Diagnostic Valve Island

Abstract

The modular valve island (100) includes a plurality of valves, a supply and discharge module 6, a data communication module 7, and a diagnostic module 8. At least one of the plurality of valves has at least one integrated sensor configured to detect an operating condition of the modular valve island. The at least one integrated sensor is electrically connected to the diagnostic module 8 and sends a sensor signal to the diagnostic module. The diagnostic module 8 is configured to receive and process the sensor signal internally to identify the operating condition. The modular valve island 100 is configured to provide data regarding the operating condition of the modular valve island 100 via at least one of a user interface provided within the diagnostic module 8; an industrial Ethernet link; or a wireless network and / or cloud communication link.

Description

Technical Field

[0001] The present invention relates to a fluid flow control device, and more particularly to a valve island including a valve for controlling a fluid power device such as an actuator or a movable element. The present invention is applicable to pneumatic and hydraulic control valves, but for the sake of convenience, the former will be mainly referred to in this specification.

Background Art

[0002] For example, in production machines and the like, it is now common for all starting cylinders to be controlled by respective direction control valves usually assembled on the same "valve island". The valves in the valve island are usually controlled by solenoids that receive electrical signals for actuating the associated valves. The valves control the direction of the pneumatic flow that operates the starting cylinders of the production machine. Each starting cylinder has an operating cycle specific to a part of the production machine. Each control valve needs to operate correctly to maintain the correct operation of the starting cylinder. Malfunctions of a single control valve and its starting cylinder can potentially stop the operation of the entire production machine.

[0003] The valve island is connected to a pneumatic line that supplies pressurized gas or air, an electrical line that provides power for the solenoids, and an electrical communication line that controls the operation of the valve island. Such valve islands have the advantage of compactness, but each requires connections for electrical, communication, and pneumatic lines. Thus, a production machine having a plurality of valve islands will require a relatively complex network for its operation, and such a network is difficult and costly to install for the end user. Furthermore, fault detection around such a complex network can be a troublesome problem. More recently, valve islands have been constructed to use wireless communication technology to transfer data captured by the valve island. All islands require means for establishing power, air, and communication.

[0004] Since each valve island can be responsible for a number of different actuators located at different places on the production machine, it can be difficult for the operator of the production machine to effectively identify and arrange for the repair of any internal faults. It would be beneficial if the pneumatic and fluid control systems on and associated with the valve island, such as the upstream compressor and air preparation equipment and the conditions of the downstream system, could be monitored, thus performing condition monitoring and / or preventing problems from occurring if they are likely to occur. If a problem has already occurred, it is considered beneficial to quickly and easily identify which component has the problem.

[0005] European Patent No. 1400702 B1 discloses a control module for controlling and monitoring the functions of valves. An external computer is used for monitoring and diagnosis via a fieldbus.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

[0007] Aspects and embodiments of the present invention provide a modular valve island and a pneumatic system as claimed in the appended claims.

[0008] According to one aspect of the present invention, in a modular valve island including a plurality of valves, a supply and discharge module, a data communication module, and a diagnostic module, at least one of the plurality of valves has at least one integrated sensor, the at least one integrated sensor is configured to detect operating conditions of the modular valve island, the at least one integrated sensor is electrically connected to the diagnostic module and sends a sensor signal to the diagnostic module; the diagnostic module is configured to receive and process the sensor signal internally to identify the operating conditions; and a user interface, an industrial Ethernet link, or a wireless network and / or a cloud communication link provided in the diagnostic module is configured to provide data regarding the operating conditions of the modular valve island via at least one of them. A modular valve island is provided.

[0009] The present invention provides a modular valve island with an integrated sensor, a diagnostic module, and a data communication module. The modular valve island monitors operating conditions and simultaneously issues warnings about interfaced products. The present invention provides a modular solution with a diagnostic feature menu that customers can select based on their specific problems and needs. With the diagnosis installed, the user can directly participate in the valve island at the point of use.

[0010] The modular valve island with an integrated sensor, a diagnostic module, and a data communication module provides, for every user, (a clear, simple, and intuitive way, namely an instantaneous diagnosis and troubleshooting represented by colors and replacement part numbers), as well as simple instructions / suggestions on how to return the occurring problems to the normal state. By monitoring the operating conditions and reporting any deviation from the normal operating conditions, the user's attention can be drawn to a failure or the progression of a failure. If deviating from the normal operating conditions, it may be possible to replace and / or repair the components of the entire operating system during regular maintenance before the failure progresses to the extent that the operation of the entire system has to be stopped for repair.

