Adaptive Two-Position Control with Binary Sensor Feedback
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Solution Overview
Problem
Two-point controllers used with actuators that have continuously adjustable manipulated variables face challenges in energy efficiency and wear reduction, as they require more maintenance-intensive and expensive level sensors for optimal operation.
Innovation Solution
A method where the first and second control values of an actuator are dynamically adjusted based on the duration of binary sensor signal values, with the actuator switching between these values to converge them, reducing the amplitude of the manipulated variable and thus minimizing wear and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a two-point controller is used with a binary sensor to control an actuator, then the control system is simple and inexpensive, but the actuator experiences frequent switching leading to increased wear and energy consumption
Solution Approach 1:
The patent applies dynamics by making the switching values dynamic rather than fixed. The first and second switching values are continuously adapted based on the actual process variable and its rate of change. This dynamic adjustment allows the control system to optimize the switching points in real-time, reducing unnecessary actuator switching and thereby decreasing wear and energy consumption while maintaining system simplicity
Solution Approach 2:
The patent implements feedback by continuously monitoring the process variable and its rate of change (derivative). The controller uses this feedback information to dynamically adjust the switching values, creating a closed-loop system that adapts to changing conditions. This feedback mechanism enables the system to avoid premature switching and optimize actuator operation without increasing device complexity
2Device complexity
If a two-point controller is used with a binary sensor to control an actuator, then the control system is simple and inexpensive, but energy consumption increases due to repetitive switching
Solution Approach 1:
The patent applies dynamics by making the switching values dynamic rather than fixed. The first and second switching values are continuously adapted based on the actual process variable and its rate of change. This dynamic adjustment allows the control system to optimize the switching points in real-time, reducing unnecessary actuator switching and thereby decreasing wear and energy consumption while maintaining system simplicity
Solution Approach 2:
The patent implements feedback by continuously monitoring the process variable and its rate of change (derivative). The controller uses this feedback information to dynamically adjust the switching values, creating a closed-loop system that adapts to changing conditions. This feedback mechanism enables the system to avoid premature switching and optimize actuator operation without increasing device complexity
3Use of energy by moving object
If a level sensor is used for needs-based speed control of a pump, then energy efficiency is improved, but the sensor is more maintenance intensive and expensive
Solution Approach 1:
The patent applies self-service by enabling the binary sensor to provide sufficient information for optimized control without requiring a more complex level sensor. The controller processes the binary sensor signals dynamically, using the timing and pattern of transitions to infer process state and optimize pump operation. This allows the system to achieve energy efficiency using a simple, maintenance-free binary sensor rather than a complex level sensor
Solution Approach 2:
The patent applies parameter changes by transforming the control strategy from fixed switching values to dynamically adapted switching values. The controller changes the switching parameters (first and second switching values) based on the binary sensor signal patterns and process variable rate of change. This parameter adaptation enables energy-efficient pump operation while continuing to use the simple binary sensor
Data Source
AI summary
The invention relates to a method for the two-position control of an actuator (1) on the basis of a binary sensor signal (y) of a sensor unit (2), which senses a process variable (P), which can be influenced by the actuator (1), in such a way that the sensor unit outputs a first sensor signal value (y1) when a first switching value (Sw1) is exceeded and a second sensor signal value (y0) when a second switching value (Sw1, Sw2) is fallen below, wherein: the actuator (1) is controlled with a manipulated variable (u), which assumes either a first control value (u1) or a second control value (u2); the first control value (u1) and the second control value (u2) are dynamically adapted during the operation of the actuator (1), in dependence on a fall time (t_fall) corresponding to the duration of the first sensor signal value (y1) and a rise time (t_rise) corresponding to the duration of the second sensor signal value (y0), in such a way that the first and second control values converge. The invention further relates to a two-position controller (10) designed to carry out the method and to an actuator (1) comprising said two-position controller (10).