESM will close the 501st stage solenoid valve and open the 532nd stage solenoid valve simultaneously and reset the internal timer. When this happens the 75LED will deactivate and, in the same instant, the 78LED will activate indicating that the 501st stage solenoid valve is closed and the 76LED will activate while the 79LED deactivates indicating that the 502nd stage solenoid valve is open.

(110) If flow is reestablished through the 66FIS the 59ESM will hold the 532nd stage solenoid valve open which will permit the compressed gas from the 412nd stage storage cylinder(s) to flow downstream into the 73cylinder(s) which are being recharged.

(111) If the flow of compressed gas from the 412nd stage storage cylinder(s) through 46pipe or tubing and through the 66FIS is below the predetermined quantity and the predetermined no-flow time expires, the 59ESM will close the 532nd stage solenoid valve and open the 563rd stage solenoid valve simultaneously and reset the internal timer. When this happens the 76LED will deactivate and, in the same instant, the 79LED will activate indicating that the 532nd stage solenoid valve is closed and the 77LED will activate while the 80LED deactivates indicating that the 563rd stage solenoid valve is open.

(112) If flow is reestablished through the 66FIS the 59ESM will hold the 563rd stage solenoid valve open which will permit the compressed gas from the 423rd stage storage cylinder(s) to flow downstream and into the 73cylinder(s) which are being recharged.

(113) The above listed sequence shall continue until either: 1The cylinder(s) which are being recharged has reached the desired pressure. 2The cylinder(s) which are being recharged pressure equalizes with that of the highest pressure storage cylinder stage. 3The system operating personnel manually stops the fill sequence. (Closes the 69block valve)

(114) Once the 59ESM has sequenced through all available stages it shall automatically reset and go back into standby mode. At this point the 59ESM will be ready to cycle through the fill sequence again once it receives the next initiating signal from the 66FIS.

(115) When the 73cylinder(s) which are being recharged reach the desired pressure, the 73cylinder valve and the 69block valve are both closed. The 71bleed valve is opened allowing the pressure which is captured between the 69block valve and 73cylinder(s) which are being recharged to exit through the 70bleed valve outlet. Once all pressure has been vented, the 73cylinder which is being recharged can be removed and replaced with the next cylinder which needs to be recharged.

(116) 2BSubdrawing is an expanded view of the 66FIS indicates one alternate placement of the 66FIS. Due to the fact that the 66FIS is responsible for the electrical current or signal which initiates and controls the 59ESM, it may be placed at a single or multiple point(s) in the system downstream of where the compressed gas flow from all compressed gas storage cylinders converge into a single pipe or tube.

(117) 2CSubdrawing demonstrates an alternate valve assembly location. NOTE: The alternate location of the 66FIS shown in 2BSubdrawing can be used in the alternate valve assembly locations. The purpose of relocation of the entire valve assembly shown in the 2CSubdrawing would be primarily for operations where the compressed gas storage cylinders and main auto-cascade valve assembly would be remotely located from the area(s) where the 69block valve and the 73cylinders which are being recharged. An example of this would be a FBARS (Firefighter Breathing air Replenishment System) which will be discussed in further detail in FIG. 4.

(118) A second example of the 2B and 2Csubdrawing would be a mobile cascade system which is brought in when needed to supply the above listed FBARS with compressed gas.

(119) A third example of the 2B and 2Csubdrawing would be where the auto-cascades storage cylinders and the auto-cascade valve assembly are located in areas of a structure or vehicle such as a trailer or Fire Truck which is remote to the SCBA fill station.

(120) NOTE: When auto-cascade is used in conjunction with a Fire Fighters SCBA RIT (Rapid Intervention Team) or RIC (Rapid Intervention Crew) connections, the 71bleed valve and/or the 69block valve may be eliminated.

(121) Hybrid Priority-Fill Operation:

(122) Recharging of the 40, 41, and 42compressed gas storage cylinders is accomplished by use of the patent pending Hybrid Priority-Fill method. The Hybrid Priority-Fill method is a combination of the industry standard Priority-Fill method combined with features of the patented Back-Fill method. The hybrid Priority-Fill system has 2 distinctive operating methods. The 1st method operates when the 59ESM is in the Stand-By mode. The 2nd method operates when the 59ESM is in Sequence-Fill mode.

(123) Stand-by Mode:

(124) When only recharging of the 401rst stage compressed gas cylinder(s), 412nd stage compressed gas cylinder(s), and 423rd stage compressed gas cylinder(s) is desired and the 69fill/block valve is closed, the 59ESM will enter the standby mode and open the 50, 53 and 56 solenoid valves. At this point the Hybrid Priority-Fill system and method will go into operation as a Back-Fill system and method.

