Inductive Valve Spindle Positioning for Retrofit Alignment-Free Sensing
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Solution Overview
Problem
Existing valve control systems face challenges in being retrofitted with position sensors, as they are sensitive to magnetic interference and require precise alignment, which can lead to incorrect installation and faulty function.
Innovation Solution
An actuating system featuring a circular-cylindrical inductive sensor that can be attached to the valve's switching spindle without misalignment, using a conductive material for position determination, and a connecting part that engages with the spindle to prevent slippage, ensuring accurate position measurement and resistance to magnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a disc-shaped position sensor with coil and capacitor is attached to the switching spindle, then the valve can be retrofitted with position measurement capability, but it requires correct alignment during assembly which cannot be directly checked and may lead to faulty function
Solution Approach 1:
The patent employs a circular-cylindrical position sensor instead of a disc-shaped sensor. This cylindrical geometry provides rotational symmetry around the switching spindle, eliminating the alignment problem. The sensor can be mounted in any rotational position and will function correctly, as the measurement capability is invariant to rotation around the spindle axis.
Solution Approach 2:
The circular-cylindrical sensor design makes the system self-aligning. The sensor automatically adapts to the correct measurement orientation through its geometric symmetry, without requiring external alignment tools or procedures. The mounting process becomes self-service in terms of alignment, as any rotational position is valid.
2Measurement precision
If magnets are arranged in the switching spindle for non-contact measurement, then position can be detected by Hall sensors, but the solution is sensitive to magnetic interference fields from solenoid valves or servomotors
Solution Approach 1:
The patent replaces the magnetic field-based measurement system (Hall sensors detecting magnets) with an inductive measurement system. The circular-cylindrical position sensor uses inductive coupling to detect the position of the switching spindle, which is made of electrically conductive material. This substitution eliminates sensitivity to magnetic interference from solenoid valves and servomotors, as inductive sensing is not affected by magnetic fields.
Solution Approach 2:
The patent changes the physical parameter used for measurement from magnetic field interaction to inductive coupling. By using the electrical conductivity of the switching spindle material and inductive sensing, the system achieves position detection without relying on magnetic fields, thereby avoiding interference from magnetic sources in the environment.
3Manufacturing precision
If a position sensor is attached to the switching spindle during manufacture, then the valve has integrated position measurement, but it cannot be used for retrofitting existing valves
Solution Approach 1:
The circular-cylindrical position sensor is designed with a universal mounting approach that works for both new valve manufacturing and retrofitting existing valves. The sensor can be attached to the switching spindle through a standardized connecting part that engages with the spindle, allowing the same sensor design to serve dual purposes: integrated manufacturing and field retrofitting.
Solution Approach 2:
The patent divides the positioning system into separate modular components: the circular-cylindrical position sensor, the connecting part for attachment to the switching spindle, and the evaluation unit. This segmentation allows the sensor to be independently mounted on existing valves during retrofitting, without requiring modification of the valve body itself, thus enabling both manufacturing integration and retrofitting applications.
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 system allows for reliable and accurate position measurement of the valve, preventing misalignment and interference issues, making it suitable for both manufacturing and retrofitting, with a robust design that ensures precise control of the valve's position.
Implementation Method 1
A movement of the switching spindle parallel to the inductive sensor can then be measured inductively by the presence of the electrically conductive material in the position transmitter
Data Source
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AI summary
An actuating system (10) for a valve (20) has an outer housing (11). A receiving area (12) for receiving a switching spindle (21) of the valve (20) extends within the outer housing (11). At least one inductive sensor extends parallel to the receiving area (12). The actuating system further comprises at least one substantially circular cylindrical position sensor (40) made of an electrically conductive material and having a channel (43) extending along its longitudinal axis. This channel is configured to receive the switching spindle (21) of the valve (20).