Self-Operated Regulator Magnetic Valve Position Monitoring
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Solution Overview
Problem
Existing self-operated regulators for processing plants lack a reliable method to verify correct functioning without external power supply, particularly in closed-loop/open-loop control scenarios, which can lead to operational inefficiencies and safety concerns.
Innovation Solution
Incorporation of a magnetic field source and sensor system that uses the working fluid's energy to operate the control valve, with a magnetic sensor that can be temporarily docked to the regulator to detect the valve's position and communicate data, allowing for verification and monitoring without an external power source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a self-operated regulator uses only the working fluid's energy without external power supply, then installation costs and operating costs are reduced, but the ability to verify correct functioning and monitor operational status becomes difficult
Solution Approach 1:
The patent replaces electronic/power-intensive monitoring systems with a magnetic field-based detection system. A magnetic field source is integrated into the control actuator, and a magnetic sensor externally detects valve position and operational status without requiring external power supply to the regulator itself, thus maintaining the self-operated principle while enabling monitoring.
Solution Approach 2:
The magnetic field acts as an intermediary between the internal control mechanism and external monitoring systems. The magnetic sensor detects the magnetic field generated by the control actuator to infer valve position and operational status, enabling verification without direct electrical connection or power supply to the regulator.
2Reliability
If magnetic sensors are permanently integrated into the regulator, then continuous monitoring is enabled, but device complexity and installation costs increase
Solution Approach 1:
The magnetic sensor is designed to be temporarily dockable rather than permanently fixed. The control actuator features a docking station that allows the magnetic sensor to be attached when monitoring is needed and removed when not needed, enabling dynamic adaptation between monitoring and non-monitoring states without permanent structural modification.
Solution Approach 2:
The monitoring function is separated from the main regulator body. The magnetic sensor is an independent, externally dockable component rather than an integrated permanent part, allowing the regulator to maintain its simple self-operated structure while acquiring monitoring capability when required.
3Object-affected harmful factors
If the regulator operates without external power supply, then explosion risk is reduced in hazardous environments, but the ability to implement complex closed-loop control algorithms is limited
Solution Approach 1:
The patent replaces electronic power-intensive control systems with a magnetic field-based detection and control system. The magnetic sensor can detect valve position and provide feedback for closed-loop control without requiring external power supply to the regulator, enabling complex control algorithms while maintaining intrinsic safety in explosion-hazardous environments.
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
Enables cost-effective and robust operation of self-operated regulators, ensuring reliable performance even in power supply failures, while reducing installation and operating costs by leveraging the working fluid's energy and allowing for easy retrofitting and monitoring of multiple regulators.
Implementation Method 1
A magnetic field source, such as a magnet, is structurally coupled to the control valve such that the magnetic field source follows the movement of the control valve
Data Source
AI summary
A self-operated regulator can be configured to control a stream of working fluid, such as of a processing plant. The self-operated regulator can include a control valve and a control actuator configured to receive supply energy for the provision of an operating force exclusively from the stream of working fluid and/or from the working fluid for operating the control valve. A magnetic field source can be coupled to the control valve such that the magnetic field source follows the movement of the control valve to determine the movement using, for example, a magnetic sensor. The position of the control valve can be detected based on the determined movement.