Integrated Valve Position Sensor for Compact Quarter-Turn Taps
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Solution Overview
Problem
Existing solutions for detecting and signaling the position of rotating quarter taps are inefficient due to indirect position indication, mechanical failures, excessive footprint, and wiring errors in industrial settings, particularly in confined spaces like pharmaceutical and agro-food industries.
Innovation Solution
A thin, non-torque-transmitting position sensor is integrated into the ring portion of the wafer and target holder, allowing direct detection of the tap shutter position without modifying the valve or actuator, using contactless and parasitic-free rotation detection, and transmitting signals through a resin-protected printed circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If position detectors are added to maneuvering members as accessories, then position indication capability is improved, but device footprint becomes excessive and installation complexity increases
Solution Approach 1:
The position detection system is merged directly into the valve body structure. The detection element is integrated into the valve body at the location where the quarter turn indicator protrudes, eliminating the need for separate accessory detectors on maneuvering members. This reduces overall device footprint while maintaining position indication capability.
Solution Approach 2:
The detection element serves multiple functions: it detects the position of the shutter directly, provides visual indication through the quarter turn indicator, and works with any type of maneuvering member (handle, manual demultiplier, pneumatic actuator, hydraulic actuator, or electric actuator) without requiring modification to the valve or actuator.
2Difficulty of detecting and measuring
If position detectors are added as accessories on maneuvering members, then position detection is enabled, but the number of mechanical parts increases leading to higher failure risk
Solution Approach 1:
The invention extracts the position detection function from the maneuvering member and its associated mechanical transmission parts. By detecting the position directly on the maneuver shaft where the shutter is attached, the system eliminates the need for intermediate mechanical parts (gears, linkages, etc.) that could fail, while maintaining accurate position detection capability.
Solution Approach 2:
The patent replaces mechanical position indication systems with a detection element that directly senses the position of the maneuver shaft. This substitution eliminates complex mechanical part chains that transmit position information, thereby reducing the number of potential failure points while maintaining detection accuracy.
3Difficulty of detecting and measuring
If multiple position detectors are installed on various faucets in confined spaces, then position monitoring is achieved, but wiring complexity and connection time increase significantly
Solution Approach 1:
The invention extracts the position detection function from complex accessory systems and integrates it directly into the valve body. This simplification reduces the number of electrical connections required, as the detection element is built-in and requires minimal wiring compared to separate accessory detectors that need to be mounted on maneuvering members.
4Measurement precision
If detection systems are integrated into the valve structure, then position detection accuracy is improved, but manufacturing complexity increases
Solution Approach 1:
The detection element is designed as a separate, modular component that can be independently manufactured and then integrated into the valve body. This segmentation allows for specialized manufacturing of the detection element using appropriate techniques while keeping the overall valve manufacturing process relatively simple and modular.
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 provides a compact, reliable, and cost-effective position detection system that minimizes mechanical failures and wiring errors, ensuring accurate position indication without altering the valve's connection or drive modes, suitable for various actuator types.
Implementation Method 1
The detectors can preferably be Reed bulbs or hall effect sensors, the target being in this case a magnet
Data Source
Figure 1
AI summary
Valve comprising a shutter (2) rotating as one (A) with a shaft (3) and a sensor sensing the rotational position of the shaft (3), which comprises a target holder (4a) push-fitted onto the shaft (3), a plate (6) slipped onto the shaft (3), the target holder (4a) and the annular part (6a) being in one and the same plane.