Valve Wear Monitoring via Expansion Element Temperature Motion
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Solution Overview
Problem
Current methods fail to accurately determine the actual wear of expansion material working elements in multi-way valves during operation without disassembling the valve, leading to potential premature failures and unnecessary replacements in complex cooling systems.
Innovation Solution
A method utilizing temperature/motion characteristic curves of the expansion material working element, combined with sensors and evaluation electronics, to monitor and calculate the wear by correlating temperature changes and piston position, allowing for real-time assessment of wear without opening the valve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the valve is opened and the expansion element is removed for inspection, then the actual wear can be determined, but the valve becomes non-functional and maintenance time increases
Solution Approach 1:
The patent replaces mechanical inspection methods (disassembly and physical examination) with a sensor-based measurement system. Sensors detect operational parameters such as actuation forces, positions, and temperatures, which are then evaluated to determine wear of the expansion element without requiring valve disassembly. This substitution enables continuous monitoring while the valve remains installed and functional.
Solution Approach 2:
The expansion element and valve components perform their normal functional operations (actuation, temperature compensation, flow control) while simultaneously providing measurement data through integrated sensors. The operational movements and forces that constitute the wear mechanism also generate the signals used to monitor wear, eliminating the need for separate inspection activities.
2Reliability
If all expansion elements are replaced early based on theoretical service life, then reliability is improved, but unnecessary replacements increase cost and downtime
Solution Approach 1:
The patent implements a feedback system where sensors continuously monitor operational parameters of the expansion element, and this data is evaluated to assess actual wear status. The system provides ongoing information about the true condition of the component, enabling maintenance decisions based on actual wear rather than theoretical service life estimates. This feedback loop allows for condition-based maintenance that replaces components only when actually needed.
Solution Approach 2:
The patent transitions from time-based maintenance (replacing components after a fixed theoretical service period) to condition-based maintenance (replacing components when actual wear parameters indicate deterioration). By monitoring parameters such as actuation forces, positional deviations, and temperature characteristics, the system identifies when wear has actually reached critical levels, allowing optimization of replacement timing.
3Ease of operation
If theoretical service life is used for maintenance planning, then simplicity is maintained, but actual wear conditions are not accurately reflected
Solution Approach 1:
The patent replaces simple time-based tracking with sensor-based measurement systems that capture actual operational conditions. Sensors record parameters such as actuation forces, positions, cycle counts, and temperatures, providing detailed information about real wear conditions. This substitution maintains operational simplicity through automated data collection and evaluation while dramatically improving accuracy of wear assessment.
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 precise, real-time monitoring of wear, reducing the risk of premature failures and unnecessary replacements by providing immediate and accurate wear data, facilitating proactive maintenance planning.
Implementation Method 1
The expansion material working element expands according to a temperature/movement characteristic curve when the temperature increases and contracts again when the temperature decreases
Data Source
Figure 1
AI summary
The invention relates to a method for determining the degree of wear of a valve (1), wherein the degree of wear of the valve (1) depends on the degree of wear of an expansion material working element (3) located within the valve (1), wherein the expansion material working element (3) performs a mechanical movement with each temperature change, which leads to wear, and wherein the expansion material working element (3) is mechanically connected to a piston (2). According to the invention, the movements of the expansion material working element (3) are calculated by first detecting the temperature change at the expansion material working element (3) and then converting the temperature changes into movements using the temperature/movement characteristic curve valid for the expansion material working element (3). Furthermore, the invention proposes a device designed for carrying out such a method.