Switch assembly for valve actuator

Abstract

A switch assembly for a valve actuator can include a bracket, a rotatable switch adjustably rotatably coupled to the bracket, a fixed switch fixedly mounted to the bracket, an arm rotatably coupled to the bracket, and an adjustable switch trigger coupled to the arm. The rotatable switch can be tripped by the valve actuator, and the trip point of the rotatable switch can be calibrated by setting the adjustable angle. The fixed switch can be tripped by the switch trigger on the arm, and the trip point of the fixed switch can be set by adjusting the switch trigger relative to the arm. The assembly can include a calibration fixture for calibrating the switch assembly to the valve actuator independent of the valve actuator.

Description

Technical Field

[0001] This invention relates generally to control valves, and more specifically to actuators and control systems for control valves. Background Technology

[0002] Flow control systems are common in process and manufacturing systems, such as those used in hazardous or harsh environments. Accurate monitoring and control of various parameters in such systems is crucial, including flow rate, valve position, pressure, valve health, and other aspects of the fluid control components. Therefore, many industries require control systems and valves that offer rapid and precise control. Furthermore, control systems and components, including valves, actuators, and their control units, are typically required to have short lead times.

[0003] Manufacturing control systems and their components can be time-consuming and labor-intensive. For example, to ensure proper operation, switches used to control valves and their actuators are often made adjustable to address various manufacturing and / or operational issues. These switches are typically preset to operate at specific points when the control valve is open and / or closed. This is usually achieved by mounting each switch on the valve's actuator and then adjusting each switch while the actuator is operated through one or more on / off cycles.

[0004] There is a need in the art for improved components to enhance manufacturing efficiency and streamline supply chain management without compromising the proper operation, reliability, and repeatability of control system components. The disclosure and teachings of this disclosure are directed to apparatus, systems, and methods for improving control valve assemblies and related processes. Summary of the Invention

[0005] In at least one embodiment, the switching assembly for the valve actuator may include a bracket for supporting multiple switches, one or more switches rotatably coupled to the bracket at one or more adjustable angles, and one or more switches fixedly mounted to the bracket. In at least one embodiment, the bracket may be non-conductive to electrically isolate the switches from the valve actuator. The valve actuator may trip or trigger the rotatably mounted switches at one or more trip points, which can be independently adjusted by calibrating the adjustable angle. A triggering mechanism may be used to trip / trigger the fixedly mounted switches at one or more trip points that can be adjusted by calibrating the triggering mechanism.

[0006] For example, in at least one embodiment, the triggering mechanism may include an arm rotatably coupled to a bracket. The indicating end of the arm may be coupled to an actuator or a portion of a valve controlled by the actuator, such as a valve stem or a valve stem position indicator. The bracket end of the arm is rotatably coupled to the bracket. Movement of the arm directly or indirectly trips a fixedly mounted switch. One or more switch triggers are adjustablely coupled to the arm and can trigger the fixedly mounted switch.

[0007] In at least one embodiment, the switching assembly further includes one or more terminals mounted to a bracket, wherein at least one of the rotary switch and the fixed switch is wired to the terminal. In at least one embodiment, the switching assembly may include a plurality of fixedly mounted switches, which may have different and independently adjustable trip points. In at least one embodiment, the switching assembly further includes a calibration fixture for calibrating the switching assembly to the valve actuator independently of the valve actuator.

[0008] In at least one embodiment, a switching assembly for a valve actuator used to control a valve can be configured by assembling a plurality of switches onto a bracket to form a switching assembly, aligning the switching assembly with a calibration fixture, and adjusting the switches while the switching assembly is fixed to the calibration fixture. Subsequently, the switching assembly can be mounted to a valve actuator that has been calibrated independently of the valve actuator for the valve actuator. The switches may include one or more switches fixed and / or directly mounted to the bracket, and one or more switches rotatably and / or pivotally mounted to the bracket. The calibration fixture can simulate the selection function, operation, and / or movement of the valve actuator.

[0009] Aligning the switching assembly with the calibration fixture may include positioning, aligning, or co-aligning one or more component references on the switching assembly to one or more corresponding fixture references on the calibration fixture. The component references and fixture references can cooperate to ensure proper alignment between the switching assembly and the calibration fixture. With the switching assembly properly aligned with the calibration fixture, the switching assembly can then be secured to the calibration fixture.

[0010] When the switch assembly is correctly aligned and fixed to the calibration fixture, the trip point of the switch can be adjusted. For example, adjusting the trip point of at least one fixed switch can be performed by adjusting a trigger between at least one fixed switch and an arm pivotally mounted to a bracket. The trip point of at least one rotatable switch can be adjusted by adjusting the angle at which it is mounted to the bracket.

