Variable Speed Valve Actuator With Solid-State Controller
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Solution Overview
Problem
Existing valve actuators require a wide variety of motors and gear sets to meet different speed and torque requirements, 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
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed speed motor is coupled to a gear set to provide specific speed and torque, then the valve actuator can deliver the required speed and torque combination, but multiple motors and gear sets must be stocked to meet different customer requirements
Solution Approach 1:
The patent applies a variable speed motor instead of a fixed speed motor, allowing the actuator to dynamically adjust its speed and torque output to meet different customer requirements. This eliminates the need to stock multiple fixed-speed motors and gear sets, as a single variable speed motor can be configured to provide the required speed-torque characteristics for various applications.
Solution Approach 2:
The patent changes the operating parameters of the motor from fixed to variable, enabling continuous adjustment of speed and torque. This parameter flexibility allows a single actuator design to serve multiple applications that previously required different fixed-speed configurations, thereby reducing inventory complexity.
2Adaptability or versatility
If multiple customers with different power supplies require valve actuators, then customized actuators must be built for each customer, but this increases manufacturing complexity and training requirements
Solution Approach 1:
The patent designs a universal actuator platform with a variable speed motor that can accept different power supply configurations (voltage, frequency, phase) without requiring different motor or gear set models. This multi-functionality allows the same basic design to serve customers with various power supply requirements, reducing the number of assembly variations and training needs.
3Ease of operation
If torque limit switches are used to control speed and torque, then mechanical adjustment is possible, but the actuator cannot set speed or torque profiles that vary over the valve stroke
Solution Approach 1:
The patent replaces mechanical torque limit switches with an electronic control system that uses sensors and a controller to regulate motor speed and torque. This substitution enables sophisticated control capabilities including variable speed and torque profiles throughout the valve stroke, which cannot be achieved with simple mechanical switches.
Solution Approach 2:
The patent incorporates feedback mechanisms (sensors monitoring valve position, speed, and torque) that allow the control system to dynamically adjust operating parameters throughout the valve stroke. This feedback enables the actuator to implement speed and torque profiles that vary continuously based on real-time conditions, rather than being limited to fixed mechanical settings.
4Reliability
If fixed speed motors are used, then the valve actuator can operate reliably, but it has limited utility as a process controller because the valve is always operated at a fixed speed
Solution Approach 1:
The patent uses a variable speed motor with electronic control to maintain reliable operation while enabling dynamic speed adjustment. The control system ensures stable and precise valve positioning even as speed varies, allowing the actuator to function both as a reliable driver and as a process controller that can respond to changing process conditions.
Solution Approach 2:
The patent incorporates feedback control that monitors valve position and process conditions, allowing the actuator to automatically adjust its speed to achieve desired control objectives. This feedback capability transforms the actuator from a simple fixed-speed driver into an intelligent process control device that can maintain stability while adapting to varying requirements.
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
This solution reduces the need for multiple motor and gear sets, allows for on-the-fly adjustment of speed and torque, and enables the valve actuator to operate as a process controller, enhancing flexibility and reducing manufacturing and operational complexities.
Implementation Method 1
a worm/worm-gear set operably connected to the variable speed motor
Data Source
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AI summary
A valve actuator (100) including an electric motor (10) is disclosed that includes a solid-state motor controller (20) capable of operating a motor at variable speeds and a gear set (40) that provides inherent braking. The speed and torque of the valve actuator may be selected. The speed and torque experienced by a valve (80) may be varied over the length of a valve stroke. The valve actuator may include logic sufficient to act as a process controller.