Programmable Proportional Valve Control for Precise Flow Positioning
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Solution Overview
Problem
Existing proportional control valves (PCVs) face limitations in speed adjustment, positional accuracy, repeatability, time lag, lack of communication, and excessive motor strain due to fixed torque settings, which affect their performance in well control methodologies like managed pressure drilling.
Innovation Solution
A proportional control valve system incorporating an electric motor, gearbox, worm gear drive, and programmable drive with a computing device that controls the positioning, speed, and torque of the sealing structure, allowing for precise fluid flow control and communication, and includes a fluid-powered actuator for backup operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the electric motor is controlled to operate at a fixed maximum RPM or limited speed settings, then the motor structure is simplified, but the PCV lacks the ability to adjust speed and achieve positional accuracy
Solution Approach 1:
The patent applies dynamics by transitioning from fixed-speed motor operation to variable-speed control. The programmable drive enables the motor to operate at different speeds dynamically adjusted based on operational requirements, allowing the PCV to achieve both speed flexibility and positional accuracy while maintaining reasonable system complexity through software-based control algorithms.
2Reliability
If the electric motor operates at maximum torque setting, then the PCV can achieve drop tight seal, but the motor experiences excessive strain and heating
Solution Approach 1:
The patent applies partial action by implementing torque modulation where the motor operates at maximum torque only when necessary to achieve drop tight seal, and at reduced torque levels for maintenance and normal operation. The programmable drive dynamically adjusts torque output based on real-time feedback from position sensors and operational requirements, minimizing energy consumption while ensuring sealing reliability when needed.
3Manufacturing precision
If the PCV uses fixed actuating speeds, then the device structure is simpler, but the sealing structure positional accuracy and repeatability are poor
Solution Approach 1:
The patent applies feedback by implementing a closed-loop control system where position indicators continuously monitor the sealing structure position and feed this information back to the programmable drive. The drive then adjusts motor speed and position dynamically to achieve accurate and repeatable positioning, with feedback enabling real-time corrections and ensuring precise control throughout the valve's operational range.
4Productivity
If the PCV operates with time lag before movement, then the motor has sufficient time to prepare, but the PCV cannot provide continuous duty cycle required for well control
Solution Approach 1:
The patent applies preliminary action by implementing anticipatory control where the programmable drive receives and processes control signals in advance, preparing the motor and control system for upcoming movements. The system pre-positions components and adjusts parameters before actual valve movement is required, eliminating time lag and enabling continuous duty cycle operation while maintaining rapid response capability.
Data Source
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AI summary
A proportional control valve system (10) and a method for operating the same is provided. The system includes a proportional control valve (12), an electric motor (14), a worm gear drive (20), and a programmable drive (16). The proportional control valve has a sealing structure that is positionable in a closed position, a fully open position, and a plurality of partially open positions there between. The worm gear drive is in driving communication with the sealing structure of the proportional control valve. The programmable drive is operable to control the positioning of the sealing structure within the proportional control valve.