Valve Assembly Position Sensing for Drive Train Failure Detection

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Solution Overview

Problem

Existing valve assemblies fail to accurately detect the rotational position of the valve body within a fluid line, leading to latent failure modes due to actuator drive train issues, which are not detectable through electrical monitoring, and limit control to only open and closed positions, causing complexity and potential aircraft dispatch delays.

Innovation Solution

A valve assembly with a sensor positioned directly on the valve body to detect its rotational position independently of the actuator, combined with a computing device that compares commanded and sensed positions, and uses current sensors to determine the valve's state, enabling detection of drive train failures and intermediate positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the valve position is detected based on actuator voltage transition, then the valve assembly can be controlled to open and closed positions, but the detection precision is insufficient and cannot detect intermediate positions or drive train failures

Engineering Contradiction:

Improvevalve position detection precisionVSAvoidposition detection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces the electrical monitoring system with an optical sensing system. An optical encoder is mounted on the valve body to directly detect rotational position, substituting the indirect electrical voltage transition method with a direct optical measurement system that provides precise position feedback without relying on actuator electrical states

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates a redundant position detection system by mounting an optical encoder directly on the valve body, independent of the actuator's electrical monitoring system. This duplicate detection mechanism provides verification of actual valve position versus commanded position, enabling detection of drive train failures

Inventive Principle:

Principle #26Copying

2Reliability

If the valve position is implicitly derived from actuator voltage, then the system can operate with simple electrical monitoring, but it cannot detect drive train failures or intermediate positions

Engineering Contradiction:

Improvefailure detection capabilityVSAvoidvalve position measurement accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent implements a feedback mechanism where the optical encoder continuously monitors the actual valve position and compares it with the commanded position from the actuator. This closed-loop feedback system enables detection of discrepancies caused by drive train failures, mechanical binding, or intermediate positions, providing reliable failure detection while maintaining accurate position measurement

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent introduces an optical encoder as an intermediary device between the valve body and the control system. This intermediary component directly senses the valve's rotational position and transmits this information to the control system, enabling independent verification of valve position without relying on actuator electrical signals

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If maintenance activities and automated system tests are used to detect valve failures, then failure detection is possible, but system complexity and aircraft dispatch delays increase

Engineering Contradiction:

Improvefailure detection capabilityVSAvoidaircraft dispatch time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent implements preliminary action by continuously monitoring valve position through the optical encoder during normal operation, rather than waiting for maintenance activities or automated tests. This continuous preliminary detection capability identifies drive train failures and position discrepancies in real-time, enabling immediate awareness of valve issues without requiring scheduled maintenance interventions or causing dispatch delays

Inventive Principle:

Principle #10Preliminary action

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 allows for direct and accurate detection of valve position and drive train failures, enabling precise control of fluid flow and reducing aircraft dispatch delays by providing redundant position monitoring and failure detection.

Implementation Method 1

The sensor is an optical encoder connected directly to the valve

Methodology Applied

Scientific EffectOptical encoding: Optical Fibre

Data Source

PatentUS20240318744A1Valve Assembly Configured for Position and Control Within a Fluid Line

Publication Date: 2024.09.26 THE BOEING CO

AI summary

A valve assembly that controls a flow of fluid along a fluid line. The valve assembly includes a valve body sized to fit within the fluid line with the valve configured to rotate within the fluid line between an open position and a closed position. A drive shaft is connected to and extends outward from a first side of the valve body. An actuator is connected to the drive shaft and configured to rotate the valve between the open position and the closed position. A sensor is configured to sense a rotation position of the valve with the sensor positioned at a second side of the valve away from the actuator.