Switch Assembly for Valve Actuator

Abstract

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

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application is a PCT adaptation of U.S. Patent Application No. 17 / 139,828, filed December 31, 2020, the entire contents of which are incorporated herein by reference.

[0002] STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not applicable.

[0003] Reference to Attachments Not applicable. [Background technology]

[0004] FIELD OF THE INVENTION The present disclosure relates generally to control valves, and more particularly to actuators and control systems for control valves.

[0005] 2. Description of Related Art: Flow control systems are common in process and manufacturing systems, such as those in hazardous or harsh environments. In such systems, it can be important to accurately monitor and control a variety of parameters, including flow rate, valve position, pressure, valve health, and other aspects of the fluid control components. Therefore, control systems and valves that provide fast and accurate control are needed in many industries. Furthermore, there is often a demand for shorter lead times for control systems and components, including valves, actuators, and their control components.

[0006] Manufacturing control systems and their components can be time-consuming and labor-intensive. For example, to ensure proper operation, the switches used to control valves and their actuators are often made adjustable to account for various manufacturing and / or operational issues. These switches are often pre-set to operate at specific points in the opening and / or closing of the control valve. This is often accomplished by attaching each switch to the valve's actuator and then adjusting each switch while operating the actuator through one or more open and closed cycles.

[0007] There is a need in the art for improved assemblies to increase manufacturing efficiency and simplify supply chain management without compromising the proper operation, reliability, and repeatability of control system components. The disclosures and teachings of the present disclosure are directed to devices, systems, and methods for improved control valve assemblies and related processes. Summary of the Invention

[0008] In at least one embodiment, a switch assembly for a valve actuator can include a bracket for supporting multiple switches, one or more switches rotatably coupled to the bracket at one or more adjustable angles, and one or more switches fixedly mounted to the bracket. In at least one embodiment, the bracket can be non-conductive to electrically isolate the switches from the valve actuator. The valve actuator can trip or trigger the rotatably mounted switches with independently adjustable trip points (or trip points) by calibrating the adjustable angles. A trigger mechanism can be used to trip / trigger the fixedly mounted switches with adjustable trip points (or trip points) by calibrating the trigger mechanism.

[0009] For example, in at least one embodiment, the trigger mechanism can include an arm rotatably coupled to a bracket. The index end of the arm can be coupled to the actuator or a portion of a valve controlled by the actuator, such as a valve stem or a valve stem position indicator of the valve. The bracket end of the arm can be rotatably coupled to the bracket. Movement of the arm can directly or indirectly trip a fixedly mounted switch. One or more switch triggers can be adjustably coupled to the arm and can trip the fixedly mounted switch.

[0010] In at least one embodiment, the switch assembly also includes one or more terminals mounted on the bracket, with at least one of the rotatable switch and the fixed switch wired to the terminals. In at least one embodiment, the switch assembly can include a plurality of fixedly mounted switches that can have different, independently adjustable trip points. In at least one embodiment, the switch assembly further includes a calibration fixture for calibrating the switch assembly to the valve actuator, independent of the valve actuator.

[0011] In at least one embodiment, a switch assembly for a valve actuator of a control valve can be configured by assembling multiple switches to a bracket. This allows the switch assembly to be fabricated, aligned with a calibration fixture, and adjusted while the switch assembly is secured to the calibration fixture. The switch assembly can then be attached to a valve actuator calibrated for the valve actuator, independent of the valve actuator. The switches can include one or more switches fixedly and / or directly mounted to the bracket, and one or more switches rotatably and / or pivotably mounted to the bracket. The calibration fixture can simulate selected functions, operations, and / or movements of the valve actuator.

[0012] Aligning the switch assembly with the calibration fixture can include positioning, aligning, or colimiting one or more assembly datums on the switch assembly with one or more corresponding fixture datums on the calibration fixture. The assembly datums and fixture datums can cooperate to ensure proper alignment between the switch assembly and the calibration fixture. Once the switch assembly is properly aligned with the calibration fixture, the switch assembly can then be secured to the calibration fixture.

[0013] Once the switch assemblies are properly aligned and secured in the calibration fixture, the trip points of the switches can be adjusted. For example, adjusting the trip point of the at least one fixed switch can be accomplished by adjusting a trigger between the at least one fixed switch and an arm pivotally mounted to the bracket. Adjusting the trip point of the at least one rotatable switch can be accomplished by adjusting the angle at which the at least one rotatable switch is mounted to the bracket.

