Patent Application
20100050863
The present invention generally relates to the field of fluid-powered actuators. More specifically, the invention relates to a hydraulic or pneumatic actuator that is equipped with an internal position sensor that may be easily serviced in case of failure.
Fluid powered actuators, whether they are hydraulic or pneumatic, are widely used for operating different pieces of equipment. In particular, these actuators may be used to operate valves on stationary machinery such as in complex pipe works in chemical plants.
As these actuators may control mixing valves, it is often necessary to know the exact position of the valve. This is typically achieved by monitoring the position of an actuator rod that is attached to the valve. A well-known solution is to install a position sensor, like a displacement linear transducer, on the outside of an actuator body, with a mobile end of the position sensor connected to the actuator rod so that the position of the valve is tracked.
However, because the actuators are commonly placed in areas that are exposed to harsh environments, the position sensor routinely fails. Moreover, because the actuators may also be installed in tight, difficult to reach areas, the replacement of the failed position sensor is cumbersome. Sometimes, the position sensor is so clogged with contaminants and the actuator so dirty, that it is necessary to completely remove the actuator since another position sensor cannot be installed in those conditions. The absence of the actuator generates equipment downtime, which translates into production, and therefore money, losses.
Different approaches have been suggested to solve this problem, mainly by protecting the position sensors from the environment. U.S. Pat. No. 7,290,476 to Glasson discloses a position sensor, such as an LVDT (linear variable displacement transducer), for a hydraulic cylinder. The position sensor is installed inside the cylinder, either on the cylinder bottom cap or on the cylinder head cap, and connected to the piston. Advantageously, the position sensor is protected from harsh environment. However, in case of failure of the position sensor, the whole actuator needs to be replaced since replacing the position sensor needs opening up the actuator.
Another solution has been proposed in U.S. Pat. No. 7,023,199 to Blubaugh et al. This patent discloses an actuator equipped with a position sensor that is fixed to the exterior of the cylinder bottom cap. The position sensor is of the magneto-restrictive type, which uses a pipe protruding inside the actuator, more precisely inside the center of the piston and rod. This type of sensor requires the use of magnets mounted on a mobile component of the actuator, such as the piston or the piston rod. An electronic module of the position sensor, mounted outside the actuator, is protected from the environment by a cover. A drawback of this design, though, is that the magnets may become contaminated, which then requires the disassembly of the actuator to access the magnets and replace them. This leads to downtime. Moreover, this type of sensor necessitates that the internal mobile components of the actuator, such as the piston and rod, be designed specifically to accommodate the pipe. This increases the price of the actuator. Furthermore, the operational temperature range of magneto-restrictive sensors is limited such that they may not work properly under certain environmental conditions.
There is therefore a need for an improved actuator capable of monitoring the position of its mobile components.
It is an object of the present invention to provide a fluid-powered actuator that overcomes or mitigates one or more disadvantages of known fluid-powered actuators, or at least provides a useful alternative.
It is an object of the invention to provide a fluid-powered actuator having a position sensor that is protected from the environment.
It is another object of the invention to provide a fluid-powered actuator offering the possibility to replace its position sensor without having to remove the whole actuator from where it is mounted.
In accordance with an embodiment of the present invention, there is provided a fluid-powered actuator comprising a cylindrical body having a base proximate one extremity and a head proximate another extremity, a piston-rod assembly, a removable cover and a position sensor. The piston-rod assembly is slidably mounted inside the cylindrical body. The base is provided with an opening adapted to accommodate the sensor therethrough. In operation, the cover seals the opening. The position sensor is mounted to an internal face of the cover so that the position sensor is operatively located inside the cylindrical body when the cover is in place. The position sensor is operative to measure a position of the piston-rod assembly.
In accordance with another embodiment of the present invention, there is provided a sensor module adapted to sealably close the opening in the base of the fluid-powered actuator. The sensor module comprises a cover structure that is operative to sealably close the opening and a position sensor. Again, the position sensor is mounted to the internal face of the cover structure so that the position sensor is operatively located inside the actuator when the cover structure closes the opening.
Optionally, the sensor module further comprises an analog converter connected to the position sensor ratiometric output for converting a signal from said position sensor to an analog electric signal such as electric voltage or current signal. The converter is mounted on the internal face of the cover structure.
