Valve Controller Self-Setup for Faster Error-Resistant Installation
Find Innovative SolutionsGenerate Solutions
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, which increases the risk of errors and requires significant engineer handling.
Innovation Solution
A valve controller with a memory unit and setup process that allows for autonomous parameter determination and storage, using sensor readings to simplify the installation process, reducing reliance on engineer handling and minimizing error risks, and includes features like manual override and error indication for operator awareness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual adjustments and pairings are performed for each valve controller 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 parameters by reading sensor signals from the valve during operation. The control unit reads sensor signals at different operating states (open/closed positions) and autonomously determines parameters such as sensor type, active polarity, and signal thresholds without requiring manual configuration by an engineer.
Solution Approach 2:
The valve controller performs automatic parameter determination and storage during the installation phase before actual operation begins. The system executes a setup routine that automatically configures all necessary parameters, eliminating the need for subsequent manual adjustments and reducing installation complexity.
2Reliability
If manual adjustments and pairings are performed for each valve controller installation, then the valve controller can be properly configured for specific valves, but the risk of installation errors increases
Solution Approach 1:
The automatic parameter determination process eliminates human intervention in the configuration process, removing the source of manual errors. The valve controller autonomously reads sensor signals, determines parameter values, and configures itself, ensuring consistent and error-free installation.
Solution Approach 2:
The system uses feedback from sensor readings at different valve positions to automatically determine correct parameter values. By monitoring the actual sensor signals during operation and comparing them against expected patterns, the system self-configures with high accuracy without relying on manual setup.
3Reliability
If extensive engineer handling is required for valve controller installation, then proper configuration can be achieved, but the complexity and resource requirements increase
Solution Approach 1:
The valve controller performs self-configuration by automatically reading sensor signals and determining its own parameters. This eliminates the need for engineers to perform manual adjustments, pairings, and configurations, significantly reducing installation complexity while maintaining configuration accuracy.
Solution Approach 2:
The system automatically completes all configuration tasks during the initial installation phase through automated parameter determination. This preliminary automatic configuration eliminates the need for subsequent manual intervention, simplifying the overall installation process and reducing engineer involvement.
Data Source
Figure 1
Figure 2a~2e
Figure 3~5
AI summary
A valve controller (10) for controlling a valve (12) and a valve (12) comprising the valve controller (10) are disclosed. The valve 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 de-energizing 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) 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 parameter values as setup parameter values in the memory unit (64).