[0011] Once the switch has been adjusted using the switch assembly fixed to the calibration fixture, the switch assembly can be removed from the calibration fixture. At this point, the switch assembly can be stored for future use with the valve actuator, or it can be used with the valve actuator immediately. In either case, the switch assembly can be aligned with the valve actuator by aligning the assembly reference on the switch assembly with the actuator reference on the valve actuator, in a manner substantially similar to that using the calibration fixture. The switch assembly can then be fixed to the valve actuator. Once the switch assembly is aligned with and fixed to the valve actuator, adjustments made during the alignment and fixing of the switch assembly to the calibration fixture can be expected to ensure that each switch is properly calibrated to the valve actuator. Attached Figure Description

[0012] Figure 1 This is a perspective view of one of many embodiments of the valve actuator assembly according to this disclosure.

[0013] Figure 2 yes Figure 1 A partial exploded perspective view of the valve actuator assembly, showing the switching assembly separate from the valve actuator.

[0014] Figure 3 yes Figure 2 A reverse perspective view of the switch component.

[0015] Figure 4 yes Figure 1 A partial perspective view of the valve actuator assembly.

[0016] Figure 5 This is a perspective view of one of many embodiments of the calibration fixture according to the present disclosure.

[0017] Figure 6 yes Figure 2 The reverse side view of the switch component.

[0018] Figure 7 This is an exploded perspective view of one of many embodiments of the switch assembly according to the present disclosure, showing a rotatably mounted switch and a fixedly mounted switch.

[0019] Figure 8 This is a perspective view of one of many embodiments of the switch assembly according to the present disclosure, showing a rotatably mounted switch and two fixedly mounted switches.

[0020] Figure 9 yes Figure 8 An exploded perspective view of the switch assembly.

[0021] Figure 10 This is a perspective view of one of many embodiments of the switch assembly according to the present disclosure, showing a rotatably mounted switch and three fixedly mounted switches.

[0022] Figure 11 yes Figure 10 An exploded perspective view of the switch assembly.

[0023] Figure 12 This is a flowchart illustrating one of many embodiments of the assembly method according to the present disclosure. Detailed Implementation

[0024] The accompanying drawings described above and the written description of the specific structures and functions below do not limit the scope of the applicant's invention or the scope of the appended claims. Rather, the drawings and written description are provided to teach those skilled in the art to make and use the invention for which patent protection is sought. Those skilled in the art will understand that, for clarity and understanding, not all features of commercial embodiments of this disclosure are described or shown. Those skilled in the art will also recognize that the development of a practical commercial embodiment incorporating various aspects of this disclosure may require numerous implementation-specific decisions to achieve the developer's ultimate goals for the commercial embodiment. Such implementation-specific decisions may include, and may not be limited to, compliance with system-related, business-related, governmental-related, and other constraints that may vary depending on the particular implementation, location, and time. While the developer's effort may be complex and time-consuming in an absolute sense, such effort will be a routine task for those skilled in the art who benefit from this disclosure. It must be understood that the embodiments disclosed and taught herein can have many different modifications and alternative forms. The use of singular terms, such as, but not limited to, "a," is not intended to limit the number of items. The use of relational terms, such as, but not limited to, “top,” “bottom,” “left,” “right,” “upper,” “lower,” “below,” “above,” “side,” “first,” “second” (“third,” etc.), “inlet,” “outlet,” etc., in the written description with specific reference to the accompanying drawings is for clarity and not for limiting the scope of this disclosure or the appended claims, unless otherwise stated. The terms “connection,” “coupler,” and similar terms are used extensively herein and may include any method or means for securing, binding, joining, fastening, attaching, engaging, inserting therein, forming thereon or therein, communicating, or otherwise relating to an intermediate element, such as mechanically, magnetically, electrically, chemically, operatively, directly or indirectly, and may further include, but not limited to, integrally forming one component with another component. Connections can occur in any direction, including rotatably. The terms “comprising” and “such as” are illustrative and not restrictive, and the word “may” means “may, but not necessarily” unless otherwise stated. Although there is no other language in this disclosure, the embodiments shown in the accompanying drawings are examples presented for illustrative and explanatory purposes and are not the only embodiments of its subject matter.

[0025] The applicant has created systems and methods for improving components to enhance manufacturing efficiency and streamline supply chain management without compromising the correct operation, reliability, and repeatability of control valves, related system components, and related processes. The applicant has created systems and methods for improving components to enhance manufacturing efficiency and streamline supply chain management without compromising the correct operation, reliability, and repeatability of control valve actuators. The applicant has created systems and methods for assembling and calibrating sub-assemblies of control valve actuators. In at least one embodiment, a switching sub-assembly may be assembled and adjusted, or otherwise calibrated, for the actuator of a control valve.

