Patent Application
20180045375
The present invention generally relates to solenoid control valves, and more particularly relates to a smart solenoid control system, which may be used to control and monitor solenoid-operated devices, such as valves.
Various fluids may be transported via pipelines. For example, various fuels, such as oil, natural gas and biofuels, and various other fluids, such as water, sewage, and slurry, may be transported via pipelines. Indeed, according to some estimates, worldwide there is presently almost 3.5 million kilometers of pipeline in 120 countries.
A fluid pipeline system may include, for example, one or more pumps, pressure regulators, gate valves, solenoid-operated shut-off valves, solenoid-operated flow valves, and various fluid sensors (e.g., temperature, pressure, flow). Typically, these valves and sensors are disposed at a substation along the pipeline, and personnel at the substation monitor, either continuously or periodically, various fluid and solenoid-related parameters. This requires constant effort from the substation personnel, and increases the likelihood of human errors. Moreover, in the highly unlikely event of a fault, there could be a time delay between fault occurrence, fault recognition, fault isolation (e.g., shut one or more valves), and ultimate restoration (e.g., re-open the shut valves) by the substation personnel.
In view of the foregoing, there is need for the capability to remotely monitor fluid and system parameters, such as fluid pressure, fluid flow, fluid temperature, solenoid temperature, solenoid position, and to automatically implement various self-tests, fault detection, fault alarm, and fault isolation/prevention procedures. The present invention addresses at least these needs.
This summary is provided to describe select concepts in a simplified form that are further described in the Detailed Description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
In one embodiment, a smart solenoid control system for controlling flow of fluid in a conduit includes a solenoid, a plurality of fluid sensors, a plurality of solenoid sensors, a display device, a communication module, and a control. The solenoid is coupled to receive a drive current and is configured, in response thereto, to move between a first position and a second position. Each fluid sensor is configured to sense a parameter associated with the fluid in the conduit and supply a fluid sensor signal representative thereof. Each solenoid sensor is configured to sense a parameter associated with the solenoid and supply a solenoid sensor signal representative thereof. The display device is coupled to receive display commands and is configured, upon receipt thereof, to render images. The communication module is coupled to receive data and is configured, upon receipt thereof, to transmit the received data to a remote station or handheld device. The control is coupled to receive the fluid sensor signals and the solenoid sensor signals and is configured, upon receipt thereof, to: determine whether the solenoid should be in the first or second position, based on the determination, selectively supply the drive current to the solenoid to cause the solenoid to move to the first or second position, at least selectively command the display device to render images representative of one or more of the parameters associated with the fluid and the parameters associated with the solenoid, and supply the data to the communication module for transmission thereby.
In another embodiment, a smart solenoid control system for controlling flow of fluid in a conduit includes a solenoid, a plurality of fluid sensors, a plurality of solenoid sensors, a display device, a communication module, and a control. The solenoid is coupled to receive a drive current and is configured, in response thereto, to move between a first position and a second position. Each fluid sensor is configured to sense a parameter associated with the fluid in the conduit and supply a fluid sensor signal representative thereof. Each solenoid sensor is configured to sense a parameter associated with the solenoid and supply a solenoid sensor signal representative thereof. The display device is coupled to receive display commands and is configured, upon receipt thereof, to render images. The communication module is configured to receive solenoid control system settings from a remote station or handheld device and, upon receipt thereof, to supply the solenoid control system settings. The control is coupled to receive the fluid sensor signals, the solenoid sensor signals, and the solenoid control system settings. The control is configured, upon receipt of these signals to: determine whether the solenoid should be in the first or second position, based on the determination, selectively supply the drive current to the solenoid to cause the solenoid to move to the first or second position, at least selectively command the display device to render images representative of one or more of the parameters associated with the fluid and the parameters associated with the solenoid, implement built-in self-tests of one or more of itself, the solenoid, the fluid sensors, the solenoid sensors, the display device, and the communication module, and prognosticate end-of-life capabilities of one or more of itself, the solenoid, the fluid sensors, the solenoid sensors, the display device, and the communication module.
