Method and device for quantifying pneumatic volume usage by a valve controller

Abstract

Methods and apparatus for quantifying pneumatic volume usage by a valve controller are disclosed. An example apparatus includes a valve controller operably coupled to a pneumatic actuator, the pneumatic actuator operably coupled to a control valve. In response to an input signal indicating that a flow control member of the control valve is to move in a specified direction, the valve controller commands a current to pressure (I / P) converter of the valve controller to pulse a relay valve of the valve controller between a closed position and an open position. The pulsation of the relay valve causes the pneumatic actuator to move the flow control member in the specified direction. The valve controller calculates the pneumatic volume usage associated with the movement of the flow control member in the specified direction. The pneumatic volume usage is based on the pulsation of the relay valve.

Description

[0001] Related Applications

[0002] This application claims priority to U.S. Patent Application No. 16 / 863,157, entitled “Methods And Apparatus for Quantifying Pneumatic Volume Usage via Valve Controllers,” filed on April 30, 2020. The entire contents of U.S. Patent Application No. 16 / 863,157 are hereby incorporated by reference herein. Technical Field

[0003] The present disclosure relates generally to valve controllers, and more particularly to methods and apparatus for quantifying pneumatic volume usage by a valve controller. Background Art

[0004] In conventional valve controllers implementing pneumatic sensors, a given amount of pneumatic medium (e.g., air) is constantly used to maintain an output signal to a pneumatic actuator operably coupled to a control valve. This continuous use and / or consumption of pneumatic medium under steady-state conditions of the pneumatic actuator and / or control valve is generally referred to as bleed. Product specifications for valve controllers generally provide a specified pneumatic medium usage rate (e.g., standard cubic feet per hour) for air, which can be easily converted to a usage rate for another pneumatic medium (e.g., natural gas).

[0005] For conventional valve controllers as described above, the total volume of pneumatic medium used to operate a pneumatic actuator and / or a control valve has three components. The first component is the volume of pneumatic medium moved from the valve controller into the pneumatic actuator to move the control valve in a first direction (e.g., toward a fully open position). The second component is the volume of pneumatic medium released (e.g., discharged) from the pneumatic actuator (e.g., via the valve controller) to move the control valve in a second direction opposite to the first direction (e.g., toward a fully closed position). The third component is the volume of pneumatic medium used to maintain an output signal to the pneumatic actuator (e.g., to maintain the distance between the nozzle and the flapper mechanism of the valve controller), wherein this volume constitutes a discharge associated with the valve controller and / or the pneumatic actuator. For example, the distance between the nozzle and the flapper of the nozzle and flapper mechanism is typically maintained by a current applied to a current-to-pressure (I / P) converter. The output pressure of the I / P converter is used to maintain the position of the pneumatic actuator, and the discharge amount from the I / P converter increases as its output pressure increases.

[0006] Continuing with reference to the above-described conventional valve controller, the total volume of pneumatic medium used and / or consumed may be measured, calculated, and / or quantified through the implementation of an upstream pressure sensor and flow meter. However, in a steady state, when the pneumatic actuator and / or control valve is not moving, the above-described exhaust continues and all exhausted pneumatic medium is exhausted and / or vented to the atmosphere. As the exhaust continues over time, a large amount of pneumatic medium is lost and / or wasted, and the efficiency of pneumatic medium conservation becomes almost zero. The consumed pneumatic medium quantification method based on the implementation of an upstream pressure sensor and flow meter cannot provide efficiency data that details the amount (e.g., percentage) of the total consumed pneumatic medium actually used to move the control valve relative to the amount (e.g., percentage) of the total consumed pneumatic medium lost and / or wasted due to leakage. Summary of the invention

[0007] Example methods and devices for quantifying pneumatic volume usage by a valve controller are disclosed. In some examples, a device is disclosed. In some disclosed examples, the device includes a valve controller operably coupled to a pneumatic actuator, which is operably coupled to a control valve. In some disclosed examples, the valve controller includes one or more processors to: in response to an input signal indicating that the valve controller is to operate the pneumatic actuator to move a flow control member of the control valve in a specified direction, command a current-to-pressure (I / P) converter of the valve controller to pulsate a relay valve of the valve controller between a closed position and an open position. In some disclosed examples, the pulsation of the relay valve causes the pneumatic actuator to move the flow control member in the specified direction. In some disclosed examples, the one or more processors are also used to calculate the pneumatic volume usage associated with the movement of the flow control member in the specified direction. In some disclosed examples, the pneumatic volume usage is based on the pulsation of the relay valve.

[0008] In some examples, a method is disclosed. In some disclosed examples, the method includes receiving an input signal at a valve controller operably coupled to a pneumatic actuator, the pneumatic actuator operably coupled to a control valve, the input signal indicating that the valve controller is to operate the pneumatic actuator to move a flow control member of the control valve in a specified direction. In some disclosed examples, the method also includes: in response to receiving the input signal, commanding a current-to-pressure (I / P) converter of the valve controller to pulsate a relay valve of the valve controller between a closed position and an open position via one or more processors of the valve controller. In some disclosed examples, the pulsation of the relay valve causes the pneumatic actuator to move the flow control member in a specified direction. In some disclosed examples, the method also includes: calculating, via one or more processors, a pneumatic volume usage associated with the movement of the flow control member in a specified direction. In some disclosed examples, the pneumatic volume usage is based on the pulsation of the relay valve.

[0009] In some examples, a non-transient computer-readable medium is disclosed. In some disclosed examples, the non-transient computer-readable medium includes instructions that, when executed, cause one or more processors of a valve controller to obtain an input signal indicating that the valve controller is to operate a pneumatic actuator to move a flow control member of a control valve in a specified direction, the pneumatic actuator being operably coupled to the valve controller, and the control valve being operably coupled to the pneumatic actuator. In some disclosed examples, when executed, the instructions also cause the one or more processors to command a current-to-pressure (I / P) converter of the valve controller to pulsate a relay valve of the valve controller between a closed position and an open position in response to the input signal. In some disclosed examples, the pulsation of the relay valve causes the pneumatic actuator to move the flow control member in a specified direction. In some disclosed examples, when executed, the instructions also cause the one or more processors to calculate a pneumatic volume usage associated with the movement of the flow control member in a specified direction. In some disclosed examples, the pneumatic volume usage is based on the pulsation of the relay valve. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a block diagram of a control system including an example valve controller for quantifying pneumatic volume usage constructed in accordance with the teachings of the present invention.

[0011] Figure 2 Shown in Figure 1 An exemplary input signal received at a processor of a valve controller of the present invention is responsive to the input signal by Figure 1 An exemplary pulse drive signal generated by a processor of a valve controller, and an exemplary pulse drive signal generated by a processor of a valve controller in response to the pulse drive signal Figure 1 A graphical representation of an exemplary plot of a position of a flow control member of a control valve.

[0012] Figure 3 Graphical representations of an exemplary I / P converter state diagram, an exemplary relay valve state diagram, and an exemplary plot of actuator port pressure are shown.

[0013] Figure 4 Shown in Figure 1 An exemplary input signal is received at a processor of a valve controller, and in response to the input signal is received by Figure 1 An exemplary pulse drive signal generated by a processor of a valve controller, and an exemplary pulse drive signal generated by a processor of a valve controller in response to the pulse drive signal Figure 1 Another graphical representation of an exemplary plot of a position of a flow control member of a control valve.

[0014] Figure 5 Another graphical representation of an exemplary I / P converter state diagram, an exemplary relay valve state diagram, and an exemplary plot of actuator port pressure is shown.

[0015] Figure 6 is a block diagram of an example process control system including an example valve controller constructed in accordance with the teachings of the present invention for quantifying pneumatic volume usage.

[0016] Figure 7 It means that it can be Figure 1 Flowchart of an example method executed at an example valve controller to quantify pneumatic volume usage.

[0017] Fig. 8A and Figure 8B It means that it can be Figure 6 Flowchart of an example method executed at an example valve controller to quantify pneumatic volume usage.

[0018] Fig. 9 Is able to execute instructions to achieve Figure 7 The example method and Figure 1 An example valve controller, and / or implementation of Figure 8A-B The example method and Figure 6 An example processor platform for an example valve controller.

[0019] Certain examples are shown in the above-mentioned figures and described in detail below. In describing these examples, the same or similar reference numerals are used to identify the same or similar elements. The drawings are not necessarily drawn to scale, and certain features and certain views of the drawings may be shown exaggerated in scale or in schematic form for the sake of clarity and / or simplicity.

[0020] Descriptors "first", "second", "third", etc. are used herein to identify multiple elements or components that can be referred to separately. Unless otherwise specified or understood based on the context of its use, such descriptors are not intended to imply any meaning of priority or ordering in time, but are merely used as labels for referring to multiple elements or components separately for ease of understanding of the disclosed examples. In some examples, the descriptor "first" can be used to refer to an element in the detailed description, while the same element can be referred to by a different descriptor such as "second" or "third" in the claims. In this case, it should be understood that the use of such descriptors is merely for the convenience of referring to multiple elements or components. DETAILED DESCRIPTION

[0021] A conventional valve controller implementing a pneumatic transducer provides an output signal to a pneumatic actuator operably coupled to a control valve. The total volume of pneumatic medium used by the valve controller to operate the pneumatic actuator and / or the control valve typically has three components. The first component is the volume of pneumatic medium moved from the valve controller into the pneumatic actuator to move the control valve in a first direction (e.g., toward a fully open position). The second component is the volume of pneumatic medium released (e.g., discharged) from the pneumatic actuator (e.g., via the valve controller) to move the control valve in a second direction opposite to the first direction (e.g., toward a fully closed position). The third component is the volume of pneumatic medium used to maintain the output signal to the pneumatic actuator (e.g., to maintain the distance between the nozzle and the flapper mechanism of the valve controller), where this volume constitutes a bleed associated with the valve controller and / or the pneumatic actuator. For example, the distance between the nozzle and the flapper of the nozzle and flapper mechanism is typically maintained by a current applied to the I / P converter. The output pressure of the I / P converter is used to maintain the position of the pneumatic actuator, and the bleed volume from the I / P converter increases as its output pressure increases.

[0022] For such conventional valve controllers, the total volume of pneumatic medium used and / or consumed can be measured, calculated and / or quantified through the implementation of an upstream pressure sensor and flow meter. However, in a steady state, when the pneumatic actuator and / or control valve is not moving, the above-mentioned exhaust continues and all the exhausted pneumatic medium is vented and / or exhausted to the atmosphere. As the exhaust continues over time, a large amount of pneumatic medium is lost and / or wasted, and the efficiency of pneumatic medium conservation becomes almost zero. The consumed pneumatic medium quantification method based on the implementation of an upstream pressure sensor and flow meter cannot provide efficiency data that details the amount (e.g., percentage) of the total consumed pneumatic medium actually used to move the control valve relative to the amount (e.g., percentage) of the total consumed pneumatic medium lost and / or wasted due to leakage.

[0023] The continued discharge of pneumatic media resulting from the use of a valve controller to operate a pneumatic actuator and / or control valve is detrimental in a number of ways. For example, from an economic standpoint, the continued discharge of pneumatic media increases operating costs associated with the production and delivery of the pneumatic media. As another example, from an environmental standpoint, the continued discharge of certain types of pneumatic media (e.g., natural gas) results in the undesirable discharge of the pneumatic media into the atmosphere.

[0024] Unlike the conventional valve controllers described above, the exemplary valve controllers disclosed herein include a pneumatic transducer implemented as a two-stage relay, wherein the first and second relay valves of the two-stage relay are operably coupled to and / or controlled by corresponding ones of the first and second I / P transducers of the valve controller. The two-stage relay advantageously reduces (e.g., eliminates) the continuous emissions typically associated with steady-state operation of the pneumatic actuator and / or control valve via the conventional valve controllers described above. Thus, the exemplary valve controllers disclosed herein provide economic and environmental benefits relative to such conventional valve controllers.

[0025] The exemplary valve controllers disclosed herein also provide improved techniques for quantifying pneumatic volume usage and / or consumption, particularly with respect to quantifying the volume of pneumatic medium used and / or consumed in association with a valve controller that operates a pneumatic actuator to move a control valve (e.g., usage and / or consumption during non-steady-state operation). In this regard, the exemplary methods and apparatus disclosed herein for quantifying pneumatic volume usage can be implemented via a valve controller having a two-stage relay operably coupled to a pneumatic actuator, which in turn is operably coupled to a control valve. In some disclosed examples, when the valve controller is to operate the pneumatic actuator to move the control valve in a first direction (e.g., toward a fully open position), a processor of the valve controller commands a first I / P converter to pulse a first relay valve (e.g., between a closed position and an open position). The pulsation of the first relay valve causes pressurized pneumatic medium (e.g., pressurized air) to be delivered from the valve controller to the pneumatic actuator in a pulsating manner. Conversely, when the valve controller is to operate the pneumatic actuator to move the control valve in a second direction opposite to the first direction (e.g., toward a fully closed position), the processor of the valve controller commands the second I / P converter to pulse the second relay valve (e.g., between a closed position and an open position). The pulsation of the second relay valve causes pressurized pneumatic medium to return from the pneumatic actuator to the valve controller and then be exhausted (e.g., vented) from the valve controller to atmosphere in a pulsed manner.

[0026] In the above examples, each pulse of pneumatic medium delivered by the first I / P converter to the first relay valve and / or by the second I / P converter to the second relay valve has a known volume. Based on such known volume of pneumatic medium pulses, together with measured pneumatic medium supply and exhaust pressures associated with the valve controller, the exemplary valve controller disclosed herein advantageously calculates and / or quantifies the volume of pneumatic medium used and / or consumed in association with the valve controller operating the pneumatic actuator to move the control valve. The pneumatic volume usage and / or consumption data calculated by the valve controller can be monitored over time to detect an unexpected and / or undesirable increase in the volume of pneumatic medium used and / or consumed by the valve controller. In some examples, detection of such an unexpected and / or undesirable increase in the volume of pneumatic medium used and / or consumed by the valve controller can indicate degradation of one or more components of the pneumatic actuator and / or control valve (including any piping and / or fittings associated therewith). Such information may advantageously enable maintenance personnel to more quickly identify and / or resolve operational issues, thereby increasing the reliability of field operations utilizing the valve controller, pneumatic actuator, and / or control valve.

[0027] As used herein, the phrase "operably coupled," including its variants (e.g., electrically coupled, mechanically coupled, fluidically coupled, etc.), encompasses direct operable coupling and / or indirect operable coupling through one or more intermediate components. As used herein, the phrase "in communication," including its variants (e.g., in electrical communication, in mechanical communication, in fluid communication, etc.), encompasses direct communication and / or indirect communication through one or more intermediate components, and does not require direct physical (e.g., wired) communication and / or constant communication, but rather includes selective communication at periodic intervals, scheduled intervals, non-periodic intervals, and / or one-time events.

[0028] Figure 1 is a block diagram of an example process control system 100 including an example valve controller 102 constructed in accordance with the teachings of the present invention for quantifying pneumatic volume usage. Figure 1 The process control system 100 also includes an example control valve assembly 104 operably coupled to the valve controller 102 . Figure 1 The control valve assembly 104 includes an example control valve 106 and an example pneumatic actuator 108 .

[0029] Figure 1The control valve 106 includes an exemplary flow control member 110 (e.g., a plug, a disk, a ball, a gate, etc.) and a valve shaft (not shown). The flow control member 110 is operably coupled to the valve shaft. When a force and / or load is applied to the valve shaft, the flow control member 110 moves toward a first position in a first direction, or moves toward a second position in a second direction opposite to the first direction. In some examples, the first position of the flow control member 110 corresponds to an open position (e.g., a fully open position) of the control valve 106, and the second position of the flow control member 110 corresponds to a closed position (e.g., a fully closed position) of the control valve 106. In other examples, the first position of the flow control member 110 corresponds to a closed position (e.g., a fully closed position) of the control valve 106, and the second position of the flow control member 110 corresponds to an open position (e.g., a fully open position) of the control valve 106.

[0030] Figure 1 The pneumatic actuator 108 is a single-acting pneumatic actuator that can be implemented by and / or as any linear or rotary actuator (e.g., a diaphragm actuator, a piston actuator, a rotary vane actuator, a rotary rack and pinion actuator, a rotary scotch yoke actuator, etc.). Figure 1 In the example shown, the pneumatic actuator 108 is operably coupled to the control valve 106, and more specifically, to the valve shaft of the control valve 106. The pneumatic actuator 108 includes an example control fluid port 112 in fluid communication with a fluid chamber of the pneumatic actuator 108. The pneumatic actuator 108 also includes an internal rod and / or piston. The control fluid port 112 of the pneumatic actuator 108 receives a pressurized control fluid (e.g., a pressurized pneumatic medium, such as pressurized air) from the valve controller 102, which causes the rod and / or piston of the pneumatic actuator 108 to move in a first direction and / or to increase the pressure in the fluid chamber of the pneumatic actuator 108. The force and / or load generated by moving the rod and / or piston of the pneumatic actuator 108 is converted into a force and / or load on the valve shaft of the control valve 106, which causes the flow control member 110 of the control valve 106 to move between the first position and the second position, as described above.

[0031] The operative coupling of the rod and / or piston of the pneumatic actuator 108 with the valve shaft and / or the flow control member 110 of the control valve 106 results in a correlation between the position of the rod and / or piston of the pneumatic actuator 108 and the position of the flow control member 110 of the control valve 106. Therefore, the position of the flow control member 110 of the control valve 106 can be determined based on the known and / or measured position of the rod and / or piston of the pneumatic actuator 108, and vice versa. In some examples, a position indicator is operably coupled to the rod and / or piston of the pneumatic actuator 108, such that movement of the rod and / or piston causes corresponding movement of the position indicator. Based on the above correlation between the position of the rod and / or piston of the pneumatic actuator 108 and the position of the flow control member 110 of the control valve 106, the position indicator can provide an indication of the position of the rod and / or piston of the pneumatic actuator 108, and / or an indication of the position of the flow control member 110 of the control valve 106. The position data generated by the position indicator of the pneumatic actuator 108 may be transmitted to a position sensor of the valve controller 102 via a wired or wireless connection.

[0032] Figure 1 The valve controller 102 is a digital valve controller. The valve controller 102 controls the supply of pressurized control fluid (e.g., pressurized pneumatic medium, such as pressurized air) to the control fluid port 112 of the pneumatic actuator 108, which in turn controls the position of the flow control member 110 of the control valve 106. Figure 1 In the example shown, the valve controller 102 includes an example control fluid inlet 114, an example pressure regulator 116, an example first I / P converter 118, an example second I / P converter 120, an example first relay valve 122, an example second relay valve 124, an example control fluid port 126, an example control fluid exhaust device 128 and an example control circuit device 130. Figure 1 The control circuit device 130 includes an exemplary first pressure sensor 132 , an exemplary second pressure sensor 134 , an exemplary processor 136 , and an exemplary memory 138 .

[0033] Figure 1 The control fluid inlet 114 is in fluid communication with an example control fluid source 140 located externally and / or remotely from the valve controller 102. The control fluid inlet 114 is also in fluid communication with the pressure regulator 116 and the first relay valve 122 of the valve controller 102. Figure 1As shown, the control fluid inlet 114 is operably positioned between the control fluid source 140 on the one hand and the pressure regulator 116 and the first relay valve 122 on the other hand. Fluid communication to the control fluid inlet 114 and / or fluid communication from the control fluid inlet 114 can be achieved by one or more fluid passages formed by one or more conduits, channels and / or tubes. The control fluid inlet 114 receives pressurized control fluid (e.g., pressurized pneumatic medium, such as pressurized air) from the control fluid source 140. The pressurized control fluid received at the control fluid inlet 114 is transferred and / or delivered to the pressure regulator 116 and the first relay valve 122 of the valve controller 102.

[0034] Figure 1 The pressure regulator 116 is in fluid communication with the control fluid inlet 114 of the valve controller 102, the first I / P converter 118, and the second I / P converter 120. Figure 1 As shown, the pressure regulator 116 is operably positioned between the control fluid inlet 114 on the one hand and the first I / P converter 118 and the second I / P converter 120 on the other hand. Fluid communication to and / or from the pressure regulator 116 can be achieved through one or more fluid passages formed by one or more conduits, channels and / or tubes. The pressure regulator 116 modifies (e.g., reduces) the pressure of the pressurized control fluid received at the control fluid inlet 114 (e.g., from the control fluid source 140) to a desired output pressure for delivery to the first I / P converter 118 and the second I / P converter 120. The pressurized control fluid exiting the pressure regulator 116 and / or delivered to the first I / P converter 118 and the second I / P converter 120 accordingly has a changed (e.g., reduced) pressure relative to the pressure of the pressurized control fluid received at the control fluid inlet 114.

[0035] Figure 1 The first I / P converter 118 is in fluid communication with the pressure regulator 116 of the valve controller 102 and the first relay valve 122. Figure 1As shown, the first I / P converter 118 is operably positioned between the pressure regulator 116 and the first relay valve 122. Fluid communication to and / or from the first I / P converter 118 can be achieved via one or more fluid passages formed by one or more conduits, channels, and / or tubes. In some examples, in response to receiving a pulse drive signal (e.g., an exemplary first pulse drive signal 144 described below) from the control circuit device 130, the first I / P converter 118 converts and / or transforms the pressurized control fluid received at the first I / P converter 118 (e.g., from the pressure regulator 116) into a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air) generated and / or output by the first I / P converter 118. The pulsed pressurized control fluid generated and / or output by the first I / P converter 118 is transmitted and / or delivered to the first relay valve 122 of the valve controller 102.

