Water softener abstract
A regeneration valve 131 is adapted for automatic activation of
ion exchange resin in a water softener. The regeneration valve includes
a switching valve 1 a control valve 32 a water injection valve
54 a cam mechanism (FIG. 13) and a timer mechanism which are compactly
integrated in a single valve assembly. The timer mechanism includes
a timer motor 80 provided with a switching gear adapted to be switched
between 50 Hz and 60 Hz (FIGS. 16 17). The ion exchange resin layer
within the resin reservoir 2 can be uniformly activated so that
the regeneration process can be achieved at a high efficiency.
Water softener claims
What is claimed is:
1. An automatic regeneration valve in a water softener having a
resin reservoir filled with ion exchange resin, a saline solution
reservoir containing saline solution used to regenerate said ion
exchange resin, and an automatic regeneration valve to which a raw
water duct supplying said resin reservoir with raw water, a softened
water duct feeding the amount of water having been softened in said
resin reservoir forward, a drained water duct draining the amount
of water used to regenerate said ion exchange resin and a saline
solution duct for suction as well as injection from and to said
saline solution reservoir so that said automatic regeneration valve
may be switched at a predetermined time from a step of softened
water collection to successive steps of a process for ion exchange
resin regeneration, said automatic regeneration valve comprising
a switching valve, a control valve, water injection valve, a cam
mechanism and a timer mechanism, wherein the timer mechanism comprises
a timer motor provided with a switching gear adapted to be switched
between 50 Hz and 60 Hz.
2. The automatic regeneration valve in the water softer according
to claim 1 wherein said switching valve contains therein a plurality
of switching pistons having their piston rods each extending vertically
so that respective steps of a regenerating process may successively
take place as positions of these switching pistons are switched.
3. The automatic regeneration valve in the water softener according
to claim 1 or 2 wherein the cam mechanism includes a drainage valve
actuating cam, a saline solution valve actuating cam and a regeneration
control lever.
4. The automatic regeneration valve in the water softener according
to claim 3 wherein a regeneration control lever provided in the
cam mechanism is actuated by said timer mechanism.
5. The automatic regeneration valve in the water softener according
to claim 1 wherein the timer motor of the timer mechanism is provided
with a conversion gear so that this conversion gear may be operated
to switch a regeneration mode to a manual regeneration mode.
Water softener description
TECHNICAL BACKGROUND
The present invention relates to a regeneration valve adapted for
automatic activation of ion exchange resin in a water softener.
Raw water supply to cooling/heating apparatus such as boiler, water
heater or cooler is usually carried out in combination with the
water softener connected to said apparatus. The water softener functions
to remove hardening component of various types (e.g., alkaline-earth
metal ion such as Ca cation or Mg cation) contained in raw water
in order to avoid scale deposition. Particularly, the water softener
of automatic regeneration type (hereinafter referred to simply as
water softener) using ion exchange resin of Na cation type to remove
the hardening component from raw water has been widely used.
In the water softener of this type, the hardening component is
substituted with Na cation of the ion exchange resin and thereby
removed from raw water. A break through point is reached as substitution
of the hardening component with Na cation is saturated, whereupon
the hardening component begins to leak into water being softened.
At this point, the ion exchange resin is brought into contact with
saline solution (NaCl) to reverse the precedent reaction and thereby
to regenerate a hardening component removing ability. More specifically,
the hardening component having been adsorped on the ion exchange
resin is eluted therefrom and Na cation is adsorpted on the ion
exchange resin.
An example of the apparatus using the regeneration valve used for
the regenerating process as has been described above is disclosed
in U.S. Pat. No. 4290451.
Construction of this well known apparatus will be briefly described
in reference with FIG. 19 in the accompanying drawings.
Referring to FIG. 19 reference numeral (151) designates a resin
reservoir filled with ion exchange resin (161) connected to a regeneration
valve (152) including a piston (162). The regeneration valve (152)
is connected to a water passage (153) vertically extending within
the resin reservoir (151) substantially axially downward to the
vicinity of a bottom of said resin reservoir (151). The water passage
(153) is provided at its lower end with a water inlet (154).
The regeneration valve (152) includes, in addition to an electric
motor serving to actuate a passage switching mechanism, a controlling
timer mechanism (155). The latter is adapted to set the regeneration
valve (152) to a position for regenerating process when a predetermined
time point or a predetermined amount of raw water has been reached.
The regeneration valve (152) further includes members as following:
a raw water inlet (156) through which the resin reservoir (151)
is supplied with raw water; a softened water outlet (157) to discharge
the amount of softened water free from the hardening component;
a saline solution pipe (159) adapted to pump up an amount of saline
solution from the saline solution reservoir (158) during the regenerating
process and, at the end of this process, to fill up an amount of
raw water necessary for preparation of saline solution to be used
in the next regenerating process; and a drainage port (160) adapted
to drain the amount of saline solution and excessive raw water having
been used for regeneration. These members are appropriately provided
at positions adapted for respective passages switched one from another
in the respective steps of process.
An air chuck (164) having its inlet (163) in the vicinity of the
bottom of the saline solution reservoir (158) is connected to the
distal end of the saline solution pipe (159). The air chuck (164)
functions to open the passage defined by said saline solution pipe
(159) so far as the inlet (163) is immersed in water. The air chuck
(164) functions to close said passage as the surface of water lowers
to a level of said inlet (163). In this way, the air chuck (164)
prevents any amount of air from entering the-saline solution pipe
(159).
Within the saline solution reservoir (158), common salt (139) for
reactivation of the ion exchange resin (161) and there is provided
a salt filter having fine meshes. Said salt filter functions to
prevent grains of common salt (139) from falling onto the bottom
of the saline solution reservoir (158).
