The present invention relates to a device for reducing water hardness as required for operation of a utilizer apparatus, in particular a household washing machine, as well as to a device for detecting the state of the resins used for softening and to the control methods thereof.
As known, household washing machines utilizing water, in particular dishwashers, are fitted with a decalcifying device of the wash water, provided for reducing water hardness degree and avoid possible calcareous deposits. Such a device is also called a decalcifier. As known, the decalcifier comprises a container with ions exchange resins or similar substance (hereafter called resins for simplicity's sake) for the softening of wash water. However, after a certain time of usage resins become exhausted, depending on the quantity of water treated and its hardness degree (obviously the higher the water hardness degree, the faster resin exhaustion will be); as a result, when resins are exhausted, the water flowing through them will substantially maintain the same hardness as it had at its inlet.
In order to avoid this drawback, a resin regeneration phase is provided, consisting to introduce a water and salt solution (NaCl) in the resins container, with salt being contained in a special tank pertaining to the softening system of the washing machine; practically, a predetermined amount of water, metered in the usual way, is supplied to said tank, for obtaining a corresponding amount of water-salt solution to flow through the resins container and regenerate them.
In most known solutions, this phase is usually executed at every wash cycle, requiring a considerable quantity of salt to be often introduced by the user in the proper container; moreover, this obviously requires a higher water usage too.
In order to reduce salt and water wastage, some washing machines are fitted as known with water hardness sensors, which cause the resins regeneration phase to start only when sensing that water hardness is exceeding a certain threshold, due to the exhausted capacity of the resins to soften the water; said sensors usually measure resistivity of the treated water and a control system will activate resins generation or not based on the information obtained.
However, even if water hardness is regularly reduced, it may possibly happen that a light calcareous layer will deposit on the sensors, before activating regeneration, thus altering detection of the water hardness degree due to an increased resistivity produced by the limestone.
Moreover, such system sensing the water hardness degree directly, but will only sense the efficiency state of the resins indirectly; therefore, resins regeneration may also be activated in those instances when it is not required yet.
Provided that as resins gradually exhaust their efficiency degree, their volume decreases, it is also known to detect such a volume change during exhaustion phase, to determine the start of a regeneration process.
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However, even if this systems are capable of exactly sensing the exhaustion state of the resins and start a relevant regeneration phase, they do not allow obtaining other parameters and useful information, such as a regeneration phase stop, too much salt or salt missing in the water softener, or relevant data for starting and/or performing and stopping the resins wash phase.
For example, according to the known technique and independently from the method used for detecting the resins exhaustion state, the resins regeneration phase is always performed with a quantity of water previously determined and supplied to the salt container; therefore, the duration of such a phase and the quantity of water used to the purpose is not directly controllable in function of the reaching of the actual restoration of resins efficiency; in other terms, the regeneration phase in some cases may be longer or use more water than actually required for obtaining complete resins regeneration; in other instances, vice-versa, duration of the regeneration phase or the quantity of water used to the purpose may not be enough for determining a complete restoration of resins efficiency.
The same applies for the resins wash phase, required after a regeneration phase, which according to the known technique has a fixed duration or is obtained with a substantially predetermined quantity of water.
In the practice, in fact, such a resins wash is performed by supplying a certain quantity of water from the mains to the machine wash tub and maintaining at the meantime a discharge pump in operation; thus, the water from the mains flows to the resins container, removing from the resins any salt rests also present because of the previous activation phase and then flow into the tub for its immediate discharge.
Such a wash phase is generally performed by the opening of a solenoid valve for a time (predetermined at design phase) letting a quantity of fresh water flow through the resins, as considered sufficient for removing salt residuals; in some solutions, to ensure a most possible correct resins wash, several subsequent wash phases are provided.
Therefore, as it can be noted, according to the known technique, also the duration of the resins wash phase and the quantity of water used to the purpose, does not depend directly on reaching a complete and actual resins wash; in other terms, in some instances such a phase could last longer or more water be used than actually required for the resins wash; in other instances, vice-versa, duration of such a phase or the quantity of water used to the purpose may not be enough for a correct resins wash.
It is the object of the present invention to solve the above drawbacks and provide a system for reducing water hardness degree as required to the functioning of a utilizer apparatus, in particular a household washing machine, as well as a detection device and control methods thereof, which allow the detection. in a way simple, easy, reliable, cost-effective and direct, of the exhaustion state of a water softening material and an efficient control of its regeneration processes.
In this frame, it is an object of the present invention to provide such a system, wherein the resins regeneration phase can be directly controlled, i.e. upon reaching of the actual restoration of resins efficiency.
A further object of the present invention is to provide such a system wherein the resins wash phases can be directly controlled, i.e. upon reaching a complete actual resins wash. A further object of the present invention is to provide a method for detecting the resins exhaustion degree, a method for controlling the resins regeneration phase and a method for controlling the resins wash phases, which are reliable and advantageous.
A further object of the present invention is to provide how the above systems and methods can be managed automatically by means of an electromechanical programmer or electronic control device.