[0036] Figure 1 The second I / P converter 120 is in fluid communication with the pressure regulator 116 of the valve controller 102 and the second relay valve 124. Figure 1 As shown, the second I / P converter 120 is operably positioned between the pressure regulator 116 and the second relay valve 124. Fluid communication to and / or from the second I / P converter 120 can be achieved via one or more fluid passages formed by one or more conduits, channels, and / or tubes. In some examples, in response to receiving a pulse drive signal (e.g., an exemplary second pulse drive signal 146 described below) from the control circuit device 130, the second I / P converter 120 converts and / or transforms the pressurized control fluid received at the second I / P converter 120 (e.g., from the pressure regulator 116) into a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air) generated and / or output by the second I / P converter 120. The pulsed pressurized control fluid generated and / or output by the second I / P converter 120 is transmitted and / or delivered to the second relay valve 124 of the valve controller 102.

[0037] Figure 1 The first relay valve 122 is in fluid communication with the control fluid inlet 114 of the valve controller 102, the first I / P converter 118, the second relay valve 124, and the control fluid port 126. Figure 1As shown, the first relay valve 122 is operably positioned between the control fluid inlet 114 on the one hand and the second relay valve 124 and the control fluid port 126 on the other hand, wherein the first relay valve 122 is fluidly controlled by the output of the pressurized control fluid from the first I / P converter 118. Fluid communication to and / or from the first relay valve 122 is achieved by one or more fluid passages formed by one or more conduits, channels and / or tubes.

[0038] Actuation of the first relay valve 122 is controlled (e.g., between a closed position and an open position) based on the pressurized control fluid (e.g., pulsed pressurized control fluid) output by the first I / P converter 118 to the first relay valve 122. In some examples, the first relay valve 122 is actuated to and / or maintained in the closed position when the pressurized control fluid output by the first I / P converter 118 is relatively high (e.g., above a threshold pressure), and the first relay valve 122 is actuated to and / or maintained in the open position when the pressurized control fluid output by the first I / P converter 118 is relatively low (e.g., below a threshold pressure). In other examples, the first relay valve 122 is actuated to and / or maintained in a closed position when the pressurized control fluid output by the first I / P converter 118 is relatively low (e.g., below a threshold pressure), and the first relay valve 122 is actuated to and / or maintained in an open position when the pressurized control fluid output by the first I / P converter 118 is relatively high (e.g., above a threshold pressure).

[0039] When the first relay valve 122 is in the closed position, pressurized control fluid received at the first relay valve 122 from the control fluid inlet 114 of the valve controller 102 is prevented from passing and / or traveling through the first relay valve 122. When the first relay valve 122 is actuated to the open position (e.g., from the closed position), pressurized control fluid received at the first relay valve 122 from the control fluid inlet 114 of the valve controller 102 passes and / or travels through the first relay valve 122 to the second relay valve 124 and / or the control fluid port 126 of the valve controller 102. When the first relay valve 122 is in the open position and the second relay valve 124 is in the closed position, the pressurized control fluid passing and / or traveling through the first relay valve 122 is forced toward, into, and / or through the control fluid port 126 of the valve controller 102. Pressurized control fluid entering and / or passing through the control fluid port 126 of the valve controller 102 from the first relay valve 122 is forced toward, into and / or through the control fluid port 112 of the pneumatic actuator 108, which causes the flow control member 110 of the control valve 106 to move in a first direction and / or causes the pressure in the fluid chamber of the pneumatic actuator 108 to increase.

[0040] Figure 1The second relay valve 124 is in fluid communication with the second I / P converter 120 of the valve controller 102, the first relay valve 122, the control fluid port 126, and the control fluid exhaust device 128. Figure 1 As shown, the second relay valve 124 is operably positioned between the first relay valve 122 and the control fluid port 126 on the one hand and the control fluid exhaust 128 on the other hand, and the second relay valve 124 is fluidly controlled by the output of the pressurized control fluid from the second I / P converter 120. Fluid communication to and / or from the second relay valve 124 can be achieved via one or more fluid passages formed by one or more conduits, channels and / or tubes.

[0041] Actuation of the second relay valve 124 is controlled (e.g., between a closed position and an open position) based on the pressurized control fluid (e.g., pulsed pressurized control fluid) output by the second I / P converter 120 to the second relay valve 124. In some examples, the second relay valve 124 is actuated to and / or maintained in the closed position when the pressurized control fluid output by the second I / P converter 120 is relatively high (e.g., above a threshold pressure), and the second relay valve 124 is actuated to and / or maintained in the open position when the pressurized control fluid output by the second I / P converter 120 is relatively low (e.g., below a threshold pressure). In other examples, the second relay valve 124 is actuated to and / or maintained in a closed position when the pressurized control fluid output by the second I / P converter 120 is relatively low (e.g., below a threshold pressure), and the second relay valve 124 is actuated to and / or maintained in an open position when the pressurized control fluid output by the second I / P converter 120 is relatively high (e.g., above a threshold pressure).

[0042] When the second relay valve 124 is in the closed position, pressurized control fluid received at the second relay valve 124 from the first relay valve 122 and the control fluid port 126 of the valve controller 102 is prevented from passing and / or traveling through the second relay valve 124. When the second relay valve 124 is actuated to an open position (e.g., from a closed position), pressurized control fluid received at the second relay valve 124 from the first relay valve 122 and the control fluid port 126 of the valve controller 102 passes and / or travels through the second relay valve 124 to the control fluid exhaust 128 of the valve controller 102. When the second relay valve 124 is in the open position and the first relay valve 122 is in the closed position, the pressurized control fluid travels, passes and / or returns from the control fluid port 112 of the pneumatic actuator 108, through the control fluid port 126 of the valve controller 102, then through the second relay valve 124 of the valve controller 102, and then toward, into and / or through the control fluid exhaust 128 of the valve controller 102. The pressurized control fluid entering and / or passing through the control fluid exhaust 128 from the second relay valve 124 is exhausted to atmosphere. The return of the pressurized control fluid from the control fluid port 126 of the control fluid valve controller 102 of the pneumatic actuator 108, combined with the subsequent exhaust of the returned pressurized control fluid via the control fluid exhaust 128 of the valve controller 102, causes the flow control member 110 of the control valve 106 to move in a second direction opposite to the first direction, and / or causes the pressure within the fluid chamber of the pneumatic actuator 108 to decrease.

[0043] Figure 1 The control fluid port 126 of the valve controller 102 is in fluid communication with the first relay valve 122 and the second relay valve 124 of the valve controller 102. The control fluid port 126 of the valve controller 102 is also in fluid communication with the control fluid port 112 of the pneumatic actuator 108. Figure 1 As shown, the control fluid port 126 is operably positioned between the first relay valve 122 and the second relay valve 124 of the valve controller 102 on the one hand and the control fluid port 112 of the pneumatic actuator 108 on the other hand. Fluid communication to the control fluid port 126 and / or fluid communication from the control fluid port 126 can be achieved via one or more fluid passages formed by one or more conduits, channels and / or tubes. The control fluid port 126 of the valve controller 102 facilitates the supply of pressurized control fluid from the first relay valve 122 and / or more generally from the valve controller 102 to the control fluid port 112 of the pneumatic actuator 108. The control fluid port 126 of the valve controller 102 also facilitates the return of pressurized control fluid from the control fluid port 112 of the pneumatic actuator 108 to the second relay valve 124, and / or more generally to the valve controller 102.

[0044] Figure 1The control fluid discharge device 128 is in fluid communication with the second relay valve 124 of the valve controller 102. Figure 1 As shown, the control fluid exhaust device 128 is operably positioned between the second relay valve 124 and the atmosphere outside the valve controller 102. Fluid communication to and / or from the control fluid exhaust device 128 can be achieved via one or more fluid passages formed by one or more conduits, channels, and / or tubes. The control fluid exhaust device 128 facilitates exhausting the pressurized control fluid from the second relay valve 124 and / or more generally from the valve controller 102 to the atmosphere.

[0045] exist Figure 1 In the example shown, the control circuit device 130 includes a first pressure sensor 132, a second pressure sensor 134, a processor 136, and a memory 138. In other examples, the control circuit device 130 may include Figure 1 Those different and / or additional components shown. For example, the control circuit device 130 may include a position sensor configured to receive position data from a position indicator of the pneumatic actuator 108. As another example, the control circuit device 130 may include a user interface having one or more input devices (e.g., buttons, switches, keypads, audio sensors, and / or liquid crystal displays with touch screens) that allow a user to input data and commands into the processor 136 and / or one or more output devices (e.g., light emitting diodes, speakers, and / or liquid crystal displays) for presenting visual, auditory, textual, and / or graphical information. As another example, the control circuit device 130 may include a network communication interface having one or more transmitters, receivers, and / or transceivers that facilitate the exchange of signals, commands, data, and / or information between the valve controller 102 and one or more external devices (e.g., process control field devices, servers, desktop computers, laptop computers, tablet computers, smart phones, etc.) over a network.

[0046] Figure 1 The first pressure sensor 132 senses and / or measures the pressure of the pressurized control fluid supplied from the control fluid inlet 114 of the valve controller 102 (e.g., the pressure of the pressurized control fluid between the control fluid inlet 114 and the first relay valve 122). Supply pressure data obtained from and / or provided by the first pressure sensor 132 may be stored in Figure 1138 of the controller 102. In some examples, the processor 136 accesses and / or obtains the supply pressure data from the memory 138. In other examples, the processor 136 instead accesses, obtains, and / or receives the supply pressure data directly from the first pressure sensor 132. In some examples, the processor 136 accesses, obtains, and / or receives the supply pressure data related to calculating one or more pneumatic volumes used when pulsating the first relay valve 122 of the valve controller 102, for moving the flow control member 110 of the control valve 106 in the first direction, and / or for increasing the pressure within the fluid chamber of the pneumatic actuator 108, as further described below.

[0047] Figure 1 The second pressure sensor 134 senses and / or measures the pressure of the pressurized control fluid at the control fluid port 126 of the valve controller 102 (e.g., the pressure of the pressurized control fluid between the first relay valve 122 and the second relay valve 124). The port pressure data obtained from and / or provided by the second pressure sensor 134 may be stored in Figure 1 138 of the controller 102. In some examples, the processor 136 accesses and / or obtains the port pressure data from the memory 138. In other examples, the processor 136 instead accesses, obtains, and / or receives the port pressure data directly from the second pressure sensor 134. In some examples, the processor 136 accesses, obtains, and / or receives the port pressure data related to calculating one or more pneumatic volumes, which are used when the second relay valve 124 of the pulsating valve controller 102 is used to move the flow control member 110 of the control valve 106 in a second direction opposite to the first direction, and / or to reduce the pressure within the fluid chamber of the pneumatic actuator 108, as further described below.

[0048] Figure 1The processor 136 of the present invention may be implemented by any type and / or any number of processors, microprocessors, controllers, microcontrollers, circuits, and / or other electrical components. The processor 136 controls and / or manages one or more operations of the first I / P converter 118 and / or the second I / P converter 120 based on an example input signal 142 received, accessed, and / or obtained by the control circuit device 130 of the valve controller 102. The input signal 142 identifies a position set point (e.g., a desired position) of the flow control member 110 of the control valve 106, which may be achieved based on one or more operations of the valve controller 102, the pneumatic actuator 108, and / or the control valve 106. In some examples, the input signal 142 may indicate to the processor 136 that the valve controller 102 is to operate the pneumatic actuator 108 in a manner that moves the flow control member 110 of the control valve 106 in a first direction. In other examples, the input signal 142 may indicate to the processor 136 that the valve controller 102 is to operate the pneumatic actuator 108 in a manner that moves the flow control member 110 of the control valve 106 in a second direction that is opposite to the first direction. In other examples, the input signal 142 may indicate to the processor 136 that the valve controller 102 is to operate the pneumatic actuator 108 in a manner that maintains the flow control member 110 of the control valve 106 in its current position. In other examples, the input signal 142 may indicate to the processor 136 that the valve controller 102 is to increase the pressure within the fluid chamber of the pneumatic actuator 108. In other examples, the input signal 142 may indicate to the processor 136 that the valve controller 102 is to decrease the pressure within the fluid chamber of the pneumatic actuator 108.

[0049] In response to an input signal 142 indicating that the valve controller 102 is to operate the pneumatic actuator 108 in a manner that moves the flow control member 110 of the control valve 106 in a first direction, the processor 136 generates an exemplary first pulse drive signal 144 that commands and / or instructs the first I / P converter 118 of the valve controller 102 to generate and / or output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air). The pulsed pressurized control fluid generated and / or output by the first I / P converter 118 is transmitted and / or delivered to the first relay valve 122 of the valve controller 102, which in turn pulses the first relay valve 122 between a closed position and an open position. When the first relay valve 122 is in the open position during pulsation of the first relay valve 122, pressurized control fluid received at the first relay valve 122 from the control fluid inlet 114 of the valve controller 102 passes and / or travels through the first relay valve 122 toward, into, and / or through the control fluid port 126 of the valve controller 102. The pressurized control fluid entering and / or through the control fluid port 126 of the valve controller 102 from the first relay valve 122 passes and / or travels toward, into, and / or through the control fluid port 112 of the pneumatic actuator 108, which causes the flow control member 110 of the control valve 106 to move in the first direction and / or causes the pressure within the fluid chamber of the pneumatic actuator 108 to increase.

[0050] Figure 2 Shown in Figure 1 An exemplary input signal 202 received at the processor 136 of the valve controller 102, and an exemplary input signal 202 received at the processor 136 of the valve controller 102 in response to the input signal 202 Figure 1 The exemplary pulse drive signal 204 generated by the processor 136 of the valve controller 102 and the pulse drive signal 204 in response to the Figure 1 FIG. 2 is a graphical representation of an exemplary graph 206 of a position of a flow control member 110 of a control valve 106 . Figure 2 The input signal 202 is an example of the input signal 142 described above, where the input signal 142 indicates that the valve controller 102 is to operate the pneumatic actuator 108 in a manner that moves the flow control member 110 of the control valve 106 in a first direction. Figure 2 As shown, the input signal 202 identifies an example position set point 208 of the flow control member 110 of the control valve 106 , with the position set point 208 being expressed as a percentage of travel of the flow control member 110 .

[0051] Figure 2 The pulse drive signal 204 is an example of the first pulse drive signal 144 described above. Figure 2 In the example shown, the pulse drive signal 204 includes pulses of different durations. In other examples, the pulses of the pulse drive signal may have uniform durations. Figure 2As shown in curve 206 of FIG. 2 , the flow control member 110 of the control valve 106 begins to move toward the position set point 208 identified by the input signal 202 (e.g., in a first direction) in response to the initiation of the first pulse of the pulsed drive signal 204. Figure 2 As further shown by curve 206 of , the flow control component 110 of the control valve 106 reaches a position set point 208 identified by the input signal 202 in response to completion of the last pulse of the pulsed drive signal 204 .

[0052] Figure 3 A graphical representation of an example I / P converter state diagram 302 , an example relay valve state diagram 304 , and an example curve 306 of actuator port pressure is shown. Figure 3 The I / P converter state diagram 302 shows Figure 1 The first I / P converter 118 responds to the first I / P converter 118 from Figure 1 The processor 136 receives Figure 1 An example pulse operation 308 of the first pulse drive signal 144 is shown. Figure 3 The relay valve state diagram 304 shows the response to Figure 1 The pulse operation 308 of the first I / P converter 118 Figure 1 FIG. 3 is an exemplary pulse operation 310 of the first relay valve 122 . Figure 3 Curve 306 represents the response to Figure 1 The pulse operation 310 of the first relay valve 122 increases Figure 1 1. An example of a pressure 312 in the control fluid port 112 of the pneumatic actuator 108.

[0053] exist Figure 3 In the example shown, the pulse operation 308 of the first I / P converter 118 includes an example first pulse 314 initiated at an example first time 316, an example second pulse 318 initiated as an example second time 320, and an example third pulse 322 initiated at an example third time 324. Figure 3 As shown, the pulse operation 308 of the first I / P converter 118 includes a total of three pulses (e.g., a first pulse 314, a second pulse 318, and a third pulse 322). In other examples, the pulse operation 308 of the first I / P converter 118 may include a different total number of pulses (e.g., 2, 4, 5, 10, 20, etc.). Figure 3 As further shown, each pulse of the pulse operation 308 of the first I / P converter 118 has a different duration. In other examples, two or more of the pulses of the pulse operation 308 of the first I / P converter 118 may have uniform (eg, the same) duration.

[0054] exist Figure 3In the illustrated example, the pulse operation 310 of the first relay valve 122 includes an example first pulse 326 corresponding to the first pulse 314 of the pulse operation 308 of the first I / P converter 118, an example second pulse 328 corresponding to the second pulse 318 of the pulse operation 308 of the first I / P converter 118, and an example third pulse 330 corresponding to the third pulse 322 of the pulse operation 308 of the first I / P converter 118. In addition, the increased pressure 312 of the control fluid port 112 of the pneumatic actuator 108 includes an example first pressure increase 332 corresponding to the first pulse 326 of the pulse operation 310 of the first relay valve 122, an example second pressure increase 334 corresponding to the second pulse 328 of the pulse operation 310 of the first relay valve 122, and an example third pressure increase 336 corresponding to the third pulse 330 of the pulse operation 310 of the first relay valve 122.

[0055] Back to Figure 1 In the illustrated example, in response to an input signal 142 indicating that the valve controller 102 is to operate the pneumatic actuator 108 in a manner that moves the flow control member 110 of the control valve 106 in a second direction opposite to the first direction, the processor 136 generates an exemplary second pulse drive signal 146 that commands and / or instructs the second I / P converter 120 of the valve controller 102 to generate and / or output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air). The pulsed pressurized control fluid generated and / or output by the second I / P converter 120 is transmitted and / or delivered to the second relay valve 124 of the valve controller 102, which in turn pulses the second relay valve 124 between a closed position and an open position. When the second relay valve 124 is in the open position during pulsation of the second relay valve 124, the pressurized control fluid travels, passes and / or returns from the control fluid port 112 of the pneumatic actuator 108, through the control fluid port 126 of the valve controller 102, then through the second relay valve 124 of the valve controller 102, and then toward, into and / or through the control fluid exhaust 128 of the valve controller 102. The pressurized control fluid entering and / or passing through the control fluid exhaust 128 from the second relay valve 124 is exhausted to atmosphere. The return of the pressurized control fluid from the control fluid port 112 of the pneumatic actuator 108 to the control fluid port 126 of the valve controller 102, combined with the subsequent exhaust of the returned pressurized control fluid via the control fluid exhaust 128 of the valve controller 102, causes the flow control member 110 of the control valve 106 to move in a second direction opposite to the first direction, and / or causes the pressure within the fluid chamber of the pneumatic actuator 108 to decrease.

[0056] Figure 4 Shown in Figure 1An exemplary input signal 402 received at the processor 136 of the valve controller 102, and an ... Figure 1 The exemplary pulse drive signal 404 generated by the processor 136 of the valve controller 102 and the pulse drive signal 404 in response to the Figure 1 4. Another graphical representation of an exemplary curve 406 of the position of the flow control member 110 of the control valve 106. Figure 4 The input signal 402 is an example of the input signal 142 described above, wherein the input signal 142 indicates that the valve controller 102 is to operate the pneumatic actuator 108 in a manner that moves the flow control member 110 of the control valve 106 in a second direction opposite to the first direction. Figure 4 As shown, the input signal 402 identifies an example position set point 408 of the flow control member 110 of the control valve 106 , with the position set point 408 being expressed as a percentage of travel of the flow control member 110 .

[0057] Figure 4 The pulse drive signal 404 is an example of the second pulse drive signal 146 described above. Figure 4 In the example shown, the pulse drive signal 404 includes pulses of different durations. In other examples, the pulses of the pulse drive signal may have uniform durations. Figure 4 As shown in curve 406 of FIG. 4 , the flow control member 110 of the control valve 106 begins to move toward the position set point 408 identified by the input signal 402 (e.g., in the second direction) in response to the initiation of the first pulse of the pulsed drive signal 404. Figure 4 As further shown by curve 406 of , the flow control component 110 of the control valve 106 reaches the position set point 408 indicated by the input signal 402 in response to the completion of the last pulse of the pulsed drive signal 404 .

[0058] Figure 5 Another graphical representation of an example I / P converter state diagram 502 , an example relay valve state diagram 504 , and an example graph 506 of actuator port pressure is shown. Figure 5 The I / P converter state diagram 502 shows Figure 1 The second I / P converter 120 is responsive to the second I / P converter 120 from Figure 1 The processor 136 receives Figure 1 508 of an exemplary pulse operation of the second pulse drive signal 146 . Figure 5 The relay valve state diagram 504 shows the response to Figure 1 The pulse operation 508 of the second I / P converter 120 Figure 1 FIG. 5 is an exemplary pulse operation 510 of the second relay valve 124 . Figure 5 Curve 506 represents the response to Figure 1 The pulse operation 510 of the second relay valve 124 is reduced Figure 1 5 is an example of a pressure 512 in the control fluid port 112 of the pneumatic actuator 108 .