In the water softener of this type, switching of the regeneration
valve (152) is effectuated by the controlling timer mechanism (155).
Specifically, the valve (152) is switched from the position for
collection of softened water to the position for regeneration of
the ion exchange resin (161) depending on a predetermined condition.
More specifically, switching occurs when a predetermined time or
a predetermined discharged amount of softened water is reached.
Once the regeneration valve (152) has been switched to the position
for the regenerating process, the steps of this process are successively
carried out. These steps include those of "back washing",
"regeneration of saline solution", "expelling saline
solution", "washing" and "water injecting".
As a result of these steps, the ion exchange resin (161) having
its initial ability deteriorated now recovers it, allowing the valve
(152) to recover the position for softened water collection.
Such regeneration valve (152) of the water softener usually comprises
a piston (162) reciprocation of which causes increases in the number
of steps included in the regenerating process to be increased to
seven: first step of washing, first step of back washing, step of
saline solution injecting, step of expelling saline solution, second
step of back washing, second step of washing and step of water injecting.
The single piston (162) reciprocates across the passage associated
with each step. In the steps of saline solution injecting/expelling
out, forward stroke of the piston (162) causes saline solution to
flow downward through the ion exchange resin layer. Then the amount
of water having been reacted with the ion exchange resin is drained.
In the step of back washing, backward stroke of the piston (162)
causes raw water to flow upward through the ion exchange resin layer.
Consequently, most of saline solution flowing downward flows through
the water inlet directly into said water duct (153) through the
resin filter. This means that the ion exchange is limited to a central
zone of the resin reservoir (151) and no regeneration occurs in
the vicinity of a side wall of the resin reservoir (151).
In addition, the amount of water to be drained after completion
of the reaction is drained through the ion exchange resin layer
in the second step of back washing. However, this water flow is
forced back by the amount of water flowing downward again in the
second step of washing. While a certain amount of water is drained,
a cycle in which these steps are repeated is too short to ensure
the complete drainage after the step of expelling out. Actually,
a considerable amount of water to be drained merely wanders within
the ion exchange resin layer.
In view of these problems, it is a principal object of the present
invention to provide a novel automatically regeneration valve in
a water softener. This valve can automate the entire process of
activating the ion exchange resin with saline solution so that said
resin within a reservoir thereof may be uniformly regenerated.
DISCLOSURE OF THE INVENTION
The object set forth above is achieved, according to the present
invention, by a water softener having components as following: a
resin reservoir filled with ion exchange resin; a saline solution
reservoir containing saline solution used to regenerate said ion
exchange resin; and an automatic regeneration valve. To this automatic
regeneration valve, a plurality of ducts are connected. Namely,
a raw water duct supplying said resin reservoir with raw water;
a softened water duct feeding the amount of water having been softened
in said resin reservoir forward; a drained water duct draining the
amount of water used to regenerate said ion exchange resin; and
a saline solution duct for suction as well as injection from and
to said saline solution reservoir. Said automatic regeneration valve
may be switched at a predetermined switched to switch a step of
softened water collection to successive steps of a process for ion
exchange, resin regeneration. Said automatic regeneration valve
comprises a switching valve, a control valve, water injection valve,
a cam mechanism and a timer mechanism.
The switching valve may contain therein a plurality of switching
pistons having their piston rods each extending vertically. According
to this embodiment, the steps of the regenerating process successively
take place as positions of these switching pistons are switched.
In this way, the process of regeneration is reliably carried out
with a relatively simplified construction. The cam mechanism may
include a drainage valve actuating cam, a saline solution valve
actuating cam and a regeneration control lever. Such construction
enables the process of regeneration to be continuously carried out.
A regeneration control lever provided in the cam mechanism may
be actuated by a timer mechanism. The timer mechanism may comprise
a timer motor provided with a switching gear adapted to be switched
between 50 Hz and 60 Hz. The timer motor of the timer mechanism
may be provided with a conversion gear so that this conversion gear
can be operated to switch a regeneration mode to a manual regeneration
mode.
Further scope of the applicability of the present invention will
become apparent from the detailed description given hereinafter.
However, it should be understood that the detailed description and
specific examples, while indicating preferred embodiments of the
invention, are given by way of illustration only, since various
changes and modifications within the spirit and scope of the invention
will become apparent to those skilled in the art from this detailed
description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the
detailed description given hereinbelow and the accompanying drawings
which are given by way of illustration only, and thus are not limitative
of the present invention, and wherein:
FIG. 1 is an axial sectional view as viewed from the front, schematically
illustrating a water softener according to the present invention;
FIG. 2 is a perspective view of an automatic regeneration valve
incorporated in the water softener;
FIG. 3 is a perspective view of the automatic regeneration valve
with a timer's main body removed;
FIG. 4 is a sectional view of the automatic regeneration valve
as viewed from the front;
FIG. 5 is a sectional view of the automatic regeneration valve
as viewed from the behind;
FIG. 6 is an exploded perspective view showing the automatic regeneration
valve as the timer mechanism has been removed;
FIG. 7 is another exploded perspective view showing the automatic
regeneration valve as the timer mechanism has been removed;
FIG. 8 is still another exploded perspective view showing the automatic
regeneration valve as the timer mechanism has been removed;
FIG. 9 is a sectional view of the control valve as viewed from
the front;
FIG. 10A is a sectional view of the water injection valve as viewed
from the front;
FIG. 10B is a side sectional view of the water injection valve;
FIG. 10C is a side view of the water injection valve seat and the
water injection valve shaft;
FIG. 11 is a fragmentary perspective view of the water injection
valve;
FIG. 12 is a diagram illustrating the cam mechanism;
FIG. 13 is a diagram illustrating operation of the cam and the
cam shaft;
FIG. 14 is a sectional view showing the timer mechanism as viewed
from the side;
FIG. 15 is a plan view of the timer mechanism;
FIG. 16 is a diagram illustrating the cycle gear of the timer motor;
FIG. 17 is a diagram illustrating a manner of engagement between
the motor gear and the cycle gear;
FIG. 18 is a schematic circuit diagram of the electric components;
and
FIG. 19 is a diagram schematically illustrating an example of the
conventional water softener.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 schematically illustrates the water softener according to
the present invention as a whole.