In particular, the present invention is aiming at the solution of the technical problem concerning the good operation of the device for detecting the resins state comprising the container containing the sample resins and their complete regeneration and/or washing when the regeneration and/or wash process of all resins contained in the softening device is performed.
Therefore, it is the object of the present invention to describe a particularly advantageous solution of such system and/or device and/or method capable of obtaining the above purposes.
The above object, according to the present invention, is obtained by a system for reducing the water hardness degree as required for operation of a utilizer apparatus, in particular a household washing machine, as well as by the control methods incorporating the features of the annexed claims, which form an integral part of the present invention.
Further objects, features and advantages of the present invention will become apparent from the following detailed description and annexed drawings, which are supplied by way of non limiting example, wherein:
In
Number 2 indicates the body of the device 1, which has a cylindrical hollow portion 3 and a ring flange 4. The cylindrical hollow portion 3 has three sections with a different inner diameter to each other, indicated with 3A, 3B and 3C, respectively. The section 3B has a smaller diameter with respect to both section 3A and 3C.
From the flange 4 two cylindrical bushings 5 and 5' departing vertically downwards are substantially divided at half height by a wall 6 and 6'; walls 6 and 6' have a central hole indicated with 7 and 7', respectively.
Number 8 indicates a hollow column or a similar tubular element, which is closed on one end by a wall 8A; on the column 8, a flange 9 is located near the closed end.
The column 8 is inserted in the section 3A of the cylindrical portion 3 of the body 2, where its insertion is stopped by the flange 9 striking against the flange 4 of the body 2. Between the column 8 and the section 3A of the cylindrical portion 3, there are common hydraulic sealing means, such as a ring gasket, not shown for simplicity's sake.
Number 10 indicates sample resins and number 11 a movable element. Number 11 A indicates the base of the movable element 11, which has substantially the shape of a hollow cylinder closed on one end, whose outer diameter is provided to match and slide within the inner diameter of the column 8 and inside the inner diameter of the section 3B of the body 3; the diameter of the section 3B is equal to the inner diameter of the column 8. Number 12 indicates a rod having on one end a cylindrical extension 12A with a larger diameter than the rod itself, apt to be inserted in the inner portion of the base 11A. Moreover, the rod 12 is divided in two portions, indicated with 12B and 12C, respectively, by a flange 12D; the portion 12B has a vertical cylindrical recess 12E between the flange 12D and the end 12A.
The cylindrical recess 12E is connected outside through a hole 12F perpendicular to it. The extension 12A of the rod 12 has a round recess apt to contain a magnetic element 13, such as a permanent magnet.
The magnetic element 13 is maintained in position by a washer 13A located between the bottom wall of the base 11A and the bottom of the portion 12A of the rod 12 when the latter is fastened to the base 11A.
The bottom wall of the base 11A of the movable element 11 and the bottom wall 8A of the column 2 have slits 14' and 14, whose size is such to let water flow through, but not the resins.
The portion 12C of the rod 12 has inside a ferromagnetic core N and is inserted inside of a coil 35, freely sliding.
The coil 35 is fastened, e.g. by means of screws, to a closure lid 36 of the upper end of the cylindrical hollow portion 3 of the body 2.
Number 15 indicates, as a whole, an element capable of sliding on the outer wall of the cylindrical portion 3 of the body 2; number 16 indicates the body of the sliding element 15, which has a threaded pin 17.
Number 18 indicates a relay with foils enclosed in a glass housing filled with inertial gas, commonly and hereafter called reed, which may be activated by a magnetic field outside. The reed 18 is vertically inserted in the body 16 of the sliding element 15, in a position to be substantially near and parallel to the outer wall of the cylindrical portion 3 of the body 2.
The reed 18 is electrically connected outside by means of a common connector.
Number 19 indicates a nut for fastening the sliding element 15 to the wall 6 of the cylindrical bushing 5, number 20 indicates a spring striking against the wall 6 of the bushing 5 and against the body 16 of the sliding element 15 to maintain the sliding element 15 in a position defined by the tightening degree of the nut 19.
Tightening and/or loosening the nut 19 on the pin 17 causes an upward or downward movement with reference to
With reference to
Projections 37 and 38 have inside a duct indicated with 39 and 40, respectively, which connects hydraulically the section 3C of the cylindrical portion 3 outside with its inside; through the hole 12F and recess 12E on the rod 12, the section 3C is hydraulically connected with the inside of the column 8 containing the resins 10.
The projection 37 has an external configuration apt for connection to a water supply connector for the water coming from the mains through a water softening device.
The projection 38 is connected hydraulically through the duct 40 to the salt tank of the wash water softener for regenerating the softening resins.
In the duct 40 is inserted a check valve 42 to hinder the water from the mains and flowing through the duct 39 from reaching the salt tank through the duct 40.
Number 36 indicates the closure lid of the upper side of the portion 3 of the body 2, which has a hole 41 in the middle for the portion 12C of the rod 12 go through.
