DEVICE AND METHOD FOR CONTROLLING AND REGULATING FLUID FLOWS

Description

[0001] The present invention relates to a device for controlling and regulating fluid flows, comprising a plurality of valve units arranged on a base. Furthermore, the present invention relates to a method for operating such a device. Finally, the present invention relates to the use of such a device. A device according to the invention can also be referred to as a multiple valve system.

[0002] US 2021 / 131459 A1 discloses a solenoid valve assembly comprising a valve body in which a magnetically actuated slide is slidably mounted. Furthermore, a distributor element with multiple flow paths to the ports of the solenoid valve assembly is provided. An intermediate block is inserted between the valve body and the distributor element, which has a plurality of through-holes for connecting ports of the distributor element to the ports of the valve body. At least one sensor is housed in the intermediate block to detect the pressure and / or flow rate in at least one of the through-holes.

[0003] Devices for controlling and / or regulating fluid flows typically comprise at least one valve unit with at least one valve. Devices known as so-called valve islands are known, which comprise multiple valve units. Such devices can be designed modularly. For example, such a device has a valve base that includes a plurality of locations for accommodating valve units. Accordingly, the device (valve island) can be completed by placing several desired valve units in suitable locations on the valve base. In this way, devices for complex applications can be realized using standardized components.

[0004] In exemplary embodiments, the present invention relates to devices for pneumatic controls comprising a plurality of valve units, in which compressed air is used as the fluidic medium.

[0005] Such valve islands are known from DE 10 2006 018 220 A1 and WO 2017 / 076430 A1. Valve units in the form of directional control valves with pilot control based on two pilot valves are known from WO 2008 / 138371 A1 and DE 10 2017 009 374 A1. Such valve units are suitable for use in valve islands with a plurality of valve units for complex control tasks.

[0006] EP 0 316 500 A1 discloses a valve assembly comprising a cylinder to be controlled, a valve unit designed as a directional control valve, and an intermediate plate arranged between a cylinder housing and the valve unit. The intermediate plate has channels for conveying a fluid between the cylinder and the valve unit. Two configurations are provided, allowing different functions to be realized depending on the positioning of the intermediate plate.

[0007] DE 11 2017 004 489 T5 discloses a sensor assembly designed as a tire pressure sensor. It comprises a plurality of sensors designed to detect vibrations, temperature, and pressure. The sensors are integrated into a common housing. The sensor assembly is compact and robust. An integrated power supply in the form of a battery is provided. The sensors of the sensor assembly are arranged on a common circuit board within the housing.

[0008] EP 3 825 788 A1 discloses a valve assembly with an optimization unit based on artificial neural networks. It proposes using such systems to optimize control loops with valve assemblies, describing specific approaches to reduce the effort required to train the optimization unit in order to improve control performance.

[0009] For example, in manufacturing technology, automation technology, intralogistics, and other applications, there is a need for complex fluidic systems, which are formed, for example, using so-called valve islands with a plurality or multitude of valve units. Naturally, the probability of failure of an entire system increases with the number of components. This regularly leads to increased maintenance and / or repair costs.

[0010] It would therefore be advantageous to monitor the components of complex valve arrangements down to the level of individual valve units, ideally to prevent any failures. Various approaches are being pursued under the heading of predictive maintenance to minimize both maintenance effort and the potential risk of failure. However, such approaches typically require a certain amount of effort for the necessary sensor technology to collect sufficient data during operation that can be evaluated for predictive maintenance purposes.

[0011] Especially in the case of valve islands with a large number of valve units, but also in other valve arrangements, there is often a desire for the smallest possible size so that a large number of valve units and other components can be combined with one another with the smallest possible space requirement.

[0012] Against this background, the object of the invention is to provide a device for controlling and regulating fluid flows with a plurality of valve units and a control device assigned to them, the design of which takes at least some of the above aspects into account. In particular, the device should allow monitoring of the operation of the valve units with as little additional effort as possible, with recorded data being able to be evaluated for the purposes of predictive maintenance, if possible. The device should be implementable with as little structural intervention as possible in existing modular systems and components for valve islands. The device should enable existing valve islands to be expanded with little effort as required. Furthermore, a method for operating such a device should be specified within the scope of the present invention.

[0013] According to a first aspect, the present invention relates to a device for controlling and regulating fluid flows, comprising: at least two electrically operated valve units, a valve base which supports at least two valve units, a control device for controlling and monitoring the at least two valve units, a first multifunctional sensor unit which is assigned to a first of the at least two electrically operated valve units, and a second multifunctional sensor unit which is assigned to a second of the at least two electrically operated valve units, wherein the first sensor unit and the second sensor unit each have a structure-borne sound sensor for detecting a structure-borne sound signal, wherein the first sensor unit and the second sensor unit each have at least one further sensor for detecting a further measured variable, wherein the control device is designed to evaluate signals provided by the sensor units on the basis of a correlation with an electrical valve excitation, and wherein the control device is designed toto carry out the evaluation on the basis of the signals of limited time windows, comprising a first time window covering a first edge of an excitation signal and a second time window covering a second edge of the excitation signal which is opposite to the first edge.

[0014] According to a further aspect, the present invention relates to a method for operating a device according to the invention for controlling and regulating fluid flows, the method comprising the following steps: Operating the control device for monitoring signals provided by the sensor units on the basis of a correlation of detected measured variables with an electrical valve excitation, in particular a valve excitation of pilot valves of the valve units, comprising: providing signals by at least the first sensor unit or the second sensor unit only in limited time windows, comprising a first transmission time window that covers a first edge of an excitation signal, and a second transmission time window that covers a second edge of the excitation signal that is opposite to the first edge, and evaluating the provided signals that are provided in the limited time windows by at least the first sensor unit or the second sensor unit.