A resin reservoir (2) is filled with ion exchange resin (130) and
connected to an automatic regeneration valve (131). A water duct
(9) extends downward from the automatic regeneration valve (131)
substantially along an axis of the resin reservoir (2) to a bottom
of said resin reservoir (2). The water duct (9) is provided on its
lower end with a water inlet (9b) having a resin filter (9a).
The automatic regeneration valve (131) includes, in addition to
an electric motor serving as a power source for a passage switching
mechanism, a controlling timer mechanism. The timer mechanism controls
the automatic regeneration valve (131) to operate at a desired position
for the regenerating process as a predetermined time point or amount
of processed water is reached.
The automatic regeneration valve (131) further includes members
as following: a raw water inlet (132) through which the resin reservoir
(2) is supplied with raw water; a softened water outlet (133) to
discharge the amount of softened water free from the hardening component;
a saline solution pipe (136) adapted to pump up an amount of saline
solution from the saline solution reservoir (135) during the regenerating
process and, at the end of this process, to fill up an amount of
raw water necessary for preparation of saline solution to be used
in the next regenerating process; and a drainage port (134) adapted
to drain the amount of saline solution having been used for regeneration
together with an excessive amount of water having been used for
preparation of saline solution. These members are appropriately
provided at positions adapted for respective passages switched one
from another in the respective steps of process.
Obviously, said raw water inlet (132), softened water outlet (133)
and drainage port (134) are associated with respective pipes.
An air chuck (138) having its inlet (137) in the vicinity of the
bottom of the saline solution reservoir (135) is connected to the
distal end of the saline solution pipe (136). The air chuck (138)
functions to open the passage defined by said saline solution pipe
(136) so far as the inlet (137) is immersed in water. The air chuck
(138) functions also to close said passage as the surface of water
lowers to a level of said inlet (137). In this way, the air chuck
(138) prevents any amount of air from entering the saline solution
pipe (136).
Within the saline solution reservoir (135), common salt (139) for
reactivation of the ion exchange resin (130) is stored and there
is provided a salt filter (not shown) having fine meshes. Said salt
filter functions to prevent grains of common salt (139) from falling
onto the bottom of the saline solution reservoir (135).
In the water softener of this type, switching of the automatic
regeneration valve (131) is effectuated by the controlling timer
mechanism. Specifically, the valve (131) is switched from the position
for collection of softened water to the position for regeneration
of the ion exchange resin (130) depending on a predetermined condition.
More specifically, switching occurs when a predetermined time or
a predetermined discharged amount of softened water is reached.
Once the regeneration valve (131) has been switched to the position
for the regenerating process, the steps of this process are successively
carried out. These steps include those of "back washing",
"regeneration of saline solution", "expelling out",
"washing" and "water injecting". As a result
of these steps, the ion exchange resin (130) having its initial
ability deteriorated now recovers it, allowing the valve (131) to
recover the position for softened water collection.
The automatic regeneration valve comprises a switching valve, a
control valve, a water injecting valve, cam mechanism and a timer
mechanism. A regeneration control lever actuates these valves and
said cam mechanisms in operative association one with another under
control by said timer mechanism to carry out the process of automatic
regeneration.
FIG. 2 is a perspective view of the automatic regeneration valve.
FIG. 3 is a perspective view of the automatic regeneration valve
with the timer mechanism removed. FIG. 4 is a front sectional view
of the automatic regeneration valve. FIG. 5 is a rear sectional
view of the automatic regeneration valve. FIG. 6 is an exploded
perspective view of the automatic regeneration valve with the timer
mechanism removed, in the step of softened water collecting. FIG.
7 is an exploded perspective view of the automatic regeneration
valve with the timer mechanism removed, in the steps of back washing
and washing. FIG. 8 is an exploded perspective view of the automatic
regeneration valve with the timer mechanism removed, in the steps
of saline solution injection and expelling out.
A main body of the switching valve (1) is mounted on the resin
reservoir (2) by a screw (3) with an O-ring (4) interposed therebetween.
The resin filter (5) is mounted on a filter supporting plate (6)
by a set screw (7) and said supporting plate (6) supports a water
duct (9) with interposition of an O-ring (8).
The main body of the switching valve is laterally provided with
the raw water inlet (132) and the softened water outlet (133). Pipe
mouthpieces (10) are mounted on said raw water inlet (132) and said
softened water outlet (133) by clamps (12) with interposition of
joints (11).
Said clamps (12) are mounted on the pipe mouthpieces (10) by set
screws (13) and the joints (11) are sealed by O-rings (14). The
pipe mouthpieces (10) are formed with pipe threads by means of which
respective pipes (15) are connected thereto.
Within the main body (1) of the switching valve, there is provided
a cylinder (16) which is sealed by an O-ring (17) so as to define
passages of raw water and softened water, respectively.
Said cylinder (16) is provided therein with a piston rod (20) by
means of O-rings (21). The piston rod (20) is, in turn, provided
a switching piston A (18) and a switching piston B (19) having O-rings
(22), respectively. A slider (23) is secured to one end of the piston
rod (20) by means of a pin (24).
A front cap (25) is mounted on an end surface of the switching
valve's main body (1) by set screws (26) and sealed by O-rings (27).
