IT202300004935A1 - INTELLIGENT CRUSHER BOX, INTENDED TO BE CONNECTED TO A SANITARY TANKER, EQUIPPED WITH AN INVERTER MOTOR TO CONTAIN ENERGY CONSUMPTION, A UPS BUFFER SYSTEM AND A CONTROL UNIT EXTERNAL TO THE WASTE TANK. - Google Patents

Description

DESCRIPTION

Of the industrial invention entitled:

?Intelligent waste disposal unit, designed to be connected to a toilet bowl, equipped with an inverter motor to reduce energy consumption, a UPS buffer system and a control unit external to the waste tank.?

The present invention concerns a grinding box for liquid and solid waste from toilet bowls, used to finely grind solid waste and allow its disposal through small diameter pipes. The device can usefully collect and dispose of waste from other sanitary fixtures (e.g. shower, bathtub, sink, bidet) whose drains are connected to the tank of the device itself.

As is known, the technical solutions currently on the market include a tank into which the contents of the toilet bowl are poured during the system flushing and into which, in some cases, the waste water from other sanitary fixtures, such as a sink and/or a shower or a bathtub, flows. An evacuation pump sucks up the contents of the tank through a grinding device placed on the bottom of a basket and discharges it towards the evacuation pipes. The grinding device is generally a cutter that rotates in front of a grid. A pressure switch is used to detect the water level in the tank in order to start the evacuation pump via a microswitch when the tank needs to be emptied. The power motor is usually of the single-phase type and equipped with a capacitor and activation microswitch, controlled by a pressure switch made with a float system, i.e. a membrane that rises with the water level, raising a lever and activating a microswitch. The conventional operation of the system is that when water from the toilet, bidet, shower or sink enters the tank, it acts on the membrane of the pressure switch which, rising, activates the microswitch that starts the motor. The pump sucks up the water and solid matter and passes them through the grinder and through the perforated basket and then evacuates them through the small diameter drain pipe.

The first models of shredders built included positioning the motor and its electrical power supply outside the tank, to simplify maintenance operations, while the pump and the shredder were placed on the bottom of the tank. However, those solutions on the one hand did not consider the safety risks related to the accessibility of the mechanical and electrical components by inexperienced third parties, such as children, on the other hand they made access to the submerged components extremely complicated.

In newer devices, it is preferred to assemble a single, watertight motor/pump/grinder assembly, which is placed in the tank, equipped with waterproof power wires that pass through the wall of the tank itself, to connect the motor to the power circuit.

Furthermore, a second assembly called the "motor control group" is created, containing a capacitor/microswitch/pressure switch, in which the microswitch and the capacitor are positioned inside the pressure switch, which is equipped in its lower part with a membrane that is fixed to the pressure switch itself by a gasket and which, under the pressure of the water rising in the tank, lifts a rod that activates the internal microswitch. The pressure switch is therefore created using a float system and the motor start-up is of the ON/OFF type and based solely on the filling level of the tank.

In order to increase the safety of the assembly, a lid is fixed to the tank by means of very resistant snap-on mounting systems.

The disadvantage of these devices is that they require the intervention of a professional for any repair, furthermore the system, being positioned behind the toilet, is difficult to access and requires a certain amount of experience to open the snap-lock systems of the lid. Furthermore, some solutions provide that, while the condenser/microswitch/pressure switch system is generally positioned on the side, the motor/pump/grinding system is positioned behind the toilet bowl pipe, making it difficult to access.

More recent solutions show greater attention to maintenance operations, to make them performable even by a non-professional, in the case of the most common faults.

For example, the patent US2012124725A1 ?Macerator device intended to be connected to a wc bowl? provides a macerator device that consists of a tank into which the water and solid waste from the toilet bowl are brought and in which there is an active system made with a motor equipped with a macerator inserted in a basket at the top and a pump at the bottom. The active system is connected to a control module, consisting of a microswitch/capacitor/pressure switch assembly, which is positioned under an access hatch provided in the lid of said tank and sealed by a removable lid. The microswitch and the capacitor are in the upper part of the control module and accessible from the hatch. Similarly, the motor/pump/expansion assembly is accessible through another access hatch provided in the lid of said tank and sealed by a removable lid. Patent US2012124725A1 provides for different system configurations, only the motor unit door, or, only with the control unit door, or the presence of both, each door being sealed by a removable cover. In the case in which the groups are both accessible, they are advantageously arranged, inside the tank, on both sides of the connection pipe to the toilet bowl.

