Valve Controller Self-Configuration for Pilot Valve Tolerance Setting
Find Innovative SolutionsGenerate Solutions
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, making it difficult to ensure proper operation and timely fault detection.
Innovation Solution
A valve controller that automatically configures itself by determining a tolerance criterion based on the number of pilot valves connected, allowing for simplified configuration and operation across various valve types, with a configuration phase that sets flow controlling elements in predefined states to acquire nominal position values and define acceptable position ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a generic valve controller is used with different types of valves, then versatility is improved, but configuration complexity increases due to type-specific validation criteria
Solution Approach 1:
The valve controller automatically detects the valve type through the detection circuitry and selects the appropriate validation criterion without requiring manual operator input. The system performs self-configuration by identifying the number of pilot valves and autonomously determining the correct validation logic, thereby eliminating the need for operators to manually configure type-specific parameters.
Solution Approach 2:
The patent replaces manual mechanical configuration processes with an automated detection and selection system. The detection circuitry automatically identifies valve characteristics and the control unit programmatically selects validation criteria, substituting the previous manual mechanical approach of physically configuring the controller for different valve types.
2Measurement precision
If manual configuration of validation criteria is required, then measurement precision is improved, but installation time increases
Solution Approach 1:
The valve controller pre-stores multiple validation criteria corresponding to different valve types in its memory. During installation, the system automatically retrieves and applies the appropriate pre-configured validation criterion based on detected valve characteristics, eliminating the need for operators to manually search and configure the correct validation parameters during installation.
3Reliability
If type-specific validation criteria are used, then fault detection accuracy is improved, but device complexity increases
Solution Approach 1:
The valve controller is designed as a universal multi-functional device that can handle multiple valve types through a single integrated control unit. The detection circuitry and programmable control unit work together to automatically adapt the controller's validation logic to match the specific valve type, allowing one controller design to serve multiple functions across different valve configurations.
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A valve controller (102, 202, 302, 402) for a valve (101, 201, 301, 401) that comprises an actuator (11) mechanically coupled to at least one flow controlling element (7). The valve controller (102, 202, 302, 402) comprises at least one pilot valve (25, 37, 72) for controlling the position of the flow controlling element(s) (7) by means of the actuator (11). The valve controller (102, 202, 302, 402) comprises a position sensor (26) for obtaining a position signal indicative of the position of one of said at least one flow controlling element (7). The valve controller (102, 202, 302, 402) is configured to execute a configuration phase comprising establishing a pilot valve integer corresponding to number of pilot valves (25, 37, 72), and determining a tolerance criterion (ΔP1, ΔP2) for the position signal based on the pilot valve integer. A valve arrangement comprising the valve controller (102, 202, 302, 402) and a valve (101, 201, 301, 401). A method of controlling a valve (101, 201, 301, 401) comprising the configuration phase.