Valve Position Sensing by Rotation Calibration Across Valve Types
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Solution Overview
Problem
Existing valve systems lack a universal method to determine the open/close status of valves, especially in diverse makes and models, as existing solutions require specific valve types and are inefficient in tracking multiple valves scattered over large areas.
Innovation Solution
A method involving a sensor system that connects to the operating device, calibrates by storing extreme positions, and detects rotation angles and directions to determine the blocking element's position, allowing the system to be used on any valve type and easily retrofitted, with features like wireless communication and power management for remote installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a position indicator with communication element is provided for each specific valve type, then the open/close status can be detected and communicated, but the system complexity increases and adaptability decreases due to needing different designs for different valve makes and models
Solution Approach 1:
The sensor system is designed as a universal solution that can be applied to multiple valve types (gate valves, ball valves, butterfly valves, plug valves) through a standardized calibration process. The system detects rotation angles and directions generically, then calibrates by storing extreme positions specific to each valve installation, enabling one sensor design to serve multiple valve makes and models without requiring valve-specific customization
2Measurement precision
If a valve-specific position indicator system is designed, then the detection accuracy for that valve type is improved, but the device complexity and installation difficulty increase
Solution Approach 1:
A single sensor system design with universal mounting capabilities is used across different valve types. The system includes a sensor for detecting rotation angle and direction, a memory for storing calibration data, and a processor for determining valve status. This standardized design reduces device complexity compared to valve-specific indicators while maintaining detection accuracy through calibration
Solution Approach 2:
The system adapts to different valve types by changing operational parameters through calibration. During calibration, the system rotates the operating device to detect extreme positions (fully open and fully closed states) and stores these reference positions in memory. This parameter adjustment allows the same hardware to accurately measure different valve configurations without redesign
3Device complexity
If traditional visual detection methods are used for valve status, then no additional equipment is needed, but the ability to track valve status from a distance or in large areas is lost
Solution Approach 1:
The sensor system acts as an intermediary between the valve operating device and the external monitoring system. It detects the rotation angle and direction of the operating device, processes this information to determine valve status, and communicates the results externally. This intermediary approach enables remote monitoring of valve status without requiring direct visual access to the valve, solving the problem of tracking scattered valves over large areas
Data Source
AI summary
A method for determining a position of a blocking element in a valve having an operating device configured so that the blocking element moves between an open and a closed position in dependency of the direction in which the operating device is rotated. A sensor system is also provided for detecting a position of a blocking element in a valve.