Valve Actuator Position Encoder for Misalignment-Free Retrofitting
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Solution Overview
Problem
Existing actuating systems for valves are not suitable for retrofitting and are sensitive to magnetic interference, making it difficult to ensure correct alignment and functionality of position encoders during assembly.
Innovation Solution
An actuating system with a circular cylindrical position encoder made of electrically conductive material, which can be attached to the switching spindle and uses inductive sensors for position measurement, ensuring rotational symmetry and resistance to misalignment, and is insensitive to magnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a disc-shaped position encoder with coil and capacitor is attached to the switching spindle, then the valve can be retrofitted with an actuating system, but it requires correct alignment during assembly which cannot be directly checked
Solution Approach 1:
The position encoder is designed as a circular cylindrical component instead of a disc shape. This cylindrical geometry provides rotational symmetry around the switching spindle, eliminating the need for precise angular alignment during assembly. The encoder can be mounted at any rotational position and will function correctly, solving the alignment precision problem while maintaining retrofit capability.
Solution Approach 2:
The connecting part of the position encoder features an asymmetric design with a specific engagement geometry that ensures correct positioning along the axial direction of the switching spindle. This asymmetric connection ensures that the encoder is mounted at the correct position without requiring complex alignment procedures, combining the benefits of simple mounting with reliable positioning.
2Measurement precision
If magnets are arranged in the switching spindle for contactless measurement, then position can be measured without contact, but the system becomes sensitive to magnetic interference fields
Solution Approach 1:
The magnetic field-based position encoder is replaced with an inductive sensor system that uses electromagnetic induction principles. The inductive sensor detects changes in inductance caused by the position of the conductive cylindrical encoder, providing contactless position measurement without using magnets. This substitution eliminates sensitivity to external magnetic interference fields while maintaining measurement precision.
3Adaptability or versatility
If a position encoder is attached to the switching spindle by means of a connecting part, then it can function as an active position encoder, but faulty assembly cannot be detected directly
Solution Approach 1:
The cylindrical geometry of the position encoder provides inherent alignment features that make correct assembly visually verifiable. The symmetric cylindrical shape allows the installer to see that the encoder is properly positioned on the switching spindle, enabling direct visual detection of correct assembly without requiring functional testing or indirect verification methods.
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 reliable and accurate position determination of the valve without the risk of misalignment during assembly, even when rotated relative to the switching spindle, and is resistant to magnetic interference, making it suitable for both manufacturing and retrofitting applications.
Implementation Method 1
A movement of the switching spindle in parallel to the inductive sensor can then be measured inductively by the presence of the electrically conductive material in the position encoder
Data Source
AI summary
An actuating system for a valve which can be used as a control valve. The valve system having an outer housing, a receiving region for a switching spindle of the valve, at least one inductive sensor running in parallel to the receiving region, and at least one substantially circular cylindrical position encorder.