WO2014033728A2 - Valve spool monitoring using anisotropic magnetoresistance sensor - Google Patents

Valve spool monitoring using anisotropic magnetoresistance sensor Download PDF

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Publication number
WO2014033728A2
WO2014033728A2 PCT/IN2013/000407 IN2013000407W WO2014033728A2 WO 2014033728 A2 WO2014033728 A2 WO 2014033728A2 IN 2013000407 W IN2013000407 W IN 2013000407W WO 2014033728 A2 WO2014033728 A2 WO 2014033728A2
Authority
WO
WIPO (PCT)
Prior art keywords
valve
solenoid
valve spool
spool
sensor
Prior art date
Application number
PCT/IN2013/000407
Other languages
French (fr)
Other versions
WO2014033728A3 (en
Inventor
Saini HITESH
Surase NILESH
Vajid SHAIKH
Original Assignee
Eaton Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Eaton Corporation filed Critical Eaton Corporation
Publication of WO2014033728A2 publication Critical patent/WO2014033728A2/en
Publication of WO2014033728A3 publication Critical patent/WO2014033728A3/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K37/00—Special means in or on valves or other cut-off apparatus for indicating or recording operation thereof, or for enabling an alarm to be given
    • F16K37/0025—Electrical or magnetic means
    • F16K37/0033—Electrical or magnetic means using a permanent magnet, e.g. in combination with a reed relays
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K31/00—Actuating devices; Operating means; Releasing devices
    • F16K31/02—Actuating devices; Operating means; Releasing devices electric; magnetic
    • F16K31/06—Actuating devices; Operating means; Releasing devices electric; magnetic using a magnet, e.g. diaphragm valves, cutting off by means of a liquid
    • F16K31/0603—Multiple-way valves
    • F16K31/061—Sliding valves
    • F16K31/0613—Sliding valves with cylindrical slides
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R33/00—Arrangements or instruments for measuring magnetic variables
    • G01R33/02—Measuring direction or magnitude of magnetic fields or magnetic flux
    • G01R33/06—Measuring direction or magnitude of magnetic fields or magnetic flux using galvano-magnetic devices
    • G01R33/09—Magnetoresistive devices
    • G01R33/093—Magnetoresistive devices using multilayer structures, e.g. giant magnetoresistance sensors

Definitions

  • Hydraulic fluid cylinders, reciprocating cylinder pumps, and other types of cylinder-based mechanical fluid-moving devices or engines use proximity sensors (also referred to as proximity switches) to sense position of spools, pistons, or other components to monitor performance, enhance safety, minimize damage to parts due to contact between parts.
  • proximity sensors also referred to as proximity switches
  • a modular valve assembly may be manufactured by coupling a first solenoid to a first end of a valve body; coupling a first end of a sensor housing to a second end of the valve body; selecting one of a second solenoid and an end plug; and coupling the selected one to a second end of the sensor housing.
  • the second end of the sensor housing is configured to be capable of receiving either one of the second solenoid and the end plug.
  • the sensor housing includes a sensor arrangement that is configured to detect a position of a valve spool within the valve body.
  • a valve assembly includes a valve module; a first solenoid; and a sensing module.
  • the valve module includes a valve spool housed within a valve body. The valve spool is configured to move axially within the valve body. The valve spool is operatively coupled to a magnet.
  • the first solenoid is coupled to a first end of the valve module to actuate movement of the valve spool.
  • the sensing module includes a housing assembly holding at least one anisotropic magnetoresistance sensor configured for sensing the magnet. A first end of the sensing module is coupled to a second end of the valve module. The second end of the sensing module is selectively coupled to one of a solenoid and a plug.
  • a valve assembly includes a valve module; a first solenoid; a valve spool extension; and a sensing module.
  • the valve module includes a valve spool housed within a valve body. The valve spool is configured to move axially within the valve body.
  • the first solenoid is coupled to a first end of the valve module to actuate movement of the valve spool.
  • the valve spool extension is coupled to the valve spool and is configured to move with the valve spool.
  • the valve spool extension encloses a magnet.
  • the sensing module is coupled to a second end of the valve module.
  • the sensing module includes at least one sensor arrangement that is configured for sensing the magnet.
  • the sensing arrangement includes a circuit board and at least one anisotropic magnetoresistance sensor.
  • the circuit board has a first major surface and a second major surface. The first major surface faces towards the spool valve extension and the second major surface faces away from the spool valve extension.
  • FIG. 1 is a side elevational view of one implementation of a dual solenoid valve module assembly with a sensing module shown in cross-section;
  • FIG. 2 is an axial cross-sectional view of the valve module assembly of FIG. 1 ;
  • FIG. 3 is an exploded perspective view of the valve module assembly of FIG . 1 ;
  • FIG. 4 is a perspective view of an example single solenoid valve module assembly with a plug exploded outwardly from one end of the valve module assembly;
  • FIG. 5 is a side elevational view of the single solenoid valve module assembly of FIG. 4 with the sensing module shown in cross-section;
  • FIG. 6 is a perspective view of an example adapter in which internal features are shown in dashed lines;
  • FIG. 7 is a cross-sectional view of the adapter of FIG. 6;
  • FIG. 8 is a perspective view of an example sensor chassis in which internal features are shown in dashed lines;
  • FIG. 9 is a cross-sectional side view of the sensor chassis of FIG.8;
  • FIG. 10 is a cross-sectional view of an example sensor module including an example spool valve extension holding an anisotropic
  • FIG. 1 1 is a bottom plan view of one example sensor arrangement suitable for use in any of the sensing modules disclosed herein;
  • FIG. 12 is a side elevational view of sensor arrangement of FIG. 1 1 ;
  • FIG. 13 is a bottom plan view of an anisotropic magnetoresistance sensor shown in relation to a magnet oriented for axial placement relative to the valve spool;
  • FIG. 14 is a cross-sectional view of one example valve spool extension
  • FIG. 15 is a perspective view of an example sensor rod shown with transparent sides to enable viewing of interior features
  • FIG. 16 is a flow chart illustrating a detection process for determining spool valve movement
  • FIG. 17 is a perspective view of another example dual solenoid valve module assembly including a sensing module
  • FIG. 18 is a longitudinal cross-sectional view of the dual solenoid valve module assembly of FIG. 17;
  • FIG. 19 is a perspective view of an exploded sensing module of FIG. 17 shown exploded from an example flange;
  • FIG. 20 is a perspective view of an exploded sensing module of FIG. 21 shown exploded from another example flange.
  • FIG. 21 is a perspective view of another example dual solenoid valve module assembly including the sensing module of FIG. 17 and the flange of FIG. 20.
  • the technology described herein has applications in monitoring hydraulic fluid spool valves and other types of directional ly-operated valves or mechanical fluid-moving devices. Additionally, the technology may be used in spool valves or similar fluid-moving devices where the working fluid is air or another gas as opposed to hydraulic fluid. For clarity, however, the following embodiments will be described as sensor monitoring systems for hydraulic fluid spool valves.
  • the modular valve assembly 10 may be configured for use with a single solenoid, a dual solenoid, or other another type of actuator.
  • FIGS. 1-3 illustrate one example dual solenoid modular valve assembly 10. As shown in the figures, the modular valve assembly 10 includes a valve module 12, a sensing module 14, a first solenoid 16, and a second solenoid 18.
  • the valve module 12 includes a body 20 that extends from a first end 21 to a second end 22.
  • the first solenoid 16 is coupled to the first end 21 of the valve module body 20.
  • the sensing module 14 also includes a housing 30 that extends from a first end 31 to a second end 32.
  • the first end 31 of the sensing module housing 30 is coupled to the second end 22 of the valve module body 20.
  • the second solenoid 18 is coupled to the second end 32 of the sensing module housing 30.
  • the valve module body 20 defines a linear channel 23 extending between the first end 21 and the second end 22.
  • the valve body 20 also defines an inlet port 24 that couples to a system pump, an outlet port 25 that couples to a return tank or reservoir, a first work port channel 26 that connects to a first system work port, and a second work port channel 27 that connects to a second system work port.
  • Each of the ports 24-27 connects to the linear channel 23.
  • the linear channel 23 may connect to additional work ports, pilot valve ports, or other valve spool ports.
  • the valve module 12 also includes a valve spool 28 disposed within the valve body 20 and configured to move axially through the channel.
  • the valve spool 28 opens and closes connections between the ports 24-27 by sliding within the channel 23 along a slide axis C.
  • the valve spool 28 is configured to move between three discrete positions: a neutral position; a first side (i.e., left) position; and a second side (i.e., right) position.
  • the valve spool 28 disconnects (i.e., blocks) the inlet port 24 and the outlet port 25 from the work ports 26, 27.
  • valve spool 28 When in the first position, the valve spool 28 connects the inlet port 24 to the first work port 26 and the outlet port 25 to the second work port 27. When in the second position, the valve spool 28 connects the inlet port 24 to the second work port 27 and the outlet port 25 to the first work port 26.