[0026] Figure 1 This is a perspective view of one of many embodiments of the valve actuator assembly according to this disclosure. Figure 2 yes Figure 1 A partial exploded perspective view of the valve actuator assembly, showing the switching assembly separate from the valve actuator. Figure 3 yes Figure 2 A reverse perspective view of the switch component. Figure 4 yes Figure 1 A partial perspective view of the valve actuator assembly. Figure 5 It is installed on the calibration fixture. Figure 2 Side view of the switch component. Figure 6 yes Figure 2 The reverse side view of the switch component. Figure 7 This is an exploded perspective view of one of many embodiments of the switch assembly according to the present disclosure, showing a rotatably mounted switch and a fixedly mounted switch. Figure 8 This is a perspective view of one of many embodiments of the switch assembly according to the present disclosure, showing a rotatably mounted switch and two fixedly mounted switches. Figure 9 yes Figure 8 An exploded perspective view of the switch assembly. Figure 10 This is a perspective view of one of many embodiments of the switch assembly according to the present disclosure, showing a rotatably mounted switch and three fixedly mounted switches. Figure 11 yes Figure 10 An exploded perspective view of the switch assembly. Figure 12 This is a flowchart illustrating one of many embodiments of the assembly method according to this disclosure. They will be described in conjunction with each other. Figure 1-12 .

[0027] In at least one embodiment, the actuator assembly 100 for controlling and / or monitoring the valve may include a valve actuator 102 and a switching assembly or subassembly 110. In at least one embodiment, the switching assembly 110 for the valve actuator 102 may include a bracket 112 for supporting a plurality of switches 114. One or more switches 114a may be rotatably coupled to the bracket 112 at one or more adjustable angles. One or more switches 114b may be fixedly mounted to the bracket 112. In at least one embodiment, the bracket 112 and / or portions thereof may be non-conductive to electrically isolate the switches 114 from the valve actuator 102 and / or other components of the subassembly 110. The valve actuator 102 may trip or trigger the rotatably mounted switches 114a at one (or more) trip points, which may be independently adjustable by calibrating the adjustable angle. A triggering mechanism 116 may be used to trip / trigger the fixedly mounted switches 114b at one (or more) trip points that may be adjustable by calibrating the triggering mechanism 116.

[0028] In at least one embodiment, the plurality of switches 114 include a high-fire switch indicating a fully open position of the valve controlled by actuator 102, a low-fire switch indicating an intermediate stroke position of the valve, a close confirmation switch indicating a fully closed position of the valve, and a limit switch controlling the stroke limit of valve actuator 102. In at least one embodiment, the limit switch may be a rotatably mounted switch 114a and may be actuated by the valve or valve actuator 102. In at least one embodiment, the high-fire switch, low-fire switch, and close confirmation switch may be a fixedly mounted switch 114b and may be actuated by one or more arms 118 of a trigger mechanism 116 mounted to bracket 112. When valve actuator 102 opens and closes the valve and / or the simulator 120a of the simulating indicator 120, the arm 118 may rotate to follow the indicator 120 as it moves with the valve stem.

[0029] In at least one embodiment, the trigger mechanism 116 may include an arm 118 rotatably coupled to a bracket 112. An indicating end 118a of the arm 118 may be coupled to an actuator 102 or a portion of a valve controlled by the actuator 102, such as a valve stem, a valve stem position indicator 120, or a simulator 120a of the analog indicator 120. A bracket end 118b of the arm 118 may be rotatably coupled to the bracket 112, for example via a shaft 122 and a retainer 123. Movement of the arm 118 may directly or indirectly trip a fixedly mounted switch 114b. In at least one embodiment, one or more switch triggers 124 may be adjustablely coupled to the arm 118, for example by using an adjustable locating screw 126 and / or a tension spring 128, and the trigger 124 may trip the fixedly mounted switch 114b. Alternatively or additionally, the locating screw 126 may be located between the trigger 124 and the fixedly mounted switch 114b, such as... Figure 11 As best shown. In this way, a pair of arms 118 and trigger 124 can trigger two or more fixedly mounted switches 114b, such as high-voltage and low-voltage switches, at different points along the valve stem stroke. It is understood that when the mechanism trips two or more switches 114, there may be some correlation between the adjustments to the trip points. However, when independent mechanisms trip different switches 114, the adjustments to the trip points can be independent.

[0030] In at least one embodiment, the rotatable switch 114a can be directly rotatably mounted to the bracket 112, or it can be rotatably mounted to the bracket 112 via a bracket 130, which in turn is rotatably mounted to the bracket 112. In at least one embodiment, the rotatable switch 114a can be fixedly or rigidly mounted to the bracket 130 using fasteners 132 (e.g., machine screws). In at least one embodiment, the bracket 130 can be rotatably mounted to the bracket 112 using fasteners and washers 134. The tripping point of the rotatable switch 114a can be configured by adjusting the positioning screw 126, which can set an adjustable angle between the rotatable switch 114a and the bracket 112. In at least one embodiment, the angle between the bracket 112 and the bracket 130, and therefore the rotatable switch 114a, can be set and adjusted using the positioning screw 126, a spring 136, and one or more nuts 138. Nut 138 may be held in place by bracket 130 or other parts of subassembly 110, and / or may include a locking nut to prevent the positioning screw from moving, thereby securing the trip point of any associated switch 114.

