Actuated Valve Failure Detection Using Step Response Analysis
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Solution Overview
Problem
Existing methods for detecting valve failures in safety-critical applications, such as gas turbine engines, are either costly due to the need for acoustic transducers, unreliable due to reliance on compressor behavior, or limited in applicability to specific valve types, and often fail to accurately distinguish genuine valve failures from spurious readings.
Innovation Solution
A method that determines and compares calibration and in-use step or frequency responses of actuated components, such as valves, to detect failures without relying on other system components, using signal processing like fast Fourier transforms and software implementation to identify shifts in resonant frequencies or inertia changes, thereby reducing the likelihood of spurious failure detection and eliminating the need for additional hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If acoustic transducers (microphones) are used to detect valve failures by measuring noise generated by fluid flow, then failure detection capability is improved, but cost and weight increase
Solution Approach 1:
The patent replaces acoustic transducers (acoustic field) with a pressure sensor and controller system (mechanical/electrical field) to detect valve failures. The controller generates a step input signal to the valve and measures the resulting pressure response, analyzing it to detect failures. This substitution eliminates the need for acoustic transducers, reducing cost and weight while maintaining failure detection capability.
2Reliability
If acoustic transducers are used to detect valve failures, then failure detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex acoustic transducer systems with a simpler pressure sensor and controller system. The controller acts as both the actuator and sensor, generating test signals and measuring pressure responses. This integration reduces device complexity and eliminates the need for separate acoustic transducers.
Solution Approach 2:
The controller serves multiple functions: it acts as the actuator to open/close the valve, generates the step input signal for testing, measures the pressure response, and analyzes the response to detect failures. This multi-functionality reduces the number of components needed and simplifies the overall system.
3Reliability
If compressor pressure spikes are monitored to detect bleed valve activation, then failure detection is possible, but the method is limited to specific valve types and applications
Solution Approach 1:
The patent creates a universal failure detection method that can be applied to any two-position valve in any application. The controller generates a step input signal to the valve and measures the pressure response, analyzing it to detect failures. This approach is not limited to bleed valves in gas turbine engines but can be used for any valve where the controller can generate test signals and measure responses, significantly increasing adaptability.
4Reliability
If compressor behavior is monitored to detect valve failures, then failure detection is possible, but spurious detections occur due to unrelated disturbances
Solution Approach 1:
The patent extracts the failure detection function from the broader compressor system behavior and isolates it to the valve itself. By applying a step input signal directly to the valve and measuring its specific pressure response, the method focuses on valve-specific behavior rather than overall compressor behavior. This isolation eliminates spurious detections caused by unrelated disturbances in the compressor system.
Solution Approach 2:
The patent uses feedback by monitoring the pressure response of the valve to the step input signal and comparing it against expected behavior. The controller analyzes the response to detect failures, providing direct feedback on valve performance. This feedback mechanism is specific to the valve being tested, not the entire compressor system, reducing false detections.
Data Source
AI summary
A method and arrangement for detecting failure of an actuated component, particularly a valve. The method comprises determining a calibration step response and an in-use step response for the actuated component, determining any difference between the responses and comparing the difference to a pre-determined threshold indicating failure.