TECHNICAL FIELD

[0001] The present invention relates to marine flushing systems. More specifically, the invention relates to a motor flushing inlet and system for use in flushing an in board boat motor, in particular heat exchangers, with fresh water.

BACKGROUND ART

[0002] Cooling systems in marine or boat motors typically intake water from the body of water that the motor is operated in. Where a boat motor is utilised in salt water, the cooling system of the boat motor therefore typically pumps salt water through the internal cavities of the motor for cooling purposes. For example, salt water is circulated through heat exchangers which extract heat generated from the motor through means of heat transfer from the internal workings of the motor to a medium such as salt water, and removes the excessive heat generated to stop the engine over heating. The flow of salt water can cause a build up of residual salt on the internal workings of the heat exchangers, and restricts heat transfer, thus causing the motor to build up excessive heat internally. This can cause large amounts of, if not catastrophic, damage to the engine. Furthermore, salt water is corrosive and can cause permanent damage to the internals of the cooling system and/or motor. In particular, a lot of corrosion occurs when the boat motor is off, and the water in the cooling system is stagnant. It is therefore desirable to flush the boat motor after use, to purge the salt water from the engine and replace it with less corrosive fresh water.

[0003] Unfortunately, flushing boat motors can be difficult and time consuming. External outboard boat motors may be flushed by running them in fresh water, or by utilise a provided a flushing system and/or procedure. However, internal inboard boat motors are not easily switched to a fresh water source, and are inherently more difficult to access. As a result, frequent chemical cleaning is often required of certain parts, such as the heat exchanges, to reduce corrosion and salt build up. This not only puts the motor out of service for a period of time, but is also expensive, time consuming, and the chemicals are generally bad for the environment.

[0004] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

SUMMARY OF INVENTION [0005] The present invention is directed to a marine flushing apparatus and method of operation, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.

[0006] With the foregoing in view, the present invention in one form, resides broadly in A marine flushing apparatus for an inboard motor, generator set or air conditioning unit of an aquatic vessel, the apparatus including a fresh water holding tank with a level indicator on board the vessel, at least one flushing pump for each motor or generator set associated with the fresh water holding tank, a solenoid valve located between the at least one flushing pump of the motor or generator set and a raw water feed and a controller to check at actuation, the level of fresh water in the fresh water holding tank and to abort startup of a flushing sequence if the level is insufficient and to actuate a flushing sequence if the level is sufficient wherein, if the level is sufficient, the controller insures that the solenoid valve these energized after actuation of the at least one flushing pump to ensure that the raw water feed is replaced by fresh water from the fresh water holding tank without substantial interruption.

[0007] The apparatus of the present invention will normally operate in one of two configurations, namely either manual or automatic and the apparatus may be switched between the two configurations.

[0008] There will typically be fluid communication lines between the components in the apparatus. Further, there will normally be electrical communication lines between the bridge or, operations centre of the aquatic vessel and or engine room into the controller, solenoid valve, flushing pump or any other electrical component.

[0009] The components of the system therefore typically include a freshwater tank containing flushing water with a level indicator, one or more flushing pumps, one or more solenoid valves, one or more raw water pumps, a timing device and appropriate power switches and the controller.

[0010] In the preferred embodiment, the freshwater tank is on board the vessel. The freshwater tank will normally be provided with a level sensor, preferably a pressure type level sensor. The level sensor will typically be capable of sensing and preferably reporting the level in the freshwater tank to the controller so that the controller and the software operating on the controller can make decisions based upon the level in the freshwater tank. It is preferred that the freshwater tank level sensor is more than simply a high or low level sensor although sensors of this type could be provided on simple systems or as a backup on more complex systems. [0011] There is preferably at least one flushing pump located between the freshwater tank and the solenoid valve for each motor or generator set in the system. It is further preferred that each flushing pump will operate on a different control circuit to allow independent flushing old each motor/generator set.

[0012] Each flushing pump is preferably controlled by the controller and normally only a single controller is provided. The controller may operate the flushing pump according to a predetermined time or alternatively utilizing a more complex control structure based on the flow rate of flushing liquid through the system in order to ensure that the system is entirely flushed.

[0013] The solenoid valve is preferably located between each motor or generator set of raw water inlet for each motor or generator set and a flushing pump for each motor or generator set.