[0059] exist Figure 5 In the example shown, the pulse operation 508 of the second I / P converter 120 includes an example first pulse 514 initiated at an example first time 516, an example second pulse 518 initiated as an example second time 520, and an example third pulse 522 initiated at an example third time 524. Figure 5 As shown, the pulse operation 508 of the second I / P converter 120 includes a total of three pulses (e.g., a first pulse 514, a second pulse 518, and a third pulse 522). In other examples, the pulse operation 508 of the second I / P converter 120 may include a different total number of pulses (e.g., 2, 4, 5, 10, 20, etc.). Figure 5 As further shown, each pulse of the pulse operation 508 of the second I / P converter 120 has a different duration. In other examples, two or more of the pulses of the pulse operation 508 of the second I / P converter 120 may have uniform (eg, the same) duration.

[0060] exist Figure 5 In the illustrated example, the pulse operation 510 of the second relay valve 124 includes an example first pulse 526 corresponding to the first pulse 514 of the pulse operation 508 of the second I / P converter 120, an example second pulse 528 corresponding to the second pulse 518 of the pulse operation 508 of the second I / P converter 120, and an example third pulse 530 corresponding to the third pulse 522 of the pulse operation 508 of the second I / P converter 120. In addition, the pressure reduction 512 of the control fluid port 112 of the pneumatic actuator 108 includes an example first pressure reduction 532 corresponding to the first pulse 526 of the pulse operation 510 of the second relay valve 124, an example second pressure reduction 534 corresponding to the second pulse 528 of the pulse operation 510 of the second relay valve 124, and an example third pressure reduction 536 corresponding to the third pulse 530 of the pulse operation 510 of the second relay valve 124.

[0061] Return to Figure 1In the example shown, the processor 136 calculates a pneumatic volume usage (e.g., a "pneumatic supply volume usage") associated with, based on, and / or corresponding to a pulse of the first relay valve 122. The pneumatic supply volume usage calculated by the processor 136 represents and / or corresponds to a pneumatic volume supplied during movement of the flow control member 110 of the control valve 106 in a first direction. In some examples, the processor 136 calculates the pneumatic supply volume usage on a pulse-by-pulse basis for a given movement of the flow control member 110 of the control valve 106 in the first direction. For example, the processor 136 can calculate the pneumatic supply volume usage for a single pneumatic pulse of the pneumatic medium by: (1) calculating (e.g., based on the ideal gas law) a mass change of the pneumatic medium during the pneumatic pulse; and (2) converting the calculated mass change into a calculated volume change (e.g., based on the density of the pneumatic medium), as generally shown by the following Equations 1-4.

[0062] Equation 1:

[0063] PV=mRT

[0064] Equation 1 is the ideal gas law. In equation 1, variable P represents pressure, variable V represents volume, variable M represents mass, variable R represents an ideal gas constant, and variable T represents temperature.

[0065] Equation 2:

[0066]

[0067] In Equation 2, the variable t represents time. In the case where V, R, and T are known and constant (e.g., unchanged) (e.g., applicable to Figure 1 1), Equation 2 is derived from Equation 1. In this regard, V represents a predetermined volume for a pneumatic pulse (e.g., determined based on a known valve size and a known flow capacity), which predetermined volume is known to and / or accessible by the processor 136 (e.g., from a memory 138 of the valve controller 102), which is coupled to the processor 136 that calculates the pneumatic volume usage for the pneumatic pulse. The predetermined values ​​for R and T are also known to and / or accessible by the processor 136 (e.g., from a memory 138 of the valve controller 102), which is coupled to the processor 136 that calculates the pneumatic volume usage for the pneumatic pulse.

[0068] Equation 3:

[0069]

[0070] Equation 3 is derived from Equation 2 by solving Equation 2 for (Δm / Δt). In Equation 3, (m2-m1) corresponds to the mass change of the pneumatic medium during the duration of the pneumatic pulse, where m1 is the mass of the pneumatic medium at the beginning of the duration of the pneumatic pulse, and m2 is the mass of the pneumatic medium at the end of the duration of the pneumatic pulse. In Equation 3, (P2-P1) corresponds to the pressure change of the pneumatic medium during the duration of the pneumatic pulse, where P1 is the supply pressure of the pneumatic medium at the beginning of the duration of the pneumatic pulse (e.g., as given by Figure 1 ), and P2 is the supply pressure of the pneumatic medium at the completion of the duration of the pneumatic pulse (e.g., as determined by Figure 1 (as sensed and / or measured by the first pressure sensor 132 ).

[0071] Equation 4:

[0072] (V2-V1)=(m2-m1) / D

[0073] Equation 4 converts the mass change (m2-m1) of the pneumatic medium during the duration of the pneumatic pulse (e.g., (m2-m1), as calculated by Equation 3 above) to the volume change (V2-V1) of the pneumatic medium during the duration of the pulse. In Equation 4, D represents a predetermined density of the pneumatic medium known and / or accessible (e.g., from the memory 138 of the valve controller 102) to the processor 136 associated with the processor 136 that calculates the pneumatic volume usage of the pneumatic pulse. The volume change (V2-V1) calculated by Equation 4 represents the pneumatic volume usage (e.g., the pneumatic supply volume usage) of a single pneumatic pulse.

[0074] In some examples, the processor 136 calculates the pneumatic supply volume usage for a given movement of the flow control member 110 of the control valve 106 by summing together the pneumatic supply volume usage calculated by the processor 136 for the individual ones of the pulses that occurred during the given movement. In some examples, the processor 136 calculates the cumulative pneumatic supply volume usage for a series of given movements of the flow control member 110 of the control valve 106 in a first direction (e.g., individual movements that occur and / or repeat over a period of time) by summing together the pneumatic supply volume usage calculated by the processor 136 for the individual ones of the given movement.

[0075] The processor 136 of the valve controller 102 additionally or alternatively calculates a pneumatic volume usage (e.g., a “pneumatic exhaust volume usage”) associated with, based on, and / or corresponding to the pulsation of the second relay valve 124. The pneumatic exhaust volume usage calculated by the processor 136 represents and / or corresponds to the pneumatic volume exhausted during movement of the flow control member 110 of the control valve 106 in the second direction. In some examples, the processor 136 calculates the pneumatic exhaust volume usage on a pulse-by-pulse basis for a given movement of the flow control member 110 of the control valve 106 in the second direction. Figure 1 The processor 136 can calculate the pulse-by-pulse pneumatic displacement volume usage using equations 1-4 above, modifying the equation so that the pressure difference (P2-P1) for a given pulse is based on Figure 1 The second pressure sensor 134 senses and / or measures the port pressure data, rather than based on Figure 1 The first pressure sensor 132 senses and / or measures supply pressure data.

[0076] In some examples, the processor 136 calculates the pneumatic discharge volume usage for a given movement of the flow control member 110 of the control valve 106 by summing together the pneumatic discharge volume usage calculated by the processor 136 for the individual ones of the pulses that occurred during the given movement. In some examples, the processor 136 calculates the cumulative pneumatic discharge volume usage for a series of given movements of the flow control member 110 of the control valve 106 in the second direction (e.g., individual movements that occur and / or repeat over a period of time) by summing together the pneumatic discharge volume usage calculated by the processor 136 for the individual ones of the given movement.

[0077] Figure 1 The memory 138 may be implemented by any type and / or any number of storage devices, such as storage drives, flash memory, read-only memory (ROM), random access memory (RAM), cache, and / or any other physical storage medium in which information is stored for any duration (e.g., for an extended period of time, permanently, for brief instances, for temporary buffering, and / or for caching of information). Figure 1 The information in memory 138 may be stored in any file and / or data structure format, organizational scheme, and / or arrangement. Figure 1 The memory 138 may be accessed by the processor 136 and / or more generally may be accessed by Figure 1 The control circuit device 130 of the valve controller 102 is accessed.

[0078] In some examples, Figure 1 The memory 138 stores Figure 1The first pressure sensor 132 senses and / or measures the supply pressure data. In some examples, Figure 1 The memory 138 stores Figure 1 The second pressure sensor 134 senses and / or measures the port pressure data. In some examples, Figure 1 The memory 138 stores one or more input signals (e.g., Figure 1 In some examples, Figure 1 The memory 138 stores one or more pulse drive signals (e.g., Figure 1 In some examples, Figure 1 The memory 138 stores pulse volume data corresponding to one or more predetermined volumes of one or more pulses of pressurized control fluid to be output from the first I / P converter 118 and / or the second I / P converter 120 of the valve controller 102 .

[0079] In some examples, Figure 1 Memory 138 stores one or more algorithms and / or equations to be used by processor 136 and / or more generally by control circuitry 130 of valve controller 102 to calculate pneumatic volume usage and / or consumption associated with first relay valve 122 of pulsating valve controller 102, associated with moving control valve 106 in a first direction, and / or associated with increasing pressure within a fluid chamber of pneumatic actuator 108. In some examples, Figure 1 Memory 138 stores one or more algorithms and / or equations to be used by processor 136 and / or more generally by control circuitry 130 of valve controller 102 to calculate pneumatic volume usage and / or consumption associated with second relay valve 124 of pulsating valve controller 102, associated with moving control valve 106 in a second direction opposite to the first direction, and / or associated with reducing pressure within a fluid chamber of pneumatic actuator 108. In some examples, Figure 1 The memory 138 stores one or more algorithms and / or equations to be used by the processor 136 and / or more generally by the control circuitry 130 of the valve controller 102 to calculate total and / or aggregate pneumatic volume usage and / or consumption over time.

[0080] In some examples, Figure 1Memory 138 stores pneumatic volume usage and / or consumption data calculated by processor 136 and / or, more generally, by control circuitry 130 of valve controller 102 associated with pulsing first relay valve 122 of valve controller 102, associated with moving control valve 106 in a first direction, and / or associated with increasing pressure within a fluid chamber of pneumatic actuator 108. In some examples, Figure 1 Memory 138 stores pneumatic volume usage and / or consumption data calculated by processor 136 and / or more generally by control circuitry 130 of valve controller 102, associated with pulsating second relay valve 124 of valve controller 102, associated with moving control valve 106 in a second direction opposite to the first direction, and / or associated with reducing pressure within a fluid chamber of pneumatic actuator 108. In some examples, Figure 1 The memory 138 stores total and / or aggregated pneumatic volume usage and / or consumption data calculated over time by the processor 136 and / or more generally by the control circuitry 130 of the valve controller 102 .

[0081] Although Figure 1 An exemplary manner of implementing an exemplary valve controller 102 is shown in FIG. Figure 1 One or more elements, processes and / or devices shown in the may be combined, divided, rearranged, omitted, eliminated and / or implemented in any other manner. Figure 1 The example pressure regulator 116, the example first I / P converter 118, the example second I / P converter 120, the example first relay valve 122, the example second relay valve 124, the example first pressure sensor 132, the example second pressure sensor 134, the example processor 136, the example memory 138, and / or more generally the example valve controller 102 may be implemented by hardware, software, firmware, and / or any combination of hardware, software, and / or firmware. Thus, for example, Figure 1 Any of the example pressure regulator 116, the example first I / P converter 118, the example second I / P converter 120, the example first relay valve 122, the example second relay valve 124, the example first pressure sensor 132, the example second pressure sensor 134, the example processor 136, the example memory 138, and / or more generally the example valve controller 102 can be implemented by one or more analog or digital circuits, logic circuits, programmable processors, programmable controllers, graphics processing units (GPUs), digital signal processors (DSPs), application specific integrated circuits (ASICs), programmable logic devices (PLDs), and / or field programmable logic devices (FPLDs). When any apparatus or system claim of this patent is read to cover pure software and / or firmware implementations, Figure 1At least one of the exemplary pressure regulator 116, the exemplary first I / P converter 118, the exemplary second I / P converter 120, the exemplary first relay valve 122, the exemplary second relay valve 124, the exemplary first pressure sensor 132, the exemplary second pressure sensor 134, the exemplary processor 136, and / or the exemplary memory 138 of the valve controller 102 is expressly defined herein as including a non-transitory computer-readable storage device or storage disk, such as a memory, a digital versatile disk (DVD), a compact disk (CD), a Blu-ray disk, etc., including software and / or firmware. In addition, Figure 1 One or more components, processes and / or devices of the exemplary valve controller 102 as Figure 1 The elements, processes and / or devices shown may be supplemented or substituted, and / or more than one of any or all of the elements, processes and devices shown may be included.

[0082] Figure 6 is a block diagram of an example process control system 600 including an example valve controller 602 constructed in accordance with the teachings of the present invention for quantifying pneumatic volume usage. Figure 6 The valve controller 602 is the above Figure 1 A modification of the valve controller 102 is implemented. Figure 6 In the illustrated example, the process control system 600 also includes an example control valve assembly 604 operably coupled to the valve controller 602 . Figure 6 The control valve assembly 604 includes the above Figure 1 The control valve 106 also includes an example pneumatic actuator 606, which is the above-mentioned Figure 1 A modified embodiment of the pneumatic actuator 108 .

[0083] Figure 6 The pneumatic actuator 606 is a double-acting pneumatic actuator that can be implemented by and / or as any linear or rotary actuator (e.g., a piston actuator, a rotary vane actuator, a rotary rack and pinion actuator, a rotary scotch yoke actuator, etc.). Figure 6In the example shown, the pneumatic actuator 606 is operably coupled to the control valve 106, and more specifically, to the valve shaft of the control valve 106. The pneumatic actuator 606 includes an exemplary first control fluid port 608 in fluid communication with a first fluid chamber of the pneumatic actuator 606, and an exemplary second control fluid port 610 in fluid communication with a second fluid chamber of the pneumatic actuator 606. The pneumatic actuator 606 also includes an internal rod and / or piston. The first control fluid port 608 of the pneumatic actuator 606 receives a pressurized control fluid (e.g., a pressurized pneumatic medium, such as pressurized air) from the valve controller 602, which causes the rod and / or piston of the pneumatic actuator 606 to move in a first direction and / or causes the pressure in the first fluid chamber of the pneumatic actuator 606 to increase. The second control fluid port 610 of the pneumatic actuator 606 receives a pressurized control fluid (e.g., a pressurized pneumatic medium, such as pressurized air) from the valve controller 602, which causes the rod and / or piston of the pneumatic actuator 606 to move in a second direction opposite to the first direction and / or causes an increase in pressure within a second fluid chamber of the pneumatic actuator 606. The force and / or load generated by moving the rod and / or piston of the pneumatic actuator 606 is converted into a force and / or load on the valve shaft of the control valve 106, which causes the flow control member 110 of the control valve 106 to move between the first position and the second position (e.g., in the first direction or the second direction), as described above.

[0084] The operative coupling of the rod and / or piston of the pneumatic actuator 606 with the valve shaft and / or the flow control member 110 of the control valve 106 results in a correlation between the position of the rod and / or piston of the pneumatic actuator 606 and the position of the flow control member 110 of the control valve 106. Therefore, the position of the flow control member 110 of the control valve 106 can be determined based on the known and / or measured position of the rod and / or piston of the pneumatic actuator 606, and vice versa. In some examples, a position indicator can be operably coupled to the rod and / or piston of the pneumatic actuator 606, such that movement of the rod and / or piston causes corresponding movement of the position indicator. Based on the above correlation between the position of the rod and / or piston of the pneumatic actuator 606 and the position of the flow control member 110 of the control valve 106, the position indicator can provide an indication of the position of the rod and / or piston of the pneumatic actuator 606, and / or an indication of the position of the flow control member 110 of the control valve 106. Position data generated by the position indicator of the pneumatic actuator 606 may be transmitted to a position sensor of the valve controller 602 via a wired or wireless connection.

[0085] Figure 6The valve controller 602 is a digital valve controller. The valve controller 602 controls the supply of pressurized control fluid (e.g., pressurized pneumatic medium, such as pressurized air) to the first control fluid port 608 and the second control fluid port 610 of the pneumatic actuator 606, which in turn controls the position of the flow control member 110 of the control valve 106. Figure 6 In the example shown, the valve controller 602 includes the above Figure 1 The valve controller 102 includes a control fluid inlet 114, a pressure regulator 116, a first I / P converter 118, a second I / P converter 120, a first relay valve 122, a second relay valve 124, a control fluid port 126 (e.g., now a first control fluid port 126), a control fluid discharge device 128 and a control circuit device 130 (e.g., including a first pressure sensor 132, a second pressure sensor 134, a processor 136 and a memory 138), wherein some of the above components are modified as further described below. Figure 6 The valve controller 602 also includes an example third I / P converter 612 , an example fourth I / P converter 614 , an example third relay valve 616 , an example fourth relay valve 618 , an example second control fluid port 620 , and an example third pressure sensor.

[0086] Figure 6 The control fluid inlet 114 is in fluid communication with the control fluid source 140. The control fluid inlet 114 is also in fluid communication with the pressure regulator 116, the first relay valve 122, and the third relay valve 616 of the valve controller 602. Figure 6 As shown, the control fluid inlet 114 is operably positioned between each of the control fluid source 140 on the one hand and the pressure regulator 116, the first relay valve 122 and the third relay valve 616 on the other hand. Fluid communication to the control fluid inlet 114 and / or fluid communication from the control fluid inlet 114 can be achieved by one or more fluid channels formed by one or more conduits, channels and / or tubes. The control fluid inlet 114 receives pressurized control fluid (e.g., pressurized pneumatic medium, such as pressurized air) from the control fluid source 140. The pressurized control fluid received at the control fluid inlet 114 is transferred and / or delivered to the pressure regulator 116, the first relay valve 122 and the third relay valve 616 of the valve controller 602.

[0087] Figure 6 The pressure regulator 116 is in fluid communication with the control fluid inlet 114 of the valve controller 602, the first I / P converter 118, the second I / P converter 120, the third I / P converter 612, and the fourth I / P converter 614. Figure 6As shown, the pressure regulator 116 is operably positioned between the control fluid inlet 114 on the one hand and each of the first I / P converter 118, the second I / P converter 120, the third I / P converter 612, and the fourth I / P converter 614 on the other hand. Fluid communication to and / or from the pressure regulator 116 can be achieved through one or more fluid channels formed by one or more conduits, channels, and / or tubes. The pressure regulator 116 modifies (e.g., reduces) the pressure of the pressurized control fluid received at the control fluid inlet 114 (e.g., from the control fluid source 140) to a desired output pressure for delivery to the first I / P converter 118, the second I / P converter 120, the third I / P converter 612, and the fourth I / P converter 614. The pressurized control fluid exiting the pressure regulator 116 and / or delivered to the first I / P converter 118, the second I / P converter 120, the third I / P converter 612, and the fourth I / P converter 614, respectively, has a changed (e.g., reduced) pressure relative to the pressure of the pressurized control fluid received at the control fluid inlet 114.

[0088] Figure 6 The first I / P converter 118 and the second I / P converter 120 of the valve controller 602 are respectively combined with the above Figure 1 The first I / P converter 118 and the second I / P converter 120 of the valve controller 102 are constructed and / or configured in substantially the same manner as described above, and thus in combination with the above Figure 1 The first I / P converter 118 and the second I / P converter 120 of the valve controller 102 operate and / or function in substantially the same manner as described above.

[0089] Figure 6 The third I / P converter 612 is in fluid communication with the pressure regulator 116 of the valve controller 602 and the third relay valve 616. Figure 6As shown, the third I / P converter 612 is operably positioned between the pressure regulator 116 and the third relay valve 616. Fluid communication to and / or from the third I / P converter 612 can be achieved via one or more fluid passages formed by one or more conduits, channels and / or tubes. In some examples, in response to receiving a pulse drive signal (e.g., an exemplary third pulse drive signal 624 described below) from the control circuit device 130, the third I / P converter 612 converts and / or transforms the pressurized control fluid received at the third I / P converter 612 (e.g., from the pressure regulator 116) into a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air) generated and / or output by the third I / P converter 612. The pulsed pressurized control fluid generated and / or output by the third I / P converter 612 is transmitted and / or delivered to the third relay valve 616 of the valve controller 602.

[0090] Figure 6 The fourth I / P converter 614 is in fluid communication with the pressure regulator 116 of the valve controller 602 and the fourth relay valve 618. Figure 6 As shown, the fourth I / P converter 614 is operably positioned between the pressure regulator 116 and the fourth relay valve 618. Fluid communication to and / or from the fourth I / P converter 614 can be achieved via one or more fluid passages formed by one or more conduits, channels and / or tubes. In some examples, in response to receiving a pulse drive signal (e.g., the example fourth pulse drive signal 626 described below) from the control circuit device 130, the fourth I / P converter 614 converts and / or transforms the pressurized control fluid (e.g., from the pressure regulator 116) received at the fourth I / P converter 614 into a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air) generated and / or output by the fourth I / P converter 614. The pulsed pressurized control fluid generated and / or output by the fourth I / P converter 614 is transmitted and / or delivered to the fourth relay valve 618 of the valve controller 602.

[0091] Figure 6 The first relay valve 122 and the second relay valve 124 of the valve controller 602 are respectively combined with the above Figure 1 The first relay valve 122 and the second relay valve 124 of the valve controller 102 are constructed and / or configured in substantially the same manner as described above, and thus in combination with the above Figure 1 The first relay valve 122 and the second relay valve 124 of the valve controller 102 operate and / or function in substantially the same manner as described above.

