Wireless Valve Shaft Position Sensing for Remote Opening Detection
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Solution Overview
Problem
Existing solutions for detecting the angular position of a valve's drive shaft are limited by the need for wired connections, which are cumbersome and difficult to maintain in industrial settings, especially in areas with limited access or harsh conditions. Additionally, these solutions often require additional components that can become dirty or non-ATEX certifiable, and they lack the ability to detect tampering attempts or provide remote access to recorded data.
Innovation Solution
A self-powered, wireless detection module that integrates magnetic sensors and a communication interface to remotely detect the angular position of a valve's drive shaft. The module is compact, battery-powered, and does not require wired connections, allowing it to be easily integrated into valves and actuators without increasing their size. It also includes features for detecting tampering attempts and storing readings for later consultation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If magnetic transducers with wired connections are used to detect the angular position of the drive shaft, then the angular position can be detected, but the wiring becomes cumbersome and difficult to maintain in industrial settings
Solution Approach 1:
The patent extracts the magnetic sensor from the wired transducer system and integrates it directly into the drive shaft assembly. The magnetic sensor is mounted on the drive shaft housing and detects the position of magnets attached to the rotating component, eliminating the need for separate wired connections while maintaining detection accuracy.
Solution Approach 2:
The patent combines the magnetic sensor, magnets, and housing into an integrated detection module that is mounted directly on the drive shaft assembly. This merging of components eliminates the need for external wiring and connectors, making the system easier to maintain while preserving the angular position detection capability.
2Measurement precision
If additional components are added to the valve assembly for detection purposes, then the detection capability is improved, but the components can become dirty or non-ATEX certifiable
Solution Approach 1:
The patent nests the magnetic sensor and magnets within the existing sealed housing of the drive shaft assembly. The magnetic sensor is mounted inside the housing, and the magnets are attached to the rotating component that rotates within the same sealed environment. This nesting approach ensures that all detection components are protected from contamination and remain within the ATEX-certified boundary.
3Measurement precision
If traditional wired detection systems are used, then the angular position can be detected, but the system lacks the ability to detect tampering attempts or provide remote access to recorded data
Solution Approach 1:
The patent incorporates a tamper-detection mechanism that monitors the integrity of the sealed housing and detection module. When tampering is detected, the system generates an alarm signal and can remotely notify operators. Additionally, the system provides remote access to recorded angular position data, enabling continuous monitoring and information retrieval without physical access to the valve.
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
The solution provides a reliable, efficient, and cost-effective means to remotely detect the angular position of valves, overcoming the limitations of traditional wired solutions. It enhances maintenance and monitoring capabilities, allows for easy integration with industrial networks, and provides tampering detection and data storage features, making it suitable for industrial applications in line with Industry 4.0 trends.
Implementation Method 1
magnetic sensors arranged in the proximity of the outer surface of the drive shaft, which are configured to detect the position of the magnets. The magnetic sensors generate an electrical signal proportional to the distance with respect to the magnets on the drive shaft
Data Source
AI summary
A module for detecting the angular position of the drive shaft of a valve includes a printed circuit proximate a drive shaft of a valve body, or of an extension element thereof or a motor shaft of a valve actuator. The module also includes a magnet(s) fastened to the drive shaft, a magnetic sensor(s) supported on the printed circuit, and a communication interface. The magnetic sensor(s) generate an electrical signal indicating the position of the magnet(s). The communication interface remotely transmits a corresponding reading. The acquisition of the reading can be carried out at pre-set time intervals, which can be managed according to the requirements of the production process. The detection module is free of wired connections with the outside. A valve and an adapter element are also provided with the module, and a method for detecting the open state of the valve remotely by the module.