The closure lid 36 is fastened to the upper side of the portion 3 of the body 2 by means of screws V.
Number 35 indicates the coil fastened to the closure lid 36 by common means, such as screws or engaging teeth, bearing internally the portion 12C of the rod 12 with the ferromagnetic core N inside it.
When the coil is electrically powered, a magnetic field is produced inside it, which draws inside it the ferromagnetic core N located in the section 12C of the rod 12 as commonly known, with a consequent upward movement of the movable element 11; when the coil is not powered, the ferromagnetic core N no longer retained by the magnetic field, due to its weight and to the action of a spring 43 located inside the coil, lowers itself until the movable element 11 will rest on the resins 10 contained in the column 8.
In order to avoid that the ferromagnetic core N, after having been released by the coil 35, may reach a position where from it cannot be drawn any more by the powered coil 35, it is provided to have insertion of the movable element 11 in the column 8 stopped by the flange 12D when striking on the step resulting from the diameter difference between the portion 38 and 3C of the body 3.
However, insertion of the movable element 11 inside the column 8 is such to be higher than a maximum volume reduction of the resins 10 in their exhaustion phase.
The present invention is based on the acknowledgement of two considerations.
A first consideration is that normal resins utilized as known for reducing water hardness tend to change their volume when becoming exhausted, which phenomenon occurs during normal operation of the softening device.
A second consideration, reached by the authors of the present invention, is that the volume of the resins themselves may be subject to changes also due to particular conditions of the sodium ions concentration (Na+) in the water solution wetting them.
Such a phenomenon is explained by both the configuration and composition of the resins. Quite schematically, resins are typically formed by granules or small pearls, each one of them consisting of a polystyrene chains structure, substantially enwrapped between them like a clew; the various polystyrene chains are tied to each other by means of smaller divinylbenzene chains, on which sites (SO4-) are available where ions are apt to reside. The inventors have found that the polystyrene structure of the resin pearls substantially form a semi-permeable membrane, which is apt to let in a portion of the ions Na+ contained in the water-salt solution wetting them during the regeneration phase.
Also the remaining portion of ions Na+ remaining outside said membrane tends to enter in the structure, but in vain; since it cannot enter in the structure of the resin pearl, the osmotic pressure exerted by such ions Na+ on the above membrane will compress the pearl and reduce its volume.
According to the present invention, such a volume reducing phenomenon of the resins when immersed in a highly concentrated salt solution, can be exploited in order to efficiently control the resins regeneration process.
Only by way of information, such a volume reduction is about 10-11%, with a water solution containing 100 g/l sodium chloride.
When the resins are at their natural or virgin state, they already contain sodium ions (NA+) to be exchanged with calcium ions (Ca++) and magnesium (Mg++) contained in the wash water.
Therefore, according to the present invention, preparation of the device 1 and of the samples resins to be introduced in the column 8 (along with the magnetic element 13 and reed 18 assembled on the sliding element 15) forming a sensor for detecting the resins state, provides the following procedure.
The quantity of sample resins 10 is metered and introduced in the column 8; it should be noticed that before being introduced in the column 8, sample resins 10 are preferably submitted to a typical operation cycle, i.e.: exhaustion - regeneration - washing. Preferably, sample resins 10 will consist of pearls with a larger diameter than the resin pearls contained in the softener device on the washing machine; moreover, their diameter will be a most consistent one as possible.
The use of pearls with a larger diameter is justified in that water flow is improved with a consequent better spraying of all sample resins and avoid leakage of resin pearls between the inner wall of column 8 and the movable element 11; the advantage obtained by their consistent diameter is to ensure a ions exchange and a more homogeneous volume change.
It should also be noted that sample resins do not necessarily need to be the same type as utilized in the softener, but they should be a most suitable type for the device 1.
The column 8 is inserted inside the cylindrical hollow portion 3 of the body 2, where the flange 9 of the column 8 will strike against the flange 4 of the body 2.
Then the movable element 11, with the magnetic element 13 inserted in the seat of the extension 12A of the rod 12, is inserted in the column 8; the movable element 13 will take a position against the upper surface of the sample resins 10 previously introduced in the column 8.
The upper end of the cylindrical portion 3 is then closed with a lid 36, which is fastened to it by means of screws as commonly known, bearing in mind to have the rod 12 going through the hole 41 in the middle of the lid 36.
Now the sliding element 15 is assembled on the outer wall of the cylindrical portion 3 of the body 2, inserting the threaded pin 17 in the hole 7, after having previously fitted the spring 20 on the threaded pin 17; the sliding element 15 is then fastened to the wall 6' of the cylindrical bushing 5' by means of the nut 19 screwed on the pin 17.
Now, with all components assembled, the device 1 is calibrated as for the following procedure; the operation is performed with the device upright, i.e. placed in its working position; such a working position with the water supply from the above downwards has been selected for improving device operation.
