Valve Actuator Predictive Torque Control With Self-Calibration
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Solution Overview
Problem
Existing valve actuators lack predictive, accurate, and fault-tolerant control over force or torque applied to valves, leading to potential damage due to measurement latency and system calibration issues over extended operational lifetimes.
Innovation Solution
An electronically controlled, motor-driven valve actuator with output current and/or voltage sensors, using a control algorithm based on motor electrical characteristics and mechanical gear train properties, includes a torque measurement sensor for initial calibration and continuous monitoring, enabling predictive torque control and fault detection to maintain accuracy and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed speed motor with gear set is used to provide constant torque and speed, then the actuator can provide optimal torque and speed, but the device complexity increases due to needing to stock multiple motor and gear set variations
Solution Approach 1:
The patent applies parameter changes by using an electronically controlled motor with variable speed and torque capabilities. Instead of using fixed motor and gear set combinations, the system electronically adjusts motor parameters (speed, torque) to match required actuator characteristics, eliminating the need to stock multiple physical variations.
Solution Approach 2:
The patent replaces the mechanical selection of different motor and gear set combinations with an electronic control system. The motor controller electronically adjusts motor output to provide the required torque and speed characteristics, substituting mechanical diversity with electronic adaptability.
2Measurement precision
If torque measurement sensor is used for reactive control, then the applied torque can be monitored, but the control accuracy deteriorates due to measurement and reaction latency
Solution Approach 1:
The patent applies preliminary action by using the torque measurement sensor to establish a calibration profile before actual valve actuation. The system pre-determines the relationship between motor input and resulting torque, storing this calibration data for use during operation. This eliminates the need for real-time reactive measurement during critical actuation moments.
Solution Approach 2:
The patent uses feedback by continuously monitoring torque with the measurement sensor and using this information to update and refine the calibration profile. The measured torque values feed back into the control system to improve the accuracy of predictive torque control for future operations.
3Adaptability or versatility
If the actuator is disassembled and reassembled with different gear set and motor, then the torque and speed characteristics can be changed, but the productivity decreases due to downtime and reassembly time
Solution Approach 1:
The patent uses parameter changes to provide adaptability without physical reconfiguration. The electronically controlled motor allows torque and speed characteristics to be changed by adjusting control parameters rather than physically replacing components, enabling quick adaptation while maintaining actuator availability.
4Reliability
If predictive torque control is implemented with continuous monitoring, then the accuracy and reliability improve, but the device complexity increases due to additional sensors and control algorithms
Solution Approach 1:
The patent applies self-service by using the torque measurement sensor to automatically calibrate and update the control profile without external intervention. The system performs self-calibration during operation, using its own measurement capabilities to refine its control accuracy, thereby justifying the added sensor complexity through autonomous operation.
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
The solution provides predictive, accurate, and fault-tolerant control of torque applied to valves, minimizing the risk of damage by continuously updating calibration parameters and switching to reactive control in case of predictive system failure, ensuring reliable operation over extended periods.
Implementation Method 1
an electric motor configured to cause a linear or rotational actuation of a valve according to a motor input received from the electronic controller, whereby application of said motor input to said electric motor determines a motor output force or torque
Implementation Method 2
a torque measurement sensor, which is configured to directly or indirectly monitor the force or torque applied to the valve, and to relay its measurements to the electronic controller
Data Source
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AI summary
An electronic controller of a valve actuator predictively calculates motor inputs that will cause the actuator to apply desired forces or torques to a valve. A force/torque sensor of the actuator measures applied force or torque at the motor output and/or valve to verify the applied force or torque and enable updating of calibration settings as needed. Upon failure of the force/torque sensor, embodiments continue predictive operation without sensor verification or calibration updates. Upon failure of the predictive control, embodiments continue valve actuation under reactive control via the force/torque sensor. Connection to a calibration valve simulator enables embodiments to perform an initial self-calibration using the force/torque sensor of the actuator. The motor can be a variable frequency driven AC motor or a DC motor. The calibration can incorporate mechanical properties of an actuator gear train.