[0015] Multifunctional sensors within the meaning of the present invention are sensors that, in addition to a basic function, can detect at least one additional measured variable (or physical variable). Thus, two or more different measured variables are detected. These include, for example, acceleration (vibrations), pressure, differential pressure, flow, temperature, and the like. In one exemplary embodiment, sensor units are designed to be self-sufficient or at least partially self-sufficient, particularly with regard to a power supply.

[0016] The structure-borne sound sensor can also be referred to as an acoustic sensor, oscillation sensor, vibration sensor, acceleration sensor, or similar. Such a sensor is typically designed as an acceleration sensor for detecting accelerations in one or more spatial directions. Acoustic sensors allow monitoring of valve units over time, not just the detection of specific events or switching states. This allows data on the service life of the valve unit to be recorded. However, an acoustic sensor is also suitable for detecting specific events, such as the opening and closing of a valve or the movement of a spool of a directional control valve.

[0017] In other words, acoustic sensors can capture both specific events and data relating to the valve unit's operating behavior throughout its lifetime. This allows for condition monitoring, as well as early failure diagnosis. Acoustic sensors are suitable for obtaining data for predictive maintenance.

[0018] In addition to the acoustic sensor, at least one additional sensor is provided for recording another measured variable, and the various sensor data can be fed into the evaluation and correlated as needed. The sensor data can also be correlated with signals and data relating to the excitation of the fluid units. This can also relate to the excitation of pilot valves, such as in pilot-operated valves. In this way, a connection can be established between the original excitation and the resulting actuation of the main valve.

[0019] The correlation can be established between recorded sensor data and the valve excitation, for example, the switching state of the electrical control of the pilot valves. The correlation can also be established between different sensor data. The correlation can be established with regard to certain properties of the signals / data, for example, frequency spectrum, amplitude, phase shift, time delay, and time windows. On this basis, statements can be made regarding wear and, if applicable, possible malfunctions during switching.

[0020] In exemplary embodiments, the valve units are designed as pneumatic valve units. The device can be referred to as a valve island or pneumatic valve island.

[0021] The valve base can be designed as a so-called base plate or base plate. This is, for example, a modular plate with multiple locations for accommodating valve units. Furthermore, the base plate is designed, for example, to support and / or accommodate a control device and / or interfaces for connecting to control devices. In this way, the plurality or multiplicity of valve units can be controlled centrally. This also applies to the fluid supply, for example, the compressed air supply.

[0022] According to a further aspect, the present invention relates to a use of a sensor arrangement for tire pressure monitoring systems as at least a first multifunctional sensor unit or a second multifunctional sensor unit of a device according to the invention.

[0023] Sensor arrays for active tire pressure monitoring systems (TPMS) typically comprise several miniaturized sensors arranged on a common circuit board and, if necessary, integrated into a common printed circuit board. Such sensor arrays are typically hermetically sealed. Furthermore, the sensors are designed to be lightweight.

[0024] A tire pressure sensor with multiple sensor units is described, for example, in DE 11 2017 004 489 T5. The sensor in this document includes an acceleration sensor and other sensors, such as temperature sensors, pressure sensors, and similar sensors for other physical variables. Tire pressure sensors are manufactured in large quantities. Tire pressure sensors often have integrated units for power supply and communication with the environment, particularly for wireless communication. Furthermore, due to their installation on / in the wheel, the assembly is often hermetically sealed and integrated into a common housing. Tire pressure sensors are highly available and cost-effective to manufacture.

[0025] One aspect of the present invention is that such sensor arrangements are also well-suited for the sensor expansion / supplementation of valve islands and similar devices with a plurality of valve units. In this way, the devices can be upgraded to detect a plurality or multiplicity of measured variables or sensor channels without significant additional effort.

[0026] According to an exemplary embodiment of the device or method, the at least one further sensor of the first sensor unit and the second sensor unit is a pressure sensor. According to an exemplary embodiment of the device or method, the at least one further sensor of the first and second sensor units is a temperature sensor. A combination of pressure sensor and temperature sensor is also conceivable. A pressure sensor can be designed as an absolute pressure sensor or a differential pressure sensor.

[0027] It is understood that three or more sensor types can also be provided within a sensor unit, at least in exemplary embodiments.

[0028] According to an exemplary embodiment of the device or method, the at least two valve units each comprise pilot-controlled valves, in particular directional control valves with piezo pilot control.

[0029] A pilot-operated valve is usually coupled to at least one so-called pilot valve. A pilot valve can be controlled with relatively little force / energy expenditure. The pilot valve can use the same medium as the main valve, but also a different medium. The pilot valve controls the actual main valve, for example, a spool of a directional control valve. The pilot valve serves to amplify the force or reduce the required actuation forces. The pilot valve is designed, for example, as a piezo pilot valve. Embodiments with two pilot valves are conceivable, which are assigned to a valve unit, for example, a main valve designed as a directional control valve. A first of the two pilot valves serves to move the spool in a first direction. The second pilot valve serves to move the valve spool or valve member in an opposite, second direction.

[0030] The main valve is designed, for example, as a directional control valve. A directional control valve according to the present invention comprises at least three ports and at least two switching positions. For example, a directional control valve comprises at least four ports and at least two switching positions (4 / 2-way valve). For example, a directional control valve comprises at least five ports and at least three switching positions (5 / 3-way valve).

