Flow Rate Valve Control Without Pressure Sensors
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Solution Overview
Problem
Conventional flow rate control devices rely on pressure sensors to detect pipe clogging, which is costly and labor-intensive, as pressure alone cannot detect situations where the flow rate is zero despite sufficient pressure, leading to increased manufacturing costs and maintenance burdens.
Innovation Solution
A flow rate control device with a flow rate adjusting valve, a flow rate measurement part, a controller that adjusts valve openings based on measurement results, and pressure deficiency detection using an opening detecting sensor, along with functions for valve life notification, internal leak detection, and flowmeter life notification, reducing the need for multiple pressure sensors and enabling early detection of abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure sensors are installed in various places in the pipe to detect pipe clogging, then the detection accuracy of pressure deficiency is improved, but the manufacturing cost and installation complexity greatly increase
Solution Approach 1:
The patent extracts the pressure deficiency detection function from the traditional pressure sensor-based system and relocates it to the control device that already has access to flow rate measurement data and valve opening position information. By analyzing the relationship between measured flow rate and expected flow rate based on valve opening degree, the system can detect pressure deficiencies without installing additional pressure sensors in the pipe.
Solution Approach 2:
The control device is given multiple functions: it not only controls the flow rate adjusting valve based on flow rate measurements but also performs pressure deficiency detection by analyzing the correlation between valve opening degree and actual flow rate. This multi-functionality eliminates the need for separate pressure sensing systems, reducing device complexity while maintaining detection accuracy.
2Measurement precision
If pressure sensors are installed in various places in the pipe to detect pipe clogging, then the detection accuracy of pressure deficiency is improved, but the manufacturing cost greatly increases
Solution Approach 1:
The patent extracts the pressure deficiency detection function from the traditional pressure sensor-based system and relocates it to the control device that already has access to flow rate measurement data and valve opening position information. By analyzing the relationship between measured flow rate and expected flow rate based on valve opening degree, the system can detect pressure deficiencies without installing additional pressure sensors in the pipe.
Solution Approach 2:
The control device is given multiple functions: it not only controls the flow rate adjusting valve based on flow rate measurements but also performs pressure deficiency detection by analyzing the correlation between valve opening degree and actual flow rate. This multi-functionality eliminates the need for separate pressure sensing systems, reducing device complexity while maintaining detection accuracy.
3Reliability
If pressure sensors are used to detect pressure abnormality, then the detection capability is provided, but the maintenance burden increases due to inability to detect early-stage pressure deficiencies
Solution Approach 1:
The patent implements preliminary detection of pressure deficiencies by continuously monitoring the relationship between valve opening degree and actual flow rate. When a discrepancy is detected indicating early-stage pressure deficiency, the system issues a warning before the condition develops into a complete blockage or failure, allowing proactive maintenance and preventing equipment damage.
Solution Approach 2:
The system establishes a feedback mechanism where the control device continuously compares the actual flow rate measurement with the expected flow rate based on valve opening position. This feedback loop enables real-time detection of pressure deficiencies and triggers appropriate warnings or control adjustments, improving system reliability and reducing maintenance burden through early intervention.
Data Source
AI summary
An object is to provide a flow rate control device that can suppress a manufacturing cost and greatly reduce burdens of setting and maintenance.A flow rate control device 11 of the invention is comprised with a flow rate adjusting valve 21 that is installed in a flow path 13, a flow rate measurement part 41 that measures a flow rate of a fluid flowing through the flow path 13, a controller 61 that controls opening degrees of the flow rate adjusting valve 21 based on a measurement result of the flow rate measurement part 41, and a pressure deficiency detecting function that detects pressure deficiency when a limit sensor 246 (an opening detecting sensor) that detects the opening of the flow rate adjusting valve 21 detects the opening degrees are full. With the structure, it becomes possible, compared with a conventional system to detect a pressure deficiency using a pressure sensor, to suppress a manufacturing cost and greatly reduce burdens of setting and maintenance and to notify of pressure deficiency at a necessary timing in an early stage before an abnormality occurs due to a flow rate decrease.