[0014] Once the switches have been adjusted while the switch assembly is secured in the calibration fixture, the switch assembly can be removed from the calibration fixture. At this point, the switch assembly can be stored and set aside for future mating with a valve actuator, or it can be immediately mated with a valve actuator. In either case, the switch assembly can be aligned with the valve actuator by aligning an assembly datum on the switch assembly with an actuator datum on the valve actuator in much the same manner as was done in the calibration fixture. The switch assembly can then be secured to the valve actuator. Once the switch assembly is aligned and secured to the valve actuator, it can be predicted that each of the switches is properly calibrated to the valve actuator due to the adjustments made while the switch assembly was aligned and secured in the calibration fixture. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a perspective view of one of many embodiments of a valve actuator assembly according to the present disclosure. [Figure 2] FIG. 2 is a partially exploded perspective view of the valve actuator assembly of FIG. 1, showing the switch assembly separated from the valve actuator. [Figure 3] FIG. 3 is a reverse perspective view of the switch assembly of FIG. 2. [Figure 4] FIG. 2 is a partial perspective view of the valve actuator assembly of FIG. 1. [Figure 5] FIG. 1 is a perspective view of one of many embodiments of a calibration fixture according to the present disclosure. [Figure 6] FIG. 3 is a rear view of the switch assembly of FIG. 2. [Figure 7] FIG. 1 is an exploded perspective view of one of many embodiments of a switch assembly according to the present disclosure, showing one rotatably mounted switch and one fixedly mounted switch. [Figure 8] FIG. 1 is a perspective view of one of many embodiments of a switch assembly according to the present disclosure, showing one rotatably mounted switch and two fixedly mounted switches. [Figure 9] FIG. 9 is an exploded perspective view of the switch assembly of FIG. 8. [Figure 10] FIG. 1 is a perspective view of one of many embodiments of a switch assembly according to the present disclosure, showing one rotatably mounted switch and three fixedly mounted switches. [Figure 11] FIG. 11 is an exploded perspective view of the switch assembly of FIG. 10. [Figure 12] 1 is a flowchart illustrating one of many embodiments of an assembly method according to the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0016] The above-described drawings and the following specific structural and functional description are not presented to limit the scope of applicant's invention or the appended claims. Rather, the drawings and description are provided to teach those skilled in the art to make and use the invention for which patent protection is sought. Those skilled in the art will understand that not all features of the commercial embodiments of the present disclosure have been described or shown for clarity and understanding. Those skilled in the art will also understand that developing an actual commercial embodiment incorporating aspects of the present disclosure may require numerous implementation-specific decisions to achieve the developer's ultimate goals for the commercial embodiment. Such implementation-specific decisions may include, but are not limited to, system-related, business-related, government-related compliance, and other constraints that may vary by particular implementation, location, and from time to time. While the developer's efforts may be complex and time-consuming in absolute terms, such efforts are nevertheless a routine undertaking for those skilled in the art having the benefit of this disclosure. It should be understood that the embodiments disclosed and taught herein are susceptible to numerous and various modifications and alternative forms. The use of singular terms (such as, but not limited to, "a") is not intended as a numerical limitation on items. Unless otherwise specified, the use of relative terms such as "top," "bottom," "left," "right," "upper," "lower," "below," "upper," "side," "first," "second" ("third" onward), "inlet," "outlet," and the like are used in the specification to clarify specific reference to the drawings and are not intended as a limitation on the scope of this disclosure or the appended claims. Terms such as "couple," "coupled," "coupled," "coupler," and the like are used broadly herein and may include, for example, any method or device of securing, joining, connecting, fastening, attaching, joining, inserting within, forming on or within, communicating with, or otherwise associating, mechanically, magnetically, electrically, chemically, operably, directly or indirectly, with an intermediate element, one or more members, and may further include, without limitation, forming one member uniformly and integrally with another member.The connection can be made in any orientation, including rotation. The terms "including" and "such as" are exemplary and not limiting, and the term "may" means "may, but not necessarily," unless otherwise specified. Notwithstanding any other language in this disclosure, the embodiments shown in the drawings are examples presented for purposes of illustration and description and are not the only embodiments of the subject matter of this disclosure.

[0017] Applicant has created systems and methods for improved assembly to increase manufacturing efficiency and simplify supply chain management without compromising proper operation, reliability, and repeatability of control valves, associated system components, and associated processes. Applicant has created systems and methods for improved assembly to increase manufacturing efficiency and simplify supply chain management without compromising proper operation, reliability, and repeatability of actuators for control valves. Applicant has created systems and methods for improved assembly to increase manufacturing efficiency and simplify supply chain management without compromising proper operation, reliability, and repeatability of subassemblies for control valve actuators. Applicant has created systems and methods for assembling and calibrating subassemblies for control valve actuators. In at least one embodiment, a switch subassembly can be assembled and adjusted or otherwise calibrated for use with an actuator for a control valve.

