Valve Positioner Smart Board Assembly for Modular Function Expansion
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Solution Overview
Problem
Industrial valve assemblies face limitations in expanding functionality without incurring costly hardware and software changes, which can lead to downtime and increased complexity.
Innovation Solution
The integration of a 'smart' circuit board that couples with the main circuit board of valve assemblies, allowing for the addition of new features and functions without altering the existing hardware or software configuration, through data storage and communication interfaces that enable automatic implementation of new operating parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If new functionality is added to process devices through hardware and software changes, then device capabilities are improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The system is divided into a fixed main circuit board and a separate, interchangeable smart circuit board. The smart circuit board contains the configurable functionality and can be swapped without modifying the main board, thus adding adaptability while keeping the core device simple and manageable.
Solution Approach 2:
The smart circuit board is designed as a universal component that can provide multiple different functions depending on the software/firmware loaded. A single hardware platform can support various functionalities through software configuration, reducing the need for multiple specialized hardware designs.
2Adaptability or versatility
If hardware and software changes are made to improve device functionality, then new features are available, but manufacturing costs increase
Solution Approach 1:
By separating the configurable functionality into a distinct smart circuit board, the manufacturing process can standardize the main circuit board production while only needing to manufacture and stock the smaller, more versatile smart boards. This reduces overall manufacturing complexity and cost.
Solution Approach 2:
Instead of changing hardware parameters to add features, the system changes software/firmware parameters on the smart circuit board. This allows feature updates without re-manufacturing hardware, significantly reducing manufacturing costs for new features.
3Adaptability or versatility
If process devices are upgraded directly to the main circuit board, then new functionality is implemented, but downtime increases
Solution Approach 1:
The smart circuit board is designed as a removable module that can be quickly swapped out. When upgrading functionality, operators can simply replace the smart board rather than performing complex main board upgrades, minimizing downtime to just the time needed for board replacement and basic configuration.
Solution Approach 2:
Multiple smart circuit boards with different functionalities can be pre-configured and tested before installation. This preliminary preparation ensures that when a upgrade is needed, the new board is ready to install immediately, reducing the time the device remains non-operational.
4Ease of manufacture
If standard configuration is used for process devices, then manufacturing is simplified, but customization for specific applications becomes difficult
Solution Approach 1:
The system separates the standardized main circuit board from the customizable smart circuit board. The main board maintains a simple, standardized design for easy manufacturing, while the smart board can be configured with different software/firmware to meet specific application requirements, achieving both standardization and customization.
Solution Approach 2:
Instead of manufacturing custom hardware for each application, the system uses software copies or configurations on the smart circuit board to replicate different functionalities. This allows extensive customization without deviating from the standardized hardware manufacturing process.
Data Source
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AI summary
A board-level assembly (114) that is useful to expand functions of a valve positioner (100) on a valve assembly (102). The board-level assembly (114) can incorporate a main circuit board (116) and a smart circuit board (118). The main circuit board (116) may be configured to communicate with the smart circuit board (118), find a storage memory (160) on the smart circuit board (118), retrieve data from the storage memory (160), and use the data to configure functions on the main circuit board (116). In one implementation, the smart circuit board (118) can release and engage the main circuit board (116). This configuration can allow different configurations of the smart circuit board (118) to swap into the board-level assembly (114), each of the different configurations providing data the main circuit board (116) can exploit to change the functions of the valve positioner (100).