In fact, the water flow from above, through the extension 37 hydraulically connected with the inside of the column 8 through the hole 12F and recess 12E, provides to keeps the contact between the movable element 11 and the resins 10, pushing the former to the upper surface of the latter.
Thus, the detection of the resins height and consequently of the resins volume, can always take place correctly through the position of the magnetic element 13.
By means of a water flow with a determined flowrate, which flows through the extension 37, with the help of the spring 43, the movable element 11 is pushed against the sample resins 10; moreover, the flow allows compaction of the sample resins 10 for an exact position of the magnetic element 13 with respect to their volume. It should be noticed that the water utilized for the calibration is previously softened.
The column 8 is made slide downwards by a value equal to 5% of the compacted resin height 10. The height of compacted resins, before displacement of the column 8, is detected by a reader according to common procedures.
Therefore the position of the magnetic element 13 is detected by the reed 18 of the sliding element 15, which is displaced by sliding the element 15 along the outer wall of the cylindrical portion 3 of the body 2 by means of the nut 19; the position of the magnetic element 13 is determined when the reed 18 is activated by the magnetic field produced by the element 13 itself and closes its own circuit (ON).
Now the point where the resins generation should start has been determined.
In fact, the displacement value of the column 8, equal to 5% of the height of the compacted sample resins, corresponds substantially to a volume reduction of the resins when they are in an exhausted state of about 80 %; as said, in fact, as they are gradually utilized during operation of the washing machine, the resins become exhausted and reduce their volume.
The column 8 is taken back to its initial position and made integral with the body 2, welding or locking the flange 9 to the flange 4 as commonly known, and the movement of the nut 19 is locked with the use of paints or common resins.
During operation of the washing machine, as the resins gradually become exhausted and reduce their volume, the movable element 11 will be displaced further down and displace downwards also the magnetic element 13, which causes the closure of the reed 18 (ON) when in line with it.
Closure of the reed 18 activates resins regeneration phase through a cam A of an electromechanical programmer, which enables the opening of a regeneration solenoid valve VR (see
Thus, therefore, resins regeneration only occurs when strictly required, avoiding water and salt wastage.
This regeneration phase consisting practically of the supply of a water-salt solution to the softener, will obviously also concern the sample resins 10, since the water-salt solution is also flown in the device 1 hydraulically connected to the softener through the extension 37 of the column 8.
In order to let the resins 10 get better mixed with the regeneration brine and make their regeneration easier, the coil 35 is activated at least once simultaneously with the opening of the regeneration solenoid valve VR, by means of a cam of the electromechanical programmer prearranged for such a function. Activation of the coil 35 produces a magnetic field inside it, which draws the ferromagnetic core N associated to the movable element 11 inside the coil 35, thus causing a vacuum in the column 8 and a space between the movable element 11 and the resins 10, which are then free to fluctuate and increase their contact with the regeneration solution. Following a predetermined time, the coil 35 is deactivated and the movable element 11 return to lean again on the resins 10 in a lower position with respect to the position it had before coil activation 35, compacting them under the thrust of the spring 43, so as to allow detecting the new position of the resins 10.
According to the calibration value used, the resins never become completely exhausted, with the risk of using too hard water for washing.
As said, during the regeneration phase, the resins come in contact with a concentrated saline solution; as a result, by virtue of the osmotic pressure exerted, the resins undergo a further volume reduction with respect to the reduction caused by their normal exhaustion. This volume reduction causes the movable element 11 to be further displaced along the magnetic element 13 associated to it. Thus, the reed 18 will be outside the magnetic field of the element 13 and reach its opening condition (OFF), stopping the regeneration phase. Thus, as it can be noticed, duration of the regeneration phase, or the quantity of water used to that purpose, can be direct function of the reaching of the actually restoration of the resins efficiency.
Now, following a likely rest interval, during which the resins may remain in contact with the saline solution, the programmer starts a first wash stage of the resins, indicatively for a time of 5-7 seconds, so as to remove excess sodium ions (Na+), activating the solenoid valve VC (see
In order to improve the wash of the resins 10, simultaneously with the opening of the regeneration solenoid valve VR, the coil 35 is activated at least once, drawing towards itself the ferromagnetic core N and consequently the movable element 11 associated to it. Thus, as already mentioned for the previous regeneration phase, a vacuum is produced in the column 8 and a space between the movable element 11 and the resins 10, which are then free to fluctuate and increase their contact with the wash water, so as to improve their capacity of removing the salt and expand freely.
Following a predetermined time, the coil 35 is deactivated and the movable element 11 will rest again on the resins 10 in a higher position with respect to the position it had before coil activation 35, compacting them under the thrust of the spring 43, so as to allow detecting the new position of the resins 10. The sudden displacing movement of the movable element 11 will also produce a vacuum in the column 8, which recalls the resins 10 and helps them to go upwards to facilitate their volume increase.
In fact, following a removal of excess sodium ions (Na+), said osmotic pressure decreases and as a result the sample resins will increase their volume; such a volume increase of the resins causes a displacement upwards of the movable element 11 with the relevant magnetic element 13 to such a position that the reed 18 is activated and reaches its closure condition (ON).
