Control Valve Position Converter for Accurate Long-Stroke Sensing

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Solution Overview

Problem

Control valves in industrial processes face accuracy issues due to mechanical linkages that are bulky, prone to vibration, and extend beyond the structural envelope, leading to reduced yield and increased downtime for maintenance and repair.

Innovation Solution

A position transfer device that converts linear position to angular position using a linearly translating shaft with an inclined surface and a rotatable mechanism, reducing complexity and susceptibility to external influences, and employing non-contact modalities like magnets for precise position measurement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional linkage mechanisms are used for position measurement, then the measurement can be obtained, but the device becomes bulky, complex, and susceptible to vibration affecting accuracy

Engineering Contradiction:

Improveposition measurement accuracyVSAvoidlinkage mechanism complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces conventional mechanical linkage mechanisms with a magnetic field-based measurement system. Magnets are positioned on the actuator and detected by a magnetic sensor, eliminating the need for bulky mechanical linkages while maintaining measurement capability and improving accuracy by removing vibration susceptibility of mechanical components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If conventional linkage mechanisms are used, then position measurement is achieved, but the device extends beyond the structural envelope and requires more space

Engineering Contradiction:

Improveposition measurement capabilityVSAvoiddevice spatial envelope

Core Design Contradiction:

Measurement precisionVSVolume of moving object

Solution Approach 1:

The magnetic field-based measurement system occupies minimal space compared to mechanical linkages. The magnets are integrated onto the actuator components and the magnetic sensor is positioned within the existing structural envelope, eliminating the need for external linkage mechanisms that extend beyond the valve body.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If mechanical linkages are used for position measurement, then the measurement system can function, but it is prone to vibration and external influences reducing reliability

Engineering Contradiction:

Improvemeasurement system reliabilityVSAvoidvibration susceptibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The magnetic field-based measurement system is inherently immune to vibration and mechanical wear. The magnets remain fixed on the actuator and the magnetic sensor detects their position through magnetic field interaction, eliminating the mechanical contact and vibration susceptibility of linkage mechanisms while improving reliability in industrial environments.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Measurement precision

If long-stroke position converters are used, then accuracy is improved, but the device complexity and susceptibility to vibration increase

Engineering Contradiction:

Improveposition measurement accuracyVSAvoidmeasurement system reliability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent achieves long-stroke measurement accuracy by using a magnetic sensor that tracks the position of magnets over an extended range of motion. This magnetic field-based approach maintains high accuracy throughout the full stroke while avoiding the vibration and mechanical wear problems that plague conventional mechanical position converters.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution provides more accurate and reliable position measurement, reducing backlash and play, and simplifying maintenance by fitting within the control valve's structural envelope, enhancing operational precision and reducing wear and damage from high flow rates.

Implementation Method 1

converts a linear position to an angular position using a linearly translating shaft with an inclined surface and a rotatable mechanism

Methodology Applied

Scientific EffectMechanical conversion from linear to angular motion:

Implementation Method 2

employing non-contact modalities like magnets for precise position measurement

Methodology Applied

Scientific EffectMagnetic field interaction: Magnetic Field

Data Source

PatentUS11421799B1Accuracy of control valves using a long-stroke position converter

Publication Date: 2022.08.23 DRESSER LLC

AI summary

A position transfer device is configured for use on a control valve. These configurations may convert a linear position of a closure member on the control valve to an angular position of magnets. A sensor in proximity to the magnets can generate a signal in response to the angular position. In one implementation, a valve positioner or controller can process the signal to identify the position of the closure member relative to a seat.