[0011] The modular valve island may further include a plurality of sub-bases, where each valve of the plurality of valves is associated with a corresponding sub-base of the plurality of sub-bases. Alternatively, the modular valve island may further include a manifold sub-base, where each valve of the plurality of valves is associated with a corresponding part of the manifold sub-base.

[0012] At least one integrated sensor may be provided on a sensor unit, and the sensor unit is positioned between the plurality of valves and the plurality of sub-bases. Alternatively, at least one integrated sensor may be provided on a sensor unit positioned between the plurality of valves and the manifold sub-base. A plurality of sensor units may be provided.

[0013] The data communication module and the diagnostic module may be combined as a single module. The modular valve island may further include at least one input / output module.

[0014] The operating conditions may be failure conditions.

[0015] At least one integrated sensor may include a first valve sensor for detecting the mechanical characteristics of the valve. Preferably, the first valve sensor is a sensor configured to detect the position of the valve spool. More preferably, the first valve sensor is selected from one of an optical sensor, an inductive sensor, and a magnetic sensor.

[0016] At least one integrated sensor may further include a second valve sensor for detecting the electrical characteristics of the valve. Preferably, the second valve sensor is an electrical sensor configured to detect changes in coil current and / or voltage.

[0017] The modular valve island may further include a sub-base sensor integrated into the sub-base or sub-base manifold for detecting the flow conditions of the sub-base or sub-base manifold, where the sub-base sensor is electrically connected to the diagnostic module and transmits a sensor signal to this diagnostic module.

[0018] The sub-base sensor may be a flow pressure sensor provided in at least one of the inlet port of the sub-base or sub-base manifold and the outlet port of the sub-base or sub-base manifold, where the flow pressure sensor is configured to detect at least one of pressure, flow rate, and temperature.

[0019] At least one sensor may be provided in the supply and exhaust module for detecting at least one of pressure, flow rate, air quality, and temperature, where at least one supply and exhaust module sensor is electrically connected to the diagnostic module and transmits a signal to this diagnostic module.

[0020] At least one sensor may be provided within at least one input / output module to detect at least one of pressure, flow rate, air quality, and temperature, where the at least one input / output module sensor is electrically connected to a diagnostic module and transmits a signal to this diagnostic module.

[0021] The diagnostic user interface may be a display. The user interface may have orientation control.

[0022] According to a further aspect of the present invention, a pneumatic system is provided that includes a modular valve island as described above, and at least one actuator or movable element fluidly connected to the modular valve island.

[0023] The at least one actuator or movable element may include a sensor electrically connected to the input / output module of the modular valve island.

[0024] In this way, the modular valve island monitors boundary conditions and at the same time issues a warning about the components connected by the interface.

[0025] According to yet another aspect of the present invention, a sensor unit for a modular valve island includes a housing adapted to be electrically connected between the valve and the sub-base of the modular valve island, defining a plurality of passages between the valve and the sub-base of the modular valve island through which fluid can flow, and a sensor unit including at least one integrated sensor configured to detect the operating conditions of the modular valve island is provided.

[0026] The housing may include an upper surface adapted to be in fluid communication with a plurality of passages of the valves of the modular valve island, and the housing may include a lower surface adapted to be in fluid communication with a plurality of passages of the sub-base of the modular valve island.

[0027] At least one integrated sensor may include a pressure sensor. The pressure sensor may be fluidly connected to one of the plurality of passages of the valves of the modular valve island.

[0028] A gasket may at least partially define a fluid connection between the pressure sensor and the passage. The gasket may be retained inside a groove defined within the sensor unit.

[0029] At least one integrated sensor may include an optical sensor. The optical sensor may be arranged so as not to obstruct the flow through the passage. The optical sensor may be electrically connected to a printed circuit board assembly (PCBA) within the housing.

[0030] It is expressly intended that within the scope of the present application, the various aspects, embodiments, examples and variant embodiments described in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular their features, can be taken up independently or in any combination. That is, the features of all embodiments and / or any embodiment can be combined in any form and / or combination, provided that such features are not mutually exclusive. The applicant reserves the right to amend any originally filed claim and to change any originally filed claim or to file an appropriate new claim, including the right to be dependent on and / or to incorporate any feature of any other claim not originally claimed in that form.

[0031] One or more embodiments of the present invention will be described by way of example only, with reference to the accompanying drawings.

