Gas Meter Valve Shutter Position Detection via Actuator Current
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Solution Overview
Problem
Current methods for controlling solenoid valves in gas meters, such as using encoders or electromechanical limit switches, are costly, require additional wiring, and fail to accurately detect shutter position or obstacles during movement, leading to unstable operation due to mechanical deformations, temperature changes, or mechanical obstacles.
Innovation Solution
A method that uses the electric current absorption by the actuator to monitor and control the solenoid valve shutter position and movement, correlating current values with predefined control parameters to determine the shutter's position and detect obstacles, without requiring additional sensors or hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If encoders or electromechanical limit switches are used to detect shutter position, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces mechanical detection systems (encoders, limit switches) with an electrical measurement system. The control unit detects shutter position by measuring electrical parameters (current, voltage, or power) of the actuator motor during operation, eliminating the need for mechanical sensors and their associated wiring complexity.
Solution Approach 2:
The actuator motor serves dual functions: it drives the shutter movement and simultaneously provides the electrical signals for position detection. The control unit utilizes the motor's own electrical characteristics (current consumption, voltage drop, power usage) to infer shutter position, eliminating the need for separate detection devices.
2Measurement precision
If limit switches are installed to detect shutter position, then measurement precision is improved, but ease of operation deteriorates due to wiring requirements in sealed compartments
Solution Approach 1:
The patent replaces mechanical limit switches with an electrical field-based detection method. By measuring electrical parameters of the actuator motor, the system achieves position detection without requiring physical contacts or additional wiring that would compromise the sealed compartment integrity.
Solution Approach 2:
The control unit performs multiple functions: it controls the actuator motor operation and simultaneously detects shutter position by analyzing the motor's electrical characteristics. This multi-functionality eliminates the need for separate limit switch wiring and maintains the sealed compartment design.
3Device complexity
If firmware controls valve plug movement for a predefined time interval, then device complexity is reduced, but reliability deteriorates due to misalignment between estimated and actual shutter position
Solution Approach 1:
The control unit continuously monitors electrical parameters of the actuator motor during operation and uses this feedback to detect actual shutter position. By comparing expected versus actual electrical characteristics, the system can identify deviations caused by obstacles, mechanical deformations, or temperature changes, and adjust control accordingly to maintain reliable operation.
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
Provides precise and reliable detection of the shutter's position and movement, ensuring stable operation even in the presence of unforeseen circumstances, while avoiding the costs and complexity of traditional solutions.
Implementation Method 1
detecting the electric current actually absorbed by the actuator for moving the shutter
Data Source
Figure 1
Figure 2~3
Figure 4a~4c
AI summary
Method for controlling a valve (1) which is of the type in which the movement of its shutter (11) is controlled by an electric or electromechanical actuator (17), said valve (1) being intended to be used and housed, entirely or at least in part, inside the casing (2) of a gas meter (3) to intercept, at least in part, the gas flow at the gas inlet and/or outlet in/by said meter, said method is characterized in that the condition and/or position of said shutter (11) is detected/verified on the basis of the electric current absorbed by said actuator (17) which causes the movement of said shutter (11) of the valve.