The front cap (25) is formed with an opening through which the piston
rod (20) extends and a bearing (28) is mounted in said opening by
a set screw (29). This bearing (28) facilitates the piston rod (20)
to slide. The bearing (28) is provided with an O-ring (30) to ensure
a sealing effect between the bearing (28) and the piston rod (20).
A rear cap (31) is mounted on another end surface of the switching
valve's main body (1) by set screws (26) and sealed by an O-ring
(27).
A water flow through the switching valve constructed as has been
described above will be explained.
(a) Flowing in the Step of Softened Water Collection
Raw water having been introduced through the raw water inlet (132)
flows along the raw water side cylinder (16) and the front cap (25)
into the filter (5). The amount of water having been softened through
the ion exchange resin (130) flows through the water duct (9) and
then through the softened water side cylinder (16) into the softened
water outlet (133).
(b) Flowing in the Step of Saline Solution Injection
The saline solution is introduced through the raw water inlet (132)
to flow in the cylinder (16) to the raw water side of an ejector.
The saline solution pumped up by the ejector flows on the side of
the rear cap into the water duct (9). The saline solution flows
from the water duct (9) into the ion exchange resin layer (130)
and the amount of saline solution having been subjected to the ion
exchange reaction then flows from the passage defined by the front
cap (25) along the outer side of the cylinder (16) to the drainage
valve.
(c) Bypass
Raw water introduced through the raw water inlet (132) into the
cylinder (16) flows to the softened water outlet (133).
FIG. 9 is a sectional view as viewed from the front, illustrating
the control valve.
The control valve (32) including the drainage valve, the saline
solution valve and the ejector is mounted on a switching valve (1)
by a set screw (33) and sealed by an O-ring (34).
A piston valve body (36) is mounted on a piston rod (35) by means
of an E-ring (37) and an O-ring (38) serves as sealing means.
The piston rod (35) is mounted on a piston valve seat (39) to constitute
a piston valve. The piston rod (35) is sealed by an O-ring (40).
Said piston valve seat (39) is, in turn, mounted on the control
valve (32) and fixed to a piston valve cap (41) by a set screw (42).
The piston valve seat (39) is sealed by O-rings (43).
Between the piston rod (35) and the piston seat (39), there is
mounted a biasing spring (44) by means of an E-ring (45). The biasing
spring (45) enables the piston rod (35) to recover its initial position
after it has been pushed forward.
The control valve (32) is incorporated with an ejector seat (46)
and an ejector blow-off port (47) sealed by O-rings (48) (49). In
addition, an eject or cap (50) is fixed to the control valve (32)
by a set screw (51) and sealed by an O-ring (52).
There is provided an ejector filter (53) between said ejector blow-off
port (47) and said ejector cap (50).
Water flow occurring in the control valve of such arrangement will
be described.
(a) Water Flow in the Step of Saline Solution Injection
Raw water is introduced through the switching valve (1) into the
passage defined between the piston valve body (36) and the piston
valve seat (39) and flows to the drainage port of the water injection
valve.
(b) Water Flow Through the Ejector
Raw water coming from the switching valve (1) flows through the
ejector filter (53) and the ejector blow-off port (47). Together
with saline solution sucked up thereby, raw water flows to the switching
valve (1).
(c) Flow of Saline Solution
Saline solution introduced through the water injection valve into
the passage defined between the piston valve body (36) and the piston
valve seat (39) flows to the inlet of the ejector.
FIG. 10(A) is a sectional view as viewed from the front, FIG. 10(B)
is aside sectional view of the water injection valve, FIG. 10(C)
is a side view of the water injection valve seat and the water injection
valve shaft and FIG. 11 is an exploded perspective view-of the water
injection valve.
The water injection valve (54) is mounted on the control valve
(32) by a set screw (55) and sealed by an O-ring (56).
The water injection valve (54) is mounted on the control valve
(32) by a set screw (55) and sealed by an O-ring (56).
The drainage pipe (57) is formed with a pipe thread on which a
drainage controller (58) is mounted so that an amount of drainage
may be regulated by an appropriate bore diameter. The drainage controller
(58) is sealed by an O-ring (59).
A water injection regulator in the form of the water injection
valve of check valve construction has a ball (60) free to roll therein.
Said ball (60) opens the passage in the step of saline solution
injection and restrict the passage in the step of water injection.
More specifically, a water injection valve seat (61) adapted to
receive said ball (60) is formed in its end surface with a water
passage defined by a central bore and a narrow fan-shaped slit.
A water injection valve shaft (62) is formed in its end surface
with a water passage defined by a central bore and a fan-shaped
shallow depression. The valve seat (61) cooperates with the valve
shaft (62) to check or regulate water injection. No water injection
occurs when these water passages are out of coincidence and water
injection is restricted or regulated depending on an extent over
which these two water passages overlap each other (See FIG. 11).
A water injection valve grip (63) is mounted on another end of
the water injection valve shaft (62) by a set screw (64). Said water
injection valve grip (63) is provided with a position indicator
adapted to indicate an actual position of the grip (63). This position
corresponds to an actual position of the fan-shaped shallow depression
of the water injection valve shaft (62).
A water injection valve cap (65) is mounted on the water injection
valve (54) by a set screw (66) and this cap (65) is provided with
graduations. The graduations are marked over an angle of 180.degree.
to, indicate an actual position of the water injection valve seat's
slit. The water injection valve seat (61), the water injection valve
shaft (62) and the water injection valve cap (65) are sealed by
O-rings (67)(68)(69), respectively.
In this manner, the amount of water to be injected can be regulated
by adjustably setting the mark of the valve grip (63) to the graduations
of the valve cap (65).
Water flow through the water injection valve of such arrangement
will be described.
