Pressure-Controlled Pneumatic Valve Testing for Opening and Stiction Detection
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Solution Overview
Problem
Manual inspection and monitoring of valves are time-consuming, error-prone, and costly, as they require operators to visually assess valve operation and sensor data simultaneously, which can lead to inadequate detection of valve opening points, closing points, and stiction.
Innovation Solution
A pressure controller system that includes a data processor and a display, which receives data characterizing air flow and pressure changes through a valve, determines valve operation data such as opening and closing points, and provides this data in a graphical format for real-time monitoring and analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection and monitoring of valves are performed, then operators can assess valve operation, but the process is time-consuming and error-prone
Solution Approach 1:
The patent replaces manual visual inspection with an automated electronic system that uses sensors to detect valve operation parameters and a data processor to analyze the data. This substitution eliminates human error and time consumption associated with manual inspection while maintaining comprehensive monitoring capabilities.
Solution Approach 2:
The system enables self-monitoring of valve operation through automated data collection and analysis. The electronic components continuously assess valve performance without requiring external human intervention, allowing the system to service itself in terms of monitoring and detection.
2Measurement precision
If operators visually assess valve operation and sensor data simultaneously, then valve performance can be monitored, but detection of opening points, closing points, and stiction is inadequate
Solution Approach 1:
The system segments the monitoring task into distinct functional components: sensors for data collection, data processor for analysis, and display for presentation. This segmentation allows each component to specialize in its function, improving detection precision while simplifying the overall operation through automated processing.
Solution Approach 2:
The data processor acts as an intermediary between the sensors and the display, automatically analyzing sensor data to identify valve opening points, closing points, and stiction. This intermediary function eliminates the need for operators to simultaneously interpret multiple data streams, improving precision while maintaining ease of operation.
3Measurement precision
If automated pressure controller system is used, then valve operation data detection precision is improved, but device complexity increases
Solution Approach 1:
The data processor is designed to perform multiple functions: collecting sensor data, analyzing valve operation parameters, identifying opening and closing points, detecting stiction, and controlling the display. This multi-functionality consolidates what could be multiple separate devices into a single system, improving precision while managing complexity through integration.
Solution Approach 2:
The system merges the pressure controller, sensors, data processor, and display into an integrated automated monitoring system. By combining these components into a unified system rather than separate devices, the patent achieves high measurement precision while controlling overall system complexity through functional integration.
Data Source
AI summary
A method is provided. The method can be used to perform valve testing for pneumatic valves. The method can include receiving, by a pressure controller including a data processor, data cauterizing an air flow through a valve coupled to the pressure controller. The method can also include determining, by the data processor, valve operation data associated with the valve. The method can further include providing, by the data processor, the valve operation data in a display coupled to the pressure controller. The valve operation data can include an opening point of the valve, a closing point of the valve, or an indication of stiction of the valve. The valve operation data can also be determined based on a rate of pressure change through the valve. Related systems and computer readable mediums performing the method are also provided.