Pressure Controller Valve Characterization via Dynamic Solenoid Current
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Solution Overview
Problem
Traditional pressure controller system valve characterization is slow, temperature-dependent, and requires external auxiliary equipment, limiting its application and suitability for field use due to the lengthy process and issues with valve plunger sticking at low temperatures.
Innovation Solution
A method and system for characterizing pressure controller valves by dynamically adjusting the electronic solenoid current to the apply and release valves based on manifold pressure thresholds, allowing for rapid characterization without external equipment and maintaining accuracy across temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional static point-to-point pressure measurement method is used, then measurement precision is maintained, but characterization time increases significantly
Solution Approach 1:
The patent transitions from static point-to-point pressure measurements to dynamic continuous pressure rate monitoring. The system continuously measures pressure rate (dp/dt) during valve actuation, enabling real-time detection of valve opening/closing events without requiring multiple static measurement points. This dynamic approach reduces characterization time from 40+ minutes to seconds while maintaining precision through continuous monitoring.
Solution Approach 2:
The patent implements continuous pressure rate monitoring throughout the entire valve actuation process, eliminating the gaps between discrete static measurements. The continuous measurement of pressure rate allows the system to track valve behavior in real-time, capturing all relevant characterization data in a single continuous operation rather than requiring repeated static measurements at multiple points.
2Quantity of substance
If external auxiliary pneumatic tank is used to test full range, then measurement completeness is improved, but device complexity increases
Solution Approach 1:
The patent extracts and removes the external auxiliary pneumatic tank from the characterization system. By using pressure rate monitoring, the system can characterize valve behavior using only the manifold's internal volume, eliminating the need for external gas storage equipment. The pressure rate measurements enable full-range characterization without requiring additional pneumatic components.
Solution Approach 2:
The system uses the manifold's own internal volume and the valve's natural actuation behavior to perform self-characterization. By monitoring pressure rate during normal valve operation, the system extracts characterization data without requiring external testing equipment or additional gas supply infrastructure. The manifold serves its dual purpose of both pressure control and characterization testing.
3Temperature
If traditional characterization method is used at low temperatures, then valve plunger sticks to seat, but reliability decreases
Solution Approach 1:
The patent applies preliminary action by monitoring pressure rate trends before the valve actually opens or closes. The system detects valve state changes by identifying characteristic pressure rate patterns, allowing it to determine valve behavior without requiring the plunger to fully overcome static friction at low temperatures. This preliminary detection method works reliably even when the plunger sticks to the seat.
Solution Approach 2:
The system uses continuous pressure rate feedback to detect valve actuation events in real-time. By monitoring the rate of pressure change, the system can identify when the valve begins to open or close, providing reliable characterization data even at low temperatures where traditional methods fail due to plunger sticking. The feedback mechanism adapts to temperature conditions automatically.
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 method significantly reduces characterization time, making it temperature-independent and suitable for field use, eliminating the need for external pneumatic tanks and ensuring precision in pressure control.
Implementation Method 1
The electronic solenoid current which drives the apply valve and the release valve
Implementation Method 2
where m is the mass flowrate, P is the pressure, V is the volume, R is the ideal gas constant, T is the temperature
Data Source
AI summary
A method and system for characterizing pressure controller valves of a pressure controller system are described herein. The pressure controller system includes a first valve and a second valve coupled to a manifold and a controller configured to control operation of the first valve and the second valve. The first valve regulates mass flowrate into the manifold and the second valve regulates mass flowrate released from the manifold. To characterize the apply valve, an electronic solenoid current to the first valve is increased until the manifold pressure rate exceeds the pressure rate threshold. When the manifold pressure rate exceeds the pressure rate threshold, the electronic solenoid current to the first valve decreases until the manifold pressure rate falls below the pressure rate threshold. These steps continue until the manifold pressure exceeds a manifold pressure threshold. At this point, the first valve is closed and characterization of the second valve commences.