[0018] FIG. 1 is a perspective view of one of many embodiments of a valve actuator assembly according to the present disclosure. FIG. 2 is a partially exploded perspective view of the valve actuator assembly of FIG. 1, showing a switch assembly separated from the valve actuator. FIG. 3 is a reverse perspective view of the switch assembly of FIG. 2. FIG. 4 is a partial perspective view of the valve actuator assembly of FIG. 1. FIG. 5 is a side view of the switch assembly of FIG. 2 mounted in a calibration fixture. FIG. 6 is a rear view of the switch assembly of FIG. 2. FIG. 7 is an exploded perspective view of one of many embodiments of a switch assembly according to the present disclosure, showing one rotatably mounted switch and one fixedly mounted switch. FIG. 8 is a perspective view of one of many embodiments of a switch assembly according to the present disclosure, showing one rotatably mounted switch and two fixedly mounted switches. FIG. 9 is an exploded perspective view of the switch assembly of FIG. 8. FIG. 10 is a perspective view of one of many embodiments of a switch assembly according to the present disclosure, showing one rotatably mounted switch and three fixedly mounted switches. FIG. 11 is an exploded perspective view of the switch assembly of FIG. 10. Figure 12 is a flow chart illustrating one of many embodiments of an assembly method according to the present disclosure. Figures 1-12 are described in conjunction with one another.

[0019] In at least one embodiment, an actuator assembly 100 for controlling and / or monitoring a control valve can include a valve actuator 102 and a switch assembly, or subassembly, 110. In at least one embodiment, the switch assembly 110 for the valve actuator 102 can include a bracket 112 for supporting multiple switches 114. One or more switches 114a can be rotatably coupled to the bracket 112 at one or more adjustable angles. One or more switches 114b can be fixedly mounted to the bracket 112. In at least one embodiment, the bracket 112 and / or portions thereof can be non-conductive to electrically isolate the switches 114 from the valve actuator 102 and / or other components of the subassembly 110. The valve actuator 102 can trip or trigger the rotatably mounted switches 114a at an independently adjustable trip point (or trip points) by calibrating the adjustable angle. The trigger mechanism 116 can be used to trip / trigger the fixedly mounted switch 114b with an adjustable trip point (or trip points) by calibrating the trigger mechanism 116.

[0020] In at least one embodiment, the plurality of switches 114 includes a high fire switch indicating a fully open position of a valve controlled by the actuator 102, a low fire switch indicating a mid-stroke position of the valve, a proof of closure switch indicating a fully closed position of the valve, and a limit switch for controlling the stroke limit of the valve actuator 102. In at least one embodiment, the limit switches may be rotatably mounted switches 114a and may be actuated by the valve or valve actuator 102. In at least one embodiment, the high fire switch, low fire switch, and proof of closure switch may be fixedly mounted to switches 114b and may be actuated by one or more arms 118 of a trigger mechanism 116 attached to the bracket 112. The arms 118 may be rotatable to follow an indicator 120 that moves with the valve stem of the valve as the valve actuator 102 opens and closes the valve, and / or a simulator 120a that simulates the indicator 120.

[0021] In at least one embodiment, the trigger mechanism 116 can include an arm 118 rotatably coupled to the bracket 112. An indexing end 118a of the arm 118 can be coupled to the actuator 102 or a portion of a valve controlled by the actuator 102, such as a valve stem of the valve, a valve stem position indicator 120 of the valve, or a simulator 120a simulating the indicator 120. A bracket end 118b of the arm 118 can be rotatably coupled to the bracket 112, such as via an axel 122 and a keeper 123. Movement of the arm 118 can directly or indirectly trip a fixedly mounted switch 114b. In at least one embodiment, one or more switch triggers 124 can be adjustably coupled to the arm 118, such as through the use of an adjustable set screw 126 and / or a tension spring 128, and the triggers 124 can trip the fixedly mounted switch 114b. Alternatively, or additionally, as best shown in FIG. 11 , a set screw 126 can be positioned between the trigger 124 and the fixedly mounted switch 114b. In this manner, one arm 118 and trigger 124 pair can trip two or more fixedly mounted switches 114b, such as a high-fire switch and a low-fire switch, at different points along the valve stem travel. As can be appreciated, there can be some dependency between the adjustment of the trip points by which mechanisms trip two or more switches 114. However, if independent mechanisms trip different switches 114, the adjustment of the trip points can be independent.

