Control Valve Actuator Position Detection Without Hall Sensors
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Solution Overview
Problem
Existing control valve position detection methods using Hall angle sensors are costly and prone to failure, leading to unreliable position detection and potential malpositioning of control valves.
Innovation Solution
Detect the position of a control valve actuator by monitoring actuator-characteristic operating variables such as power, force, and torque, eliminating the need for Hall sensors and leveraging existing vehicle electronics for diagnostics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Hall angle sensors are used for position detection, then position detection capability is provided, but manufacturing costs increase and reliability decreases
Solution Approach 1:
The patent extracts the position detection function from external Hall sensors and implements it through the actuator's existing feedback electronics. The actuator's built-in sensors and control electronics are used to detect position by monitoring operating variables during actuation, eliminating the need for separate Hall angle sensors and reducing manufacturing complexity.
Solution Approach 2:
The actuator serves its own position detection needs by using its existing feedback electronics and control capabilities. The actuator monitors its own operating variables (current, voltage, position feedback) to determine its position state, making the system self-sufficient without requiring additional dedicated position sensors.
2Measurement precision
If Hall angle sensors are used for position detection, then position information is obtained, but device complexity increases
Solution Approach 1:
The patent merges the position detection function with the actuator's existing control system. The actuator's feedback electronics, which already exist for control purposes, are utilized to detect position by analyzing operating variables during actuation. This combines multiple functions (actuation and position detection) into a single integrated system, reducing overall device complexity.
Solution Approach 2:
The actuator's feedback electronics serve multiple purposes: both controlling the actuator's operation and detecting its position. By making the feedback system multi-functional, the patent eliminates the need for separate dedicated position sensing components, thereby reducing device complexity while maintaining measurement precision.
3Reliability
If indirect position detection at actuator rod is used, then position is measured, but detection accuracy decreases
Solution Approach 1:
The patent segments the position detection into multiple discrete position states (first position, second position, intermediate position) based on operating variable thresholds. By detecting transitions between these segmented states rather than continuous indirect measurement, the system achieves more reliable and precise position information directly from the actuator's operational characteristics.
Data Source
AI summary
A method for detecting the position of an actuator includes adjustment of a control valve by an actuator. An actuator-characteristic operating variable may include a drive power, a drive operating force and/or a drive torque, and is detected continuously or discontinuously for determining the actuator position.