Brief Description of the Drawings

[0032]

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Figure 13

Mode for Carrying Out the Invention

[0033] The valve island 100 includes a plurality of valves 1.

[0034] In the embodiments of FIGS. 1a and 1b, a plurality of valves 1 are assembled on the upper surfaces of a plurality of sub-bases 2. Each valve 1 and sub-base 2 are collectively referred to as a valve slice. Thus, the valve island 100 has a modular structure. The sub-base 2 guides air through the base of the valve island 100 and provides connections for the valves 1 to an air supply source as well as connections from pneumatic devices connected downstream of each valve 1. The sub-bases 2 are typically held together using clamps or tie rods that are fixed through the length of the valve island 100.

[0035] A plurality of sub-bases 2 are joined together in a row with a first end plate 3 attached at one end of the row of sub-bases 2. Attached to the other end of the row of sub-bases 2 is the supply and exhaust module 6. Attached to the supply and exhaust module 6 is the second end plate 3. Attached to the second end plate 3 is the data communication module 7. Attached to the data communication module 7 is the diagnostic module 8. In one alternative embodiment, the data communication module 7 and the diagnostic module 8 are combined as a single module. Attached to the diagnostic module 8 is the input / output module 9. The valve island 100 may be provided with two or more input / output modules 9. As is understood in the art, the order of the said modules, valves and sub-bases may be varied according to the requirements of the user.

[0036] Each valve is responsible for controlling the direction of the flow of pressurized fluid to and from its respective actuator or movable element (not shown in FIG. 1). The term actuator or movable element is used to describe many different features including grippers, vacuum devices and valves. The pressurized fluid is supplied to the valve island 100 via the supply and exhaust module 6.

[0037] The specific number of valves depends on the field of use of the production machine. In the specific embodiment of FIG. 1, there are six valve slices with six valves 1 assembled on the upper surfaces of six sub-bases 2. These valves 1 and sub-bases 2 are respectively called the first, second, third, fourth, fifth, and sixth valve slices from right to left. Each of the sub-bases 2 is provided with a pneumatic connection 4. It is considered that the valve slices can be arranged in other combinations not explicitly described in this specification.

[0038] Each of the valve slices is pneumatically connected to the supply and discharge module 6. Each of the valves 1 is a solenoid 5 valve. Each solenoid 5 valve is electrically connected to a data communication module 7 and a diagnostic module 8 (or a combined data communication and diagnostic module).

[0039] The first sub-base 2 has a sub-base sensor incorporated in the sub-base 2. The sub-base sensor is a flow pressure sensor 11. This can detect the downstream pressure, flow rate, and temperature through the pneumatic connection 4 to any actuator or movable element.

[0040] The second valve 1 has an intelligent coil 12. The solenoid valve has a printed circuit board electrically connected to the solenoid coil. While supplying power to the solenoid coil, the printed circuit board can detect changes in current and / or voltage to determine the performance of the solenoid coil. Thus, the intelligent coil 12 monitors the coil performance.

[0041] The second valve 1 also has an intelligent valve with an optical sensor 15. The intelligent valve detects the position of the spool. The optical sensor 15 is disposed at either end of the intelligent valve. In one variant embodiment, the intelligent valve has at least one magnetic sensor arrangement instead of or in addition to the optical sensor. In yet another variant embodiment, the intelligent valve has at least one inductive sensor arrangement instead of or in addition to the optical sensor.

[0042] The third valve slice has a standard valve 1 and a standard sub-base 2.

[0043] The fourth valve slice has a standard valve 1 and a standard sub-base 2.

[0044] The fifth valve slice has a standard valve 1 and a standard sub-base 2.

[0045] The sixth valve slice has a standard valve 1 and a standard sub-base 2.

[0046] The supply and discharge module 6 is a diagnostic supply and discharge module (DSEM) 13 with integrated flow pressure. The supply and discharge module 6 may further have at least one environmental sensor 14.

[0047] An inlet pressure sensor is disposed at the inlet of the DSEM 13. The DSEM 13 detects the inlet pressure and the inlet flow rate of the pressurized fluid. An outlet pressure sensor is disposed at the outlet of the DSEM 13. The DSEM 13 detects the outlet pressure and the outlet flow rate of the pressurized fluid.

[0048] If any deviation from the operating conditions during use, normal operating conditions such as the set pressure, for example a set inlet pressure of 6 bar, or a set outlet pressure of 3 bar, is detected, it may be considered to indicate a fault or the progression of a fault inside the valve island 100 or the associated actuator or movable element. For example, such a fault may be considered to include a leakage of pressurized fluid within a particular valve 1 or within a particular actuator or movable element.