(a) Flow of Drained Water
Water drained through the drainage valve flows to the drainage
section of the water injection vale and the amount thereof regulated
by the drainage controller (58) flows into the drainage pipe (57).
(b) Water Flow in the Step of Saline Solution Injection
Saline solution sucked up by the ejector flows through the saline
solution pipe (136) into the central bore of the water injection
valve shaft (62). Then saline solution flows along the passage defined
between the ball (60) and the water injection valve seat (61) into
the saline solution valve.
(c) Water Flow in the Step of Water Injection
Water injected through the saline solution valve flows along the
slit of the water injection valve seat (61) and then through the
central bore of the water injection valve shaft (62) into the saline
solution pipe (136).
FIG. 12 is sectional view of a cam mechanism and FIG. 13 is a diagram
illustrating a manner in which the cam and the cam shaft operate.
The cam mechanism comprises a piston, an actuator cam for the drainage
valve and the saline solution valve, and driving means.
The cam shaft (71) is provided at one end a regeneration lever
(70), a regeneration gear (73), a drainage cam (74) and a saline
solution cam (75). Transmission of a driving force is achieved by
a key-shaped projection of the cam shaft (71). The other end of
the cam shaft (71) is shaped like a flange provided with a groove
adapted to turn a microswitch (120) ON or OFF.
The regeneration lever (70) is secured to said key-shaped projection
of the cam shaft (71) by a set screw (72). A slide pin (106) mounted
on a rotatable regeneration day dial (104) kicks and rotates the
regeneration lever (70) at a predetermined time point for regeneration.
This rotation of the regeneration lever (70) is transmitted to the
cam shaft (71) to rotate this cam shaft (71).
The key-shaped projection of the cam shaft (71) has the regeneration
gear (73) mounted thereon so that said gear (73) may be driven by
a timer's slide gear (94). Rotation of said gear (73) rotates the
cam shaft (71) in a cam shaft bearing (76).
A shaft sleeve (78) cooperates with said cam shaft bearing (76)
to stabilize rotation of the cam shaft (71).
The drainage cam (74) and the saline solution cam (75) are operatively
associated with the respective piston rods (35) of the drainage
valve and saline solution valve. Specifically, respective projections
of these cams function to push the piston rods (35) forward and
respective depressions of these cams function to retract the piston
rods (35).
An actual situation of the regeneration step is determined by relative
positions of these cams, the switching piston A (18) and the switching
piston B (19).
Teeth of the regeneration gear (73) is partially cut out and normally
not driven by the slide gear (94). The cam shaft (71) is rotated
as the regeneration lever (70) is rotated and rotation of the cam
shaft (71) is followed by the regeneration gear (73). Thus the regeneration
gear (73) is rotated into engagement with the slide gear (94) so
that said regeneration gear (73) may be driven by said slide gear
(94).
After a complete rotation, the cut out portion of the regeneration
gear (73) comes in engagement with said slide gear (94) and becomes
free from the driving effect of the slide gear (94).
Said cut out portion of the gear (73) is formed with a narrow groove
to avoid a possibility that the engagement of these gears (73),
(94) might be accompanied with undesirable flexture. The engagement
of these gears is thereby facilitated. Such flexture might occur
due to preadjustment of a position at which these gears (73), (94)
should begin to engage with each other.
Now a manner in which the cam mechanism of such construction transmits
the driving force will be described.
(a) At the Start of Regeneration
A driving force is transmitted from the timer to the regeneration
lever (70) via the slide pin (106) of the regeneration day dial
(104) which, in turn, rotates the cam shaft (71), bringing the regeneration
gear (73) into engagement with the slide gear (94).
(b) In the Course of Regeneration
The regeneration gear (73) engaged with the slide gear (94) rotates
the cam shaft (71) which, in turn, rotates the drainage cam (74)
and the saline solution (75) to move the slider (23).
(c) Completion of Regeneration
The cut out portion of the regeneration gear (73) disengage this
gear (73) from the gear (94) and thereby said gear (73) is relieved
of the driving force.
FIG. 14 is a sectional view of a timer mechanism. FIG. 15 is a
plan view of the timer mechanism. FIG. 16 is a diagram illustrating
a cycle gear of a timer motor. FIG. 17 is a diagram illustrating
a gearing transmission between a motor gear and the cycle gear.
FIG. 18 is a schematic circuit diagram of an electric section.
The timer mechanism comprises the timer motor, a clock display,
a transmission of the driving force for regeneration, electric components
and a cover.
The timer motor (80) is fixed to a timer table (81) by a set screw
(82) and the motor gear (83) is mounted on an output shaft of the
motor (80). According to an embodiment of the present invention,
the timer motor (80) operates at 60 Hz and a reduction gear ratio
of 1/40 rpm. The motor gear has 12 gear teeth.
The timer table (81) is provided with a rotatable cycle gear holder
(84) which is secured by a set screw (86) to the timer table (81)
with interposition of a holder retainer (85).
The cycle gear holder (84) is provided at predetermined positions
with a 50 cycle gear (87) and a 60 cycle gear (88). These cycle
gears (87), (88) are mounted by a set screw (90) with interposition
of a cycle gear cover (89).
The 50 cycle gear (87) is provided in the form of a stepped gear
comprising two gear portions. One of these gear portions is adapted
to be engaged with the motor gear (83) and the other gear portion
is adapted to be engaged with a conversion gear (93). A gear ratio
of these two gear portions is 50:60. According to the embodiment
of the present invention, said gear ratio is realized by 15 gear
teeth to 18 gear teeth. It should be understood that the 60 cycle
gear (88) is provided in the form of a straight gear having 15 gear
teeth in the case of this embodiment.
The cycle gear holder (84) is secured by a set screw (91) and a
nut (92) to the timer table (81) at one of two predetermined positions.
