Valve Controller Auto-Setup for Faster, Error-Resistant Installation
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Solution Overview
Problem
The installation of valve controllers in industrial settings is complex and time-consuming due to the need for manual adjustments and pairings with specific valves, increasing the risk of errors and requiring extensive engineer handling.
Innovation Solution
A valve controller with an actuator, flow controlling unit, and pilot valves that execute a setup process using pressurized fluids to determine and store parameter values indicative of its functionality, allowing for autonomous setup and reduced dependency on engineer handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual adjustments and pairings are performed for each valve controller during installation, then the valve controller can be properly configured for specific valves, but the installation process becomes complex and time-consuming
Solution Approach 1:
The valve controller automatically determines its own parameters by executing a setup process that involves actuating the valve through pilot valves and sensing disc positions. This self-service approach eliminates the need for manual adjustments and pairings, allowing the controller to self-configure when installed on a specific valve, thereby reducing installation time while ensuring proper configuration.
Solution Approach 2:
The system performs preliminary parameter determination during the initial setup phase by automatically testing valve responses at different disc positions. This preliminary action captures all necessary configuration data before normal operation begins, preventing the need for time-consuming manual adjustments later while ensuring the controller is properly configured for the specific valve.
2Reliability
If manual adjustments and pairings are performed for each valve controller during installation, then the valve controller can be properly configured for specific valves, but the risk of errors increases
Solution Approach 1:
The automatic parameter determination process eliminates human intervention in the configuration phase, removing the source of manual errors. The valve controller autonomously tests and records parameters by actuating the valve and sensing disc positions, ensuring accurate configuration without the error risks associated with manual adjustments and pairings.
Solution Approach 2:
The system uses feedback from position sensors to automatically adjust and confirm parameter settings during the setup process. By continuously monitoring valve responses and disc positions, the system can verify correct configuration and detect anomalies, reducing error risk while ensuring proper configuration for the specific valve.
3Reliability
If manual adjustments and pairings are performed for each valve controller during installation, then the valve controller can be properly configured for specific valves, but extensive engineer handling is required
Solution Approach 1:
The valve controller performs all configuration tasks autonomously through an automated setup process that involves actuating the valve via pilot valves and sensing disc positions. This eliminates the need for extensive engineer handling and manual adjustments, making installation simple while ensuring proper configuration for the specific valve type.
4Adaptability or versatility
If a valve controller is adjusted and paired for different valves, then the controller can work with various valve types, but the adjustment process becomes complicated
Solution Approach 1:
The valve controller is designed with universal adaptability to work with different valve types through an automated parameter determination process. The controller executes a setup process that automatically captures the specific characteristics of any connected valve, eliminating the need for type-specific manual adjustments. This universal approach maintains versatility while simplifying the adjustment process to a single automated routine.
Solution Approach 2:
The system automatically determines and stores parameter values that are specific to each valve-controller combination. By dynamically adjusting parameters based on automated sensing and actuation during setup, the controller adapts to different valve types without requiring complex manual reconfiguration, maintaining versatility while reducing adjustment complexity.
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
Simplifies the installation process by allowing the valve controller to autonomously determine and store necessary parameter values, reducing the risk of errors and minimizing operator involvement, thus streamlining the setup process.
Implementation Method 1
The first pilot valve is configured to control the position of the first disc by means of energizing an actuator by allowing a first pressurized fluid to enter the actuator and by means of de-energizing the actuator by allowing the first pressurized fluid to leave the actuator
Implementation Method 2
The valve controller also comprises a second pilot valve configured to control the position of the first disc by means of energizing the actuator by allowing a second pressurized fluid to enter the actuator and by means of de-energizing the actuator by allowing the second pressurized fluid to leave the actuator
Implementation Method 3
The valve controller also comprises a first sensor for providing a sensor reading indicative of the position of the first disc
Data Source
AI summary
A valve controller for controlling a valve and a valve comprising the valve controller are disclosed. The valve has an actuator and a flow controlling unit. The valve controller is configured to execute a setup process and comprises a first pilot valve that can energize the actuator by allowing a first pressurized fluid to enter the actuator and de-energizing the actuator by allowing the fluid to leave the actuator. The valve controller further has an input device by which the setup process can be initiated, and a memory unit for storing setup parameter values. The setup process comprises: determining parameter values indicative of the functionality of at least one of the valve controller, the actuator and the flow controlling unit, and storing the parameter values as setup parameter values in the memory unit.