[0049] The environmental sensor 14 monitors the humidity and / or water content and / or temperature of the inflow of the pressurized fluid. The environmental sensor 14 can likewise detect any oil / particles / water droplets in the inflow of the pressurized fluid. The environmental sensor 14 can be a humidity sensor disposed at the inlet of the DSEM 13. The environmental sensor 14 can be a humidity sensor disposed at the outlet of the DSEM 13. The environmental sensor 14 can be an oil droplet / particle sensor disposed at the inlet of the DSEM 13. During use, the environmental sensor 14 can indicate the quality of the pressurized fluid entering the DSEM 13. It is also possible to use two or more environmental sensors 14.

[0050] Each sensor within the valve island 100 is electrically connected to the diagnostic module 8. The diagnostic module 8 is configured to receive signals from each sensor of the valve island 100 via the electrical connection, as will be described in more detail below.

[0051] The data communication module 7 has a sub-base 16. The data communication module 7 is equipped with an industrial Ethernet link 17 via a programmable logic computer (PLC). Thus, the industrial Ethernet link 17 provides a means of communication between the valve island 100 and the PLC. The data communication module 7 is equipped with a wireless network 18. Alternatively or additionally, the data communication module 7 is equipped with a cloud communication link 18. Signals from the sensors proceed through the data communication module 7 and it is possible to send these signals to the PLC (without diagnostic processing). In normal use, the diagnosis is performed on the diagnostic module 8.

[0052] In another embodiment of the present invention, no wireless network and / or cloud communication link 18 is provided. Instead, the data communication module 7 is provided only with an industrial Ethernet link 17. Since this is an Ethernet connection, several other devices including a PLC may be connected. For example, additional on-site or off-site Internet of Things (IoT) to a cloud processing / Industry 4.0 system, or an open platform communication / integration architecture (OPC-UA) for monitoring or analysis, or local users on a connected network can view web pages from the device. Two or more network connections can be used for control or data communication.

[0053] The diagnostic module 8 has a diagnostic user interface. The diagnostic user interface may be a color display screen 10. The color display screen 10 may be a liquid crystal display (LCD). The color display screen 10 may be a full-color thin film transistor (TFT) LCD. Alternatively, the color display screen 10 may be an organic light emitting diode (OLED) display. The user interface has orientation control so that the valve island 100 can be installed in any orientation. The color display screen 10 may be removable, or an existing HMI can also be used.

[0054] The diagnostic module 8 has a built-in artificial intelligence unit (MIU). The MIU can include a printed circuit board (PCB) and a processor, where the PCB receives various signals to be decoded by the processor. The processor monitors operating conditions and executes the necessary algorithms to identify any changes or deviations from the operating conditions that can indicate a fault or the progression of a fault that can be identified from the signals. The MIU is software that has the ability to capture data from all connected sensors, store the data, and use built-in algorithms to process this data to provide useful notifications. The diagnostic module 8 collects and processes data from sensors inside the valve island 100 and from sensors on the upstream and downstream sides of the pneumatic system (components before and after the valve island). The diagnostic module 8 similarly has the ability to collect data from sensors and offload it to an alternative site via the data communication module 7. The alternative site can be, for example, a cloud service.

[0055] Sensor signals from the intelligent coil 12 and the intelligent valve may be combined in such a way that each sensor is treated as a pair of integrated sensors. Thus, for example, a signal from an optical sensor indicating the spool position is combined with a signal from the intelligent coil 12 indicating whether the coil has switched and thus what position the spool should be in, and is used to identify a deviation from normal or expected operating conditions and thus whether a fault exists or there is a risk of a fault progressing.

[0056] The input / output module 9 enables the connection of external system devices and sensors to the PLC through the valve island 100. The input / output module 9 is electrically connected to the data communication module 7 through the diagnostic module 8. Any data from these sensors can be queried by the diagnostic module 8 in combination with signals for sensors 11, 12, 15. For example, a position sensor on an actuator (for detecting the stroke position of the actuator). This signal can be combined with the measured signals from the coil and the valve to identify the operating conditions.

[0057] Both the data communication module 7 and the diagnostic module 8 can monitor the operating conditions. This can be done by monitoring the sensing data to create operating reference values and then repeatedly comparing the periodic data against these operating reference values.

