Valve Actuator Micro-Movement Diagnostics Without Flow Disruption
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Solution Overview
Problem
On/off actuator devices used in critical applications face challenges in maintaining reliability due to low-frequency emergency maneuvers, making it difficult to diagnose their performance without interfering with industrial processes, and existing monitoring systems require macroscopic valve movements that disrupt fluid flow and lack detailed anomaly identification.
Innovation Solution
A monitoring system equipped with pressure, temperature, linear position, and deformation sensors, along with an electronic processing unit that performs micro-movements to diagnose the actuator's ability to apply sufficient torque or force without altering the fluid flow, allowing for real-time, high-frequency reliability assessment and anomaly detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If macroscopic valve movements are performed for diagnosis, then the actuator's operational capability can be verified, but the fluid flow is disrupted and industrial processes are interfered with
Solution Approach 1:
The patent applies partial action by performing only a micro-movement (partial movement) of the valve member instead of a complete macroscopic movement. The micro-movement is sufficient to verify actuator operational capability and diagnose anomalies while minimizing interference with fluid flow and industrial processes.
2Reliability
If emergency maneuvers are performed frequently to maintain actuator reliability, then the actuator's performance can be verified, but the industrial process is disrupted
Solution Approach 1:
The patent enables frequent reliability verification by performing partial micro-movements instead of complete emergency maneuvers. These micro-movements are sufficient to diagnose actuator performance and detect anomalies while causing minimal disruption to industrial process continuity.
Solution Approach 2:
The monitoring system performs preliminary diagnostic micro-movements to detect potential anomalies before they lead to complete actuator failure. This allows for early intervention and maintenance planning without requiring frequent disruptive emergency maneuvers or complete valve operations.
3Measurement precision
If multiple sensors are installed to detect operating parameters, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The monitoring system uses a multi-functional sensor suite where each sensor serves specific diagnostic purposes: pressure sensors detect fluid pressure changes, temperature sensors monitor thermal conditions, linear position sensors track actuator rod position, and deformation sensors detect structural changes. This universal approach enables comprehensive actuator health assessment through multiple parameters simultaneously.
Data Source
AI summary
A monitoring system (500) of an on/off type actuator device (1) for activating a valve for fluid pipelines is described, the actuator device (1) being configured to move a valve member of said valve between a first position and a second position. The actuator device (1) comprises at least one fluid cylinder (6) configured to control a linear movement of an actuator rod (8). The monitoring system (500) comprises a plurality of sensors mounted on the actuator device (1) and configured to detect a plurality of operating parameters of the actuator device, and an electronic processing and control unit (50). The electronic processing and control unit (50) is configured to impart a micro-movement to the valve member, to detect signals indicative of the values of said operating parameters during said micro-movement of the valve member, and as a function of said values of said detected operating parameters to estimate if said actuator device (1) is capable of applying a torque or force value sufficient to make said valve member perform the entire movement from the first position to the second position. The micro-movement is such as to constitute only the start of movement of the movable member of the valve, corresponding only to the overcoming of mechanical clearances and dissipative and deformation effects internal to the actuator (1), and furthermore is such as not to substantially involve any alteration in the flow of fluid controlled by the valve. In this way, it is possible to estimate the state of health of the actuator device (1) without causing variations in the flow of fluid through the aforesaid valve.