  • the first solenoid 16 is configured to move the valve spool 28 between the neutral position and the first side position.
  • the second solenoid 18 is configured to move the valve spool 28 between the neutral position and the second side position.
  • Each of the first and second solenoids 16, 18 includes a spring 17, 19, respectively, that biases the spool valve 28 towards the neutral position.
  • Each of the solenoids 16, 18 may be electronically controlled to move the valve spool 28. In other implementations, other types of actuators may be moved in place of the solenoids 16, 18.
  • the sensing module 14 is configured to detect the position of the valve spool 28 within the valve body 20. In some implementations, the sensing module 14 may detect a discrete position of the valve spool 28 within the valve body 20. As the term is used herein, the "discrete position" of the valve spool 28 refers to one of a finite number of positions into which the valve spool 28 may be moved within the valve body 20 (e.g., a neutral position, a first side position, etc.). In other implementations, the sensing module 14 may detect an absolute position of the valve spool 28 within the valve body 20.
  • the "absolute position" of the valve spool 28 refers to one of a theoretically infinite number (subject to tolerances of the system) of positions of the valve spool 28 within the valve body 20 including the positions through which the valve spool 28 passes when moving between the discrete positions.
  • the sensing module 14 includes a sensor arrangement 40 that senses the position of a magnetic element 39 that is operatively coupled to the spool valve 28 and adapted to move therewith as will be disclosed in more detail herein. Movement of the magnetic element 39 into different positions affects the angles of the magnetic field generated by the magnetic element 39.
  • the sensor arrangement 40 measures the direction/angle of the magnetic field generated by the magnetic element 39 as the magnetic element 39 moves along with the valve spool 28.
  • the sensor arrangement 40 includes at least one anisotropic magnetoresistance sensor.
  • the magnetic element 39 is coupled to a valve spool extension 35 that couples to the valve spool 28 for movement therewith along the slide axis C.
  • the housing assembly 30 defines a linear channel 34 extending from the first end 31 to the second end 32 of the housing 30.
  • the linear channel 34 aligns with the linear channel 23 of the valve body 20 when the housing assembly 30 is coupled to the valve body 20.
  • the valve spool extension 35 is configured to slide axially through the housing assembly 30 when the valve spool 28 slides through the valve body 20.
  • a first end of the valve spool extension 35 couples to the valve spool 28 and a second end of the valve spool extension 35 couples to the second solenoid 18.
  • the second solenoid 18 acts on the valve spool extension 35 to move the valve spool 28 relative to the valve body 20.
  • the valve spool 28 is sufficiently long to extend through the linear channel 34 of the sensing module housing 30 and to interact with the second solenoid 18.
  • the magnetic element 39 is coupled directly to the valve spool 28.
  • the sensor housing 30 defines a sensor chamber 33 in which the sensor arrangement 40 is disposed (see FIGS. 1 and 4).
  • the chamber 33 is isolated from the liner channel 34, thereby protecting the sensor arrangement 40 from the moving valve spool extension 35.
  • a controller 48 (FIG. 1) may be coupled to the sensor arrangement 40 and configured to analyze the output of the sensor arrangement 40.
  • the controller 48 determines the position of the magnetic element 39, and hence the position of the valve spool 28, based on the output of the sensor arrangement 40.
  • the controller 48 is a microcontroller and forms part of the sensor arrangement 40 and connecting wires 49 or other signal carriers may extend from the controller 40 within the chamber 33 to an exterior of the sensing housing 40 for communication with a monitoring system.
  • the controller 48 may be located remote from the sensing housing 40 and the connecting wires 49 couple the controller 48 to the sensor arrangement 40.
  • a wireless connection may be used instead of wires 49.
  • FIGS. 4 and 5 illustrate another example modular valve assembly 50 that includes the valve module 12, sensing module 14, and first solenoid 16 of the first modular valve assembly 10. These components operate substantially the same as described above with reference to FIGS. 1-3.
  • the modular valve assembly 50 includes an end plug arrangement 52 coupled to the second end 32 of the sensing module housing 30 instead of the second solenoid 18.
  • the end plug arrangement 52 seals the linear channel 34 of the housing assembly 30.
  • the end plug arrangement 52 also biases the valve spool extension 35, and hence the valve spool 28, towards the neutral position when the first solenoid 16 is not acting on the valve spool 28 as will be described in more detail herein.
  • the same sensing module 14 may be utilized with either of the modular valve assemblies 10, 50 described herein.
  • the second end 32 of the housing 30 is capable of interfacing with a solenoid, such as second solenoid 18.
  • the second end 32 of the housing 30 also is capable of interfacing with an end plug, such as end plug arrangement 52. Accordingly, fewer sensing modules 14 need to be kept in stock since the same part may be used with either assembly 10, 50.
  • the housing assembly 30 of the sensing module 14 includes an adapter 60 and a sensor chassis 65.
  • the adapter 60 and the chassis 65 couple together to define the sensor chamber 33.
  • the adapter 60 includes a mounting section 61 that is configured to couple to the second end 22 of the valve body 20.
  • the mounting section 61 defines fastener openings 62 that are configured to align with fastener Openings defined at the second side of the valve body 20.
  • a protruding section 63 of the adapter 60 extends outwardly from the mounting section 61.
  • the mounting section 61 and the protruding section 63 cooperate to define a through passage 64 extending therethrough.
  • the passage 64 forms the linear channel 34 of the sensor module housing 30.
  • the inner passage 64 has a generally round transverse lateral cross-sectional shape. In other implementations, the passage 64 may have any desired transverse lateral cross-sectional shape.
  • one side of the protruding section 63 defines a flat surface 66.
  • the flat surface 66 may have one or more bores 67 for insertion of screws or other similar fasteners.
  • the flat surface 66 extends generally parallel to a slide axis C of the valve spool 28. As will be discussed in more detail herein, the flat surface 66 may provide a level surface for mounting the sensor arrangement 40 within the sensing module housing 30.
  • the mounting section 61 also defines a cavity 65 to receive a portion of a sealing plug 80 (FIG. 1) that facilitates couplings the sensing module housing 30 to the valve body 20.
  • the cavity 65 has a larger cross-dimension than the passage 64.
  • the plug 80 has a first end that extends into the second end 22 of the valve body 20 and a second end that extends into the first end 31 of the sensing module housing 30.
  • the plug 80 also defines a passage through which the valve spool 28 and/or valve spool extension 35 may extend.
  • the valve spool 28 couples to the valve spool extension 35 within the plug 80.
  • the plug 80 may cooperate with a gasket (e.g., an O-ring) to inhibit fluid from leaking from the modular valve assembly 10, 50.
  • a gasket e.g., an O-ring
  • the sensor chassis 70 (FIGS. 8 and 9) is sized to fit around the protruding section 63 of the adapter 60.
  • the sensor chassis 70 has a first end 71 and an opposite second end 73.
  • One or more fastener passages 72 extend between the first and second ends 71, 73.
  • the fastener passages 72 align with the fastener openings 62 of the adapter 60.
  • Fasteners 82 extend through the fastener passages 72, the fastener openings 62 of the adapter 60, and the fastener openings of the valve body 20 to secure the sensing module housing 30 to the valve body 20 (see FIG. 3).
  • the sensor chassis 70 also defines a through passage 74 extending between the first and second ends 71, 73.
  • the through passage 74 has a first section 75 and a second section 76.
  • the first section 75 of the passage 74 has a larger cross- dimension than the second section 76 of the passage 74.
  • the first section 75 is sized to receive at least a portion of the valve spool extension 35 for sliding movement therein.
  • the second section 76 is sized to receive a portion of a solenoid or an end plug arrangement.
  • the second spring 1 9 may be disposed within the second section 76 of the passage 74 between a portion of the valve spool extension 35 and either the second solenoid 18 (see FIG. 2) or the end plug arrangement 52 (see FIG. 5).
  • FIG. 2 shows a portion of the second solenoid 18 extending into the second section 76 of the passage 74.
  • the second spring 19 is disposed within the second passage section 76.
  • FIG. 5 shows a portion of the end plug arrangement 52 extending into the second passage section 76.
  • the plug arrangement 52 includes a head 53 that remains external to the chassis 70 and a protruding section 54 that extends into the second passage section 76.
  • the second spring 19 cooperates with the first spring 17 to bias the valve spool 28 and extension 35 to a neutral position.
  • an O-ring or other gasket 56 may be provided at the interface between the chassis 70 and the solenoid 18 or plug 52. The O-ring 56 may minimize wear and help to ensure an adequate seal between the sensing module and the plug.
  • the portion of the plug 52 or second solenoid 18 that extends into the chassis 70 may be threaded to enable a threaded coupling between the sensing module 14 and the plug 52 or solenoid 18.
  • the portion of the plug 52 or solenoid 18 that extends into the chassis 70 may be smooth and have a diameter that provides a press-fit connection between the sensing module 14 and the plug 52 or solenoid 18.