[0058] Both the data communication module 7 and the diagnostic module 8 can locally transmit the operating conditions externally via the color display screen 10 on the diagnostic module 8. Both the data communication module 7 and the diagnostic module 8 can remotely communicate the operating conditions externally either via the industrial Ethernet link 17 or via the wireless network and / or the cloud communication link 18. These can be displayed to the operator of the production machine via a portable device such as a mobile phone, tablet or laptop computer. Deviations from normal operating conditions, and thus faults or the progression of faults, are communicated using status / warning messages. The status / warning messages identify the location and type of the fault. The status / warning messages can identify solutions.

[0059] When the control valve or its respective activation cylinder indicates a performance degradation, visual indication is provided via the user interface provided within the diagnostic module as described above, and / or via an industrial Ethernet link and / or a wireless network and / or a cloud communication link 18. This enables the replacement of the control valve or activation cylinder at the next convenient maintenance opportunity.

[0060] Identifiable operating conditions and faults or fault progression include valve sticking; valve leakage; pressure change; cycle count; flow rate change; air consumption (i.e., flow rate); energy consumption (i.e., power); air quality (e.g., particles, humidity, etc.); solenoid / coil performance / problems; actuator / sensor problems (e.g., leakage, actuator sticking, etc.); valve end position; spool failure or sticking. What goes into the diagnosis is what is happening inside the valve and where, i.e., which valve is being identified and displayed as a status / warning message.

[0061] Both the data communication module 7 and the diagnostic module 8 can enable the update of algorithms from external sources. Software updates on remotely sent nodes (not local updates), the advantage of having an external connection combined with an on-board diagnostic module. A subprogram that can be activated based on a PLC command to change the activation characteristics of the valve can be stored on the data communication module 7 and the diagnostic module 8.

[0062] The valve island 200 according to the second embodiment of the present invention is shown in FIGS. 2a and 2b. The valve island 200 is similar to the valve island 100, and thus, the same reference numbers are used, and only the main differences of the valve island 200 will be detailed.

[0063] The valve island 200 has a plurality of valves 1 assembled on the upper surface of the sub-base 202. Each valve 1 is associated with a corresponding portion of the manifold sub-base 202.

[0064] The valve island 300 according to the third embodiment of the present invention is shown in FIGS. 3a and 3b. The valve island 300 is similar to the valve island 100, and thus, the same reference numerals are used where applicable, and only the main differences of the valve island 300 will be described in detail.

[0065] Similar to the valve island 100, in the valve island 300, a plurality of valves 1 are assembled on the upper surfaces of a plurality of sub-bases 2. Each valve 1 and sub-base 2 are collectively referred to as a valve slice. Thus, the valve island 300 has a modular structure. The sub-base 2 guides air through the fluid connection 20 within the base of the valve island 100 and also provides an air connection 4 from the pneumatic device connected downstream of each valve 1, similar to the connection for the valve 1 to the air supply source 312. The plurality of valves 1 of the valve island 300 are assembled on the upper surfaces of the plurality of sub-bases 2, and a plurality of sensor units 303 are positioned therebetween in a sandwich arrangement. Each sensor unit 303 has at least one integrated sensor. The sensor unit 303 serves to detect the characteristics of the valve slice, and thus, individual sensors may not be required.

[0066] In a specific embodiment of the valve island 300 of FIG. 3, the first sensor unit 303 has a sub-base sensor which is a flow rate and / or pressure sensor 11. The second sensor unit 303 has a sub-base sensor which is a flow rate and / or pressure sensor 11. The third sensor unit 303 has an intelligent coil sensor 12 which is positioned within the sensor unit 303 in contrast to the valve 1 of the valve island 100. The fourth sensor unit 303 has an intelligent valve optical sensor 15 which is positioned within the sensor unit 303 in contrast to the valve 1 of the valve island 100. The fifth sensor unit 303 has an intelligent valve magnetic sensor 15. The sixth sensor unit 303 has an intelligent valve inductive sensor 15.

[0067] Referring to FIG. 4, the valve island 300 is shown in an alternative configuration, with many valves 1 (similar to the valve island 100) being directly assembled on the upper surface of the corresponding sub-base 2, many valves 1 being assembled on the upper surface of the sensor unit 303, and the sensor unit being assembled on the upper surface of the corresponding sub-base 2. Further, a shut-off valve 19 is assembled on the upper surface of the sub-base 2, and two supply and discharge modules 6 are provided.

[0068] The sensor unit 303 includes an upper housing 304, an intermediate housing 306, and a bottom part 308. The upper housing 304 is connected to the intermediate housing using snap fits and / or screw connections 307. The bottom part 308 is connected to the intermediate housing 306 using snap fits.

