Off-Axis Valve Position Sensing for Precise Flow Control
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Solution Overview
Problem
Conventional position detection systems for flow control valves have accuracy limitations and are not conducive to off-axis installations, necessitating improved monitoring and control methods for precise positioning and flow rate determination.
Innovation Solution
An off-axis position monitoring and control system utilizing a transducer array assembly with Hall effect sensors and a magnetic-field source that moves in an arcuate path parallel to the sensors, allowing precise determination of the rotational position and flow rate through the valve without physical engagement, thereby overcoming the limitations of axial alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional position detection systems are connected axially to the valve stem, then the system structure is simple, but the measurement precision and adaptability are limited
Solution Approach 1:
The patent transitions from axial (one-dimensional) position detection to off-axis (two-dimensional) detection by arranging transducers in an arcuate pattern around the valve stem. This dimensional change enables precise angular position measurement while maintaining a compact structure, resolving the contradiction between measurement precision and device complexity.
Solution Approach 2:
The patent replaces mechanical contact-based position detection with non-contact magnetic field sensing using transducers that detect the position of a magnet on the valve stem. This substitution eliminates mechanical wear and improves measurement precision without significantly increasing structural complexity.
2Adaptability or versatility
If axial aligned position detection systems are used, then the installation is straightforward, but the adaptability to different valve installations is poor
Solution Approach 1:
The off-axis transducer array design creates a universal position detection system that can accommodate various valve stem orientations and installation configurations. The arcuate arrangement of transducers around the valve stem allows the system to function effectively regardless of the specific installation geometry, enhancing adaptability while maintaining reasonable installation simplicity.
3Reliability
If non-contact position monitoring is implemented, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The patent implements non-contact magnetic field sensing to monitor valve position, eliminating mechanical wear and improving reliability. The transducer array detects the position of a magnet mounted on the valve stem without physical contact, ensuring reliable operation in demanding environments while the modular transducer design keeps the overall system complexity manageable.
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 provides accurate and non-contact monitoring and control of valve positions and flow rates, enhancing the performance and efficiency of flow control valves in various applications.
Implementation Method 1
The transducers can be Hall effect sensors
Data Source
AI summary
A flow control valve and a valve-position monitoring and control system coupled to the valve member and configured to precisely determine valve conditions related to the rotary position of the valve member. The system has an array of spaced apart transducers in an arcuate arrangement and in a fixed, non-moveable position relative to the valve's housing. A magnetic-field source is fixed to and rotates with the valve member as a unit. The magnetic-field source includes magnetic members adjacent to and out of physical engagement with the transducers. The magnetic member moves along an arcuate path parallel to the arcuate arrangement of the transducers as the valve member rotates through the plurality of rotary positions. The magnetic-field source provides magnetic flux detectable by at least a plurality of the transducers to precisely determine the rotational position of the magnetic-field source and/or the valve member, and the fluid flow rate through the control valve.