In yet another embodiment, a smart solenoid control system for controlling flow of fluid in a conduit includes an explosion-proof enclosure, a solenoid, a plurality of fluid sensors, a plurality of solenoid sensors, a touchscreen display device, a communication module, and a control. The solenoid is disposed within the explosion-proof enclosure, is solenoid coupled to receive a drive current, and is configured, in response thereto, to move between a first position and a second position. The fluid sensors are disposed within the explosion-proof enclosure. Each fluid sensor is configured to sense a parameter associated with the fluid in the conduit and supply a fluid sensor signal representative thereof. The solenoid sensors are disposed within the explosion-proof enclosure. Each solenoid sensor is configured to sense a parameter associated with the solenoid and supply a solenoid sensor signal representative thereof. The touchscreen display device is disposed within the explosion-proof enclosure. The touchscreen display device is coupled to receive display commands and is configured, upon receipt thereof, to render images. The communication module is disposed within the explosion-proof enclosure. The communication module is coupled to receive data and is configured, upon receipt thereof, to transmit the received data to a remote station or handheld device. The control is disposed within the explosion-proof enclosure. The control is coupled to receive the fluid sensor signals and the solenoid sensor signals and is configured, upon receipt thereof, to: determine whether the solenoid should be in the first or second position, based on the determination, selectively supply the drive current to the solenoid to cause the solenoid to move to the first or second position, at least selectively command the display device to render images representative of one or more of the parameters associated with the fluid and the parameters associated with the solenoid, and supply the data to the communication module for transmission thereby.
Furthermore, other desirable features and characteristics of the smart solenoid control system will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the preceding background.
The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” Thus, any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. All of the embodiments described herein are exemplary embodiments provided to enable persons skilled in the art to make or use the invention and not to limit the scope of the invention which is defined by the claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary, or the following detailed description.
Referring to
Referring first to
The explosion-proof enclosure 216, as noted houses at least the various electronic and electrical devices and systems that comprise the smart solenoid control system 108. The explosion-proof enclosure 216 is configured to provide a wiring connection via, for example, a detachable connector pair or for a suitable wiring harness. The connector pair can be variously configured. Preferably, however, it is configured as a suitable industrial grade polymer connector or military grade circular connector. The explosion-proof enclosure 216 may be manufactured of metallic or non-metallic composite material, using any one of numerous known manufacturing processes such as, but not limited to, forging, 3D printing, machining, molding.
The solenoid 202 is coupled to receive a drive current and is configured, in response thereto, to move between a first position, which is the position depicted in
Regardless of the type of valve element 226 that is used, the armature 218 is axially movable within the enclosure 216 between the first position and the second position. More specifically, in the depicted embodiment, the solenoid 202 is configured as a pull-type solenoid. Thus, the armature 218, in response to the coil 222 being energized with the drive current, moves from the first position to the second position, to thereby move the valve element 226 from a closed position (
Each of the fluid sensors 204 is configured to sense a parameter associated with the fluid in the conduit 102, and to supply a fluid sensor signal representative of the parameter to the control 214. Although the number and type of fluid sensors 204 may vary, in the depicted embodiment, each smart solenoid control system 108 includes a fluid pressure sensor 204-1, a fluid temperature sensor 204-2, and a fluid flow sensor 204-3. The fluid pressure sensor 204-1, as may be appreciated, is configured to sense the pressure of the fluid in the conduit 102, and supply fluid pressure signals representative thereof. The fluid pressure sensor 204-1 may be implemented using any one of numerous types of pressure sensors. The fluid temperature sensor 204-2 is configured to sense the temperature of the fluid in the conduit 102, and supply fluid temperature signals representative thereof. The fluid temperature sensor 204-2 may be implemented using any one of numerous types of temperature sensors. The fluid flow sensor 204-3 is configured to sense the flowrate of the fluid in the conduit 102, and supply fluid flowrate signals representative thereof. The fluid flow sensor 204-3 may be implemented using any one of numerous types of flow sensors.
Each of the solenoid sensors 206 is configured to sense a parameter associated with the solenoid 202, and to supply a solenoid sensor signal representative of the parameter to the control 214. Although the number and type of solenoid sensors 206 may vary, in the depicted embodiment, each smart solenoid control system 108 includes a solenoid current sensor 206-1, a solenoid position sensor 206-2, and a solenoid temperature sensor 206-3. The solenoid current sensor 206-1 is configured to sense the current in the solenoid coil 222, and supply current signals representative thereof. The solenoid current sensor 206-1 may be implemented using any one of numerous types of current sensors, and may be used to measure, for example, solenoid pull-in current, solenoid drop-out current, and solenoid hold current. The solenoid position sensor 206-2 is configured to sense the position of the armature 218, and supply position signals representative thereof. The solenoid position sensor 206-2 may be implemented using any one of numerous types of position sensors. The solenoid temperature sensor 206-3 is configured to sense the temperature of the solenoid 202, and supply solenoid temperature signals representative thereof. The solenoid temperature sensor 206-3 may be implemented using any one of numerous types of flow sensors, and may be used to measure one or both of solenoid coil temperature and solenoid body temperature.