With reference to the access hatches provided, the patent US2012124725A1 specifies that they are defined by a vertical cylindrical skirt including a shoulder and are sealed by a removable cover, for example screwed to the tank cover. Furthermore, the access hatch to the shredding system is equipped with an additional watertight cover.

The invention referred to in patent US2012124725A1 allows, by removing said cover or covers, access to the active components susceptible to maintenance, without dismantling the toilet bowl or the snap-on cover and thus solves some of the main technical problems of the sanitary bowl macerator systems currently on the market.

Another problem solved by the patent US2012124725A1 is the accessibility of the non-return valves for carrying out maintenance activities, which in this model are positioned externally to the tank, while in previous devices, they were accessible only from the tank itself. More precisely, in the patent US2012124725A1, these non-return valves, which are provided on the pipes that carry the water outgoing from a sink and/or a shower or a bathtub, are arranged outside the tank and placed in the inlet pipes, which are made up of short pipes that can be coupled, by means of threaded parts, to the outlet pipes from the sink and/or shower or bathtub. By dismantling these joints, the user has access to the non-return valves to replace them or to remove an object that could obstruct or jam them in the open or closed position.

The device aims to solve the technical problem of crushing solid and liquid matter from sanitary vessels to allow their disposal with small diameter pipes. The solutions known over time have also aimed to solve the main maintenance problems of the system, ensuring access to the functional parts (control group, motor/pump/chopper group) through doors closed by removable covers.

All these solutions do not take into account or do not solve the following problems: a. Simplify maintenance work on the sensor, since in the known solutions it is a membrane pressure switch that is immersed in the sewage present in the tank and therefore requires the operator to work in contact with the sewage during the intervention phase;

b. Excessive energy consumption and system rigidity: existing devices, consisting of single-phase motors controlled by a capacitor and microswitch, create ON/OFF systems that start each time at the maximum set power, with a unidirectional motion, without considering the surrounding conditions;

c. Monitoring the system status and the possibility of receiving indications regarding the type or location of any malfunctions, as soon as an anomaly is detected with respect to the set parameters; in fact, in existing systems, the detection of any fault or malfunction occurs only when it would be necessary to empty the tank, but the system does not activate; the intervention occurs with the tank completely full and with the risk of stagnation of dirty water in the sanitary fixtures, due to the lack of flow of water through the crusher system;

d. The possibility of solving some small technical problems autonomously or without manual intervention by the operator, which can be solved either automatically thanks to the system control software or remotely thanks to the possibility of controlling the device via 5G connectivity; e. The need for an electrical power supply to function, in the absence of which, once the sewage has filled the tank, users cannot use the toilet or any other sanitary fixture connected to it, including the sink. Consider that if the level of the wastewater were by chance almost at the limit at the time of the power failure, an event which is possible precisely because of the ON/OFF nature of the system which is controlled by the position of the pressure switch membrane, the non-usability of the sanitary fixtures would be almost immediate, regardless of the capacity of the tank.

These are the technical problems that are still unresolved, to which this intention intends to give an answer. In particular:

1. with reference to technical problem a), the invention simplifies maintenance or repair interventions on the sensors, allowing them to be carried out safely and in a clean manner, as it proposes to use sensors that do not require direct contact with the sewage, such as, by way of example but not limited to, optical, ultrasonic or capacitive sensors, which are positioned in a dry partition of the container, separate from the portion that functions as a waste tank for the toilet bowl.

2. with reference to technical problem b), the invention uses an inverter motor, which offers a variety of advantages, as it is programmable to respond to the boundary conditions recorded by the sensors, it can operate at different speeds, generally starting from programmed combinations of power/speed/operating time capable of optimising energy consumption and results, but it is able to modify its own power or speed in response to any inputs from the system (e.g.: blocking of the propellers, excessive resistance, etc.), and can also reverse the direction of rotation of the propellers if necessary.

