Valve Actuator Predictive Torque Control With Self-Calibration
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Solution Overview
Problem
Existing electronically controlled, motor-driven valve actuators lack predictive, accurate, and fault-tolerant control over torque and force application, leading to potential over-torque and calibration issues over extended operational lifetimes.
Innovation Solution
The solution involves 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, combined with a torque measurement sensor for continuous calibration and feedback, enabling predictive torque control and fault tolerance.
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 hundreds of different variations
Solution Approach 1:
The patent applies dynamics by replacing fixed-speed motors with variable speed motors that can dynamically adjust their operating parameters. The electronic controller enables continuous variation of motor speed and torque output, eliminating the need for multiple fixed-configuration motor-gear sets while maintaining optimal performance across different operating conditions.
Solution Approach 2:
The patent implements parameter changes by using electronic control to continuously adjust motor speed, torque, and other operational parameters. This allows a single actuator design to adapt to different valve requirements by changing electrical and mechanical parameters rather than requiring different physical hardware configurations.
2Adaptability or versatility
If the actuator is disassembled to change gear set and motor, then the torque and speed characteristics can be changed, but the loss of time increases due to service interruption
Solution Approach 1:
The variable speed motor and electronic controller enable dynamic reconfiguration of torque-speed characteristics without physical disassembly. The controller can programmatically adjust motor parameters to match different valve requirements, providing adaptability while the actuator remains installed and operational.
Solution Approach 2:
The patent replaces mechanical reconfiguration (disassembly and physical gear set changes) with electronic control systems. The electronic controller manages motor parameters and torque output through software programming, substituting mechanical adaptation with electrical and computational methods that require no service interruption.
3Speed
If torque is controlled according to a specified speed/torque profile, then the desired constant actuation speed can be obtained, but the manufacturing precision requirements increase for motor and gear calibration
Solution Approach 1:
The patent employs feedback mechanisms where the electronic controller continuously monitors motor performance and adjusts control parameters in real-time. This closed-loop control compensates for manufacturing tolerances and calibration variations, maintaining precise speed and torque profiles without requiring extremely tight manufacturing tolerances on motor and gear components.
Solution Approach 2:
The electronic control system performs self-calibration and self-adjustment during operation, automatically compensating for manufacturing variations. The controller can programmatically determine optimal parameters and adjust motor output to achieve desired performance, reducing dependency on high-precision manual calibration during manufacturing.
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
This approach provides accurate and continuous control of torque and force, maintaining calibration accuracy despite wear or drift, and ensures fault-tolerant operation by switching to reactive control if predictive systems fail, thus preventing damage to the valve.
Implementation Method 1
at least one torque measurement sensor configured to measure a force or torque that is related to the valve force or torque
Implementation Method 2
an electric motor configured to cause a linear or rotational actuation of a valve according to a motor input received from the electronic controller
Data Source
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.