Valve Position Indicator Using LED Array and Mirror
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Solution Overview
Problem
It is difficult to determine the position of valves, such as ball, butterfly, needle, and gate valves, from the location of their actuators, leading to a need for an improved valve position indicator that effectively communicates the valve's position.
Innovation Solution
A valve position indicator system that includes an indicator cover with an array of LED lights and a mirror, coupled with a sensor that communicates the valve's position to the LED lights, allowing them to illuminate and indicate whether the valve is open or closed, and the direction of opening or closing, using color and incremental lighting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If traditional valve actuators are used without position indicators, then the device complexity is reduced, but the ability to determine valve position becomes difficult
Solution Approach 1:
The patent introduces an intermediary indicator system that includes LED lights, a mirror, and a diffuser positioned between the actuator and the observer. This intermediary converts the mechanical position information into visible optical signals without requiring direct observation of the actuator mechanism, thereby solving the information loss problem while maintaining manageable system complexity.
Solution Approach 2:
The patent replaces traditional mechanical position indicators with an optical system using LEDs and a mirror. This substitution eliminates complex mechanical linkages and moving parts, reducing device complexity while improving the reliability and clarity of position information transmission through optical fields instead of mechanical fields.
2Illumination intensity
If simple position indicators are used, then the device complexity is reduced, but the illumination intensity and visibility are insufficient
Solution Approach 1:
The patent employs a mirror positioned at a 45-degree angle to redirect light from the LEDs located on the actuator shaft into the observer's line of sight. This dimensional change in light propagation direction allows the indicator to be visible from the front without requiring the LEDs to face directly outward, thereby achieving high illumination intensity while maintaining a compact and simple structure.
Solution Approach 2:
The patent uses color-coded LED lights to indicate different valve positions and states. By assigning specific colors to different operational states (e.g., green for open, red for closed), the system achieves high visibility and intuitive information transmission without requiring complex mechanical indicators or high-intensity single-color lighting, thus balancing illumination intensity with system simplicity.
3Measurement precision
If multiple LED lights are used to indicate incremental position, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The patent divides the valve position indication into discrete segments using multiple LEDs arranged in a circular pattern. Each LED represents a specific angular position or state, allowing the system to indicate incremental position changes with high precision. This segmentation approach converts continuous mechanical rotation into discrete, easily interpretable optical signals, achieving measurement precision while keeping the LED array configuration simple and manageable.
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
The system provides clear and effective indication of the valve's position, allowing operators to easily determine if the valve is open or closed and the direction of change, enhancing operational safety and efficiency.
Implementation Method 1
a mirror mounted internal and concentric to the indicator cover
Implementation Method 2
an array of LED lights arranged on the indicator mounting surface
Data Source
AI summary
A valve in conjunction with an actuator has a valve position indicator coupled to the actuator. The valve position indicator has an indicator cover mounted over an indicator mounting surface, an array of LED lights arranged on the indicator mounting surface, and a mirror mounted internal and concentric to the indicator cover. A sensor in communication with the actuator and the plurality of LED lights communicates the position of the valve to the plurality of LED lights. The plurality of LED lights may illuminate to indicate an incremental degree that the valve is open, if any, and/or indicate by color the direction that the opening (or respective closing) of the valve is changing. In another embodiment with or without the mirror equiangular spaced single points of light each have one high intensity LED oriented to emit light horizontally and one high intensity LED oriented to emit light vertically.