Valve Wear Monitoring via Temperature-Based Piston Tracking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods cannot accurately determine the actual wear of an expandable material operating element within a multi-way valve during operation without disassembling the valve, leading to potential premature failure and system disruptions due to assumptions based on empirical values and time-in-use criteria.
Innovation Solution
A method utilizing temperature and movement data to track the precise distance covered by the expandable material operating element, accounting for hysteresis and current temperature changes, allowing for real-time wear assessment and predictive maintenance planning without valve disassembly, using sensors and evaluation electronics integrated into the valve's cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the valve is opened and the expandable material operating element is removed for diagnosis, then the actual degree of wear can be determined, but the function of the valve is no longer available and system shutdown occurs
Solution Approach 1:
The patent replaces the mechanical diagnostic approach (disassembly and physical inspection) with a sensor-based measurement system. Sensors continuously monitor the position of the piston and the state of the expandable material operating element during operation, enabling wear assessment without mechanical intervention. This substitution eliminates system shutdown while maintaining measurement capability.
Solution Approach 2:
The valve performs self-diagnosis through integrated sensors that automatically monitor the condition of the expandable material operating element during normal operation. The system generates its own diagnostic data through continuous measurement of position and temperature, eliminating the need for external intervention or system shutdown for wear assessment.
2Reliability
If maintenance schedules assume above-average wear for safety reasons, then system reliability is improved, but wearing parts are replaced prematurely in valves where wear has not reached the limit
Solution Approach 1:
The patent implements a feedback mechanism where sensors continuously provide data on the actual wear state of the expandable material operating element. This real-time feedback replaces assumption-based maintenance schedules with condition-based maintenance, allowing interventions only when actual wear thresholds are approached, thereby eliminating premature replacements while maintaining reliability.
Solution Approach 2:
The patent transitions from time-based maintenance parameters to condition-based parameters by monitoring physical quantities such as piston position, temperature, and movement characteristics. This parameter change enables precise determination of actual wear state, replacing the conservative time-in-use criteria with accurate condition assessment.
3Ease of operation
If the expandable material operating element is monitored during ongoing operation, then wear can be determined without disassembly, but additional sensors and evaluation electronics must be integrated into the valve
Solution Approach 1:
The patent integrates multiple functions into the valve structure: the valve body simultaneously serves as the fluid control device and the housing for sensor mounting and signal evaluation. The cover structure provides both sealing function and mounting surface for sensors. This multi-functionality reduces the need for separate diagnostic hardware and simplifies overall system architecture.
Solution Approach 2:
The patent merges the diagnostic measurement system with the valve structure itself. Sensors are integrated into the cover and body, and signal evaluation is performed within the valve housing. This merging eliminates separate diagnostic equipment and reduces system complexity while enabling continuous wear monitoring during operation.
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 accurate, real-time monitoring of wear, reducing unnecessary replacements and preventing system failures by providing immediate feedback on the expandable material's condition and allowing for timely maintenance, thus enhancing operational reliability and efficiency.
Implementation Method 1
The expandable material operating element expands corresponding to a temperature/movement curve with an increase in temperature and contracts again when the temperature drops
Implementation Method 2
at least one sensor arranged in the cover (7) and/or in the valve body (1) for detecting a temperature and/or a position
Data Source
AI summary
Disclosed is a method for determining the degree of wear of a valve, the degree of wear of the valve being dependent on the degree of wear of an operating element that is made of an expandable material and performs a mechanical movement each time the temperature changes, the change in temperature resulting in wear, the operating element made of an expandable material being mechanically connected to a piston; the movements of the operating element (3) made of an expandable material are calculated by initially sensing the change in temperature on the operating element (3), whereupon the changes in temperature are recalculated as movements on the basis of the temperature/expansion curve applicable to the operating element (3) made of an expandable material.