3. with reference to technical problem c), it is highlighted how the use of sensors and an electronic control and programming software for the inverter motor allow for detailed knowledge of the device's situation, to identify any anomalies and, through a specific system app, capable of communicating with fixed and mobile devices in 5G connectivity, can send alarms and warnings even remotely, optimising the speed and precision of maintenance interventions.

4. with reference to technical problem d), strictly related to point c), the invention, using expert control software, appropriately programmed, is able to implement virtuous and resolutive behaviors autonomously; through the app in 5G connectivity it is also possible to intervene remotely even by expert operators, for in-depth diagnostics and in-depth self-monitoring and command sending procedures, avoiding, as far as possible, direct intervention on the system or, in the case of repairs, being able to know in advance where the fault is located and the possible need for replacement components.

5. with reference to technical problem e), the system integrates a UPS buffer battery which, in combination with the use of an inverter motor controlled by intelligent software, allows for the optimization of system performance and battery life, prolonging the operation of the device even in the event of a power blackout.

The proposed solutions are implemented in a macerator system of dimensions comparable to those of most existing systems, easily industrializable, inexpensive and with a high level of environmental sustainability due to the reduced energy consumption achievable through the soft-start technology typical of inverter motors.

Therefore, the present invention proposes a sanitary toilet bowl grinder which comprises a base divided into 2 compartments, separately accessible by means of removable doors or lids, in which the first compartment consists of a container element containing the sensor system, the inverter, the electronic control board with the possible user interface and the UPS battery, and the second is a tank into which the liquid and solid parts arriving from the toilet bowl and from any other sanitary fixtures (shower, bidet, sink) connected to the device are brought, via one or more supply pipes, and in which an inverter motor is placed connected to a grinder element and to an electric pump, constituting an active group controlled by the electronic control board of the inverter, and regulating the operation of the active group based on the quantity of material present in the tank and detected by the sensor system, IR or capacitive, also connected to the inverter. to an external manual switch and to a UPS battery system external to the tank, which allows it to operate even in the absence of mains power supply, and can also send alarms to report any malfunctions and anomalies both via a light signal on the device and by sending messages over the 5G network via computer applications active in an Ios or Android environment. Downstream of the shredding element, the resulting liquid is evacuated from the tank into a small diameter outflow pipe towards the wastewater disposal network.

Brief description of the drawings

The present invention will now be described in detail with reference to the following figures:

- In fig.1, for purely explanatory purposes of operation, the schematic front view of the inside of the shredding device is represented according to a first embodiment of the invention,

- In fig.2 is represented the schematic planimetric view of the inside of the shredding device according to a first embodiment of the invention in fig.1

In all figures, the same reference numerals are used to designate identical elements in the present invention.

It should be noted that given the purposes of this patent, in which the innovation is given by the application of an intelligent system that uses sensors external to the tank and inverter motors with UPS battery support, those elements that are not relevant because they are known to all in the art have not been included in the drawings. In particular, the electrical connections between the components are neither represented in the drawings because they are known to those who are skilled in the art. The threads of the inlet or outlet pipe couplings are not represented, as they are standard commercial solutions, just as the non-return valves that can be screwed externally to the pipe couplings have not been represented.

The figures show an asymmetric system, with the tank placed on the right side with respect to the connection to the toilet bowl; it is understood that the position of the partition (3) or of the tank (1) as well as of the relative internal components can be inverted without affecting the present invention.

Detailed description

The macerating device according to the present invention comprises a tank (1) with a generally parallelepiped shape, for which tapering, chamfering, rounding or other aesthetic solutions to soften its shape are not excluded, sealed by a lid (2) attached to the tank (1) by means of snap-fit systems or other secure fastening solutions (e.g.: screws, cantilever, etc.), which lid features technical solutions such as to create a watertight seal.

