Rotary Valve Position Sensor with Integrated Failure Detection
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Solution Overview
Problem
Existing rotary actuated valve systems lack effective mechanisms for indicating valve position and detecting failures in the actuator linkage without additional sensors, which can lead to positional errors and mechanical malfunctions.
Innovation Solution
A rotary actuated valve with a mechanical position indicator that uses a separate input and output shaft connected through a moveable member, where a position sensor detects the positional configuration of the input shaft and provides feedback signals for both position and failure detection, allowing for integrated position sensing and fault detection without additional error detection means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate position sensor and input shaft are added to detect valve position and failure, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines the position sensing function and failure detection function into a single position sensor that monitors both the input shaft position and the actuator output. By merging these two detection functions into one sensor system, the patent achieves reliable failure detection without proportionally increasing device complexity.
Solution Approach 2:
The position sensor serves multiple functions: it detects the angular position of the input shaft for normal operation and simultaneously detects failures by monitoring whether the input shaft position matches the expected position based on actuator output. This multi-functionality reduces the need for separate dedicated failure detection sensors.
2Reliability
If additional sensors are added for failure detection, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The position sensor is designed to perform both position indication and failure detection functions, eliminating the need for additional dedicated failure detection sensors. This reduces component count and manufacturing cost while maintaining reliable failure detection capability.
Solution Approach 2:
The system uses the existing position sensor to self-diagnose failures by comparing the actual input shaft position with the expected position derived from actuator output. This self-service approach eliminates the need for separate failure detection hardware, reducing manufacturing costs.
3Reliability
If the position sensor is spaced apart from the moveable member, then reliability is improved by reducing mechanical coupling failures, but measurement precision may be affected
Solution Approach 1:
The patent introduces the input shaft as a mechanical intermediary that transmits the position information from the moveable member to the position sensor. This intermediary allows the sensor to be spaced apart from the moveable member for reliability while still achieving precise position detection through the input shaft's rotational position.
Data Source
AI summary
The subject matter of this specification can be embodied in, among other things, a positioning device that includes an actuator assembly configured to actuate an output shaft based on an input signal, and a position sensor assembly. The position sensor assembly includes a position sensor configured to detect a position of an input shaft not directly coupled to the output shaft, a first input receiver configured to receive the input signal, a first output transmitter configured to provide an output signal based on the position of the input shaft, and a second output transmitter configured to provide another output signal indicative of a failure of at least one of the input shaft and the output shaft. A moveable member is coupled to both the output shaft and the input shaft and is configured to alter the positional configuration of the input shaft and to be actuated by the output shaft.