Zone Valve DC Motor Control Without Constant Hold Power
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Solution Overview
Problem
Current high voltage zone valves are energy inefficient due to the constant need for voltage to maintain the valve open and require specific voltage compatibility, limiting their interchangeability across different voltage environments.
Innovation Solution
A zone valve control system utilizing a direct current rotary electric motor with dual DC current sources and an electronic control system, including a microprocessor and rechargeable storage systems, to efficiently control the valve's operation based on sensor inputs, allowing for reversible polarity and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a constantly tensed return spring is used to close the valve, then the valve can be reliably closed, but energy is continuously consumed to maintain the valve in the open position
Solution Approach 1:
The patent removes the constantly tensed return spring from the system and replaces it with a DC motor that only activates when valve position change is needed. This extraction of the continuous force mechanism eliminates the need for continuous energy consumption while maintaining reliable valve closing through controlled motor actuation.
Solution Approach 2:
Instead of continuous spring tension, the system uses periodic motor activation controlled by a microprocessor. The motor is activated only when the valve needs to open or close, based on sensor inputs and control signals, transforming continuous energy consumption into periodic, demand-based action.
2Ease of operation
If synchronous motors are used with specific voltage requirements, then precise control is achieved, but interchangeability across different voltage environments is lost
Solution Approach 1:
The patent employs a DC motor with adjustable speed control capability, allowing the motor to operate across a wide voltage range (24V, 120V, 277V). The microprocessor controls the motor speed and direction by varying the electrical parameters, enabling the same motor design to adapt to different voltage environments while maintaining precise valve control.
Solution Approach 2:
The DC motor design is made universal by implementing a control system that can accept multiple voltage inputs. The same motor unit can function in residential (24V), commercial (120V), and industrial (277V) applications, eliminating the need for different motor models for different voltage environments.
3Loss of energy
If high voltage is used to reduce current, then energy efficiency improves, but the complexity of the control system increases
Solution Approach 1:
The patent replaces traditional mechanical valve actuation mechanisms with an electronically controlled DC motor system. This substitution allows for efficient high-voltage operation with electronic control, reducing energy losses while managing complexity through integrated microprocessor-based control that simplifies the overall system architecture.
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 system achieves efficient and flexible control of fluid flow in multiple zones with reduced energy usage and compatibility across various voltage ranges, eliminating the need for constant power and specific voltage requirements.
Implementation Method 1
A direct current rotary electric motor... The polarity of the DC current powering the motor determines the direction of rotation of the output shaft
Implementation Method 2
one or more rechargeable electrical storage systems having a total storage capacity sufficient to power the DC electric motor to fully open or close the valve
Data Source
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AI summary
A zone valve control system for a flow valve comprising a direct current rotary electric motor connected to a valve shaft, an electronic control system comprising a microprocessor, an electric measuring device for signaling the presence of a predetermined electrical stall current, a rectifier and a regulator to convert and regulate external AC voltage to a desired DC power output; and one or more storage capacitors having a total storage capacity sufficient to power the DC electric motor; an external sensor for signaling when a certain condition exists in an external zone; the microprocessor controlling the flow and polarity of DC current to the motor; whereby the electronic control system controls movement of a valve shaft operably connected to the output shaft to open or close a valve to maintain a desired predetermined condition in the external zone.