As is known, the tank comprises an opening (5) of relatively large dimensions for the connection to the sanitary vessel and the entry of solid matter and water coming from the latter, in addition to further inlets (4a-4b-4c) of small diameter for liquid waste coming from other sanitary fixtures (e.g. shower, bidet, sink, etc.). Fig. 1 shows by way of example the presence of 3 connections (4a-4b-4c) for inlet pipes, however a smaller or larger number of inlets could be had, as well as their different positioning without affecting the present invention. The figure does not show the threads present at the mouth of such inlets nor the non-return valves, conventionally present in the macerator boxes, which can be conveniently mounted on the inlets by screwing them from the outside and before screwing the waste water supply pipes. Then the outlet pipes from the sink and/or shower or bathtub (not shown) are coupled to the tank outlets and the check valves by means of threaded parts. By dismantling these joints, the user has access to the check valves to replace them or to remove an object that could block or jam them.

In addition to the inlets, the small diameter outlet pipe (10) for the crushed waste evacuated by the electric pump is also visible, to be connected to the building's waste disposal network, as well as a further outlet on the cover designed for the installation of a vapour vent valve equipped with active filters against odours, or for connection to a controlled mechanical ventilation device.

Inside the tank (1), there is an active group (6) consisting of an inverter motor connected at the bottom to an electric pump (9) which evacuates into an outlet pipe (10), at the top to a shredding element (7a) visible in figure 2, which is placed inside a perforated basket (7) connected to the connection pipe to the sanitary bowl (5), in order to avoid the dispersion of solid waste before its shredding. The waste shredded by the blades (7a) disperses into the tank through the holes in the basket (7), represented in the figure, for purely illustrative purposes, as elongated slots. It is understood that the result of the invention does not change in the case in which the container basket has holes of different shapes, distributions or densities (e.g. circular, elliptical or polygonal), the perforation being aimed at dispersing the shredded waste into the liquid present in the tank.

The active group (6) is controlled by an inverter (13) which in turn is managed by an electronic board (12) connected to the sensors (11), of the IR, capacitive or ultrasonic type, for monitoring the level of waste water present in the basket and possibly in the tank. All the electrical wires connecting the active components are housed in a watertight sheath longer than the distance between the parts, to allow for separate movement, if necessary. The electrical connections between the outside and the motor are neither shown nor described because they are known to those skilled in the art.

The active group (6) has a perforated basket shape (7) that ensures the correct position is maintained inside the tank (1), also by means of quick coupling/uncoupling systems to the dividing wall between the tank (1) and the external compartment (3), which systems are not shown in the figures. The shape of the lid helps maintain the position of the active group (6) thanks to the use of spacers and containment shoulders.

The active group (6) can be accessed by means of a watertight door (20), hinged to the lid (2) or fixed to the latter by means of removable screws or bolts in case of intervention. After opening or removing the door, the operator has access to the basket and can proceed with maintenance/repair activities. Between the lid and the door there is an electrical safety contact such that, when the door is opened or removed, the flow of current to the motor is automatically cut off, preventing its operation. A second similar sensor is advantageously placed between the lid (2) and the tank (1).

English: The control group contained in the compartment (3) is made up of sensors (11), by way of example but not limited to, optical, ultrasonic or capacitive sensors, by the intelligent electronic board (12), capable of communicating in a 5G network with various mobile devices, via a dedicated app running on an IoS or Android system, for remote control, which can advantageously be equipped with a user interface display, and by an inverter (13). The compartment (3) also contains a UPS buffer battery (14) capable of allowing the system to operate in the event of a power failure from the mains. A switch allows the battery/active group bridge to be activated or deactivated. A manual operation switch (18) on the cover (2) and a luminous alarm system (19) made with small 3-colour LEDs for simple error message coding is also connected to the control group. The compartment (3) is accessible by removing a side door (16) fixed to the container (1) using screws or a snap-fit or cantilever system.

The system works in a conventional way: when water from the toilet, bidet, shower or sink enters the tank (1), it is detected by external sensors, in response to the signal the motor is activated following the set programming. The pump sucks up the water and the matter and passes them through the crusher element, dispersing them in the tank, the liquid waste is evacuated through the tube (10).