The display device 208 is coupled to receive display commands and is configured, upon receipt of the display commands, to render images. The display device 208 may be variously implemented, but in the depicted embodiment it is implemented using a touchscreen display that is driven by a suitable display driver 209. It will be appreciated that the display device 208 may be commanded to display various types of information. Some examples of the types of information that the display device 208 may be commanded to display includes, but is not limited to, one or more of the sensed fluid parameters, one or more of the sensed solenoid parameters, various alerts, fault data, and various tests being conducted, just to name a few.
The communication module 212 is coupled to receive various types of data and is configured to transmit the received data to a remote station 402 and/or a handheld device (e.g., tablet, smartphone, custom device, etc.) 404 (see
It should be noted that the communication module 212 may also be configured to implement numerous other functions. These other functions will be described further below. Before doing so, however, a description of the control 214 will be provided.
The control 214, as shown more clearly in
Before proceeding further, it is noted that the solenoid driver 408 may be variously configured and implemented. In the depicted embodiment, however, the solenoid driver is configured as a pulse width modulation (PWM) current driver. Such drivers, as is generally known, regulate current with a well-controlled waveform to ensure activation and reduce power consumption. Preferably, the solenoid driver 408 is configured to rapidly ramp up the solenoid drive current to ensure quick movement of the armature 218 to the second position. Thereafter, the solenoid drive current is set at a constant peak value, and then reduced to a lower hold magnitude to reduce power and thermal load.
Returning to a description of the functions that the control 214 implements, it is noted that the control 214 is additionally configured, upon receipt of the fluid and solenoid sensor signals, to at least selectively command the display device 208 to render images representative of one or more of the parameters associated with the fluid and the parameters associated with the solenoid. As noted above, in addition to the fluid-related and solenoid-related parameters, the control 214 may also command the display device 208 to display, for example, various alerts, fault data, and various tests being conducted, just to name a few. The control 214 is also configured, upon receipt of the fluid and solenoid sensor signals, to supply the data to the communication module 212 for transmission thereby to the remote station 402 and/or handheld device 404.
The control 214 may also be configured to implement numerous other functions. For example, the control 214 is also preferably configured to implement built-in self-tests of one or more of the solenoid 202, the fluid sensors 204, the solenoid sensors 206, the display device 208, the communication module 212, and even itself. For example, each time the smart solenoid control system 108 is powered up, and/or periodically thereafter, the control 214 may perform self-tests to determine various control system parameters, such as pull-in current, coil resistance, flow calibration, pressure calibration, temperature calibration, just to name a few. These parameters may then be compared to control system parameters stored in memory (e.g., EEPROM) on-board the control 214. In the event one or more of the parameters is outside of a predefined limit, the data and a warning alert may be supplied to the communication module 212 for transmission to the remote station 404 and/or handheld device 404. If needed or desired, the control 214 could also command a shutdown until service personnel intervened. One example of a built-in self-test process that the control may implement is depicted in flowchart form in
The process 500 is initiated (502), for example, upon power up. As
With quick reference back to
Returning to
The built-in self-test for the solenoid 202 determines if the measured values from one or more of the fluid sensors 204 and solenoid sensors 206 meets a predetermined criterion. For example, at least in the depicted embodiment, the process first determines if the solenoid pull-in current is in range (514). If so, the process then determines if the position of the solenoid is properly changed (516) and, if so, if the measured fluid flow is in within a predetermined range (518). If the measure fluid flow is within the predetermined range, the process then determines if the measured coil temperature is within the predetermined range (522). If so, then the built-in self-test has passed (508), and the process transitions to the below-described EOL process. If not, then the built-in self-test has failed and a system shutdown is initiated, and the communication module 212 transmits an alarm to the remote station 402 (512).
As
The control 214 is also preferably configured to prognosticate end-of-life (EOL) capabilities of one or more of the solenoid 202, the fluid sensors 204, the solenoid sensors 206, the display device 208, the communication module 212, and even itself. For example, the control 214 may track the endurance cycles completed and available, the total active hours of operation, the life of the solenoid 202, the fluid sensors 204, the solenoid sensors 206, the display device 208, the communication module 212, and even itself, faulted operations, just to name a few parameters. The control 214 may then generate and transmit EOL capabilities data to the communication module 212 for transmission to the remote station 402 and/or hand-held device 404. One example of an EOL process that the control may implement is depicted in flowchart form in
The process 600 is initiated (602), for example, upon power up. As
No matter the specific mechanical and electrical endurance data, the process 600 then determines, based on the input from the solenoid position sensor 206-2 and from the solenoid driver 408, whether the solenoid 202 has operated properly (e.g., moved to the commanded position) (606). If not, then a failure count is incremented, and the failure count is compared to a predetermined number (608). If the failure count exceeds the predetermined number, then a system shutdown is initiated, and the communication module 212 transmits an alarm to the remote station 402 (612). If it does not exceed the predetermined number, then the EOL process 600 is reinitiated.
