Valve Position Sensor Assembly With Rollers to Reduce Magnetic Hysteresis
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Solution Overview
Problem
Conventional fluid control valve systems in hydrocarbon well systems experience delays and inaccuracies in position sensing due to magnetic hysteresis and friction, requiring frequent recalibration, which affects operational efficiency and costs.
Innovation Solution
The implementation of a position sensor assembly with a roller mechanism instead of sliders, coupled with optimized magnetic coupling geometry and higher magnetic field flux density, reduces friction and improves responsiveness, allowing for precise indication of fluid valve position without the need for frequent recalibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sliding mechanism is used in the position sensor assembly, then the structure is simple, but magnetic hysteresis and friction cause delays and inaccuracies in position indication
Solution Approach 1:
The patent replaces the traditional sliding mechanical mechanism with a magnetic field-based sensing system. The position sensor assembly uses magnetic coupling between the valve magnetic assembly and the sensor to detect valve position, eliminating physical contact and friction. This substitution of mechanical sliding with magnetic field interaction resolves the contradiction by removing the source of friction and hysteresis delays while maintaining structural simplicity.
2Measurement precision
If recalibration is performed frequently to correct position indication errors, then measurement accuracy is maintained, but operational time and costs increase
Solution Approach 1:
The position sensor assembly is designed to automatically compensate for position indication errors through its magnetic coupling mechanism. The system self-adjusts by maintaining accurate magnetic field alignment between the valve magnetic assembly and sensor, eliminating the need for manual recalibration operations. This self-correcting capability maintains measurement precision while preserving operational efficiency.
3Measurement precision
If magnetic coupling force is increased to improve position sensing, then measurement precision improves, but friction and magnetic hysteresis effects worsen
Solution Approach 1:
The patent eliminates the harmful effects of magnetic hysteresis and friction by replacing the mechanical sliding contact system with a non-contact magnetic field sensing system. The position is detected through magnetic field interaction without physical contact between moving parts, thereby achieving high measurement precision while completely avoiding friction and hysteresis losses that plague traditional magnetic coupling systems.
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 reduces the time to adjust the fluid valve by 50% to 70%, enhancing operational efficiency and reducing costs by minimizing recalibration time and improving accuracy.
Implementation Method 1
The roller set enables the PSA sub-assembly to roll within the PSA housing
Implementation Method 2
coupling a set of VMA magnets with a set of PSA magnets, wherein the VMA moves proportionally with the fluid valve utilizing linear movement
Implementation Method 3
optimized magnetic coupling geometry and higher magnetic field flux density
Data Source
AI summary
This disclosure presents an apparatus to improve the indication of an amount that a fluid valve is opened. The fluid control assembly includes an improved position sensor assembly (PSA), where the PSA uses rollers rather than sliding within the PSA housing. The rollers, which can be wheels, ball bearings, and other types of rolling devices, can reduce the friction experienced by the moving component within the PSA. Since the PSA mechanism can move with less friction, the coupled valve magnetic assembly (VMA) can also be enhanced. The VMA can utilize magnets in orientations that enhance the magnetic tensile and compressive forces. For example, some magnets in the VMA can be in a perpendicular orientation to improve directional control and some magnets can be in an angled orientation to reduce the spread of the magnetic field flux lines between the magnets of the VMA and the magnets of the PSA.