Non-Contact Valve Control via Motor Current Sensing
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Solution Overview
Problem
Existing valve operation systems require multiple wires for wiring between switches, batteries, and valves, and rely on physical contact-based limit switches, which are vulnerable to liquid exposure and complex to manage.
Innovation Solution
A micro-controller based control module that uses non-contact switching methods, such as capacitive or inductive sensing, to control a motor-driven valve, reducing the number of wires needed and eliminating the need for physical contact switches by monitoring motor current and time to determine valve position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical contact-based limit switches are used to control valve operation, then the valve can be operated reliably, but the system requires multiple wires and is prone to liquid exposure and mechanical failure
Solution Approach 1:
The patent replaces mechanical contact-based limit switches with a microcontroller-based control system that uses non-contact sensing methods. The microcontroller monitors motor current draw and operational parameters to detect valve position and control opening/closing operations, eliminating the need for physical contact switches and reducing wiring requirements to just power and control signal connections.
2Ease of operation
If physical contact switches are used for valve control, then the control mechanism is simple, but the switches are prone to liquid exposure and mechanical failure
Solution Approach 1:
The patent substitutes mechanical switches with a microcontroller-based electronic control system that determines valve position through motor current monitoring and operational timing. This eliminates mechanical contact components that are susceptible to liquid exposure and physical wear, while maintaining straightforward control through electronic signal processing.
3Reliability
If multiple wires are used for connecting switches, batteries, and valves, then the system can function properly, but the wiring becomes complex and prone to failure
Solution Approach 1:
The patent combines multiple control functions into a single microcontroller unit that integrates power management, motor control, and position sensing. This consolidation reduces the wiring from multiple separate connections to just power and control signal wires, simplifying the overall system architecture while maintaining full functionality.
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 solution enables reliable, efficient, and waterproof operation of valves with reduced wiring complexity and enhanced reliability by using non-contact switching and current sensing technology, allowing for precise control and alerting mechanisms for potential issues.
Implementation Method 1
The non-contact switching method of actuation may be in the micro-controller. The term 'non-contact' is understood to mean that there is no mechanical switching method. This can take the form of a capacitive, inductive, optic or other types of similar sensing method.
Implementation Method 2
This can take the form of a capacitive, inductive, optic or other types of similar sensing method.
Implementation Method 3
each time that the micro-controller turns on the motor it also begins to run a continuous subroutine to measure and monitor the current of the motor. Once the valve is completely closed or opened, the current of the motor increases up to a value that depends on the electrical parameters of the particular motor being used, that current is detected by the micro-controller
Data Source
AI summary
The present invention provides a control device featuring a control module featuring one or more modules configured to provide a first control signal for controlling a first device in order to open or close a second device; and also configured to respond to a change in a parameter sensed in relation to controlling the first device, and to provide a second control signal for controlling the first device based at least partly on the change in the parameter in relation to time. The first device may be a motor; the second device is a valve; and the parameter may be current. In operation, the first control signal is for turning on the motor in order to open or close the valve, and the second control signal is for turning off the motor in order to open or close the valve.