  • the portion of the plug 52 or solenoid 18 that extends into the chassis 70 may be bonded to the chassis 70 using adhesive.
  • the plug 52 or solenoid 18 may be otherwise secured to the sensing module 14.
  • the sensor chassis 70 also defines a cavity 78 that is connected to the first section 75 of the passage 74.
  • the cavity 78 is radially offset from the first section 75 and is sized to receive the sensor arrangement 40.
  • the cavity 78 is closed by protruding section 63 of the adapter 60 when the adapter 60 is coupled to the sensor chassis 70.
  • the closed cavity 78 forms the sensor chamber 33 in which the sensor arrangement 40 is located.
  • the flat surface 66 of the protruding section 63 faces the cavity 78.
  • a conduit or aperture 79 connects the sensor chamber 33 to an exterior of the chassis 70.
  • At least a portion of the sensor chassis 70 is formed of a magnetic material for shielding the sensor arrangement 40 from external magnetic fields and external magnetic interferences.
  • magnetic materials that are suitable for constructing the sensor chassis include, but are not limited to, magnetic carbon steels, magnetic stainless steels, and other materials containing iron, nickel, and/or cobalt.
  • FIG. 10 is an enlarged view of the sensing module 14 shown in cross- section so that the valve spool extension 35, the magnetic element 39, and the sensor arrangement 40 are visible.
  • the sensor arrangement 40 includes one or more sensors 41 mounted to a circuit board 43 disposed within the cavity 33 of the housing assembly 30.
  • the circuit board 43 is oriented so that at least one of the sensors 41 faces towards the magnetic element 39.
  • the circuit board 43 may have a first major surface 44 facing towards the channel 34 in the sensing housing 30 and a second major surface 45 facing away from the channel 34.
  • Active electronic components 46 may be mounted to the second major surface 45 of the circuit board 43 (see FIG. 12).
  • Non-limiting examples of active electronic components 46 include a diode, a triode vacuum tube, a transistor, an integrated circuit, a power source, and a switch.
  • the circuit board 43 is mounted to the flat surface 66 of the adapter 60. One or more screws or other such fasteners may couple the circuit board 43 to the adapter 60.
  • each sensor 41 is disposed between the first surface 44 of the circuit board 43 and the flat surface 66 of the adapter 60.
  • one or more "washers or other such structures may be placed between the circuit board 43 and the flat surface 66 of the adapter 60 to space the circuit board 43 above the surface 66.
  • the circuit board 43 may include an array 42 of two or more sensors 41.
  • the sensor array 42 includes two rows of sensors 41 . In certain implementations, the sensors 41 in one row are redundant to the sensors 41 in the other row.
  • the rows extend parallel to the sliding axis C of the valve spool 28. Accordingly, the sensors 41 are positioned to increase the range of the sensor arrangement 40. As the magnetic element 39 moves along the axis C, the controller 48 monitors the output of consecutive sensors 41 to track the position of the magnetic element 39.
  • the magnetic element 39 may be positioned and oriented so that the poles of the magnet are aligned along the sliding axis C of the valve spool 28. Aligning the poles along the movement axis C of the magnetic element 39 creates a magnetic field that is generally symmetrical with 'respect to rotation about the axis C. . Accordingly, rotation of the magnetic element 39 (e.g., caused by rotation of the valve spool 28 and/or extension 35) will not cause fluctuations in the sensor readings produced by the sensor arrangement 40.
  • the magnetic element 39 may be offset from the movement axis C.
  • the magnetic element 39 is shown disposed on the valve spool extension 35. In other implementations, the magnetic element 39 may be disposed on the valve spool 28. In other implementations, however, the magnetic element 39 may be radially orientated so that the poles align along an axis transverse to the sliding axis C.
  • the magnetic element 39 may be disposed within the valve spool extension 35.
  • the magnetic element 39 may be disposed along a central longitudinal axis of the valve spool extension 35.
  • the valve spool 35 protects the magnetic element 39 during movement.
  • the magnetic element 39 may be disposed at an exterior of the valve spool extension 35.
  • FIG. 14 is a cross-sectional view of an example valve spool extension 35 that has a first end 36 and an opposite second end 37.
  • the valve spool extension 35 has a partially hollow interior 38 that opens to an exterior of the extension 35 at the first end 36.
  • a section 38a of the hollow interior 38 may have a larger cross- dimension than the rest of the hollow interior 38.
  • At least a portion of the spool extension 35 may be formed from a nonmagnetic material, such as a non-magnetic stainless steel.
  • the magnetic element 39 may be insulated from the valve spool extension 35 so that vibrations from the solenoids 16, 18 and valve spool 24 are not passed to the magnetic element 39.
  • the magnetic element 39 may be insulated within the spool extension 35 using insulation members and/or air gaps (e.g., see FIG. 10).
  • the magnetic element 39 is included as part of a magnetic rod 90 that may be mounted within the valve spool extension 35.
  • the rod 90 also may be insulated from the spool extension 35 using insulation members and/or air gaps.
  • FIG. 15 illustrates an example magnetic rod 90 that may be placed within the hollow interior 38.
  • the rod 90 has a body extending between a first end 91 and a second end 92.
  • the rod 90 defines a hollow cavity 93 at the second end 92.
  • the magnetic element 39 may be placed within the hollow cavity 93 of the rod 90, which may be placed within the hollow interior 38 of the spool extension 35.
  • one or more insulators also may be placed with the magnetic element 39 within the rod 90 to buffer or cushion the magnetic element 39. Air gaps also may be left between the magnetic element 39 and the sides of the rod 90.
  • the first side 91 of the rod 90 defines a cavity 94 that is configured to receive a screw that interfaces with the valve spool 28 (e.g., see FIG. 2).
  • a screw that interfaces with the valve spool 28
  • valve spool extension 35 encloses the magnetic element 39 alone.
  • each sensor 41 has a specific reading distance (e.g., the stroke length of the valve spool) defined by an approximately linear relationship between the output of the sensor and the position of the spool 28 within the valve body 20. For this reason, each sensor 41 can be calibrated and characterized with a linear equation that uses the sensor voltage output to approximate valve spool 28 position. Since external factors may affect the linear relationship between the sensor output and the spool position, the output of each sensor 41 may be characterized by applying an independent linear regression analysis. The linear equation derived by the linear regression for each sensor 41 may be programmed into the controller 48.
  • spool valve movement is determined as an output from a series of steps executed by a microcontroller based electronics module.
  • FIG. 16 is a flowchart illustrating one example monitoring process
  • the monitoring process 100 by which the position of the valve spool 28 may be determined using the sensor arrangement 40 including three sensors 41.
  • the monitoring process 100 is performed by the controller 48 in combination with one or more anisotropic magnetoresistance sensors 41.
  • the example monitoring process 100 begins at a start module 102, performs any appropriate initialization procedures, and proceeds to an analyze operation 104.
  • the controller 48 analyzes (see operation 104) the output from a sensor 41, for example, the first sensor.
  • the output (voltage) of the sensor 41 is compared to a first threshold value Tl of the first sensor 41 to determine whether the spool 28 is within the proper sensing range of the first sensor 41. If the sensor output from the first sensor is less than the first threshold value Tl, then it is determined that the spool 28 is within the proper sensing range of the first sensor 41.
  • a linear equation associated with the first sensor is obtained from memory (see operation 110) and applied to calculate the position of the spool 28 (see operation 1 16) and data analysis process ends.
  • the controller 48 determines that the sensor output is not within the proper sensing range of the first sensor, however, then the output signal is compared against a second threshold value T2. If output is not greater than the second threshold value, then it is determined that the spool 28 is within the proper sensing range of the second sensor 41.
  • a linear equation associated with the second sensor 41 is obtained from memory (see operation 12) and applied to calculate the position of the spool 28 (see operation 116) and data analysis process ends.
  • a linear equation associated with the third sensor is instead obtained from memory (see operation 114) and applied to calculate the position of the spool 28 (see operation 1 16).
  • the monitoring process ends at a stop module 1 18.
  • FIGS. 17-21 illustrate other example dual solenoid modular valve assemblies 200, 300.
  • each of the modular valve assemblies 200, 300 includes a valve module 212, 312, a first solenoid 216, 316, and a second solenoid 218, 318, respectively.
  • the valve module 212, 312 includes a body 220 that extends from a first end 221 to a second end 222.
  • the first solenoid 216, 316 is coupled to the first end 221 of the valve module body 220.
  • Each of the modular valve assemblies 200, 300 also includes a sensing module 214.
  • the sensing module 214 has a housing 230 that extends from a first end 231 to a second end 232.
  • the first end 231 of the sensing module housing 230 is coupled to the second end 222 of the valve module body 220.
  • the housing 230 has a peripheral (e.g., annular) wall extending between the first and second ends 231 , 232.
  • one section of the peripheral wall extends flat to enable a connector 248 to extend therethrough.
  • a flange 250, 350 is coupled between the second end 232 of the sensing module housing 230 and the second solenoid 218, 318, respectively.
