Autonomous Valve Control with MR Sensor Array
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Solution Overview
Problem
Industrial valves lack precise control and monitoring systems for optimal operation, leading to inefficiencies in fluid management, increased maintenance needs, and reduced lifespan due to vibration and hammering issues during positioning.
Innovation Solution
An autonomous valve system equipped with an MR sensor array that measures valve stem position and speed, allowing for precise control and optimization of valve operations, including calibration, cleaning, and predictive maintenance, by generating control signals for the valve actuator to move the stem to predetermined positions that promote turbulent flow during cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional valve control systems are used, then the valve can operate between closed and fully-open positions, but the positioning precision is insufficient leading to vibration and hammering issues
Solution Approach 1:
The patent replaces traditional mechanical position sensing methods with magnetic field-based MR sensor arrays. The magnet coupled to the valve stem generates a magnetic field that is detected by multiple MR sensors, providing precise non-contact measurement of valve stem position without mechanical wear or contact interference, thereby eliminating vibration and hammering while improving positioning precision.
Solution Approach 2:
The patent implements a closed-loop feedback control system where the MR sensor array continuously monitors valve stem position and provides real-time feedback to the control system. This feedback enables dynamic adjustment of valve actuation to achieve precise positioning and eliminate oscillations, directly resolving the contradiction between measurement precision and operational reliability.
2Productivity
If the valve is cleaned by flowing cleaning solution through the valve, then cleaning is achieved, but the cleaning efficiency is insufficient without optimized positioning
Solution Approach 1:
The patent applies preliminary action by pre-determining optimal cleaning positions for the valve stem based on fluid dynamics principles. The system automatically positions the valve at these predetermined locations before cleaning operations, ensuring that the cleaning solution flows through paths that maximize cleaning efficiency without requiring complex real-time adjustments during the cleaning process.
Solution Approach 2:
The patent employs dynamic valve positioning during cleaning operations, adjusting the valve stem position to optimize cleaning effectiveness. The system can transition between predetermined cleaning positions and fully-open/closed positions dynamically, allowing the cleaning solution to create optimal flow patterns for thorough cleaning while maintaining operational simplicity through automated control.
3Productivity
If the valve operates frequently between positions, then fluid management is achieved, but maintenance needs increase due to wear and vibration
Solution Approach 1:
The patent replaces traditional mechanical position feedback mechanisms with magnetic field-based sensing, eliminating mechanical wear in the position detection system. This substitution significantly reduces maintenance needs while enabling frequent valve operations for efficient fluid management, as there are no mechanical contacts to wear in the sensing portion of the system.
Solution Approach 2:
The closed-loop feedback control system precisely monitors and controls valve stem position, preventing excessive vibrations and hammering that cause mechanical wear. By maintaining smooth, controlled motion and avoiding oscillations, the system extends component lifespan and reduces maintenance frequency while allowing frequent operational cycles for optimized fluid management.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides precise control of valve stem positioning, reduces vibration and hammering, minimizes maintenance needs, and optimizes cleaning efficiency by using precise measurement data to determine optimal operating parameters and positions, thereby extending valve lifespan and improving fluid management.
Implementation Method 1
a valve-stem position sensor that includes a magnet coupled to a valve stem and at least two magnetic-field sensors arranged to sense the position of the magnet along the travel path
Data Source
AI summary
Apparatus and associated methods relate to an autonomous controllable valve system for providing turbulent flow to a cleaning solution during a valve-cleaning operation, the valve system includes a valve and a valve controller, the valve has an MR sensor array arranged to receive a magnetic field from a magnet coupled to the valve stem, the MR sensor array generating signals indicative of a valve stem position, the valve controller receiving the position signals and generating a control signal for a valve actuator to move the valve stem to a cleaning position between a closed position and a maximal-open position. The cleaning position may be less than twenty percent of a distance between the closed position and the maximal open position. In an illustrative embodiment, the cleaning position may be predetermined to cause a turbulent flow of the cleaning solution.