Variable-Speed Valve Actuator With Solid-State Controller

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Solution Overview

Problem

Existing valve actuators require multiple motor and gear sets to meet varying customer needs, necessitating extensive inventory and training, and lack the ability to adjust speed and torque without disassembly or operate as process controllers.

Innovation Solution

A valve actuator system featuring a variable-speed motor, solid-state motor controller, and a worm/worm-gear set, along with a universal power converter and braking device, allowing for adjustable speed and torque without mechanical switches and enabling operation as a process controller.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple motors and gear sets are stocked to meet varying customer needs, then customer requirements can be satisfied, but inventory complexity and training requirements increase

Engineering Contradiction:

Improveability to meet varying customer needsVSAvoidinventory complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements a universal actuator platform that can operate with different power supplies (single-phase AC, three-phase AC, DC) by allowing external connection of field windings. A single motor design with configurable field connections can serve multiple customer requirements without needing separate stocked units for each power type, thereby reducing inventory complexity while maintaining versatility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system allows dynamic reconfiguration of motor characteristics through external field connections. By changing the field winding connections externally, the same motor can adapt to different power supply types and operational requirements, eliminating the need to stock multiple fixed-configuration motors.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If fixed speed motors are used, then simple motor design is maintained, but speed and torque adjustment requires disassembly and reassembly

Engineering Contradiction:

Improvemotor design simplicityVSAvoidspeed and torque adjustment

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The patent enables dynamic adjustment of speed and torque characteristics by allowing external connection of field windings to different power supplies. This dynamic reconfiguration capability allows operators to adjust motor performance without disassembling the actuator, maintaining manufacturing simplicity while greatly improving operational flexibility.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system replaces mechanical adjustment mechanisms (such as physical gear changes or mechanical switches) with electrical reconfiguration through external field connections. This substitution allows speed and torque adjustment through electrical means rather than mechanical disassembly and reassembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If torque limit switches are used to control speed and torque, then mechanical control is achieved, but bulky mechanical switches are required and speed/torque profiles cannot vary over valve stroke

Engineering Contradiction:

Improvemechanical control capabilityVSAvoidmechanical switch complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces bulky mechanical torque limit switches and mechanical control systems with electrical field connection control. By externally connecting field windings to different power supplies, speed and torque profiles can be varied over the valve stroke without requiring mechanical switches, thereby reducing device complexity while maintaining control capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If separate braking mechanisms are added to variable speed motors, then braking capability is provided, but device complexity increases

Engineering Contradiction:

Improvebraking capabilityVSAvoidmechanical system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the braking function with the existing motor and gear set system. The reversible motor can operate in reverse to provide braking, and the gear set provides inherent holding capability, eliminating the need for separate braking mechanisms and reducing overall device complexity while maintaining reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system uses its own motor and gear set components to provide braking capability without requiring external or separate braking mechanisms. The motor's ability to reverse and the gear set's inherent properties are utilized to create the braking function, allowing the system to serve its own braking needs.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10094485B2Variable-speed actuator

Publication Date: 2018.10.09 FLOWSERVE PTE LTD

AI summary

A valve actuator including an electric motor is disclosed that includes a solid-state motor controller capable of operating a motor at variable speeds and a gear set that provides inherent braking. The speed and torque of the valve actuator may be selected. The speed and torque experienced by a valve may be varied over the length of a valve stroke. The valve actuator may include logic sufficient to act as a process controller.