Valve Controller Self-Configuration for Multi-Valve Fault Detection
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Solution Overview
Problem
The configuration and installation of valve controllers in industrial environments are cumbersome, especially when generic valve controllers are used with different types of valves, as they require type-specific validation criteria to ensure proper operation, leading to increased complexity and potential errors in fault detection.
Innovation Solution
A valve controller that executes a configuration phase by establishing a pilot valve integer and determining a tolerance criterion based on it, allowing for automatic selection of the tolerance criterion, which simplifies the configuration process and facilitates the use of a single controller with multiple valve types by setting acceptable position ranges for flow controlling elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a generic valve controller is used with different types of valves, then the versatility and adaptability of the controller is improved, but the complexity of configuration and installation increases due to the need for type-specific validation criteria
Solution Approach 1:
The patent applies preliminary action by automatically determining the valve type and selecting appropriate validation criteria during a configuration phase before the controller enters normal operation. The controller executes a configuration phase that includes determining a valve type based on valve-specific parameters and automatically selecting validation criteria from a stored set, eliminating the need for manual configuration of type-specific parameters by the operator.
Solution Approach 2:
The controller performs self-configuration by automatically identifying the valve type and selecting the appropriate validation criteria without external intervention. The system serves itself by storing multiple validation criteria internally and autonomously determining which criterion to apply based on the detected valve type, thereby simplifying the operator's task while maintaining type-specific accuracy.
2Measurement precision
If manual configuration of type-specific validation criteria is required, then the measurement precision and fault detection accuracy is improved, but the ease of operation deteriorates due to increased operator burden
Solution Approach 1:
The controller automatically determines the valve type and selects the appropriate validation criterion from its stored set, eliminating the need for operators to manually configure type-specific parameters. This self-service approach maintains high fault detection accuracy by ensuring the correct validation criterion is applied while significantly reducing the operational burden on users.
Solution Approach 2:
The system incorporates feedback mechanisms during the configuration phase where the controller determines valve type based on detected parameters and automatically adjusts the selected validation criterion accordingly. This feedback loop ensures that the appropriate measurement precision is maintained while the system adapts automatically to different valve types without requiring manual intervention.
3Reliability
If multiple validation criteria are stored for different valve types, then the reliability of fault detection is improved, but the device complexity increases due to additional memory and selection logic
Solution Approach 1:
The controller is designed with multi-functionality to handle multiple valve types using a single device. It stores multiple validation criteria internally and includes logic to automatically determine valve type and select the appropriate criterion. This universal design maintains high fault detection reliability across different valve types while avoiding the need for separate dedicated controllers for each valve type, thereby managing complexity through software rather than hardware multiplication.
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 the configuration of valve controllers, enhances reliability, and allows for the use of a single controller with various valve types, improving fault detection accuracy and reducing operational complexity.
Implementation Method 1
The valve controller comprises at least one pilot valve for controlling the position of the flow controlling element(s) by energizing the actuator by allowing a pressurized fluid to enter the actuator and de-energizing the actuator by allowing the pressurized fluid to leave the actuator
Data Source
AI summary
A valve controller for a valve that comprises an actuator mechanically coupled to at least one flow controlling element. The valve controller comprises at least one pilot valve for controlling the position of the flow controlling element(s) by the actuator. The valve controller comprises a position sensor for obtaining a position signal indicative of the position of one of said at least one flow controlling element. The valve controller is configured to execute a configuration phase comprising establishing a pilot valve integer corresponding to number of pilot valves, and determining a tolerance criterion for the position signal based on the pilot valve integer. A valve arrangement comprising the valve controller and a valve. A method of controlling a valve comprising the configuration phase.