The closure condition (ON) of the reed 18, through a third cam B (see
During this second resins wash phase, the resins will further increase their volume (due to a progressive osmotic pressure reduction), so that displacement of the movable element 11 with the relevant magnetic element 13 will continue; displacement of the element 13 is such that the reed 18 will be outside its magnetic field and go back to its open condition (OFF), stopping the resins wash cycle, since the resins have gone back to their initial state.
Therefore, as it can be seen, the duration of the resins wash phase, or the quantity of water utilized to that purpose, can be direct function of the reaching of the actual resins wash and avoid water and power wastage.
Since resins exhaustion occurs gradually with every was cycle, the programmer will not be able to activate the regeneration solenoid valve VR when the resins are only partially exhausted, since in such a condition the reed 18 is still in its open position (OFF) and will not consent to it.
In this instance, the programmer will go on to the subsequent phases, namely to the rest phase, to the first resins wash phase which, does not change the resins state (since there are no exceeding sodium ions (NA+) to be removed), will leave the reed 18 in its open condition (OFF).
Now, a second resins wash phase should be started; however, this will not take place since the open condition (OFF) of the reed 18 does not consent it as required.
As described above, it should be noticed that the second resins wash phase is performed only when required and therefore with a further saving of water and power.
It should be noticed that if the reed 18 still maintains its own closure condition (ON) after starting of a regeneration phase, this means that the resins have not been regenerated, since the saline solution has not enough salt.
In order to signal such a failure, it will be enough to utilize e.g. a warning light in series with the reed 18, which lights up at the end of the wash cycle since the reed 18 is in its closure condition (ON).
The warning light will also be lit during the regenerating phase, when the reed 18 is in its closure condition (ON), but it is always out at cycle end when the reed 18 is in open condition (OFF) after the regeneration has been performed.
Thus, with the device according to the present invention, it is possible to obtain a further advantageous feature, i.e. signalling a lack of salt, without requiring the special sensing devices presently only used to this specific purpose.
The various operating phases of the device described above are schematically shown in
The phase 1 relates to the position of the magnetic element 13 with the sample resins 10 in their initial condition and with the reed 18 in the open condition (OFF).
The phase 2 relates to the position of the magnetic element 13 with the exhaustion of the sample resins 10; the reed 18 is in its closure condition (ON) as being under the effect of the magnetic field of the magnetic element 13, which is displaced downwards due to the reduced volume of the resins 10. During this phase is activated the regeneration valve VR and at least an activation/deactivation cycle of the coil 35.
The phase 3 relates to the position of the magnetic element 13 when the resins 10 come in contact during the regeneration phase with the saline solution with a high sodium chloride concentration (NaCl), the reed 18 is in its open condition (OFF) as it is no longer under the effect of the magnetic field of the magnetic element 13. This situation occurs because the magnetic element 13, following a further resins volume reduction caused by the osmotic pressure, is displaced to a still lower extent.
The phase 4 relates to the position of the magnetic element 13 during the first resins wash cycle; the reed 18 is in its closure condition (ON) due to the displacement of the magnetic element 13 upwards following a volume increase of the resins caused by an osmotic pressure reduction. During this phase at least an activation/deactivation cycle of the coil 35 is activated.
The phase 5 relates to the position of the magnetic element 13 at the end of the resins wash cycle; the reed 18 is in its open condition (OFF) following a further displacement of the magnetic element 13 upwards due to a further volume increase of the resins caused by a further osmotic pressure reduction.
Therefore, as it can be seen, the invention as described above is susceptible of advantageous application combined with an electromechanical programmer, since all information generated by the device 1 related to the state of the sample resins 10 can be managed automatically at low costs using simple cams of the programmer itself.
The device 1 A differs from the device 1 of
Both elements for detecting the position of the magnetic element 13 of the device 1A, either alone or jointly, allow generating a higher number of information with respect to the example of the device 1 of
In the practice, as described more in detail hereafter, both detection elements produce a binary signal suitable to be sent to a microprocessor.
Assembly procedures of the device 1 and device 1A are similar, save that in the device 1A also the sliding element 15 A is mounted according to the same assembly procedure for the sliding element 15 of the device represented in
After calibration of the reed 18 of the sliding element 15, which is performed according to the same procedures and scopes used for the device 1, calibration of the reed 18A of the sliding element 15A will be performed, according to the following procedure.
The column 8 is sliding downwards for a value equal to 10% of the height of compacted resins.
The position of the magnetic element 13 is detected by the reed 18A of the sliding element 15A, which is displaced causing the element 15A to slide along the outer wall of the cylindrical portion 3 of the body 2 by means of the nut 19; the position of the magnetic element 13 is determined when the reed 18A is activated by the magnetic field produced by the same magnetic element 13 and will close its own circuit (ON).