  • the valve module body 220 defines a linear channel extending between the first end 221 and the second end 222.
  • the valve body 220 also defines an inlet port that couples to a system pump, an outlet port that couples to a return tank or reservoir, a first work port channel that connects to a first system work port, and a second work port channel that connects to a second system work port.
  • Each of the ports connects to the linear channel.
  • the linear channel may connect to additional work ports, pilot valve ports, or other valve spool ports.
  • the valve module 212, 312 also includes a valve spool 228 disposed within the valve body 220 and configured to move axially through the channel.
  • the valve spool 228 opens and closes connections between the ports by sliding within the channel.
  • the valve spool 228 is configured to move between three discrete positions: a neutral position; a first side (i.e., left) position; and a second side (i.e., right) position.
  • the valve spool 228 disconnects (i.e., blocks) the inlet port and the outlet port from the work ports.
  • the valve spool 228 connects the inlet port to the first work port and the outlet port to the second work port.
  • the valve spool 228 connects the inlet port to the second work port and the outlet port to the first work port.
  • the first solenoid 216, 316 is configured to move the valve spool 228 between the neutral position and the first side position.
  • the second solenoid 218, 318 is configured to move the valve spool 228 between the neutral position and the second side position.
  • Each of the first and second solenoids includes a spring 217, 219, respectively, that biases the spool valve 228 towards the neutral position.
  • Each of the solenoids may be electronically controlled to move the valve spool 228. In other implementations, other types of actuators may be moved in place of the solenoids.
  • the sensing module 214 is configured to detect the position of the valve spool 228 within the valve body 220. In some implementations, the sensing module 214 may detect a discrete position of the valve spool 228 within the valve body 220. As the term is used herein, the "discrete position" of the valve spool 228 refers to one of a finite number of positions into which the valve spool 228 may be moved within the valve body 220 (e.g., a neutral position, a first side position, etc.). In other implementations, the sensing module 214 may detect an absolute position of the valve spool 228 within the valve body 220.
  • the "absolute position" of the valve spool 228 refers to one of a theoretically infinite number (subject to tolerances of the system) of positions of the valve spool 228 within the valve body 220 including the positions through which the valve spool 228 passes when moving between the discrete positions.
  • the sensing module 214 includes a sensor arrangement 240 that senses the position of a magnetic element 239 that is operatively coupled to the spool valve 228 and adapted to move therewith as will be disclosed in more detail herein. Movement of the magnetic element 239 into different positions affects the angles of the magnetic field generated by the magnetic element 239.
  • the sensor arrangement 240 measures the direction/angle of the magnetic field generated by the magnetic element 239 as the magnetic element 239 moves along with the valve spool 228.
  • the sensor arrangement 240 includes at least one anisotropic magnetoresistance sensor.
  • the magnetic element 239 is coupled to a valve spool extension 235 that couples to the valve spool 228 for movement therewith.
  • the housing assembly 230 also includes a sleeve 234 through the housing 230 between the first end 231 and the second end 232.
  • the sleeve 34 aligns with the linear channel of the valve body 220 when the housing assembly 230 is coupled to the valve body 220.
  • the valve spool extension 235 is configured to slide axially through the sleeve 234 of the housing assembly 230 when the valve spool 228 slides through the valve body 220.
  • the sleeve 234 is formed of stainless steel or other nonmagnetic metals.
  • a first end of the valve spool extension 235 couples to the valve spool 228 and a second end of the valve spool extension 235 couples to the second solenoid 218, 318.
  • the second solenoid 218, 318 acts on the valve spool extension 235 to move the valve spool 228 relative to the valve body 220.
  • the valve spool 228 is sufficiently long to extend through the sleeve 234 of the sensing module housing 230 and to interact with the, second solenoid 218, 31 8.
  • the magnetic element 239 is coupled directly to the valve spool 228.
  • the sensor housing 230 defines a sensor chamber 233 in which the sensor arrangement 240 is disposed.
  • the sensor chamber 233 is open to an exterior surface of the sensor housing 230.
  • a connector 248 can be disposed at the chamber 233 to provide electrical access to the sensor arrangement 240.
  • the sleeve 234 isolates the chamber 233 from the valve spool extension 235, thereby protecting the sensor arrangement 240 from the moving valve spool extension 235.
  • the sensor housing 230 also defines a channel 236 enabling working fluid to enter to dissipate the induced heat.
  • a controller may be coupled to the sensor arrangement 240 and configured to analyze the output of the sensor arrangement 240.
  • the controller determines the position of the magnetic element 239, and hence the position of the valve spool 228, based on the output of the sensor arrangement 240.
  • the controller is a microcontroller and forms part of the sensor arrangement 240 and connecting wires or other signal carriers may extend from the controller 240 within the chamber to an exterior of the sensing housing 240 for communication with a monitoring system.
  • the controller may be located remote from the sensing housing 240 and the connecting wires couple the controller to the sensor arrangement 240.
  • a wireless connection may be used instead of wires.
  • the sensing module 214 can be connected to flanges 250, 350 of various designs and sizes to enable coupling of the sensing module 214 to various sizes of solenoids 218, 318 or other components.
  • the flanges 250, 350 each define channels 251, 351 through which fasteners (e.g., bolts, tie-rods, etc.) pass to secure the sensing module 214 to the solenoid 218, 318.
  • the fasteners may pass through the channels 251, 351, over an exterior of the sensor module housing 230, and into the valve module body 220. In certain implementations, about four fasteners extend around the sensor module housing 230.
  • One example tie-rod 260 is shown in FIG. 17.
  • the flange 250, 350 also defines an opening 252, 352 through which the valve spool extension 235 extends to connect to the second solenoid 218, 318.
  • the flange 250 has a generally rectangular (e.g., square) shape.
  • the flange 350 has a generally circular shape. In other implementations, however, the flange 250, 350 may have any desired shape.
  • the flanges 250, 350 are formed of metal.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • General Physics & Mathematics (AREA)
  • Indication Of The Valve Opening Or Closing Status (AREA)
  • Magnetically Actuated Valves (AREA)

Abstract

A valve assembly includes a valve module, a first solenoid, and a sensing module. The first solenoid moves a valve spool axially within the valve module. The sensing module determines a position of the valve spool within the valve module. A second solenoid or an end cap may plug a distal end of the sensing module. The sensing module includes at least one anisotropic magnetoresistance sensor disposed within a housing. At least one magnetic element is operatively coupled to the valve spool (e.g., to a spool extension).

Description

VALVE SPOOL MONITORING USING ANISOTROPIC
MAGNETORESISTANCE SENSOR
Cross Reference to Related Applications
This application claims the benefit of U.S. Provisional Application Serial No. 61/666,270, filed June 29, 2012, entitled VALE SPOOL MONITORING USING ANISOTROPIC MAGNETORESISTANCE SENSOR, which is incorporated herein by reference in its entirety.
Background
Hydraulic fluid cylinders, reciprocating cylinder pumps, and other types of cylinder-based mechanical fluid-moving devices or engines use proximity sensors (also referred to as proximity switches) to sense position of spools, pistons, or other components to monitor performance, enhance safety, minimize damage to parts due to contact between parts.
Summary
In accordance with some aspects of the disclosure, a modular valve assembly may be manufactured by coupling a first solenoid to a first end of a valve body; coupling a first end of a sensor housing to a second end of the valve body; selecting one of a second solenoid and an end plug; and coupling the selected one to a second end of the sensor housing. The second end of the sensor housing is configured to be capable of receiving either one of the second solenoid and the end plug. The sensor housing includes a sensor arrangement that is configured to detect a position of a valve spool within the valve body.
In accordance with other aspects of the disclosure, a valve assembly includes a valve module; a first solenoid; and a sensing module. The valve module includes a valve spool housed within a valve body. The valve spool is configured to move axially within the valve body. The valve spool is operatively coupled to a magnet. The first solenoid is coupled to a first end of the valve module to actuate movement of the valve spool. The sensing module includes a housing assembly holding at least one anisotropic magnetoresistance sensor configured for sensing the magnet. A first end of the sensing module is coupled to a second end of the valve module. The second end of the sensing module is selectively coupled to one of a solenoid and a plug.
In accordance with other aspects of the disclosure, a valve assembly includes a valve module; a first solenoid; a valve spool extension; and a sensing module. The valve module includes a valve spool housed within a valve body. The valve spool is configured to move axially within the valve body. The first solenoid is coupled to a first end of the valve module to actuate movement of the valve spool. The valve spool extension is coupled to the valve spool and is configured to move with the valve spool. The valve spool extension encloses a magnet. The sensing module is coupled to a second end of the valve module. The sensing module includes at least one sensor arrangement that is configured for sensing the magnet. The sensing arrangement includes a circuit board and at least one anisotropic magnetoresistance sensor. The circuit board has a first major surface and a second major surface. The first major surface faces towards the spool valve extension and the second major surface faces away from the spool valve extension.
A variety of other aspects are set forth in the description that follows. The aspects relate to individual features as well as to combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive aspects disclosed herein.