[0031] According to the invention, the control device is designed to evaluate signals provided by the sensor units based on a correlation with electrical valve excitation. Since the sensor unit of a valve unit is designed to detect a plurality of physical variables and determine corresponding sensor data, a plurality or multiplicity of data can be used as the basis for the correlation. The valve excitation is represented, for example, by a binary signal, which represents the de-energized and energized states of a pilot valve through the states 0 and 1.

[0032] The excitation signals (excitation of the pilot valve) can be correlated with the function of the valve unit, whereby the function is represented by sensor data provided by the sensor unit.

[0033] The control device is designed to perform the evaluation based on the signals in limited time windows, comprising a first time window covering a first edge of an excitation signal and a second time window covering a second edge of the excitation signal that is opposite to the first edge. It is understood that the first time window and the second time window can be repeated periodically or aperiodically.

[0034] The excitation signal is, for example, a binary or approximately binary excitation signal for at least one pilot valve. The two edges of the excitation signal can represent the activation and deactivation states. Such a signal has steep (ideally perpendicular / vertical) edges and almost completely flat (ideally horizontal) sections between the edges. Particularly in the vicinity of the edges—from a temporal perspective—significant changes in the sensor data used for the correlation can be expected.

[0035] Therefore, it is conceivable to focus on significant subsections (time periods) of the signal for correlation. This increases the significance of the data correlation.

[0036] According to an exemplary embodiment of the device or method, at least the first sensor unit or the second sensor unit are configured or operable to transmit signals only in a first transmission time window and in a second transmission time window. In other words, the sensor units can be operated such that signals are not transmitted continuously, but rather only when the excitation signal experiences significant changes. The transmission time windows can, for example, comprise the first edge and the second edge of the excitation signal and the resulting changes in the sensor signal(s). No signal needs to be transmitted during the remaining time periods. In this way, the correlation can concentrate on interesting time periods with relevant changes. Furthermore, the energy consumption of the sensor unit and the control device used for correlation purposes can be reduced.

[0037] According to an exemplary embodiment of the device or method, the control device is configured to determine, for evaluation purposes, at least one variable selected from the group consisting of the following: frequency spectrum, amplitude, phase, time delay, and combinations thereof based on the sensor signals. Similar variables can also be determined based on the excitation signal.

[0038] According to an exemplary embodiment of the device or method, the control device is configured to determine a switching state of the valve units based on the signals provided by the sensor units. In this way, the switching cycles of the valve units can be recorded and monitored. Furthermore, the condition monitoring can also be used to control the valve unit, the device comprising a plurality of valve units, and a system in which the device is used.

[0039] In one exemplary embodiment, condition monitoring takes place directly at the main valve (e.g., directional control valve) of the valve unit. The excitation signal itself acts on the pilot valve, for example. Therefore, the condition of the main valve can only be determined indirectly based solely on the excitation signal. Direct condition monitoring can enable more precise control and regulation of the valve unit.

[0040] According to an exemplary embodiment of the device or method, the control device is designed to determine at least one parameter based on the signals provided by the sensor units, which parameter can be used for diagnostic purposes, in particular for the purposes of early failure diagnosis and / or for predictive maintenance. Continuous condition monitoring allows, on the one hand, the current switching state of the valve to be recorded. Furthermore, data can be recorded and derived over time, allowing conclusions to be drawn about the state of wear and possible defects. Ideally, early detection of any malfunctions can be implemented based on the additionally provided sensor data, using the sensor data correlated with the excitation signal.

[0041] According to an exemplary embodiment of the device or method, the control device is designed to evaluate acquired sensor data using artificial intelligence, for example in the form of artificial neural networks. Such an artificial neural network can, for example, be designed to recognize certain signal patterns or data patterns. This can relate to the data provided by the sensor units, but also to data obtained as a result of a correlation. One goal of the neural network is, for example, to recognize certain patterns that indicate an imminent failure of the valve unit or the entire device. Furthermore, one goal of the neural network can be to recognize certain operating states based on specific patterns. Pattern recognition for monitoring and evaluation purposes can be combined with machine learning measures for training the neural network.

[0042] According to an exemplary embodiment of the device or method, the control device is configured to perform a machine-assisted self-learning procedure to determine a reference state. According to a further exemplary embodiment of the device or method, the self-learning procedure comprises unsupervised machine learning based on neural networks. The self-learning procedure can be used, for example, to determine a reference state (good state) for a new valve unit, which serves as a reference for monitoring operating behavior and any wear.

[0043] For example, the self-learning procedure uses an algorithm that trains the neural network, which can be used for pattern recognition and classification in a defined state. In the field of machine learning, there are approaches for supervised learning and unsupervised learning.

[0044] Supervised learning is based on training data provided to an algorithm. This training data can include, for example, reference states as well as undesirable states (wear, defects, and the like). The algorithm can then be trained to recognize certain patterns based on the provided sensor data, allowing for classification.

[0045] So-called unsupervised learning does not require specifically provided training data. Nevertheless, learning occurs based on a large amount of information that is provided to train the artificial neural network. The artificial neural network can be designed as a so-called self-organizing map (SOM). A self-organizing map consists, for example, of a layer of artificial neurons whose synaptic couplings (weight function) are adapted by an unsupervised learning rule. In this way, multidimensional information (for example, data provided by the various sensors as well as the excitation signal) can be converted into simplified structures, whereby certain relationships (neighborhood) between the input data are preserved. The multidimensional input data is mapped, and on this basis, patterns, similarities, groups (clusters), and the like can be recognized.

