Patent Application
20200256713
The present disclosure relates to a system for shutting-off fluid flow and measuring fluid flow rate, and more particularly, to a system for shutting-off fluid flow and measuring fluid flow rate having improved turndown ratio characteristics.
The control of fluid flow in systems and machines may be important for the proper and efficient operation of the system or machine. Fluid systems may include various sensors, valves, and other devices to control the flow of fluid in the fluid system. For example, some fluid systems may include one or more sensors configured to generate signals indicative of characteristics of the fluid flow, and the fluid system may include flow regulators and valves to cause the fluid to flow through the fluid system in a manner that facilitates operation of the system or machine in which the fluid flows. For example, it may be desirable to measure the flow rate of fluid at one or more locations in the fluid system and/or, under some circumstances, to shut-off the fluid flow at one or more locations of the fluid system. In systems and machines, the flow rate of the fluid may vary greatly at particular locations in the fluid system depending on operation of the systems and machines. Accurately measuring flow rates throughout the range of flow rates may present difficulties. For example, a device may be capable of measuring flow rate only within a limited range of flow rates. As a result, it may be desirable to provide a device for measuring flow rate across a broad range of flow rates that may occur in the fluid system. In some applications, it may also be desirable to stop fluid flow under particular circumstances. Thus, it may also be desirable to provide a device that effectively stops fluid flow.
An attempt to measure and control fluid flow rate is described in U.S. Patent Application Publication No. US 2017/0090485 A1 to Ohashi et al. (“the '485 publication”), published Mar. 30, 2017. Specifically, the '485 publication describes a method and system for measuring and controlling a flow rate of a valve by correcting a valve opening measurement value with the use of a correction value. According to the '485 publication, the correction value corresponds to an amount of twist of a valve stem determined using the valve opening measurement value and a differential pressure detection value. The '485 publication also describes calculating a flow rate of a fluid flowing in a pipeline on the basis of a corrected valve opening and the differential pressure detection value. According to the '485 publication, the calculated flow rate of the fluid is set as a measured flow rate, and the amount of rotation of the valve stem is controlled, so that the measured flow rate matches a set flow rate.
Although the '485 publication purports to provide a flow rate calculating device and a flow rate calculation method capable of enhancing measurement precision for flow rate and a device capable of realizing a flow rate control with high precision, the device and method of the '485 publication may be unsuitable for measuring flow rates across a wide range of flow rates. The device and method disclosed herein may be directed to mitigating or overcoming one or more of the possible drawbacks set forth above.
According to a first aspect, a system for shutting-off fluid flow and measuring fluid flow rate may include a housing defining an inlet configured to receive a fluid, a valve body chamber, and an outlet opposite the inlet relative to the valve body chamber. The system may also include a valve body at least partially received in the valve body chamber, and an actuator coupled to the valve body and configured to at least one of reposition the valve body relative to the valve body chamber or re-orient the valve body relative to the valve body chamber. The system may also include at least one pressure sensor in flow communication with the housing. The at least one pressure sensor may be configured to generate a pressure differential signal indicative of a pressure difference between an inlet fluid pressure associated with the inlet and an outlet fluid pressure associated with the outlet. The system may also include a controller configured to receive a valve body signal indicative of at least one of a valve body position of the valve body or a valve body orientation of the valve body. The controller may also be configured to receive the pressure differential signal indicative of the pressure difference, and determine a flow rate of a fluid flowing through the housing based at least in part on at least one of the valve body signal and the pressure differential signal.
According to a further aspect, a system for shutting-off fluid flow and measuring fluid flow rate may include a housing defining an inlet configured to receive a fluid, a valve body chamber, and an outlet opposite the inlet relative to the valve body chamber. The system may also include a valve body at least partially received in the valve body chamber, and an actuator coupled to the valve body and configured to change at least one of an area through which the fluid flows through the housing or a flow coefficient associated with fluid flow through the housing. The system may also include at least one pressure sensor in flow communication with the housing. The at least one pressure sensor may be configured to generate a pressure differential signal indicative of a pressure difference between an inlet fluid pressure associated with the inlet and an outlet fluid pressure associated with the outlet. The system may also include a controller configured to receive a valve body signal indicative of at least one of a valve body position or a valve body orientation, and receive the pressure differential signal indicative of the pressure difference. The controller may also be configured to determine a flow rate of a fluid flowing through the housing based at least in part on at least one of the valve body signal and the pressure differential signal.