[0092] Figure 6The third relay valve 616 is in fluid communication with the control fluid inlet 114 of the valve controller 602, the third I / P converter 612, the fourth relay valve 618 and the second control fluid port 620. Figure 6 As shown, the third relay valve 616 is operably positioned between the control fluid inlet 114 on the one hand and the fourth relay valve 618 and the second control fluid port 620 on the other hand, and the third relay valve 616 is fluidly controlled by the output of the pressurized control fluid from the third I / P converter 612. Fluid communication to and / or from the third relay valve 616 can be achieved via one or more fluid passages formed by one or more conduits, channels and / or tubes.

[0093] Actuation of the third relay valve 616 is controlled (e.g., between a closed position and an open position) based on the pressurized control fluid (e.g., pulsed pressurized control fluid) output by the third I / P converter 612 to the third relay valve 616. In some examples, the third relay valve 616 is actuated to and / or maintained in a closed position when the pressurized control fluid output by the third I / P converter 612 is relatively high (e.g., above a threshold pressure), and the third relay valve 616 is actuated to and / or maintained in an open position when the pressurized control fluid output by the third I / P converter 612 is relatively low (e.g., below a threshold pressure). In other examples, the third relay valve 616 is actuated to and / or maintained in a closed position when the pressurized control fluid output by the third I / P converter 612 is relatively low (e.g., below a threshold pressure), and the third relay valve 616 is actuated to and / or maintained in an open position when the pressurized control fluid output by the third I / P converter 612 is relatively high (e.g., above a threshold pressure).

[0094] When the third relay valve 616 is in the closed position, pressurized control fluid received at the third relay valve 616 from the control fluid inlet 114 of the valve controller 602 is prevented from passing and / or traveling through the third relay valve 616. When the third relay valve 616 is actuated to an open position (e.g., from a closed position), pressurized control fluid received at the third relay valve 616 from the control fluid inlet 114 of the valve controller 602 passes and / or travels through the third relay valve 616 to the fourth relay valve 618 and / or the second control fluid port 620 of the valve controller 602. When the third relay valve 616 is in the open position and the fourth relay valve 618 is in the closed position, the pressurized control fluid passing and / or traveling through the third relay valve 616 is forced toward, into, and / or through the second control fluid port 620 of the valve controller 602. The pressurized control fluid entering and / or passing through the second control fluid port 620 of the valve controller 602 from the third relay valve 616 is forced toward, into and / or through the second control fluid port 610 of the pneumatic actuator 606, which causes the flow control member 110 of the control valve 106 to move in a second direction and / or causes the pressure in the second fluid chamber of the pneumatic actuator 606 to increase.

[0095] Figure 6 The fourth relay valve 618 of the valve controller 602 is in fluid communication with the fourth I / P converter 614, the third relay valve 616, the second control fluid port 620 and the control fluid exhaust device 128. Figure 6 As shown, the fourth relay valve 618 is operably positioned between the third relay valve 616 and the second control fluid port 620 on the one hand and the control fluid exhaust device 128 on the other hand, wherein the fourth relay valve 618 is fluidly controlled by the output of the pressurized control fluid from the fourth I / P converter 614. Fluid communication to and / or from the fourth relay valve 618 can be achieved via one or more fluid passages formed by one or more conduits, channels and / or tubes.

[0096] Actuation of the fourth relay valve 618 is controlled (e.g., between a closed position and an open position) based on the pressurized control fluid (e.g., pulsed pressurized control fluid) output by the fourth I / P converter 614 to the fourth relay valve 618. In some examples, the fourth relay valve 618 is actuated to and / or maintained in the closed position when the pressurized control fluid output by the fourth I / P converter 614 is relatively high (e.g., above a threshold pressure), and the fourth relay valve 618 is actuated to and / or maintained in the open position when the pressurized control fluid output by the fourth I / P converter 614 is relatively low (e.g., below a threshold pressure). In other examples, the fourth relay valve 618 is actuated to and / or maintained in a closed position when the pressurized control fluid output by the fourth I / P converter 614 is relatively low (e.g., below a threshold pressure), and the fourth relay valve 618 is actuated to and / or maintained in an open position when the pressurized control fluid output by the fourth I / P converter 614 is relatively high (e.g., above a threshold pressure).

[0097] When the fourth relay valve 618 is in the closed position, pressurized control fluid received at the fourth relay valve 618 from the third relay valve 616 and the second control fluid port 620 of the valve controller 602 is prevented from passing and / or traveling through the fourth relay valve 618. When the fourth relay valve 618 is actuated to an open position (e.g., from a closed position), pressurized control fluid received at the fourth relay valve 618 from the third relay valve 616 and / or the second control fluid port 620 of the valve controller 602 passes and / or travels through the fourth relay valve 618 to the control fluid exhaust 128 of the valve controller 602. When the fourth relay valve 618 is in the open position and the third relay valve 616 is in the closed position, the pressurized control fluid travels from the second control fluid port 610 of the pneumatic actuator 606, through and / or back, through the second control fluid port 620 of the valve controller 602, then through the fourth relay valve 618 of the valve controller 602, and then toward, into and / or through the control fluid exhaust 128 of the valve controller 602. The pressurized control fluid entering and / or through the control fluid exhaust 128 from the fourth relay valve 618 is exhausted to atmosphere. The return of the pressurized control fluid from the second control fluid port 610 of the pneumatic actuator 606 to the second control fluid port 620 of the valve controller 602, combined with the subsequent exhaust of the returned pressurized control fluid via the control fluid exhaust 128 of the valve controller 602, causes the flow control member 110 of the control valve 106 to move in the first direction, and / or causes the pressure in the second fluid chamber of the pneumatic actuator 606 to decrease.

[0098] Figure 6The first control fluid port 126 of the valve controller 602 is in fluid communication with the first relay valve 122 and the second relay valve 124. The first control fluid port 126 of the valve controller 602 is also in fluid communication with the first control fluid port 608 of the pneumatic actuator 606. Figure 6 As shown, the first control fluid port 126 is operably positioned between the first relay valve 122 and the second relay valve 124 of the valve controller 602 on the one hand and the first control fluid port 608 of the pneumatic actuator 606 on the other hand. Fluid communication to and / or from the first control fluid port 126 can be achieved via one or more fluid passages formed by one or more conduits, channels and / or tubes. The first control fluid port 126 of the valve controller 602 facilitates the supply of pressurized control fluid from the first relay valve 122 and / or more generally from the valve controller 602 to the first control fluid port 608 of the pneumatic actuator 606. The first control fluid port 126 of the valve controller 602 also facilitates the return of pressurized control fluid from the first control fluid port 608 of the pneumatic actuator 606 to the second relay valve 124, and / or more generally to the valve controller 602.

[0099] Figure 6 The second control fluid port 620 of the valve controller 602 is in fluid communication with the third relay valve 616 and the fourth relay valve 618 of the valve controller 602. The second control fluid port 620 of the valve controller 602 is also in fluid communication with the second control fluid port 610 of the pneumatic actuator 606. Figure 6 As shown, the second control fluid port 620 is operably positioned between the third relay valve 616 and the fourth relay valve 618 of the valve controller 602 on the one hand and the second control fluid port 610 of the pneumatic actuator 606 on the other hand. Fluid communication to the second control fluid port 620 and / or fluid communication from the second control fluid port 620 can be achieved via one or more fluid passages formed by one or more conduits, channels and / or tubes. The second control fluid port 620 of the valve controller 602 facilitates the supply of pressurized control fluid from the third relay valve 616 and / or more generally from the valve controller 602 to the second control fluid port 610 of the pneumatic actuator 606. The second control fluid port 620 of the valve controller 602 also facilitates the return of pressurized control fluid from the second control fluid port 610 of the pneumatic actuator 606 to the fourth relay valve 618, and / or more generally to the valve controller 602.

[0100] Figure 6 The control fluid discharge device 128 is in fluid communication with the second relay valve 124 and the fourth relay valve 618 of the valve controller 602. Figure 6As shown, the control fluid exhaust device 128 is operably positioned between the second relay valve 124 and the fourth relay valve 618 on the one hand and the atmosphere outside the valve controller 602 on the other hand. Fluid communication to and / or from the control fluid exhaust device 128 can be achieved via one or more fluid passages formed by one or more conduits, channels and / or tubes. The control fluid exhaust device 128 facilitates the exhaust of pressurized control fluid from the second relay valve 124 and the fourth relay valve 618 to the atmosphere, and / or more generally, from the valve controller 602 to the atmosphere.

[0101] Figure 6 The first pressure sensor 132 senses and / or measures the pressure of the pressurized control fluid supplied from the control fluid inlet 114 of the valve controller 602 (e.g., the pressure of the pressurized control fluid between the control fluid inlet 114 and the first relay valve 122 and / or between the control fluid inlet 114 and the third relay valve 616). The supply pressure data obtained from and / or provided by the first pressure sensor 132 may be stored in Figure 6 138 of the controller 602. In some examples, the processor 136 accesses and / or obtains the supply pressure data from the memory 138. In other examples, the processor 136 instead accesses, obtains, and / or receives the supply pressure data directly from the first pressure sensor 132. In some examples, the processor 136 accesses, obtains, and / or receives the supply pressure data related to calculating one or more pneumatic volumes that are used when the first relay valve 122 of the valve controller 602 is pulsed and / or the third relay valve 616 is pulsed to move the flow control member 110 of the control valve 106 in a first direction and / or a second direction opposite to the first direction, and / or to increase the pressure in the first fluid chamber and / or the second fluid chamber of the pneumatic actuator 606, as further described below.

[0102] Figure 6 The second pressure sensor 134 senses and / or measures the pressure of the pressurized control fluid at the first control fluid port 126 of the valve controller 602 (e.g., the pressure of the pressurized control fluid between the first relay valve 122 and the second relay valve 124). The first port pressure data obtained from and / or provided by the second pressure sensor 134 may be stored in Figure 6138 of the memory 138. In some examples, the processor 136 accesses and / or obtains the first port pressure data from the memory 138. In other examples, the processor 136 instead accesses, obtains and / or receives the first port pressure data directly from the second pressure sensor 134. In some examples, the processor 136 accesses, obtains and / or receives the first port pressure data associated with calculating one or more pneumatic volumes, which are used when the second relay valve 124 of the pulsating valve controller 602 is used to move the flow control member 110 of the control valve 106 in a second direction opposite to the first direction, and / or to reduce the pressure in the first fluid chamber of the pneumatic actuator 606, as further described below.

[0103] Figure 6 The third pressure sensor 622 senses and / or measures the pressure of the pressurized control fluid at the second control fluid port 620 of the valve controller 602 (e.g., the pressure of the pressurized control fluid between the third relay valve 616 and the fourth relay valve 618). The second port pressure data obtained from and / or provided by the third pressure sensor 622 can be stored in Figure 6 138 of the memory 138. In some examples, the processor 136 accesses and / or obtains the second port pressure data from the memory 138. In other examples, the processor 136 instead accesses, obtains and / or receives the second port pressure data directly from the third pressure sensor 622. In some examples, the processor 136 accesses, obtains and / or receives the second port pressure data associated with calculating one or more pneumatic volumes, which are used when the fourth relay valve 618 of the pulsating valve controller 602 is used to move the flow control member 110 of the control valve 106 in the first direction, and / or to reduce the pressure in the second fluid chamber of the pneumatic actuator 606, as further described below.

[0104] Figure 6The processor 136 of the present invention may be implemented by any type and / or any number of processors, microprocessors, controllers, microcontrollers, circuits, and / or other electrical components. The processor 136 controls and / or manages one or more operations of the first I / P converter 118, the second I / P converter 120, the third I / P converter 612, and / or the fourth I / P converter 614 based on an input signal 142 received, accessed, and / or obtained by the control circuit device 130 of the valve controller 602. The input signal 142 identifies a position set point (e.g., a desired position) of the flow control member 110 of the control valve 106, which may be achieved based on one or more operations of the valve controller 602, the pneumatic actuator 606, and / or the control valve 106. In some examples, the input signal 142 may indicate to the processor 136 that the valve controller 602 is to operate the pneumatic actuator 606 in a manner that moves the flow control member 110 of the control valve 106 in a first direction. In other examples, the input signal 142 may indicate to the processor 136 that the valve controller 602 is to operate the pneumatic actuator 606 in a manner that moves the flow control member 110 of the control valve 106 in a second direction opposite to the first direction. In other examples, the input signal 142 may indicate to the processor 136 that the valve controller 602 is to operate the pneumatic actuator 606 in a manner that maintains the flow control member 110 of the control valve 106 in its current position. In other examples, the input signal 142 may indicate to the processor 136 that the valve controller 602 is to increase the pressure within both the first fluid chamber of the pneumatic actuator 606 and the second fluid chamber of the pneumatic actuator 606. In other examples, the input signal 142 may indicate to the processor 136 that the valve controller 602 is to decrease the pressure within both the first fluid chamber of the pneumatic actuator 606 and the second fluid chamber of the pneumatic actuator 606.

[0105] In response to the input signal 142 indicating that the valve controller 602 is to operate the pneumatic actuator 606 in a manner that moves the flow control member 110 of the control valve 106 in a first direction, the processor 136 generates a first pulse drive signal 144 that commands and / or instructs the first I / P converter 118 of the valve controller 602 to generate and / or output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air). The pulsed pressurized control fluid generated and / or output by the first I / P converter 118 is transmitted and / or delivered to the first relay valve 122 of the valve controller 602, which in turn pulses the first relay valve 122 between a closed position and an open position. When the first relay valve 122 is in the open position during pulsation of the first relay valve 122, the pressurized control fluid received at the first relay valve 122 from the control fluid inlet 114 of the valve controller 602 passes and / or travels through the first relay valve 122 toward, into and / or through the first control fluid port 126 of the valve controller 602. The pressurized control fluid entering and / or through the first control fluid port 126 of the valve controller 602 from the first relay valve 122 passes and / or travels toward, into and / or through the first control fluid port 608 of the pneumatic actuator 606, which causes the flow control member 110 of the control valve 106 to move in the first direction. Figure 6 The above-described operations of the first I / P converter 118 and the first relay valve 122 may be performed in the same manner as Figure 3 The operation of the first I / P converter 118 and the first relay valve 122 shown and described above is realized in the same manner, modified to be dedicated to Figure 6 The first control fluid port 608 of the pneumatic actuator 606 is not Figure 1 The pneumatic actuator 108 controls the fluid port 112 .

[0106] Also in response to the input signal 142 indicating that the valve controller 602 is to operate the pneumatic actuator 606 in a manner that moves the flow control member 110 of the control valve 106 in the first direction, the processor 136 additionally generates an example fourth pulse drive signal 626 that commands and / or instructs the fourth I / P converter 614 of the valve controller 602 to generate and / or output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air). The pulsed pressurized control fluid generated and / or output by the fourth I / P converter 614 is transmitted and / or delivered to the fourth relay valve 618 of the valve controller 602, which in turn pulses the fourth relay valve 618 between a closed position and an open position. In some examples, the fourth I / P converter 614 outputs the pulsed pressurized control fluid to the fourth relay valve 618 (e.g., based on the fourth pulsed drive signal 626) simultaneously and / or in parallel with the first I / P converter 118 outputting the pulsed pressurized control fluid to the first relay valve 122 (e.g., based on the first pulsed drive signal 144). When the fourth relay valve 618 is in an open position during pulsation of the fourth relay valve 618, the pressurized control fluid travels through and / or back from the second control fluid port 610 of the pneumatic actuator 606, through the second control fluid port 620 of the valve controller 602, then through the fourth relay valve 618 of the valve controller 602, and then toward, into, and / or through the control fluid exhaust 128 of the valve controller 602. The pressurized control fluid entering and / or passing through the control fluid exhaust 128 from the fourth relay valve 618 is exhausted to atmosphere. The return of pressurized control fluid from the second control fluid port 610 of the pneumatic actuator 606 to the second control fluid port 620 of the valve controller 602 combined with the subsequent discharge of the returned pressurized control fluid via the control fluid discharge device 128 of the valve controller 602 enables the flow control member 110 of the control valve 106 to move in the first direction. Figure 6 The above-described operations of the fourth I / P converter 614 and the fourth relay valve 618 can be performed in the same manner as Figure 5 The operation of the second I / P converter 120 and the second relay valve 124 shown and described above is realized in a manner consistent with the operation of the second I / P converter 120 and the second relay valve 124, modified to be dedicated to Figure 6 The second control fluid port 610 of the pneumatic actuator 606 is not Figure 1 The pneumatic actuator 108 controls the fluid port 112 .

[0107] In response to the input signal 142 indicating that the valve controller 602 is to operate the pneumatic actuator 606 in a manner that moves the flow control member 110 of the control valve 106 in a second direction opposite to the first direction, the processor 136 generates a second pulse drive signal 146 that commands and / or instructs the second I / P converter 120 of the valve controller 602 to generate and / or output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air). The pulsed pressurized control fluid generated and / or output by the second I / P converter 120 is transmitted and / or delivered to the second relay valve 124 of the valve controller 602, which in turn pulses the second relay valve 124 between the closed position and the open position. When the second relay valve 124 is in the open position during pulsation of the second relay valve 124, the pressurized control fluid travels, passes and / or returns from the first control fluid port 608 of the pneumatic actuator 606, passes through the first control fluid port 126 of the valve controller 602, then passes through the second relay valve 124 of the valve controller 602, and then toward, into and / or through the control fluid exhaust 128 of the valve controller 602. The pressurized control fluid entering and / or passing through the control fluid exhaust 128 from the second relay valve 124 is exhausted to the atmosphere. The return of the pressurized control fluid from the first control fluid port 608 of the pneumatic actuator 606 to the first control fluid port 126 of the valve controller 602, combined with the subsequent exhaust of the returned pressurized control fluid via the control fluid exhaust 128 of the valve controller 602, enables the flow control member 110 of the control valve 106 to move in the second direction. Figure 6 The above-described operation of the second I / P converter 120 and the second relay valve 124 can be performed in the same manner as Figure 5 The operation of the second I / P converter 120 and the second relay valve 124 shown and described above is realized in a manner consistent with the operation of the second I / P converter 120 and the second relay valve 124, modified to be dedicated to Figure 6 The first control fluid port 608 of the pneumatic actuator 606 is not Figure 1 The pneumatic actuator 108 controls the fluid port 112 .

[0108] Also in response to the input signal 142 indicating that the valve controller 602 is to operate the pneumatic actuator 606 in a manner that moves the flow control member 110 of the control valve 106 in the second direction, the processor 136 additionally generates an exemplary third pulse drive signal 624 that commands and / or instructs the third I / P converter 612 of the valve controller 602 to generate and / or output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air). The pulsed pressurized control fluid generated and / or output by the third I / P converter 612 is transmitted and / or delivered to the third relay valve 616 of the valve controller 602, which in turn pulses the third relay valve 616 between a closed position and an open position. In some examples, the third I / P converter 612 outputs the pulsed pressurized control fluid to the third relay valve 616 (e.g., based on the third pulsed drive signal 624) simultaneously and / or in parallel with the second I / P converter 120 outputting the pulsed pressurized control fluid to the second relay valve 124 (e.g., based on the second pulsed drive signal 146). When the third relay valve 616 is in an open position during pulsation of the third relay valve 616, the pressurized control fluid received from the control fluid inlet 114 of the valve controller 602 at the third relay valve 616 passes and / or travels through the third relay valve 616 toward, into, and / or through the second control fluid port 620 of the valve controller 602. The pressurized control fluid that enters and / or passes through the second control fluid port 620 of the valve controller 602 from the third relay valve 616 passes and / or travels toward, into, and / or through the second control fluid port 610 of the pneumatic actuator 606, which causes the flow control member 110 of the control valve 106 to move in the second direction. Figure 6 The above operations of the third I / P converter 612 and the third relay valve 616 can be performed in the same manner as Figure 3 The operation of the first I / P converter 118 and the first relay valve 122 shown and described above is realized in the same manner, modified to be dedicated to Figure 6 The second control fluid port 610 of the pneumatic actuator 606 is not Figure 1 The pneumatic actuator 108 controls the fluid port 112 .

[0109] In response to the input signal 142 indicating that the valve controller 602 is to increase the pressure within both the first fluid chamber of the pneumatic actuator 606 and the second fluid chamber of the pneumatic actuator 606, the processor 136 generates a first pulse drive signal 144, which commands and / or instructs the first I / P converter 118 of the valve controller 602 to generate and / or output a pulse pressurized control fluid (e.g., a pulse pressurized pneumatic medium, such as a pulse of pressurized air). The pulse pressurized control fluid generated and / or output by the first I / P converter 118 is transmitted and / or delivered to the first relay valve 122 of the valve controller 602, which in turn pulses the first relay valve 122 between a closed position and an open position. When the first relay valve 122 is in the open position during pulsation of the first relay valve 122, the pressurized control fluid received at the first relay valve 122 from the control fluid inlet 114 of the valve controller 602 passes and / or travels through the first relay valve 122 toward, into and / or through the first control fluid port 126 of the valve controller 602. The pressurized control fluid entering and / or through the first control fluid port 126 of the valve controller 602 from the first relay valve 122 passes and / or travels toward, into and / or through the first control fluid port 608 of the pneumatic actuator 606, which causes the pressure within the first fluid chamber of the pneumatic actuator 606 to increase. Figure 6 The above-described operations of the first I / P converter 118 and the first relay valve 122 may be performed in the same manner as Figure 3 The operation of the first I / P converter 118 and the first relay valve 122 shown and described above is realized in the same manner, modified to be dedicated to Figure 6 The first control fluid port 608 of the pneumatic actuator 606 is not Figure 1 The pneumatic actuator 108 controls the fluid port 112 .