[0046] According to an exemplary embodiment of the device or method, at least the first sensor unit or the second sensor unit is designed as a structurally integrated sensor unit. This includes, for example, a single housing that houses components of the respective sensor unit. The sensor units can be encapsulated. Data exchange can take place via uniform interfaces; this can also include wireless data exchange. Furthermore, a sensor unit can have a common power supply for the installed components, for example in the form of an integrated battery or other energy storage device.

[0047] According to an exemplary embodiment of the device or method, the device is designed as a modular valve island, wherein the valve base has a plurality of valve positions configured to accommodate a valve unit, and wherein at least two of the valve positions support valve units to which similar sensor units are assigned. In this way, uniform sensor units can be installed in large quantities. This allows the use of highly available, cost-effective sensor units.

[0048] According to an exemplary embodiment of the device or method, at least the first valve unit or the second valve unit is coupled to an additional plate that supports the associated first sensor unit or second sensor unit. According to a further exemplary embodiment of the device or method, the additional plate is arranged between the valve base and the valve unit, wherein the additional plate provides a fluidic connection between the valve base and the valve unit. An additional plate designed in this way can also be referred to as an intermediate plate or sandwich plate. It is understood that the additional plate can also be flanged to the valve unit or coupled to it in another way.

[0049] Integrating the sensor units into an additional plate simplifies the upgrade of existing devices with multifunctional sensor units. When the sensor units are integrated into an additional plate or intermediate plate, no complex structural changes to the valve base and / or the valve units used are required.

[0050] According to an alternative embodiment of the device or method, the sensor unit is provided directly on the valve unit or integrated into it. According to a further alternative embodiment of the device or method, the sensor unit is provided directly on the valve base or integrated into it.

[0051] According to an exemplary embodiment of the device or method, at least the first sensor unit or the second sensor unit is formed on the basis of a sensor arrangement for tire pressure monitoring systems, wherein the sensor arrangement has an integrated circuit comprising multiple sensor types. In this way, a cost-effective and powerful sensor arrangement can be provided that is suitable for use in fluidic systems, in particular for use in pneumatic valve units. Sensor arrangements for tire pressure monitoring systems are also sufficiently robust and suitable for use in industrial environments.

[0052] A sensor array for tire pressure monitoring systems is typically designed to be sufficiently self-contained and, for example, equipped with an integrated power supply. The sensor array comprises, for example, two or more sensors for detecting physical variables such as pressure, temperature, acceleration, battery voltage, and the like. The sensor array typically comprises a plurality of sensors structurally integrated into a common housing / encapsulation.

[0053] The use of multifunctional sensor units to monitor multiple valve units in valve islands and the like increases the availability of the entire system that uses one or more such valve islands. Furthermore, maintenance effort can be reduced. Performance can be increased, enabling precise control and regulation of the fluid.

[0054] The multifunctional sensor concept can enable the construction of control systems with real-time or near-real-time behavior, as well as complex multivariable control systems that take into account a wide variety of physical variables. The acquisition and provision of a wide variety of measured variables allows the application of advanced control approaches, including nonlinear matrix control, neural networks, and / or the use of artificial intelligence, in the control and regulation of the systems.

[0055] It is understood that the features of the invention mentioned above and those to be explained below can be used not only in the combination specified in each case, but also in other combinations without departing from the scope of the present invention as defined by the claims.

[0056] Further features and advantages of the present invention will become apparent from the following description of several preferred embodiments with reference to the drawings. Fig. 1: a schematically simplified plan view of a device designed as a valve island; Fig. 2: a side view of the device according to Fig. 1 in a first configuration; Fig. 3: a side view of the device according to Fig. 1 in a second configuration; Fig. 4: a side view of the device according to Fig. 1 in a third configuration; Fig. 5: a highly simplified schematic sectional view of an additional plate of the third configuration according to Fig. 4 along the line VV in Fig. 4; Fig. 6: a schematic, highly simplified block diagram to illustrate functional aspects in an embodiment of a device according to the invention; Fig. 7: a schematic, highly simplified block diagram to illustrate data streams and data processing in an embodiment of a device according to the invention; Fig. 8: a sequence of successive diagrams to illustrate exemplary signal curves during operation and monitoring of a valve unit according to the invention; and Fig. 9: a schematic, highly simplified block diagram to illustrate an embodiment of a method for operating a device for controlling and regulating fluid flows.

[0057] Fig. 1shows a schematic view of a device, designated overall by 10, for controlling and regulating fluid flows. The device 10 can also be referred to as a so-called valve island, at least in exemplary embodiments. The device 10 has a modular design. In the exemplary embodiment, the device 10 serves for the controlled provision of gaseous fluids, in particular for the provision of compressed air. This is not to be understood as limiting.

[0058] In addition, the Figures 2-5 which shows further views of various configurations of the device 10 according to Fig. 1 In the embodiments according to the Figures 1-5 the device 10 is designed modularly.

[0059] The device 10 comprises a valve base 12, which can also be referred to as a base plate. The valve base 12 carries a control device 14. The valve base 12 also serves to accommodate a valve group 16, which is at least partially controlled and / or regulated by the control device 14. In the embodiment according to Fig. 1 the valve base 12 provided a plurality of locations 20, 22, 24, 26 for receiving valve units.

[0060] Fig. 1 shows four positions 20, 22, 24, 26 for each valve unit. The partially dashed representation of the valve base 12 in Fig. 1 and other figures shown herein indicate that additional locations for accommodating valve units may be provided. The device 10 comprises at least two locations 20, 22, 24, 26 for accommodating at least two valve units.