Brief Description of the Drawings
There are shown in the drawings, embodiments which are presently preferred, it being understood, however, that the technology is not limited to the precise arrangements and instrumentalities shown. FIG. 1 is a side elevational view of one implementation of a dual solenoid valve module assembly with a sensing module shown in cross-section;
FIG. 2 is an axial cross-sectional view of the valve module assembly of FIG. 1 ;
FIG. 3 is an exploded perspective view of the valve module assembly of FIG . 1 ;
FIG. 4 is a perspective view of an example single solenoid valve module assembly with a plug exploded outwardly from one end of the valve module assembly;
FIG. 5 is a side elevational view of the single solenoid valve module assembly of FIG. 4 with the sensing module shown in cross-section;
FIG. 6 is a perspective view of an example adapter in which internal features are shown in dashed lines;
FIG. 7 is a cross-sectional view of the adapter of FIG. 6; FIG. 8 is a perspective view of an example sensor chassis in which internal features are shown in dashed lines;
FIG. 9 is a cross-sectional side view of the sensor chassis of FIG.8; FIG. 10 is a cross-sectional view of an example sensor module including an example spool valve extension holding an anisotropic
magnetoresistance sensor;
FIG. 1 1 is a bottom plan view of one example sensor arrangement suitable for use in any of the sensing modules disclosed herein;
FIG. 12 is a side elevational view of sensor arrangement of FIG. 1 1 ; FIG. 13 is a bottom plan view of an anisotropic magnetoresistance sensor shown in relation to a magnet oriented for axial placement relative to the valve spool;
FIG. 14 is a cross-sectional view of one example valve spool extension; FIG. 15 is a perspective view of an example sensor rod shown with transparent sides to enable viewing of interior features;
FIG. 16 is a flow chart illustrating a detection process for determining spool valve movement;
FIG. 17 is a perspective view of another example dual solenoid valve module assembly including a sensing module;
FIG. 18 is a longitudinal cross-sectional view of the dual solenoid valve module assembly of FIG. 17;
FIG. 19 is a perspective view of an exploded sensing module of FIG. 17 shown exploded from an example flange;
FIG. 20 is a perspective view of an exploded sensing module of FIG. 21 shown exploded from another example flange; and
FIG. 21 is a perspective view of another example dual solenoid valve module assembly including the sensing module of FIG. 17 and the flange of FIG. 20.
Detailed Description
References will not be made in detail to the exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Whenever possible, the same reference numbers will be used throughout the drawings to refer to the same or like structure.
The technology described herein has applications in monitoring hydraulic fluid spool valves and other types of directional ly-operated valves or mechanical fluid-moving devices. Additionally, the technology may be used in spool valves or similar fluid-moving devices where the working fluid is air or another gas as opposed to hydraulic fluid. For clarity, however, the following embodiments will be described as sensor monitoring systems for hydraulic fluid spool valves. In various embodiments, the modular valve assembly 10 may be configured for use with a single solenoid, a dual solenoid, or other another type of actuator. FIGS. 1-3 illustrate one example dual solenoid modular valve assembly 10. As shown in the figures, the modular valve assembly 10 includes a valve module 12, a sensing module 14, a first solenoid 16, and a second solenoid 18. The valve module 12 includes a body 20 that extends from a first end 21 to a second end 22. The first solenoid 16 is coupled to the first end 21 of the valve module body 20. The sensing module 14 also includes a housing 30 that extends from a first end 31 to a second end 32. The first end 31 of the sensing module housing 30 is coupled to the second end 22 of the valve module body 20. The second solenoid 18 is coupled to the second end 32 of the sensing module housing 30.
The valve module body 20 defines a linear channel 23 extending between the first end 21 and the second end 22. The valve body 20 also defines an inlet port 24 that couples to a system pump, an outlet port 25 that couples to a return tank or reservoir, a first work port channel 26 that connects to a first system work port, and a second work port channel 27 that connects to a second system work port. Each of the ports 24-27 connects to the linear channel 23. In other implementations, the linear channel 23 may connect to additional work ports, pilot valve ports, or other valve spool ports.
The valve module 12 also includes a valve spool 28 disposed within the valve body 20 and configured to move axially through the channel. The valve spool 28 opens and closes connections between the ports 24-27 by sliding within the channel 23 along a slide axis C. In the example shown, the valve spool 28 is configured to move between three discrete positions: a neutral position; a first side (i.e., left) position; and a second side (i.e., right) position. When in the neutral position, the valve spool 28 disconnects (i.e., blocks) the inlet port 24 and the outlet port 25 from the work ports 26, 27. When in the first position, the valve spool 28 connects the inlet port 24 to the first work port 26 and the outlet port 25 to the second work port 27. When in the second position, the valve spool 28 connects the inlet port 24 to the second work port 27 and the outlet port 25 to the first work port 26.
The first solenoid 16 is configured to move the valve spool 28 between the neutral position and the first side position. The second solenoid 18 is configured to move the valve spool 28 between the neutral position and the second side position. Each of the first and second solenoids 16, 18 includes a spring 17, 19, respectively, that biases the spool valve 28 towards the neutral position. Each of the solenoids 16, 18 may be electronically controlled to move the valve spool 28. In other implementations, other types of actuators may be moved in place of the solenoids 16, 18.
The sensing module 14 is configured to detect the position of the valve spool 28 within the valve body 20. In some implementations, the sensing module 14 may detect a discrete position of the valve spool 28 within the valve body 20. As the term is used herein, the "discrete position" of the valve spool 28 refers to one of a finite number of positions into which the valve spool 28 may be moved within the valve body 20 (e.g., a neutral position, a first side position, etc.). In other implementations, the sensing module 14 may detect an absolute position of the valve spool 28 within the valve body 20. As the term is used herein, the "absolute position" of the valve spool 28 refers to one of a theoretically infinite number (subject to tolerances of the system) of positions of the valve spool 28 within the valve body 20 including the positions through which the valve spool 28 passes when moving between the discrete positions.
In some implementations, the sensing module 14 includes a sensor arrangement 40 that senses the position of a magnetic element 39 that is operatively coupled to the spool valve 28 and adapted to move therewith as will be disclosed in more detail herein. Movement of the magnetic element 39 into different positions affects the angles of the magnetic field generated by the magnetic element 39. The sensor arrangement 40 measures the direction/angle of the magnetic field generated by the magnetic element 39 as the magnetic element 39 moves along with the valve spool 28. In certain implementations, the sensor arrangement 40 includes at least one anisotropic magnetoresistance sensor.
In some implementations, the magnetic element 39 is coupled to a valve spool extension 35 that couples to the valve spool 28 for movement therewith along the slide axis C. In such implementations, the housing assembly 30 defines a linear channel 34 extending from the first end 31 to the second end 32 of the housing 30. The linear channel 34 aligns with the linear channel 23 of the valve body 20 when the housing assembly 30 is coupled to the valve body 20. For example, the valve spool extension 35 is configured to slide axially through the housing assembly 30 when the valve spool 28 slides through the valve body 20. In the example shown in FIG. 2, a first end of the valve spool extension 35 couples to the valve spool 28 and a second end of the valve spool extension 35 couples to the second solenoid 18. Accordingly, in the example shown in FIG. 2, the second solenoid 18 acts on the valve spool extension 35 to move the valve spool 28 relative to the valve body 20. In other implementations, the valve spool 28 is sufficiently long to extend through the linear channel 34 of the sensing module housing 30 and to interact with the second solenoid 18. In some such implementations, the magnetic element 39 is coupled directly to the valve spool 28.
In some implementations, the sensor housing 30 defines a sensor chamber 33 in which the sensor arrangement 40 is disposed (see FIGS. 1 and 4). In certain implementations, the chamber 33 is isolated from the liner channel 34, thereby protecting the sensor arrangement 40 from the moving valve spool extension 35. A controller 48 (FIG. 1) may be coupled to the sensor arrangement 40 and configured to analyze the output of the sensor arrangement 40. The controller 48 determines the position of the magnetic element 39, and hence the position of the valve spool 28, based on the output of the sensor arrangement 40. In some implementations, the controller 48 is a microcontroller and forms part of the sensor arrangement 40 and connecting wires 49 or other signal carriers may extend from the controller 40 within the chamber 33 to an exterior of the sensing housing 40 for communication with a monitoring system. In other implementations, the controller 48 may be located remote from the sensing housing 40 and the connecting wires 49 couple the controller 48 to the sensor arrangement 40. In still other
implementations, a wireless connection may be used instead of wires 49.
FIGS. 4 and 5 illustrate another example modular valve assembly 50 that includes the valve module 12, sensing module 14, and first solenoid 16 of the first modular valve assembly 10. These components operate substantially the same as described above with reference to FIGS. 1-3. However, the modular valve assembly 50 includes an end plug arrangement 52 coupled to the second end 32 of the sensing module housing 30 instead of the second solenoid 18. The end plug arrangement 52 seals the linear channel 34 of the housing assembly 30. The end plug arrangement 52 also biases the valve spool extension 35, and hence the valve spool 28, towards the neutral position when the first solenoid 16 is not acting on the valve spool 28 as will be described in more detail herein.
