Magnetic Valve Force Compensation for Pilotless Pneumatic Positioners
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Solution Overview
Problem
Conventional valve positioners with pneumatic output face a trade-off between requiring high pneumatic pressure for operation and stringent low power consumption, leading to inefficient and costly pilot stage designs with complex and bulky setups.
Innovation Solution
A magnetic force compensator is integrated with a positioner drive to directly control the valve positioner, eliminating the need for a pilot stage and pressure reducer, using a magnetic device and counterpart to create an attracting force that compensates for the closing force, allowing for efficient operation with reduced system complexity and bulk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a pilot stage with pressure reducer is used to control pneumatic pressure, then high pneumatic pressure can be achieved, but system complexity and bulk increase
Solution Approach 1:
The patent extracts and eliminates the pilot stage and pressure reducer from the system. Instead of using a complex two-stage pneumatic control system, the invention directly controls the main pneumatic stage using an electromagnetic actuator, thereby achieving high pneumatic pressure without the complexity and bulk of additional subsystems.
Solution Approach 2:
The patent replaces the mechanical pneumatic control system (pilot stage with pressure reducer) with an electromagnetic actuation system. The electromagnetic actuator directly generates the force needed to control the pneumatic valve, substituting complex mechanical pneumatic control with a more compact electromagnetic system.
2Ease of operation
If a pilot stage is used to amplify force, then control capability is improved, but energy consumption increases
Solution Approach 1:
The patent removes the energy-consuming pilot stage from the system. By directly actuating the main pneumatic stage with an electromagnetic actuator, the system eliminates the need for the pilot stage's pneumatic amplification mechanism, thereby reducing steady-state air flow requirements and overall energy consumption while maintaining control capability.
Solution Approach 2:
The electromagnetic actuator operates in a periodic or pulsed manner to control the pneumatic valve, eliminating the need for continuous pneumatic pressure maintenance by the pilot stage. This periodic action reduces steady-state air flow requirements and energy consumption compared to continuous pneumatic amplification.
3Use of energy by moving object
If compensation springs are used to balance forces, then low energy control is achieved, but system bulk increases
Solution Approach 1:
The patent replaces mechanical compensation springs with an electromagnetic actuator that provides active force compensation. The electromagnetic actuator generates the necessary balancing forces electronically and magnetically, eliminating the need for large mechanical spring components and reducing system bulk while maintaining low energy consumption through precise electronic control.
4Measurement precision
If multiple submodules are used for force amplification, then control precision is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of multiple submodules (pilot stage, pressure reducer, main stage) into a single integrated pneumatic stage controlled by an electromagnetic actuator. This consolidation maintains control precision through direct electromagnetic force application while eliminating the complexity of multiple separate components and their interconnections.
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, energy consumption, and design space while enhancing robustness and control precision, as each main stage component can be individually controlled, minimizing reliance on pneumatic pressure and eliminating steady-state air flow requirements.
Implementation Method 1
a magnetic device, including a permanent magnet, and a magnetic counterpart for the magnetic device, wherein the magnetic device and the magnetic counterpart are configured to interact to create an attracting force
Data Source
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 using a magnetic device, the magnetic device including a permanent magnet; and a magnetic counterpart; wherein the magnetic device 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.