The invention therefore simplifies maintenance or repair work on the sensors, as they are not in direct contact with the wastewater, but are positioned in a dry partition of the container, separate from the portion that functions as a tank for the wastewater from the toilet bowl. The use of an inverter motor combined with an electronic board offers a variety of advantages, as the system is programmable to respond to the boundary conditions recorded by the sensors, can operate at different speeds, starting from programmed power/speed/operating time combinations capable of optimising energy consumption and efficiency, but can also modify its power or speed in response to any system inputs (e.g. blade blockage, excessive resistance, etc.), and can also reverse the direction of rotation of the shredder blades if necessary.

Furthermore, the use of sensors and electronic control and programming software allow for detailed knowledge of the device's situation, to quickly identify any anomalies and to independently implement virtuous and resolutive behaviors; in the event that the problem persists, the specific system app, capable of communicating with fixed and mobile devices in 5G connectivity, is able to send detailed alarms and warnings, optimizing the speed and precision of maintenance interventions, even remotely, interaction by expert operators, for in-depth diagnostics and in-depth self-monitoring and self-correction procedures, avoiding, as far as possible, direct intervention on the system or in any case providing detailed information on the fault, thus speeding up repair times.

Claims (10)

1. Sanitary toilet bowl grinder box characterised by the fact that it comprises a base, divided into a tank (1) and an external compartment (3) closed by a removable door (16), and a removable upper cover (2), such that: - the external compartment (3) contains both a programmable control module, consisting of a system of sensors for detecting the level of fluids present in the tank (1), an inverter, and an intelligent electronic control board with user interface, as well as a UPS buffer battery, - the tank (1), into which the liquid and solid waste arriving from the toilet bowl and any other sanitary fixtures connected to the device flow through the openings (4,5) and from which the shredded waste flows, houses an active group (6), consisting of an inverter motor, connected to a shredding element included in a basket (7) and to an electric pump (9), which active group is connected to the aforementioned control group, to an external manual switch positioned on the lid (2), to the UPS battery system and to the discharge pipe for the shredded waste. - the removable upper cover (2) in correspondence with the tank (1) has a removable cover (20), which allows independent access to the active group (6), an outlet (10) for the exhaust pipe, an outlet (15) and all the joining edges are appropriately structured to prevent the leakage of liquids from the tank (1); in correspondence with the external compartment (3) said cover is further prepared for the insertion of a manual control device and a luminous alarm. 2. Shredder cassette according to claim 1, characterised in that the control module and the active group are advantageously mounted adjacent to each other. 3. Shredder box according to claim 1, characterised in that both the main cover (2) and the doors (16) and (20) are removable and are fixed to the counterpart by means of quick, snap or screw fastenings. 4. Shredder box according to claim 1, characterised in that the wastewater level detection sensors are positioned externally to the tank (1), not requiring direct contact or immersion in the wastewater itself, and are made up, by way of example and not exhaustively, of IR sensors, and/or ultrasonic sensors and/or capacitive sensors. 5. Shredder box according to claim 1, characterised in that the control module comprises an intelligent electronic board programmed to process information from the sensors and configured to connect to the network and allow remote interaction via Apps usable in an Android or IoS environment. 6. Shredder box according to claim 1, characterised in that the UPS battery is connected to both the control module and the active module and there is also a switch command for connecting or excluding the UPS battery from the motor power circuit. 7. Shredder box according to claim 1, characterised in that between the tank (1) and the removable lid (2) or between the lid (2) and the removable watertight door (20), there are safety contact sensors which, in the absence of contact between the aforementioned parts, cut off the current and prevent the activation of the active group. 8. Shredder box according to claim 1, characterised in that the outlet (15) present on the lid (2) further mounts a vapour release valve equipped with active filters against odours, or a connection element to a controlled mechanical ventilation device, or a threaded or otherwise fixed lid to close the outlet itself. 9. Shredder box according to claim 1, characterised in that the tank has a supply mouth (5) of a diameter suitable to allow connection to a sanitary vessel for the entry of waste water coming from the latter, and a discharge pipe for the shredded waste water, which passes through the lid (2) through the opening (10). 10. A crusher box according to claims 1 and 9, characterised in that the tank further features at least one opening (4), configured to allow the assembly of standard hydraulic elements, such as, by way of example and not limited to, plugs, non-return valves, pipes, butterfly valves, etc., for connection to other sanitary fixtures and the reception of their waste.