Valve Position Sensing for Vibration-Resistant State Verification
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Solution Overview
Problem
Industrial facilities face challenges in accurately determining the state of manual valves due to human error, safety concerns, and regulatory compliance, especially under conditions like vibration, which can cause unintended adjustments, and there is a need for a more reliable method to measure and verify valve positions.
Innovation Solution
A device comprising a housing affixed to a valve handle with a sensor and indicator that moves relative to the sensor during valve operation, allowing for precise detection of the valve's state, including fully opened, fully closed, or intermediate positions, using additive manufacturing for customized and vibration-resistant designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual valve manipulation is used, then operation flexibility is maintained, but measurement accuracy and reliability deteriorate due to human error
Solution Approach 1:
The patent replaces manual mechanical observation of valve state with an automated sensor system. The sensor device detects valve position through mechanical coupling with the valve stem, converting mechanical position into detectable signals that are processed to determine valve state, thereby eliminating human error in measurement while maintaining the mechanical valve operation.
2Adaptability or versatility
If traditional valve monitoring methods are used, then simplicity is maintained, but adaptability to different valve designs deteriorates
Solution Approach 1:
The sensor device is designed with universal adaptability to work with multiple valve types including ball valves, gate valves, butterfly valves, and needle valves. The housing can be configured in different orientations and the sensor can detect various indicator positions, allowing one device design to serve multiple valve applications without requiring complete redesign for each valve type.
3Productivity
If fixed valve positions are maintained, then stability is improved, but productivity deteriorates due to recertification and recalibration requirements
Solution Approach 1:
The sensor device enables automatic self-verification of valve state without requiring external recertification or recalibration procedures. The continuous monitoring and detection capabilities allow the system to autonomously track valve position changes, eliminating the need for periodic manual verification and reducing downtime associated with maintenance activities.
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 solution provides non-intrusive, accurate, and real-time monitoring of valve states, reducing recertification and recalibration costs and downtime, while being adaptable to various valve designs and resistant to operational vibrations, thus enhancing safety and compliance.
Implementation Method 1
a sensor supported on the housing and configured to detect a position of the indicator to determine a state of the valve
Data Source
AI summary
A device for measuring a state of a valve may include a housing configured to connect to a handle of a valve or a body of a valve, a sensor supported on one of the housing or the valve stem, and an indicator detectable by the sensor. The indicator may be configured to move relative to the sensor in response to movement of a valve stem or valve handle during opening and closing of the valve. The sensor may be configured to detect a position of the indicator to determine a state of the valve. Related systems and methods are also described.