According to another aspect, a system for shutting-off fluid flow and measuring fluid flow rate may include a housing defining an inlet configured to receive a fluid, a valve body chamber, and an outlet opposite the inlet relative to the valve body chamber. The system may also include a valve body at least partially received in the valve body chamber, and an actuator coupled to the valve body and configured to at least one of reposition the valve body or re-orient the valve body. The system may also include at least one pressure sensor in flow communication with the housing. The at least one pressure sensor may be configured to generate a pressure differential signal indicative of a pressure difference between an inlet fluid pressure associated with the inlet and an outlet fluid pressure associated with the outlet. The system may further include a controller configured to determine a first flow rate through the housing based at least in part on a first pressure differential signal, the first flow rate being within a first range of flow rates. The controller may also be configured to cause the actuator to at least one of (1) reposition the valve body from a first position to a second position or (2) re-orient the valve body from a first orientation to a second orientation. The controller may also be configured to determine a second flow rate through the housing based at least in part on a second pressure differential signal. The second flow rate may be within a second range of flow rates, and the second range of flow rates may be different than the first range of flow rates.
The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit of a reference number identifies the figure in which the reference number first appears. The same reference numbers in different figures indicate similar or identical items.
Example fuel system 102 shown in
In some examples, fuel system 102 may include a fuel filter, for example, between fuel source 104 and pressure regulator 108, and/or between pressure regular 108 and multi-position shut-off valve 110. In some examples, fuel system 102 may provide fuel to one or more combustion chambers (or cylinders) of internal combustion engine 106. In some examples, fuel system 102 may be one of a plurality of at least similar fuel systems providing fuel to internal combustion engine 106. Additionally, or alternatively, fuel system 102 may include a plurality of branches providing flow communication to one or more other components of fuel system 102, for example, such that there may be multiple multi-position fluid shut-off valves, multiple pressure regulators, and/or multiple fuel valves. In some examples, a plurality of multi-position fluid shut-off valves may be placed in series, for example, such that one or more of the plurality of multi-position fluid shut-off valves serve as a backup or backups to others.
Some examples of fuel system 102 may include at least a second multi-position fluid shut-off valve 114 different to, similar to, or the same as, multi-position shut-off valve 110 shown in
As shown in
As shown in
In some examples, second multi-position fluid shut-off valve 114 facilitates a variable fuel flow rate through second multi-position fluid shut-off valve 114. For example, second multi-position fluid shut-off valve 114 may facilitate adjustment from a first flow rate between zero flow and maximum flow to and/or from a second flow rate between zero flow and/or maximum flow. For example, second multi-position fluid shut-off valve 114 may be configured to increase or decrease a fuel flow rate to and/or from 20% of maximum flow rate, to and/or from 30% of maximum flow rate, to and/or from 50% of maximum flow rate, to and/or from 75% of maximum flow rate, and/or the like. In some such examples, the fuel flow rate of fuel through second multi-position fluid shut-off valve 114 may depend on the position and/or orientation of the valve body of second multi-position fluid shut-off valve 114, which may be controlled, for example, by engine control module 116, for example, via an electrically controlled actuator. As a result, second multi-position fluid shut-off valve 114 may facilitate additional fuel flow rates through fuel system 102 other than zero flow (0% of maximum flow rate) and maximum flow (100% of maximum flow rate), though second multi-position fluid shut-off valve 114 may facilitate zero flow, maximum flow of fuel, and/or flow rates between zero flow and maximum flow.
In some examples, one or more additional multi-position fluid shut-off valves, for example, similar to second multi-position fluid shut-off valve 114, may be provided in parallel relative to one or more other components of fuel system 102. For example, an additional multi-position fluid shut-off valve may be provided in parallel relative to fuel valve 112. In some such examples, the additional multi-position fluid shut-off valve may be used to control an amount of fuel, a pressure of fuel, and/or a flow rate of fuel directly injected into internal combustion engine 106. The additional multi-position fluid shut-off valve may be used under certain operating conditions, for example, upon startup of internal combustion engine 106) as determined by engine control module 116 associated with internal combustion engine 106.
