Valve Controller Self-Setup Using Sensor Feedback
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Solution Overview
Problem
The installation of valve controllers in industrial applications is complex and time-consuming, requiring extensive adjustments and pairings for different types of valves, which increases the risk of errors and depends heavily on skilled engineers.
Innovation Solution
A valve controller system that includes pilot valves and sensors to automatically determine and store setup parameter values, allowing for simplified installation by minimizing operator involvement and enabling self-control of the valve's functionality, with error indication to ensure proper operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment and pairing operations are performed for each valve type, then the valve controller can be adapted to specific valve variants, but the installation becomes complex and time-consuming
Solution Approach 1:
The valve controller automatically detects valve parameters and performs self-configuration by reading signals from the valve position sensor during installation, eliminating the need for manual adjustment and pairing operations. The controller autonomously determines valve type, stroke length, and other parameters through the sensor feedback mechanism.
Solution Approach 2:
The valve position sensor is pre-configured to provide signals that contain valve identification information. During installation, the controller automatically reads these pre-encoded signals to determine valve parameters before operation begins, avoiding post-installation configuration steps.
2Adaptability or versatility
If manual adjustment and pairing operations are performed for each valve type, then the valve controller can be adapted to specific valve variants, but the installation time increases
Solution Approach 1:
The valve controller automatically detects valve parameters and performs self-configuration by reading signals from the valve position sensor during installation, eliminating the need for manual adjustment and pairing operations. The controller autonomously determines valve type, stroke length, and other parameters through the sensor feedback mechanism.
Solution Approach 2:
The valve position sensor is pre-configured to provide signals that contain valve identification information. During installation, the controller automatically reads these pre-encoded signals to determine valve parameters before operation begins, avoiding post-installation configuration steps.
3Reliability
If manual adjustment operations are performed by skilled engineers, then proper valve configuration can be achieved, but the process depends heavily on engineer expertise
Solution Approach 1:
The valve controller automatically detects valve parameters and performs self-configuration by reading signals from the valve position sensor during installation, eliminating the need for manual adjustment and pairing operations. The controller autonomously determines valve type, stroke length, and other parameters through the sensor feedback mechanism.
Solution Approach 2:
The valve position sensor provides continuous feedback signals to the controller during installation. The controller uses this feedback to automatically determine valve parameters and verify correct configuration, ensuring reliability without requiring engineer expertise.
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 reducing the need for manual adjustments and minimizing operator intervention, thereby reducing the risk of errors and ensuring proper valve functionality through automated parameter determination and error detection.
Implementation Method 1
a first sensor (34) for providing a first sensor reading indicative of the position of the first disc (20)
Implementation Method 2
a first pilot valve (24) for energizing the actuator (14) by allowing a first pressurized fluid to enter the actuator (14) and for de-energizing the actuator (14) by allowing the first pressurized fluid to leave the actuator (14)
Data Source
Figure 1
Figure 2a~2e
Figure 3~5
AI summary
A valve controller (10) for controlling a valve (12) is disclosed. The valve controller has an actuator (14) and a flow controlling unit (16). The valve controller (10) is configured to execute a setup process and comprises a first pilot valve (24) that can energize the actuator by allowing a first pressurized fluid to enter the actuator and deenergizing the actuator by allowing the fluid to leave the actuator. The valve controller (10) further has an input device (66) by which the setup process can be initiated, and a memory unit (64) for storing setup parameter values. The setup process comprises: determining (102) one or more parameter values indicative of the functionality of at least one of the valve controller (10), the actuator and the flow controlling unit (16), and storing (104) the one or more parameter values as one or more setup parameter values in the memory unit (64).