The same sensing module 14 may be utilized with either of the modular valve assemblies 10, 50 described herein. As will be described, the second end 32 of the housing 30 is capable of interfacing with a solenoid, such as second solenoid 18. The second end 32 of the housing 30 also is capable of interfacing with an end plug, such as end plug arrangement 52. Accordingly, fewer sensing modules 14 need to be kept in stock since the same part may be used with either assembly 10, 50.
Referring to FIGS. 3 and 6-9, the housing assembly 30 of the sensing module 14 includes an adapter 60 and a sensor chassis 65. The adapter 60 and the chassis 65 couple together to define the sensor chamber 33. As shown in FIGS. 6-7, the adapter 60 includes a mounting section 61 that is configured to couple to the second end 22 of the valve body 20. In the example shown, the mounting section 61 defines fastener openings 62 that are configured to align with fastener Openings defined at the second side of the valve body 20.
A protruding section 63 of the adapter 60 extends outwardly from the mounting section 61. The mounting section 61 and the protruding section 63 cooperate to define a through passage 64 extending therethrough. The passage 64 forms the linear channel 34 of the sensor module housing 30. In the example shown, the inner passage 64 has a generally round transverse lateral cross-sectional shape. In other implementations, the passage 64 may have any desired transverse lateral cross-sectional shape. In the example shown, one side of the protruding section 63 defines a flat surface 66. The flat surface 66 may have one or more bores 67 for insertion of screws or other similar fasteners. In certain implementations, the flat surface 66 extends generally parallel to a slide axis C of the valve spool 28. As will be discussed in more detail herein, the flat surface 66 may provide a level surface for mounting the sensor arrangement 40 within the sensing module housing 30.
The mounting section 61 also defines a cavity 65 to receive a portion of a sealing plug 80 (FIG. 1) that facilitates couplings the sensing module housing 30 to the valve body 20. The cavity 65 has a larger cross-dimension than the passage 64. As shown in FIGS. 1 and 3, the plug 80 has a first end that extends into the second end 22 of the valve body 20 and a second end that extends into the first end 31 of the sensing module housing 30. The plug 80 also defines a passage through which the valve spool 28 and/or valve spool extension 35 may extend. In certain implementations, the valve spool 28 couples to the valve spool extension 35 within the plug 80. The plug 80 may cooperate with a gasket (e.g., an O-ring) to inhibit fluid from leaking from the modular valve assembly 10, 50.
The sensor chassis 70 (FIGS. 8 and 9) is sized to fit around the protruding section 63 of the adapter 60. The sensor chassis 70 has a first end 71 and an opposite second end 73. One or more fastener passages 72 extend between the first and second ends 71, 73. The fastener passages 72 align with the fastener openings 62 of the adapter 60. Fasteners 82 extend through the fastener passages 72, the fastener openings 62 of the adapter 60, and the fastener openings of the valve body 20 to secure the sensing module housing 30 to the valve body 20 (see FIG. 3).
The sensor chassis 70 also defines a through passage 74 extending between the first and second ends 71, 73. The through passage 74 has a first section 75 and a second section 76. The first section 75 of the passage 74 has a larger cross- dimension than the second section 76 of the passage 74. The first section 75 is sized to receive at least a portion of the valve spool extension 35 for sliding movement therein. The second section 76 is sized to receive a portion of a solenoid or an end plug arrangement. The second spring 1 9 may be disposed within the second section 76 of the passage 74 between a portion of the valve spool extension 35 and either the second solenoid 18 (see FIG. 2) or the end plug arrangement 52 (see FIG. 5).
For example, FIG. 2 shows a portion of the second solenoid 18 extending into the second section 76 of the passage 74. The second spring 19 is disposed within the second passage section 76. FIG. 5 shows a portion of the end plug arrangement 52 extending into the second passage section 76. For example, the plug arrangement 52 includes a head 53 that remains external to the chassis 70 and a protruding section 54 that extends into the second passage section 76. In both FIGS. 2 and 5, the second spring 19 cooperates with the first spring 17 to bias the valve spool 28 and extension 35 to a neutral position. In both cases, an O-ring or other gasket 56 may be provided at the interface between the chassis 70 and the solenoid 18 or plug 52. The O-ring 56 may minimize wear and help to ensure an adequate seal between the sensing module and the plug.
In some embodiments, the portion of the plug 52 or second solenoid 18 that extends into the chassis 70 may be threaded to enable a threaded coupling between the sensing module 14 and the plug 52 or solenoid 18. In other
embodiments, the portion of the plug 52 or solenoid 18 that extends into the chassis 70 may be smooth and have a diameter that provides a press-fit connection between the sensing module 14 and the plug 52 or solenoid 18. In yet another embodiment, the portion of the plug 52 or solenoid 18 that extends into the chassis 70 may be bonded to the chassis 70 using adhesive. In still other implementations, the plug 52 or solenoid 18 may be otherwise secured to the sensing module 14.
The sensor chassis 70 also defines a cavity 78 that is connected to the first section 75 of the passage 74. The cavity 78 is radially offset from the first section 75 and is sized to receive the sensor arrangement 40. The cavity 78 is closed by protruding section 63 of the adapter 60 when the adapter 60 is coupled to the sensor chassis 70. The closed cavity 78 forms the sensor chamber 33 in which the sensor arrangement 40 is located. In certain implementations, the flat surface 66 of the protruding section 63 faces the cavity 78. A conduit or aperture 79 connects the sensor chamber 33 to an exterior of the chassis 70.
In some implementations, at least a portion of the sensor chassis 70 is formed of a magnetic material for shielding the sensor arrangement 40 from external magnetic fields and external magnetic interferences. Examples of magnetic materials that are suitable for constructing the sensor chassis include, but are not limited to, magnetic carbon steels, magnetic stainless steels, and other materials containing iron, nickel, and/or cobalt.
FIG. 10 is an enlarged view of the sensing module 14 shown in cross- section so that the valve spool extension 35, the magnetic element 39, and the sensor arrangement 40 are visible. As shown in FIGS. 10-12, the sensor arrangement 40 includes one or more sensors 41 mounted to a circuit board 43 disposed within the cavity 33 of the housing assembly 30. The circuit board 43 is oriented so that at least one of the sensors 41 faces towards the magnetic element 39. For example, the circuit board 43 may have a first major surface 44 facing towards the channel 34 in the sensing housing 30 and a second major surface 45 facing away from the channel 34. Active electronic components 46 may be mounted to the second major surface 45 of the circuit board 43 (see FIG. 12). Non-limiting examples of active electronic components 46 include a diode, a triode vacuum tube, a transistor, an integrated circuit, a power source, and a switch.
In some implementations, the circuit board 43 is mounted to the flat surface 66 of the adapter 60. One or more screws or other such fasteners may couple the circuit board 43 to the adapter 60. In certain implementations, each sensor 41 is disposed between the first surface 44 of the circuit board 43 and the flat surface 66 of the adapter 60. In certain implementations, one or more "washers or other such structures may be placed between the circuit board 43 and the flat surface 66 of the adapter 60 to space the circuit board 43 above the surface 66. As shown in FIG. 1 1, the circuit board 43 may include an array 42 of two or more sensors 41. In some implementations, the sensor array 42 includes two rows of sensors 41 . In certain implementations, the sensors 41 in one row are redundant to the sensors 41 in the other row. In certain implementations, the rows extend parallel to the sliding axis C of the valve spool 28. Accordingly, the sensors 41 are positioned to increase the range of the sensor arrangement 40. As the magnetic element 39 moves along the axis C, the controller 48 monitors the output of consecutive sensors 41 to track the position of the magnetic element 39.
As shown in FIG. 13, the magnetic element 39 may be positioned and oriented so that the poles of the magnet are aligned along the sliding axis C of the valve spool 28. Aligning the poles along the movement axis C of the magnetic element 39 creates a magnetic field that is generally symmetrical with 'respect to rotation about the axis C. . Accordingly, rotation of the magnetic element 39 (e.g., caused by rotation of the valve spool 28 and/or extension 35) will not cause fluctuations in the sensor readings produced by the sensor arrangement 40. In other implementations, the magnetic element 39 may be offset from the movement axis C. In the example shown, the magnetic element 39 is shown disposed on the valve spool extension 35. In other implementations, the magnetic element 39 may be disposed on the valve spool 28. In other implementations, however, the magnetic element 39 may be radially orientated so that the poles align along an axis transverse to the sliding axis C.
Referring back to FIG. 10, the magnetic element 39 may be disposed within the valve spool extension 35. For example, the magnetic element 39 may be disposed along a central longitudinal axis of the valve spool extension 35. In such implementations, the valve spool 35 protects the magnetic element 39 during movement. In other implementations, the magnetic element 39 may be disposed at an exterior of the valve spool extension 35.
