Embedded Sensor Compressor Valve for Predictive Maintenance
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Solution Overview
Problem
Reciprocating compressors experience frequent downtimes due to valve failures and maintenance needs, necessitating improved monitoring and predictive maintenance to minimize downtime.
Innovation Solution
A valve system with embedded sensors and wireless communication, powered by energy harvesting systems, to monitor valve health and predict maintenance needs, featuring sensors for temperature, pressure, and vibration detection, and energy generation from thermoelectric and piezoelectric means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If frequent valve maintenance and shutdowns are performed to ensure reliable operation, then valve reliability is improved, but compressor productivity deteriorates due to costly downtimes
Solution Approach 1:
The sensor system performs preliminary monitoring of valve operation parameters (acoustic emissions, temperature, pressure) to detect anomalies before they lead to failure. This allows maintenance to be scheduled in advance during planned shutdowns rather than experiencing unplanned failures, thus maintaining reliability while minimizing productivity loss.
Solution Approach 2:
The system continuously monitors valve operation and provides feedback through acoustic emission detection and parameter measurement. This feedback enables real-time assessment of valve health, allowing operators to optimize maintenance scheduling based on actual condition rather than fixed intervals, thereby improving both reliability and productivity.
2Reliability
If comprehensive valve monitoring systems are implemented to detect valve anomalies, then valve reliability is improved, but device complexity increases due to additional sensors and monitoring equipment
Solution Approach 1:
The valve effectively monitors itself through acoustic emission sensors that capture the valve's own operational sounds and vibrations. This self-diagnosis capability eliminates the need for complex external monitoring systems, reducing device complexity while maintaining high reliability through continuous self-assessment of valve health.
Solution Approach 2:
The system replaces complex mechanical monitoring equipment with acoustic emission sensors that detect valve anomalies through sound waves. This substitution simplifies the monitoring system while providing comprehensive valve health assessment, reducing device complexity without compromising reliability.
3Measurement precision
If wired sensors are mounted on valves to monitor cylinder conditions, then measurement capability is improved, but ease of operation deteriorates due to wiring requirements and installation complexity
Solution Approach 1:
The patent replaces wired electrical sensors with acoustic emission sensors that detect valve operation through sound waves. This eliminates the need for physical wiring connections, significantly improving ease of installation and maintenance while maintaining measurement precision for monitoring cylinder conditions and valve health.
Solution Approach 2:
Acoustic waves serve as an intermediary medium to transmit information about cylinder conditions and valve operation without requiring direct physical or electrical contact. This intermediary approach simplifies sensor installation and maintenance while preserving the ability to accurately monitor cylinder conditions.
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
Enables remote monitoring and predictive maintenance, reducing unplanned shutdowns and extending compressor operation by assessing valve health and scheduling maintenance effectively.
Implementation Method 1
at least one energy harvesting system, which could be for example thermoelectric (=TEG) or piezoelectric (=PEG), located preferably in or on or at the valve body
Implementation Method 2
at least one energy harvesting system, which could be for example thermoelectric (=TEG) or piezoelectric (=PEG), located preferably in or on or at the valve body
Data Source
AI summary
The valve system, to be used as a suction valve and/or as a discharge valve in a reciprocating compressor, comprises a valve body, at least one sensor mounted on the valve body and configured to detect a parameter associated to operation of the valve device, and a wireless communication unit electrically coupled to the at least one sensor and configured to transmit information detected by the at least one sensor; the at least one sensor is associated with a fixing member that is inserted in holes of the valve body and that seals the holes. The innovative valve system may comprise further at least one energy harvesting system, which could be for example thermoelectric or piezoelectric, located preferably in or on or at the valve body.