Modular Control Valve With Integrated Controller for Plug-and-Play Valve Banks
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Solution Overview
Problem
Conventional valve banks require external electronic controllers for control and diagnostics, limiting their modular tailorability and capability.
Innovation Solution
Integration of an onboard electronic controller within the modular control valve, enabling intelligent diagnostics, feedback, and control, which minimizes the need for intermediate external controllers and allows for standalone operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional valve banks use external electronic controllers for control and diagnostics, then the system can achieve basic control functionality, but the device complexity and system integration requirements increase
Solution Approach 1:
The patent merges the electronic controller directly into the valve body, creating an integrated control unit. The controller is mounted within the valve housing and directly interfaces with the valve spool and solenoid, eliminating the need for separate external control boxes and reducing wiring complexity. This integration maintains full control functionality while significantly reducing device complexity and system integration requirements.
Solution Approach 2:
The integrated controller serves multiple functions including diagnostic monitoring, feedback processing, and actuator control within a single unit. It can detect valve position, monitor fluid pressure, and communicate system status back to the control system, combining what were previously separate external components into one multi-functional unit that reduces overall system complexity.
2Loss of information
If external intermediate controllers are used for diagnostics and feedback, then diagnostic capability is provided, but the number of components and wiring requirements increase
Solution Approach 1:
The diagnostic and feedback functions are merged into the integrated controller within the valve assembly. Sensors for detecting valve position, pressure, and flow conditions are connected directly to the controller, which processes this information and communicates diagnostic data to the control system. This eliminates the need for separate external diagnostic controllers and reduces the number of components while maintaining full diagnostic capability.
Solution Approach 2:
The integrated controller incorporates feedback mechanisms that continuously monitor valve position and system parameters through integrated sensors. This feedback is processed immediately by the controller, enabling real-time diagnostics and adjustment without requiring external intermediate controllers, thereby reducing component count while maintaining information integrity.
3Ease of manufacture
If modular control valves are designed without onboard intelligence, then manufacturing and installation are simpler, but adaptability and intelligent control capabilities are limited
Solution Approach 1:
The controller is integrated into the valve assembly as a unified modular unit that maintains the simplicity of modular installation while adding intelligent capabilities. The controller is mounted within the valve housing and connects to existing valve components, allowing the valve to be installed as a single module while providing advanced control and diagnostic functions that enhance adaptability without complicating the manufacturing or installation process.
Solution Approach 2:
The integrated controller provides multiple functions including position control, diagnostic monitoring, feedback processing, and communication with external systems, all within a single modular valve unit. This multi-functionality enhances adaptability and intelligent control capability while maintaining the modular design that ensures ease of manufacture and installation.
Data Source
AI summary
An exemplary valve bank and/or modular control valve having a valve body, a valve member movable in a fluid flow of the valve body to control flow of fluid, and an onboard electronic controller that is operably mounted to the valve bank or valve body. The onboard controller is operably connected to at least one actuator of the valve, which is configured to control movement of the valve member in response to commands from the onboard controller. The onboard controller may provide diagnostics, feedback and/or control of the control valve, such as via inputs from one or more sensors that may be included in the valve. The modular control valve may be used with conventional non-intelligent valve banks to thereby impart smart diagnostics and/or feedback into the valve bank in a plug-and-play manner. A communications interface may be provided in the control valve to interface and communicate with an upper-level PLC controller.