FIG. 14 is a cross-sectional view of an example valve spool extension 35 that has a first end 36 and an opposite second end 37. The valve spool extension 35 has a partially hollow interior 38 that opens to an exterior of the extension 35 at the first end 36. A section 38a of the hollow interior 38 may have a larger cross- dimension than the rest of the hollow interior 38. At least a portion of the spool extension 35 may be formed from a nonmagnetic material, such as a non-magnetic stainless steel.
The magnetic element 39 may be insulated from the valve spool extension 35 so that vibrations from the solenoids 16, 18 and valve spool 24 are not passed to the magnetic element 39. For example, the magnetic element 39 may be insulated within the spool extension 35 using insulation members and/or air gaps (e.g., see FIG. 10). In some implementations, the magnetic element 39 is included as part of a magnetic rod 90 that may be mounted within the valve spool extension 35. The rod 90 also may be insulated from the spool extension 35 using insulation members and/or air gaps.
FIG. 15 illustrates an example magnetic rod 90 that may be placed within the hollow interior 38. The rod 90 has a body extending between a first end 91 and a second end 92. The rod 90 defines a hollow cavity 93 at the second end 92. The magnetic element 39 may be placed within the hollow cavity 93 of the rod 90, which may be placed within the hollow interior 38 of the spool extension 35. In certain implementations, one or more insulators also may be placed with the magnetic element 39 within the rod 90 to buffer or cushion the magnetic element 39. Air gaps also may be left between the magnetic element 39 and the sides of the rod 90. The first side 91 of the rod 90 defines a cavity 94 that is configured to receive a screw that interfaces with the valve spool 28 (e.g., see FIG. 2). In other
implementations, the valve spool extension 35 encloses the magnetic element 39 alone.
As noted above, two or more sensors 41 may be included in a sensor arrangement 40 to increase the detectable linear stoke length of the valve spool 28. Each sensor 41 has a specific reading distance (e.g., the stroke length of the valve spool) defined by an approximately linear relationship between the output of the sensor and the position of the spool 28 within the valve body 20. For this reason, each sensor 41 can be calibrated and characterized with a linear equation that uses the sensor voltage output to approximate valve spool 28 position. Since external factors may affect the linear relationship between the sensor output and the spool position, the output of each sensor 41 may be characterized by applying an independent linear regression analysis. The linear equation derived by the linear regression for each sensor 41 may be programmed into the controller 48.
As shown in FIG. 16, spool valve movement is determined as an output from a series of steps executed by a microcontroller based electronics module.
FIG. 16 is a flowchart illustrating one example monitoring process
100 by which the position of the valve spool 28 may be determined using the sensor arrangement 40 including three sensors 41. In some implementations, the monitoring process 100 is performed by the controller 48 in combination with one or more anisotropic magnetoresistance sensors 41. The example monitoring process 100 begins at a start module 102, performs any appropriate initialization procedures, and proceeds to an analyze operation 104.
The controller 48 analyzes (see operation 104) the output from a sensor 41, for example, the first sensor. The output (voltage) of the sensor 41 is compared to a first threshold value Tl of the first sensor 41 to determine whether the spool 28 is within the proper sensing range of the first sensor 41. If the sensor output from the first sensor is less than the first threshold value Tl, then it is determined that the spool 28 is within the proper sensing range of the first sensor 41. A linear equation associated with the first sensor is obtained from memory (see operation 110) and applied to calculate the position of the spool 28 (see operation 1 16) and data analysis process ends.
If the controller 48 determines that the sensor output is not within the proper sensing range of the first sensor, however, then the output signal is compared against a second threshold value T2. If output is not greater than the second threshold value, then it is determined that the spool 28 is within the proper sensing range of the second sensor 41. A linear equation associated with the second sensor 41 is obtained from memory (see operation 12) and applied to calculate the position of the spool 28 (see operation 116) and data analysis process ends.
However, if sensor output was greater than the second threshold value T2, a linear equation associated with the third sensor is instead obtained from memory (see operation 114) and applied to calculate the position of the spool 28 (see operation 1 16). The monitoring process ends at a stop module 1 18.
FIGS. 17-21 illustrate other example dual solenoid modular valve assemblies 200, 300. As shown in the figures, each of the modular valve assemblies 200, 300 includes a valve module 212, 312, a first solenoid 216, 316, and a second solenoid 218, 318, respectively. The valve module 212, 312 includes a body 220 that extends from a first end 221 to a second end 222. The first solenoid 216, 316 is coupled to the first end 221 of the valve module body 220.
Each of the modular valve assemblies 200, 300 also includes a sensing module 214. The sensing module 214 has a housing 230 that extends from a first end 231 to a second end 232. The first end 231 of the sensing module housing 230 is coupled to the second end 222 of the valve module body 220. In certain implementations, the housing 230 has a peripheral (e.g., annular) wall extending between the first and second ends 231 , 232. In the example shown, one section of the peripheral wall extends flat to enable a connector 248 to extend therethrough. A flange 250, 350 is coupled between the second end 232 of the sensing module housing 230 and the second solenoid 218, 318, respectively.
The valve module body 220 defines a linear channel extending between the first end 221 and the second end 222. The valve body 220 also defines an inlet port that couples to a system pump, an outlet port that couples to a return tank or reservoir, a first work port channel that connects to a first system work port, and a second work port channel that connects to a second system work port. Each of the ports connects to the linear channel. In other implementations, the linear channel may connect to additional work ports, pilot valve ports, or other valve spool ports.
The valve module 212, 312 also includes a valve spool 228 disposed within the valve body 220 and configured to move axially through the channel. The valve spool 228 opens and closes connections between the ports by sliding within the channel. In the example shown, the valve spool 228 is configured to move between three discrete positions: a neutral position; a first side (i.e., left) position; and a second side (i.e., right) position. When in the neutral position, the valve spool 228 disconnects (i.e., blocks) the inlet port and the outlet port from the work ports. When in the first position, the valve spool 228 connects the inlet port to the first work port and the outlet port to the second work port. When in the second position, the valve spool 228 connects the inlet port to the second work port and the outlet port to the first work port.
The first solenoid 216, 316 is configured to move the valve spool 228 between the neutral position and the first side position. The second solenoid 218, 318 is configured to move the valve spool 228 between the neutral position and the second side position. Each of the first and second solenoids includes a spring 217, 219, respectively, that biases the spool valve 228 towards the neutral position. Each of the solenoids may be electronically controlled to move the valve spool 228. In other implementations, other types of actuators may be moved in place of the solenoids.
The sensing module 214 is configured to detect the position of the valve spool 228 within the valve body 220. In some implementations, the sensing module 214 may detect a discrete position of the valve spool 228 within the valve body 220. As the term is used herein, the "discrete position" of the valve spool 228 refers to one of a finite number of positions into which the valve spool 228 may be moved within the valve body 220 (e.g., a neutral position, a first side position, etc.). In other implementations, the sensing module 214 may detect an absolute position of the valve spool 228 within the valve body 220. As the term is used herein, the "absolute position" of the valve spool 228 refers to one of a theoretically infinite number (subject to tolerances of the system) of positions of the valve spool 228 within the valve body 220 including the positions through which the valve spool 228 passes when moving between the discrete positions.
In some implementations, the sensing module 214 includes a sensor arrangement 240 that senses the position of a magnetic element 239 that is operatively coupled to the spool valve 228 and adapted to move therewith as will be disclosed in more detail herein. Movement of the magnetic element 239 into different positions affects the angles of the magnetic field generated by the magnetic element 239. The sensor arrangement 240 measures the direction/angle of the magnetic field generated by the magnetic element 239 as the magnetic element 239 moves along with the valve spool 228. In certain implementations, the sensor arrangement 240 includes at least one anisotropic magnetoresistance sensor.
In some implementations, the magnetic element 239 is coupled to a valve spool extension 235 that couples to the valve spool 228 for movement therewith. In certain implementations, the housing assembly 230 also includes a sleeve 234 through the housing 230 between the first end 231 and the second end 232. The sleeve 34 aligns with the linear channel of the valve body 220 when the housing assembly 230 is coupled to the valve body 220. For example,* the valve spool extension 235 is configured to slide axially through the sleeve 234 of the housing assembly 230 when the valve spool 228 slides through the valve body 220. In one example, the sleeve 234 is formed of stainless steel or other nonmagnetic metals.
In the example shown in FIG. 18, a first end of the valve spool extension 235 couples to the valve spool 228 and a second end of the valve spool extension 235 couples to the second solenoid 218, 318. Accordingly, in the example shown in FIG. 18, the second solenoid 218, 318 acts on the valve spool extension 235 to move the valve spool 228 relative to the valve body 220. In other implementations, the valve spool 228 is sufficiently long to extend through the sleeve 234 of the sensing module housing 230 and to interact with the, second solenoid 218, 31 8. In some such implementations, the magnetic element 239 is coupled directly to the valve spool 228.
