Valve Positioner Assembly With Rotary Sensing for Long-Stroke Alignment
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Solution Overview
Problem
Existing valve positioners face issues such as pinch points, physical damage from environmental exposure, and misalignment, leading to malfunctions and increased maintenance costs due to inaccurate readings.
Innovation Solution
A positioner assembly with a rotatable element and follower system that converts linear movement of the valve stem into rotational movement, allowing for precise position sensing using sensors, and is designed to be robust and compact with reduced pinch points and minimal interference with adjacent structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the positioner is mounted on the outside of the actuator with a transmitter on the sliding stem, then the position sensing function is achieved, but pinch points are created in the wiring and the receiver is exposed to physical damage from environmental factors
Solution Approach 1:
The patent integrates the transmitter and receiver into a single unified positioner assembly that is mounted directly on the actuator body. This merging eliminates the need for separate external mounting and wiring connections, thereby removing pinch points and protecting the sensing components from environmental damage while maintaining position sensing functionality.
Solution Approach 2:
The patent introduces a magnetically coupled transmission system as an intermediary between the moving valve stem and the stationary positioner. Magnetic coupling allows signal transmission without physical wire connections, eliminating pinch points in the wiring and providing electrical isolation that protects the receiver from environmental factors.
2Ease of manufacture
If the receiver is mounted onto the housing using simple brackets, then the installation is simple, but misalignment occurs leading to inaccurate readings
Solution Approach 1:
The patent designs the positioner assembly with built-in alignment features that ensure the transmitter and receiver are positioned at equivalent alignment levels. This eliminates misalignment issues while maintaining simple installation, as the alignment is achieved through the design itself rather than complex adjustment mechanisms.
Solution Approach 2:
The positioner assembly incorporates self-aligning features such as keyed mounting positions and rigid internal structures that automatically ensure proper alignment during installation. This eliminates the need for complex external alignment mechanisms while maintaining installation simplicity and reading accuracy.
3Device complexity
If a sliding stem valve configuration is used, then the valve structure is simple, but the positioner requires extensive space and volume for long stroke actuators
Solution Approach 1:
The patent nests the transmitter and receiver components within a compact positioner assembly that is mounted directly on the actuator body. This nested configuration allows the positioner to occupy minimal space while still accommodating long stroke actuators, as the sensing components are integrated into the existing actuator structure rather than requiring additional external volume.
Solution Approach 2:
The patent transitions from a linear wiring arrangement to a three-dimensional magnetic coupling field for signal transmission. This dimensional change allows the positioner to sense valve position without requiring extensive linear space, as the magnetic field can penetrate through the actuator structure in multiple directions simultaneously, reducing the overall volume requirement.
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 accurate and reliable position sensing with reduced maintenance needs, improved durability, and enhanced safety in harsh environments, while accommodating valve actuators with long strokes without requiring extensive space or volume.
Implementation Method 1
A rotatable element of the positioner assembly is configured to rotate about a second axis of movement, where the first axis of movement is substantially parallel to the second axis of movement
Implementation Method 2
at least one position sensor coupled to the rotatable element that is configured to sense an angular position of the rotatable element
Data Source
AI summary
Positioner assemblies may be configured to sense at least one position of at least a portion of a valve assembly that is moved along a first axis of movement. A movable element of the positioner assembly is configured to rotate about a second axis of movement, where the first axis of movement is substantially parallel to the second axis of movement. Valve systems and methods of sensing a position of a component of a valve system may include such a positioner assembly.