Example 1

(125) In this instant a compressor or alternate compress gas source is attached to the 74Priority-Fill inlet. As the outlet pressure of the compressor or alternate air source becomes equal to, or greater than, that of the pressure of the 401st stage storage cylinder(s) the compressed gas shall begin to flow through the 63check valve, 501st stage solenoid valve and into the 401st stage storage cylinder(s).

(126) When the outlet pressure of the compressor or alternate air source and the 401st stage storage cylinder(s) becomes equal to, or greater than that of the pressure of the 412nd stage storage cylinder(s), the compressed gas shall begin to flow through the 64check valve and the 532nd stage solenoid valve and then into the 22nd stage storage cylinder(s). At this point the gas flow from the compressor or alternate air source shall be recharging the 401st and 412nd stage storage cylinders simultaneously at an equal rate of flow.

(127) When the outlet pressure of the compressor or alternate air source and the 401st stage storage cylinder(s) and 412nd stage storage cylinder(s) becomes equal to or greater than that of the pressure of the 423rd stage storage cylinder(s), the compressed gas shall begin to flow through the 65check valve and the 563rd stage solenoid valve and then into the 423rd stage storage cylinder(s). At this point the gas flow from the compressor or alternate air source shall be recharging the 401st, 412nd and 423rd stage storage cylinders simultaneously at an equal rate of flow.

(128) Sequence-Fill Mode:

(129) When in Sequence-Fill mode the Priority-Fill system and method is active, and the compressor or alternate air source output is above the predetermined volume of flow required to activate the 66FIS, the compressors output will flow solely into the 73cylinder which is being recharged.

(130) When in the Sequence-Fill mode the Priority-Fill system and method are active, and the compressor or alternate air source output is below the predetermined volume of flow required to activate the 66FIS, the compressors output flow will Track the 73cylinder which is being recharged through the entire fill sequence. While this Tracking is taking place the compressor or alternate air source output will only flow into the 73cylinder which is being recharged and the single stage of the compressed gas storage cylinder(s) which is open at that specific time. The Tracking of the 73cylinder which is being recharged enables the compressor or alternate air source to maintain only enough pressure to achieve the recharge operation while enabling the system pressure to build quickly so that it always will remain equal to, or greater than, that of the 73cylinder which is being recharged. This process will take advantage of the compressors higher recovery rate which is inherent when operating at lower pressures while at the same time giving the compressor the ability to utilize its maximum pressure capacity when needed.

Example #1

(131) The following example will describe the Hybrid Priority-Fill method and system when used with a 3-stage auto-cascade where the Sequence-Fill and Priority-Fill operations are initiated simultaneously.

(132) The compressor or alternate compress gas source is attached to the 74Priority-Fill inlet. Flow passing through the 66FIS will trigger the initiation of the 59ESM which will close 50, 53 and 56 solenoid valves. As the outlet flow/pressure of the compressor or alternate air source becomes equal to, or greater than, that of the pressure within 46pipe or tubing upstream of the 63check valve the compressor output will begin to flow to the path of least resistance. Initially this path would be through the 63, 64, 65check valves and the 66FIS then into the 73cylinder which is being recharged.

(133) If the rate of flow remains above the minimum required to activate the 66FIS, The 59ESM will continue to hold closed 50, 53 and 56solenoid valves and the compressor output will continue to flow through 46pipe or tubing and past the 66FIS then solely into the 73cylinder which is being recharged until the 73cylinder which is being recharged achieves the desired pressure.

(134) If the rate of flow falls below the minimum required to maintain activation of the 66FIS, the 59ESM will open the 501st stage solenoid valve. As the outlet flow/pressure of the compressor or alternate air source becomes equal to, or greater than, that of the pressure within 46pipe or tubing upstream of the 63check valve the compressor output will begin to flow to the path of least resistance. Since the 501st stage solenoid valve is open, flow from the 401st stage fluid cylinder along with that of the compressor or alternate air source output will jointly flow through the 46pipe or tube, 64check valve, 65check valve 66FIS and into the 73cylinder which is being recharged.

(135) If the rate of flow remains above the minimum required to activate the 66FIS, the 59ESM will continue to hold closed the 53 and 56solenoid valves allowing flow from the 401st stage fluid cylinder along with that of the compressor or alternate air source output will jointly flow through the 46pipe or tube, 64check valve, 65check valve 66FIS and into the 73cylinder which is being recharged until the 73cylinder which is being recharged achieves the desired pressure.

(136) If the rate of flow falls below the minimum required to maintain activation of the 66FIS, the 59ESM will close the 501st stage solenoid valve and open the 532nd stage solenoid valve. As the outlet flow/pressure of the compressor or alternate air source becomes equal to, or greater than, that of the pressure within 46pipe or tubing upstream of the 64check valve the compressor output will begin to flow to the path of least resistance. Since the 532nd stage solenoid valve is open, flow from the 412nd stage fluid cylinder along with that of the compressor or alternate air source output will jointly flow through the 46pipe or tube, appropriate check valves, the 66FIS and into the 73cylinder which is being recharged.

