Valve Position Transmitter Calibration Using Controller Data
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Solution Overview
Problem
In process control systems, calibrating valve controllers separately from transmitters is time-consuming and disrupts system operation, as both require individual calibration procedures.
Innovation Solution
A valve controller system where the position controller generates a calibration table or chart based on valve position sensor values, allowing the transmitter to use this data to determine accurate output values without separate calibration, thereby integrating calibration aspects to ensure operating performance of both devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate calibration procedures are performed for both position controller and transmitter, then calibration accuracy is ensured, but calibration time and system downtime increase
Solution Approach 1:
The patent combines the calibration procedures for the position controller and transmitter into a single integrated process. The position controller generates calibration data that is automatically transferred to the transmitter, eliminating the need for separate calibration procedures while maintaining accuracy for both devices.
Solution Approach 2:
The position controller performs calibration measurements and generates calibration data in advance during its calibration process. This preliminary action provides the transmitter with the necessary calibration information without requiring a separate calibration procedure, thus reducing total calibration time.
2Reliability
If separate calibration procedures are performed for position controller and transmitter, then device reliability is maintained, but operational efficiency decreases
Solution Approach 1:
The calibration processes of both devices are merged into a single operation. The position controller's calibration data is automatically transferred to the transmitter, ensuring both devices are calibrated together while improving operational efficiency by reducing downtime.
Solution Approach 2:
The position controller automatically generates and transfers its calibration data to the transmitter without requiring separate manual calibration procedures. This self-service approach maintains device reliability while significantly improving operational efficiency.
3Loss of time
If integrated calibration is implemented where position controller generates calibration data for transmitter, then calibration time is reduced, but device complexity increases
Solution Approach 1:
The position controller is given multiple functions: it not only controls the valve position but also generates calibration data for the transmitter. This multi-functionality reduces calibration time without significantly increasing overall system complexity, as the additional function leverages existing controller capabilities.
Solution Approach 2:
The calibration data serves as an intermediary between the position controller and transmitter. The controller generates this data during its calibration process, and it automatically transfers the data to the transmitter, simplifying the integration process while reducing calibration time.
Data Source
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AI summary
A system and method using a valve controller to control a valve. The valve controller including a position controller for moving the valve and a transmitter for providing information about the position of the valve. A calibration table and/or chart based on calibration data of the position controller is generated to provide a transmitter output value, wherein the transmitter need not be separately calibrated. The calibration table and/or chart may be stored in the position controller and provided to the transmitter upon completion of the calibration of the position controller. Dual power supply circuitry may be configured wherein a first power source supplies power to both the position controller and the transmitter to facilitate automatic calibration of the transmitter even when only the position controller is powered.