Valve Assembly Position Sensing for Intermediate Flow Control
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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, preventing detection of intermediate positions.
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 verify the actuator's state, allowing for precise control of intermediate positions and failure detection.
Engineering Contradictions & Design Principles
Engineering 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 intermediate positions cannot be determined
Solution Approach 1:
The patent replaces the electrical monitoring system with an optical sensing system. An optical encoder is used to directly detect the rotational position of the valve body, substituting the indirect electrical voltage transition method with a direct optical measurement system that provides precise positional feedback.
Solution Approach 2:
The patent introduces an optical encoder as an intermediary component between the valve body and the control system. This encoder serves as a mediator that converts mechanical rotational position into optical signals, enabling precise detection of valve position including intermediate positions without directly modifying the valve body structure.
2Reliability
If the valve position is implicitly derived from actuator voltage, then the system structure remains simple, but latent failure modes cannot be detected
Solution Approach 1:
The patent implements a feedback mechanism where the optical encoder continuously monitors the actual rotational position of the valve body and provides real-time positional feedback to the control system. This feedback loop enables detection of discrepancies between commanded and actual positions, allowing identification of drive train failures and ensuring reliable operation.
3Reliability
If maintenance activities and automated system tests are used to confirm valve operation, then failure detection is possible, but system complexity increases and aircraft dispatch delays occur
Solution Approach 1:
The patent enables the valve assembly to perform self-diagnosis through the optical encoder's continuous monitoring capability. The system automatically detects its own operational status and failure conditions in real-time during normal operation, eliminating the need for separate maintenance activities and automated system tests that would cause aircraft dispatch delays.
Data Source
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AI summary
A valve assembly (20) that controls a flow of fluid along a fluid line (100). The valve assembly includes a valve body (21) sized to fit within the fluid line with the valve (22) configured to rotate within the fluid line between an open position and a closed position. A drive shaft (24) 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 (40) 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.