For example, as shown in
As mentioned above, multi-position fluid shut-off valve 110 may be configured to selectively shut-off or allow fluid flow through multi-position fluid shut-off valve 110 and, in some examples, measure fluid flow rate through multi-position fluid shut-off valve 110. In some examples, multi-position fluid shut-off valve 110 may not be configured to be used solely to alter fluid flow rate in the fluid system 100. In some such examples, second multi-position fluid shut-off valve 114 (
Sensor(s) 118 may include any type of sensor configured to measure one or more parameters of fuel system 100, internal combustion engine 106, or one or more ambient conditions. Sensor(s) 118 may be sensors of a sensor system that is communicatively coupled with controller 202 and/or engine control module 116, as described herein. For example, sensor(s) 118 may include temperature sensors, for example, configured to generate signals indicative of fluid temperature (e.g., fuel temperature), ambient air temperature, exhaust temperature, a component temperature, coolant temperature, and/or the like), position sensors, for example, configured to generate signals indicative of a position and/or orientation of a valve body, an actuator, an engine part (e.g., a piston), and/or the like, speed sensors, for example, configured to generate signals indicative of engine speed, a machine speed, and/or the like, pressure sensors, for example, configured to generate signals indicative of compression of air and/or fuel in fuel system 100, emissions sensors, for example, configured to generate one or more signals indicative of emission levels associated with operation of internal combustion engine 106, combustion sensors, for example, configured to generate signals indicative of one or more components of combustion, and/or other sensors.
Sensor(s) 118 may be associated with a sensing parameter that may be used in determining a fuel flow rate, fuel pressure, fuel mass flow, and/or the like associated with fuel system 100. For example, a value of the sensing parameter for one or more sensor(s) 118 may represent or indicate a measurement of the sensor(s) 118, such as, for example, a measured pressure of a pressure sensor, a measured temperature of a temperature sensor, a measured timing of a valve (e.g., fuel valve 112) opening and/or closing by a position sensor, a measured engine speed (e.g., engine speed of internal combustion engine 106) by a speed sensor, a measured position and/or orientation of an actuator or valve body (e.g., a valve body of multi-position fluid shut-off valve 110, fuel valve 112, and/or the like) by a position/orientation sensor, measured emissions by an emissions sensor, and/or the like.
In some examples, engine control module 116 may facilitate control of second multi-position fluid shut-off valve 114, for example, in order to control a fuel flow rate through fuel system 102 and/or through various components of fuel system 102 according to one or more signals generated by one or more of sensor(s) 118. Engine control module 116 and/or controller 202, in some examples, may be implemented as a processor, such as a central processing unit (CPU), a graphics processing unit (GPU), an accelerated processing unit (APU), a microprocessor, a microcontroller, a digital signal processor (DSP), a field-programmable gate array (FPGA), an application-specific integrated circuit (ASIC), or another type of processing component. The processor may be implemented in hardware, firmware, or a combination of hardware and software. In some implementations, engine control module 116 and/or controller 202 may include one or more processors capable of being programmed to perform a function. In some examples, one or more memories, including a random-access memory (RAM), a read-only memory (ROM), and/or another type of dynamic or static storage device (e.g., a flash memory, a magnetic memory, and/or an optical memory) may store information and/or instructions for use by engine control module 116 and/or controller 202. In some examples, engine control module 116 and/or controller 202 may include a memory (e.g., a non-transitory computer-readable medium) capable of storing instructions, that when executed, cause the processor to perform one or more processes and/or methods described herein. A computer-readable medium may be defined herein as a non-transitory memory device. A memory device may include memory space within a single physical storage device or memory space spread across multiple physical storage devices.
Engine control module 116 and/or controller 202 may execute the instructions to perform various control functions and processes to control multi-position fluid shut-off valve 110 and/or second multi-position fluid shut-off valve 114, and, as such, to automatically control a flow rate of fuel through fuel system 100 and/or through various components of fuel system 100. Engine control module 116 and/or controller 202 may include any appropriate type of engine control system configured to perform engine control functions, such that internal combustion engine 106 may operate properly. In some examples, engine control module 116 and/or controller 202 may also at least partially control other systems of a machine, such as transmission systems, electronic systems, hydraulics systems, actuators, and/or the like.
In some examples, in operation, computer software instructions may be stored in and/or loaded onto engine control module 116 and/or controller 202. Engine control module 116 and/or controller 202 may execute the computer software instructions to perform various control functions and processes related to multi-position fluid shut-off valve 110 and/or second multi-position fluid shut-off valve 114, for example, to adjust (automatically or otherwise) one or more parameters of fuel system 102, such as, for example, an inlet pressure of a pressure regulator (e.g., pressure regulator 108), a fuel mass flow of fuel through at least portions of fuel system 102, measure flow rate through multi-position fluid shut-off valve 110 and/or fuel system 102, and/or the like. Additionally, or alternatively, engine control module 116 and/or controller 202 may execute computer software instructions to generate and/or cause one or more of sensor(s) 118 to provide fuel system and/or engine temperature values, fuel system and/or engine pressure values, engine emission values, engine speed values, actuator and/or valve body position/orientation values, and/or other parameter values that may be used to monitor fuel system 102 and/or internal combustion engine 106.
