Valve Manifold Driver Zoning for Selective Safety Shutdown
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Solution Overview
Problem
Current fieldbus controllers for valve manifolds have limitations in powering and addressing valve drivers, leading to inefficiencies and safety issues, such as the need for single power inputs and addresses, which restrict the distribution of drivers among valves and result in entire manifold shutdowns during safety events.
Innovation Solution
A system with separate power sources for each valve driver, using a power board with distinct V+ and V- pins, allowing individual power control and addressing of valve drivers, and a safety module for precise shutdowns, enabling independent operation of valve zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single power input is used for all valve drivers, then the device complexity is reduced, but the adaptability and flexibility in distributing drivers among valves deteriorates
Solution Approach 1:
The power input structure is segmented into multiple independent power inputs, with each valve driver having its own dedicated power input. This segmentation allows flexible distribution of drivers among valves without increasing overall system complexity, as each driver can be independently configured and powered.
2Measurement precision
If safety zones cover small groups of valves on the manifold, then the precision of shutdown control is improved, but the system fails to separately power or control the drivers, acting merely as an emergency stop
Solution Approach 1:
The system segments both the valve groups into safety zones and the driver power supply into independent zones. Each driver has its own power input that can be independently controlled, allowing precise shutdown of specific drivers while maintaining operation of others, rather than treating the entire manifold as a single unit.
Solution Approach 2:
The controller acts as an intermediary between the safety zone configuration and the driver power inputs. It receives safety zone information and selectively controls power distribution to individual drivers based on which zones need to be shut down, enabling both precise shutdown control and independent driver operation.
3Reliability
If the controller shuts off the entire valve manifold during a safety event, then safety is ensured, but backups occur and system productivity is reduced
Solution Approach 1:
The valve manifold is segmented into multiple independently powerable zones corresponding to safety zones. During a safety event, only the drivers in the affected zone are shut off while other zones can continue operating, maintaining productivity while ensuring safety in the problematic area.
Solution Approach 2:
The system applies local quality control by allowing different operational states for different zones based on local safety conditions. Each zone can be independently shut down or continued based on its specific safety requirements, rather than applying a uniform shutdown to the entire manifold.
4Adaptability or versatility
If numerous systems are used for addressing new valves in a manifold, then addressing capability is improved, but the addresses are not adaptable for splitting among valve drivers
Solution Approach 1:
The addressing system is segmented to work with individual drivers rather than treating the manifold as a single unit. Each driver has its own addressable space and can be independently configured, allowing addresses to be split and distributed among multiple drivers according to the specific application needs.
Data Source
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AI summary
A valve driver system for driving a plurality of valves of a valve manifold. The system includes a plurality of valve drivers, wherein each valve driver is configured to drive a zone of one or more valves of the manifold; and, a power board that separately powers the respective valve drivers such that the valve drivers are powered separately with a separate power source that can individually power the valve driver. A multiple safety zone valve driver system for driving a plurality of valves of a valve manifold. The system includes a plurality of valve drivers; a first safe PM output; and a second safe PM output. The first and second safe PM outputs are configured such that in response to a first type of safety event the first PM output shuts off power to the first one or more valve drivers and the second PM output maintains power to the second one or more valve drivers. A zoning adapter for adapting logical addresses of valve drivers to physical addresses of valves of a valve manifold. A conversion portion converts logical addresses to physical addresses of the valves in the different zones of the valve manifold with a spacing in one or more portions of the logical addresses.