Fail-Safe Electric Valve Actuator With Closed-Loop Air Storage
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Solution Overview
Problem
Existing electric actuators in hazardous locations lack reliability, fail to maintain valve positions during power loss, and suffer from torque output issues, large size, and high maintenance requirements, while pneumatic systems face efficiency and responsiveness problems due to line leakage and distance from fluid supply sources.
Innovation Solution
The development of an electric power actuator that converts a pneumatic actuator to an electric actuator using a closed loop air transfer system, eliminating the need for air filters, reducing leaks, and providing a self-contained fluid supply, which enhances efficiency and responsiveness by utilizing compressed air as a pressurized fluid source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pneumatic actuators are used in hazardous locations, then valve control reliability is improved, but line leakage and distance from fluid supply sources reduce system efficiency and responsiveness
Solution Approach 1:
The pneumatic actuator is converted into a self-contained energy storage system that stores compressed air during normal operation and automatically releases it to actuate the valve in emergency conditions. This self-service mechanism eliminates dependence on external pneumatic supply lines, resolving the contradiction between reliability and productivity by making the system both highly reliable and efficient without external connections.
Solution Approach 2:
A conversion assembly acts as an intermediary between the existing pneumatic actuator and the valve, transforming the actuator into a fail-safe electric power platform. This intermediary device enables the pneumatic actuator to function as an energy storage device that can independently control the valve, thereby improving both reliability and system efficiency simultaneously.
2Reliability
If traditional electric actuators are used to provide fail-safe operation, then valve closure on power loss is achieved, but torque output is limited and unit size becomes very large
Solution Approach 1:
The invention utilizes pneumatic pressure storage within the actuator to provide fail-safe operation. By storing compressed air in the actuator chamber and using pneumatic force to actuate the valve, the system achieves high torque output in a compact form factor, avoiding the large size associated with traditional electric fail-safe actuators while maintaining reliable fail-safe operation.
Solution Approach 2:
The invention changes the operational parameters of the pneumatic actuator by modifying its control mechanism. The actuator is converted from a conventional externally-controlled device to one that autonomously responds to pressure changes and electrical signals, enabling fail-safe operation with enhanced torque output in a compact design.
3Ease of repair
If pneumatic actuators are converted to electric power platform, then maintenance needs are reduced and leaks are minimized, but conversion complexity increases
Solution Approach 1:
The conversion assembly is designed to be universally applicable to various pneumatic actuator types while providing multiple functions: it serves as both a control interface and an energy storage system. This multi-functionality reduces the number of additional components needed, thereby minimizing conversion complexity while achieving reduced maintenance needs and leak prevention.
4Speed
If compressed air is stored in the actuator, then responsiveness and repeatability are increased, but air pressure management becomes more critical
Solution Approach 1:
The control system incorporates feedback mechanisms that monitor air pressure within the actuator and adjust control signals accordingly. This feedback loop enables precise pressure management, allowing the system to maintain optimal responsiveness and repeatability while automatically compensating for pressure variations, thereby managing air pressure complexity without sacrificing performance.
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 improves the reliability and efficiency of valve operations by reducing maintenance needs, minimizing leaks, and increasing responsiveness and repeatability, while allowing for higher torque outputs and simplified integration into industrial systems.
Implementation Method 1
The pneumatic system moves the piston by forcing air (gas) into the first end of the cylinder while simultaneously withdrawing or exhausting air out of a second end of the cylinder
Implementation Method 2
The compressed air is typically sourced from a compressor driven by an electric motor or an internal combustion engine
Implementation Method 3
a spring return mechanism to return the piston to its initial position
Data Source
AI summary
An electric-powered fail-safe actuator for use with a valve, where the actuator stores potential energy for conversion to kinetic energy to close or open the valve to the fail-safe position.