Valve Actuator Control for Position Drift and Torque Adaptation
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Solution Overview
Problem
Conventional valve actuators face challenges in accurately controlling torque to ensure proper valve positioning due to varying operating conditions, such as material buildup and wear, which can lead to incomplete valve closure or increased wear, disrupting process flows and potentially causing valve failure.
Innovation Solution
A control system for valve actuators that monitors characteristics during movement, detects position drift, and adjusts the valve's position dynamically to maintain optimal torque levels and prevent excessive wear, using adaptive speed and torque control algorithms to ensure precise valve seating and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed torque threshold is set by the user at startup, then the actuator can prevent excessive wear and ensure proper valve positioning, but the valve actuator may cease operation without completing movement of the valve due to varying operating conditions such as material buildup and wear
Solution Approach 1:
The patent implements dynamic torque threshold adjustment where the control system continuously monitors valve position and operating conditions, then adapts the torque threshold in real-time. This allows the actuator to maintain reliable positioning accuracy while adapting to varying conditions such as material buildup and wear, preventing premature cessation of valve movement.
Solution Approach 2:
The control system incorporates feedback mechanisms that monitor valve position, torque levels, and operating conditions. Based on this feedback, the system dynamically adjusts the torque threshold to match actual valve conditions, ensuring the valve completes its full movement cycle while preventing excessive wear through adaptive torque control.
2Manufacturing precision
If the actuator is configured to move the valve element to a selected fully seated or closed position, then the valve can be positioned accurately, but the fully seated or closed position may drift over time due to variation in operation conditions such as material buildup and wear
Solution Approach 1:
The control system continuously monitors the valve position and compares it against the target closed position. When drift is detected due to material buildup or wear, the system provides feedback to adjust the torque application and reposition the valve element to maintain the correct closed position, ensuring both precision and long-term stability.
Solution Approach 2:
The system performs self-adjustment by monitoring its own operation and automatically compensating for position drift. The control system detects when the valve closed position has shifted and autonomously adjusts torque thresholds and positioning commands to maintain accurate valve seating without external intervention.
3Device complexity
If conventional valve actuators operate with fixed torque thresholds, then the control system is simple, but the actuator cannot dynamically adapt to changing valve conditions, leading to incomplete closure or excessive wear
Solution Approach 1:
The patent transitions from static torque threshold settings to dynamic adjustment mechanisms. The control system continuously adapts torque thresholds based on real-time monitoring of valve position and operating conditions, improving reliability while adding only moderate complexity through standard control algorithms and sensors.
Data Source
AI summary
Valve systems and related methods include valve actuators and control systems configured to monitor at least one characteristic of the valve system during movement of a valve element to a position in the valve system and to determine a drift of the position based on the monitored at least one characteristic of the valve system.