[0110] Also in response to the input signal 142 indicating that the valve controller 602 is to increase the pressure within both the first fluid chamber of the pneumatic actuator 606 and the second fluid chamber of the pneumatic actuator 606, the processor 136 additionally generates a third pulse drive signal 624, which commands and / or instructs the third I / P converter 612 of the valve controller 602 to generate and / or output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air). The pulsed pressurized control fluid generated and / or output by the third I / P converter 612 is transmitted and / or delivered to the third relay valve 616 of the valve controller 602, which in turn pulses the third relay valve 616 between a closed position and an open position. In some examples, the third I / P converter 612 outputs the pulsed pressurized control fluid to the third relay valve 616 (e.g., based on the third pulsed drive signal 624) simultaneously and / or in parallel with the first I / P converter 118 outputting the pulsed pressurized control fluid to the first relay valve 122 (e.g., based on the first pulsed drive signal 144). When the third relay valve 616 is in an open position during pulsation of the third relay valve 616, the pressurized control fluid received from the control fluid inlet 114 of the valve controller 602 at the third relay valve 616 passes and / or travels through the third relay valve 616 toward, into, and / or through the second control fluid port 620 of the valve controller 602. The pressurized control fluid that enters and / or passes through the second control fluid port 620 of the valve controller 602 from the third relay valve 616 passes and / or travels toward, into, and / or through the second control fluid port 610 of the pneumatic actuator 606, which causes the pressure in the second fluid chamber of the pneumatic actuator 606 to increase. Figure 6 The above operations of the third I / P converter 612 and the third relay valve 616 can be performed in the same manner as Figure 3 The operation of the first I / P converter 118 and the first relay valve 122 shown and described above is realized in the same manner, modified to be dedicated to Figure 6 The second control fluid port 610 of the pneumatic actuator 606 is not Figure 1 The pneumatic actuator 108 controls the fluid port 112 .

[0111] In response to the input signal 142 indicating that the valve controller 602 is to reduce the pressure within both the first fluid chamber of the pneumatic actuator 606 and the second fluid chamber of the pneumatic actuator 606, the processor 136 generates a second pulse drive signal 146, which commands and / or instructs the second I / P converter 120 of the valve controller 602 to generate and / or output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air). The pulsed pressurized control fluid generated and / or output by the second I / P converter 120 is transmitted and / or delivered to the second relay valve 124 of the valve controller 602, which in turn pulses the second relay valve 124 between the closed position and the open position. When the second relay valve 124 is in the open position during pulsation of the second relay valve 124, the pressurized control fluid travels, passes and / or returns from the first control fluid port 608 of the pneumatic actuator 606, passes through the first control fluid port 126 of the valve controller 602, then passes through the second relay valve 124 of the valve controller 602, and then toward, into and / or through the control fluid exhaust 128 of the valve controller 602. The pressurized control fluid entering and / or passing through the control fluid exhaust 128 from the second relay valve 124 is exhausted to the atmosphere. The return of the pressurized control fluid from the first control fluid port 608 of the pneumatic actuator 606 to the first control fluid port 126 of the valve controller 602, combined with the subsequent exhaustion of the returned pressurized control fluid via the control fluid exhaust 128 of the valve controller 602, results in a reduction in pressure within the first fluid chamber of the pneumatic actuator 606. Figure 6 The above-described operation of the second I / P converter 120 and the second relay valve 124 can be performed in the same manner as Figure 5 The operation of the second I / P converter 120 and the second relay valve 124 shown and described above is realized in a manner consistent with the operation of the second I / P converter 120 and the second relay valve 124, modified to be dedicated to Figure 6 The first control fluid port 608 of the pneumatic actuator 606 is not Figure 1 The pneumatic actuator 108 controls the fluid port 112 .

[0112] Also in response to the input signal 142 indicating that the valve controller 602 is to reduce the pressure within both the first fluid chamber of the pneumatic actuator 606 and the second fluid chamber of the pneumatic actuator 606, the processor 136 additionally generates a fourth pulse drive signal 626 that commands and / or instructs the fourth I / P converter 614 of the valve controller 602 to generate and / or output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air). The pulsed pressurized control fluid generated and / or output by the fourth I / P converter 614 is transmitted and / or delivered to the fourth relay valve 618 of the valve controller 602, which in turn pulses the fourth relay valve 618 between a closed position and an open position. In some examples, the fourth I / P converter 614 outputs the pulsed pressurized control fluid to the fourth relay valve 618 (e.g., based on the fourth pulsed drive signal 626) simultaneously and / or in parallel with the second I / P converter 120 outputting the pulsed pressurized control fluid to the second relay valve 124 (e.g., based on the second pulsed drive signal 146). When the fourth relay valve 618 is in an open position during pulsation of the fourth relay valve 618, the pressurized control fluid travels from the second control fluid port 610 of the pneumatic actuator 606, through the second control fluid port 620 of the valve controller 602, then through the fourth relay valve 618 of the valve controller 602, and then toward, into, and / or through the control fluid exhaust 128 of the valve controller 602. The pressurized control fluid that enters and / or passes through the control fluid exhaust 128 from the fourth relay valve 618 is exhausted to atmosphere. The return of pressurized control fluid from the second control fluid port 610 of the pneumatic actuator 606 to the second control fluid port 620 of the valve controller 602, combined with the subsequent discharge of the returned pressurized control fluid through the control fluid discharge device 128 of the valve controller 602, causes the pressure in the second fluid chamber of the pneumatic actuator 606 to decrease. Figure 6 The above-described operations of the fourth I / P converter 614 and the fourth relay valve 618 can be performed in the same manner as Figure 5 The operation of the second I / P converter 120 and the second relay valve 124 shown and described above is realized in a manner consistent with the operation of the second I / P converter 120 and the second relay valve 124, modified to be dedicated to Figure 6 The second control fluid port 620 of the pneumatic actuator 606 is not Figure 1 The pneumatic actuator 108 controls the fluid port 112 .

[0113] The processor 136 of the valve controller 602 calculates a pneumatic volume usage (e.g., a “first port pneumatic supply volume usage”) associated with, based on, and / or corresponding to the pulsation of the first relay valve 122. The first port pneumatic supply volume usage calculated by the processor 136 represents and / or corresponds to the pneumatic volume supplied during movement of the flow control member 110 of the control valve 106 in the first direction and / or during an increase in pressure within the first fluid chamber of the pneumatic actuator 606. In some examples, the processor 136 calculates the first port pneumatic supply volume usage on a pulse-by-pulse basis for a given movement of the flow control member 110 of the control valve 106 in the first direction and / or for a given increase in pressure within the first fluid chamber of the pneumatic actuator 606. Figure 6 The processor 136 may calculate the pulse-by-pulse first port pneumatic supply volume usage using the above equations 1-4. In some examples, the processor 136 calculates the first port pneumatic supply volume usage for a given movement of the flow control member 110 of the control valve 106 in the first direction and / or for a given increase in pressure within the first fluid chamber of the pneumatic actuator 606 by summing together the first port pneumatic supply volume usages calculated by the processor 136 for the individual pulses in the pulses occurring during a given movement and / or during a given pressure increase. In some examples, the processor 136 calculates the cumulative first port pneumatic supply volume usage for a series of given movements of the flow control member 110 of the control valve 106 along the first direction (e.g., individual movements that occur and / or are repeated over a period of time) and / or a series of given pressure increases of the first fluid chamber of the pneumatic actuator 606 (e.g., individual pressure increases that occur and / or are repeated over a period of time) by summing together the first port pneumatic supply volume usages calculated by the processor 136 for each movement in a given movement and / or each increase in a given pressure increase.

[0114] The processor 136 of the valve controller 602 additionally or alternatively calculates a pneumatic volume usage (e.g., a “first port pneumatic exhaust volume usage”) associated with, based on, and / or corresponding to the pulsation of the second relay valve 124. The first port pneumatic exhaust volume usage calculated by the processor 136 represents and / or corresponds to the pneumatic volume displaced during movement of the flow control member 110 of the control valve 106 in the second direction and / or during a reduction in pressure within the first fluid chamber of the pneumatic actuator 606. In some examples, the processor 136 calculates the first port pneumatic exhaust volume usage on a pulse-by-pulse basis for a given movement of the flow control member 110 of the control valve 106 in the second direction and / or for a given reduction in pressure within the first fluid chamber of the pneumatic actuator 606. Figure 6The processor 136 can calculate the first port pneumatic exhaust volume usage on a pulse-by-pulse basis using equations 1-4 above, modifying the equation so that the pressure difference (P2-P1) for a given pulse is based on Figure 6 The second pressure sensor 134 senses and / or measures the first port pressure data, rather than based on Figure 6 The processor 136 calculates the first port pneumatic exhaust volume usage for a given movement of the flow control member 110 of the control valve 106 in the second direction and / or for a given reduction in pressure within the first fluid chamber of the pneumatic actuator 606 by summing together the first port pneumatic exhaust volume usages calculated by the processor 136 for individual pulses in the pulses occurring during the given movement and / or during the given pressure reduction. In some examples, the processor 136 calculates the cumulative first port pneumatic exhaust volume usage for a series of given movements of the flow control member 110 of the control valve 106 in the second direction (e.g., individual movements occurring and / or repeated over a period of time) and / or a series of given pressure reductions of the first fluid chamber of the pneumatic actuator 606 (e.g., individual pressure reductions occurring and / or repeated over a period of time) by summing together the first port pneumatic exhaust volume usages calculated by the processor 136 for individual movements in the given movement and / or individual pressure reductions in the given pressure reduction.

[0115] The processor 136 of the valve controller 602 additionally or alternatively calculates a pneumatic volume usage (e.g., a “second port pneumatic supply volume usage”) associated with, based on, and / or corresponding to the pulsation of the third relay valve 616. The second port pneumatic supply volume usage calculated by the processor 136 represents and / or corresponds to the pneumatic volume supplied during movement of the flow control member 110 of the control valve 106 in the second direction and / or during an increase in pressure within the second fluid chamber of the pneumatic actuator 606. In some examples, the processor 136 calculates the second port pneumatic supply volume usage on a pulse-by-pulse basis for a given movement of the flow control member 110 of the control valve 106 in the second direction and / or for a given increase in pressure within the second fluid chamber of the pneumatic actuator 606. Figure 6The processor 136 may calculate the pulse-by-pulse second port pneumatic supply volume usage using the above equations 1-4. In some examples, the processor 136 calculates the second port pneumatic supply volume usage for a given movement of the flow control member 110 of the control valve 106 in the second direction and / or for a given increase in pressure within the second fluid chamber of the pneumatic actuator 606 by summing together the second port pneumatic supply volume usages calculated by the processor 136 for the individual pulses in the pulses occurring during the given movement and / or during the given pressure increase. In some examples, the processor 136 calculates the cumulative second port pneumatic supply volume usage for a series of given movements of the flow control member 110 of the control valve 106 in the second direction (e.g., each movement that occurs and / or is repeated over a period of time) and / or a series of given pressure increases of the second fluid chamber of the pneumatic actuator 606 (e.g., each pressure increase that occurs and / or is repeated over a period of time) by summing together the second port pneumatic supply volume usages calculated by the processor 136 for each movement in a given movement and / or each increase in a given pressure increase.

[0116] The processor 136 of the valve controller 602 additionally or alternatively calculates a pneumatic volume usage (e.g., a “second port pneumatic exhaust volume usage”) associated with, based on, and / or corresponding to the pulsation of the fourth relay valve 618. The second port pneumatic exhaust volume usage calculated by the processor 136 represents and / or corresponds to the pneumatic volume displaced during movement of the flow control member 110 of the control valve 106 in the first direction and / or during a pressure reduction within the second fluid chamber of the pneumatic actuator 606. In some examples, the processor 136 calculates the second port pneumatic exhaust volume usage on a pulse-by-pulse basis for a given movement of the flow control member 110 of the control valve 106 in the first direction and / or for a given pressure reduction within the second fluid chamber of the pneumatic actuator 606. Figure 6 The processor 136 can use the above equations 1-4 to calculate the second port pneumatic exhaust volume usage on a pulse-by-pulse basis, modifying equations 1-4 so that the pressure difference (P2-P1) for a given pulse is based on Figure 6 The third pressure sensor 622 senses and / or measures the second port pressure data, rather than based on Figure 6The processor 136 calculates the second port pneumatic exhaust volume usage for a given movement of the flow control member 110 of the control valve 106 in the first direction and / or for a given reduction in pressure within the second fluid chamber of the pneumatic actuator 606 by summing together the second port pneumatic exhaust volume usages calculated by the processor 136 for individual pulses in the pulses occurring during the given movement and / or during the given pressure reduction. In some examples, the processor 136 calculates the cumulative second port pneumatic exhaust volume usage for a series of given movements of the flow control member 110 of the control valve 106 in the first direction (e.g., each movement occurring and / or repeated within a period of time) and / or a series of given pressure reductions of the second fluid chamber of the pneumatic actuator 606 (e.g., each pressure reduction occurring and / or repeated within a period of time) by summing together the second port pneumatic exhaust volume usages calculated by the processor 136 for each movement in the given movement and / or each movement in the pressure reduction.

[0117] Figure 6 The memory 138 may be implemented by any type and / or any number of storage devices, such as storage drives, flash memory, read-only memory (ROM), random access memory (RAM), cache, and / or any other physical storage medium, in which information is stored for any duration (e.g., for an extended period of time, permanently, for a brief instance, for temporary buffering, and / or for caching of information). Figure 6 The information in memory 138 may be stored in any file and / or data structure format, organizational scheme, and / or arrangement. Figure 6 The memory 138 may be accessed by the processor 136 and / or more generally may be accessed by Figure 6 The control circuit device 130 of the valve controller 602 is accessed.

[0118] In some examples, Figure 6 The memory 138 stores Figure 6 The first pressure sensor 132 senses and / or measures the supply pressure data. In some examples, Figure 6 The memory 138 stores Figure 6 The second pressure sensor 134 senses and / or measures the first port pressure data. In some examples, Figure 6 The memory 138 stores Figure 6 The third pressure sensor 622 senses and / or measures the second port pressure data. In some examples, Figure 6 The memory 138 stores one or more input signals (e.g., Figure 6 In some examples, Figure 6 The memory 138 stores one or more pulse drive signals (e.g., Figure 6 In some examples, Figure 6 The memory 138 stores pulse volume data corresponding to one or more predetermined volumes of one or more pulses of pressurized control fluid to be output from the first I / P converter 118, the second I / P converter 120, the third I / P converter 612 and / or the fourth I / P converter 614 of the valve controller 602.

[0119] In some examples, Figure 6 Memory 138 stores one or more algorithms and / or equations to be used by processor 136 and / or more generally by control circuitry 130 of valve controller 602 to calculate pneumatic volume usage and / or consumption associated with first relay valve 122 of pulsating valve controller 602, associated with moving control valve 106 in a first direction, and / or associated with increasing pressure in a first fluid chamber of pneumatic actuator 606. In some examples, Figure 6 Memory 138 stores one or more algorithms and / or equations to be used by processor 136 and / or more generally by control circuitry 130 of valve controller 602 to calculate pneumatic volume usage and / or consumption associated with second relay valve 124 of pulsating valve controller 602, associated with moving control valve 106 in a second direction opposite to the first direction, and / or associated with reducing the pressure in the first fluid chamber of pneumatic actuator 606. In some examples, Figure 6 Memory 138 stores one or more algorithms and / or equations to be used by processor 136 and / or more generally by control circuitry 130 of valve controller 602 to calculate pneumatic volume usage and / or consumption associated with third relay valve 616 of pulsating valve controller 602, associated with moving control valve 106 in the second direction, and / or associated with increasing pressure in the second fluid chamber of pneumatic actuator 606. In some examples, Figure 6 Memory 138 stores one or more algorithms and / or equations to be used by processor 136 and / or more generally by control circuitry 130 of valve controller 602 to calculate pneumatic volume usage and / or consumption associated with fourth relay valve 618 of pulsating valve controller 602, associated with moving control valve 106 in a first direction, and / or associated with reducing pressure in a second fluid chamber of pneumatic actuator 606. In some examples, Figure 6The memory 138 stores one or more algorithms and / or equations to be used by the processor 136 and / or more generally by the control circuitry 130 of the valve controller 602 to calculate total and / or aggregate pneumatic volume usage and / or consumption over time.

[0120] In some examples, Figure 6 Memory 138 stores pneumatic volume usage and / or consumption data calculated by processor 136 and / or more generally by control circuitry 130 of valve controller 602, associated with pulsating first relay valve 122 of valve controller 602, associated with moving control valve 106 in a first direction, and / or associated with increasing pressure in a first fluid chamber of pneumatic actuator 606. In some examples, Figure 6 Memory 138 stores pneumatic volume usage and / or consumption data calculated by processor 136 and / or more generally by control circuitry 130 of valve controller 602, the pneumatic volume usage and / or consumption data associated with pulsating second relay valve 124 of valve controller 602, associated with moving control valve 106 in a second direction opposite to the first direction, and / or associated with reducing the pressure in the first fluid chamber of pneumatic actuator 606. In some examples, Figure 6 Memory 138 stores pneumatic volume usage and / or consumption data calculated by processor 136, and / or more generally, by control circuitry 130 of valve controller 602, associated with pulsating third relay valve 616 of valve controller 602, associated with moving control valve 106 in the second direction, and / or associated with increasing pressure in the second fluid chamber of pneumatic actuator 606. In some examples, Figure 6 Memory 138 stores pneumatic volume usage and / or consumption data calculated by processor 136 and / or more generally by control circuitry 130 of valve controller 602, the pneumatic volume usage and / or consumption data associated with pulsating fourth relay valve 618 of valve controller 602, associated with moving control valve 106 in a first direction, and / or associated with reducing pressure in a second fluid chamber of pneumatic actuator 606. In some examples, Figure 2 The memory 138 stores total and / or aggregated pneumatic volume usage and / or consumption data calculated over time by the processor 136 and / or more generally by the control circuitry 130 of the valve controller 602 .

[0121] Although Figure 6 An exemplary manner of implementing an exemplary valve controller 602 is shown in FIG. Figure 6One or more elements, processes and / or devices shown in the can be combined, divided, rearranged, omitted, eliminated and / or implemented in any other manner. In addition, the exemplary pressure regulator 116, the exemplary first I / P converter 118, the exemplary second I / P converter 120, the exemplary third I / P converter 612, the exemplary fourth I / P converter 614, the exemplary first relay valve 122, the exemplary second relay valve 124, the exemplary third relay valve 616, the exemplary fourth relay valve 618, the exemplary first pressure sensor 132, the exemplary second pressure sensor 134, the exemplary third pressure sensor 622, the exemplary processor 136, the exemplary memory 138 and / or more generally, Figure 6 The exemplary valve controller 602 may be implemented by hardware, software, firmware, and / or any combination of hardware, software, and / or firmware. Thus, for example, Figure 6 Any of the exemplary pressure regulator 116, the exemplary first I / P converter 118, the exemplary second I / P converter 120, the exemplary third I / P converter 612, the exemplary fourth I / P converter 614, the exemplary first relay valve 122, the exemplary second relay valve 124, the exemplary third relay valve 616, the exemplary fourth relay valve 618, the exemplary first pressure sensor 132, the exemplary second pressure sensor 134, the exemplary third pressure sensor 622, the exemplary processor 136, the exemplary memory 138 and / or more generally the exemplary valve controller 602 may be implemented by one or more analog or digital circuits, logic circuits, programmable processors, programmable controllers, graphics processing units (GPUs), digital signal processors (DSPs), application specific integrated circuits (ASICs), programmable logic devices (PLDs) and / or field programmable logic devices (FPLDs). When any apparatus or system claim of this patent is read to cover pure software and / or firmware implementations, at least one of the exemplary pressure regulator 116, the exemplary first I / P converter 118, the exemplary second I / P converter 120, the exemplary third I / P converter 612, the exemplary fourth I / P converter 614, the exemplary first relay valve 122, the exemplary second relay valve 124, the exemplary third relay valve 616, the exemplary fourth relay valve 618, the exemplary first pressure sensor 132, the exemplary second pressure sensor 134, the exemplary third pressure sensor 622, the exemplary processor 136, and / or Figure 6 The example memory 138 of the valve controller 602 is expressly defined herein to include a non-transitory computer-readable storage device or storage disk, such as a memory, a digital versatile disk (DVD), a compact disk (CD), a Blu-ray disk, etc., including software and / or firmware. In addition, Figure 6 The example valve controller 602 may include one or more components, processes and / or devices to supplement or replace Figure 6 Those elements, processes and / or devices shown, and / or may include more than one of any or all of the elements, processes and devices shown.