[0014] The solenoid valve is normally electrically connected to the vessel's power supply, normally through a power switch connected to the engine room. The solenoid valve is used to control the flow raw or cooling fluid to the motor/generator set and also the flow of fresh or flushing fluid to the motor/generator set including when each respective fluid is used.

[0015] The preferred solenoid valve according to the present invention will have a pair of inlets, one for the raw or cooling fluid and one for the fresh or flushing fluid and one outlet which is connected to the fluid communication conduit leading to the motor or generator set.

[0016] The solenoid valve will have a "normally closed" configuration in which the raw or cooling fluid flows through the valve and out through the outlet, and then to the motor or generator set. The fresh water or flushing fluid is normally not allowed to flow through the outlet. In the open configuration, flow of the raw or cooling fluid through the valve is prevented and the fresh water or flushing fluid is allowed to flow.

[0017] Movement of the solenoid valve between the closed and open configurations is preferably actuated by current supplied through the controller. The closed and open configuration of the valve are preferably a de-energized and energized configuration respectively.

[0018] Preferably, one solenoid valve is provided for each motor or generator set circuit.

[0019] The operation of the solenoid valve may be manually actuated from the bridge of the vessel and/or the engine room of the vessel.

[0020] The other components in the apparatus of the present invention and in each circuit (where multiple motors or generator sets are provided) are preferably conventional components. For example, the flushing pump and raw water pump may be any type of pump provided to pump fluid through a fluid circuit. Appropriate screens or sitting devices may be located adjacent each pump in order to ensure that detritus does not enter the inlet for the pumps and cause damage.

[0021] As mentioned previously, the apparatus of the present invention may be operated in a manual or automatic configuration. Each configuration or operational mode may be partially one or the other. Preferably, the automatic mode is fully automatic. The automatic mode is typically actuated upon the ignition key for each motor or generator circuit being moved to the off position following which, the controller assumes control of the components in the system to ensure the correct flushing sequence and operation.

[0022] The manual mode is preferably actuated manually and operation of the flushing pump occurs subsequently according to the operator.

[0023] In the manual mode, the motor or generator set to be flushed continues operation, normally at idle. An operator will typically operate a toggle switch which polls the level sensor in the freshwater tank to ascertain the level therein. The level sensor preferably communicates the level of the tank to the controller and if the level in the tank is sufficient, an indicator preferably shows that the flushing sequence can be run. If the level is insufficient for flushing, an indicator will preferably show that the flushing sequence cannot be run at that time and that further freshwater is required in the freshwater tank before flushing can commence.

[0024] If sufficient water is available in the freshwater tank for flushing, upon the indication that the flushing sequence can be run, the operator will preferably operate the toggle switch into an operative position which actuates flushing pump. Actuation is normally by connection of the vessels power to the flushing pump. The solenoid pump is also actuated shortly thereafter. The toggle switch is preferably held in the operative position by the operator for the duration of the flush. The duration of the flush can be any length of time but generally, is a fixed period set by an installer or by the operator.

[0025] Once the duration of the flush has been exceeded, the engine is typically deactivated while the flush is still operative. This will ensure that flushing liquid is entrained in the fluid circuit of the motor or generator set.

[0026] The duration of the flush will normally be approximately 60 seconds but is dependent upon the extent and complexity of the fluid circuit. Clearly, a more expensive or more complex fluid circuit will require a longer flushing time.

[0027] The toggle switch is typically maintained in an operative condition for a further period. Typically approximately 10 seconds in order to allow freshwater two back flush through the fluid circuit and allow freshwater to be maintained in the solenoid valve. '

[0028] In order for the flushing sequence to take place, the level in the freshwater tank will need to be in excess of the amount required for the flushing period plus the further period.

[0029] As mentioned above, the amount of flushing water required will depend on the size of the motor or generator set, the flushing period, the size of the flushing pump and the connecting pipework. Once these parameters have been optimized, the amount of water in the freshwater tank which is required for flushing will typically be used as a set point for the level sensor in the tank.

[0030] In the automatic mode, the level in the freshwater tank will typically be polled by operation all the toggle switch as described above. However once it has been identified that sufficient freshwater is held in the freshwater tank for the flushing sequence, and automatic flush controller will typically assume responsibility for the flushing sequence. Once the automatic flush controller has taken over, the ignition key for the motor or generator set can be turned off.