(137) If the rate of flow remains above the minimum required to activate the 66FIS, The 59ESM will continue to hold closed the 501st stage and 563rd stage solenoid valves allowing flow from the 412nd stage fluid cylinder along with that of the compressor or alternate air source output will jointly flow through the 46pipe or tube, 64check valve, appropriate check valves, the 66FIS and into the 73cylinder which is being recharged until the 73cylinder which is being recharged until it achieves the desired pressure.

(138) If the rate of flow falls below the minimum required to maintain activation of the 66FIS, the 59ESM will close the 532nd stage solenoid valve and open the 563rd stage solenoid valve. As the outlet flow/pressure of the compressor or alternate air source becomes equal to, or greater than, that of the pressure within 46pipe or tubing upstream of the 65check valve the compressor output will begin to flow to the path of least resistance. Since the 563rd stage solenoid valve is open, flow from the 423rd stage fluid cylinder along with that of the compressor or alternate air source output will jointly flow through the 46pipe or tube, appropriate check valves, the 66FIS and into the 73cylinder which is being recharged.

(139) If the rate of flow remains above the minimum required to activate the 66FIS, The 59ESM will continue to hold closed the 501st stage and 532nd stage solenoid valves allowing flow from the 412nd stage fluid cylinder along with that of the compressor or alternate air source output will jointly flow through the 46pipe or tube, 65check valve, appropriate check valves, the 66FIS and into the 73cylinder which is being recharged until the 73cylinder which is being recharged until it achieves the desired pressure.

(140) The flow process will continue until the 73cylinder which is being recharged either achieves the desired pressure or the fill process is stopped by personnel operating the Auto-Cascade system.

Example #2

(141) The following example will describe the Hybrid Priority-Fill method and system when used with a 3-stage auto-cascade where the Sequence-Fill and Priority-Fill operations have already began and compressed gas is flowing from the 412nd stage fluid cylinder and into the 73cylinder which is being recharged. The compressor or alternate compress gas source is attached to the 74Priority-Fill inlet.

(142) When the pressure from the compressor or alternate air source becomes equal to, or greater than that of the pressure in the 46pipe or tube upstream of the 64check valve, it will begin to flow past the 64 check valve and then jointly with that of the compressor or alternate air source output.

(143) If the rate of flow remains above the minimum required to activate the 66FIS, The 59ESM will continue to hold closed the 501st stage and 563rd stage solenoid valves allowing flow from the 412nd stage fluid cylinder along with that of the compressor or alternate air source output will jointly flow through the 46pipe or tube, 64check valve, appropriate check valves, the 66FIS and into the 73cylinder which is being recharged until the 73cylinder which is being recharged until it achieves the desired pressure.

(144) If the rate of flow falls below the minimum required to maintain activation of the 66FIS, the 59ESM will close the 532nd stage solenoid valve and open the 563rd stage solenoid valve. As the outlet flow/pressure of the compressor or alternate air source becomes equal to, or greater than, that of the pressure within 46pipe or tubing upstream of the 65check valve the compressor output will begin to flow to the path of least resistance. Since the 563rd stage solenoid valve is open, flow from the 423rd stage fluid cylinder along with that of the compressor or alternate air source output will jointly flow through the 46pipe or tube, appropriate check valves, the 66FIS and into the 73cylinder which is being recharged.

(145) The flow process will continue until the 73cylinder which is being recharged either achieves the desired pressure or the fill process is stopped by personnel operating the Auto-Cascade system.

(146) NOTE: While these 2 examples describe the Hybrid Priority-Fill system and method as used on a 3-stage Auto-Cascade system, in actuality, an infinite number of stages may be used.

(147) FIG. 3 is a valve sub-assembly schematic used to install additional stage(s) in the Back-Fill or Priority-Fill auto-cascade systems.

(148) This figure demonstrates how one or more of the valve sub-assemblies as seen in the 3Asubdrawing can be installed to add additional stage(s) into either the Back-Fill or Priority-Fill Flow Indicating Switch based auto-cascade systems.

(149) The valve assembly described in the 3Asubdrawing consists of the 91compressed gas storage cylinder(s) inlet, 92interconnecting pipe or tube, 93pressure gauge, 94solenoid valve, 95 and 96electrical wires, 97check valve and the 98pipe or tubing.

(150) FIG. 3 shows the main system connection points the components listed in the 3A-subdrawing will connect to such as the 98pipe or tubing, 95 and 96electrical wires.

(151) If the number of added valve sub-assemblies exceed the available connection points of the PCB (printed circuit boards) within the 99ESM, additional auto-cascade PCB(s) can be connected in series and installed within the 99ESM to allow for the infinite expansion of the number of auto-cascade stages.

(152) FIG. 4 is a flow switch triggered auto-cascade demonstrated supplying Firefighters Breathing Air Replenishment System (FBARS).

