Valve Flow Sensor Integration for Threshold-Based Flow Control
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Solution Overview
Problem
Existing valve actuators in fluid systems face accuracy issues due to discrepancies between expected and actual flow rates, leading to increased power consumption and wear when using feedback mechanisms for continuous adjustments, and existing calibration methods may not provide the most suitable characteristic curve over the entire range of valve openings.
Innovation Solution
An actuator and method that utilize a modified characteristic curve, calculated as a function of a basic characteristic curve and measured flow rate, to regulate valve openings, with adjustments made only when the difference between measured and design flow rates exceeds a threshold, reducing frequent adjustments and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If continuous feedback adjustments are made using flow sensor data, then flow rate accuracy is improved, but power consumption increases and actuator wear increases
Solution Approach 1:
The patent applies periodic action by implementing threshold-based triggering for characteristic curve updates. Instead of continuous real-time adjustments, the system periodically recalibrates the characteristic curve only when the difference between measured and expected flow rates exceeds a predetermined threshold. This reduces the frequency of actuator adjustments and sensor readings, thereby lowering power consumption and actuator wear while maintaining acceptable flow rate accuracy over time.
2Measurement precision
If continuous feedback adjustments are made using flow sensor data, then flow rate accuracy is improved, but actuator wear increases
Solution Approach 1:
The system implements periodic calibration actions triggered by threshold exceedances rather than continuous adjustments. The actuator only moves to recalibrate the characteristic curve when necessary, significantly reducing the number of operational cycles and mechanical wear events, thereby extending actuator lifespan while maintaining flow rate accuracy within acceptable bounds.
Solution Approach 2:
The patent uses feedback from the flow sensor to detect deviations between measured and expected flow rates. This feedback mechanism triggers selective recalibration actions only when the deviation exceeds a threshold, rather than initiating continuous adjustment cycles. This intelligent feedback approach maintains accuracy while minimizing actuator intervention frequency.
3Measurement precision
If calibration is based on changing actuator settings at periodical intervals, then flow rate accuracy is improved, but the characteristic curve may not be suitable over the whole range of valve openings
Solution Approach 1:
The patent applies local quality by implementing threshold-based triggering for characteristic curve updates. Instead of continuous real-time adjustments, the system periodically recalibrates the characteristic curve only when the difference between measured and expected flow rates exceeds a predetermined threshold. This reduces the frequency of actuator adjustments and sensor readings, thereby lowering power consumption and actuator wear while maintaining flow rate accuracy over time.
Data Source
AI summary
An actuator (3) for regulating a valve (1) in a fluid system is adapted to operate according to a characteristic curve (4) containing information correlating a valve opening with a flow through the valve (1) and to a flow rate measured by a flow measuring device (5), wherein, the regulation of the valve (1) is based on a modified characteristic curve (4M) that is based on a basic characteristic curve (4B) and the measured flow rate by the flow measuring device (5) compared to a design flow rate. The disclosure further relates to the method of controlling the valve.