[0031] The automatic flushing controller is typically positioned between a power source of the vessel and the bridge or operation centre of the vessel allowing the operative condition of the motor or generator set to be controlled by the flushing controller. In particular, the automatic flushing controller will typically continue to supply power to run the motor or generator set in order to maintain operation while the flushing sequence is undertaken.

[0032] The automatic flushing controller will typically include a timer set to maintain the engine or generator set in operation for the particular set flushing period. Once the flushing period has expired, the automatic flushing controller may continue operation of the flushing pump but deactivate the motor or generator set for a purge period. Again, this is to allow flushing water to back flush through the system and into the solenoid valve.

[0033] Once the flushing period has expired, the motor or generator set is powered down and once the purge period had expired,, the freshwater pump and solenoid valve are normally deactivated and closed respectively.

[0034] In the automatic mode, if the level in the freshwater tank falls below a low setpoint, the automatic flushing control shuts the flushing sequence down or interrupts the flushing sequence in order to prevent damage to the motor and/or fluid pumps. Therefore, in the automatic mode, the level sensor in the freshwater tank may be polled periodically or may supply the level of fresh water remaining to the automatic flushing controller substantially continuously.

[0035] According to an alternative embodiment, the present invention resides in a method for operating a marine flushing apparatus in a manual mode substantially as described above.

[0036] According to yet another embodiment, the present invention resides in a method for operating a marine flushing apparatus in an automatic mode substantially as described above.

[0037] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

[0038] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

BRIEF DESCRIPTION OF DRAWINGS

[0039] Various embodiments of the invention will be described with reference to the following drawings, in which:

[0040] Figure 1 is a schematic view of a motor flushing system for a marine craft having a pair of inboard motors according to a preferred embodiment of the present invention.

[0041] Figure 2 is a cross-sectional view of a solenoid valve having two inlets and one outlet to control the flow of liquid through the valve according to one embodiment of the present invention.

[0042] Figure 3 is a schematic view of a solenoid valve in an de-energised condition.

[0043] Figure 4 is a schematic view of a solenoid valve in an energised condition.

[0044] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: [00451 Figure 1 DESCRIPTION OF EMBODIMENTS

[0046] According to a particularly preferred embodiment of the present invention, a marine flushing system and method of operation is provided.

[0047] As illustrated schematically in Figure 1, the marine flushing apparatus for an inboard motor or generator set of an aquatic vessel includes a fresh water holding tank with a level indicator on board the vessel, at least one flushing pump for each motor or generator set, a solenoid valve located between the at least one flushing pump and the motor or generator set and a raw water feed and the fresh water holding tank and a controller to check at actuation, the level of fresh water in the fresh water holding tank and to abort startup of a flushing sequence if the level is insufficient and to actuate a flushing sequence if the level is sufficient wherein, if the level is sufficient, the controller insures that the solenoid valve these energized after actuation of the at least one flushing pump to ensure that the raw water feed is replaced by fresh water from the fresh water holding tank without substantial interruption.

[0048] There are fluid communication lines between the components in the apparatus. Further, there are electrical communication lines between the bridge or, operations centre of the aquatic vessel and/or engine room into the controller, solenoid valve, flushing pump or any other electrical component.

[0049] In the preferred embodiment, the freshwater tank is on board the vessel. The freshwater tank will normally be provided with a level sensor, preferably a pressure type level sensor. The level sensor will typically be capable of sensing and preferably reporting the level in the freshwater tank to the controller so that the controller and the software operating on the controller can make decisions based upon the level in the freshwater tank. It is preferred that the freshwater tank level sensor is more then simply a high or low level sensor although sensors of this type could be provided on simple systems or as a backup on more complex systems.

[0050] There is preferably one flushing pump located between the freshwater tank and the solenoid valve for each motor or generator set in the system. It is preferred that each flushing pump operates on a . different control circuit to allow independent flushing of each motor/generator set.

[0051] Each flushing pump is preferably controlled by the controller and normally only a single controller is provided. The controller may operate the flushing pump according to a predetermined time. Utilizing a time a or a more complex control structure based on the flow rate of flushing liquid through the system in order to ensure that the system is entirely flushed.

[0052] The solenoid valve is preferably located between each motor or generator set of raw water inlet for each motor or generator set and a flushing pump for each motor or generator set.

[0053] The solenoid valve is normally electrically connected to the vessel's power supply, normally through a power switch connected to the engine room. The solenoid valve is used to control the flow raw or cooling fluid to the motor/generator set and also the flow of fresh or flushing fluid to the motor/generator set including when each respective fluid is used.

