Actuator Position Signal Transmission via Binary and Analog Integration
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Solution Overview
Problem
Existing solutions for communicating electrical positioning information of actuator-positioned final control elements, such as valve elements, in process engineering and nuclear technology require expensive and complex designs to balance continuous position sensing with low energy consumption and safety in explosive environments.
Innovation Solution
A method and device that combines continually sensed positioning information with a binary signal to form a single positioning signal, allowing for optional invocation of signal conditions, using a Namur-contact-like binary signal and modulating analog information using protocols like HART, to transmit both position and alarm information efficiently, reducing hardware needs and energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If continuous position sensing is implemented using sensors like Hall sensors, then closed loop control and precise position monitoring are improved, but energy consumption and system complexity increase
Solution Approach 1:
The system uses periodic pulse signals from the incremental encoder instead of continuous analog sensing. The encoder generates position information only when the valve stem moves, creating discrete position updates rather than continuous signal transmission. This periodic action significantly reduces energy consumption while maintaining the ability to track position changes for closed loop control.
Solution Approach 2:
The patent replaces traditional inductive proximity switches and continuous analog sensors with an incremental encoder that uses optical or magnetic fields to generate digital pulse signals. This substitution of the sensing mechanism provides more precise position information with lower energy requirements, as the encoder only consumes power during position changes rather than maintaining continuous signal output.
2Reliability
If both continuous position sensing and alarm functionality are provided, then system monitoring capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines continuous position sensing and alarm functionality into a single integrated system using the incremental encoder. The same encoder that provides continuous position information for closed loop control also generates the binary alarm signal by detecting when the valve stem reaches predefined positions. This merging eliminates the need for separate alarm switches and reduces overall system complexity while maintaining both monitoring capabilities.
Solution Approach 2:
The incremental encoder serves multiple functions simultaneously: it provides continuous position feedback for control, generates binary alarm signals for safety monitoring, and enables precise positioning without requiring additional dedicated sensors or switches. This multi-functionality reduces the number of components needed and simplifies the overall device architecture.
3Use of energy by moving object
If binary alarm signals are used instead of continuous sensing, then energy consumption is reduced, but position monitoring capability deteriorates
Solution Approach 1:
The system segments position information into two distinct types: continuous position data from the incremental encoder for normal operation, and discrete binary alarm signals for safety monitoring. The incremental encoder divides the rotation into discrete pulses that provide precise position information, while separate alarm switches provide binary signals for critical position detection. This segmentation allows each type of information to be optimized for its specific purpose.
Data Source
AI summary
In a method for communicating electrical positioning information of an actuator-positioned final control element such as a valve element, the positioning information resulting from continually sensing the position of the final control element, a binary signal is formed or received signalling a condition 0 (zero) when the final control element has attained a predefined position and a condition 1 (one) when the final control element has not attained the predefined position or the predefined position range. For forming a positioning signal, the corresponding signal condition of the binary signal and the associated continually sensed positioning information are combined such that the corresponding signal condition of the binary signal or the positioning information or both can be optionally invoked from the positioning signal.