In some implementations, the sensor housing 230 defines a sensor chamber 233 in which the sensor arrangement 240 is disposed. In the examples shown in FIGS. 19 and 20, the sensor chamber 233 is open to an exterior surface of the sensor housing 230. A connector 248 can be disposed at the chamber 233 to provide electrical access to the sensor arrangement 240. In certain implementations, the sleeve 234 isolates the chamber 233 from the valve spool extension 235, thereby protecting the sensor arrangement 240 from the moving valve spool extension 235. The sensor housing 230 also defines a channel 236 enabling working fluid to enter to dissipate the induced heat.
A controller may be coupled to the sensor arrangement 240 and configured to analyze the output of the sensor arrangement 240. The controller determines the position of the magnetic element 239, and hence the position of the valve spool 228, based on the output of the sensor arrangement 240. In some implementations, the controller is a microcontroller and forms part of the sensor arrangement 240 and connecting wires or other signal carriers may extend from the controller 240 within the chamber to an exterior of the sensing housing 240 for communication with a monitoring system. In other implementations, the controller may be located remote from the sensing housing 240 and the connecting wires couple the controller to the sensor arrangement 240. In still other implementations, a wireless connection may be used instead of wires.
Referring to FIGS. 19 and 20, the sensing module 214 can be connected to flanges 250, 350 of various designs and sizes to enable coupling of the sensing module 214 to various sizes of solenoids 218, 318 or other components. The flanges 250, 350 each define channels 251, 351 through which fasteners (e.g., bolts, tie-rods, etc.) pass to secure the sensing module 214 to the solenoid 218, 318. For example, the fasteners may pass through the channels 251, 351, over an exterior of the sensor module housing 230, and into the valve module body 220. In certain implementations, about four fasteners extend around the sensor module housing 230. One example tie-rod 260 is shown in FIG. 17.
The flange 250, 350 also defines an opening 252, 352 through which the valve spool extension 235 extends to connect to the second solenoid 218, 318. In the example shown in FIG. 19, the flange 250 has a generally rectangular (e.g., square) shape. In the example shown in FIG. 20, the flange 350 has a generally circular shape. In other implementations, however, the flange 250, 350 may have any desired shape. In an example, the flanges 250, 350 are formed of metal.
The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.

Claims

What is claimed is:
1. A valve assembly comprising:
a valve module having a first end and a second end, the valve module including a valve spool housed within a valve body, the valve spool being configured to move axially within the valve body, the valve spool being operatively coupled to a magnet; a first solenoid coupled to the first end of the valve module to actuate movemer of the valve spool; and
a sensing module including a housing assembly holding at least one anisotropic magnetoresistance sensor configured for sensing the magnet, the sensing module havin; a first end and an opposite second end, the first end of the sensing module being coupled to the second end of the valve module, the second end of the sensing module being selectively coupled to one of a second solenoid and a plug.
2. The valve assembly of claim 1, wherein the magnet is enclosed within a valve spool extension along a central axis of the valve spool extension, the magnet being oriented relative to the anisotropic magnetoresistance sensor for axial mode sensing.
3. The valve assembly of claim 2, wherein the anisotropic magnetoresistance sensor is mounted to a first major surface of a circuit board, the first major surface facing towards the valve spool extension and a second major surface of the circuit boar facing away from the valve spool extension.
4. The valve assembly of claim 3, wherein active components are disposed on the second major surface of the circuit board, the active components including at least one of a diode, a triode vacuum tube, a transistor, an integrated circuit, a power source, and a switch.
5. The valve assembly of claim 3, further comprising a redundant anisotropic magnetoresistance sensor adjacently positioned on the first major surface of the circuit board.
6. The valve assembly of claim 2, wherein the housing assembly of the sensor module includes a sleeve extending therethrough, the sleeve being coaxially aligned with the valve spool extension so that the valve spool extension is slidable within the sleeve.
7. The valve assembly of claim 2, wherein the second end of the sensing module ii selectively coupled to the second solenoid, wherein the first solenoid moves the valve spool within the valve body between a first axial position and a neutral axial position, and wherein the second solenoid is operationally coupled to the valve spool to move th< valve spool between the neutral axial position and a second axial position within the valve body.
8. The valve assembly of claim 7, wherein the second end of the sensing module is selectively coupled to the second solenoid using a flange and a plurality of tie-rods, the second solenoid having a generally rectangularly-shaped transverse cross-section, the flange having a rectangular shape that generally matches the transverse cross-section of the second solenoid, wherein the tie-rods extend through the flange, over an exterior of the sensing module, and into the valve body.
9. The valve assembly of claim 7, wherein the second end of the sensing module i: selectively coupled to the second solenoid using a flange and a plurality of tie-rods, the second solenoid having a generally circularly-shaped transverse cross-section, the flange having a circular shape that generally matches the transverse cross-section of the second solenoid, wherein the tie-rods extend through the flange, over an exterior of the sensing module, and into the valve body.
10. The valve assembly of claim 1, wherein an output of the anisotropic
magnetoresistance sensor indicates an absolute position of the valve spool within the valve body.
11. The valve assembly of claim 1 , wherein an output of the anisotropic
magnetoresistance sensor indicates a discrete position of the valve spool within the valve body.
12. A method of assembling a modular valve assembly as claimed in claim 1, comprising:
a. selecting one of the second solenoid and the end plug; and
b. coupling the selected one to the second end of the sensor housing.
13. The method of claim 12, wherein the second solenoid is selected.
14. The method of claim 13, further comprising:
a. selecting a flange based on at least one of size and shape of the second solenoid; b. clamping the sensing module between the valve module and the second solenoid by positioning tie-rods around an exterior of the sensing module between the valve module and the second solenoid.
15. The method of claim 12, wherein the end plug is selected.
16. A method of assembling a modular valve assembly comprising:
a. coupling a first solenoid to a first end of a valve body;
b. coupling a first end of a sensor housing to a second end of the valve body, the sensor housing including a sensor arrangement that is configured to detect a position of a valve spool within the valve body; c. selecting one of a second solenoid and an end plug; and
d. coupling the selected one to a second end of the sensor housing, whereir the second end of the sensor housing is capable of receiving either one of the second solenoid and the end plug.
17. The method of claim 16, wherein the second solenoid is selected.
18. The method of claim 16, wherein the end plug is selected.
19. The method of claim 16, wherein the valve spool is operably coupled to a magnetic element and wherein the sensor arrangement includes at least one anisotropic magnetoresistance sensor.
20. A valve assembly comprising:
a valve module having a first end and a second end, the valve module including a valve spool housed within a valve body, the valve spool being configured to move axially within the valve body;
a first solenoid coupled to the first end of the valve module to actuate movemer of the valve spool;
a valve spool extension coupled to the valve spool and configured to move with the valve spool, the valve spool extension enclosing a magnet; and
a sensing module coupled to the second end of the valve module, the sensing module including at least one sensor arrangement configured for sensing the magnet, the sensing arrangement including a circuit board and at least one anisotropic magnetoresistance sensor, the circuit board having a first major surface and a second major surface, the first major surface facing towards the spool valve extension and the second major surface facing away from the spool valve extension.
21. The valve assembly of claim 20, wherein the anisotropic magnetoresistance sensor is disposed on the first major surface of the circuit board.
22. The valve assembly of claim 21, wherein the active components are disposed on the second major surface of the circuit board.
23. The valve assembly of claim 22, wherein the active components includes at leasi one of a diode, a triode vacuum tube, a transistor, an integrated circuit, a power source, and a switch.
24. The valve assembly of claim 20, wherein the magnet is oriented relative to the anisotropic magnetoresistance sensor for axial mode sensing.
25. The valve assembly of claim 20, wherein the magnet is disposed along a centra, axis of the valve spool.
26. The valve assembly of claim 25, wherein the sensing arrangement includes at least two anisotropic magnetoresistance sensors adjacently positioned on the first majoi surface of the circuit board generally parallel to the central axis.
27. The valve assembly of claim 25, wherein the sensing arrangement includes at least two anisotropic magnetoresistance sensors adjacently positioned on the first majoi surface of the circuit board generally perpendicular to the central axis for providing sensing redundancy.
28. The valve assembly of claim 20, further comprising a flange and a second solenoid, the flange coupling the sensing module to the second solenoid.
29. The valve assembly of claim 28, wherein the flange defines a rectangular shape.
30. The valve assembly of claim 28, wherein the flange defines a circular shape.
PCT/IN2013/000407 2012-06-29 2013-07-01 Valve spool monitoring using anisotropic magnetoresistance sensor WO2014033728A2 (en)

Applications Claiming Priority (2)

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US201261666270P 2012-06-29 2012-06-29
US61/666,270 2012-06-29

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EP3945232A1 (en) * 2020-07-30 2022-02-02 MSG Mechatronic Systems GmbH Actuator for a valve for a motor vehicle
WO2023034048A1 (en) * 2021-09-03 2023-03-09 Parker-Hannifin Corporation Solenoid valve assembly with configurable solenoid connection

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