[0031] When the switch assembly 110 is mounted to the actuator 102, the switch 114 can be wired to the switch terminal 140a, which in turn can be wired to the actuator terminal 140b. The switch terminal 140a can be secured to the bracket 112 using an additional fastener 132. The switch terminal 140a can also be wired to terminals on the calibration fixture 104 for adjustment or calibration of the switch 114.

[0032] In at least one embodiment, the bracket 112 itself is made of a non-conductive material, thereby insulating the switches 114 from each other and / or from the actuator 102. In at least one embodiment, the insulator 142 may be used to cover a portion of one or more switches 114, thereby insulating the switches 114 from each other, from the bracket 112, and / or from the actuator 102.

[0033] In at least one embodiment, the switches 114 may be adjusted or calibrated using a calibration fixture 104 before being installed onto the actuator 102 to which they will be used. In at least one embodiment, the calibration fixture 104 may include a simulator 120a or other structure simulating the indicator 120. In at least one embodiment, the calibration fixture 104 may include a simulator or structure simulating the valve and / or other components of the valve actuator 102. In at least one embodiment, the calibration fixture 104 may be a portion of the valve actuator 102. In at least one embodiment, the calibration fixture 104 may be the complete valve actuator 102 for adjusting or calibrating multiple switch assemblies 110 used with other valve actuators 102. Once adjusted or calibrated, the switch assemblies 110 may be installed onto the valve actuator 102 as needed, or placed in storage for future assembly onto the valve actuator 102. In this way, the switch assembly 110 can be assembled, and all switches 114 can be adjusted once before being installed into the valve actuator 102 where they will be used. Furthermore, the switch assembly 110 can be assembled, adjusted, inspected, and stored as sub-assemblies to shorten the time from order receipt to the fully assembled actuator assembly 100 being ready for shipment.

[0034] In at least one embodiment, the high-power switch, low-power switch, and off confirmation switch can be rigidly mounted to bracket 112. One or more arms 118 can be pivotally mounted to bracket 112. Adjusting the tripping points of the high-power switch, low-power switch, and off confirmation switch when the switch assembly 110 is secured to calibration fixture 104 can include adjusting the relationship between the arms 118 and the high-power switch, low-power switch, and / or off confirmation switch. For example, one or more locating screws 126 can be used to adjust the angle between the arms 118 and one or more triggers 124, which triggers the switch 114 based on the movement of actuator 102, indicator 120, or simulator 120a. In at least one embodiment, a single pair of arms 118 and triggers 124 can control the tripping points of the high-power switch and low-power switch using two locating screws 126. In at least one embodiment, the pair of arms 118 and triggers 124 can control the tripping point of each rigidly mounted switch 114b. In at least one embodiment, adjusting the tripping point of one switch 114 does not affect the tripping points of any other switch 114. In at least one embodiment, adjusting the trip point of one switch 114 does indeed affect the trip point of another switch 114, and this interaction can be adjusted using different locating screws. In at least one embodiment, the switch assembly 110 may include a plurality of fixedly mounted switches 114b, each of which may have a different trip point that can be adjusted independently.

[0035] In at least one embodiment, the limit switch is pivotally mounted to the bracket 112. Adjusting the trip point of the limit switch when the switch assembly 110 is secured to the calibration fixture 104 may include adjusting the angle at which the limit switch is pivotally mounted to the bracket 112. For example, the limit switch may be rigidly mounted to the bracket 130, which in turn is rotatably mounted to the bracket 112. The angle between the bracket 112 and the bracket 130, as well as the limit switch, may be adjusted using the locating screw 126.

[0036] In at least one embodiment, the calibration fixture 104 can be used to calibrate the switch assembly 110 to the valve actuator 102 independently of the valve actuator 102. In at least one embodiment, at least one of the rotary switch 114a and the fixed switch 114b is wired to a terminal 140a mounted to the bracket 112. The calibration fixture 104 and / or the valve actuator 102 may include a terminal 140b to which the terminal 140a mounted to the bracket 112 can be wired when the switch assembly 110 is mounted to the calibration fixture 104 or the valve actuator 102.