[0022] In at least one embodiment, the rotatably mounted switch 114a can be rotatably mounted directly to the bracket 112 or can be rotatably mounted to the bracket 112 via a carrier 130 that is in turn rotatably mounted to the bracket 112. In at least one embodiment, the rotatably mounted switch 114a can be fixedly or rigidly mounted to the carrier 130 using fasteners 132, such as machine screws. In at least one embodiment, the carrier 130 can be rotatably mounted to the bracket 112 using fasteners and washers 134. The trip point of the rotatably mounted switch 114a can be configured by adjusting a set screw 126, which can set an adjustable angle between the rotatably mounted switch 114a and the bracket 112. In at least one embodiment, the angle between the bracket 112 and the carrier 130, and therefore the rotatably mounted switch 114a, can be set and adjusted using the set screw 126, a spring 136, and one or more nuts 138. The nut 138 may be captured by the carrier 130 or other portion of the subassembly 110 and / or may include a locking nut that prevents the set screw from moving, thereby fixing the trip point of any associated switch 114.

[0023] The switch 114 can be wired to a switch terminal 140a, which can then be wired to an actuator terminal 140b when the switch assembly 110 is attached to the actuator 102. The switch terminal 140a can be secured to the bracket 112 using additional fasteners 132. The switch terminal 140a can also be wired to a terminal on the calibration fixture 104 for use during adjustment or calibration of the switch 114.

[0024] In at least one embodiment, the bracket 112 itself is made from a non-conductive material, thereby insulating the switches 114 from each other and / or from the actuator 102. In at least one embodiment, an insulator 142 is used to cover one or more portions of the switches 114, thereby insulating the switches 114 from each other, the bracket 112, and / or the actuator 102.

[0025] In at least one embodiment, the calibration fixture 104 can be used to adjust or calibrate the switch 114 before it is attached to the actuator 102 in which it will be used. In at least one embodiment, the calibration fixture 104 can include a simulator 120a or other structure that simulates the indicator 120. In at least one embodiment, the calibration fixture 104 can include a simulator or structure that simulates the valve and / or other components of the valve actuator 102. In at least one embodiment, the calibration fixture 104 can be a partial valve actuator 102. In at least one embodiment, the calibration fixture 104 can be a complete valve actuator 102 used for adjustment or calibration purposes, or multiple switch assemblies 110 for use with other valve actuators 102. Once adjusted or calibrated, the switch assemblies 110 can be attached to the valve actuator 102 in which it will be used, or can be placed in storage for assembly into future valve actuators 102 as needed. In this manner, the switch assemblies 110 can be assembled and all of the switches 114 adjusted at once before being attached to the valve actuators 102 that will be used. Additionally, the switch assemblies 110 can be assembled, adjusted, inspected, and stored as subassemblies to reduce the time between when an order is placed and when a fully assembled actuator assembly 100 is ready for shipment.

[0026] In at least one embodiment, the high fire switch, the low fire switch, and the closure evidence switch can be rigidly mounted to the bracket 112. One or more arms 118 can be pivotally mounted to the bracket 112. Adjusting the trip points of the high fire switch, the low fire switch, and the closure evidence switch can include adjusting the relationship between the arm 118 and the high fire switch, the low fire switch, and / or the closure evidence switch while the switch assembly 110 is secured to the calibration fixture 104. For example, one or more set screws 126 can be used to adjust the angle between the arm 118 and one or more triggers 124 that trip the switch 114 according to movement of the actuator 102, the indicator 120, or the simulator 120a. In at least one embodiment, a single arm 118 and trigger 124 pair can use two set screws 126 to control the trip points of the high fire switch and the low fire switch. In at least one embodiment, the pair of arm 118 and trigger 124 can control the trip point of each of the rigidly mounted switches 114b. In at least one embodiment, adjusting the trip point of one switch 114 does not affect the trip point of any other switch 114. In at least one embodiment, adjusting the trip point of one switch 114 affects the trip point of another switch 114, and such interaction is adjustable using different set screws. In at least one embodiment, the switch assembly 110 can include multiple rigidly mounted switches 114b, each of which can have a different trip point that can be independently adjustable.

[0027] In at least one embodiment, the limit switch may be pivotally mounted to the bracket 112. Adjusting the trip point of the limit switch may include adjusting the angle at which the limit switch is pivotally mounted to the bracket 112 while the switch assembly 110 is secured to the calibration fixture 104. For example, the limit switch may be rigidly mounted to a carrier 130 that is in turn rotatably mounted to the bracket 112. The angle between the bracket 112 and the carrier 130, and therefore the limit switch, may be adjusted using a set screw 126.

