Valve Opening Mechanism Using Motor Speed for Precise Torque Cutoff
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Solution Overview
Problem
Existing valve opening and closing control systems are not precise due to wear and geometric changes, and current-based torque limiters are complex, inaccurate, and prone to fluctuations, failing to effectively protect valve actuators from over-torque.
Innovation Solution
A precision opening and closing mechanism that uses motor rotation speed measurement to determine torque levels, eliminating the need for current measurement, and incorporates a control unit connected to the valve actuator motor, mechanical reducer, and limit switches to ensure accurate and efficient torque protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current-based torque limiters are used to protect valve actuators, then motor protection is provided, but the system becomes complex and measurement accuracy deteriorates due to fluctuations and variations
Solution Approach 1:
The patent replaces the electrical current measurement system with a mechanical torque sensing mechanism. The torque sensor directly measures the mechanical torque transmitted through the drive shaft, eliminating the need for complex electrical current monitoring and processing systems. This mechanical substitution simplifies the overall system while providing more direct and reliable torque protection.
Solution Approach 2:
The patent extracts the torque measurement function from the electrical control system and implements it as a separate mechanical torque sensing component. By taking out the torque measurement function and implementing it mechanically through a torque sensor and strain gauge, the system avoids the complexity of electrical current-based torque estimation while maintaining dedicated torque protection capability.
2Reliability
If current-based torque limiters are used, then motor protection is provided, but measurement precision deteriorates due to fluctuations and variations
Solution Approach 1:
The patent replaces the electrical current measurement system with a mechanical torque sensing mechanism. The torque sensor directly measures the mechanical torque transmitted through the drive shaft, eliminating the need for complex electrical current monitoring and processing systems. This mechanical substitution simplifies the overall system while providing more direct and reliable torque protection.
Solution Approach 2:
The patent introduces a torque sensor as an intermediary component that directly measures mechanical torque between the motor and the valve actuator. This intermediary device provides accurate torque measurement by physically sensing the torque through strain gauges, serving as a mediator between the motor output and the control system, thereby achieving precise measurement without electrical fluctuations.
3Ease of operation
If stroke limiters are used to control valve opening and closing, then basic positioning is achieved, but precision deteriorates due to wear and geometric changes in the plug and seat
Solution Approach 1:
The patent implements a feedback mechanism using a torque sensor that continuously monitors the torque during valve operation. When the valve plug reaches its seating position, the torque characteristic changes, providing feedback to the control system. This feedback allows the system to dynamically adjust and maintain precise positioning despite wear or geometric changes, as the torque-based detection adapts to the actual physical state of the valve components.
Solution Approach 2:
The patent utilizes changes in torque parameters as the valve transitions between open and closed positions. By monitoring torque variations rather than relying on fixed mechanical stops, the system can detect the precise moment when the plug seats against the valve seat. This parameter-based approach allows adaptation to wear and geometric changes since the torque signature changes with the actual physical condition of the components.
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 mechanism provides effective and economical torque protection for valve actuators, maintaining precision despite wear and geometric changes without the complexity of current-based systems, ensuring accurate valve positioning and reduced risk of damage.
Implementation Method 1
a beam (131) with a first end (1311) and a second end (1312), the first end (1311) being connected to the drive shaft (12) and the second end (1312) being connected to the cap (11), characterised in that it comprises a torque sensor (13) arranged to measure the torque transmitted by the drive shaft (12)
Data Source
Figure 1
AI summary
Opening and closing mechanism which is comprised of the following: - A power supply (1) - A rotation direction setter (2) - A control unit (3) which is connected to the rotation direction setter (2) - A valve actuator motor (5) which is connected to the control unit in which one of the connections is for sending a BREAK instruction from the control unit (3) to the motor (5), a signal which is sent when a shutdown occurs due to over-torque inferred from the motor rotation speed. This opening and closing mechanism is not limited by any wear of the plug, has no need to use measurement of the current drawn and establishes the torque level based on measurement of the motor rotation speed, the rotation speed corresponding to the nominal torque having been previously established.