[0122] Figure 7 shows a representation for Figure 1 Flow chart of an example method for an example valve controller 102 to quantify pneumatic volume usage. Figure 8A-B shows a representation for Figure 6 Flowchart of an example method for quantifying pneumatic volume usage by an example valve controller 602. In these examples, the method can be implemented using machine-readable instructions including one or more executable programs or portions of executable programs for execution by a computer processor, such as the above-mentioned Figure 1 and Figure 6 The example processor 136 of FIG. 1 is combined with Fig. 9 The program may be implemented in software stored on a non-transitory computer-readable storage medium such as a CD-ROM, floppy disk, hard drive, DVD, Blu-ray disk, or memory associated with processor 136, but the entire program and / or portions thereof may alternatively be executed by a device other than processor 136 and / or implemented in firmware or dedicated hardware. In addition, although reference is made to Figure 7 and Figure 8A-B The flowchart shown describes an exemplary procedure, but the Figure 1 The exemplary valve controller 102 and / or by Figure 6 Many other methods of quantifying pneumatic volume usage by the exemplary valve controller 602 of the present invention are described. For example, the order of execution of the boxes can be changed, and / or some of the boxes described can be changed, eliminated, or combined. Additionally or alternatively, any or all of these boxes can be implemented by one or more hardware circuits (e.g., discrete and / or integrated analog and / or digital circuits, field programmable gate arrays (FPGAs), ASICs, comparators, operational amplifiers (op-amps), logic circuits, etc.) that are configured to perform corresponding operations without executing software or firmware.

[0123] Machine-readable instructions for performing the methods described herein may be stored in one or more of a compressed format, an encrypted format, a segmented format, a packaged format, and the like. Machine-readable instructions may be stored as data (e.g., portions of instructions, code, representations of code, and the like) that can be used to create, manufacture, and / or generate machine-executable instructions. For example, machine-readable instructions may be segmented and stored on one or more storage devices and / or computing devices (e.g., servers). Machine-readable instructions may require one or more of installation, modification, adaptation, updating, combination, supplementation, configuration, decryption, decompression, unpacking, distribution, redistribution, and the like so that they may be directly read and / or executed by a computing device and / or other machine. For example, machine-readable instructions may be stored in multiple parts that are individually compressed, encrypted, and stored on separate computing devices, where the parts, when decrypted, decompressed, and combined, form a set of executable instructions that implement a program such as described herein. In another example, the machine-readable instructions may be stored in a state where they are computer-readable but require the addition of a library (e.g., a dynamic link library (DLL)), a software development kit (SDK), an application programming interface (API), etc. in order to execute the instructions on a particular computing device or other device. In another example, the machine-readable instructions and / or corresponding programs may need to be configured (e.g., stored settings, data inputs, recorded network addresses, etc.) before they can be executed in whole or in part. Therefore, the disclosed machine-readable instructions and / or corresponding programs are intended to cover such machine-readable instructions and / or programs regardless of the particular format or state of the machine-readable instructions and / or programs when stored or otherwise at rest or in transmission.

[0124] As mentioned above, Figure 7 and Figure 8A-B The example methods of can be implemented using executable instructions (e.g., computer and / or machine readable instructions) stored on a non-transitory computer and / or machine readable medium, such as a hard drive, flash memory, read-only memory, compact disk, digital versatile disk, cache, random access memory, and / or any other storage device or storage disk where information is stored for any duration (e.g., for an extended period of time, permanently, for brief examples, for temporary buffering, and / or for caching of information). As used herein, the term "non-transitory computer readable medium" is expressly defined to include any type of computer readable storage device and / or storage disk, and to exclude propagating signals and to exclude transmission media.

[0125] "Include" and "comprising" (and all forms and tenses thereof) are used herein as open-ended terms. Thus, whenever a claim employs any form of "include" or "comprising" (e.g., includes, comprises, includes, includes, has, etc.) as a preamble or in any kind of claim narrative, it should be understood that additional elements, terms, etc. may be present without falling outside the scope of the corresponding claim or narrative. As used herein, when the phrase "at least" is used as a transitional term, such as in the preamble of a claim, it is open-ended in the same manner as the terms "include" and "comprising" are open-ended. When used, for example, in a form such as A, B, and / or C, the term "and / or" refers to any combination or subset of A, B, and C, such as (1) A alone, (2) B alone, (3) C alone, (4) A and B, (5) A and C, (6) B and C, and (7) A and B and C. As used herein in the context of describing structures, components, items, objects, and / or things, the phrase “at least one of A and B” is intended to refer to implementations that include any of (1) at least one A, (2) at least one B, and (3) at least one A and at least one B. Similarly, as used herein in the context of describing structures, components, items, objects, and / or things, the phrase “at least one of A or B” is intended to refer to implementations that include any of (1) at least one A, (2) at least one B, and (3) at least one A and at least one B. As used herein in the context of describing the execution or performance of processes, instructions, actions, activities, and / or steps, the phrase “at least one of A and B” is intended to refer to implementations that include any of (1) at least one A, (2) at least one B, and (3) at least one A and at least one B. Similarly, as used herein in the context of describing the execution or performance of processes, instructions, actions, activities, and / or steps, the phrase "at least one of A or B" is intended to refer to an implementation that includes any of (1) at least one A, (2) at least one B, and (3) at least one A and at least one B.

[0126] Figure 7 It means that it can be Figure 1 Flow chart of an example method 700 executed at an example valve controller 102 to quantify pneumatic volume usage. Figure 1 The processor 136 of the valve controller 102 determines whether the valve controller 102 is to operate Figure 1 The pneumatic actuator 108 moves in a first direction Figure 1 When the flow control member 110 of the control valve 106 is Figure 7 The method 700 begins at block 702. For example, the processor 136 and / or more generally, Figure 1 The control circuitry 130 of the valve controller 102 may receive an input signal (e.g., Figure 1142) that indicates to the processor 136 that the valve controller 102 is to operate the pneumatic actuator 108 in a manner that moves the flow control member 110 of the control valve 106 in the first direction. If the processor 136 determines at block 702 that the valve controller 102 is to operate the pneumatic actuator 108 to move the flow control member 110 of the control valve 106 in the first direction, then Figure 7 The method 700 proceeds to block 704. If the processor 136 instead determines at block 702 that the valve controller 102 is not operating the pneumatic actuator 108 to move the flow control member 110 of the control valve 106 in the first direction, then Figure 7 Method 700 proceeds to box 708.

[0127] At block 704, the processor 136 instructs the first I / P converter 118 of the valve controller 102 to pulse the first relay valve 122 of the valve controller 102. For example, the processor 136 may generate a pulse drive signal (e.g., Figure 1 The first pulse drive signal 144 of the valve controller 102 is outputted to the first relay valve 122 of the valve controller 102, wherein the pulse pressurized control fluid pulses the first relay valve 122 between the closed position and the open position. After block 704, Figure 7 Method 700 proceeds to box 706.

[0128] At block 706, the processor 136 calculates one or more pneumatic volume usages associated with the pulsation of the first relay valve 122. For example, the processor 136 may calculate the pulse-by-pulse pneumatic supply volume usage associated with the pulsation of the first relay valve 122 using Equations 1-4 above. The processor 136 may also calculate the pneumatic supply volume usage associated with the pulsation of the first relay valve 122 by summing together the pneumatic supply volume usages calculated by the processor 136 for individual pulses in the pulses that occurred during the pulsing of the first relay valve 122. After block 706, Figure 7 Method 700 proceeds to box 714.

[0129] At block 708, the processor 136 determines whether the valve controller 102 operates the pneumatic actuator 108 to move the flow control member 110 of the control valve 106 in a second direction opposite to the first direction. For example, the processor 136 and / or more generally, Figure 1 The control circuitry 130 of the valve controller 102 may receive an input signal (e.g., Figure 1142) that indicates to the processor 136 that the valve controller 102 is to operate the pneumatic actuator 108 in a manner that moves the flow control member 110 of the control valve 106 in the second direction. If the processor 136 determines at block 708 that the valve controller 102 is to operate the pneumatic actuator 108 to move the flow control member 110 of the control valve 106 in the second direction, then Figure 7 The method 700 advances to block 710. If the processor 136 instead determines at block 708 that the valve controller 102 is not operating the pneumatic actuator 108 to move the flow control member 110 of the control valve 106 in the second direction, then Figure 7 Method 700 proceeds to box 716.

[0130] At block 710, the processor 136 instructs the second I / P converter 120 of the valve controller 102 to pulse the second relay valve 124 of the valve controller 102. For example, the processor 136 may generate a pulse drive signal (e.g., Figure 1 The second pulse drive signal 146 of the valve controller 102 is outputted to the second relay valve 124 of the valve controller 102, wherein the pulse pressurized control fluid pulses the second relay valve 124 between the closed position and the open position. After block 710, Figure 7 Method 700 proceeds to box 712.

[0131] At block 712, the processor 136 calculates one or more pneumatic volume usages associated with the pulsation of the second relay valve 124. For example, the processor 136 may calculate the pulse-by-pulse pneumatic discharge volume usage associated with the pulsation of the second relay valve 124 using Equations 1-4 above, modifying the equations so that the pressure difference (P2-P1) for a given pulse is based on the pressure difference (P2-P1) given by Figure 1 The second pressure sensor 134 senses and / or measures the port pressure data, rather than based on Figure 1 The processor 136 may further calculate the pneumatic exhaust volume usage associated with the pulsation of the second relay valve 124 by summing together the pneumatic exhaust volume usage calculated by the processor 136 for the individual pulses in the pulses that occurred during the pulsation of the second relay valve 124. After block 712, Figure 7 Method 700 proceeds to box 714.

[0132] At block 714, the processor 136 calculates one or more total pneumatic volume usages. For example, the processor 136 may calculate the cumulative pneumatic supply volume usage associated with a single instance of the pulsating first relay valve 122 by summing together each pneumatic supply volume usage calculated by the processor 136 over time at block 706 (e.g., based on repeated execution of blocks 702 to 706). The processor 136 may additionally calculate the cumulative pneumatic exhaust volume usage associated with a single instance of the pulsating second relay valve 124 by summing together each pneumatic exhaust volume usage calculated by the processor 136 over time at block 712 (e.g., based on repeated execution of blocks 708 to 712). The processor 136 may additionally calculate the total pneumatic volume usage associated with the pulsation of the first relay valve 122 and the pulsation of the second relay valve 124 by summing together the pneumatic supply volume usage calculated at block 706 and the pneumatic exhaust volume usage calculated at block 712. The processor 136 may also calculate the cumulative total pneumatic volume usage by summing up the successive calculations of total pneumatic volume usage that occur over time. Figure 7 Method 700 proceeds to box 716.

[0133] At block 716, the processor 136 determines whether the valve controller 102 should continue to quantify pneumatic volume usage. For example, the processor 136 and / or more generally, Figure 1 The control circuitry 130 of the valve controller 102 may receive a control signal to the processor 136 indicating that the valve controller 102 will stop quantifying the pneumatic volume usage. If the processor 136 determines at block 716 that the valve controller 102 will continue to quantify the pneumatic volume usage, then Figure 7 The method 700 returns to block 702. In contrast, if the processor 136 determines at block 716 that the valve controller 102 is not continuing (eg, stopping) quantifying pneumatic volume usage, then Figure 7 The method 700 ends.

[0134] Fig. 8A and Figure 8B It means that it can be Figure 6 Flow chart of an example method 800 executed at an example valve controller 602 to quantify pneumatic volume usage. Figure 6 The processor 136 of the valve controller 602 determines whether the valve controller 602 is to operate Figure 6 The pneumatic actuator 606 moves in a first direction Figure 6 When the flow control member 110 of the control valve 106 is Figure 8A-B The method 800 begins at block 802. For example, the processor 136 and / or more generally, Figure 6 The control circuitry 130 of the valve controller 602 may receive an input signal (e.g., Figure 6142) that indicates to the processor 136 that the valve controller 602 is to operate the pneumatic actuator 606 in a manner that moves the flow control member 110 of the control valve 106 in the first direction. If the processor 136 determines at block 802 that the valve controller 602 is to operate the pneumatic actuator 606 to move the flow control member 110 of the control valve 106 in the first direction, then Figure 8A-B The method 800 proceeds to block 804. Conversely, if the processor 136 determines at block 802 that the valve controller 602 is not operating the pneumatic actuator 606 to move the flow control member 110 of the control valve 106 in the first direction, then Figure 8A-B Method 800 proceeds to box 808.

[0135] At block 804, the processor 136 commands the first I / P converter 118 of the valve controller 602 to pulse the first relay valve 122 of the valve controller 602, and also commands the fourth I / P converter 614 of the valve controller 602 to pulse the fourth relay valve 618 of the valve controller 602. For example, the processor 136 may generate a pulse drive signal (e.g., Figure 6 The processor 136 may also generate a pulsed drive signal (e.g., a first pulsed drive signal 144) that commands and / or instructs the first I / P converter 118 of the valve controller 602 to output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air) to the first relay valve 122 of the valve controller 602, wherein the pulsed pressurized control fluid pulses the first relay valve 122 between a closed position and an open position. Figure 6 804 ), the pulsed drive signal commands and / or instructs the fourth I / P converter 614 of the valve controller 602 to output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as pulses of pressurized air) to the fourth relay valve 618 of the valve controller 602, wherein the pulsed pressurized control fluid pulses the fourth relay valve 618 between a closed position and an open position (e.g., simultaneously and / or in parallel with the pulsation of the first relay valve 122). After block 804, Figure 8A-B Method 800 proceeds to box 806.

[0136] At box 806, the processor 136 calculates one or more pneumatic volume usages associated with the pulsation of the first relay valve 122 and / or the pulsation of the fourth relay valve 618. For example, the processor 136 can calculate the pulse-by-pulse first port pneumatic supply volume usage associated with the pulsation of the first relay valve 122 using Equations 1-4 above. The processor 136 can additionally calculate the first port pneumatic supply volume usage associated with the pulsation of the first relay valve 122 by summing together the first port pneumatic supply volume usages calculated by the processor 136 for the individual pulses in the pulses that occurred during the pulsing of the first relay valve 122. The processor 136 can also calculate the pulse-by-pulse second port pneumatic exhaust volume usage associated with the pulsation of the fourth relay valve 618 using Equations 1-4 above, modifying the equations so that the pressure difference (P2-P1) for a given pulse is based on the pressure difference calculated by Figure 6 The third pressure sensor 622 senses and / or measures the second port pressure data, rather than based on Figure 6 The processor 136 may also calculate the second port pneumatic exhaust volume usage associated with the pulse of the fourth relay valve 618 by summing together the second port pneumatic exhaust volume usages calculated by the processor 136 for the individual pulses in the pulses that occurred during the pulse of the fourth relay valve 618. After block 806, Figure 8A-B Method 800 proceeds to box 826.

[0137] At block 808, the processor 136 determines whether the valve controller 602 operates the pneumatic actuator 606 to move the flow control member 110 of the control valve 106 in a second direction opposite to the first direction. For example, the processor 136 and / or more generally, Figure 6 The control circuitry 130 of the valve controller 602 may receive an input signal (e.g., Figure 6 142) that indicates to the processor 136 that the valve controller 602 is to operate the pneumatic actuator 606 in a manner that moves the flow control member 110 of the control valve 106 in the second direction. If the processor 136 determines at block 808 that the valve controller 602 is to operate the pneumatic actuator 606 to move the flow control member 110 of the control valve 106 in the second direction, then Figure 8A-B The method 800 proceeds to block 810. Conversely, if the processor 136 determines at block 808 that the valve controller 602 is not operating the pneumatic actuator 606 to move the flow control member 110 of the control valve 106 in the second direction, then Figure 8A-B Method 800 proceeds to box 814.

[0138] At block 810, the processor 136 commands the second I / P converter 120 of the valve controller 602 to pulse the second relay valve 124 of the valve controller 602, and also commands the third I / P converter 612 of the valve controller 602 to pulse the third relay valve 616 of the valve controller 602. For example, the processor 136 may generate a pulse drive signal (e.g., Figure 6 The processor 136 may also generate a pulsed drive signal (e.g., a second pulsed drive signal 146) that commands and / or instructs the second I / P converter 120 of the valve controller 602 to output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air) to the second relay valve 124 of the valve controller 602, wherein the pulsed pressurized control fluid pulses the second relay valve 124 between a closed position and an open position. Figure 6 The third pulse drive signal 624 of the valve controller 602 is commanded and / or instructs the third I / P converter 612 of the valve controller 602 to output a pulse pressurized control fluid (e.g., a pulse pressurized pneumatic medium, such as a pulse of pressurized air) to the third relay valve 616 of the valve controller 602, wherein the pulse pressurized control fluid pulses the third relay valve 616 between a closed position and an open position (e.g., simultaneously and / or in parallel with the pulsation of the second relay valve 124). After block 810, Figure 8A-B Method 800 proceeds to box 812.

[0139] At box 812, the processor 136 calculates one or more pneumatic volume usages associated with the pulsation of the second relay valve 124 and / or the pulsation of the third relay valve 616. For example, the processor 136 can calculate the pulse-by-pulse second port pneumatic supply volume usage associated with the pulsation of the third relay valve 616 using Equations 1-4 above. The processor 136 can additionally calculate the second port pneumatic supply volume usage associated with the pulsation of the third relay valve 616 by summing together the second port pneumatic supply volume usages calculated by the processor 136 for the individual pulses in the pulses that occurred during the pulsing of the third relay valve 616. The processor 136 can also calculate the pulse-by-pulse first port pneumatic exhaust volume usage associated with the pulsation of the second relay valve 124 using Equations 1-4 above, modifying the equations so that the pressure difference (P2-P1) for a given pulse is based on the pressure difference calculated by Figure 6 The second pressure sensor 134 senses and / or measures the first port pressure data, rather than based on Figure 6The processor 136 may also calculate the first port pneumatic exhaust volume usage associated with the pulse of the second relay valve 124 by summing together the first port pneumatic exhaust volume usage calculated by the processor 136 for the individual pulses in the pulse that occurred during the pulse of the second relay valve 124. After block 812, Figure 8A-B Method 800 proceeds to box 826.

[0140] At block 814, the processor 136 determines whether the valve controller 602 is to increase Figure 6 The pressure in the first chamber and the second chamber of the pneumatic actuator 606. For example, the processor 136 and / or more generally, Figure 6 The control circuitry 130 of the valve controller 602 may receive an input signal (e.g., Figure 6 If the processor 136 determines at block 814 that the valve controller 602 is to increase the pressure in both the first chamber and the second chamber of the pneumatic actuator 606, then Figure 8A-B The method 800 proceeds to block 816. If the processor 136 instead determines at block 814 that the valve controller 602 does not increase the pressure in both the first chamber and the second chamber of the pneumatic actuator 606, then Figure 8A-B Method 800 proceeds to box 820.

[0141] At block 816, the processor 136 instructs the first I / P converter 118 of the valve controller 602 to pulse the first relay valve 122 of the valve controller 602, and also instructs the third I / P converter 612 of the valve controller 602 to pulse the third relay valve 618 of the valve controller 602. For example, the processor 136 may generate a pulse drive signal (e.g., Figure 6 The processor 136 may also generate a pulsed drive signal (e.g., a first pulsed drive signal 144) that commands and / or instructs the first I / P converter 118 of the valve controller 602 to output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air) to the first relay valve 122 of the valve controller 602, wherein the pulsed pressurized control fluid pulses the first relay valve 122 between a closed position and an open position. Figure 6The third pulse drive signal 624 of the valve controller 602 is commanded and / or instructs the third I / P converter 612 of the valve controller 602 to output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air) to the third relay valve 616 of the valve controller 602, wherein the pulsed pressurized control fluid pulses the third relay valve 616 between a closed position and an open position (e.g., simultaneously and / or in parallel with the pulsation of the first relay valve 122). After block 816, Figure 8A-B Method 800 proceeds to box 818.

[0142] At box 818, the processor 136 calculates one or more pneumatic volume usages associated with the pulsation of the first relay valve 122 and / or the pulsation of the third relay valve 616. For example, the processor 136 can calculate the pulse-by-pulse first port pneumatic supply volume usage associated with the pulsation of the first relay valve 122 using Equations 1-4 above. The processor 136 can additionally calculate the first port pneumatic supply volume usage associated with the pulsation of the first relay valve 122 by summing together the first port pneumatic supply volume usages calculated by the processor 136 for the individual pulses in the pulses that occurred during the pulsation of the first relay valve 122. The processor 136 can also calculate the pulse-by-pulse second port pneumatic supply volume usage associated with the pulsation of the third relay valve 616 using Equations 1-4 above. The processor 136 may additionally calculate the second port pneumatic supply volume usage associated with the pulsing of the third relay valve 616 by summing together the second port pneumatic supply volume usages calculated by the processor 136 for the individual ones of the pulses that occurred during the pulsing of the third relay valve 616. After block 818, Figure 8A-B Method 800 proceeds to box 826.

[0143] At block 820, the processor 136 determines whether the valve controller 602 is to reduce Figure 6 The pressure in the first chamber and the second chamber of the pneumatic actuator 606. For example, the processor 136 and / or more generally, Figure 6 The control circuitry 130 of the valve controller 602 may receive an input signal (e.g., Figure 6 820 ), which indicates to the processor 136 that the valve controller 602 is to reduce the pressure in both the first chamber and the second chamber of the pneumatic actuator 606. If the processor 136 determines at block 820 that the valve controller 602 is to reduce the pressure in both the first chamber and the second chamber of the pneumatic actuator 606, then Figure 8A-B The method 800 proceeds to block 822. If the processor 136 determines at block 820 that the valve controller 602 does not reduce the pressure in the first and second chambers of the pneumatic actuator 606, then Figure 8A-B Method 800 proceeds to box 828.

