Control Valve Operating Point Diagnosis Without Extra Sensors
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Solution Overview
Problem
Existing methods for diagnosing changes in control valves require additional sensors or complex monitoring systems, failing to account for the operating point or operating range of the valve, which limits early detection of malfunctions or design issues.
Innovation Solution
A method that records data on the position of the control element at regular intervals, determines characteristics such as operating point and range, and compares these over time to diagnose changes without additional sensors, using a control module or centralized monitoring system to establish a diagnosis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional force sensors or scanning devices are used to detect valve wear, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The control valve uses its own existing position sensor to record and evaluate its positional data for diagnosing wear and malfunctions. The valve essentially monitors itself using data already being collected during normal operation, eliminating the need for separate diagnostic sensors or scanning devices.
Solution Approach 2:
The patent introduces an intermediary evaluation process that analyzes existing position data to extract diagnostic information about valve wear and malfunctions. This intermediary layer of data processing enables wear detection without requiring additional physical sensors.
2Reliability
If process data are related to normal values in a complex system control, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent extracts the essential diagnostic function from complex system control by focusing specifically on position data analysis. Instead of implementing comprehensive system monitoring, it isolates and evaluates only the positional characteristics needed to detect valve wear and malfunctions, simplifying the control approach.
Solution Approach 2:
The system establishes reference values and evaluation criteria in advance for comparing against actual position data. This preliminary preparation enables reliable malfunction detection through straightforward comparison rather than complex real-time analysis.
3Manufacturing precision
If operating point and operating range are evaluated, then manufacturing precision is improved, but loss of time increases due to detailed analysis
Solution Approach 1:
The patent replaces complex mechanical or computational analysis methods with a simplified statistical approach using histograms. By converting position data into frequency distributions and identifying local maxima, the system efficiently determines operating points and ranges without time-consuming detailed analysis.
Solution Approach 2:
The system transforms the analysis from examining individual position values to evaluating frequency distributions and statistical characteristics. This parameter transformation enables rapid identification of operating points through histogram analysis rather than processing each data point individually.
Data Source
AI summary
A method for diagnosing possible causes of changes in at least one control valve, in a plant of which the control valve is a part, or in a process which is carried out on the plant is proposed, wherein at least in a first and in a second time interval the position of the actuator is detected, an operating point or operating range is determined from the first and from the second time interval, these are compared, and possible causes of changes in the at least one control valve, in the plant or in the process are diagnosed from detected differences. Such a diagnosis does not require any additional sensors and makes it possible to detect emerging problems or undesirable developments solely from the operating state of the valve.