[0061] In the embodiment according to Fig. 1The control device 14 comprises a fluid supply interface 30, a (local) control unit 32, a data exchange interface 34, and a power supply interface 36. The interface 34 is designed, for example, as a bus interface. Data can be exchanged with higher-level control devices as well as with lower-level units (valve units, sensor units, etc.) via the interface 34. Designs with exclusively local control are also conceivable. In exemplary embodiments, the (local) control unit 32 assumes at least some of the control and regulation tasks. The power supply interface 36 regularly serves to supply electrical energy. Alternatively or additionally, an energy storage device can also be provided.

[0062] The control device 14 is designed to control a plurality of valve units. This includes, for example, electrically energizing the valve units. This can include electrically controlling pilot valves for controlling main valves of the valve units. Direct electrical control of the main valves is also conceivable.

[0063] Fig. 2illustrates that the fluid supply interface 30 of the control device 14 has various connections for the fluid supply. This includes, for example, a media connection 40 for supply air and a media connection 42 for exhaust air. In an exemplary embodiment, a media connection 44 for excitation supply air or pilot supply air is also provided. In the exemplary embodiment, the connections 40, 42 and, if necessary, the connection 44 serve to supply a gaseous fluid. The connections 40, 42 and, if necessary, the connection 44 provide a central fluid supply and fluid removal, so that a plurality of valve units can be supplied and operated jointly.

[0064] In the Fig. 1-4The valve base 12 of the device 10 supports a plurality of valve units 50, 52, 54, 56, which are located in / on the positions 20, 22, 24, 26. Typically, the device 10 provides at least two valve units 50, 52, 54, 56, which occupy at least two of the positions 20, 22, 24, 26. The positions 20, 22, 24, 26 can be equipped with one or more valve units 50, 52, 54, 56. Unoccupied positions 20, 22, 24, 26 are referred to as empty positions.

[0065] In the embodiment according to Fig. 1The valve units 50, 52, 54, 56 each carry at least one valve 60, 62, 64, 66. In the exemplary embodiment, the valves 60, 62, 64, 66 are each designed as a 5 / 3-way valve with electrical actuation, pilot control via two pilot valves for actuation and reset (i.e., both directions of movement of a valve spool or valve element), and manual override for actuation and reset. It is understood that other types of valves can also be used. The modular design of the device 10 allows the use of different valve units 50, 52, 54, 56, thus resulting in a broad range of applications.

[0066] At least in exemplary embodiments, the valves 60, 62, 64, 66 are designed as directional control valves with electrical pilot control. At least in exemplary embodiments, the electrical pilot control comprises at least one pilot valve. At least in exemplary embodiments, the electrical pilot control comprises at least one piezo pilot valve. At least in exemplary embodiments, the pilot control is provided for the control (activation) of the valve. At least in exemplary embodiments, electrical actuation is provided for both the control and the reset. At least in exemplary embodiments, manual actuation or manual override is additionally or alternatively possible. With regard to the available connections / positions, directional control valves include, for example, 2 / 2, 3 / 2, 4 / 2, 5 / 2, and 5 / 3-way valves.

[0067] The Figures 2 , 3 and 4show that the valve base 12 at positions 20, 22, 24, 26 (compare Fig. 1 ) Provides ports 70, 72, 74, 76, 80, 82, 84, 86 for the installed valve units 50, 52, 54, 56. A fluid flow can be provided or stopped as required via ports 70, 72, 74, 76, 80, 82, 84, 86. Valve units 50, 52, 54, 56 are used to control and regulate this process.

[0068] Based on the schematic representation according to Fig. 1 illustrate the Figures 3-5 based on further schematic representations various conceivable configurations of the device 10. The Figures 2-4 illustrated conceivable variants for the placement of multifunctional sensor units 90, 92, 94, 96, which are functionally assigned to the valve units 50, 52, 54, 56. The sensor units 90, 92, 94, 96 serve, for example, to monitor the functionality and any wear of the valve units 50, 52, 54, 56.

[0069] The sensor units 90, 92, 94, 96 allow finely granulated and close-meshed monitoring of the valve units 50, 52, 54, 56. The monitoring is functionally carried out directly at the level of the individual valve units 50, 52, 54, 56. In exemplary embodiments, the sensor units 90, 92, 94, 96 are based on sensors that were originally designed as a sensor arrangement for tire pressure monitoring systems.

[0070] Fig. 2 illustrates a configuration of the device 10 in which the sensor units 90, 92, 94, 96 are structurally integrated into the valve units 50, 52, 54, 56. Such a design requires corresponding structural measures for the valve units 50, 52, 54, 56.

[0071] Fig. 3illustrates a configuration of the device 10 in which the sensor units 90, 92, 94, 96 are structurally integrated into the valve base 12. The sensor units 90, 92, 94, 96 are each assigned to one of the locations 20, 22, 24, 26 in order to monitor a valve unit 50, 52, 54, 56 mounted there. This design requires little or no structural modification of the valve units 50, 52, 54, 56. Nevertheless, structural modifications are required for the valve base 12.

[0072] Fig. 4 illustrates a configuration of the device 10 in which the sensor units 90, 92, 94, 96 are structurally integrated into so-called additional plates 100, 102, 104, 106. The additional plates 100, 102, 104, 106 are each arranged between the valve base 12 and the valve units 50, 52, 54, 56. The additional plates 100, 102, 104, 106 can therefore also be referred to as intermediate plates or sandwich plates.