[0144] At block 822, the processor 136 instructs the second I / P converter 120 of the valve controller 602 to pulse the second relay valve 124 of the valve controller 602, and also instructs the fourth I / P converter 614 of the valve controller 602 to pulse the fourth relay valve 618 of the valve controller 602. For example, the processor 136 may generate a pulse drive signal (e.g., Figure 6 The processor 136 may also generate a pulsed drive signal (e.g., a second pulsed drive signal 146) that commands and / or instructs the second I / P converter 120 of the valve controller 602 to output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as a pulse of pressurized air) to the second relay valve 124 of the valve controller 602, wherein the pulsed pressurized control fluid pulses the second relay valve 124 between a closed position and an open position. Figure 6 826 ) that commands and / or instructs the fourth I / P converter 614 of the valve controller 602 to output a pulsed pressurized control fluid (e.g., a pulsed pressurized pneumatic medium, such as pulses of pressurized air) to the fourth relay valve 618 of the valve controller 602, wherein the pulsed pressurized control fluid pulses the fourth relay valve 618 between a closed position and an open position (e.g., simultaneously and / or in parallel with the pulsation of the second relay valve 124). After block 822, Figure 8A-B Method 800 proceeds to box 824.

[0145] At block 824, the processor 136 calculates one or more pneumatic volume usages associated with the pulsation of the second relay valve 124 and / or the pulsation of the fourth relay valve 618. For example, the processor 136 may calculate the pulse-by-pulsation first port pneumatic exhaust volume usage associated with the pulsation of the second relay valve 124 using Equations 1-4 above, modifying the equations so that the pressure difference (P2-P1) for a given pulse is based on the pressure difference (P2-P1) given by Figure 6 The second pressure sensor 134 senses and / or measures the first port pressure data, rather than based on Figure 6 The processor 136 may also calculate the first port pneumatic exhaust volume usage associated with the pulse of the second relay valve 124 by summing together the first port pneumatic exhaust volume usages calculated by the processor 136 for individual pulses in the pulses that occur during the pulse of the second relay valve 124. The processor 136 may also calculate the pulse-by-pulse second port pneumatic exhaust volume usage associated with the pulse of the fourth relay valve 618 using Equations 1-4 above, modifying the equations so that the pressure difference (P2-P1) for a given pulse is based on the pressure difference (P2-P1) calculated by Figure 6 The third pressure sensor 622 senses and / or measures the second port pressure data, rather than based on Figure 6The processor 136 may also calculate the second port pneumatic exhaust volume usage associated with the pulse of the fourth relay valve 618 by summing together the second port pneumatic exhaust volume usages calculated by the processor 136 for the individual pulses in the pulses that occurred during the pulse of the fourth relay valve 618. After block 824, Figure 8A-B Method 800 proceeds to box 826.

[0146] At block 826, the processor 136 calculates one or more total pneumatic volume usages. For example, the processor 136 may calculate the cumulative first port pneumatic supply volume usage associated with a single instance of the pulsating first relay valve 122 by summing together each first port pneumatic supply volume usage calculated by the processor 136 over time at block 806 and / or at block 818 (e.g., based on repeated execution of blocks 802 to 806 and / or repeated execution of blocks 814 to 818). The processor 136 may also calculate the cumulative first port pneumatic exhaust volume usage associated with a single instance of the pulsating second relay valve 124 by summing together each first port pneumatic exhaust volume usage calculated by the processor 136 over time at block 812 and / or at block 824 (e.g., based on repeated execution of blocks 808 to 812 and / or repeated execution of blocks 820 to 824). The processor 136 may additionally calculate a cumulative second port pneumatic supply volume usage associated with a separate instance of the pulsating third relay valve 616 by summing together each second port pneumatic supply volume usage calculated by the processor 136 over time at block 812 and / or at block 818 (e.g., based on repeated execution of blocks 808 to 812 and / or repeated execution of blocks 814 to 818). The processor 136 may additionally calculate a cumulative second port pneumatic exhaust volume usage associated with a separate instance of the pulsating fourth relay valve 618 by summing together each of the second port pneumatic exhaust volume usages calculated by the processor 136 over time at block 806 and / or at block 824 (e.g., based on repeated execution of blocks 802 to 806 and / or repeated execution of blocks 820 to 824). The processor 136 may additionally calculate a total pneumatic volume usage associated with the pulse of the first relay valve 122, the pulse of the second relay valve 124, the pulse of the third relay valve 616, and the pulse of the fourth relay valve 618 by summing together the first port pneumatic supply volume usage calculated at box 806 and / or box 818, the first port pneumatic exhaust volume usage calculated at box 812 and / or box 824, the second port pneumatic supply volume usage calculated at box 812 and / or box 818, and the second port pneumatic exhaust volume usage calculated at box 806 and / or box 824. The processor 136 may also calculate a cumulative total pneumatic volume usage by summing successive calculations of total pneumatic volume usage that occur over time. After box 826, Figure 8A-B Method 800 proceeds to box 828.

[0147] At block 828, the processor 136 determines whether the valve controller 602 continues to quantify pneumatic volume usage. For example, the processor 136 and / or more generally, Figure 6 The control circuitry 130 of the valve controller 602 may receive a control signal to the processor 136 indicating that the valve controller 602 will stop quantifying pneumatic usage. If the processor 136 determines at block 828 that the valve controller 602 will continue to quantify pneumatic volume usage, then Figure 8A-B The method 800 returns to block 802. In contrast, if the processor 136 determines at block 828 that the valve controller 602 is not continuing (eg, stopping) quantifying pneumatic volume usage, then Figure 8A-B The method 800 ends.

[0148] Fig. 9 Is able to execute instructions to achieve Figure 7 Example method 700 and Figure 1 An example valve controller 102 of the invention, and / or implementation Figure 8A-B Example method 800 and Figure 6 An example processor platform 900 of an example valve controller 602 is shown. The processor platform 900 of the example shown includes Figure 1 and Figure 6 The example processor 136 of the illustrated example is hardware. For example, the processor 136 can be implemented by one or more integrated circuits, logic circuits, microprocessors, or controllers from any desired series or manufacturer. The processor 136 of the illustrated example includes a local memory 902 (e.g., a cache).

[0149] The processor 136 of the illustrated example communicates with one or more example sensors 904 via a bus 906. The sensors 904 include Figure 1 and Figure 6 The exemplary first pressure sensor 132 and the exemplary second pressure sensor 134 may also optionally include Figure 6 The exemplary third pressure sensor 622 (eg, in the processor platform 900 to execute instructions to Figure 6 An exemplary valve controller 602 implements Figure 8A-B In the case of exemplary method 800).

[0150] The processor 136 of the illustrated example also communicates with one or more example I / P converters 908 via bus 906. The I / P converters 908 include Figure 1 and Figure 6 The exemplary first I / P converter 118 and the second I / P converter 120 of FIG. 1 may also optionally include Figure 6The exemplary third I / P converter 612 and the exemplary fourth I / P converter 614 (eg, in the processor platform 900 to execute instructions to Figure 6 An exemplary valve controller 602 implements Figure 8A-B In the case of exemplary method 800).

[0151] The processor 136 of the illustrated example also communicates with a main memory including a volatile memory 910 and a non-volatile memory 912 via a bus 906. The volatile memory 910 may be implemented by a synchronous dynamic random access memory (SDRAM), a dynamic random access memory (DRAM), a RAMBUS dynamic random access memory (RDRAM), and / or any other type of random access memory device. The non-volatile memory 912 may be implemented by a flash memory and / or any other desired type of memory device. Access to the volatile memory 910 and the non-volatile memory 912 is controlled by a memory controller.

[0152] The processor 136 of the illustrated example is also in communication with one or more mass storage devices 914 for storing software and / or data. Examples of such mass storage devices 914 include floppy disk drives, hard disk drives, optical disk drives, Blu-ray disk drives, RAID systems, and digital versatile disk (DVD) drives. Figure 1 and Figure 6 An exemplary memory 138 may be composed of Fig. 9 The volatile memory 910 , the non-volatile memory 912 , and / or the mass storage device 914 of the processor platform 900 are implemented and / or implemented therein.

[0153] The processor platform 900 of the illustrated example also includes a user interface circuit 916. The user interface circuit 916 can be implemented by any type of interface standard, such as an Ethernet interface, a universal serial bus (USB) and / or a PCI express interface. In the illustrated example, one or more example input devices 918 are connected to the user interface circuit 916. The input device 918 allows the user to input data and commands into the processor 136. The input device 918 can be implemented by, for example, one or more buttons, one or more switches, a keypad, an audio sensor and / or a liquid crystal display with a touch screen. One or more example output devices 920 are also connected to the user interface circuit 916 of the illustrated example. The output device 920 can be implemented, for example, by one or more light emitting diodes for presenting visual information, one or more speakers for presenting auditory information, and / or a display device (such as a liquid crystal display) for presenting text and / or graphic information. Therefore, the user interface circuit 916 of the illustrated example can include a graphics driver, such as a graphics driver chip and / or a processor.

[0154] The processor platform 900 of the illustrated example also includes a network communication interface circuit 922 to facilitate the exchange of data and / or signals with an external machine via a network 924. In some examples, the network 924 may be implemented via 4mA-20mA wiring and / or via one or more communication protocols including, for example, Basic Fieldbus, Highway Addressable Remote Transducer (HART), Transmission Control Protocol / Internet Protocol (TCP / IP), Profinet, Modbus, and / or Ethernet.

[0155] To achieve Figure 7 The example method 700 and / or Figure 8A-B The encoded instructions 926 of the example method 800 may be stored in the local memory 902, in the volatile memory 910, in the non-volatile memory 912, in the mass storage device 914, and / or on a removable tangible computer-readable storage medium such as a CD or DVD.

[0156] As can be appreciated from the above, the example valve controller disclosed herein includes a pneumatic converter implemented as a two-stage relay, wherein a first relay valve and a second relay valve of the two-stage relay are operably coupled to and / or controlled by a corresponding one of a first I / P converter and a second I / P converter of the valve controller. The two-stage relay advantageously reduces (e.g., eliminates) the continuous emissions typically associated with steady-state operation of a pneumatic actuator and / or control valve via the conventional valve controller described above. Therefore, the example valve controller disclosed herein provides economic and environmental benefits relative to such conventional valve controllers.

[0157] The exemplary valve controllers disclosed herein also provide improved techniques for quantifying pneumatic volume usage and / or consumption, particularly with respect to quantifying the volume of pneumatic medium used and / or consumed in association with a valve controller that operates a pneumatic actuator to move a control valve (e.g., usage and / or consumption during non-steady-state operation). The pneumatic volume usage and / or consumption data calculated by these exemplary valve controllers disclosed herein can be monitored over time to detect unexpected and / or undesirable increases in the volume of pneumatic medium being used and / or consumed by the valve controller. In some examples, detection of such unexpected and / or undesirable increases in the volume of pneumatic medium used and / or consumed by the valve controller can indicate degradation of one or more components of the pneumatic actuator and / or control valve (including any piping and / or fittings associated therewith). Such information can advantageously enable maintenance personnel to more quickly identify and / or resolve operational problems, thereby increasing the reliability of field operations utilizing the valve controller, pneumatic actuator, and / or control valve.

[0158] In some examples, a device is disclosed. In some disclosed examples, the device includes a valve controller operably coupled to a pneumatic actuator, which is operably coupled to a control valve. In some disclosed examples, the valve controller includes one or more processors to command a first I / P converter of the valve controller to pulsate a first relay valve of the valve controller between a first closed position and a first open position in response to a first input signal indicating that the valve controller is to operate the pneumatic actuator to move a flow control member of the control valve in a first direction. In some disclosed examples, the pulsation of the first relay valve causes the pneumatic actuator to move the flow control member in the first direction. In some disclosed examples, the one or more processors are also used to calculate a first pneumatic volume usage associated with the movement of the flow control member in the first direction. In some disclosed examples, the first pneumatic volume usage is based on the pulsation of the first relay valve.

[0159] In some disclosed examples, the one or more processors also instruct a second I / P converter of the valve controller to pulse a second relay valve of the valve controller between a second closed position and a second open position in response to a second input signal indicating that the valve controller is to operate the pneumatic actuator to move the flow control member in a second direction opposite to the first direction. In some disclosed examples, the pulsation of the second relay valve causes the pneumatic actuator to move the flow control member in the second direction. In some disclosed examples, the one or more processors are also used to calculate a second pneumatic volume usage associated with the movement of the flow control member in the second direction. In some disclosed examples, the second pneumatic volume usage is based on the pulsation of the second relay valve.

[0160] In some disclosed examples, the pneumatic actuator is a single-acting pneumatic actuator.

[0161] In some disclosed examples, the pneumatic actuator is a double-acting pneumatic actuator. In some disclosed examples, the one or more processors also command a third I / P converter of the valve controller to pulse a third relay valve of the valve controller between a third closed position and a third open position in response to the second input signal. In some disclosed examples, the pulsation of the third relay valve causes the pneumatic actuator to move the flow control member in a second direction. In some disclosed examples, the one or more processors are also used to calculate a third pneumatic volume usage associated with the movement of the flow control member in the second direction. In some disclosed examples, the third pneumatic volume usage is based on the pulsation of the third relay valve.

[0162] In some disclosed examples, the one or more processors further command a fourth I / P converter of the valve controller to pulse a fourth relay valve of the valve controller between a fourth closed position and a fourth open position in response to the first input signal. In some disclosed examples, the pulsation of the fourth relay valve causes the pneumatic actuator to move the flow control member in the first direction. In some disclosed examples, the one or more processors are further configured to calculate a fourth pneumatic volume usage associated with the movement of the flow control member in the first direction. In some disclosed examples, the fourth pneumatic volume usage is based on the pulsation of the fourth relay valve.

[0163] In some disclosed examples, the one or more processors also instruct the first I / P converter to pulse the first relay valve between the first closed position and the first open position in response to a third input signal indicating that the valve controller is to increase the first pressure of the first fluid chamber of the pneumatic actuator and the second pressure of the second fluid chamber of the pneumatic actuator. In some disclosed examples, the pulsation of the first relay valve is to increase the first pressure of the first fluid chamber. In some disclosed examples, the one or more processors also instruct the third I / P converter to pulse the third relay valve between the third closed position and the third open position in response to the third input signal. In some disclosed examples, the pulsation of the third relay valve is to increase the second pressure of the second fluid chamber. In some disclosed examples, the one or more processors are also used to calculate a fifth pneumatic volume usage associated with the increase in the first pressure of the first fluid chamber and the increase in the second pressure of the second fluid chamber. In some disclosed examples, the fifth pneumatic volume usage is based on the pulsation of the first relay valve and the pulsation of the third relay valve.

[0164] In some disclosed examples, the one or more processors also instruct the second I / P converter to pulsate the second relay valve between the second closed position and the second open position in response to a fourth input signal indicating that the valve controller is to reduce the first pressure of the first fluid chamber and the second pressure of the second fluid chamber. In some disclosed examples, the pulsation of the second relay valve is to reduce the first pressure of the first fluid chamber. In some disclosed examples, the one or more processors also instruct the fourth I / P converter to pulse the fourth relay valve between the fourth closed position and the fourth open position in response to the fourth input signal. In some disclosed examples, the pulsation of the fourth relay valve is to reduce the second pressure of the second fluid chamber. In some disclosed examples, the one or more processors are also used to calculate a sixth pneumatic volume usage associated with a reduction in the first pressure of the first fluid chamber and a reduction in the second pressure of the second fluid chamber. In some disclosed examples, the sixth pneumatic volume usage is based on the pulsation of the second relay valve and the pulsation of the fourth relay valve.

[0165] In some examples, a method is disclosed. In some disclosed examples, the method includes receiving a first input signal at a valve controller operably coupled to a pneumatic actuator, the pneumatic actuator operably coupled to a control valve, the first input signal indicating that the valve controller is to operate the pneumatic actuator to move a flow control member of the control valve in a first direction. In some disclosed examples, the method also includes: in response to receiving the first input signal, commanding a first I / P converter of the valve controller via one or more processors of the valve controller to pulsate a first relay valve of the valve controller between a first closed position and a first open position. In some disclosed examples, the pulsation of the first relay valve causes the pneumatic actuator to move the flow control member in the first direction. In some disclosed examples, the method also includes calculating a first pneumatic volume usage associated with the movement of the flow control member in the first direction via one or more processors. In some disclosed examples, the first pneumatic volume usage is based on the pulsation of the first relay valve.

[0166] In some disclosed examples, the method also includes receiving a second input signal at the valve controller, the second input signal indicating that the valve controller is to operate the pneumatic actuator to move the flow control member in a second direction opposite to the first direction. In some disclosed examples, the method also includes: in response to receiving the second input signal, commanding the second I / P converter of the valve controller via one or more processors to pulsate the second relay valve of the valve controller between a second closed position and a second open position. In some disclosed examples, the pulsation of the second relay valve causes the pneumatic actuator to move the flow control member in the second direction. In some disclosed examples, the method also includes calculating a second pneumatic volume usage associated with the movement of the flow control member in the second direction via one or more processors. In some disclosed examples, the second pneumatic volume usage is based on the pulsation of the second relay valve.

[0167] In some disclosed examples of the method, the pneumatic actuator is a single-acting pneumatic actuator.

[0168] In some disclosed examples of the method, the pneumatic actuator is a double-acting pneumatic actuator. In some disclosed examples, the method further includes: in response to receiving a second input signal, commanding a third I / P converter of the valve controller via one or more processors to pulsate a third relay valve of the valve controller between a third closed position and a third open position. In some disclosed examples, the pulsation of the third relay valve causes the pneumatic actuator to move the flow control member in a second direction. In some disclosed examples, the method further includes calculating a third pneumatic volume usage associated with the movement of the flow control member in the second direction via one or more processors. In some disclosed examples, the third pneumatic volume usage is based on the pulsation of the third relay valve.

[0169] In some disclosed examples, the method further includes: in response to receiving the first input signal, commanding a fourth I / P converter of the valve controller via one or more processors to pulsate a fourth relay valve of the valve controller between a fourth closed position and a fourth open position. In some disclosed examples, the pulsation of the fourth relay valve causes the pneumatic actuator to move the flow control member in the first direction. In some disclosed examples, the method further includes calculating, via the one or more processors, a fourth pneumatic volume usage associated with the movement of the flow control member in the first direction. In some disclosed examples, the fourth pneumatic volume usage is based on the pulsation of the fourth relay valve.

[0170] In some disclosed examples, the method further includes receiving a third input signal at the valve controller. In some disclosed examples, the third input signal indicates that the valve controller is to increase the first pressure of the first fluid chamber of the pneumatic actuator and the second pressure of the second fluid chamber of the pneumatic actuator. In some disclosed examples, the method further includes: in response to receiving the third input signal, commanding the first I / P converter via one or more processors to pulsate the first relay valve between the first closed position and the first open position. In some disclosed examples, the pulsation of the first relay valve increases the first pressure of the first fluid chamber. In some disclosed examples, the method further includes: in response to receiving the third input signal, commanding the third I / P converter via one or more processors to pulsate the third relay valve between the third closed position and the third open position. In some disclosed examples, the pulsation of the third relay valve increases the second pressure of the second fluid chamber. In some disclosed examples, the method further includes calculating a fifth pneumatic volume usage associated with the increase in the first pressure of the first fluid chamber and the increase in the second pressure of the second fluid chamber via the one or more processors. In some disclosed examples, the fifth pneumatic volume usage is based on a pulsation of the first relay valve and a pulsation of the third relay valve.

[0171] In some disclosed examples, the method further includes receiving a fourth input signal at the valve controller. In some disclosed examples, the fourth input signal indicates that the valve controller is to reduce the first pressure of the first fluid chamber and the second pressure of the second fluid chamber. In some disclosed examples, the method further includes: in response to receiving the fourth input signal, commanding the second I / P converter via one or more processors to pulsate the second relay valve between the second closed position and the second open position. In some disclosed examples, the pulsation of the second relay valve reduces the first pressure of the first fluid chamber. In some disclosed examples, the method further includes: in response to receiving the fourth input signal, commanding the fourth I / P converter via the one or more processors to pulse the fourth relay valve between the fourth closed position and the fourth open position. In some disclosed examples, the pulsation of the fourth relay valve reduces the second pressure of the second fluid chamber. In some disclosed examples, the method further includes calculating a sixth pneumatic volume usage associated with a reduction in the first pressure of the first fluid chamber and a reduction in the second pressure of the second fluid chamber via the one or more processors. In some disclosed examples, the sixth pneumatic volume usage is based on a pulsation of the second relay valve and a pulsation of the fourth relay valve.

[0172] In some examples, a non-transitory computer-readable storage medium is disclosed. In some disclosed examples, the non-transitory computer-readable storage medium includes instructions, which, when executed, cause one or more processors of a valve controller to obtain a first input signal, the first input signal indicating that the valve controller is to operate a pneumatic actuator operably coupled to the valve controller to move a flow control member of a control valve in a first direction, the control valve being operably coupled to the pneumatic actuator. In some disclosed examples, the instructions, when executed, further cause the one or more processors to pulse a first relay valve of the valve controller between a first closed position and a first open position in response to the first input signal by a first I / P converter of the valve controller. In some disclosed examples, the pulsation of the first relay valve causes the pneumatic actuator to move the flow control member in a first direction. In some disclosed examples, the instructions, when executed, also cause the one or more processors to calculate a first pneumatic volume usage associated with the movement of the flow control member in the first direction. In some disclosed examples, the first pneumatic volume usage is based on the pulsation of the first relay valve.

