Control Valve Testing Device Error Analysis
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Solution Overview
Problem
Manual testing of control valves in foundries and chemical processing factories is prone to errors due to subjective determination of error percentages, leading to incorrect assessments of valve opening accuracy.
Innovation Solution
A method using a testing device to input data, apply specific pressure to the control valve, and analyze the error percentage between actual and testing openings, generating a calibration curve and report if the error is within a tolerance range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual determination of error percentage is used, then the testing process is simple and quick, but the accuracy and reliability of the testing result deteriorates due to human error
Solution Approach 1:
The patent replaces the manual mechanical reading and determination process with an automated electronic computing system. The testing device automatically calculates the error percentage by comparing actual opening data with testing opening data, eliminating human subjective judgment and visual reading errors while maintaining fast testing capability
Solution Approach 2:
The testing device performs self-analysis by automatically computing the error percentage and determining whether the control valve meets requirements. The system serves itself by having the computer automatically process the comparison between actual and testing openings without requiring human intervention for calculation or judgment
2Measurement precision
If automated testing device is used, then the measurement precision and reliability are improved, but the device complexity increases
Solution Approach 1:
The testing device integrates multiple functions into a single system: it controls the air compressor, reads the location transmitter data, inputs actual opening data, calculates error percentage, and generates test results. This multi-functionality reduces the need for separate devices for each operation while achieving automated precise measurement
Solution Approach 2:
The patent uses an electric current air transformer as an intermediary device that converts electrical current signals into pneumatic pressure signals to actuate the control valve. This intermediary enables precise control and measurement while maintaining a relatively simple overall system architecture
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
This method reduces human error by providing an objective analysis of control valve accuracy, ensuring qualified results and generating a calibration curve for improved testing reliability.
Implementation Method 1
the testing device providing an electric current with a testing opening to an electric current air transformer, the electric current air transformer controlling an air compressor to apply a specific pressure to the control valve
Implementation Method 2
The sensor installed on the control valve senses the testing opening data of the control valve
Data Source
AI summary
A control valve testing method comprises steps: providing a testing device, inputting data in the testing device, electrically connecting the testing device to the location transmitter installed on the control valve, the transmitter connected with a pointer of a valve spindle, the testing device providing an electric current with a testing opening to an electric current air transformer, the electric current air transformer controlling air compressor applying a specific pressure according to the current on the control valve for triggering a valve spindle action to drive the location transmitter to obtain valve spindle action strokes data, transferring the data and performing a comparison between the data with the previously inputted actual opening data for analyzing the error percentage of the actual opening and the testing opening. If the error percentage is within a tolerance range, the result is qualified, and if not, the result is not qualified.