Actuator and controller system for valves and regulating components

Abstract

The present invention was developed primarily for operation in locations where no local power source is available (or where the local power source provides only intermittent energy), thereby enabling the remote and programmable automation of various industrial processes, including control of fluids, be they liquids or gases, in pipelines, water treatment systems, and industrial production facilities, inter alia. The inventive system employs a motor (1) configured to perform the operation of opening and closing the regulating component (2) by rotation of its spindle (1A), which is directly coupled to the handwheel shaft (2A) of the regulating component (2), thereby performing regulating component opening and closing operations according to the direction of rotation applied to the spindle (1A). The inventive system further comprises hardware (4), which, for its part, may include an STM32 chip for controlling motor drivers, and which is provided with at least one output port for a display (4A), thereby enabling physical control of the device. The hardware (4) may additionally include at least one RS-485 output (4E) for connection to a communication module (5), in order to enable communication with multiple devices, such as PLCs (programmable logic controllers) or remote communication equipment.

Description

[0001] "ACTUATOR AND CONTROLLER SYSTEM FOR VALVES AND REGISTERS" FIELD OF THE INVENTION

[0002] [1] The present invention falls within the technical field of mechanical engineering and industrial automation, with specific applications in valve control systems and manual registers, more specifically for fluid flow control.

[0003] FUNDAMENTALS OF THE INVENTION

[0004] [2] The objective of the invention is to solve the problem of the need for manual operation of valves and registers in locations where there is no local power source available. Manual operation is susceptible to errors, mechanical failures, and exposure to operational risks. Furthermore, the lack of automation limits efficiency and the ability to precisely control torque, position, and speed. Thus, the present invention aims to provide a solution that allows for remote and programmed control of these mechanisms, increasing precision, safety, and operational efficiency.

[0005] [3] Furthermore, its use is widespread, and it can be used both in the field and in industrial environments where process automation is essential to increase efficiency, safety and accuracy in the operation of valves and registers that were previously operated manually.

[0006] [4] The invention was developed primarily for operation in locations where there is no local power source available (or where the local power source only generates intermittent power), allowing for remote and programmed automation of various industrial processes, including the control of fluids, whether liquid or gaseous, in pipelines, water treatment systems, industrial production facilities, etc. Furthermore, the present invention can be applied to various types of valves, including butterfly, quarter-turn, ball, guillotine, gate and sluice valves.

[0007] BRIEF DESCRIPTION OF THE FIGURES

[0008] [5] To assist in identifying the main features of the invention, reference is provided to the following figures:

[0009] [6] Figure 1 illustrates a profile image of the register with the motor coupled via a base structure.

[0010] [7] Figure 2 illustrates in detail the coupling between the motor shaft and the register flywheel, provided by a connecting element.

[0011] [8] Figure 3 illustrates the register being closed with the projection of the closing element as the motor shaft rotates in a given direction.

[0012] [9] Figure 4 illustrates the register being opened with the closing element retracting as the motor shaft rotates in the opposite direction to closing.

[0013]

[0010] Figure 5 illustrates the complete assembly between the motor, the connecting element and the register, with the presence of a base structure that assists in the support and safety of the system.

[0014]

[0011] Figure 6 illustrates the hardware used in the system.

[0012] Figure 7 illustrates the communication module used in the system.

[0015]

[0013] Figure 8 illustrates the motor driver used in the system.

[0016]

[0014] Figure 9 illustrates a component that can be used for flexible torsional coupling between the motor shaft and the register flywheel.

[0017]

[0015] Figures 10A to 10C illustrate another component that can also be used for coupling between the motor shaft and the register flywheel.

[0018] DETAILED DESCRIPTION OF THE INVENTION

[0019]

[0016] The system of the present invention is initially composed of a motor (1), which can be a direct current or alternating current motor. Furthermore, the motor (1) may have an encoder coupled to it in order to control its operation, and may also have a planetary reduction to ensure greater torque. The planetary reducer to be used in the system may be scalable, and may be interchangeable, in order to adjust to the working force required for the opening and closing operations of the valves and registers. An example of a motor to be applied in the system of the present invention is the stepper motor, which is an electromechanical device that converts electrical impulses into discrete mechanical movements.

[0020]

[0017] The direct current motor can also be employed, being a widely used motor in devices such as electric screwdrivers, which has a simple design that includes a rotor with wire windings, a stator with permanent magnets or electromagnets, a commutator and brushes that conduct the electric current. These motors are valued for their efficient speed control, ability to provide high starting torque and ease of maintenance.

[0021]

[0018] Brushless DC motors (BLDC) can also be used, and these electric motors operate without brushes, using an electronic controller to switch the current in the stator windings, eliminating the need for a mechanical commutator. These motors comprise a rotor with permanent magnets and a stator with windings. The main advantages of using this type of motor include higher efficiency, lower maintenance, longer lifespan, and quieter operation, as there is no physical contact between brushes and commutator. Brushless motors are widely used in applications requiring high reliability and performance, such as drones, electric vehicles, fans, and computer equipment, due to their ability to provide high torque and precise speed control.

[0022]

[0019] In the system of the present invention, the use of any of the referenced motors may include the presence of an encoder, resulting in a significant improvement in the control and precision of the equipment, ensuring that the position is always maintained.

[0020] In addition to the motors mentioned, the DC brushed motor is also an option to replace the stepper motor with the coupling of an encoder to guarantee the position of the equipment.

[0023]

[0021] Figure 1 illustrates an embodiment of the present invention in which a motor (1) is used to perform the procedure of opening and closing the valve (2) by means of the rotation of its shaft (IA) which is directly coupled to the flywheel (2A) of the valve (2), performing the procedures of opening and closing the valve according to the direction of rotation applied to the shaft (IA).

