Ball Valve Position Verification for Reliable Remote Actuation
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Solution Overview
Problem
Existing systems for remotely controlling ball valves in fluid pipelines face uncertainties regarding the actual success of opening and closing maneuvers due to potential valve blocking, and require adaptations for different types of ball valves, necessitating robust and reliable control devices.
Innovation Solution
A control device with positional and detection means to monitor the angular position and actuation parameters of ball valves, using fork sensors and encoders to ensure accurate data transmission to an electronic processing unit, which recalculates and verifies the actual position, ensuring reliable operation with or without a speed reducer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a gearmotor unit is equipped with a sensor device to detect valve rotation, then the automation of valve operation is improved, but uncertainty remains regarding the absolute certainty of successful valve maneuver execution
Solution Approach 1:
The system implements a feedback mechanism where the sensor device detects the actual rotation of the valve and communicates this information back to the control unit. The control unit compares the detected position with the expected position to verify successful execution of the maneuver, thereby resolving the uncertainty about whether the valve actually reached the desired position.
Solution Approach 2:
The patent replaces direct mechanical coupling between the gearmotor and valve with an electronic detection and verification system. Instead of relying solely on mechanical connection, the system uses sensors and electronic processing to detect and verify the actual valve position, substituting mechanical certainty with electronic verification.
2Adaptability or versatility
If different types of ball valves are used in the network, then the adaptability of the system is improved, but additional intermediate speed reducers are required for some valve types
Solution Approach 1:
The control device is designed with universal functionality to work with different types of ball valves. The electronic control unit can adapt to various valve configurations and requirements, providing a single versatile solution that replaces the need for multiple specialized mechanisms for different valve types.
Solution Approach 2:
The system adapts to different valve types by changing operational parameters such as rotation speed, torque, and timing through the electronic control unit, rather than requiring physical modifications or additional mechanical components like speed reducers for each valve type.
3Reliability
If periodic manual inspection and maneuvering of valves is performed, then valve blocking is prevented, but operational costs and time consumption increase
Solution Approach 1:
The system enables the valve to perform self-service maintenance through automated periodic maneuvers executed by the gearmotor unit under electronic control. The valve automatically opens and closes at predetermined intervals without requiring external intervention, preventing blocking while eliminating the need for manual inspection and operation.
Solution Approach 2:
The control unit is programmed to execute periodic opening and closing maneuvers of the valve at predetermined time intervals. This automated periodic action prevents valve blocking by maintaining movement of the valve components without requiring continuous manual intervention, thereby reducing both time loss and operational costs.
Data Source
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AI summary
SUMMARY The control device (100, 200) is associated with a gearmotor group (2) which operates a ball valve (Vs) to open and close it, upon command of an electronic processing and control unit (3). A transceiver apparatus (4) is interfaced with said electronic processing and control unit (3) and communicates via radio frequency with a remote operations centre (5). The control device (100, 200) comprises a positional control organ (101, 201), associated with said gearmotor unit (2), which obtains in real time the angular position assumed by the aforementioned ball valve (Vs) and transmits the acquired data to said electronic processing and control unit (3). Furthermore, a first and a second sensor organs (21, 22) are provided, associated with said gearmotor unit (2); the first detects the direction of rotation and activation time, while the second detects the angular amplitude completed from the start of the actuation; the data acquired by said sensor organs (21, 22) are transmitted to the aforementioned electronic processing and control unit (3), in which a program software interfaces them with the data supplied by the positional control organ (101, 201), to recalculate and verify, in a redundant manner, the actual angular position of the ball valve (Vs), gradually assumed during the actuation of said gearmotor group (2), before a report is sent to the remote operations centre (5).