One of these two predetermined positions is allocated to 50 cycle
and the other is allocated to 60 cycle.
At the position allocated to 50 cycle, the motor gear (83) is engaged
with the 50 cycle gear (87). At the position allocated to 60 cycle,
the motor gear (83) is engaged with the 60 cycle gear (88). In this
way, the water softener can be adapted to the frequency peculiar
to a particular region in which the water softener is used.
The conversion gear (93) is supported by a bearing provided in
the timer table (81), on one hand, and by a bearing provided in
a timer mechanism (101), on the other hand. This gear (93) functions
to reverse the rotating direction of the timer motor (80) and has
15 gear teeth in this embodiment.
The slide gear (94) is provided in the form of a stepped gear comprising
an input portion and an output portion (having 12 gear teeth and
54 gear teeth), respectively, in this embodiment). In other words,
a gear ratio of 2:9 is defined by these two gear portions. This
slide gear (94) is supported by a bearing provided in the timer
table (81), on one hand, and by a bearing provided in the timer
mechanism (101), on the other hand. The slide gear (94) functions
to transmit a driving force from the conversion gear (93) to a clock
gear (96) and the regeneration gear (73).
A shaft of the slide gear (94) is loaded with a slide spring (95).
This spring has its one end bearing against the gear itself of this
slide gear (94) and the other end bearing against the timer table
(81). The shaft of the slide gear (94) may be pushed against a biasing
force of the slide spring (95) to disengage the slide gear from
that having been engaged therewith. The biasing force of the slide
spring (95) causes the slide gear (94) to restore the normal state
of engagement.
Such arrangement of the slide gear (94) advantageously facilitates
the slide gear (94) to be disengaged from the clock gear (96) for
time setting of the clock gear (96).
Similarly, such arrangement of the slide gear (94) advantageously
facilitates the slide gear (94) to be disengaged from the regeneration
gear (73) for manual operation of regeneration.
The clock gear (96) is retained by a clock gear retainer (97) secured
by a set screw (98) and driven by the slide gear (94). Rotation
transmitted from the timer motor (80) is reduced by said slide gear
(94) and said clock gear at the respective gear ratios so that the
desired clock display may occur with a complete rotation per day.
The clock gear (96) is provided on its predetermined position with
a projection adapted to rotate the regeneration day dial (104) so
that the process of regeneration may be carried out at a preset
time.
A clock disc (99) is disposed between the clock gear (96) and the
clock gear retainer (97) with interposition of an O-ring (100) and
carries thereon graduations of 24 hours. The time at which the process
of regeneration should be started can be set by a procedure as follows:
the corresponding graduation is aligned with a regeneration mark
.diamond. on the clock gear (96); and then the clock gear (96) is
rotated until the present time is aligned with a .gradient. mark
on the timer mechanism (101).
Said timer mechanism (101) is fixed to the shaft sleeve (78) and
the control valve (32) by means of a set screw (102). The timer
mechanism (101) is fixed also to the timer table (81) by means of
a set screw (103). Consequently, the conversion gear (93) and the
slide gear (94) are disposed between the timer mechanism (101) and
the timer table (81).
The regeneration day dial (104) is provided with a cutout adapted
to be engaged with a projection (96a) of the clock gear (96) which
functions to rotate said dial (104). The regeneration day dial (104)
is further provided with a groove adapted to keep a position of
said dial (104) relative to the timer mechanism (101). The regeneration
day dial (104) is positioned under a biasing action of a positioning
pin (105) as will be described.
Said positioning pin (105) comprises a pin itself received in a
long groove of the timer mechanism (101) and a spring biasing said
pin itself backward along said groove. In this way, the relative
positions of the regeneration day dial (104) and the timer mechanism
(101).
The opposite side is formed with irregularities used to position
the slide pin (106).
The slide pin (106) is slidably movable in the regeneration day
dial (104) in its radial direction and provided with a positioning
projection. A spring structure formed integrally with this positioning
projection enables the latter to extend radially beyond the projection
of the regeneration day dial (104). The day on which the process
for regeneration is carried out may be set as "out" and
the other days may be set as "in".
A regeneration day dial cap (107) is formed with a groove along
which the slide pin can slide and fixed to the regeneration day
dial by means of a set screw (108). The slide pin (106) is disposed
between said cap (107) and said dial (104).
The regeneration day dial (104) and the regeneration day dial cap
(107) assembled together is mounted to the timer mechanism (101)
by means of a set screw (111) with interposition of a regeneration,
day dial retainer (110). This regeneration day dial assembly can
be exchangeable as an unit. According to the embodiment of the present
invention, the regeneration date may be set to one of weekdays or
to one or more of twelve days.
The timer table (81) is mounted by a nut (112) received in a nut
receptacle (113) and a set screw (114). A blue neon tube (118) and
a red neon tube (119) are fixed to the timer table (81) by means
of nuts. Lead wires of the respective neon tubes are connected to
a terminal board (123) are predetermined positions. The blue neon
tube (118) is turned ON during collection of softened water and
the red neon tube (119) is turned ON during regeneration.
A main cover (115) is installed with its groove engaged with the
side wall of the timer table (81) and a front cover (116) is overlapped
with said main cover (115). The front cover is fixed to the main
cover (115) by threading a decorative screw (117) into the nut (112).
The microswitch (120) is fixed to the terminal board (123) by a
set screw (121) with interposition of the cam shaft bearing (76)
and a jack (122). The microswitch (120) is turned ON or OFF depending
on a position of the groove formed in the cam shaft (71).
The terminal board (123) is fixed to the timer table (81) by a
set screw (124). Power line (124) and lead wires of said timer motor
(80), blue neon tube (118), red neon tube (119) and microswitch
(120) are connected to said terminal board (123) at predetermined,
positions.
