Liquid Level Control Loop Optimizer for Latency Reduction
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Solution Overview
Problem
The transition from pneumatic to electric control systems in liquid level control loops introduces non-negligible latencies due to actuator latencies, field power supply voltage influences, and liquid inflow characteristics, which were not previously considered in configuring typical pneumatic level control loops, affecting the efficiency and accuracy of liquid level control.
Innovation Solution
A method for optimizing liquid level control loops by simulating the operation of electric components based on user-specified requirements, including vessel type, parameters, flow parameters, and potential valve and actuator configurations, to determine usable configurations and rank them according to performance, thereby accounting for latency and other previously unconsidered factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electric level controllers and electric actuators are used in liquid level control loops, then the system can be modernized and integrated with digital control systems, but control latency increases significantly compared to pneumatic systems
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing optimal control parameters (such as PID controller settings, valve positioning schedules, and actuator command sequences) before control scenarios occur. When a control situation arises, the pre-computed parameters are immediately retrieved and applied, eliminating the need for real-time complex calculations and reducing control latency while maintaining digital system integration capabilities
2Adaptability or versatility
If electric actuators are used instead of pneumatic actuators, then system integration is improved, but the response speed and actuation time of valves decrease
Solution Approach 1:
The patent applies dynamics by implementing adaptive actuation strategies that adjust actuator command profiles in real-time based on the current system state. The control system dynamically modifies voltage signals, current limits, and positioning rates to optimize valve response speed while preventing mechanical stress and ensuring precise positioning, thereby maintaining both system integration benefits and fast response characteristics
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting electrical parameters (voltage, current, frequency) and control parameters (positioning rate, overshoot limits, damping factors) of electric actuators based on real-time feedback and predicted control scenarios. This allows the system to optimize valve response speed for different operating conditions while maintaining precise control and system integration
3Adaptability or versatility
If multiple valve and actuator configurations are evaluated, then the optimal configuration can be selected for specific applications, but the complexity of system configuration increases
Solution Approach 1:
The patent applies copying by creating and maintaining a digital library of pre-characterized valve and actuator configurations with their performance parameters, control characteristics, and application suitability data. Instead of evaluating multiple physical configurations, the system uses digital copies and simulations to predict performance, allowing optimal configuration selection without the complexity of physical prototyping and testing
Data Source
AI summary
A liquid level control loop optimizer receives a selection of a vessel configuration and a variety of parameters specifying the vessel dimensions, the fluid type(s), and the flow parameters of the liquid level control loop. The optimizer also receives a selection of various valve and actuator options and determines a variety of available configurations based on the selected options. The optimizer simulates each of the available configurations under the conditions specified by the parameters, and determines control loop characteristics and/or properties based on the simulations. The optimizer may display and/or rank the various configurations to assist a user in selecting a configuration that best meets the requirements of the control loop.