Switchless Valve Position Detection Using Adaptive Current Analytics
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Solution Overview
Problem
Existing valve control systems rely on position indicating switches, which are costly and prone to failure due to environmental conditions like ageing and tampering, necessitating a solution that can detect valve positions without switches and adapt to changing conditions.
Innovation Solution
A switchless valve control system that uses current magnitude measurements and current profile analytics to detect valve positions, with a learning algorithm that adapts to new valve performance and environmental changes, eliminating the need for physical end position switches by recognizing positions through steep current thresholds and monitoring current consumption patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If position indicating switches are used to detect valve positions, then position detection accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent removes the position indicating switches from the system and extracts only the essential function of position detection. Instead of using physical switches, the system uses current magnitude measurements and current profile analytics to detect valve positions, thereby eliminating unnecessary components while maintaining the core detection capability.
Solution Approach 2:
The current measurements serve multiple functions simultaneously: they monitor valve position, detect valve state (open/closed), provide diagnostic information about valve health, and enable the learning algorithm to adapt to environmental changes. This multi-functionality replaces the specialized position indicating switches with a more versatile measurement approach.
2Reliability
If position indicating switches are used to detect valve positions, then position detection reliability is improved, but reliability deteriorates due to environmental conditions like ageing and tampering
Solution Approach 1:
The patent replaces the mechanical position indicating switches with an electrical measurement system that monitors current magnitude and current profiles. This substitution eliminates the mechanical contact points that are susceptible to ageing, wear, and tampering, thereby improving reliability in harsh environmental conditions while maintaining position detection capability.
Solution Approach 2:
The system uses the existing current measurements required for valve operation to simultaneously detect position and diagnose health issues. The learning algorithm continuously adapts to environmental changes using these self-generated data, making the system self-adjusting and more reliable without additional sensors or components.
3Ease of manufacture
If position indicating switches are removed to reduce cost, then manufacturing cost is reduced, but measurement precision deteriorates
Solution Approach 1:
The current measurements serve multiple functions simultaneously: they monitor valve position, detect valve state (open/closed), provide diagnostic information about valve health, and enable the learning algorithm to adapt to environmental changes. This multi-functionality replaces the specialized position indicating switches with a more versatile measurement approach.
Solution Approach 2:
The learning algorithm continuously learns from current profile data and adapts to environmental changes, improving position detection precision over time. The system uses feedback from ongoing operations to refine its understanding of valve behavior, compensating for the absence of dedicated position switches and maintaining high measurement accuracy.
4Loss of substance
If switches are removed to minimize material costs, then loss of substance is reduced, but device complexity increases due to software algorithm requirements
Solution Approach 1:
The system uses the existing current measurements required for valve operation to simultaneously detect position and diagnose health issues. The learning algorithm continuously adapts to environmental changes using these self-generated data, making the system self-adjusting and more reliable without additional sensors or components.
Data Source
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AI summary
A valve without position indicating switches. Positions of the valve are detected from current magnitude measurements and current profile analytics. The current profile may be learned initially and relearned and adapted at each operation. The valve may be opened and closed by a driver that is actuated byan electrical current to control the opening and closing of the valve. The current may be regulated by a controller to open and close the valve appropriately.