A driving system for the timer mechanism constructed as has been
described above will be described.
(a) A driving system for the timer functioning as a clock starts
from the timer motor (80). A driving force output from the timer
motor (80) to the motor gear (83) is transmitted to the conversion
gear (93). Such transmission occurs via the 50 cycle gear (87) or
the 60 cycle gear (88) depending on whether the system is used in
50 Hz region or 60 Hz region. The driving force transmitted to said
conversion gear (93) is then transmitted to the clock gear (96)
via the slide gear (94). As a result, the clock gear (96) completes
a single rotation per day.
(b) During a complete rotation of the regeneration day dial (104)
by the clock gear (96), the slide pin (106) rotates the regeneration
lever (70) to start the process of regeneration as said pin (106)
is set.
(c) Rotation of the regeneration lever (70) brings the regeneration
gear (73) into engagement with the slide gear (94) and thereupon
drives the drainage cam (74), the saline solution cam (75) and the
slider (23) via the cam shaft (71). Thus, the step of regeneration
progresses.
Now water flow in the respective steps of the process executed
by the water softener constructed as has been described hereinabove
will be described.
(a) In the step of collecting softener water, raw water containing
the hardening component flows through the raw water inlet (132)
into the upper part of the resin reservoir (2). Passing through
the ion exchange resin (11), raw water is softened as said hardening
component is substituted by Na cation. The amount of water softened
in this manner flows through the resin filter (9a) in the water
inlet (9b) upward to the softened water outlet (133). This amount
of softened water is supplied outward from the softened water outlet
(133) to an apparatus using softened water.
As will be apparent from FIG. 6 no amount of raw water can flow
into the passage for softened water. This is for the reason that
the switching piston A (18) occupies the position at which said
piston A (18) seals this passage.
Both the drainage valve and the saline solution valve are closed
at this time point and there is no possibility that any amount of
softened water might flow out from these valves.
(b) The step of "back washing" is the first step after
the automatic regeneration valve (131) has been switched to the
step of regeneration. This switching occurs under control of the
timer control mechanism after collection of softened water has continued
for a predetermined period or a predetermined amount of softened
water has been discharged. Raw water introduced into the raw water
inlet (132) flows through the automatic regeneration valve (131),
the water duct (9) and the water inlet (9b) into the resin reservoir
(2). Then raw water flows upward in the resin reservoir (2), loosening
the layer (130) of ion exchange resin layer, through the automatic
regeneration valve (131) to the drainage port (134). Waste water
is drained out from the system through this drainage port (134).
In this manner, water flow occurs in the direction opposed to the
direction in said step of collecting softened water.
More specifically, the switching piston A (18) mounted on the slider
(24) moves rightward as viewed in FIG. 7 and switches the sealing
position to "B". Thereupon, the drainage cam (74) coaxial
with the piston rod (20) is rotated to open the drainage valve.
Consequently, raw water is guided through the water duct (9), then
the resin filter (9a) to flow through the layer of ion exchange
resin (130) from its bottom toward its top. Flowing through said
layer of ion exchange resin (130), raw water loosens the ion exchange
resin (130) and is drained through the drainage valve.
While raw water may be supplied to the softened water side as a
bypass flow, such bypass flow will be blocked if the softened water
side is closed on this time point.
In this step of "back washing", any amount of suspension
accumulated in the ion exchange resin (130) during collection of
softened water is washed away from the system. At the same time,
the layer of ion exchange resin (130) tightened during collection
of softened water is loosened. Said layer loosened in this manner
ensures homogeneous catalytic reaction between saline solution and
the ion exchange resin (130) in the subsequent "step of saline
solution regeneration".
(c) In "the step of saline solution regeneration", the
automatic regeneration valve (131) occupies the position allocated
to this step. i.e., at this position, only the amount of raw water
having passed through the injector within the automatic regeneration
valve (131) can flow into the resin reservoir (2). Under suction
effect of the injector mechanism, saline solution is sucked from
the saline solution reservoir (135) through the saline solution
pipe (136) and the air chuck (138). Saline solution sucked in this
manner is mixed with raw water injected from the injector and the
mixture is introduced into the upper part of the resin reservoir
(2).
Saline solution introduced into the resin reservoir (2) functions
to elute the hardening component adsorpted on the ion exchange resin
(130). In the place of said hardening component, Na cation is then
adsorpted on the ion exchange resin (130).
Waste water containing the hardening component thus eluted is introduced
through the water inlet (9b) and the water duct (9) to the drainage
port (134). From the drainage port (134), waste water is drained
away from the system.
More specifically, the switching piston B (19) mounted on the slider
(24) moves rightward as viewed in FIG. 8 and switches the sealing
position to "C".
Thereupon, the saline solution cam (75) coaxial with the piston
rod (20) is rotated to open the saline solution valve. As a result,
raw water is ejected from the ejector and sucks saline solution
from the saline solution reservoir (135). The mixture flows through
the resin filter (9a), the water duct (136) and the layer of ion
exchange resin (130) in which the ion exchange occurs before drained
away.
(d) A compressed air introducing mechanism (not shown) is provided
in the inlet (137). This mechanism is activated as the level of
saline solution lowers within the saline solution reservoir (135)
near to the inlet (137) of the air chuck (138). The inlet (137)
is thereby closed to prevent any amount of air from flowing into
the saline solution pipe (136). At the same time, a negative pressure
is maintained within the saline solution pipe (136) under a suction
effect of the injector.
Under such condition, only a small amount of raw water having been
injected from the injector continues to flow into the resin reservoir
(2). Such small amount of raw water slowly expels saline solution
out from the resin reservoir (2). This is "the step of expelling
out".