[0069] Externally, each sensor unit 303 cooperates in shape with a valve slice including the valve 1 and the sub-base 2 of the valve island 300. Thus, two sensor units 303 can be positioned side by side within adjacent valve slices, as shown in FIG. 4. With this arrangement, the sensor unit 303 can measure the pressure on each side of the spool 22. The screw 44 can pass through the assembled sensor unit 303 through the screw hole 310 to connect the sub-base 2 of the valve slice and the valve 1.

[0070] Internally, the sensor unit 303 is adapted to cooperate with the pneumatic galleries 312 of the valve 1 and the sub-base 2. The sensor unit 303 is adapted to accommodate an electrical connection between the valve 1 and the sub-base 2. The inner surface of the sensor cavity 320 engages with the valve connector seal 52. Similarly, the sensor unit connector seal 322 engages with the inner surface of the sensor cavity provided within the sub-base 2.

[0071] Pneumatic connection Referring to FIG. 5, a cross-sectional view of the valve slice containing the sensor unit 303 is shown. The cross-section is taken in the intermediate plane of the combination of the non-disassembled valve 1 and the sensor unit 303.

[0072] The standard valve 1 has an arrangement of a spool 22 and a solenoid 24. The movement of the spool 22 controls the pneumatic flow through the individual passages 30, 32, 34, 36, 38 of the pneumatic gallery 312, as is known in the art. The... drives the movement of the exemplary actuator 21 via the pneumatic connection 4.

[0073] The upper housing 304 and the intermediate housing 306 have passages 330, 332, 334, 336, 338 that are collectively fluidly connected to the passages 30, 32, 34, 36, 38 of the valve 1 called the pneumatic gallery 312 and equivalent passages within the sub-base 2.

[0074] The intermediate housing 306 is shown in detail in FIG. 8. A delivery path 348 fluidly couples the delivery sensing chamber 344 to a passage 336 that constitutes a main source of the valve slice. A supply path 350 fluidly couples the supply sensing chamber 346 to a passage 332 that constitutes a first delivery passage of the valve slice.

[0075] An integral gasket 340 is provided on the upper surface of the intermediate housing 306. The gasket is installed in a groove 342 provided in the upper surface of the intermediate housing 306. The gasket 340 is arranged to surround each of the passages 330, 332, 334, 336, 338 together with their respective delivery paths and sensing chambers.

[0076] The supply path 350 utilizes the shape of the gasket 340 to fluidly couple the supply sensing chamber 346 to the passage 332.

[0077] The delivery path 348 depends not only on the shape of the gasket 340 but also on the bypass path 349 shown in FIGS. 9 and 10 to fluidly couple the delivery sensing chamber 344 to the passage 336. An ultrasonically welded plate 351 can block a portion of the bypass path 349.

[0078] Electrical connection Referring back to FIG. 5, the sensor unit 303 is provided with two printed circuit board assemblies (PCBA) 352, 354. The PCBA 352, 354 are electrically connected to each other. In one variant embodiment, any number of PCBA can be provided. The lower PCBA 354 is electrically connected to the valve electrical connector array 50. The valve electrical connector array 50 carries power and electrical signals between the valve 1 and the sub-base 2. The sensor unit 303 has a pass-on connector array 358 that is electrically connected to the printed circuit board assembly 60 of the sub-base. The sensor unit 303 may have an additional connector array 356 depending on the field of use. The sub-base printed circuit board assembly 60 is electrically connected to the sub-bus 16 of the data communication module 7 through the valve island 300.

[0079] Sensor The upper PCBA 352 is electrically connected to the optical sensor 372. The optical sensor 372 is aligned inside the passage 328. According to the specific embodiment shown, the optical sensor 372 is aligned inside the discharge passage 328. The optical sensor 372 is arranged so as not to obstruct the flow inside the discharge passage 328. The optical sensor 372 observes the position of the spool 22. The optical sensor 372 can observe the position of the spool 22 by irradiating light on the spool 22 and detecting the difference in the reflected light signal between the spool 22 and the seal on the spool 22. The optical sensor 372 may be firmly fixed in place in contact with the ultrasonically welded plate as shown in FIG. 6. The optical sensor 372 is electrically connected to the connector 355 on the upper PCBA 352 through a wired connection routed through the sensor unit 303, specifically through the pocket 353.