[0073] Fig. 5shows an exemplary schematic sectional view through the additional plate 106, compare the Fig. 4 indicated section line VV. In the embodiment according to Fig. 5 The sensor unit 96 is integrated into a housing 110 of the additional plate 106. The additional plate 106 also carries interfaces 112, 114, which also ensure a connection between the valve base 12 and the valve units 50, 52, 54, 56 with regard to any control signals and other data. The interfaces 112, 114 can also ensure a power supply between the valve base 12 and the valve units 50, 52, 54, 56, for example, with regard to electrical energy for energizing pilot valves.

[0074] The additional plates 100, 102, 104, 106 each have channels 120, 122, 124, 126, 128, which are adapted to the connections of the valve units 50, 52, 54, 56. Additional plates 100, 102, 104, 106 with different configurations regarding the channels 120, 122, 124, 126, 128 are also conceivable. In this way, various variants regarding the fluidic connection between the valve units 50, 52, 54, 56 and the valve base 12 can be realized.

[0075] Fig. 5 further illustrates an embodiment in which an additional sensor unit 130 is optionally provided in addition to the sensor unit 96. This is useful, for example, when various of the channels 120, 122, 124, 126, 128 are to be monitored separately, if possible.

[0076] It is understood that embodiments of the device 10 are also conceivable in which features of at least two of the Figures 2-5The configurations shown are combined with one another. In this way, the modular device can be used to construct 10 different valve islands with integrated multi-sensor technology for monitoring the individual valve units 50, 52, 54, 56.

[0077] Fig. 6 illustrates, using a simplified block diagram, further functionalities in a device 10 for controlling and regulating fluid flows using the valves 60, 62, 64, 66 of the valve units 50, 52, 54, 56. The sensor units 90, 92, 94, 96 are each arranged between the valves 60, 62, 64, 66 and the common control device 14 of the device 10 - at least with regard to data acquisition.

[0078] In the embodiment according to Fig. 6Each of the sensor units 90, 92, 94, 96 comprises two sensors 140, 142, 144, 146, 150, 152, 154, 156. It is understood that the sensor units 90, 92, 94, 96 may also comprise three or more sensors. Therefore, the sensor units 90, 92, 94, 96 may be referred to as multifunctional sensor units.

[0079] The sensor units 90, 92, 94, 96 comprise a plurality of sensors 140, 142, 144, 146, 150, 152, 154, 156 for detecting multiple physical quantities. This is typically done using transducers that convert the physical quantities to be detected into electrical signals. Furthermore, the sensors typically include electronics for detecting the electrical signals as well as for further conversion, storage, processing, and transmission.

[0080] The physical quantities detected by the sensors 140, 142, 144, 146, 150, 152, 154, 156 of the sensor units 90, 92, 94, 96 include, for example, pressure, differential pressure, flow, temperature, acceleration / vibration (resonance frequencies), acoustic quantities (structure-borne and airborne sound), valve voltage and valve current, orientation of the sensor in the room (e.g. inclination and direction), number of switching cycles, position / position of the valves, charge level of the energy storage device, status of the information transmission, transmission quality and the like.

[0081] The sensors 140, 142, 144, 146, 150, 152, 154, 156 of the sensor units 90, 92, 94, 96 detect signals for describing and quantifying physical quantities and transmit corresponding sensor data via the interface 34 to the control device 14 and, if necessary, to a higher-level control device 158 for further processing. Serial communication 160 can be used for transmission, for example, using a bus system. Wireless communication 162 is conceivable if necessary.

[0082] The sensor data can be transmitted wired or wirelessly to one or more transceivers. Data can be transmitted between the sensors (mesh networking to increase range, transmission reliability, and coverage) or to a local or central control unit. Transmission occurs, for example, via electromagnetic waves, with energy-efficient transmission paths such as RFID, NFC, ISM band, LoRa or LoRaWAN, Bluetooth low energy (BLE), Bluetooth Smart, or Bluetooth ultra low power. Transmission can also be optical, for example, using infrared signals or visible light and photoreceivers.

[0083] Fig. 6Further, using sensor 90, it is illustrated that sensor arrangements 164 can be used that structurally integrate several of the sensors 150, 160, for example, with a common encapsulation or a common housing 166. Furthermore, the sensors 150, 160 can be integrated into or connected to a common circuit 168. The circuit 168 can also include further components, for example, a power supply unit 170 and / or a communication unit 172. In an exemplary embodiment, the sensor arrangement 164 is an arrangement suitable as a tire pressure sensor for tire pressure monitoring systems. The use of such sensor arrangements 164 allows a significant expansion of the functional scope of the device 10 with little additional effort.

[0084] Fig. 71 illustrates, in addition, using a highly simplified block diagram, signal and data streams during operation of a device 10 according to the invention, particularly with regard to the processing of the data acquired by the sensor units 90, 92, 94, 96. A block designated 174 represents an input interface to which sensor data is fed (see block arrow 176). The sensor data passes through a filter 178, which filters out outliers and similar undesirable components and allows fundamentally relevant data to pass. The data is fed to a processing unit 180. Based on the provided data, the processing unit 180 determines an actual state, which is stored in an actual state memory 182.

[0085] Actual state data is fed to a machine-assisted evaluation 186, comprising a machine-assisted classification 188 and / or a machine-assisted correlation 190 of acquired data. The correlation 190 can, for example, be performed with reference to signals that describe the valve excitation. In an exemplary embodiment, the machine-assisted evaluation 186 includes a self-learning procedure 192 for the algorithms used in the evaluation. The machine-assisted evaluation 186 can be used to define a reference state. This is stored in a reference state memory 182. The machine-assisted evaluation 186 can then also be used to record and evaluate deviations of the actual state from the reference state. In this way, statements can be made regarding wear behavior and / or any defects, ideally predictions before critical wear conditions or defects occur.