In some examples, engine control module 116 and/or controller 202 may identify, obtain, and/or determine parameters that are associated with conditions (e.g., as sensed by one or more of sensor(s) 118) or settings corresponding to the operations of fuel system 102 and/or internal combustion engine 106, such as, for example, fuel rate or quantity, engine speed, fuel injection timing, intake manifold temperature (IMAT), intake manifold pressure (IMAP), intake valve actuation (IVA), IVA timing, intake throttle valve position, air injection pressure, fuel injection pressure, torque delivered by internal combustion engine 106, total fuel injection quantity, exhaust pressure, oxygen/fuel molar ratio, ambient temperature, ambient pressure (e.g., barometric pressure), mass flow through fuel system 102, exhaust backpressure valve position, coolant temperature, and/or the like.
As schematically shown in
In some examples, multi-position fluid shut-off valve 300 may be configured to operate as both a fluid shut-off valve and a device for measuring flow rate of fluid flowing through multi-position fluid shut-off valve 300. For example, multi-position fluid shut-off valve 300 may operate as multi-position fluid shut-off valve 110 shown in
In some examples, controller 202 may include one or more devices configured to control multi-position fluid shut-off valve 300, as described herein. For example, controller 202 may be configured, in some examples, via a user interface and/or default settings, to shut-off flow through multi-position fluid shut-off valve 300 by causing actuator 310 to reposition and/or re-orient (e.g., rotate) valve body 308, such that valve body passage 320 is closed relative to inlet 314 and/or outlet 318 of housing 302. In some examples, controller 202 may be configured, for example, via a user interface and/or default settings, to measure fluid flow rate through multi-position fluid shut-off valve 300 across a wide range of turndown ratios (e.g., a wide range of ratios of maximum fluid flow rates to minimum fluid flow rates). For example, multi-position fluid shut-off valve 300 may be configured to accurately measure fluid flow rates through multi-position fluid shut-off valve 300 across a wide range of fluid flow rates by repositioning and/or re-orienting valve body 308 and measuring pressure differential across inlet 314 and outlet 318 of multi-position fluid shut-off valve 300. For example, the effective range of flow rate measurement capability of multi-position fluid shut-off valve 300 may be altered by rotating valve body 308 between measurement positions from zero degrees (e.g., with valve body passage 320 aligned with respect to inlet 314 and outlet 318) to ninety degrees (e.g., with valve body passage 320 completely orthogonal with respect to inlet 314 and outlet 318) at which point multi-position fluid shut-off valve 300 effectively shuts-off fluid flow through multi-position fluid shut-off valve 300. In some examples, each position and/or orientation between zero degrees and ninety degrees corresponds to a capability to accurately measure a different range of fluid flow rates through multi-position fluid shut-off valve 300.
For example, some examples of controller 202 may be configured to receive a valve body signal indicative of a valve body position of valve body 308 relative to valve body chamber 316 and/or a valve body orientation of valve body 308 relative to valve body chamber 316. For example, controller 202 may be configured store in memory and/or access data corresponding to positions and/or orientations of valve body 308 (e.g., from data 120 and or other data 208, see
In some examples, controller 202 may be configured to determine a flow rate of fluid flowing through multi-position fluid shut-off valve 300 based at least in part on the valve body signal and the pressure differential signal. For example, referring to
In some examples, controller 202 may also be configured to receive a temperature signal indicative of a temperature of fluid flowing through multi-position fluid shut-off valve 300 and determine the flow rate of the fluid flowing through multi-position fluid shut-off valve 300 based at least in part on the temperature signal and the valve body signal and/or the pressure differential signal. In some examples, the temperature sensor(s) may be integrated into multi-position fluid shut-off valve 300, and in some examples, the temperature sensor(s) may be independent of multi-position fluid shut-off valve 300. The use of any suitable known temperature sensors is contemplated.
In some examples, controller 202 may also be configured to receive a fluid characterization signal indicative of at least one characteristic of the fluid and determine the flow rate of the fluid flowing through multi-position fluid shut-off valve 300 based at least in part on the fluid characterization signal, the valve body signal, the pressure differential signal, and/or the temperature signal. In some examples, the fluid characterization signal may be manually entered via an input device, such as a computer input device. In some examples, the fluid characterization signal may be generated by one or more of the sensor(s) 118. The at least one fluid characteristic may include one or more of fluid type, fluid density, fluid components, viscosity, or any other known fluid characteristics, such as those that might affect fluid flow.