[0054] The preferred solenoid valve according to the present invention will have a pair of inlets, one for the raw or cooling fluid and one for the fresh or flushing fluid and one outlet which is connected to the fluid communication conduit leading to the motor or generator set.

[0055] The solenoid valve will have a "normally closed" configuration in which the raw or cooling fluid flows through the valve and out through the outlet. The fresh or flushing fluid is normally not allowed to flow through the outlet. In the open configuration, flow of the raw or cooling fluid through the valve is prevented and the fresh or flushing fluid is allowed to flow.

[0056] Movement of the solenoid valve between the closed and open configurations is preferably actuated by current supplied through the controller. The closed and open configuration of the valve are preferably a de-energized and energized configuration respectively.

[0057] Preferably, one solenoid valve is provided for each motor or generator set circuit.

[0058] The operation of the solenoid valve may be manually actuated from the bridge of the vessel and/or the engine room of the vessel.

[0059] The other components in the apparatus of the present invention and in each circuit (where multiple motors or generator sets are provided) are preferably conventional components. For example, the flushing pump and raw water pump may be any type of pump provided to pump fluid through a fluid circuit. Appropriate screens or sitting devices may be located adjacent each pump in order to ensure that detritus does not enter the inlet for the pumps and cause damage.

[0060] Manual Operation

[0061] When a rocker or toggle switch in the fly-bridge/engine room is toggled and a red or green light is illuminated, this indicates insufficient water in fresh water holding tank, water from the dock, marina or onboard water maker will need to be used until there is sufficient fresh water to carry out the process.

[0062] When the rocker or toggle switch in the bridge or engine room is toggled and a red or green light is illuminated, holding the rocker switch in the down position:

[0063] 1. receives a signal from the onboard fresh water tank sensor or sensors to determine if the water level is sufficient, if level is above predetermined or preset setting, a sequence is initiated to allow the electrical power relay for the Fresh Water Flushing motor/pump and the electrical power relay for the solenoid valve to be energized and the Fresh Water Flushing of the system to activate. After approx 60 seconds or time specified by the installers of the system of running time, with the rocker switch manually held down the master engine key switch for the corresponding main or auxiliary engine may now be turned "off, one engine at a time. If unable to initiate sequence, fresh water may be required in holding tank to continue with sequence.

[0064] 2. The above action activates a solenoid valve (which has a copper coil on top that can be energized by either 12V, 24V 110V or 240Vand when electrical power is applied to said electrical coil a thin plunger inside the valve assembly which is attached to a rubber disc or urethane shape, raises and opens the inner valve water way to allow Fresh Water to pass through the constructed plumbing system). The solenoid valve is placed between the sea strainer and motor raw water pump to allow fresh water from the onboard fresh water tank to be admitted into raw water side of cooling system of the desired apparatus.

[0065] 3. The above action also activates a designated Fresh Water flushing pump (pump and motor size for the Fresh Water Flushing System will vary according to the volume of raw water output of the motor raw water pump while the said motor is running at minimum revolutions per minute or at manufacturer's set idle speed) to allow fresh water to flow through the solenoid valve and replace the salt water flow through the raw water pump and heat exchangers and is discharged through the exhaust system.

[0066] 4. This process of holding the rocker switch needs to be held for approx 60 seconds or time specified by the installers of the system to replace the salt water within the system where upon completion the main or auxiliary engine switch may be turned off, rocker switch may be held for another 10 seconds before release to allow fresh water to back flush the sea strainer to remove any foreign objects and place fresh water to the skin fitting to help stop the growth of barnacles within the plumbing system. [0067] Automatic Operation

[0068] When a switch in the fly-bridge/engine room is toggled and a red light is illuminated, this indicates insufficient water in fresh water holding tank, water from the dock, marina or onboard water maker unit will need to be added to the fresh water tank until there is sufficient to carry out the process.

[0069] When switch in the bridge or engine room is toggled and a green light is illuminated-

[0070] 1. Automatic Flush Controller (which is described in detail in an additional document) receives a signal from the onboard fresh water tank sensor or sensors to determine if the water level is sufficient, if level is above predetermined or preset setting a sequence is initiated to allow the electrical power relay for the Fresh Water Flushing motor/pump and the electrical power relay for the solenoid valve to be energized. The master key switch for the main engines may now be turned "off as the Automatic Flush Controller takes over. If unable to initiate sequence, water may be required in the fresh water tank to continue with sequence.

