Magnetic Valve Positioner Drive for High-Pressure Pneumatic Control
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Solution Overview
Problem
Existing valve positioner systems with pneumatic output face challenges in achieving high pneumatic pressure while maintaining low power consumption, leading to complex and bulky designs due to the use of pilot stages, which are inefficient and cost-intensive.
Innovation Solution
The implementation of a positioner drive system that is mechanically coupled to the valve of the valve positioner, eliminating the need for a pilot stage by directly driving the main stage using an electromagnetic actuator and a magnetic force compensator, which compensates for the closing force required to shift the valve into a closed position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a pilot stage is used to control the main stage, then the valve positioner can operate at high pneumatic pressure, but the system becomes complex and bulky
Solution Approach 1:
The patent extracts and eliminates the pilot stage from the valve positioner system. By directly coupling the positioner drive to the main stage, the complex subsystem of pressure reduction and pilot control is removed entirely, resolving the contradiction between achieving high pneumatic pressure and maintaining system simplicity
Solution Approach 2:
The patent merges the positioner drive directly with the main stage components, eliminating the separation between pilot stage and main stage. This direct mechanical coupling integrates control and actuation functions into a unified structure, reducing overall system complexity while maintaining high pressure operation capability
2Stress or pressure
If a pilot stage is used to control the main stage, then the valve positioner can operate at high pneumatic pressure, but the system becomes bulky
Solution Approach 1:
By removing the pilot stage subsystem entirely, the patent eliminates the volume occupied by pressure reduction mechanisms and pilot control components. This extraction directly reduces the overall design space while preserving the main stage's high pressure operation capability
Solution Approach 2:
The direct mechanical coupling of the positioner drive to the main stage merges previously separate functional volumes into a compact integrated structure, reducing the total volume required for the valve positioner system while maintaining high pneumatic pressure operation
3Use of energy by moving object
If a pressure reducer is used to provide low pressure to the pilot stage, then the system can control valve position with low electrical power, but energy is lost through constant blow-off of pneumatic medium
Solution Approach 1:
The patent replaces the pneumatic pressure reduction mechanism with a direct mechanical coupling system. The positioner drive mechanically couples to the main stage components, eliminating the need for pressure reduction and the associated continuous pneumatic blow-off, thereby eliminating pneumatic energy loss while maintaining low electrical power control capability
Solution Approach 2:
The system uses the positioner drive's direct mechanical action on the main stage components to achieve control, making the system self-sufficient without requiring external pressure reduction infrastructure. This self-service approach eliminates the energy-inefficient pressure reduction cycle and its associated blow-off losses
4Stress or pressure
If multiple submodules are used as force amplifiers, then the valve positioner can operate at high pneumatic pressure, but the design becomes complex and costly
Solution Approach 1:
The patent extracts and eliminates the multiple force amplifier submodules from the design. By using direct mechanical coupling between the positioner drive and main stage, the complex array of force amplification mechanisms is removed, simplifying manufacturing and reducing costs while maintaining high pressure operation
Solution Approach 2:
The patent merges the force amplification function directly into the main stage structure through direct mechanical coupling. This integration eliminates the need for separate force amplifier submodules, reducing manufacturing complexity and cost while preserving the high pneumatic pressure operation capability
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
This solution reduces system complexity, increases robustness, and improves controllability by allowing individual control of each main stage component, while also reducing energy consumption and design space, making the system more efficient and cost-effective.
Implementation Method 1
The magnetic means and the magnetic counterpart are configured to interact to create an attracting force for the at least partially compensation of the closing force
Implementation Method 2
The implementation of a positioner drive system that is mechanically coupled to the valve of the valve positioner, eliminating the need for a pilot stage by directly driving the main stage using an electromagnetic actuator
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3c
AI summary
A magnetic force compensator for at least partially compensating a closing force required to shift a valve of a pneumatic positioner into a closed position, is described, with a magnetic means, including a permanent magnet; and a magnetic counterpart; wherein the magnetic means and the magnetic counterpart are configured to interact to create an attracting force for the at least partially compensation of the closing force; and wherein the magnetic force compensator is configured to be mechanically coupled to the valve of the pneumatic positioner.