Electric Valve Actuator Failure Diagnosis via Sensor Feedback
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Solution Overview
Problem
Electric valve actuators face challenges in diagnosing potential failures, such as trim failure, packing failure, and internal loading spring failure, which can lead to reduced reliability and inefficiency, especially when used in high-pressure applications.
Innovation Solution
The implementation of an electric valve actuator system that includes rotation sensors, valve position sensors, current sensors, and a processor to monitor the distance traveled by the drive shaft and the position of the flow control member, generating alerts for potential failures by comparing measured data against reference profiles, thereby distinguishing between different failure modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electric valve actuators are used without diagnostic capabilities, then the device complexity is low, but the reliability of detecting and diagnosing valve failures is poor
Solution Approach 1:
The patent implements feedback mechanisms by incorporating rotation sensors to monitor drive shaft rotation, valve position sensors to detect valve position, and current sensors to measure motor current. These sensors continuously feed back operational data to a processor that compares actual measurements against expected profiles, enabling real-time detection of deviations indicating trim failure, packing failure, or spring failure.
Solution Approach 2:
The patent introduces a processor as an intermediary component that acts as a diagnostic brain. This processor receives data from multiple sensors, compares measurements against reference profiles, and generates diagnostic alerts. The intermediary processor enables sophisticated failure detection without requiring complex wiring or direct integration of diagnostic logic into the motor control circuitry.
2Measurement precision
If multiple sensors and diagnostic features are added to the actuator, then the ability to distinguish between different failure modes improves, but the device complexity increases
Solution Approach 1:
The patent segments the diagnostic function into distinct sensor modules (rotation sensor, valve position sensor, current sensor), each responsible for monitoring a specific parameter. This segmentation allows the system to collect comprehensive diagnostic data while maintaining modularity, making the system easier to implement and maintain despite the multiple sensing functions.
Solution Approach 2:
The processor serves multiple functions: it processes data from all sensors, compares measurements against reference profiles, distinguishes between different failure modes (trim failure, packing failure, spring failure), and generates appropriate alerts. This multi-functionality consolidates diagnostic logic into a single component, reducing overall system complexity despite the sophisticated diagnostic capabilities.
3Productivity
If the actuator continuously monitors valve operation with multiple sensors, then the productivity of maintenance operations improves, but the use of energy increases
Solution Approach 1:
The actuator system performs self-diagnosis by continuously monitoring its own operational parameters through integrated sensors and processor. The system automatically detects failures, distinguishes between different failure modes, and generates alerts without requiring external diagnostic equipment or manual inspection, enabling proactive maintenance and reducing downtime.
Solution Approach 2:
The diagnostic system operates by periodically comparing sensor measurements against reference profiles during valve operation. The processor continuously analyzes data streams from rotation, position, and current sensors, performing periodic assessments to detect deviations indicating failures. This periodic monitoring approach enables timely failure detection while managing energy consumption through efficient data processing.
Data Source
AI summary
Methods and apparatus to diagnose a valve using electric valve actuators are disclosed. An example apparatus includes an electric motor to actuate a valve, rotation sensors to monitor a rotation of a drive shaft associated with the electric motor to determine a distance travelled by the drive shaft, and a valve position sensor to monitor a position of a flow control member of the valve. The example electric valve actuator further includes a processor to generate an alert based on feedback from the rotation sensors and the valve position sensor, the alert associated with a failure of the valve.