(153) This figure demonstrates the Single FIS (Flow Indicating Switch) based auto-cascade system when the applied use is to provide Auto-Cascade refilling of Fire Fighters SCBA using a Firefighter Breathing Air Replenishment System (FBARS) The FBARS requirements are set forth in the International Association of Plumbing and Mechanical Officials (IAPMO) documentation.

(154) The FIS (Flow Indicating Switch) controlled Auto-Cascading systems, as discussed in the FIG. 1 and FIG. 2 detailed descriptions, is designed to function as intended when used in conjunction with the FBARS. A stationary Flow Indicating Switch (FIS) controlled Auto-Cascade used in conjunction with a bank of compressed gas storage cylinders can be permanently installed within a structure to provide compressed breathing air to the structures FBARS panel(s). An alternate to the permanently mounted FIS controlled Auto-Cascade system would be a Mobile (truck or trailer mounted) Flow Indicating Switch (FIS) controlled Auto-Cascade used in conjunction with a bank of compressed gas storage cylinders which would connect to the FBARS 119Fire Department connection point on the structure to provide compressed breathing air to the structures FBARS panel(s).

(155) Basic Component Description:

(156) In the FIG. 4 design, the compressed gas supply needed at each of the 111, 112 and 113FBARS panels will originate at the 118primary fill panel then flow through the 127compressor outlet pipe or tube and then be discharged into the structures 115compressed gas pipe or tube at the 119Fire Department connection point. The flow exiting the 118primary fill panel will pass through a single FIS installed within, or in close proximity, to the primary fill panel.

(157) The FIS will send an electrical current or signal to the ESM (Electronic Sequencing Module), any time the flow of compressed gas flow through the FIS exceeds a minimum predetermined quantity. The ESM will interpret this electrical current or signal and then open or close solenoid valves as required any time a SCBA cylinder is being recharged at one of the remote FBARS panels.

(158) The 4Asubdrawing show expanded details of the 118primary fill panel while the 4B and 4Csubdrawings show expanded details of two different styles of individual FBARS panels.

(159) The individual 111, 112, 113 and 114FBARS panels are interconnected with the 115compressed gas distribution pipe or tubing. The FBARS panels may be equipped with an optional 121isolation block valve which, when closed, will isolate the compress gas feed to all FBARS panels which are located above or distal to the 121isolation block valve. The FBARS panels may also be equipped with an optional 116wire bundle which is used to transmit an electric current or signal from the 118primary fill panel which will enable the individual FBARS panel 125visual indication of stage activity lights or readout to mimic that of the 118primary panel 120visual indication of stage activity lights or readout. An optional 122wire bundle disconnect should be installed on each of the FBARS panels which, when opened, will isolate the electrical feed to all FBARS panels which are located above or distal to the 122wire bundle disconnect.

(160) FBARS Function when Used with a Mobile FIS Controlled Auto-Cascade System:

(161) While both the stationary permanently installed or Fix Mount and the Mobile FIS controlled Auto-Cascade system functions identically when used in conjunction with the FBARS, in the following example a mobile type cascade will be used.

Example

(162) A fire has occurred on the 4th floor of a 5 story structure. A Mobile FIS controlled Auto-Cascade system has been brought in to supply compressed breathing air to the structures FBARS.

(163) The 126wire bundle and the 127pipe or tubing supplying compressed gas from the mobile cascade systems 118primary fill panel are attached to their corresponding 116wire bundle and 115compressed gas distribution pipe or tubing at the structures 119Fire Department connection point.

(164) If the Fire Fighters or Rescue Personnel arriving on the 3rd floor of the structure suspect that the 114FBARS panel, 115FBARS compressed gas distribution pipe or tubing and/or the 116wire bundle on the 4th floor has been damaged by fire, explosion or other malfunction, the Fire Fighter(s) will close the FBARS 121isolation valve and open the 122wire bundle disconnect which is located directly above the 113FBARS thus isolating the FBARS components which are located on the 4th floor. The Fire Fighter or Rescue Personnel then notify the Incident Commander that the 110structure FBARS is ready for operation. The Incident Commander then notifies the Cascade system operator who will then open the 118primary fill panel 128fill valve.

(165) Opening the 118primary fill panel 128fill valve will pressurize the 115compressed gas distribution pipe or tube via the 127pipe or tubing thus pressurizing the 111, 112 and 113FBARS panels. At the same time of pressurization, the optional 116wire bundle will receive an electric current or signal from the 118primary fill panel via the 126wire bundle which will enable the individual 111, 112 and 113FBARS panels 125visual indication of stage activity lights or readout to mimic that of the 118primary panel 120visual indication of stage activity lights or readout.