[0028] In at least one embodiment, the calibration fixture 104 can be used to calibrate the switch assembly 110 relative to the valve actuator 102, independently of the valve actuator 102. In at least one embodiment, at least one of the rotatable switch 114a and the fixed switch 114b is wired to a terminal 140a attached to the bracket 112. The calibration fixture 104 and / or the valve actuator 102 can include a terminal 140b to which the terminal 140a attached to the bracket 112 can be wired when the switch assembly 110 is attached to the calibration fixture 104 or the valve actuator 102, respectively.

[0029] In at least one embodiment, in accordance with certain aspects of the present disclosure, there may be a distinction between securing the switch assembly 110 to the actuator 102 and / or calibration fixture 104 and aligning the switch assembly 110 to the actuator 102 and / or calibration fixture 104. It will be understood by those skilled in the art that proper alignment of the switch assembly 110 affects its adjustment or calibration. Accordingly, in at least one embodiment, the switch assembly 110, the actuator 102, and / or the calibration fixture 104 may include datums 150a, b, c to ensure proper alignment of the switch assembly 110 relative to the actuator 102 and / or calibration fixture 104. In at least one embodiment, the switch assembly 110 may include a switch datum 150a that physically mates with an actuator datum 150b when the switch assembly 110 is properly aligned relative to the actuator 102. Switch datum 150a can also physically mate with fixture datum 150c when switch assembly 110 is properly aligned relative to calibration fixture 104. In at least one embodiment, datums 150a, b, c support switch assembly 110 on actuator 102 and / or calibration fixture 104, so that aligning switch assembly 110 with actuator 102 and / or calibration fixture 104 does not necessarily secure switch assembly 110 to actuator 102 and / or calibration fixture 104. Switch assembly 110 can be separately secured to actuator 102 and / or calibration fixture 104 using fasteners such as machine screws. In at least one embodiment, the switch assembly 110 can be separately secured to the calibration fixture 104 using a toggle clamp 152 mechanically coupled to a bumper 154, which holds the switch assembly 110 securely against the calibration fixture 104.

[0030] In at least one embodiment, a switch assembly 110 for a valve actuator 102 of a control valve can be fabricated and / or configured as shown in assembly method 1000 of FIG. 12. For example, as shown in step 1002, assembly can begin by mounting a plurality of switches 114 to a bracket 112. The switches 114 can include one or more switches fixedly and / or directly mounted to the bracket 112, as well as one or more switches rotatably and / or pivotally mounted to the bracket 112. As mentioned above, the bracket 112, or portions thereof, can be fabricated from a non-conductive material to electrically isolate the switches 114 from each other and / or from the valve actuator 102.

[0031] As shown in step 1004, the switch assembly 110 may then be aligned with the calibration fixture 104. Aligning the switch assembly 110 with the calibration fixture 104 may include positioning, aligning, or matching one or more assembly datums 150a on the switch assembly 110 with one or more corresponding fixture datums 150b on the calibration fixture 104. The assembly datums 150a and the fixture datums 150b may cooperate to ensure proper alignment between the switch assembly 110 and the calibration fixture 104. Once the switch assembly 110 is properly aligned with the calibration fixture 104, the switch assembly 110 may then be secured to the calibration fixture 104, as shown in step 1006. As described above, the calibration fixture 104 may mimic selected functions, operations, and / or movements of the valve actuator 102.

[0032] As shown in step 1008, each of the switches 114 can be adjusted while the switch assembly 110 is aligned with and secured to the calibration fixture 104. In at least one embodiment, once the switch assembly 110 is properly aligned with the calibration fixture 104, the trip points of the switches 114 can be adjusted. For example, adjustment of the trip point of the at least one fixed switch 114b can be performed by adjusting the trigger 124 between the at least one fixed switch 114b and the arm 118 pivotally mounted to the bracket 112. Adjustment of the trip point of the at least one rotatable switch 114a can be performed by adjusting the angle at which the at least one rotatable switch 114a is mounted to the bracket 112.

[0033] Once the switch 114 has been adjusted while the switch assembly 110 is secured to the calibration fixture 104, the switch assembly 110 may be removed from the calibration fixture 104, as shown in step 1010. At this point, the switch assembly 110 may be stored and set aside for future mating with a valve actuator 102, or may be immediately mated with the valve actuator 102.