[0037] In at least one embodiment, according to certain aspects of this disclosure, there may be a difference between securing the switch assembly 110 to the actuator 102 and / or the calibration fixture 104 and aligning the switch assembly 110 to the actuator 102 and / or the calibration fixture 104. Upon reading this disclosure, it will be understood that proper alignment of the switch assembly 110 affects its adjustment or calibration. Therefore, in at least one embodiment, the switch assembly 110, the actuator 102, and / or the calibration fixture 104 may include references 150a, b, and c to ensure proper alignment of the switch assembly 110 with the actuator 102 and / or the calibration fixture 104. In at least one embodiment, the switch assembly 110 may include a switch reference 150a, which physically mates with the actuator reference 150b when the switch assembly 110 is properly aligned with the actuator 102. The switch reference 150a may also physically mate with the fixture reference 150c when the switch assembly 110 is properly aligned with the calibration fixture 104. In at least one embodiment, references 150a, b, c support the switch assembly 110 on the actuator 102 and / or calibration fixture 104 such that alignment of the switch assembly 110 with the actuator 102 and / or calibration fixture 104 does not necessarily secure the switch assembly 110 to the actuator 102 and / or calibration fixture 104. The switch assembly 110 can be individually secured to the actuator 102 and / or calibration fixture 104 using fasteners (e.g., machine screws). In at least one embodiment, the switch assembly 110 can be individually secured to the calibration fixture 104 using a toggle clamp 152 mechanically coupled to a buffer 154, which securely holds the switch assembly 110 to the calibration fixture 104.

[0038] In at least one embodiment, the switching assembly 110 of the valve actuator 102 for controlling the valve can be as follows: Figure 12 The assembly method 1000 is used to create and / or configure the device. For example, as shown in step 1002, assembly can begin by mounting a plurality of switches 114 to a bracket 112. Switches 114 may include one or more switches fixed and / or directly mounted to the bracket 112, and one or more switches rotatably and / or pivotally mounted to the bracket 112. As described above, the bracket 112 or portions thereof may be made of a non-conductive material to electrically isolate the switches 114 from each other and / or the valve actuator 102.

[0039] As shown in step 1004, the switching assembly 110 can then be aligned with the calibration fixture 104. Aligning the switching assembly 110 with the calibration fixture 104 may include positioning, aligning, or co-aligning one or more component references 150a on the switching assembly 110 to one or more corresponding fixture references 150b on the calibration fixture 104. The component references 150a and the fixture references 150b can cooperate to ensure proper alignment between the switching assembly 110 and the calibration fixture 104. As shown in step 1006, with the switching assembly 110 properly aligned with the calibration fixture 104, the switching assembly 110 can then be secured to the calibration fixture 104. As described above, the calibration fixture 104 can simulate the selection function, operation, and / or movement of the valve actuator 102.

[0040] As shown in step 1008, when the switch assembly 110 is aligned with and fixed to the calibration fixture 104, each switch 114 can be adjusted. In at least one embodiment, the trip point of the switch 114 can be adjusted when the switch assembly 110 is correctly aligned with the calibration fixture 104. For example, adjusting the trip point of at least one fixed switch 114b can be performed by adjusting the trigger 124 between at least one fixed switch 114b and the arm 118 pivotally mounted to the bracket 118. The trip point of at least one rotatable switch 114a can be adjusted by adjusting the angle at which at least one rotatable switch 114a is mounted to the bracket 112.

[0041] Once the switch 114 has been adjusted with the switch assembly 110 secured to the calibration fixture 104, the switch assembly 110 can be removed from the calibration fixture 104 as shown in step 1010. At this point, the switch assembly 110 can be stored for future use with the valve actuator 102, or it can be used with the valve actuator 102 immediately.

[0042] For example, as shown in step 1012, by positioning the component reference 150a on the switch assembly 110 to the actuator reference 150b on the valve actuator 102, the switch assembly 102 can be aligned with the valve actuator 102 in a manner very similar to that of the calibration fixture 104. As shown in step 1014, once correctly aligned, the switch assembly 110 can be fixed to the valve actuator 102. With the switch assembly 110 fixed to the valve actuator 102, it is expected that each switch 114 will be properly calibrated relative to the valve actuator 102, relying on the adjustments made when the switch assembly 110 is fixed to the calibration fixture 104.

[0043] In at least one embodiment, the switching assembly for the valve actuator may include a bracket for supporting multiple switches, one or more switches rotatably coupled to the bracket at one or more adjustable angles, and one or more switches fixedly mounted to the bracket. In at least one embodiment, the bracket may be non-conductive to electrically isolate the switches from the valve actuator. The valve actuator may trip or trigger the rotatably mounted switches at one or more trip points, which can be independently adjusted by calibrating the adjustable angle. A triggering mechanism may be used to trip / trigger the fixedly mounted switches at one or more trip points that can be adjusted by calibrating the triggering mechanism. In at least one embodiment, the triggering mechanism may include an arm rotatably coupled to the bracket. An indicating end of the arm may be coupled to the actuator or a portion of a valve controlled by the actuator, such as the valve stem or a valve stem position indicator. The bracket end of the arm is rotatably coupled to the bracket. Movement of the arm may directly or indirectly trip the fixedly mounted switches. One or more switch triggers are adjustablely coupled to the arm and may trip the fixedly mounted switches.

