Valve Control System Using Pressure Sensors for Safety Compliance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional valve control systems face complexity and increased costs when trying to meet safety standards, as they require special safety-standard-meeting valves that complicate design, management, and detection of intermediate valve states, while general-purpose valves lack the necessary detection capabilities for safety standards like ISO 13849-1.
Innovation Solution
A valve control system comprising general-purpose valves and sensors, with a control device that uses pressure switches to detect fluid flow and manage valve states, allowing for easy design and maintenance while meeting safety standards by duplicating the control logic and monitoring for reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If safety-standard-meeting valves with limit switches are used to meet safety standards, then safety detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical limit switch system with an electronic sensor system. Pressure sensors detect fluid flow states to determine valve positions, substituting the mechanical contact-based limit switches. This reduces mechanical complexity while maintaining safety detection capability through electronic monitoring of the actual fluid flow rather than just valve position.
Solution Approach 2:
The patent introduces pressure sensors as intermediary detection devices between the valve and the control system. These sensors detect fluid flow states and provide information to the control device, which then determines valve positions indirectly through flow detection rather than direct mechanical contact. This intermediary approach enables safety monitoring without requiring mechanical limit switches integrated into the valve.
2Reliability
If safety-standard-meeting valves with limit switches are used, then safety compliance is improved, but ease of manufacture and maintenance deteriorate
Solution Approach 1:
The patent segments the detection function from the valve body. Instead of integrating limit switches into the valve structure, the system uses separate pressure sensors positioned in the fluid line that detect flow states. This segmentation allows standard valves to be used while adding safety detection capability through independent sensor units, simplifying valve manufacturing while maintaining safety compliance.
Solution Approach 2:
The patent makes the pressure sensors serve multiple functions: they detect fluid flow states for safety monitoring, provide information for control decisions, and enable detection of intermediate valve positions. This multi-functional approach allows standard valves to be used with universal sensor-based monitoring that provides safety compliance without requiring specialized safety valves.
3Reliability
If limit switches are used to detect valve states, then safety detection is improved, but ability to detect intermediate states deteriorates
Solution Approach 1:
The patent implements continuous feedback through pressure sensors that monitor fluid flow states in real-time. The control device receives ongoing flow information and can determine valve positions dynamically. This continuous feedback mechanism provides precise measurement of valve states including intermediate positions, as the flow state changes progressively with valve position rather than in discrete steps like limit switches.
Solution Approach 2:
The patent changes the detection parameter from discrete mechanical contact (limit switch on/off) to continuous physical measurement (fluid flow state). Pressure sensors detect variations in fluid flow parameters that correspond to different valve positions, enabling precise measurement of intermediate states. The control device interprets these parameter changes to determine exact valve positions, achieving high measurement precision.
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 simplifies system design and management, reduces costs, and allows for precise detection of valve states, including intermediate positions, without the need for special safety-standard-meeting valves, thus achieving safety standards like category 4 of ISO 13849-1.
Implementation Method 1
Each of the first and second sensors includes a switch operating in response to flowing of the fluid through the flow path
Implementation Method 2
a solenoid valve... When the electric signal turns on a solenoid 103, solenoid 103 moves spool 102
Implementation Method 3
When solenoid 103 is turned off, a force of spring 104 returns spool 102 to an original position
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A valve control system (50) includes general-purpose valves (11 and 12) arranged in a pipe (1) for flowing a fluid, first and second sensors (13 and 14), and a safety controller (20). The general-purpose valves (11 and 12) are valves that can be opened and closed according to the electric signals, and are, e.g., solenoid valves, respectively. The first and second sensors (13 and 14) are sensors that detect a state of flowing of the fluid from the corresponding valves, and are formed of, e.g., pressure switches, respective The safety controller (20) is configured to satisfy the safety standards, and outputs signals (out1 and out2) for controlling the valves (11 and 12) based on signals (in1 and in2) provided from the first and second sensors (13 and 14), respectively.