Valve Piston Position Monitoring With Redundant Hall Sensors
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Solution Overview
Problem
Existing valve devices lack reliable position monitoring for the valve piston, which can lead to malfunction and reduced diagnostic coverage, especially in fluid valves like hydraulic valves.
Innovation Solution
The implementation of a redundant sensor system using Hall sensors interacting with the motor and gear shafts, coupled with a two-stage planetary gear to reduce motor speed and enable fail-safe operation, along with independent housing units for enhanced retrofittability and diagnostic capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single sensor monitors the motor shaft position, then the device structure remains simple, but the position monitoring reliability is insufficient
Solution Approach 1:
The patent implements redundant sensor monitoring of the motor shaft position before failures can occur. By having multiple sensors (first and second sensors) monitor the same critical parameter, the system prepares in advance for potential sensor failures, ensuring continuous reliable position monitoring without requiring complex active redundancy management.
2Productivity
If the motor speed is high, then the productivity is improved, but the valve piston actuation reliability deteriorates due to insufficient speed reduction
Solution Approach 1:
The patent introduces an intermediary mechanism (rack and pinion gear system) between the high-speed motor and the valve piston. The motor shaft rotates a pinion gear that engages with a rack attached to the valve piston, providing mechanical speed reduction and motion conversion. This intermediary mechanism allows the motor to operate at high speeds for productivity while reliably actuating the valve piston at appropriate speeds.
3Loss of information
If redundant sensors are implemented for position monitoring, then the diagnostic coverage increases, but the device complexity increases
Solution Approach 1:
The patent makes the sensor system multi-functional by using the same sensors for both primary position monitoring and diagnostic coverage. The first and second sensors on the motor shaft not only provide continuous position feedback for control but also enable diagnostic functions such as detecting sensor failures, motor shaft malfunctions, and absolute position determination. This universal use of sensors maximizes diagnostic coverage without proportionally increasing system complexity.
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
This solution provides reliable position monitoring and increased diagnostic coverage, ensuring functional reliability and fail-safe operation of the valve device, even during dynamic movements and voltage loss, while allowing for direct system status display and central control integration.
Implementation Method 1
The sensor used in each case is a so-called Hall sensor, which is housed in the drive housing and interacts with the motor or gear shaft, which each have a permanent magnet for tapping the corresponding measured value.
Implementation Method 2
a planetary gear, preferably a two-stage planetary gear, is used as the gear for reducing the engine speed for driving the drive pinion for the rack and pinion drive of the valve piston between the engine and gear shaft
Implementation Method 3
a drive pinion which meshes with a rack which cooperates with the valve piston
Data Source
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AI summary
A valve device, consisting of at least one valve piston (2) which is arranged in a valve housing (4) so as to be able to move longitudinally and which, when moved by means of a drive (34) with an associated drivetrain (32), ensures that individual fluid ports (A, B, P, T) that are present in the valve housing (4) are either fluidically connected to one another or separated from one another, is characterized in that a sensor device (38) monitors the respective position of the drivetrain (32) and hence the respective position of the valve piston (2) in the valve housing (4).