[0034] For example, as shown in step 1012, the switch assembly 102 may be aligned with the valve actuator 102 by positioning the assembly datum 150a on the switch assembly 110 with the actuator datum 150b on the valve actuator 102 in much the same manner as was done with the calibration fixture 104. Once properly aligned, the switch assembly 110 may be secured to the valve actuator 102, as shown in step 1014. Once the switch assembly 110 is secured to the valve actuator 102, each of the switches 114 may be expected to be properly calibrated to the valve actuator 102 due to the adjustments made while the switch assembly 110 was secured in the calibration fixture 104.

[0035] In at least one embodiment, a switch assembly for a valve actuator can include a bracket for supporting multiple switches, one or more switches rotatably coupled to the bracket at one or more adjustable angles, and one or more switches fixedly mounted to the bracket. In at least one embodiment, the bracket can be non-conductive to electrically isolate the switches from the valve actuator. The valve actuator can trip or trigger the rotatably mounted switches at an independently adjustable trip point (or trip points) by calibrating the adjustable angles. A trigger mechanism can be used to trip / trigger the fixedly mounted switches at an adjustable trip point (or trip points) by calibrating the trigger mechanism. In at least one embodiment, the trigger mechanism can include an arm rotatably coupled to the bracket. An indicating end of the arm can be coupled to the actuator or a portion of a valve controlled by the actuator, such as a valve stem or a valve stem position indicator. A bracket end of the arm can be rotatably coupled to the bracket. Movement of the arm can directly or indirectly trip the fixedly mounted switch. One or more switch triggers may be adjustably coupled to the arm and may be capable of tripping a fixedly mounted switch.

[0036] In at least one embodiment, the switch assembly can include one or more terminals mounted to the bracket, with at least one of the rotatable switch and the fixed switch wired to the terminal. In at least one embodiment, the switch assembly can include multiple fixedly mounted switches, each of which can have different, independently adjustable trip points. In at least one embodiment, the switch assembly can include a calibration fixture for calibrating the switch assembly to a valve actuator independently of the valve actuator. In at least one embodiment, a switch assembly for a valve actuator can be configured by assembling multiple switches to a bracket. This allows the switch assembly to be fabricated, aligned with the calibration fixture, and adjusted while the switch assembly is secured to the calibration fixture. The switch assembly can then be attached to a valve actuator calibrated for the valve actuator independently of the valve actuator. The switches can include one or more switches fixedly and / or directly mounted to the bracket and one or more switches rotatably and / or pivotally mounted to the bracket. The calibration fixture can simulate selected functions, operations, and / or movements of the valve actuator.

[0037] Aligning the switch assembly with the calibration fixture can include positioning, aligning, or matching one or more assembly datums on the switch assembly with one or more corresponding fixture datums on the calibration fixture. The assembly datum and the fixture datum can cooperate to ensure proper alignment between the switch assembly and the calibration fixture. Once the switch assembly is properly aligned with the calibration fixture, the switch assembly can then be secured to the calibration fixture. Once the switch assembly is properly aligned and secured to the calibration fixture, the trip points of the switches can be adjusted. For example, adjusting the trip point of the at least one fixed switch can be performed by adjusting a trigger between the at least one fixed switch and an arm pivotally mounted to the bracket. Adjusting the trip point of the at least one rotatable switch can be performed by adjusting an angle at which the at least one rotatable switch is mounted to the bracket.

[0038] Once the switches are adjusted while the switch assembly is secured in the calibration fixture, the switch assembly can be removed from the calibration fixture. At this point, the switch assembly can be stored and set aside for future mating with a valve actuator, or it can be immediately mated to a valve actuator. In either case, the switch assembly can be aligned with the valve actuator by aligning an assembly datum on the switch assembly with an actuator datum on the valve actuator in much the same manner as was done in the calibration fixture. The switch assembly can then be secured to the valve actuator. Once the switch assembly is aligned and secured to the valve actuator, it can be predicted that each of the switches is properly calibrated to the valve actuator due to the adjustments made while the switch assembly was aligned and secured in the calibration fixture.

[0039] The systems and methods disclosed herein are not limited to the exemplary valve and / or actuator types shown in the figures for illustrative purposes, but are applicable to many different types and styles of control valves, actuators, and related systems. Furthermore, while the teachings of the present disclosure may be particularly advantageous to solenoid valves, they are not necessarily limited thereto; the control valve may be or include, in whole or in part, any type of valve, whether now known or hereafter developed, separately or in combination, such as, for example, linear valves, rotary valves, solenoid valves, pilot valves, diaphragm valves, mechanical valves, electromechanical valves, hydraulic valves, pneumatic valves, and other types of valves for manipulating the passage of one or more fluids across a distance or point. As used herein, the term "fluid" includes any substance or material capable of flowing, e.g., liquids, gases, and combinations thereof (whether or not one or more solids or other non-fluids are present therein).