(166) The initial flow of compressed gas through the 118primary panel FIS, will initiate an electrical current or signal which will activate the ESM and initiate the fill sequence program. As the pressure within the 115distribution pipe or tubing equalizes with that of the pressure output of the 118primary fill panel and compressed gas flow volume drops below a predetermined quantity, the ESM will go into the Stand-By mode. At the same time an electrical current or signal from the ESM will travel through the 126wire bundle, into the 116wire bundle and activate the active/operational FBARS panel 125visual indicator of stage activity lights or readout. The 125visual indicator of stage activity will, at this point, indicate that all solenoid valves are in the open position which will indicate that the ESM is in Stand-By mode.

(167) When a Fire Fighter within the fire structure needs to recharge their Self Contained Breathing Apparatus (SCBA), the SCBA cylinder(s) is attached to the 124SCBA connection point of any of the active/operational FBARS panels. NOTE: The connection method used should comply with industry accepted methods such as a quick fill connection, a commercially fabricated Fill enclosure or the Fire Fighters SCBA RIT (Rapid Intervention Team) or RIC (Rapid Intervention Crew) fittings, if the situation so necessitates.

(168) When a SCBA cylinder is connected to a FBARS panel 124SCBA connection point and the 123fill valve is opened compressed gas from the 115compressed gas distribution pipe or tube will begin to flow through the FBARS panel and into the SCBA cylinder(s) which is being recharged. As compressed gas begins to flow into the SCBA cylinder(s) which are being recharged, pressure within the 115compressed gas distribution pipe or tube will begin to drop. This pressure drop will cause flow from the 118primary fill panel to begin as the 118primary fill panel 129pressure regulator attempts to maintain a consistent pressure within the FBARS 115compressed gas distribution pipe or tube.

(169) This compressed gas flow through the FIS, which is installed in the 118primary fill panel, will initiate the ESM which will now go into Sequence-Fill mode. At this point the FIS controlled Auto-Cascade shall operate as described in the FIG. 1 and FIG. 2 detailed descriptions of this document.

(170) NOTE 1: The Fire Fighter performing SCBA fill operation using any of the FBARS panel may use the optional 125visual indication of stage activity to determine if other FBARS panels are in use and, if so, which stage the FIS controlled Auto-Cascade is in at any specific point in time. This information combined with the FBARS panel 131regulated pressure gauge and the SCBA pressure gauge will provide vital information to the Fire Fighter performing the SCBA recharge operation. The visual indication of stage activity will also visible to the operator that is monitoring the 118primary fill panel 120visual indicator of stage activity. This information will help the operator of the 118primary panel determine the approximate numbers of SCBA recharges which are taking place and the total rate of breathing air consumption. This information will assist the 118primary panel operator in determining whether there is a sufficient quantity of compressed gas on scene for the duration of the incident or if additional compressed gas will be required to complete the operation.

(171) NOTE 2: Since the active/operational 111, 112 and 113FBARS panels function as a remote extension of the 118primary fill panel. The 118primary fill panel operator's sole purpose will be to monitor the system and initiate either the Back-Fill or Hybrid Priority-Fill procedure in the event that the 117fluid cylinder pressures are depleted to a predetermined pressure.

(172) NOTE 3: The 118primary fill panel shall remain fully operational for use by exterior Fire/Rescue personnel. Since the FIS controlled Auto-Cascade system functions by compressed gas Flow through the system, SCBA cylinder(s) can be recharged directly from the 118primary fill panel 130ground level SCBA fill point.

(173) In the case where the Auto-Cascade system Sequence-Fill mode has already been initiated, and a second or third SCBA cylinder fill is initiated at another location in the system, the ESM will hold the Auto-Cascade system in the fill stage which it was in when the additional SCBA cylinder was attached. The ESM will continue to hold the Auto-Cascade in this stage until the SCBA cylinder pressures equalizes. When the two SCBA cylinders pressure equalize and the flow of compressed gas through the FIS drops to a predetermined quantity, the ESM shall initiate and continue the remainder of the fill sequence.

(174) Optional FBARS Panel Design:

(175) NOTE 1: The 4Csubdrawing demonstrate an alternate FBARS panel design where the pressure regulator has been omitted. When this design of FBARS panel is used, the FBARS panel discharge pressure is set solely by use of the 118primary panel 129pressure regulator.

(176) NOTE 2: If FBARS panels are used in conjunction with a Fire Fighters SCBA RIT (Rapid Intervention Team) or RIC (Rapid Intervention Crew) fittings and local codes and regulations permit, the FBARS panel Fill and Bleed valve may be omitted.

(177) FIG. 5 is an alternate to FIG. 4.

(178) This figure demonstrates the Multiple FIS (Flow Indicating Switch) based auto-cascade system when the applied use is to provide Auto-Cascade refilling of Fire Fighters SCBA using a Firefighter Breathing Air Replenishment System (FBARS) The FBARS requirements are set forth in the International Association of Plumbing and Mechanical Officials (IAPMO) documentation.