[0044] In at least one embodiment, the switching assembly may include one or more terminals mounted to a bracket, wherein at least one of a rotatable switch and a fixed switch is wired to the terminals. In at least one embodiment, the switching assembly may include a plurality of fixedly mounted switches, which may have different and independently adjustable trip points. In at least one embodiment, the switching assembly may include a calibration fixture for calibrating the switching assembly to the valve actuator independently of the valve actuator. In at least one embodiment, the switching assembly for the valve actuator may be configured by assembling a plurality of switches to a bracket to form a switching assembly, aligning the switching assembly with the calibration fixture, and adjusting the switch while the switching assembly is fixed to the calibration fixture. The switching assembly may then be mounted to a valve actuator that has been calibrated to the valve actuator independently of the valve actuator. The switches may include one or more switches fixed and / or directly mounted to the bracket, and one or more switches rotatably and / or pivotally mounted to the bracket. The calibration fixture may simulate the selection function, operation, and / or movement of the valve actuator.

[0045] Aligning the switch assembly with the calibration fixture may include positioning, aligning, or co-aligning one or more component references on the switch assembly with one or more corresponding fixture references on the calibration fixture. The component references and fixture references can cooperate to ensure proper alignment between the switch assembly and the calibration fixture. With the switch assembly properly aligned with the calibration fixture, the switch assembly can be secured to the calibration fixture. When the switch assembly is properly aligned with and secured to the calibration fixture, the trip point of the switch can be adjusted. For example, adjusting the trip point of at least one fixed switch can be performed by adjusting a trigger between at least one fixed switch and an arm pivotally mounted to a bracket. The trip point of at least one rotatable switch can be adjusted by adjusting the angle at which at least one rotatable switch is mounted to the bracket.

[0046] Once the switch has been adjusted using the switch assembly fixed to the calibration fixture, the switch assembly can be removed from the calibration fixture. At this point, the switch assembly can be stored for future use with the valve actuator, or it can be used with the valve actuator immediately. In either case, the switch assembly can be aligned with the valve actuator by aligning the assembly reference on the switch assembly with the actuator reference on the valve actuator, in a manner substantially similar to that using the calibration fixture. The switch assembly can then be fixed to the valve actuator. Once the switch assembly is aligned with and fixed to the valve actuator, adjustments made during the alignment and fixing of the switch assembly to the calibration fixture can be expected to ensure that each switch is properly calibrated with the valve actuator.

[0047] The systems and methods disclosed herein are not limited to the exemplary valve and / or actuator types shown in the accompanying drawings for illustrative purposes, and can be applied to or utilized in many different types and styles of control valves, actuators, and related systems. Furthermore, while the teachings of this disclosure are particularly advantageous for solenoid valves, they are not necessarily limited thereto, and control valves can be or include any type of valve, whether now known or later developed, such as linear valves, rotary valves, solenoid valves, pilot valves, diaphragm valves, mechanical valves, electromechanical valves, hydraulic valves, pneumatic valves, and other types of valves, for individually or in combination, integrally or partially, manipulating one or more fluids through a distance or point. The term "fluid" as used herein includes any substance or material capable of flow, such as liquids, gases, and combinations thereof (regardless of the presence of one or more solids or other non-fluids).

[0048] Other and further embodiments utilizing one or more aspects of the systems and methods described above can be devised without departing from the spirit of the applicant's disclosure. For example, the systems and methods disclosed herein can be used alone or formed into one or more parts of other valves, valve components, and / or fluid control systems. Furthermore, various methods and embodiments of valves and modules can be combined with each other to produce variations of the disclosed methods and embodiments. Discussion of a singular element can include a plural element, and vice versa. A reference to at least one item followed by a reference to that item can include one or more items. Moreover, various aspects of the embodiments can be used in combination with each other to achieve the objectives of this disclosure.

[0049] Unless the context otherwise requires, the words “comprising,” “including,” and “having” (including variations and modifications thereof) should be understood to imply the inclusion of at least the stated elements or steps, groups of elements, or steps or equivalents thereof, without excluding a larger number or any other elements or steps, groups of elements, or steps or equivalents thereof. These devices, apparatuses, and systems may be used in multiple directions and orientations. Unless specifically defined, the order of steps may occur in various sequences. The various steps described herein may be combined with other steps, inserted into said steps, and / or divided into multiple steps. Similarly, elements have been described functionally, and these elements may be embodied as individual components and / or may be combined into components having multiple functions.