[0040] Other and further embodiments utilizing one or more aspects of the above-described systems and methods may be devised without departing from the spirit of Applicant's disclosure. For example, the devices, systems, and methods disclosed herein may be used alone or to form one or more parts of other valves, valve components, and / or fluid control systems. Furthermore, various methods and embodiments of valves and modules may be included in combination with each other to create variations of the disclosed methods and embodiments. Discussion of a singular element may include a plurality of elements, and vice versa. Reference to at least one item followed by a subsequent item may include one or more items. Also, various aspects of the embodiments may be used in combination with each other to achieve an understanding of the present disclosure.

[0041] Unless the context clearly indicates otherwise, the terms "comprise," "include," and "has" (and their variations and conjugations, such as "comprises," "including," and "have") should be understood to mean the inclusion of at least the recited elements or steps or groups of elements or steps, or their equivalents, and not the exclusion of greater quantities or other elements or steps or groups of elements or steps, or their equivalents. Apparatus, devices, and systems can be used in many directions and orientations. Unless specifically limited, the sequence of steps can occur in various orders. Various steps described herein can be combined with other steps, interconnected with recited steps, and / or divided into multiple steps. Similarly, elements are functionally described and can be embodied as separate components and / or combined into components having multiple functions.

[0042] The embodiments are described in the context of preferred and other embodiments, and not all embodiments of Applicant's disclosure are described. Obvious modifications and variations to the described embodiments will be available to those skilled in the art having the benefit of this disclosure. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of Applicant's disclosure; rather, in accordance with patent laws, Applicant intends to fully protect all such modifications and improvements that are within the scope or range of equivalents of the claims.

Claims

1. 1. A method of configuring a switch assembly for a valve actuator configured to control a valve, comprising: assembling the plurality of switches to the bracket by fixedly mounting at least one fixed switch to the bracket and rotatably mounting at least one rotatable switch to the bracket, thereby creating a switch assembly; providing a calibration fixture that simulates the valve actuator; aligning the switch assembly with the calibration fixture by positioning an assembly datum on the switch assembly with a fixture datum on the calibration fixture, the assembly datum and the fixture datum cooperating to ensure alignment between the switch assembly and the calibration fixture; securing the switch assembly to the calibration fixture; adjusting a first trip point of the at least one fixed switch by adjusting a trigger between the at least one fixed switch and an arm pivotally mounted to the bracket while the switch assembly is secured to the calibration fixture; adjusting a second trip point of the at least one rotatable switch by adjusting an angle at which the at least one rotatable switch is attached to the bracket while the switch assembly is secured to the calibration fixture; removing the switch assembly from the calibration fixture; aligning the switch assembly with the valve actuator by positioning an assembly datum on the switch assembly with an actuator datum on the valve actuator, the assembly datum and the actuator datum cooperating to ensure alignment between the switch assembly and the valve actuator; securing the switch assembly to the valve actuator, wherein the adjusting step calibrates each of the plurality of switches to the valve actuator; A method comprising:

2. 10. The method of claim 1, wherein the at least one fixed switch comprises a high fire switch indicating a fully open position of the valve, a low fire switch indicating a mid-stroke position of the valve, and a closed proof switch indicating a fully closed position of the valve, and the at least one rotatable switch comprises a limit switch for controlling a stroke limit of the valve actuator.

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

4. The method of claim 3 , wherein the calibration fixture comprises a simulator that simulates the indicator.

5. The method of claim 1 , wherein assembling the plurality of switches to the bracket comprises wiring at least one of the plurality of switches to a set of terminals attached to the bracket.

6. 1. A method of setting a switch assembly for a valve actuator, comprising: assembling a plurality of switches to a non-conductive bracket, thereby creating a switch assembly; providing a calibration fixture that mimics the valve actuator; aligning the switch assembly with the calibration fixture by positioning an assembly datum on the switch assembly with a fixture datum on the calibration fixture, the assembly datum and the fixture datum cooperating to ensure alignment between the switch assembly and the calibration fixture; securing the switch assembly to the calibration fixture; adjusting trip points of the plurality of switches while the switch assembly is secured to the calibration fixture; removing the switch assembly from the calibration fixture; placing the switch assembly in a storage location; removing the switch assembly from storage; aligning the switch assembly with the valve actuator by positioning an assembly datum on the switch assembly with an actuator datum on the valve actuator, the assembly datum and the actuator datum cooperating to ensure alignment between the switch assembly and the valve actuator; securing the switch assembly to the valve actuator, wherein each of the plurality of switches is calibrated to the valve actuator by adjusting trip points of the plurality of switches while the switch assembly is secured to the calibration fixture; A method comprising:

7. 7. The method of claim 6, wherein the plurality of switches comprises a high fire switch indicating a fully open position of a valve controlled by the actuator, a low fire switch indicating a mid-stroke position of the valve, a closed proof switch indicating a fully closed position of the valve, and a limit switch for controlling a stroke limit of the valve actuator.

