Smart Modular Control Valve With Onboard Diagnostics
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Solution Overview
Problem
Conventional valve banks require external electronic controllers for control and diagnostics, limiting their modular tailorability and capability.
Innovation Solution
Incorporation of an onboard electronic controller in modular control valves that enable intelligent diagnostics, feedback, and control, reducing the need for intermediate external controllers and allowing plug-and-play integration with conventional valve banks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional valve banks use external electronic controllers for control and diagnostics, then the system can achieve basic control functionality, but the device complexity and system integration requirements increase
Solution Approach 1:
The patent combines the electronic controller, sensors, and communication interfaces directly into the valve body, creating an integrated smart valve unit. This merging eliminates the need for separate external controllers and intermediate wiring, thereby reducing device complexity while maintaining or enhancing modular adaptability.
Solution Approach 2:
The smart valve incorporates multiple functions within a single modular unit, including control valve functionality, diagnostic capabilities, feedback sensing, and communication interfaces. This multi-functionality allows the same modular component to serve multiple purposes, reducing the number of separate components needed and simplifying the overall system.
2Reliability
If external intermediate controllers are used for diagnostics and feedback, then diagnostic capability is provided, but the number of components and system complexity increase
Solution Approach 1:
The diagnostic sensors, feedback mechanisms, and communication interfaces are integrated directly into the valve assembly, eliminating the need for separate external intermediate controllers. This reduces the number of components while maintaining comprehensive diagnostic capability.
Solution Approach 2:
The smart valve performs self-diagnostics and self-monitoring through integrated sensors and controllers that continuously report on valve status, position, and performance. This self-service capability provides reliable diagnostic information without requiring additional external monitoring equipment.
3Adaptability or versatility
If modular control valves are made more capable with onboard controllers, then adaptability and functionality improve, but manufacturing complexity and cost increase
Solution Approach 1:
The smart valve is designed as a modular segment that can be independently manufactured and then integrated into the larger valve bank system. This segmentation allows for specialized manufacturing of the electronic components as a separate module, reducing the complexity burden on the overall manufacturing process and enabling economies of scale.
Solution Approach 2:
By designing the onboard controller and electronic components to serve multiple functions (control, diagnostics, feedback, communication), the patent reduces the total number of separate components that would need to be manufactured and assembled. This multi-functionality approach simplifies manufacturing despite the enhanced capabilities.
Data Source
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AI summary
An exemplary valve bank and/or modular control valve having a valve body, a valve member movable in a fluid flow of the valve body to control flow of fluid, and an onboard electronic controller that is operably mounted to the valve bank or valve body. The onboard controller is operably connected to at least one actuator of the valve, which is configured to control movement of the valve member in response to commands from the onboard controller. The onboard controller may provide diagnostics, feedback and/or control of the control valve, such as via inputs from one or more sensors that may be included in the valve. The modular control valve may be used with conventional non-intelligent valve banks to thereby impart smart diagnostics and/or feedback into the valve bank in a plug-and-play manner. A communications interface may be provided in the control valve to interface and communicate with an upper-level PLC controller.