[0086] The evaluation can be supplemented by a switching cycle detection 194, which detects switching cycles of the individual valve units 50, 52, 54, 56 and / or the entire device 10 based on excitation signals and / or signals provided by the sensor units 90, 92, 94, 96. This data can also be used in the machine-assisted evaluation 186 and the conclusions based thereon. A block labeled 196 represents an interface via which the results of the machine-assisted evaluation 186 are provided; see block arrow 198. Furthermore, feedback to the input interface 174 is also conceivable. The interface 196 can also be used to receive training data for algorithms used in the machine-assisted evaluation 186 (see block arrow 198, designed as a double arrow).

[0087] Fig. 8illustrates, using several diagrams 210, 212, 214, 216, approaches to energy-consumption-optimized recording, transmission and evaluation of the provided sensor data.

[0088] Diagram 210 illustrates a switching state or excitation state of a valve unit. This concerns, for example, the energization of a pilot valve. Diagram 212 illustrates a resulting spool position of a spool of a directional control valve. Diagram 214 illustrates data transmission windows for the data transmission between a sensor unit and a control device. Diagram 216 illustrates correlation windows for the correlation between provided sensor data and the valve excitation. Diagrams 210, 212, 214, 216 are arranged with respect to their time axes (abscissas 222, 232, 242, 252) in Fig. 8 synchronized.

[0089] Diagram 210 illustrates, by way of example, a binary signal 224 that can assume two states: 0 and 1 (compare ordinate 220). Signal 224 has two steep / vertical edges 226, 228. The rising edge 226 defines an activation time T1. The falling edge 228 defines a deactivation time T2.

[0090] Diagram 212 illustrates the resulting position changes in a valve spool or valve element using signal 234. Due to inertia, position signal 234 follows excitation signal 224 only with a delay. Therefore, rising edges 236 and falling edges 238 are flatter than the steep edges 226, 228 of excitation signal 224 and are offset in time. The spool is moved between two positions P1 and P2 by the excitation to switch the valve; see ordinate 230.

[0091] Diagram 214 illustrates, by way of example, a binary signal 244 that can assume two states, 0 and 1; compare ordinate 240. 246 and 248 denote two time windows in which data transmission from the sensor unit is possible. Transmission window 246 extends between times T11 and T12. Transmission window 248 extends between times T21 and T22. Transmission windows 246, 248 are selected such that the rising edges 226, 236 are covered by transmission window 246 and the falling edges 228, 238 are covered by transmission window 248. This ensures that relevant data is transmitted. During time periods in which relevant data is not expected, no data transmission and, if applicable, no data acquisition need take place. This reduces energy consumption.

[0092] Diagram 216 illustrates, by way of example, a binary signal 254 that can assume two states, 0 and 1 (compare ordinate 250). 256 and 258 denote two time windows in which a correlation of the data provided by the sensor unit is performed. The correlation window 256 extends between times T13 and T14. The correlation window 258 extends between times T23 and T24. The correlation windows 256, 258 are selected such that the rising edges 226, 236 are covered by the correlation window 256 and the falling edges 228, 238 are covered by the correlation window 258. Furthermore, the correlation window 256 is selected such that it is completely overlapped by the transmission window 246 and is shorter than it. The correlation window 258 is selected so that it is completely overlapped by the transmission window 256 and is shorter than it.This ensures that the data actually collected and transmitted is included in the correlation.

[0093] It is understood that signals 210, 212, 214, and 216 can repeat with each new switching cycle of the valve unit. This can occur periodically, alternately, or aperiodically.

[0094] With reference to Fig. 9 An embodiment of a method for controlling and regulating fluid flows is illustrated using a schematic block diagram. The steps shown start at step S10 and end in the exemplary embodiment at step S24. It is understood that the illustration according to Fig. 9 This can only be an excerpt from a more extensive procedure. Additions are conceivable.

[0095] Step S10 is followed by step S12, which is directed toward providing a device according to the invention. The device can be used, for example, as a modular valve island. This is followed by step S14, which involves equipping a valve base or base plate of the device with a plurality of valve units. The valve units are placed in valve positions on the base plate of the device. Multifunctional control devices are provided at the level of the valve units, each of which has at least two sensors for detecting two or more physical variables.

[0096] In step S16, the device for controlling and regulating a fluid system is operated. This can occur within the framework of a complex system, for example, in the field of automation technology. Step S16 includes, for example, energizing pilot valves for pilot control of a directional control valve of a valve unit of the device.

[0097] Step S18 relates to monitoring the valve units with the control units during operation of the valve device. In the exemplary embodiment, step S18 comprises substeps S20, S22, and S24. Substep S20 relates to signal acquisition by the sensors of the sensor units. Substep S22 relates to an evaluation of the acquired sensor data. This includes, for example, a correlation with data relating to the valve excitation. Step S24 involves deriving information based on the acquired and evaluated sensor data.

[0098] Step S24, for example, involves the use of an artificial neural network to classify and / or correlate data. In this way, valve states can be detected. Furthermore, information about the wear status of the valve units can be determined. This information can be used for predictive maintenance purposes, but also for optimizing the control of the valve unit. Therefore, information obtained during monitoring S18 can also be used as feedback during the operational operation of the device (step S16).