If, on the other hand, the solenoid 202 has operated properly (e.g., moved to the commanded position) (606), then an operational cycle count is incremented and stored, and various solenoid characteristics are retrieved (614). The solenoid operational characteristics that are retrieved may vary, but in one embodiment include, but are not limited to, drive current, temperature, total accumulated endurance hours of operation. These values are supplied to an empirical model that calculates the remaining useful life of each of the system components (616). It will be appreciated that anyone of numerous known empirical models may be implemented in the control 214 for making this calculation. A determination is then made as to whether the calculated remaining useful life indicates that one or more system components has reached a predetermined percentage of its life expectancy (618). It will be appreciated that the predetermined percentage may vary. In one particular embodiment, 80% is used.
If no component is determined to have reached predetermined percentage of its life expectancy, then the process 600 may repeat. Conversely, if it is determined that one or more system components may have reached the predetermined percentage of its life expectancy, then the process determines which of the components (e.g., solenoid coil, solenoid actuator, a solenoid sensor, a fluid sensor, the solenoid driver, the display driver, a fluid sensor, a circuit module sensor, etc.) this may be (622). Upon determining that a particular component has reached the predetermined percentage of its life expectancy, the communication module 212 transmits this information to the remote station 402 (624). If no particular component has reached the predetermined percentage of its life expectancy, the process transitions to the above-described built-in self-test process 500.
It will be appreciated that the control 214 may be configured to schedule Smart solenoid can be configured to schedule system 108 maintenance. To do so, the control 214 may interface with maintenance tools or centralized maintenance software stored, for example, in on-board memory. Alternatively, it may interface with the maintenance tools or centralized maintenance software stored in the remote station 402 or handheld device 404.
The control 214 may also be configured to track various alarms, if or when these occur. Such alarms may vary, but may include, for example, intruder alarms, leak alarms, over-pressure alarms, over-temperature alarms, and various hazard alarms, such as fire, smoke, leak, earthquake, floods, and physical damage (e.g. display panel tempering). Thus, as
It was previously noted that the communication module 212 may also be configured to implement numerous other functions. For example, in some embodiments, the communication module 212 is further configured to receive solenoid control commands from the remote station 402 or handheld device 404 and, upon receipt thereof, supply the solenoid control commands to the control 214. The control 214, upon receipt of the commands, would command the solenoid 202 to move to the commanded (e.g., first or second) position. In some embodiments, the communication module 212 is further configured to receive solenoid control system settings from the remote station 402 or handheld device 404 and, upon receipt thereof, supply the solenoid control system settings to the control 214. In some embodiments, the communication module 212 is further configured to communicate with other devices, such as pumps and valves, associated with the conduit 102. Moreover, if one or more of these other devices becomes faulty, the control 214 can further implement the functions of a master controller.
The control 214 may also be configured to store various system, device, health, and prognostic data. The control 214, in response to one or more requests from, for example, the remote station 402 and/or handheld device 404, may transmit all or portions of the stored data. Alternatively, the control 214 may be configured to automatically transmit all or portions of the stored data automatically upon connection of the handheld device 404 (wired or wirelessly) to the system 108.
The smart solenoid control system 108 described herein provides the capability to remotely monitor fluid and system parameters, such as fluid pressure, fluid flow, fluid temperature, solenoid temperature, solenoid position, and to automatically implement various self-tests, fault detection, fault alarm, and fault isolation/prevention procedures.
Those of skill in the art will appreciate that the various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. Some of the embodiments and implementations are described above in terms of functional and/or logical block components (or modules) and various processing steps. However, it should be appreciated that such block components (or modules) may be realized by any number of hardware, software, and/or firmware components configured to perform the specified functions. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention. For example, an embodiment of a system or a component may employ various integrated circuit components, e.g., memory elements, digital signal processing elements, logic elements, look-up tables, or the like, which may carry out a variety of functions under the control of one or more microprocessors or other control devices. In addition, those skilled in the art will appreciate that embodiments described herein are merely exemplary implementations.
The various illustrative logical blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
In this document, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Numerical ordinals such as “first,” “second,” “third,” etc. simply denote different singles of a plurality and do not imply any order or sequence unless specifically defined by the claim language. The sequence of the text in any of the claims does not imply that process steps must be performed in a temporal or logical order according to such sequence unless it is specifically defined by the language of the claim. The process steps may be interchanged in any order without departing from the scope of the invention as long as such an interchange does not contradict the claim language and is not logically nonsensical.
Furthermore, depending on the context, words such as “connect” or “coupled to” used in describing a relationship between different elements do not imply that a direct physical connection must be made between these elements. For example, two elements may be connected to each other physically, electronically, logically, or in any other manner, through one or more additional elements.
While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims.
