Valve Actuator Self-Powered Encoder via Stem Motion
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Solution Overview
Problem
Valve actuators using incremental encoders face challenges in maintaining accurate position information during power outages without a backup or redundant power supply, leading to potential valve damage and incorrect operation, while absolute encoders lose position information during total power loss and require recalibration upon power restoration.
Innovation Solution
A method and system for generating electrical power within a valve actuator by converting mechanical energy into electrical energy using a generator, allowing for self-sustaining operation of accessory electronics during power failures, eliminating the need for external power sources and backup batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If incremental encoders are used to monitor valve actuator position, then position changes can be tracked relative to a starting point, but position information is lost during power outages requiring backup power supplies
Solution Approach 1:
The valve actuator system generates its own electrical energy through a generator driven by the valve stem movement. This self-generated power eliminates the need for external backup power supplies while maintaining encoder operation and position information retention during power outages.
Solution Approach 2:
The system dynamically switches between manual operation mode (handwheel cranking) and automated operation mode (electric motor). During manual operation, the generator is engaged to produce electrical energy, while during automated operation, the electric motor drives the valve stem. This dynamic operation allows the system to adapt to different power availability conditions.
2Measurement precision
If absolute encoders are used to determine valve actuator position, then unique position signatures are available, but position information is lost during total power loss requiring recalibration
Solution Approach 1:
The valve actuator system generates its own electrical energy through a generator driven by the valve stem movement. This self-generated power eliminates the need for external backup power supplies while maintaining encoder operation and position information retention during total power loss.
3Reliability
If backup or redundant power supplies are installed to maintain encoder operation during power outages, then position information is preserved, but device complexity and cost increase
Solution Approach 1:
The valve actuator system generates its own electrical energy through a generator driven by the valve stem movement. This self-generated power eliminates the need for external backup power supplies, batteries, or complex power management systems while maintaining encoder operation during power outages.
Solution Approach 2:
The generator serves multiple functions: it generates electrical energy to power the encoder during manual operation, it can charge energy storage devices, and it provides a self-sufficient power source that eliminates the need for external backup power supplies.
4Adaptability or versatility
If handwheel manual operation is allowed during power outages, then valve operation can continue, but position tracking becomes erroneous without backup power
Solution Approach 1:
The valve actuator system generates its own electrical energy through a generator driven by the valve stem movement during manual handwheel operation. This self-generated power maintains encoder operation and accurate position tracking while allowing continued manual valve operation during power outages.
Solution Approach 2:
The system dynamically engages the generator during manual handwheel operation to provide electrical power to the encoder. This dynamic engagement ensures that position tracking remains accurate during manual operation while allowing the handwheel to be cranked to any position.
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
Enables continuous and accurate position monitoring and operation of valve actuators during power outages, preventing damage and ensuring correct operation by providing a reliable power source for electronic components, even in the absence of external electricity.
Implementation Method 1
converting a portion of the mechanical energy into electrical energy
Data Source
AI summary
The present invention utilizes operation of a valve actuator to generate electrical power. A portion of the mechanical energy generated by operation of a valve actuator is converted to electrical energy. The mechanical energy may be converted to electrical energy at the same time as the valve actuator is operating or the mechanical energy may be stored for later conversion. A valve actuator may be operated manually, electrically, pneumatically, or hydraulically. Generated electrical energy may also be stored.