Integrated Valve Electronics for Wear Intensity Diagnosis
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Solution Overview
Problem
Existing valve arrangements lack efficient mechanisms for early detection and indication of wear or imminent malfunction, leading to potential sudden failures and high costs associated with machine or installation downtime.
Innovation Solution
Incorporating a diagnostic module within the valve electronics that senses actuation parameters and forms diagnostic parameters to measure the intensity of use over time, using a sensing device and diagnosis-forming device to evaluate wear and potential malfunctions, which can be implemented as an analog, digital, or microcontroller-based system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a diagnostic module is added to the valve electronics, then early detection of wear and malfunctions is enabled, but device complexity increases
Solution Approach 1:
The diagnostic module is merged with the existing valve electronics control unit, combining diagnostic functions with the amplifier and control circuitry into a single integrated housing. This eliminates the need for separate diagnostic hardware and reduces overall system complexity while maintaining reliability benefits.
Solution Approach 2:
The control unit is designed to perform multiple functions: it controls the amplifier unit for valve actuation, processes encoder signals for position feedback, and simultaneously executes diagnostic routines to monitor wear and detect malfunctions. This multi-functionality reduces the need for additional dedicated components.
2Measurement precision
If actuation parameters are sensed and evaluated continuously, then wear intensity is accurately measured, but energy consumption increases
Solution Approach 1:
The diagnostic module performs periodic evaluation of actuation parameters rather than continuous monitoring. The control unit samples parameters such as current, voltage, and position at defined intervals to calculate wear intensity, reducing computational load and energy consumption while maintaining sufficient measurement precision for wear detection.
3Manufacturing precision
If a closed-loop control unit with position encoder is used, then piston position accuracy is improved, but device complexity increases
Solution Approach 1:
The position encoder and closed-loop control unit are integrated into the same housing as the amplifier and diagnostic module. The encoder signals are processed directly within the control unit without requiring external processing hardware, reducing system complexity while maintaining high position accuracy for wear measurement.
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
Enables early detection of wear and potential malfunctions, allowing operators to take preventative measures and prevent failures, with the diagnostic module using existing hardware to form informative diagnostic parameters that can be calculated and communicated efficiently.
Implementation Method 1
a valve with at least one activation magnet which is arranged on the valve, for activating a piston of the valve
Implementation Method 2
The flow of electrical current through the proportional magnet is generally formed by the duty cycle of a pulse-width modulation process of the supply voltage
Data Source
AI summary
Valve electronics include a control unit with a diagnostic module. The diagnostic module has a sensing device configured to sense at least one actuation parameter. The diagnostic module also has a diagnosis-forming device that forms a diagnostic parameter from the sensed actuation parameter such that the diagnostic parameter corresponds to a measure for the intensity of use of the valve over a preceding time period.