[0024]

[0022] The connection between the motor shaft (IA) (1) and the register flywheel (2A) (2) can be made using a connecting element (3) as illustrated in Figure 2. However, this connection can also be made in other ways, such as by means of a flexible torque coupling, where a robust component is used to connect shafts in power transmission systems. This component consists of two interconnected metal parts and an elastomer insert, as can be seen in Figure 9. The metal parts, made of polished steel, have teeth or claws that fit perfectly with the elastomer insert. This insert serves to transmit torque between the two metal parts while absorbing shocks and vibrations, providing flexibility to the assembly. One of the metal parts has a round hole with a fixing screw that allows secure adjustment to the shaft.The fastening screws ensure that both parts are firmly attached to the shafts, preventing slippage and guaranteeing efficient torque transmission.

[0025]

[0023] The connection between the motor shaft (IA) (1) and the valve flywheel (2A) (2) can also be made by means of a metal connection with neodymium magnet support. This type of connection is made by a component consisting of a metal support with elongated teeth, and containing neodymium magnets placed parallel to these teeth, which causes the two supports to have no mechanical contact. Figures 10A to 10C illustrate this component. Once the force to be applied to the valve is known, it is possible to place the necessary number of magnets to create protection against excessive force, forming a "switch", in case the valve jams or needs to be fully closed.

[0026]

[0024] In addition, a base structure (6) can be used, in order to provide support and safety for the coupling between the motor (1), the connecting element (3) and the register (2), as can be clearly seen from figure 5.

[0027]

[0025] Figure 3 illustrates the register being closed with the projection of the closing element (2B) as a function of the rotation of the motor shaft (IA) (1) in a given direction.

[0028]

[0026] Figure 4 illustrates the register being opened with the retraction of the closing element (2B) as a function of the rotation of the motor shaft (IA) (1) in the opposite direction to the closing.

[0029]

[0027] The system of the present invention also comprises a hardware (4) as illustrated in Figure 6, which, in turn, may comprise an STM32 chip for controlling the motor drivers, in addition to having at least one output port for display (4A) having physical control of the equipment. The hardware (4) may also interact with the equipment through a dashboard to be generated by the hardware's own Wi-Fi, thus allowing direct configuration of the equipment. This dashboard is an app that can be accessed via IP 192.168.4.1 or Ijs, where it is possible to configure: number of actuator revolutions; time to complete full opening, in seconds; time to complete full closing, in seconds; waiting time to start opening the actuator, if there is a command to open; waiting time to start closing the actuator, if there is a command to close; selection of the number of encoder pulses to complete a full rotation (360°).Selection of the type of reducer to be used (ratio number, if 1:10 for example). Configuration for AC and DC inputs and outputs.

[0030]

[0028] The hardware (4) may also have alternating current input and output ports (4B) for controlling the equipment inputs directly from the panel, as well as direct current input and output ports (4C) for parallel use if it is necessary to interconnect two or more registers, i.e., if direct use with direct current is required. Both alternating current input ports (4B) and direct current input ports (4C) have a fault output, and both fault outputs remain in NC (normally closed contact), in order to ensure that the equipment correctly executes what is requested.

[0031]

[0029] The hardware (4) may also have at least one RS-485 output (4E) for connection to a communication module (5), as illustrated in figure 7, in order to enable communication with various equipment, whether PLCs (programmable logic controllers) or remote communication equipment, such as those described below:

[0032] - Wlfi: the wifi communication hardware is additional and connects via R$-485 to the main control hardware and allows you to configure all the equipment parameters.

[0033] - GPRS (3G / 4G) or LoRa: the additional communication hardware via R$-485 connected to the main control hardware will send the equipment parameters to the online platform for configuration and visualization of the register's performance.

[0034] - Physical display: the hardware with physical display connects to the main hardware board enabling local integration of equipment settings and enabling its configuration.

[0030] Considering that the main objective of the invention is related to the operation of the system in locations where there is no availability of local power source, the system of the present invention can have remote and / or programmed actuation, via internet or intranet, using a stepper motor with a control driver, which can be powered by a renewable energy source such as solar panels or stacks connected to DC batteries. Furthermore, considering that the system comprises a specific hardware (4), coupled directly to the motor driver (1) and also to a communication module (5), it is possible to remotely control the torque speed, the angular length applied to the torque, as well as communication with the encoder for position marking.

[0031] The system can be used in any type of valve, such as butterfly, return, ball, guillotine, gate, and is suitable for various types of fluids.

Claims

CLAIMS 1. DC REGISTRY ACTUATOR AND CONTROLLER SYSTEM characterized in that it comprises: a motor (1) having its shaft (IA) directly coupled to the flywheel (2A) of the register (2); and a hardware (4) connected to the motor driver (1).

2. SYSTEM, according to claim 1, characterized in that the connection between the motor shaft (IA) (1) and the register flywheel (2A) (2) can be made through a connecting element (3).

3. SYSTEM, according to claim 1, characterized in that a basic structure (6) can be used.

4. SYSTEM, according to claim 1, characterized in that the motor (1) may comprise an encoder.

5. SYSTEM, according to claim 1, characterized in that a planetary reducer can be coupled to the motor (1).

6. SYSTEM, according to claim 1, characterized in that the hardware (4) may comprise an STM32 chip and at least one display output port (4A).

7. SYSTEM, according to claim 1, characterized in that the hardware (4) may comprise alternating current input and output ports (4B) and direct current input and output ports (4C).

8. SYSTEM, according to claim 7, characterized in that the alternating current input ports (4B) and direct current input ports (4C) each comprise a normally closed (NC) contact fault output.

9. SYSTEM, according to claim 1, characterized in that the hardware (4) may also comprise at least one RS-485 output (4E) for connection to a communication module (5).

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