[0080] The upper PCBA 352 has a first pressure sensor 372 and a second pressure sensor 374. The first pressure sensor 372 is fluidly connected to the delivery detection chamber 344. The second pressure sensor 374 is fluidly connected to the supply detection chamber 346.

[0081] The upper PCBA 352 has a current sensor 376. The current sensor 376 detects the current draw of the pilot valve solenoid.

[0082] The sub-base 2 is held together using clamps or tie rods that fix it along the length of the valve island 100. The valve 1 wears over time and requires replacement. To facilitate replacement, the valve 1 is designed to be easily removable from the sub-base 2 without having to disassemble the valve island 300. This is typically (e.g., within the valve island 100) achieved using screws 44 that firmly fix the valve 1 directly to the sub-base 2. Thus, the user can easily replace or upgrade / change the valve function with the valve island 100 in place. The valve island 300 maintains these benefits in the field of sensor addition.

[0083] By having a sensor unit 303 that mates between the sub-base 2 and the valve 1, there is no need for a dedicated sub-base 2. Similarly, this means that a user who wishes to add sensors or upgrade the valve island to switch sensing between different channels can easily do so without disassembling the valve island 300. The sensor unit 303 allows the standard valve electrical connector array 50 for the valve 1 to "pass through" and connect to the sub-base printed circuit board assembly (PCBA) 60, eliminating the need for any modifications or additional connectors.

[0084] The sensor electronics inside the sensor unit 303 are compatible with any type of valve 1 and are thus interchangeably usable within the valve island 300.

[0085] In a fourth embodiment (not shown) of the present invention, a plurality of sensor units are sandwiched between a plurality of valves and a manifold sub-base, where the plurality of sensor units are associated with corresponding portions of the manifold sub-base.

[0086] In a variant embodiment, the sensor unit 303 can be provided on top of further functional elements such as a shut-off valve. Thus, the valve slice includes a standard valve 1, a sensor unit 303, a shut-off valve, and a sub-base 2.

Explanation of Signs

[0087] 1 Valve 2 Sub-base 3 End plate 4 Pneumatic connection 5 Solenoid valve 6 Feed and drain module 7 Data communication module 8 Diagnostic module 9 Input / output module 10 Color display screen 11 Integrated base flow pressure sensor 12 Intelligent coil 13 Diagnostic feed and drain module 14 Integrated flow pressure and environment sensor 15 Optical sensor 16 Sub-base 17 Industrial Ethernet link 18 Wireless network and / or cloud communication link 18 19 Shut-off valve 20 Fluid connection 21 Exemplary actuator 22 Spool 24 Solenoid 30, 32, 34, 36, 38 Passage 44 Screw 50 Valve electrical connector array 52 Valve connector seal 60 Sub - base Printed Circuit Board Assembly (PCBA) 100, 200, 300 Valve Islands 202 Manifold Sub - base 303 Sensor Unit 304 Upper Housing 306 Intermediate Housing 307 Screwed Connection 308 Bottom Component 310 Screw Hole 312 Pneumatic Gallery 320 Sensor Cavity 322 Sensor Unit Connector Seal 330, 332, 334, 336 Passages 338 Discharge Passage 340 Gasket 342 Groove 344 Delivery Detection Chamber 346 Supply Detection Chamber 348 Delivery Path 349 Bypass Path 350 Supply Path 351 Plate 352 Upper Printed Circuit Board Assembly (PCBA) 353 Pocket 354 Lower Printed Circuit Board Assembly (PCBA) 355 Connector 358 Pass - on Connector 372 Optical Sensor 373 Plate 374 First Pressure Sensor 376 Second Pressure Sensor 378 Current Sensor

Claims

1. a plurality of valves (1); a supply and discharge module (6); a data communication module (7); a diagnostic module (8); In a modular valve island (100) comprising: at least one of the plurality of valves has at least one integrated sensor, the at least one integrated sensor being configured to detect operating conditions of the modular valve island (100), the at least one integrated sensor being electrically connected to the diagnostic module (8) and sending a sensor signal to this diagnostic module; the diagnostic module (8) is configured to receive and process the sensor signal internally to identify the operating conditions; and - a user interface provided within the diagnostic module (8); - an industrial Ethernet link; or - a wireless network and / or a cloud communication link; A modular valve island (100) configured to provide data regarding the operating conditions of the modular valve island (1) via at least one of these.

2. The modular valve island (100) according to claim 1, further comprising a plurality of sub-bases, each valve of the plurality of valves being associated with a corresponding one of the plurality of sub-bases.