These and other features of the present invention will become more apparent from the following description in which reference is made to the appended drawings wherein:
The present invention relates to an actuator of the type used with a pneumatic or a hydraulic source of power. The actuator is provided with a position sensor allowing the measurement of the location of its piston-rod assembly with respect to its cylindrical body. Conveniently, the position sensor is mounted on the internal face of a removable cover located in a base of the actuator. Not only is the position sensor protected from the harsh environment where such actuators are sometimes used, but also the position sensor may easily be replaced, without removing the actuator from its location, by simply removing the cover from the base.
In the present invention, however, the base 14 is provided with an opening 26 and a removable cover 28 used to sealably close the opening 26. Indeed, an o-ring 30 (best shown in
A position sensor 34 is mounted to an internal face 36 (best shown in
Different types of position sensors may be used, such as those using lasers, ultrasounds, or magnetic properties (such as magnetostrictive linear position sensors). These, however, have some drawbacks. They are still rather expensive and some of them are adversely affected by vibrations, to which the actuators are sometimes exposed. Hence, for cost reasons and because it provides adequate performance, it was found preferable to use a draw wire transducer as the position sensor. The accuracy achieved with the draw wire transducer is typically ±0.5% and better, which is sufficient in most applications. Moreover, once their wire is retracted, this type of position sensor is relatively compact, which is an advantage for its replacement when the actuator is installed in a confined area.
As the position sensor 34 is mounted on the internal face 36 of the cover 28, the opening 26 must be sufficiently large to accommodate the position sensor 34 therethrough. Conveniently, the design of the opening 26 and of the cover 28 may be standardized across a product line of actuators. Hence, even if different sizes of actuators are required for different applications, only one sensor module 37, comprising the position sensor 34 mounted on the cover 28, is required. In a simple design, the cover 28 may fit over the opening 26. Alternatively, the cover 28 may fit at least partially within the opening 26.
If a draw wire transducer is used as the position sensor 34, its wire 38 must be attached to the piston-rod assembly 18. It is preferable to center the wire 38 on the piston-rod assembly 18 in case the piston-rod assembly 18 would rotate as it travels in the cylindrical body 12. Similarly, a wire outlet 40 of the position sensor 34 should also be centered in the cylindrical body 12. Hence, even if the piston-rod assembly 18 rotates, the length of the wire 38 remains constant.
The actuator 10 may be provided with a stopper 42 to prevent the piston-rod assembly 18 from retracting too much and crush the position sensor 34. This stopper 42 may take the form of a tube that is concentric with, and inside the cylindrical body 12.
The typical position sensor 34 provides a ratiometric analog output signal and, with the addition of an optional signal converter 44 connected to this position sensor 34, can provide an analog electric signal such as electric voltage or electrical current from the ratiometric analog output signal. The electrical analog signal is then sent to an analog connector 46. However, if the signal converter 44 is not used, the analog connector 46 is directly connected to the position sensor 34. Conveniently, the converter 44 is also mounted on the internal face 36 of the cover 28 while the analog connector 46 is mounted to an external face 50 of the cover 28.
In another embodiment of the invention, the position sensor 34 may additionally be equipped with a cam-switch unit with integrated digital discrete switches 45, best shown in
Conveniently, if ever one of the component of the sensor module 37 fails, be it the position sensor 34, the wire 38 or the converter 44, the whole sensor module 37 may be replaced with a new one without having to disassemble the actuator 10 from where it is mounted. This is a huge advantage as often, the actuator 10 is difficult to reach and there is not much space to work. Hence, having to replace only a relatively small sensor module 37 is a benefit. When such a replacement is required, a maintenance person may easily remove the screws 32 holding the cover 28 against the base 14, remove the sensor module 37 and disconnect the wire 38 by reaching inside the actuator with one hand. The wire 38, attached to the piston-rod assembly through an optional threaded attachment 52, may easily be unscrewed. Similarly, the installation of a new sensor module is as easily accomplished by doing the same steps in the reverse order. If ever the opening 26 is too small to accommodate the arm of a person, a special elongate tool may be used to reach inside and unscrew/screw the threaded attachment 52.
The present invention has been described with regard to preferred embodiments. The description as much as the drawings were intended to help the understanding of the invention, rather than to limit its scope. It will be apparent to one skilled in the art that various modifications may be made to the invention without departing from the scope of the invention as described herein, and such modifications are intended to be covered by the present description. The invention is defined by the claims that follow.