8. 8. The method of claim 7, wherein the high fire switch, the low fire switch, and the closure proof switch are actuated by at least one arm attached to the non-conductive bracket, the at least one arm configured to follow an indicator that moves with a valve stem of the valve as the valve actuator opens and closes the valve.

9. The method of claim 8 , wherein the calibration fixture comprises a simulator that simulates the indicator.

10. 9. The method of claim 8, wherein the high fire switch, the low fire switch, and the closure evidence switch are rigidly mounted to the non-conductive bracket, the at least one arm is pivotally mounted to the non-conductive bracket, and the step of adjusting the trip points of the high fire switch, the low fire switch, and the closure evidence switch includes adjusting a relationship between the at least one arm and the high fire switch, the low fire switch, and the closure evidence switch while the switch assembly is secured to the calibration fixture.

11. 9. The method of claim 8, wherein the high-fire switch, the low-fire switch, and the closure-proof switch are rigidly mounted to the non-conductive bracket, the at least one arm comprises a first arm and a second arm, the first arm and the second arm pivotally mounted to the non-conductive bracket, and while the switch assembly is secured to the calibration fixture, adjusting a trip point of the high-fire switch includes adjusting a high-fire trigger between the first arm and the high-fire switch, adjusting a trip point of the low-fire switch includes adjusting a low-fire trigger between the first arm and the low-fire switch, and adjusting the trip point of the closure-proof switch includes adjusting a closure trigger between the second arm and the closure-proof switch.

12. 12. The method of claim 11, wherein the high-fire trigger, the low-fire trigger, and the closure trigger are independently adjustable, and adjusting one of the high-fire trigger, the low-fire trigger, and the closure trigger does not affect adjustment of another of the high-fire trigger, the low-fire trigger, and the closure trigger.

13. 12. The method of claim 11, wherein high and low fire trip points are independently adjustable, and adjusting one of the high and low fire trip points affects adjustment of the other of the high and low fire trip points.

14. 8. The method of claim 7, wherein the limit switch is pivotally mounted to the non-conductive bracket, and wherein adjusting the trip point of the limit switch comprises adjusting an angle at which the limit switch is pivotally mounted to the non-conductive bracket while the switch assembly is secured to the calibration fixture.

15. 7. The method of claim 6, wherein the step of assembling the plurality of switches to the non-conductive bracket includes wiring at least one of the plurality of switches to a set of terminals attached to the non-conductive bracket.

16. 1. A switch assembly for a valve actuator configured to control a valve, comprising: a bracket for supporting a plurality of switches; a rotatable switch rotatably coupled to the bracket at an adjustable angle; a first fixed switch fixedly attached to the bracket; a terminal attached to the bracket, at least one of the rotatable switch and the fixed switch being wired to the terminal; a first arm rotatably coupled to the bracket, the first arm having an indicator end configured to couple to at least one of a valve stem of the valve and a valve stem position indicator of the valve, and a bracket end rotatably coupled to the bracket; a first switch trigger adjustably coupled to the first arm; Equipped with the rotatable switch is configured to be tripped by the valve actuator; The switch assembly, wherein the first fixed switch is configured to be tripped by the first switch trigger.

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

18. a second fixed switch fixedly attached to the bracket; a first trip point of the first fixed switch is independently adjustable according to a position of the first switch trigger relative to the first arm; 17. The switch assembly of claim 16, wherein a second trip point of the second fixed switch is adjustable depending upon a position of the first switch trigger relative to the first arm.

19. a second fixed switch fixedly attached to the bracket; a second arm rotatably coupled to the bracket; a second switch trigger adjustably coupled to the second arm; and Furthermore, a first trip point of the first fixed switch is independently adjustable according to a first position of the first switch trigger relative to the first arm; 17. The switch assembly of claim 16, wherein a second trip point of the second fixed switch is independently adjustable according to a second position of the second switch trigger relative to the second arm.

20. 17. The switch assembly of claim 16, further comprising a calibration fixture for calibrating the switch assembly to the valve actuator independently of the valve actuator.

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