3. The modular valve island (100) according to claim 1, further comprising a manifold sub-base, each valve of the plurality of valves being associated with a corresponding part of the manifold sub-base.

4. The modular valve island (100) according to claim 2, wherein the at least one integrated sensor is provided on a sensor unit (303), and the sensor unit (303) is positioned between the plurality of valves and the plurality of sub-bases.

5. The modular valve island (100) according to claim 3, wherein the at least one integrated sensor is provided on a sensor unit (303), and the sensor unit (303) is positioned between the plurality of valves and the manifold sub-base.

6. The modular valve island (100) according to claim 4 or 5, comprising a plurality of sensor units (303).

7. The modular valve island (100) according to claim 1, wherein the data communication module (7) and the diagnostic module (8) are combined as a single module.

8. The modular valve island (100) according to claim 1, further comprising at least one input / output module (9).

9. The modular valve island (100) according to claim 1, wherein the operating condition is a fault condition.

10. The modular valve island (100) according to claim 1, wherein the at least one integrated sensor includes a first valve sensor for detecting mechanical characteristics of the valve, preferably, the first valve sensor is a sensor configured to detect the position of the valve spool, and more preferably, the first valve sensor is selected from one of an optical sensor, an inductive sensor, and a magnetic sensor.

11. The modular valve island (100) according to claim 1, wherein the at least one integrated sensor further includes a second valve sensor for detecting electrical characteristics of the valve, preferably, the second valve sensor is an electrical sensor configured to detect changes in coil current and / or voltage.

12. The modular valve island (100) according to claim 2 or 3, further comprising a sub-base sensor integrated into the sub-base or sub-base manifold for detecting flow conditions of the sub-base or sub-base manifold, wherein the sub-base sensor is electrically connected to the diagnostic module (8) and transmits a sensor signal to this diagnostic module.

13. The modular valve island (100) according to claim 12, wherein the sub-base sensor is a flow pressure sensor provided in at least one of the inlet port of the sub-base or sub-base manifold and the output port of the sub-base or sub-base manifold, and the flow pressure sensor is configured to detect at least one of pressure, flow rate, and temperature.

14. At least one sensor is provided in the supply and exhaust module to detect at least one of pressure, flow rate, air quality, and temperature, and the at least one supply and exhaust module sensor is electrically connected to the diagnostic module (8) to transmit a signal to this diagnostic module. The modular valve island (100) according to claim 1.

15. At least one sensor is provided in the at least one input / output module (9) to detect at least one of pressure, flow rate, air quality, and temperature, and the at least one input / output module sensor is electrically connected to the diagnostic module (8) to transmit a signal to this diagnostic module. The modular valve island (100) according to claim 8.

16. The diagnostic user interface is a display, and preferably the user interface has orientation control. The modular valve island (100) according to claim 1.

17. The modular valve island (100) according to any one of claims 1 to 16, and a pneumatic system including at least one actuator or movable element fluidly connected to the modular valve island (100).

18. The at least one actuator or movable element includes a sensor electrically connected to the input / output module (9) of the modular valve island (100). The pneumatic system according to claim 18.

19. In a sensor unit (303) for a modular valve island (100), including a housing adapted to be electrically connected between the valve and the sub-base of the modular valve island, defining a plurality of passages between the valve and the sub-base of the modular valve island so that fluid can flow therebetween, and including at least one integrated sensor configured to detect the operating conditions of the modular valve island. A sensor unit (303).

20. The housing includes an upper surface adapted to be in fluid communication with a plurality of passages of a valve of a modular valve island, and the housing includes a lower surface adapted to be in fluid communication with a plurality of passages of a sub-base of the modular valve island, the sensor unit according to claim 19.

21. The sensor unit according to claim 19, wherein the at least one integrated sensor includes a pressure sensor.

22. The sensor unit according to claim 21, wherein the pressure sensor is in fluid communication with one of the plurality of passages of the valve of the modular valve island.

23. The sensor unit according to claim 22, wherein a gasket (340) at least partially defines the fluid communication between the pressure sensor and the passage.

24. The sensor unit according to claim 23, wherein the gasket is retained inside a groove defined within the sensor unit (303).

25. The sensor unit according to claim 19, wherein the at least one integrated sensor includes an optical sensor (372).

26. The sensor unit according to claim 25, wherein the optical sensor (372) is arranged so as not to impede the flow through the passage.

27. The sensor unit according to claim 25 or 26, wherein the optical sensor (372) is electrically connected to a printed circuit board assembly (PCBA) within the housing.

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