Claims

1. A device (10) for controlling and regulating fluid flows, comprising: - at least two electrically actuated valve units (50, 52, 54, 56), - a valve base (12) which supports the at least two valve units (50, 52, 54, 56), - a control device (14) for controlling and monitoring the at least two valve units (50, 52, 54, 56), - a first multifunctional sensor unit (90, 92, 94, 96, 130) associated with a first of the at least two electrically actuated valve units (50, 52, 54, 56), and - a second multifunctional sensor unit (90, 92, 94, 96, 130) associated with a second of the at least two electrically actuated valve units (50, 52, 54, 56), wherein the first sensor unit (90, 92, 94, 96, 130) and the second sensor unit (90, 92, 94, 96, 130) each comprise a structure-borne sound sensor (140, 142, 144, 146) for detecting a structure-borne sound signal, and wherein the first sensor unit (90, 92, 94, 96, 130) and the second sensor unit (90, 92, 94, 96, 130) each have at least one further sensor (150, 152, 154, 156) for detecting a further measured variable, wherein the control device (14) is configured to evaluate signals provided by the sensor units (90, 92, 94, 96, 130) on the basis of a correlation with an electrical valve excitation, characterized in that the control device (14) is configured to perform the evaluation on the basis of the signals within limited time windows (256, 258), comprising a first time window (256), which covers a first edge (226) of an excitation signal (224), and a second time window (258), which covers a second edge (228) of the excitation signal (224), which is opposite to the first edge (226).

2. The device (10) according to claim 1, wherein the at least one further sensor (150, 152, 154, 156) of the first sensor unit (90, 92, 94, 96, 130) and the second sensor unit (90, 92, 94, 96, 130) is a pressure sensor, and / or wherein the at least one further sensor (150, 152, 154, 156) of the first and second sensor unit (90, 92, 94, 96, 130) is a temperature sensor.

3. The device (10) according to claim 1 or 2, wherein the at least two valve units (50, 52, 54, 56) each comprise pilot-controlled valves (50, 52, 54, 56), in particular directional control valves (50, 52, 54, 56) with piezo pilot control.

4. The device (10) according to any one of claims 1-3, wherein at least the first sensor unit (90, 92, 94, 96, 130) or the second sensor unit (90, 92, 94, 96, 130) are configured or operable to transmit signals only in a first transmission time window (246) and in a second transmission time window (248).

5. The device (10) according to any one of claims 1-4, wherein the control device (14) is adapted to determine, for evaluation purposes, based on the sensor signals, at least one quantity selected from the group consisting of the following: Frequency spectrum, amplitude, phase, time delay and combinations thereof.

6. The device (10) according to any one of claims 1-5, wherein the control device (14) is configured to determine, on the basis of the signals provided by the sensor units (90, 92, 94, 96, 130), at least one parameter that can be used for diagnostic purposes, in particular for the purposes of early failure diagnosis and / or for the purposes of predictive maintenance.

7. The device (10) according to any one of claims 1-6, wherein the control device (14) is adapted to perform a machine-based self-learning procedure to determine a reference state, and wherein the self-learning procedure comprises in particular an unsupervised machine learning based on neural networks.

8. The device (10) according to any one of claims 1-7, wherein at least the first sensor unit (90, 92, 94, 96, 130) or the second sensor unit (90, 92, 94, 96, 130) is configured as a structurally integrated sensor unit (90, 92, 94, 96, 130).

9. The device (10) according to any one of claims 1-8, wherein the device (10) is configured as a modular valve island, wherein the valve base (12) has a plurality of valve locations (20, 22, 24, 26) that are configured to accommodate a valve unit (50, 52, 54, 56), and wherein at least two of the valve locations (20, 22, 24, 26) support valve units (50, 52, 54, 56) to which similar sensor units (90, 92, 94, 96, 130) are assigned.

10. The device (10) according to any one of claims 1-9, wherein at least the first valve unit (50, 52, 54, 56) or the second valve unit (50, 52, 54, 56) are coupled to a supplementary plate (100, 102, 104, 106) carrying the associated first sensor unit (90, 92, 94, 96, 130) or second sensor unit (90, 92, 94, 96, 130).

11. The device (10) according to claim 10, wherein the supplementary plate (100, 102, 104, 106) is arranged between the valve base (12) and the valve unit (50, 52, 54, 56) and provides a fluidic connection between the valve base (12) and the valve unit (50, 52, 54, 56).

12. The device (10) according to any one of claims 1-11, wherein at least the first sensor unit (90, 92, 94, 96, 130) or the second sensor unit (90, 92, 94, 96, 130) is formed on the basis of a sensor arrangement (164) for tire pressure monitoring systems, and wherein the sensor arrangement (164) comprises an integrated circuit (168) comprising a plurality of sensor types.

13. A use of a device (10) according to any one of claims 1-12 for tire pressure monitoring systems.

14. A method of operating a device (10) for controlling and regulating fluid flows according to any one of claims 1-12, comprising the following steps: - operating the control device (14) for monitoring signals provided by the sensor units (90, 92, 94, 96, 130) on the basis of a correlation of detected measured variables with an electrical valve excitation, in particular a valve excitation of pilot valves of the valve units (50, 52, 54, 56), comprising: - providing signals by at least the first sensor unit (90, 92, 94, 96, 130) or the second sensor unit (90, 92, 94, 96, 130) only in limited time windows (246, 248), comprising a first transmission time window (246) covering a first edge (226) of an excitation signal, and a second transmission time window (248) covering a second edge (228) of the excitation signal which is opposite to the first edge (226), and - evaluating the signals that are provided in the limited time windows (246, 248) by at least the first sensor unit (90, 92, 94, 96, 130) or the second sensor unit (90, 92, 94, 96, 130).