Discrete Valve Flow Conversion for Sensorless Hydronic Control
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Solution Overview
Problem
In hydronic systems, determining the flow rate of a valve without a flow meter or pump sensor is challenging, especially in dynamic environments where adaptive pressure control is needed, and existing technologies rely on costly installations and complex sensor systems.
Innovation Solution
A discrete valve flow rate converter that uses differential pressure and hydronic characteristics calibration data to calculate the flow rate through a signal processor, enabling accurate flow rate determination and control across various valve positions, employing a 3D discrete distribution function and numerical interpolations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If flow meters or pump sensors are installed to determine flow rate, then measurement precision is improved, but device complexity and installation cost increase
Solution Approach 1:
The patent extracts the flow rate measurement capability from traditional flow meters and pump sensors by using only differential pressure sensors across the valve. The flow rate is derived mathematically from pressure measurements and valve characteristics, eliminating the need for dedicated flow measurement devices.
Solution Approach 2:
The patent introduces valve characteristics calibration data as an intermediary element that links differential pressure measurements to flow rate determination. This calibration data serves as a mediator that enables flow rate calculation without direct flow measurement, resolving the contradiction between measurement accuracy and system simplicity.
2Reliability
If traditional sensor systems are used for flow rate determination, then reliability is improved, but loss of substance and installation cost increase
Solution Approach 1:
The system uses existing differential pressure sensors that are already installed for valve control purposes. By leveraging these existing sensors and combining them with valve characteristics data, the system determines flow rate without requiring additional measurement devices, thereby reducing installation costs while maintaining reliability.
3Use of energy by moving object
If adaptive pressure control is implemented without flow rate data, then energy efficiency is improved, but measurement precision deteriorates
Solution Approach 1:
The patent replaces direct mechanical flow measurement with a computational approach. By substituting physical flow meters with mathematical calculations based on pressure measurements and valve characteristics, the system achieves the precision needed for adaptive pressure control without the complexity and cost of traditional measurement systems.
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 precise and automatic control of valve flow rates in hydronic systems without the need for flow meters or sensors, improving energy efficiency and reducing installation costs by accurately determining flow rates across different valve positions.
Implementation Method 1
receive signaling containing information about a differential pressure sensed across a valve in an open position
Data Source
AI summary
A discrete valve flow rate converter is provided to obtain a system flow through a valve in a dynamic hydronic pumping system, e.g., based on signaling containing information about the valve's differential pressure and the valve's hydronic characteristics calibration data. The discrete valve flow rate converter resolves the valve system flow rate directly and accurately with the valve's open position and the corresponding valve differential pressure signals associated therewith. The discrete valve flow rate converter may be applied to all kinds of valves as long as their open position and differential pressure associated with is available, e.g., including implementations for control valve applications, e.g., where the valve open position is controlled automatically and accurately, as well as implementations either for pumping system pressure controls with the flow rate known, such as adaptive hydronic system pressure controls, or as an alternative to sensorless pump monitoring and control.