[0173] In some disclosed examples, the instructions, when executed, also cause the one or more processors to obtain a second input signal, the second input signal indicating that the valve controller is to operate the pneumatic actuator to move the flow control member in a second direction opposite to the first direction. In some disclosed examples, the instructions, when executed, also cause the one or more processors to command the second I / P converter of the valve controller to pulsate the second relay valve of the valve controller between a second closed position and a second open position in response to the second input signal. In some disclosed examples, the pulsation of the second relay valve causes the pneumatic actuator to move the flow control member in the second direction. In some disclosed examples, the instructions, when executed, also cause the one or more processors to calculate a second pneumatic volume usage associated with the movement of the flow control member in the second direction. In some disclosed examples, the second pneumatic volume usage is based on the pulsation of the second relay valve.

[0174] In some disclosed examples, the instructions, when executed, further cause the one or more processors to command a third I / P converter of the valve controller to pulse a third relay valve of the valve controller between a third closed position and a third open position in response to the second input signal. In some disclosed examples, the pulsation of the third relay valve causes the pneumatic actuator to move the flow control member in a second direction. In some disclosed examples, the instructions, when executed, further cause the one or more processors to calculate a third pneumatic volume usage associated with the movement of the flow control member in the second direction. In some disclosed examples, the third pneumatic volume usage is based on the pulsation of the third relay valve.

[0175] In some disclosed examples, the instructions, when executed, further cause the one or more processors to command a fourth I / P converter of the valve controller to pulse a fourth relay valve of the valve controller between a fourth closed position and a fourth open position in response to the first input signal. In some disclosed examples, the pulsation of the fourth relay valve causes a pneumatic actuator to move a flow control member in a first direction. In some disclosed examples, the instructions, when executed, further cause the one or more processors to calculate a fourth pneumatic volume usage associated with the movement of the flow control member in the first direction. In some disclosed examples, the fourth pneumatic volume usage is based on the pulsation of the fourth relay valve.

[0176] In some disclosed examples, the instructions, when executed, also cause one or more processors to obtain a third input signal. In some disclosed examples, the third input signal indicates that the valve controller is to increase the first pressure of the first fluid chamber of the pneumatic actuator and the second pressure of the second fluid chamber of the pneumatic actuator. In some disclosed examples, the instructions, when executed, also cause the one or more processors to command the first I / P converter to pulse the first relay valve between the first closed position and the first open position in response to the third input signal. In some disclosed examples, the pulsation of the first relay valve increases the first pressure of the first fluid chamber. In some disclosed examples, the instructions, when executed, also cause the one or more processors to command the third I / P converter to move the third relay valve between the third closed position and the third open position in response to the third input signal. In some disclosed examples, the pulsation of the third relay valve increases the second pressure of the second fluid chamber. In some disclosed examples, the instructions, when executed, also cause the one or more processors to calculate a fifth pneumatic volume usage associated with the increase in the first pressure of the first fluid chamber and the increase in the second pressure of the second fluid chamber. In some disclosed examples, the fifth pneumatic volume usage is based on a pulsation of the first relay valve and a pulsation of the third relay valve.

[0177] In some disclosed examples, the instructions, when executed, also cause one or more processors to obtain a fourth input signal. In some disclosed examples, the fourth input signal indicates that the valve controller is to reduce the first pressure of the first fluid chamber and the second pressure of the second fluid chamber. In some disclosed examples, the instructions, when executed, also cause the one or more processors to command the second I / P converter to pulse the second relay valve between the second closed position and the second open position in response to the fourth input signal. In some disclosed examples, the pulsation of the second relay valve reduces the first pressure of the first fluid chamber. In some disclosed examples, the instructions, when executed, also cause the one or more processors to command the fourth I / P converter to pulse the fourth relay valve between the fourth closed position and the fourth open position in response to the fourth input signal. In some disclosed examples, the pulsation of the fourth relay valve reduces the second pressure of the second fluid chamber. In some disclosed examples, the instructions, when executed, also cause the one or more processors to calculate a sixth pneumatic volume usage associated with a reduction in the first pressure of the first fluid chamber and a reduction in the second pressure of the second fluid chamber. In some disclosed examples, the sixth pneumatic volume usage is based on a pulsation of the second relay valve and a pulsation of the fourth relay valve.

[0178] Although certain exemplary methods, devices, articles, and systems have been disclosed herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, devices, articles, and systems that fully fall within the scope of the claims of this patent.

Claims

1. A device for characterizing pneumatic volume usage associated with moving a flow control member of a control valve, the device comprising: a valve controller operably coupled to a pneumatic actuator operably coupled to the control valve, the valve controller comprising one or more processors for: commanding a first current-to-pressure converter of the valve controller to pulse a first relay valve of the valve controller between a first closed position and a first open position using a control signal in response to a first input signal, the first input signal instructing the valve controller to operate the pneumatic actuator to move the flow control member of the control valve in a first direction, the control signal having (i) at least one pulse of a first duration within a first time interval and (ii) at least one pulse of a second duration within a second time interval, the second duration being different from the first duration, the pulsation of the first relay valve of the first duration causing the pneumatic actuator to move the flow control member in the first direction, and the pulsation of the first relay valve of the second duration causing the pneumatic actuator to move the flow control member in the first direction; as well as A first pneumatic volume usage associated with movement of the flow control member in the first direction is calculated, wherein the first pneumatic volume usage is calculated based on a predetermined volume of a pneumatic pulse associated with pulsation of the first relay valve.

2. The apparatus of claim 1 , wherein the one or more processors are further configured to: In response to a second input signal, commanding a second current-to-pressure converter of the valve controller to pulsate a second relay valve of the valve controller between a second closed position and a second open position, the second input signal instructing the valve controller to operate the pneumatic actuator to move the flow control member in a second direction opposite to the first direction, the pulsation of the second relay valve causing the pneumatic actuator to move in the second direction the flow control member; and A second pneumatic volume usage associated with movement of the flow control member in the second direction is calculated, the second pneumatic volume usage based on pulsation of the second relay valve.

3. The device of claim 2, wherein the pneumatic actuator is a single-acting pneumatic actuator.

4. The apparatus of claim 2, wherein the pneumatic actuator is a double-acting pneumatic actuator, and wherein the one or more processors are further configured to: in response to the second input signal, commanding a third current-to-pressure converter of the valve controller to pulse a third relay valve of the valve controller between a third closed position and a third open position, the pulsation of the third relay valve causing the pneumatic actuator to move the flow control member in the second direction; and Calculate a third pneumatic volume usage associated with movement of the flow control member along the second direction, wherein the third pneumatic volume usage is calculated based on the pulsation of the third relay valve and also based on supply pressure data measured by a first pressure sensor of the valve controller, wherein the first pressure sensor is operatively disposed between a control fluid inlet of the valve controller and the third relay valve.

5. The apparatus of claim 4, wherein the one or more processors are further configured to: In response to the first input signal, commanding a fourth current-to-pressure converter of the valve controller to pulse a fourth relay valve of the valve controller between a fourth closed position and a fourth open position, the pulsation of the fourth relay valve causing the pneumatic actuator to move the flow control member in the first direction; and A fourth pneumatic volume usage associated with movement of the flow control member along the first direction is calculated, the fourth pneumatic volume usage being based on pulsation of the fourth relay valve and also based on port pressure data measured by a third pressure sensor of the valve controller, the third pressure sensor being operatively disposed between the third relay valve and the fourth relay valve.

6. The apparatus of claim 5, wherein the one or more processors are further configured to: commanding the first current-to-pressure converter to pulse the first relay valve between the first closed position and the first open position in response to a third input signal, the third input signal instructing the valve controller to increase a first pressure in a first fluid chamber of the pneumatic actuator and a second pressure in a second fluid chamber of the pneumatic actuator, the pulsating of the first relay valve increasing the first pressure in the first fluid chamber; commanding the third current-to-pressure converter to pulsate the third relay valve between the third closed position and the third open position in response to the third input signal, the pulsation of the third relay valve increasing the second pressure of the second fluid chamber; as well as A fifth pneumatic volume usage associated with the increase in the first pressure of the first fluid chamber and the increase in the second pressure of the second fluid chamber is calculated, wherein the fifth pneumatic volume usage is calculated based on a predetermined volume of a pneumatic pulse associated with the pulsation of the first relay valve and the pulsation of the third relay valve.

7. The apparatus of claim 6, wherein the one or more processors are further configured to: commanding the second current-to-pressure converter to pulse the second relay valve between the second closed position and the second open position in response to a fourth input signal instructing the valve controller to reduce the first pressure of the first fluid chamber and the second pressure of the second fluid chamber, the pulsating of the second relay valve reducing the first pressure of the first fluid chamber; in response to the fourth input signal, commanding the fourth current-to-pressure converter to pulsate the fourth relay valve between the fourth closed position and the fourth open position, the pulsation of the fourth relay valve reducing the second pressure of the second fluid chamber; and A sixth pneumatic volume usage associated with a decrease in the first pressure of the first fluid chamber and a decrease in the second pressure of the second fluid chamber is calculated, wherein the sixth pneumatic volume usage is calculated based on a predetermined volume of a pneumatic pulse associated with a pulsation of the second relay valve and a pulsation of the fourth relay valve.

8. The device according to claim 1, wherein the first control flow of the valve controller A body port is operatively disposed between the first relay valve and the second relay valve and is operatively coupled to a second control fluid port of the pneumatic actuator.

9. The apparatus of claim 8, wherein the second relay valve is operatively disposed between the first relay valve and a control fluid discharge of the valve controller.

10. An apparatus according to claim 1, wherein the first pneumatic volume usage is calculated on a pulse-by-pulse basis for each of the pneumatic pulses associated with the pulse of the first relay valve, and wherein the one or more processors further calculate the total pneumatic volume usage by adding the individually calculated pneumatic volume usages of the pneumatic pulses.

11. The apparatus of claim 1 , wherein the one or more processors further instruct the first current-to-pressure converter of the valve controller to pulse the first relay valve of the valve controller with at least one pulse of a third duration following at least one pulse of the second duration, the third duration being shorter than the second duration.

12. The apparatus of claim 2, wherein the one or more processors further determine a condition of the valve based on the first pneumatic volume usage and the second pneumatic volume usage.

13. The apparatus of claim 1, wherein the second time interval does not overlap with the first time interval.

14. The apparatus of claim 13, wherein at least one pulse of the first duration occurs before at least one pulse of the second duration, the first duration being longer than the second duration.

15. The apparatus of claim 1, wherein the first pneumatic volume usage is further calculated based on: (i) the first duration and the second duration, and (ii) Supply pressure data measured by a first pressure sensor of the valve controller, the first pressure sensor being operatively disposed between a control fluid inlet of the valve controller and the first relay valve.

16. A method for characterizing the pneumatic motion associated with moving a flow control member of a control valve. Volumetric dosage methods include: receiving, at a valve controller operably coupled to a pneumatic actuator operably coupled to the control valve, a first input signal instructing the valve controller to operate the pneumatic actuator to move the flow control member of the control valve in a first direction; in response to receiving the first input signal, commanding, via one or more processors of the valve controller, a first current-to-pressure converter of the valve controller to pulse a first relay valve of the valve controller between a first closed position and a first open position using a control signal, the control signal having (i) at least one pulse of a first duration within a first time interval and (ii) at least one pulse of a second duration within a second time interval, the second duration being different from the first duration, the pulsation of the first relay valve causing the pneumatic actuator to move the flow control member in the first direction, the pulsation of the first relay valve of the second duration causing the pneumatic actuator to move the flow control member in the first direction; as well as A first pneumatic volume usage associated with movement of the flow control member in the first direction is calculated, via the one or more processors, wherein the first pneumatic volume usage is calculated based on a predetermined volume of a pneumatic pulse associated with pulsation of the first relay valve.

17. The method according to claim 16, further comprising: receiving a second input signal at the valve controller, the second input signal instructing the valve controller to operate the pneumatic actuator to move the flow control member in a second direction opposite to the first direction; in response to receiving the second input signal, commanding, via the one or more processors, a second current-to-pressure transducer of the valve controller to pulse a second relay valve of the valve controller between a second closed position and a second open position, the pulsation of the second relay valve causing the pneumatic actuator to move the flow control member in the second direction; and calculating, via the one or more processors, a second pneumatic volume usage associated with movement of the flow control member in the second direction, wherein the second pneumatic volume usage The volume usage is calculated based on a predetermined volume of a pneumatic pulse associated with pulsation of the second relay valve and also based on port pressure data measured by a second pressure sensor operatively disposed between the first relay valve and the second relay valve.

18. The method of claim 17, wherein the pneumatic actuator is a single-acting pneumatic actuator.

19. The method of claim 17, wherein the pneumatic actuator is a double-acting pneumatic actuator, the method further comprising: In response to receiving the second input signal, commanding, via the one or more processors, a third current-to-pressure converter of the valve controller to pulse a third relay valve of the valve controller between a third closed position and a third open position, the pulsation of the third relay valve causing the pneumatic actuator to move the flow control member in the second direction; and Via the one or more processors, a third pneumatic volume usage associated with the movement of the flow control member along the second direction is calculated, wherein the third pneumatic volume usage is based on the pulsation of the third relay valve and also based on supply pressure data measured by a first pressure sensor of the valve controller, wherein the first pressure sensor is operatively disposed between a control fluid inlet of the valve controller and the third relay valve.

20. The method according to claim 19, further comprising: In response to receiving the first input signal, commanding, via the one or more processors, a fourth current-to-pressure converter of the valve controller to pulse a fourth relay valve of the valve controller between a fourth closed position and a fourth open position, the pulsation of the fourth relay valve causing the pneumatic actuator to move the flow control member in the first direction; and calculating, via the one or more processors, a fourth pneumatic volume usage associated with movement of the flow control member in the first direction, wherein the fourth pneumatic volume usage is based on a predetermined volume of a pneumatic pulse associated with pulsation of the fourth relay valve and further based on a port pressure data measured by a third pressure sensor of the valve controller. According to calculation, the third pressure sensor is operatively disposed between the third relay valve and the fourth relay valve.

21. The method according to claim 20, further comprising: receiving a third input signal at the valve controller, the third input signal instructing the valve controller to increase a first pressure in a first fluid chamber of the pneumatic actuator and a second pressure in a second fluid chamber of the pneumatic actuator; in response to receiving the third input signal, commanding, via the one or more processors, the first current-to-pressure transducer to pulse the first relay valve between the first closed position and the first open position, the pulsating of the first relay valve increasing the first pressure of the first fluid chamber; in response to receiving the third input signal, commanding, via the one or more processors, the third current-to-pressure transducer to pulse the third relay valve between the third closed position and the third open position, the pulsation of the third relay valve increasing the second pressure of the second fluid chamber; as well as A fifth pneumatic volume usage associated with an increase in the first pressure of the first fluid chamber and an increase in the second pressure of the second fluid chamber is calculated via the one or more processors, wherein the fifth pneumatic volume usage is calculated based on a predetermined volume of a pneumatic pulse associated with the pulsation of the first relay valve and the pulsation of the third relay valve.

22. The method according to claim 21, further comprising: receiving a fourth input signal at the valve controller, the fourth input signal instructing the valve controller to reduce the first pressure of the first fluid chamber and the second pressure of the second fluid chamber; in response to receiving the fourth input signal, commanding, via the one or more processors, the second current-to-pressure transducer to pulse the second relay valve between the second closed position and the second open position, the pulsating of the second relay valve reducing the first pressure of the first fluid chamber; In response to receiving the fourth input signal, the one or more processors command the fourth current-to-pressure converter to close the fourth relay valve at the fourth the fourth relay valve pulsates between the second open position and the fourth open position, the pulsation of the fourth relay valve reducing the second pressure of the second fluid chamber; as well as A sixth pneumatic volume usage associated with a reduction in the first pressure of the first fluid chamber and a reduction in the second pressure of the second fluid chamber is calculated via the one or more processors, wherein the sixth pneumatic volume usage is calculated based on a predetermined volume of a pneumatic pulse associated with the pulsation of the second relay valve and the pulsation of the fourth relay valve.

23. A non-transitory computer readable storage medium comprising instructions that, when executed, cause one or more processors of a valve controller to at least: obtaining a first input signal, the first input signal instructing the valve controller to operate a pneumatic actuator to move a flow control member of a control valve in a first direction, the pneumatic actuator being operably coupled to the valve controller and the control valve being operably coupled to the pneumatic actuator; In response to the first input signal, command a first current-to-pressure converter of the valve controller to pulse a first relay valve of the valve controller between a first closed position and a first open position using a control signal, the control signal having (i) at least one pulse of a first duration in a first time interval and (ii) at least one pulse of a second duration in a second time interval, the second duration being different from the first duration, the pulsation of the first relay valve of the first duration causing the pneumatic actuator to move the flow control member in the first direction, the pulsation of the first relay valve of the second duration causing the pneumatic actuator to move the flow control member in the first direction; as well as A first pneumatic volume usage associated with movement of the flow control member in the first direction is calculated, wherein the first pneumatic volume usage is calculated based on a predetermined volume of a pneumatic pulse associated with pulsation of the first relay valve.

24. The non-transitory computer readable storage medium of claim 23, wherein the instructions, when executed, further cause the one or more processors to: A second input signal is obtained, wherein the second input signal instructs the valve controller to operate the pneumatic actuator to move the flow valve in a second direction opposite to the first direction. Control components; commanding a second current-to-pressure converter of the valve controller to pulse a second relay valve of the valve controller between a second closed position and a second open position in response to the second input signal, the pulsation of the second relay valve causing the pneumatic actuator to move the flow control member in the second direction; as well as Calculating a second pneumatic volume usage associated with movement of the flow control member along the second direction, wherein the second pneumatic volume usage is based on a predetermined volume of a pneumatic pulse associated with pulsation of the second relay valve and is also based on port pressure data measured by a second pressure sensor of the valve controller, wherein the second pressure sensor is operatively disposed between the first relay valve and the second relay valve.

25. The non-transitory computer readable storage medium of claim 24, wherein the instructions, when executed, further cause the one or more processors to: in response to the second input signal, commanding a third current-to-pressure converter of the valve controller to pulse a third relay valve of the valve controller between a third closed position and a third open position, the pulsation of the third relay valve causing the pneumatic actuator to move the flow control member in the second direction; and Calculate a third pneumatic volume usage associated with movement of the flow control member along the second direction, wherein the third pneumatic volume usage is based on a predetermined volume of a pneumatic pulse associated with pulsation of the third relay valve and is also based on supply pressure data measured by a first pressure sensor of the valve controller, wherein the first pressure sensor is operatively disposed between a control fluid inlet of the valve controller and the third relay valve.

26. The non-transitory computer readable storage medium of claim 25, wherein the instructions, when executed, further cause the one or more processors to: In response to the first input signal, commanding a fourth current-to-pressure converter of the valve controller to pulse a fourth relay valve of the valve controller between a fourth closed position and a fourth open position, the pulsation of the fourth relay valve causing the pneumatic actuator to move the flow control member in the first direction; and Calculating a fourth factor associated with movement of the flow control member along the first direction Pneumatic volume usage, wherein the fourth pneumatic volume usage is calculated based on a predetermined volume of a pneumatic pulse associated with the pulsation of the fourth relay valve and also based on port pressure data measured by a third pressure sensor of the valve controller, the third pressure sensor being operatively disposed between the third relay valve and the fourth relay valve.

27. The non-transitory computer readable storage medium of claim 26, wherein the instructions, when executed, further cause the one or more processors to: obtaining a third input signal instructing the valve controller to increase a first pressure in a first fluid chamber of the pneumatic actuator and a second pressure in a second fluid chamber of the pneumatic actuator; commanding the first current-to-pressure converter to pulse the first relay valve between the first closed position and the first open position in response to the third input signal, the pulsation of the first relay valve increasing the first pressure of the first fluid chamber; commanding the third current-to-pressure converter to pulsate the third relay valve between the third closed position and the third open position in response to the third input signal, the pulsation of the third relay valve increasing the second pressure of the second fluid chamber; as well as A fifth pneumatic volume usage associated with the increase in the first pressure of the first fluid chamber and the increase in the second pressure of the second fluid chamber is calculated, wherein the fifth pneumatic volume usage is calculated based on a predetermined volume of a pneumatic pulse associated with the pulsation of the first relay valve and the pulsation of the third relay valve.

28. The non-transitory computer readable storage medium of claim 27, wherein the instructions, when executed, further cause the one or more processors to: obtaining a fourth input signal instructing the valve controller to reduce a first pressure in the first fluid chamber and a second pressure in the second fluid chamber; commanding the second current-to-pressure converter to pulse the second relay valve between the second closed position and the second open position in response to the fourth input signal, the pulsation of the second relay valve reducing the first pressure of the first fluid chamber; In response to the fourth input signal, the fourth current-to-pressure converter is commanded to pulse the fourth relay valve between the fourth closed position and the fourth open position. actuation, the pulsation of the fourth relay valve reduces the second pressure of the second fluid chamber; and A sixth pneumatic volume usage associated with the decrease in the first pressure of the first fluid chamber and the decrease in the second pressure of the second fluid chamber is calculated, wherein the sixth pneumatic volume usage is calculated based on the pulsation of the second relay valve and the pulsation of the fourth relay valve.

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