Control Valve Spring Breakage Detection From Pressure-Position Signatures

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Solution Overview

Problem

Existing methods for detecting spring breakage in pre-tensioned actuators of control valves are unreliable and can lead to late detection or false positives, especially in non-equilibrium situations, and often require interrupting the process or causing process disturbances.

Innovation Solution

A method using a position sensor and pressure sensor to measure the actual position and pressure of the valve element, comparing these measurements against a pre-defined valve signature and fracture signature to detect spring breakage without interrupting the process, incorporating factors like friction and process medium influences to enhance reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing methods for detecting spring breakage are used during test runs, then spring breakage can be detected, but the detection is unreliable and can be delayed due to process disturbances and friction losses

Engineering Contradiction:

Improvespring breakage detection reliabilityVSAvoiddetection accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent replaces mechanical detection methods with a diagnostic system that uses measured values (pressure, position, temperature) and evaluates them against predefined thresholds and patterns. This substitution of mechanical test runs with a measurement-based diagnostic approach eliminates the reliability issues caused by friction losses and process disturbances during physical testing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system continuously monitors measured values from sensors and compares them against expected ranges and patterns. When deviations indicate spring breakage, the system generates diagnostic information. This closed-loop feedback mechanism improves detection reliability by constantly evaluating the actual state against known good operating parameters.

Inventive Principle:

Principle #23Feedback

2Reliability

If test runs are performed to detect spring breakage, then detection is possible, but operation must be interrupted causing delays

Engineering Contradiction:

Improvespring breakage detectionVSAvoidoperational delay

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The diagnostic system operates continuously during normal valve operation without requiring test runs or interruptions. Sensors continuously measure pressure, position, and temperature, and the evaluation unit continuously analyzes these measurements. This allows spring breakage detection to occur seamlessly during ongoing operations, eliminating operational delays.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system performs self-diagnosis by monitoring its own operational parameters. The measurement and evaluation components work autonomously to detect spring breakage without requiring external testing or intervention, enabling continuous operation while maintaining detection capability.

Inventive Principle:

Principle #25Self-service

3Productivity

If process disturbances occur during test runs, then testing can be performed, but misinterpretation of results can occur

Engineering Contradiction:

Improvetesting capabilityVSAvoiddetection accuracy

Core Design Contradiction:

ProductivityVSLoss of information

Solution Approach 1:

The system monitors multiple parameters (pressure, position, temperature) simultaneously and evaluates their relationships rather than relying on a single measurement. By analyzing the interrelationships between these parameters and comparing against expected patterns, the system can distinguish between normal process variations and actual spring breakage, preventing misinterpretation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The evaluation unit acts as an intermediary that processes raw measurement data and translates it into diagnostic information. It uses predefined thresholds, patterns, and logic to interpret measurements, filtering out noise and process disturbances while identifying genuine spring breakage conditions. This intermediary processing layer prevents direct misinterpretation of raw data.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables early and reliable detection of spring breakage by analyzing instantaneous changes in valve element behavior, reducing delays and false positives, and adapting to specific installation conditions and process fluctuations.

Implementation Method 1

a pressure sensor for measuring an actual pressure in the pneumatic actuator

Methodology Applied

Scientific EffectPressure measurement:

Implementation Method 2

a position sensor for measuring an actual position of the valve element

Methodology Applied

Scientific EffectPosition measurement:

Implementation Method 3

pneumatic actuators are frequently used, which are pre-tensioned on one side by spring forces

Methodology Applied

Scientific EffectSpring force: Spring

Data Source

PatentEP4193083B1Spring breakage detection in a preloaded drive of a control valve

Publication Date: 2026.04.22 SAMSON AG

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AI summary

The invention relates to a method for detecting a spring breakage in a preloaded drive of a control valve. The method is based on the fact that the pressure which must be applied to achieve a certain valve member position falls significantly after the breakage or failure of the spring. The breakage of a spring in a preloaded drive can thus be detected reliably using the sensor system already present in the control valve, moreover without having to disrupt or interrupt operation.