[0050] Embodiments have been described within the context of preferred and other embodiments, and not every embodiment disclosed by the applicant has been described. Those skilled in the art who benefit from this disclosure can make obvious modifications and alterations to the described embodiments. The disclosed and undisclosed embodiments are not intended to limit or constrain the scope or applicability of the applicant's disclosure, but rather, in accordance with patent law, the applicant intends to fully protect all such modifications and improvements falling within the scope of the equivalents of the claims.

Claims

1. A method of providing a switching assembly for a valve actuator, the valve actuator being configured to control a valve, the method comprising: A switch assembly is formed by assembling multiple switches onto a bracket by fixing at least one fixed switch to the bracket and rotatably mounting at least one rotatable switch to the bracket. Provides calibration fixtures for analog valve actuators; The switch assembly is aligned with the calibration fixture by positioning the component reference on the switch assembly to the fixture reference on the calibration fixture, wherein the component reference and the fixture reference cooperate to ensure alignment between the switch assembly and the calibration fixture. Secure the switch assembly to the calibration fixture; When the switch assembly is fixed to the calibration fixture, the first trip point of at least one fixed switch is adjusted by adjusting the trigger between at least one fixed switch and the arm pivotally mounted to the bracket; When the switch assembly is fixed to the calibration fixture, the second trip point of at least one rotatable switch is adjusted by adjusting the angle at which at least one rotatable switch is mounted on the bracket; Remove the switch assembly from the calibration fixture; The switching assembly is aligned with the valve actuator by positioning the component reference on the switching assembly to the actuator reference on the valve actuator, wherein the component reference and the actuator reference cooperate to ensure alignment between the switching assembly and the valve actuator; as well as The switching assembly is fixed to the valve actuator, wherein each of the plurality of switches is calibrated to the valve actuator by adjusting a first trip point of at least one fixed switch and adjusting a second trip point of at least one rotatable switch.

2. The method according to claim 1, wherein, The at least one fixed switch includes a high-fire switch indicating the fully open position of the valve, a low-fire switch indicating the intermediate stroke position of the valve, and a closing confirmation switch indicating the fully closed position of the valve, wherein the at least one rotatable switch includes a limit switch controlling the stroke limit of the valve actuator.

3. The method according to claim 1, wherein, The arm is configured to follow an indicator that moves together with the valve stem when the valve actuator opens and closes the valve.

4. The method according to claim 3, wherein, The calibration fixture includes a simulator that mimics the indicator.

5. The method according to claim 1, wherein, Assembling the plurality of switches to the bracket includes wiring at least one of the plurality of switches to a set of terminals mounted on the bracket.

6. A method of configuring a switching assembly for a valve actuator, the method comprising: Multiple switches are assembled onto a non-conductive bracket to form a switch assembly; Provides calibration fixtures for analog valve actuators; The switch assembly is aligned with the calibration fixture by positioning the component reference on the switch assembly to the fixture reference on the calibration fixture, wherein the component reference and the fixture reference cooperate to ensure alignment between the switch assembly and the calibration fixture. Secure the switch assembly to the calibration fixture; When the switch assembly is fixed to the calibration fixture, adjust the trip points of multiple switches; Remove the switch assembly from the calibration fixture; Place the switch components in the warehouse; Take the switch assembly from the warehouse; The switching assembly is aligned with the valve actuator by positioning the component reference on the switching assembly to the actuator reference on the valve actuator, wherein the component reference and the actuator reference cooperate to ensure alignment between the switching assembly and the valve actuator; as well as The switching assembly is fixed to the valve actuator, wherein the tripping point of a plurality of switches is adjusted when the switching assembly is fixed to the calibration fixture, and each of the plurality of switches is calibrated to the valve actuator.

7. The method according to claim 6, wherein, The plurality of switches includes a high-power switch indicating the fully open position of the valve controlled by the actuator, a low-power switch indicating the intermediate stroke position of the valve, a closing confirmation switch indicating the fully closed position of the valve, and a limit switch controlling the stroke limit of the valve actuator.

8. The method according to claim 7, wherein, The high-voltage switch, the low-voltage switch, and the close confirmation switch are actuated by at least one arm mounted to the non-conductive bracket, wherein the at least one arm is configured to follow an indicator that moves with the valve stem as the valve actuator opens and closes the valve.

9. The method according to claim 8, wherein, The calibration fixture includes a simulator that mimics the indicator.

10. The method according to claim 8, wherein, The high-voltage switch, the low-voltage switch, and the off confirmation switch are rigidly mounted to the non-conductive bracket, wherein at least one arm is pivotally mounted to the non-conductive bracket, and wherein adjusting the tripping point of the high-voltage switch, the low-voltage switch, and the off confirmation switch includes adjusting the relationship between the at least one arm and the high-voltage switch, the low-voltage switch, and the off confirmation switch, while the switch assembly is fixed to the calibration fixture.