The 10% displacement value of the height of the compacted resins, correspond to a volume reduction of the resins when are immersed in a water solution with a high sodium chloride concentration (NaCl); as mentioned, under this condition a portion of sodium ions (Na+) of such a solution enters in the structure of the resin pearl, whereas the remaining portion of sodium ions (Na+), unable to enter in the pearl structure, produce an osmotic pressure on its external surface that compresses it and consequently reduces its volume.
Calibration of the device I A is now completed.
The column 8 is brought back to its initial position and made integral with the body 2, welding or locking as known the flange 9 to the flange 4, and the nut 19 is locked using common paints or resins.
During operation of the washing machine, as the resins become gradually exhausted and their volume decreases, the movable element 11 is consequently displaced further down, and will consequently also displace the electric element 13 downwards, which, when coming in line with the reed 18, causes its closure condition (ON).
In such a situation, the reed 18A is still in its open position (OFF), since it is not involved by the magnetic element 13.
The closure (ON) of the reed 18 activates the resins regeneration phase with the opening of the regeneration solenoid valve; the opening of the regeneration solenoid valve is controlled by the electronic device detecting the closure condition (ON) of the reed 18. At the same time at least an activation/deactivation cycle of the coil 35 is activated for the same purposes described for the device 1. With the deactivation of the coil 35, the movable element 11 return to lean again on the resins 10 in a lower position with respect to the position it had before activation of the coil 35, and compact them under the thrust of the spring 43, to allow detecting the new position of the resins 10.
The displacement downwards of the magnetic element 13, due to a further volume reduction of the resins in contact with the regeneration water-salt solution involves the reed 18A and causes its closure (ON).
Now the reed 18 is still in its closed condition (ON), since the reeds 18 and 18A are appropriately arranged to be both involved by the magnetic field of the element 13.
The electronic device detecting the closure condition (ON) of both the reeds 18 and 18A, activates the closure of the regeneration solenoid valve.
After closing of the regeneration solenoid valve, the electronic device will activate a rest interval in the washing machine cycle.
After a predetermined time. with the reeds 18 and 18A in closed position (ON), the electronic device activates the water inlet solenoid valve for a first resins wash phase, indicatively for a time of 5-7 seconds, so as to reduce excess sodium ions (Na+). Simultaneously with the water inlet valve, at least an activation/deactivation cycle of the coil 35 is activated through the electronic programmer, for the purposes already described for the device 1.
After deactivation of the coil 35, the movable element 11 return to lean again on the resins 10 in a higher position with respect to the position before activation of the coil 35, compacting them under the thrust of the spring 43, to allow the detection of the new position of the resins 10.
In fact, removal of the sodium ions (Na+) in excess causes the osmotic pressure to decrease and the volume of the resins to increase; such a volume increase of the resins causes an upward displacement of the movable element 11 with the relevant magnetic element 13.
With the upward displacement of the element 13, its magnetic field does no longer affect the reed 18A, which therefore assumes the open condition (OFF), whereas the reed 18 remains in the closed position (ON), being still involved by the magnetic field of the magnetic element 13.
The electronic control device detecting such reeds conditions, activates a second resin wash phase.
Also during this second resins wash phase, at least an activation/deactivation cycle of the coil 35 is activated to fulfil the same purposes and procedures related to the first rinse phase.
During this second wash phase, the resins go on increasing their volume with a consequent ongoing displacement of the movable element 11 along with the relevant magnetic element 13; this displacement is such that the reed 18 will be out of the magnetic field of the magnetic element 13 and go back to its open condition (OFF), stopping the wash cycle of the resins now back to their initial state.
Therefore, as it can be seen, both the reeds 18 and 18A are practically forming a 2 bit digital signal, suitable for interfacing a binary logic, such as the one superintending to the operation of a microprocessor normally used in the electronic control device of a washing machine.
Therefore, also in this instance, resins washing is only performed for a required time, to avoid water and power wastage.
Moreover, provided that resins exhaustion occurs gradually at each wash cycle, the electronic control device will not activate the regeneration solenoid valve when the resins are only partially exhausted; in this condition, in fact, the reed 18 is still in its open position (OFF).
In this instance the electronic control device will skip all phases previously described (regeneration, rest interval, first and second resins wash steps).
If regeneration is activated, and after closing the regeneration solenoid valve the reed 18 is in the open condition (OFF) while the reed 18A is still in the closed condition (ON), this means that there is too much salt in the device 1, i.e. the water-salt solution in contact with the resins is saturated with sodium chloride (NaCl).
The electronic control device detects this situation and activate a signal, such as a warning line signalling this faulty condition.
A subsequent opening (OFF) also of the reed 18A indicates a faulty condition of the device, such as missing sample resins.
In this instance, the electronic control device, detecting such a situation, can inform the user about the faulty condition by means of a warning light or similar device, and restore resins regeneration of the softener at every wash cycle, excluding the device 1A.
If, at the end of the regeneration cycle, the reed 18 is still in the closed condition (ON) and the reed 18A is in the open condition (OFF), this means that the resins have not been regenerated because the saline solution utilized does not contain enough salt; the electronic control device, detecting such a condition, can inform the user through a luminescent and/or acoustic signal that salt needs to be added in the relevant tank.