Purpose of this "step of expelling out" is to maintain
the ion exchange resin (130) in contact with saline solution as
long as possible to improve an efficiency at which the ion exchange
resin (130) is regenerated.
(e) In "the step of washing", raw water is supplied through
the raw water inlet (132) to the upper part of the resin reservoir
(2). Any amount of saline solution remaining within the resin reservoir
(2 is thereby drained away from the system through the water inlet
(138), the water duct (136), the automatic regeneration valve (131)
and the drain pipe.
More specifically, the switching piston B (19) moves leftward from
the sealing position "C" as viewed in FIG. 7 and opens
the passage.
Thereupon, the saline solution cam (75) coaxial with the piston
rod (20) is rotated to close the saline solution valve. Consequently,
raw water is guided through the water duct (136), the resin filter
(9b) so as to flow upward through the layer of ion exchange resin
(130). Any excessive salinity is thereby washed and drained away
through the drainage valve.
It should be understood that an amount of water sufficient to completely
expel saline solution out of the system must be consumed in "the
step of washing". This is for the reason that any amount of
saline solution may harmfully affect the apparatus using softened
water.
(f) In the step of water injection which is the final step of the
regenerating process, the amount of saline solution having been
consumed in said step (c) is filled up. Specifically, the amount
of raw water corresponding to the amount of saline solution consumed
in the precedent step (c) is injected into the saline solution reservoir
(135). To this end, said amount of raw water is made flow back through
the injector mechanism provided within the automatic regeneration
valve (131).
More specifically, the drainage cam (74) coaxial with the piston
rod (20) is rotated to close the drainage valve, as shown in FIG.
8.
At the same time, the saline solution cam (75) coaxial with the
piston rod (16) is rotated to open the saline solution valve. Raw
water passing through the saline solution valve has its flow rate
regulated by the water injection regulator valve. Thus the desired
amount of raw water is supplied to the saline solution reservoir
(135) via the air chuck (138) and the saline solution filter.
Then the switching piston A (18) moves back to the sealing position
"A". Thereupon, the saline solution cam (75) coaxial with
the piston rod (20) is rotated to close the saline solution valve.
The process now returns to said step (a). In the course of the
process from the step of back washing (b) to the step of water injection
(f), raw water is supplied as bypass flow to the side of softened
water.
As will be apparent from the foregoing description of the embodiment,
the automatic regeneration valve comprises the switching valve,
the control valve, the water injection valve, the cam mechanism
and the timer mechanism. These components are compactly integrated
in the form of a single valve assembly. With an advantageous consequence,
the ion exchange resin layer within the resin reservoir can be uniformly
activated and the process of regeneration can be achieved at a high
efficiency.
The progress of automatic regeneration is successively carried
out as a plurality of switching pistons are successively reciprocated.
These switching pistons are arranged within the switching valve
which is, in turn, provided within the automatic regeneration valve.
Such construction enables the process of regeneration to be reliably
achieved by a relatively simplified operation.
Furthermore, the cam mechanism including the drainage valve cam,
the saline solution valve cam, the regeneration control lever etc.
enables the process of regeneration to be continuously carried out.
Moreover, the single timer motor enables the automatic regeneration
to be continuously carried and, in addition, enables the regeneration
cycle to be set on one of week days or one or more of 12 days. Operation
of regeneration can be manually carried out at any time by disengaging
the conversion gear mounted on the timer motor from the regeneration
gear.
The system can be used in the 50 Hz region as well as in the 60
Hz region so far as the intermediate gear associated with the timer
motor is appropriately switched.
Any way, the automatic regeneration valve according to the present
invention is distinguished from that of prior art which relies upon
reciprocation of a single piston. According to the invention, the
timer mechanism enables the automatic regeneration to be performed
at a preset hour on a preset day. In addition, the timer mechanism
enables the steps of back washing, saline solution injection, expelling
out, washing and water injection to be continuously carried out
in full automatic fashion. Furthermore, the present invention enables
the ion exchange resin within the resin reservoir to be uniformly
regenerated and thereby provides a highly efficient water softener.
While the relatively small-scaled water softener using the water
ducts has been described above as a specific embodiment, the present
invention is not limited to such embodiment. The present invention
is applicable also to a large-scaled water softener using no water
duct.
EFFECT OF THE INVENTION
The switching valve contains therein a plurality of switching pistons
having their piston rods each extending vertically. The steps of
the regenerating process successively take place as positions of
these switching pistons are switched. In this way, the process of
regeneration is reliably carried out with a relatively simplified
construction.
According to the embodiment defined by claim 2 the switching valve
contains therein a plurality of switching pistons having their piston
rods each extending vertically. The steps of the regenerating process
successively take place as positions of these switching pistons
are switched. In this way, the process of regeneration is reliably
carried out with a relatively simplified construction.
The cam mechanism includes the drainage valve actuating cam, the
saline solution valve actuating cam and the regeneration control
lever. Such construction enables the process of regeneration to
be continuously carried out.
The regeneration control lever provided in the cam mechanism is
actuated by the timer mechanism. Such construction enables the process
of regeneration to be continuously carried out in full automatic
fashion.
The timer mechanism comprises the timer motor provided with the
switching gear adapted to be switched between 50 Hz and 60 Hz. Such
feature enables the system to be used in the 50 Hz region as well
as in the 60 Hz region using the simplified construction.
The timer motor provided in the timer mechanism is provided with
the conversion gear. This conversion gear may be operated to switch
a regeneration mode to a manual regeneration mode and to start the
operation of regeneration at any time.
The invention being thus described, it will be obvious that the
same may be varied in many ways. Such variations are not to be regarded
as a departure from the spirit and scope of the invention, and all
such modifications as would be obvious to one skilled in the art
are intended to be included within the scope of the following claims. |