[0071] 2. Automatic Flush Controller activates solenoid valve (which has a copper coil on top that can be energized by either 12V, 24V 110V or 240Vand when electrical power is applied to said electrical coil a thin plunger inside the valve assembly which is attached to a rubber disc or urethane shape, raises and opens the inner valve water way to allow Fresh Water to pass through the constructed plumbing system). The solenoid valve is placed between the sea strainer and motor raw water pump to allow fresh water from the onboard fresh water tank to be admitted into raw water side of cooling system of the desired apparatus.

[0072] 3. Automatic Flush Controller activates designated fresh water flushing pumps by of electrical power relay to allow fresh water to flow through solenoid valve and replace salt water for flow through the raw water pump and heat exchangers and is discharged through the exhaust system.

[0073] 4. Automatic Flush Controller timer keeps system operating for approx 60 seconds (or for a predetermined time during commissioning) to replace the salt water within the system where upon completion the Automatic Flush Controller shuts down the appropriate items, (in following sequence ):

[0074] A - both (or more) main engines, depending on vessel size and motor configuration. [0075] B - 10 seconds later - designated fresh water pumps. This is to allow fresh water to back flow through the sea strainers to remove any obstruction or foreign materials which may have been picked up or sucked up in the vessel's travels.

[0076] C - At same 10 second delay, one or both fresh water solenoid valves by means of electrical power relays are closed. -

[0077] 5. Automatic Flush Controller keeps track of water level in the fresh water tank. If fresh water tank level drops below predetermined water level the system will automatically advance to shut down mode stopping the Fresh Water Pumps and closing the solenoid valves to restrict and stop any damage being done to the motor raw water pump impeller or engine.

[0078] Pump and motor size for the Fresh Water Flushing System will vary according to the volume of raw water output of the motor raw water pump while the said motor is running at minimum revolutions per minute or at manufacturer's set idle or running speed.

[0079] The above processes and systems may also be used for onboard generator sets and air conditioning units. The idle speed of this type of apparatus is not applicable as manufacturers set the motor revolutions at a set speed for the appropriate electrical output of the item. The calculations for the amount of fresh water required into the system to flush out the salt water under normal operating revolutions per minute must be applied accordingly.

[0080] An important component in the motor flushing system of the present invention, whether any automatic or manual configuration, is the solenoid valve which controls the flow of flushing liquid and cooling liquid through the import motor or generator set. One form of solenoid valve is illustrated in Figure 2.

[0081] A solenoid valve includes a valve body 9 with two inlets, a cooling liquid inlet and a flushing liquid inlet and a single outlet which is connected to the respective motor or generator set illustrated in Figure 1. Located within the valve body is a valve seat 11 against which a valve member having a resilient disc 10 seals. The valve member has an elongate the valve stem 8 extending upwardly and which is associated with a plunger 4 located within the coil 3. A plunger spring 12 biases the plunger and valve member downwardly into the sealed condition. This allows cooling liquid to flow through the cooling liquid inlet and out off the outlet to the motor or generator set.

*

[0082] A lift washer 7 is provided between the valve stem 8 and the plunger 4. A centering washer 6 guides the reciprocal action of the plunger 4 during movement. The coil 3 is attached to the valve body by a body union nut 5 and a cover nut 1 maintains the coil housing 15 relative to the valve body 9.

[0083] A conduit opening 2 is provided in the coil housing 15 in order to provide access for an electrical connection 17 to energize the coil 3.

[0084] As illustrated in Figure 3, when the coil of the solenoid is not energized, it is the natural bias of the plunger spring 12 forces the foul member 18th downward until the resilient disc 10 seals the flushing water inlet 14. This is the "normal operating configuration" when the motor/generator set is operating allowing cooling liquid from the cooling liquid inlet 13 to flow through the valve body 9 and out through the outlet 16.

[0085] When the coil 3 of the solenoid valve is energized, as is illustrated in Figure 4, the coil 3 attracts the plunger 4 upwardly, which allows the flushing liquid to enter the valve body 9 through the flushing liquid inlet 14 and out through the outlet 16 whilst preventing flow of the cooling liquid through the cooling liquid inlet 13.

[0086] In the present specification and claims (if any), the word "comprising" and its derivatives including "comprises" and "comprise" include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0087] Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.