Fluid System Power-On Self-Test for Sensor and Valve Fault Detection
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Solution Overview
Problem
Conventional fluid systems lack active verification of their health before use, leading to unplanned equipment shutdowns and economic impacts due to undetected errors during normal operations.
Innovation Solution
A diagnostic method that verifies the proper functioning of flow devices in a fluid system by checking the functionality of pressure sensors, pumps, bypass valves, and flow sensors during the power-on process, allowing for timely detection and alternative control strategies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If no active verification is performed before system use, then the system can start operations immediately, but undetected errors cause unplanned shutdowns and economic losses
Solution Approach 1:
The patent implements a power-on self-test that actively verifies system health before normal operations begin. The test sequence checks sensors, pumps, valves, and actuators during startup, identifying potential failures before they cause unplanned shutdowns during customer service operations.
Solution Approach 2:
The system performs self-diagnosis through automated power-on testing, eliminating the need for manual pre-operation checks by service personnel. The control board automatically executes test sequences and identifies functional anomalies without human intervention.
2Measurement precision
If comprehensive diagnostic tests are performed during power-on, then system anomalies can be detected timely, but the system complexity and test duration increase
Solution Approach 1:
The diagnostic system is divided into modular test sequences for different system components: sensor functionality tests, pump operation tests, valve control tests, and actuator verification. Each component group has its own dedicated test routine that can be executed independently.
Solution Approach 2:
Critical safety-related components such as pressure sensors and flow sensors are tested early in the power-on sequence before normal operations begin. This ensures that essential protective functions are verified first, allowing the system to identify critical faults before they can cause damage.
3Reliability
If the system shuts down immediately upon detecting a fault, then safety is maintained, but operational continuity and customer service are disrupted
Solution Approach 1:
When a non-critical fault is detected during power-on testing, the system implements a limp-home mode that allows limited operational functionality to continue. For example, if a secondary sensor fails, the system can still operate using alternative sensors or reduced functionality, maintaining customer service while avoiding complete shutdown.
Solution Approach 2:
The control board acts as an intermediary between fault detection and system shutdown. It evaluates the severity and type of anomaly, determining whether immediate shutdown is necessary or whether alternative control strategies can maintain safe operation. This intermediate decision-making layer prevents unnecessary complete shutdowns for non-critical faults.
Data Source
AI summary
A diagnostic method for verifying the proper functioning of a fluid flow control device of a fluid system, the method including determining whether at least one pressure sensor is functional and if the at least one pressure sensor is considered functional, determining whether a bypass valve is functional and if the bypass valve is considered functional, determining whether at least one flow sensor is functional, if the at least one flow sensor is considered dysfunctional, a flow sensor fault is raised; and otherwise if the at least one pressure sensor is considered dysfunctional, using the at least one flow sensor to determine whether the bypass valve is functional, if the bypass valve is considered functional, determining whether at least one pump is functional, a pump alert is raised if the at least one pump is considered dysfunctional.