(179) The Multiple-FIS (Flow Indicating Switch) controlled Auto-Cascading systems is similar to the Single FIS controlled Auto-Cascade system, as discussed in the FIG. 1 and FIG. 2 detailed descriptions, and is designed to function as intended when used in conjunction with the FBARS.

(180) A stationary Multiple-Flow Indicating Switch (FIS) controlled Auto-Cascade used in conjunction with a bank of compressed gas storage cylinders may be permanently installed within a structure to provide compressed breathing air to the structures FBARS panel(s). An alternate to the permanently mounted FIS controlled Auto-Cascade system would be a Mobile (truck or trailer mounted) Flow Indicating Switch (FIS) controlled Auto-Cascade used in conjunction with a bank of compressed gas storage cylinders which would connect to the FBARS 159Fire Department connection point on the structure to provide compressed breathing air to the structures FBARS panel(s).

(181) FIS Location:

(182) The FIG. 5 drawing design and operation is the same as that of FIG. 4 with two exceptions. In this design the FIS (Flow Indicating Switch) which is located within or in close proximity to, the 158primary fill panel, is either removal or disabled and then a FIS has been installed in each FBARS panel.

(183) In this design a FIS has been relocate within each of the 151, 152, 153 and 154FBARS panels. The preferential location in the 5Bsubdrawing would be downstream of the 172pressure regulator or 163fill valve and upstream of the 173bleed valve. Preferential FIS location in the 5Csubdrawing would be upstream of the 172SCBA pressure gauge. In this way the FIS controlled Auto-Cascade system will be much quicker to respond to flow due to the FIS being installed near the point of discharge into a SCBA cylinder.

(184) Multiple FIS Operating Principle:

(185) The FIS operates by the Making or Breaking of a circuit through which an electrical current or signal is passing. For clarity of this description, a simple electrical current will be used.

(186) The FIS located in each FBARS panel will have a pair, one positive and one negative, of electrical signal wires which run in parallel with each other through the 156wire bundle. The multiple pairs of FIS electrical signal wires will terminate within the 159Fire Department connection point. Here the electrical signal wires shall be grouped into positive and negative sets and then connected to a single positive and negative terminal at the 159Fire Department connection point. In this way the electrical current or signal from all FIS will be combined into a single pair of wires. These wires will then continue to the 158primary fill panel ESM (Electronic Sequencing Module) through the 166wire bundle. In this manner a single electrical current or signal from the multiple individual FIS will be obtained and transmitted to the ESM.

(187) Note: It must be remembered that the only external events that will initiate and control the ESM sequencing program will be an electrical current or signal or lack of an electrical current or signal that is received from the total group of individual FIS which are installed in the FBARS panels.

(188) Example of a Simple Multi-FIS Controlled Auto-Cascade System in Use:

(189) An SCBA cylinder is being recharged at the 153FBARS panel installed on the 3rd floor of the structure. The flow passing through the 153FBARS panel FIS will complete or Make the electrical circuit and sending an electrical current or signal to the ESM thus activating the sequencing program. The initial electrical current or signal from the FIS will initiate the ESM Sequence-Fill program and the Auto-Cascade will open the 1st stage solenoid valve while simultaneously closing the 2nd and 3rd stage solenoid valves thus permitting compressed gas from the 1st stage storage cylinder to flow into the SCBA. When the differential pressure between the 1st stage fluid cylinder nears equalization with that of the SCBA cylinder which is being recharged and the flow of compressed gas through the FIS decreases to a predetermined minimal quantity, the FIS electrical circuit will Break. When the electrical current or signal is lost, the ESM sequencing program will open the 2nd stage solenoid valve thus permitting compressed gas to flow from the 2nd stage storage cylinder into the SCBA cylinder which is being recharged.

(190) Now, at this point, if a second SCBA cylinder is connected to the 151FBARS panel which is installed on the 1st floor. The flow passing through the 151FBARS panel FIS will complete the electrical circuit and sending an electrical current or signal to the ESM. However, since all FIS wire pairs are installed in parallel and the ESM is already receiving the electrical current or signal from the 153FBARS panel FIS, the ESM will remain locked into the 2nd stage of the fill sequence and will not sequence up and open the 3rd stage solenoid valve until flow through both FIS drops below a predetermined quantity and the electrical current or signal from both FIS ceases.

(191) Since the compressed gas will flow towards the point of least resistance, the compressed gas discharge from the 2nd stage fluid cylinder will flow into the SCBA cylinder which has the lowest pressure. The compressed gas will continue to flow into this cylinder until the pressure equalizes with that of the next higher pressure SCBA cylinder. At this point the compressed gas will flow into both SCBA cylinders simultaneously and at an equal rate.

(192) NOTE: Due to the secondary check valve function of the FIS, no compressed gas from the highest pressure SCBA cylinder which is connected to the system, will be lost due to upstream flow into the FBARS.