In some examples, controller 202 may be configured to determine fluid flow rate at different flow rate ranges and/or according to different flow rate turndown ratios. For example, multi-position fluid shut-off valve 300 and controller 202 may be configured to determine flow rate within a first range of flow rate ranges and/or at a first turndown ratio. This first determination may correspond to a first position and/or orientation of valve body 308. Therefore, for example, if flow conditions in the fluid system change such that the fluid flow rate through multi-position fluid shut-off valve 300 changes to a magnitude outside of the first range and/or the first turndown ratio, controller 202 may cause the actuator to reposition and/or re-orient valve body 308, such that controller 202 determines fluid flow rate through multi-position fluid shut-off valve 300 within a second range of flow rates and/or at a second turndown ratio, where the second range of flow rates and/or the second turndown ratio differs respectively from the first range of flow rates and/or the first turndown ratio. In such examples, multi-position fluid shut-off valve 300 may be capable of repositioning and/or reorienting of valve body 308 to measure fluid flow rates through multi-position fluid shut-off valve 300 based on repositioning and/or reorienting valve body 308 using controller 202. In some such examples, controller 202 may access one or more of look-up tables 206 and/or other data 208 (e.g., temperature, fluid system characteristics, and/or fluid characteristics) to determine fluid flow rate through multi-position fluid shut-off valve 300 based on one or more of the valve body signals, the pressure differential signals, temperature signals, or fluid characterization signals.
For example, controller 202 may be configured to receive a parameter signal indicative of operation of a fluid system in flow communication with the system, and cause actuator 310 to (1) reposition valve body 308 relative to the valve body chamber 316 from a first position to a second position and/or (2) re-orient valve body 308 relative to valve body chamber 316 from a first orientation to a second orientation. The parameter signal may be indicative of any characteristic (or change thereof) related to the fluid, the fluid system (e.g., pressure and/or flow rate in another part of the fluid system), and/or other components of the fluid system. Thereafter, in some examples, controller 202 may be configured to receive a second valve body signal indicative of a second position and/or a second orientation, receive a second pressure differential signal indicative of the pressure difference, and determine a second flow rate of the fluid flowing through the multi-position fluid shut-off valve 300 based at least in part on at least the second valve body signal and the second pressure differential signal, wherein the second flow rate is within a second range of flow rates, the second range of flow rates being different than the first range of flow rates. In some such examples, the upper end of the second range of flow rates may be higher than the upper end of the first range of flow rates by a multiplication factor. The multiplication factor may range from, for example, above one to about ten-thousand, for example, from about two to about ten-thousand, from about ten to about ten-thousand, from about one-hundred to about ten-thousand, from above about one to about one-thousand, from above about one to about one-thousand, or from above about one to about one-hundred. In some examples, the range of flow rates may be limited by the measuring capabilities of one or more of the pressure sensors 400.
In some examples, controller 202 may be configured to cause actuator 310 to reposition and/or reorient valve body 308, thereby increasing the turndown ratio associated with the range of flow rates measurable by multi-position fluid shut-off valve 300. In some examples, the turndown ratio may range, for example, from about ten to about sixty-thousand, from about twenty to about sixty-thousand, from about thirty to about sixty-thousand, from about fifty to about sixty-thousand, from about one-hundred to about sixty-thousand, from about one-thousand to about sixty-thousand, from about twenty to about fifty-thousand, from about twenty to about ten-thousand, from about twenty to about one-thousand, or from about twenty to about one-hundred. In some examples, the range of turndown ratios may be limited by the capabilities of one or more of the pressure sensors 400.
The exemplary system and related methods of the present disclosure may be applicable to a variety of fluid systems and fluid types. For example, the system for shutting-off fluid flow and measuring fluid flow rate may be incorporated into a fuel system, for example, for an internal combustion engine. Some examples of the system may be incorporated into other types of fluid systems, such as, for example, cooling systems, hydraulic systems, lubrication systems, HVAC systems, or any other fluid system for which fluid flow shut-off and/or fluid flow rate measurement may be desirable.
Some examples of the system may provide an ability to measure a wide range of fluid flow rates within a fluid system, for example, by control of the position and/or orientation of a valve body in a multi-position fluid shut-off valve, for example, as described herein. Some such examples may result in a providing a fluid flow rate measurement having a large turndown ratio, for example, a relatively larger turndown ratio than conventional fluid flow rate measuring devices.
While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems, and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.