If after adding salt, the reed 18A is still in the open condition (OFF), the electronic control device will signal a failure of the regeneration valve operation or a jam of the detecting device mechanism.
Before signalling such a failure, the control device will activate and deactivate the coil 35 to remove a possible locking of the movable element 11, which can be due e.g. to broken resin pearls rests. If the failure cannot be removed, then the electronic control device will indicate it. In this case is therefore necessary to call the Technical Service.
The various operation phases of the device described above are schematically represented in
The phase 1 relates to the position of the magnetic element 13 with the resins 10 in their initial condition and with the reeds 18 and 18A in their open condition (OFF).
The phase 2 relates to the position of the magnetic element 13 after exhaustion of the resins 10; the reed 18 is in the closed condition (ON) being under the effect of the magnetic field of the magnetic element 13, which is displaced downwards due to a volume reduction of the resins 10. During this phase the solenoid valve for resins regeneration is activated as well as at least an activation/deactivation cycle of the coil 35. The reed 18 A, vice-versa, is in the open condition (OFF) as it is not yet involved by the magnetic field of the element 13.
The phase 3 relates to the position of the magnetic element 13 when the regeneration solenoid valve is deactivated; the reeds 18 and 18A are both in their closed condition (ON), being both involved by the magnetic field of the element 13. Therefore, the electronic control device, detecting the closed condition (ON) of the reeds 18 and 18A, provides to the deactivation of the regeneration solenoid valve.
If the reed 8A, after a predetermined time, is still in the open condition (OFF) instead of the closed condition (ON) as provided, the electronic control device provides to inform the user by means of luminescent or acoustic signals that salt needs to be added.
If, after adding salt, the reed 18A is still in the open condition (OFF), the electronic control device provides to signal a failure of the regeneration valve operation or a jam of the detecting device mechanism.
The phase 4 relates to the position of the magnetic element 13 when, during the regeneration phase, the resins 10 come in contact with a saline solution with a high sodium chloride concentration (NaCl), which determines a further volume reduction of the resins due to the osmotic pressure. The reed 18 is in the open condition (OFF) and the reed 18A in the closed condition (ON); these conditions are conferred by the displacement of the magnetic element 13 following a volume reduction of the resins 10. The electronic control device, detecting at this point the faulty open condition (OFF) of the reed 18 and the closed condition (ON) of the reed 18A, provides to activate a signal, such as a warning light or similar device, to indicate the presence of too much salt.
The phase 5 relates to the position of the magnetic element 13 when in the device are lacking of the sample resins 10 due to a device failure; in this instance, the reeds 18 and 18A are in the open condition (OFF) and the electronic control device, detecting such conditions, provides to inform the user of such a failure by means of a warning light or similar device, and to restore resins regeneration of the softener at every wash cycle, excluding the device 1A, as long as the missing sample resins 10 will not be restored again.
The phases 6 and 7, though detected by the electronic control device, are not used in the implementation described above of the invention.
The phase 8 relates to the position of the magnetic element 13 when starting the resins wash cycle, the reed 18 is in the closed condition (ON) due to the upward displacement of the magnetic element 13, following a volume increase of the resins, while the reed 18A is in the open position (OFF). During this phase at least an activation/deactivation cycle of the coil 35 is activated.
The phase 9 relates to the position of the magnetic element 13 at the end of the resins wash cycle; the reeds 18 and 18A are both in the open position (OFF) due to the upward displacement of the magnetic element 13 following a further volume increase of the resins 10; the electronic device, detecting such conditions of the reeds 18 and 18A, provides to deactivate the water inlet valve used for resins wash.
From the above description it is clear that more information can be obtained with the device 1A; the detection of such data and their use can be advantageously managed by an electronic control device, such as a microprocessor, as previously mentioned.
The electronic control device, not represented nor described as being a common type, detect and elaborate the data from the conditions of the reeds 18 and 18A, eventually storing them, and manage all operations of the washing machine.
Reference 45 indicates an insertion hole of the extension 37 of the device 1 in the softener body D, for the hydraulic connection of the former to the latter.
The hole 45 is hydraulically connected to a recess 46 inside to the resins container R of the softener D. The recess 46 has slits 46A on its lower wall for hydraulic connection of the recess to the internal side of the resins container. The slits 46A are sized to let the water flow through, but not the resins R.
It should be noticed that the lower wall of the recess 46 is located on the softener D at a height above the lower level of the resins R contained in the softener device.
Such a height is so predetermined to have the water from the softener D entering in the device 1 through the slits 46A already partially softened by the resins R of the softener D. Such a measure is dictated by the requirement to avoid that the resins 10 of the device 1 to become exhausted when the resins of the softener D are not yet fully exhausted.
In fact, should the water from the mains directly reach the device 1 as supplied and provided that the quantity of resins 10 contained therein is lower than the quantity of resins contained in the softener D, the device 1 may operate under different conditions of own resins than for the resins of the softener D.
