Control Valve Position Converter Using Magnetic Short-Stroke Sensing

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Solution Overview

Problem

Control valves in industrial processes face accuracy issues due to mechanical linkages that are bulky, prone to vibration, and extend beyond the structural envelope, leading to reduced process yields and increased maintenance costs.

Innovation Solution

A position transfer device that converts linear position to angular position using a compact, rotatable mechanism with a linearly translating shaft, integrating non-contact sensors like magnets to provide accurate and reliable position measurement, reducing backlash and fitting within the control valve's structural envelope.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional linkage mechanisms are used to measure component position, then the structural envelope can accommodate the measurement system, but the measurement accuracy deteriorates due to vibration and mechanical complexity

Engineering Contradiction:

Improveposition measurement accuracyVSAvoidmechanical linkage complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces conventional mechanical linkage mechanisms with a magnetic field-based measurement system. Magnets are positioned on the closure member and detected by sensors, eliminating mechanical linkages that are prone to vibration and wear. This substitution directly improves measurement accuracy while reducing mechanical complexity in the position measurement system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If conventional linkage mechanisms are used for position measurement, then the measurement system can be implemented, but the device becomes bulky and extends beyond the structural envelope

Engineering Contradiction:

Improveposition measurement capabilityVSAvoidmeasurement system volume

Core Design Contradiction:

Measurement precisionVSVolume of moving object

Solution Approach 1:

By replacing bulky mechanical linkages with compact magnets and sensors, the measurement system volume is dramatically reduced. The magnets can be mounted directly on the closure member and the sensors positioned close by, allowing the entire measurement system to fit within the control valve's structural envelope without extending outward.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnetic measurement components (magnets and sensors) are nested within the existing structural envelope of the control valve. The magnets are positioned on or near the closure member, and the sensors are integrated into the valve body, allowing the measurement system to be contained within the existing spatial boundaries rather than extending beyond them.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If mechanical linkages are used to convert linear position to angular position, then the position conversion can be achieved, but the system becomes susceptible to vibration and backlash

Engineering Contradiction:

Improveposition measurement reliabilityVSAvoidvibration and backlash effects

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent eliminates mechanical linkages that convert linear position to angular position by using a direct magnetic field measurement approach. Sensors detect the position of magnets on the closure member without requiring mechanical conversion mechanisms, thereby eliminating susceptibility to vibration and backlash while improving measurement reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enhances measurement accuracy, reduces maintenance complexity, and prevents wear and damage by maintaining precise closure member positioning, ensuring accurate flow regulation and extended valve lifespan.

Implementation Method 1

a linearly translating shaft that couples with a rotatable mechanism. In one implementation, this mechanism can register an angular position that correlates directly to the linear position of the shaft

Methodology Applied

Scientific EffectLinear to angular position conversion:

Implementation Method 2

Integrating non-contact sensors like magnets to provide accurate and reliable position measurement

Methodology Applied

Scientific EffectMagnetic field sensing: Magnetic Field

Data Source

PatentUS11454334B1Accuracy of control valves using a short-stroke position converter

Publication Date: 2022.09.27 DRESSER LLC

AI summary

A position transfer device is configured for use on a control valve. These configurations may convert a linear position of a closure member on the control valve to an angular position of magnets. A sensor in proximity to the magnets can generate a signal in response to the angular position. A valve positioner or controller can process the signal to identify the position of the closure member relative to a seat. In one implementation, the position transfer device includes a shaft that clamps onto a pin. This arrangement causes the pin to translate radially about an axis that is perpendicular to the shaft. The magnets move in response to the pin.