11. The method according to claim 8, wherein, The high-voltage switch, the low-voltage switch, and the off confirmation switch are rigidly mounted to the non-conductive bracket. The at least one arm includes a first arm and a second arm, which are pivotally mounted to the non-conductive bracket. Adjusting the trip point of the high-voltage switch includes adjusting the high-voltage trigger between the first arm and the high-voltage switch. Adjusting the trip point of the low-voltage switch includes adjusting the low-voltage trigger between the first arm and the low-voltage switch. Adjusting the trip point of the off confirmation switch includes adjusting the off trigger between the second arm and the off confirmation switch. Simultaneously, the switch assembly is fixed to the calibration fixture.

12. The method according to claim 11, wherein, The high-fire trigger, low-fire trigger, and shutdown trigger can be adjusted independently, so that adjusting one of the high-fire trigger, low-fire trigger, and shutdown trigger will not affect the adjustment of the other of the high-fire trigger, low-fire trigger, and shutdown trigger.

13. The method according to claim 11, wherein, The high-fire trip point and the low-fire trip point can be adjusted in a related manner, such that adjusting one of the high-fire trip point and the low-fire trip point affects the adjustment of the other.

14. The method according to claim 7, wherein, The limit switch is pivotally mounted to the non-conductive bracket, and adjusting the trip point of the limit switch includes adjusting the angle at which the limit switch is pivotally mounted to the non-conductive bracket, while the switch assembly is fixed to the calibration fixing device.

15. The method according to claim 6, wherein, Assembling the plurality of switches onto the non-conductive bracket includes wiring at least one of the plurality of switches to a set of terminals mounted on the non-conductive bracket.

16. A switching assembly for a valve actuator configured to control a valve, comprising: A bracket for supporting multiple switches; A rotatable switch that is rotatably connected to the bracket at an adjustable angle; The first fixed switch is fixedly installed on the bracket; A second fixed switch is fixedly installed to the bracket; Terminals mounted to the bracket, wherein at least one of the rotatable switch and the first fixed switch is wired to the terminals; A first arm rotatably connected to a bracket, the first arm having an indicating end and a bracket end, the indicating end being configured to be connected to at least one of a valve stem and a valve stem position indicator, the bracket end being rotatably connected to the bracket; as well as A first switch trigger is adjustablely connected to the first arm; The rotary switch is configured to be tripped by a valve actuator; and The first fixed switch is configured to trip via a first switch trigger. The first trip point of the first fixed switch can be independently adjusted according to the position of the first switch trigger relative to the first arm; and The second trip point of the second fixed switch can be adjusted in relation to the position of the first switch trigger relative to the first arm. The switching assembly further includes a calibration fixing device for calibrating the switching assembly to the valve actuator independently of the valve actuator. The component reference on the switch assembly is positioned to the fixture reference on the calibration fixture to align the switch assembly with the calibration fixture, wherein the component reference and the fixture reference cooperate to ensure alignment between the switch assembly and the calibration fixture.

17. The switching assembly of claim 16, wherein, The trip point of the rotatable switch can be adjusted according to the adjustable angle, and the trip point of the first fixed switch can be adjusted according to the position of the first switch trigger relative to the first arm.

18. A switching assembly for a valve actuator configured to control a valve, comprising: A bracket for supporting multiple switches; A rotatable switch that is rotatably connected to the bracket at an adjustable angle; The first fixed switch is fixedly installed on the bracket; Terminals mounted to the bracket, wherein at least one of the rotatable switch and the first fixed switch is wired to the terminals; A first arm rotatably connected to a bracket, the first arm having an indicating end and a bracket end, the indicating end being configured to be connected to at least one of a valve stem and a valve stem position indicator, the bracket end being rotatably connected to the bracket; as well as A first switch trigger is adjustablely connected to the first arm; A second fixed switch is fixedly installed to the bracket; The second arm is rotatably connected to the bracket; A second switch trigger that is adjustablely connected to the second arm; The rotary switch is configured to trip via a valve actuator. The first fixed switch is configured to trip via a first switch trigger. The first trip point of the first fixed switch can be independently adjusted according to the first position of the first switch trigger relative to the first arm; and The second tripping point of the second fixed switch can be independently adjusted according to the second position of the second switch trigger relative to the second arm. The switching assembly further includes a calibration fixing device for calibrating the switching assembly to the valve actuator independently of the valve actuator. The component reference on the switch assembly is positioned to the fixture reference on the calibration fixture to align the switch assembly with the calibration fixture, wherein the component reference and the fixture reference cooperate to ensure alignment between the switch assembly and the calibration fixture.

19. The switching assembly of claim 18, wherein, The trip point of the rotatable switch can be adjusted according to the adjustable angle, and the trip point of the first fixed switch can be adjusted according to the position of the first switch trigger relative to the first arm.

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