Valve Stem Rotation Sensing for Timely Maintenance Warning
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Solution Overview
Problem
Manual recording of valve rotation frequency is inefficient and costly, leading to maintenance being performed only when issues arise, resulting in increased maintenance costs and potential valve damage due to wear and tear.
Innovation Solution
A warning device mounted on the valve comprising a base, shaft, sensing module, control module, and warning module, which automatically detects the frequency of rotation and predicts the valve's usage status by using an asymmetrical shaft design, inductive position sensors, torque sensors, and pressure sensors to generate warning signals for maintenance personnel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual recording of valve rotation frequency is used, then labor cost and time consumption are reduced, but measurement precision and reliability of valve status detection deteriorate
Solution Approach 1:
The patent replaces the manual mechanical recording system with an automated sensing system. The sensing module includes a sensing member with an asymmetric profile that detects valve stem rotations through electromagnetic or optical means, automatically generating digital signals for rotation frequency measurement. This substitution eliminates manual intervention while providing precise, reliable detection of valve usage status.
2Device complexity
If manual recording method is used, then device complexity is reduced, but productivity and efficiency of maintenance management deteriorate
Solution Approach 1:
The valve maintenance system performs self-service through automated detection and monitoring. The sensing module continuously monitors valve stem rotations and automatically calculates usage frequency without requiring external manual intervention. The system self-manages data collection, processing, and maintenance scheduling, significantly improving productivity while keeping the device structure relatively simple through integrated sensing and processing components.
3Reliability
If maintenance is performed only when issues arise, then maintenance cost is reduced in the short term, but reliability and duration of valve operation deteriorate
Solution Approach 1:
The patent implements a feedback mechanism where the sensing module continuously monitors valve stem rotation frequency and provides real-time data to the processing unit. The system compares detected rotation counts against predetermined thresholds and automatically generates maintenance warnings when limits are reached. This closed-loop feedback system ensures reliable valve operation by enabling proactive maintenance before failures occur, while maintaining relatively simple device architecture through integrated sensing and control components.
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 device enables timely maintenance by automatically detecting valve rotation frequency and status, reducing maintenance costs and preventing valve damage through efficient notification of maintenance needs.
Implementation Method 1
a sensing module having a second sensing member received in the base and corresponded to the first sensing member to detect changes in position of the first sensing member and generate a sensing signal accordingly
Data Source
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AI summary
A warning device is mounted on a valve including a valve body, a valve seat and a valve stem. The warning device comprises a base, a shaft, a sensing module, a control module and a warning module. The base is connected to the valve body. The shaft has a shaft body and a first sensing member. A profile of a cross section of the shaft being passed through by the first sensing member is asymmetric along at least a radial direction. The sensing module has a second sensing member received in the base and corresponded to the first sensing member to detect changes in position of the first sensing member and generate a sensing signal accordingly. The control module receives the sensing signal generated by the sensing module and calculates a rotation data accordingly. The warning module generates a warning signal according to the rotation data from the control module.