(193) This flow will continue until the flow through both FIS decrease to a predetermine minimal level at which time electrical current or signal going to the ESM is stopped by both FIS. When this event occurs, the ESM shall continue through its normal sequence-Fill program until the desired SCBA pressure is achieved or the recharge operation is stopped by one or both personnel who are performing the individual SCBA recharge operations.

(194) NOTE: If only one of the SCBA recharging operations is stopped, the recharge operation of the second SCBA cylinder will automatically continue through the remainder of the ESM recharging sequence.

(195) Basic Component Description:

(196) In the FIG. 5 design, the compressed gas supply needed at each of the 151, 152 and 153FBARS panels will originate at the 158primary fill panel. The flow exiting the 158primary fill panel will pass through the 167pipe or tube and into the 155compressed gas distribution pipe or tube at the 159Fire Department connection point.

(197) The individual 151, 152, 153 and 154FBARS panels are interconnected with the 155compressed gas distribution pipe or tubing. The FBARS panels may be equipped with an optional 161isolation block valve which, when closed, will isolate the compress gas feed to all FBARS panels which are located above or distal to the 161isolation block valve. The FBARS panels are equipped with a 156wire bundle which has the primary function of transmitting a electric current or signal from the individual FIS to the 158primary fill panel ESM (Electronic Sequencing Module) which in turn will control the auto-cascade discharge of the various fluid cylinder stages.

(198) As an option, additional wires will be included in the 156wire bundle and will be used to transmit an electric current or signal from the 158primary fill panel which will enable the individual FBARS panel 165visual indication of stage activity lights or readout to mimic that of the 158primary panel 160visual indication of stage activity lights or readout. An optional 162wire bundle disconnect should be installed on each of the FBARS panels which, when opened, will isolate the electrical feed to all FBARS panels which are located above or distal to the 162wire bundle disconnect.

(199) The 5Asubdrawing show expanded details of the 118primary fill panel while the 4B and 4Csubdrawings show expanded details of two different styles of individual FBARS panels.

(200) FBARS Function when Used with a Mobile Multiple FIS Controlled Auto-Cascade System:

(201) While both the stationary permanently installed or Fix Mount and the Mobile FIS controlled Auto-Cascade system functions identically when used in conjunction with the FBARS, in the following example a mobile type cascade will be used.

Example: Multi-FIS Controlled Auto-Cascade System when Used Under Emergency Conditions

(202) A fire has occurred on the 4th floor of a 5 story structure. A Mobile FIS controlled Auto-Cascade system has been brought in to supply compressed breathing air to the structures FBARS.

(203) The 166wire bundle and the 167pipe or tubing supplying compressed gas from the mobile cascade systems 158primary fill panel are attached to their corresponding 156wire bundle and 155compressed gas distribution pipe or tubing at the structures 159Fire Department connection point.

(204) If Fire Fighters or Rescue Personnel arriving on the 3rd floor of the structure suspect that the 154FBARS panel, 155FBARS compressed gas distribution pipe or tubing and/or the 156wire bundle on the 4th floor has been damaged by fire, explosion or other malfunction, the Fire Fighter(s) will close the FBARS 161isolation valve and open the 162wire bundle disconnect which is located directly above the 153FBARS thus isolating the FBARS components which are located on the 4th floor. The Fire Fighter or Rescue Personnel then notify the Incident Commander that the 150structure FBARS is ready for operation. The Incident Commander then notifies the Cascade system operator who will then open the 158primary fill panel 168fill valve.

(205) Opening the 158primary fill panel 168fill valve will pressurize the 155compressed gas distribution pipe or tube via the 167pipe or tubing thus pressurizing the 151, 152 and 153FBARS panels. At the same time of pressurization, the optional 156wire bundle will receive an electric current or signal from the 158primary fill panel via the 166wire bundle which will enable the individual 151, 152 and 153FBARS panels 165visual indication of stage activity lights or readout to mimic that of the 158primary panel 160visual indication of stage activity lights or readout.

(206) Since all FBARS panels have FIS installed in each and no flow is passing through any of the FIS, the 158primary fill panel ESM will initiate into Stand-By mode and open all of the compressed gas storage cylinders solenoid valves.

(207) NOTE: At the time of system initiation the 158primary fill panel 160visual indication of stage activity lights or readout will mimic the entire group of FBARS panels 165visual indication of stage activity lights or readout. If the 158primary fill panel 160visual indication of stage activity lights or readout indicates a compressed gas flow from one of more individual stage(s) BEFORE Fire Fighting or Rescue Personnel have entered the structure, the 158primary panel operator will be able to quickly determine that damage may have occurred to one or more of the FBARS components.

(208) When a Fire Fighter within the fire structure needs to recharge their Self Contained Breathing Apparatus (SCBA), the SCBA cylinder(s) is attached to the 164SCBA connection point of any of the active/operational FBARS panels. NOTE: The connection method used should comply with industry accepted methods such as a quick fill connection, a commercially fabricated Fill enclosure or the Fire Fighters SCBA RIT (Rapid Intervention Team) or RIC (Rapid Intervention Crew) fittings, if the situation so necessitates.

