Solenoid Valve Manifold Monitoring With Sensor Intermediate Block
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Solution Overview
Problem
Existing solenoid valve control systems in manifold assemblies lack a reliable method to predict and prevent sudden failures, particularly in already installed valves, as they require initial design modifications and cannot efficiently monitor multiple control valves for degradation.
Innovation Solution
A solenoid valve assembly with an intermediate block housing sensors for pressure, flow, and coil current monitoring, which can be retrofitted to existing systems, allowing for the detection of parameter deviations from a normalized cycle profile to anticipate valve failures and trigger alarms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors and magnets are built into the valve body during initial design, then failure prediction capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
An intermediate block is introduced as a mediator component between the manifold block and the control valve body. This intermediate block houses all sensors (pressure sensors, flow sensors, coil current sensors) and magnets, eliminating the need to modify the control valve body itself. The intermediate block serves as a retrofit adapter that provides failure prediction capabilities while maintaining the original valve body design.
Solution Approach 2:
The system is segmented into distinct functional modules: the control valve body remains separate from the sensing components, which are housed in the intermediate block. This segmentation allows the valve body to remain simple while the intermediate block contains all the complexity of sensors and magnets for failure prediction.
2Measurement precision
If multiple sensors are installed to monitor pressure, flow, and coil current, then measurement precision is improved, but device complexity increases
Solution Approach 1:
Multiple sensors (pressure sensors, flow sensors, coil current sensors) are merged into a single intermediate block housing. This consolidation provides comprehensive monitoring of all critical parameters while containing the complexity within one modular component rather than distributing sensors throughout the entire valve assembly.
Solution Approach 2:
The intermediate block serves multiple functions simultaneously: it houses pressure sensors, flow sensors, coil current sensors, and magnets. This multi-functionality reduces the need for separate components and simplifies the overall system architecture while maintaining comprehensive monitoring capabilities.
3Reliability
If the system monitors multiple control valves for degradation, then reliability is improved, but loss of time for data processing increases
Solution Approach 1:
The system continuously monitors parameters (pressure, flow, coil current) and provides real-time feedback by comparing actual readings against predetermined tolerance boundaries. When parameters exceed these boundaries, immediate alerts are generated, enabling rapid response without requiring extensive data processing delays.
Solution Approach 2:
Predetermined tolerance boundaries are established in advance for each parameter. This preliminary action allows the system to quickly compare sensor readings against pre-set thresholds without requiring complex real-time analysis, thereby reducing data processing time while maintaining reliable failure detection.
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 early detection of valve degradation and failure prediction, allowing for scheduled maintenance and preventing unscheduled line stoppages by monitoring pressure, flow, and coil current, without requiring modifications to existing manifold blocks or control valve bodies.
Implementation Method 1
at least one sensor is in the form of a sensor board and has a plurality of pressure transducers mounted thereon for detecting pressure in a plurality of the through holes
Implementation Method 2
The position of a spool is detected by the use of a magnet mounted on the spool valve and a Hall effect sensor protruding into the valve body for sensing the proximity of the magnet
Implementation Method 3
the at least one sensor also includes a current sensor housed in the intermediate block for sensing current supplied to the coil
Implementation Method 4
there is a leakage sensor that detects ultrasound caused by leaks in one of the flow paths
Data Source
AI summary
A solenoid valve assembly has a valve body in which a spool is slidably mounted and operated by a solenoid having a coil. A manifold member has a plurality of flow paths for supplying and discharging pressurized fluid to and from ports of the solenoid valve assembly. An intermediate block is interposed between the valve body and the manifold member. The intermediate block has a plurality of through holes for connecting ports of the manifold member to ports on the valve body. At least one sensor is housed in the intermediate block for sensing at least one of pressure and flow in at least one of the through holes.