The position of the supply point of the device 1 on the softener D is also determined to have it operate a regeneration when the resins R of the softener D have not yet reached their total exhaustion. In fact, mains water flows in the softener D is from the bottom to the top: this causes that the resins R to become exhausted starting from the bottom, i.e. the lower ones will become exhausted first and then all the other ones gradually raising. The hydraulic location of the device 1 above the lower level of the resins R of the softener D, is so provided to have the latter operate for regeneration purposes when the resins R of the softener D, above the supply point of the device 1, are not yet exhausted. Thus, a complete exhaustion of all resins R of the softener D will not occur before their regeneration.
Reference 24 indicates a duct, for draining the water flowing in the device 1 and its letting in the conduit of the water supply to the washing machine.
The duct 24A has a shape for housing inside the column 8 of the device I ; such a coupling is made integral by common means; the coupling between the duct 21 A and column 8 is hydraulically sealed by means of at least a gasket, such as a sealing ring. The extension 38 of the device 1 is directly connected through a connector 47 to the salt container, for the regeneration of the resins 10 contained in the device 1.
From the above description and annexed claims, the features of the present invention as well as the relevant advantages thereof are clear.
As it can be seen from the above description, the system according to the invention employs a simple small-sized device, easy to manufacture at low cost. In particular, since the coil 35 is able to displace the movable element 11 and provide more room for the resins 10 to fluctuate during the regeneration and/or washing process, operation of the system for detecting the resins state is improved.
Moreover, according to one of the above embodiments, the device provides efficient automatic control of the regenerating operations, including a resins wash after regeneration, also when a standard electromechanical programmer is used. As said, resins regeneration and/or washing according to the invention can be directly controlled to avoid wastage of resources.
Moreover, the device has a high operating reliability, since resins exhaustion is detected by direct monitoring, and without keeping water hardness under control, from which the resins exhaustion degree can only be deduced indirectly.
Also replacing a likely faulty detection device is very simple, since the latter is assembled outside the softener D; this obviously improved the technical features of the device according to the invention.
The detectors of the position of the magnetic element 13 are calibrated, for example, to enable the regeneration when resins exhaustion reaches about 80%, which corresponds a well determined position of the magnetic element 13; thus, the regeneration of the resins R only take place when it is strictly required, avoiding water and salt wastage; moreover, by so doing, the resins R never reach their complete exhaustion with the risk of using a too hard water for washing.
With such a calibration and detection method is further possible to determine whether the salt in the relevant tank is in excess or missing.
Therefore, is possible to have an optical or acoustic signalling of a lack of salt without using a floating system, as typical for the present state of the art, which appears to be reliable enough to switch off a warning light after the user has added salt to the relevant container, but is often very rough in signalling a lack of salt.
Moreover, also the resins washing take place only when actually required, even if a standard electromechanical programmer is used, saving water and power.
The working position, with water supplied from the top to the bottom, improves the operating conditions of the device according to the invention, avoiding an incorrect position of the movable element 11, which could cause detection problems of the position of the magnetic element 13 with respect to the height of the resins 10.
The possibility of having the movable element 11 performing extra movements through the coil 35, allows an improvement of the regeneration of the sample resins 10 and facilitate the mixing of the brine with the resins, an improvement of the removal of excess salt during their rinsing, reduce probable jamming of the movable element 11 due to resin pearls rests.
It is obvious that many changes are possible for the man skilled in the art to the system, device and methods covered by the present invention, without departing from the novelty spirit of the innovative idea.
According to a possible implementation, a Hall-effect sensor or electric microswitch may be used instead of a reed.
The detection device may be incorporated either in full or partially in the softener device. According to a further implementation, the detection device could be realized without the coil 35 for the temporary activation of the movable element 11, as represented in the
The number 36' indicates a closing cover of the upper end of the cylindrical hollow portion 3 of the body 2. With 12' is indicated a rod having on one end the cylindrical extension 12A with a larger diameter than the rod itself, apt to be inserted in the inner portion of the base I 1A of the movable element 11, and containing the magnetic element 13. The rod 12' has on the inside a through vertical cylindrical recess 12'E, apt to put in hydraulic connection the sample resins 10 with the ducts 39 and 40 by means the slits 14'.
With this implementation the vertical movement of the movable element 11 will occur only in function of the volume change of the sample resins 10.
To help the movable element 11 in its downwards displacement, to overcome the small frictions that can occur between the movable element 11 and the inner wall of the column 8, can be inserted a spring between the movable element 11 and the closing cover 36' of the upper end of the cylindrical hollow portion 3 of the body 2.
The
A further implementation may be to realize a seal between the movable element 11 and the inner wall of the column 8, hindering a leakage of resin particles capable of jamming the movement of the movable element; sealing may be obtained through a lip gasket on the edge of the movable element 11.
Obviously, various implementations to the invention are possible for the man skilled in the art, both for machines with an electronic control system and machines with an electromechanical control system.
This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.