(209) When a SCBA cylinder is connected to a FBARS panel 164SCBA connection point and the 163fill valve is opened, compressed gas from the 155compressed gas distribution pipe or tube will begin to flow into the SCBA cylinder(s) which is being recharged. The compressed gas flow through the FIS, which is installed the FBARS fill panel being used, will initiate the ESM which will then go into Sequence-Fill mode. At this point the FIS controlled Auto-Cascade shall operate as described in the FIG. 1 and FIG. 2 detailed descriptions of this document.

(210) NOTE 1: The Fire Fighter performing SCBA fill operation using any of the FBARS panel may use the optional 165visual indication of stage activity to determine if other FBARS panels are in use and, if so, which stage the FIS controlled Auto-Cascade is in at any specific point in time. This information combined with the FBARS panel 171regulated pressure gauge and the 173SCBA pressure gauge will provide vital information to the Fire Fighter performing the SCBA recharge operation. The visual indication of stage activity will also visible to the operator that is monitoring the 158primary fill panel 160visual indicator of stage activity. This information will help the operator of the 158primary panel determine the approximate numbers of SCBA recharges which are taking place and the total rate of breathing air consumption. This combined information will assist the 158primary panel operator in determining whether there is a sufficient quantity of compressed gas on scene for the duration of the incident or if additional compressed gas will be required to complete the operation.

(211) NOTE 2: Since the active/operational 151, 152 and 153FBARS panels function as a remote extension of the 158primary fill panel. The 118primary fill panel operator's sole purpose will be to monitor the system and initiate either the Back-Fill or Hybrid Priority-Fill procedure in the event that the 157fluid cylinder pressures are depleted to a predetermined pressure.

(212) Optional FBARS Panel Design:

(213) NOTE 1: The 4Csubdrawing demonstrate an alternate FBARS panel design where the pressure regulator has been omitted. When this design of FBARS panel is used, the FBARS panel discharge pressure is set solely by use of the 158primary panel 169pressure regulator.

(214) NOTE 2: If FBARS panels are used in conjunction with a Fire Fighters SCBA RIT (Rapid Intervention Team) or RIC (Rapid Intervention Crew) fittings and local codes and regulations permit, the FBARS panel Fill and Bleed valve may be omitted.

(215) FIG. 6 is a single flow indicating switch auto cascade system.

(216) FIG. 6 demonstrates the use of the Single FIS (Flow Indicating Switch) based auto-cascade system, as described in FIG. 4, however, the applied use in this figure is to provide Auto-Cascade refilling of one or more multiple cylinder storage bank(s), such as a 6 pack, located at a distance remote to a tube trailer. The breathing air 6 pack is then used for recharging SCBA cylinders, diving SCUBA cylinders, providing air to SAR (supplied air respirators) and/or providing compressed air for pneumatically operated tools. It must be remembered that this configuration is not limited to simple compressed air but can be used with any type of compressed gas transfer such as nitrogen, H2S or SO2 just to name a few.

(217) For the purpose of FIG. 6, the three stage valve bodies discussed in FIGS. 1 and 2, have been used and 3 additional stages have been added in accordance with FIG. 3 making this figure demonstration a 6 stage FIS Auto-Cascade system.

(218) The sub-drawing 6AFIS Auto-Cascade valve assembly panel is located inside the 190tube trailer rear valve compartment and is connected to the tube trailer 191individual high pressure tubes via the 192tubing/pipes.

(219) The connection 6AFIS Auto-Cascade valve assembly panel to available tubes may be on a 1 to 1 basis or multiple 191tubes could be connected to a single valve.

(220) When multiple 191tubes are connected to an individual stage valve located inside the 6AFIS Auto-Cascade valve assembly panel it may be done in a descending order beginning with stage 1 or the lowest pressure bank. An example of multiple 191tubes connected to each individual 6AFIS Auto-Cascade valve assembly panel stage valves via the 192tubing/pipes could be eight 191tubes connected to the 6AFIS Auto-Cascade valve assembly panel stage 1 valve, six 191tubes connected to the 6AFIS Auto-Cascade valve assembly panel stage 2 valve and so on.

(221) Pressure from the 191individual high pressure tubes are directed by the 6AFIS Auto-Cascade valve assembly panel individual valves into the 195discharge tub/piping. The 195discharge tube/pipe transports the compressed gas flow to a remote location where it is connected to the 196compressed gas storages cylinders.

(222) In this way the 6AFIS Auto-Cascade valve assembly panel automatically cascade refills, at an unlimited distance, the remote 196compressed gas storage cylinders via a single 195discharge tube/pipe.

(223) While these embodiments have been described with emphasis on the embodiments, it should be understood that within the scope of the appended claims, the embodiments might be practiced other than as specifically described herein.