Valve Control Unit and System for Use Therewith

The invention relates to a control unit for operating valves and the like and, more specifically, to a valve control unit operated by a controller such as a computer and adapted to report the position of the controlled valve to the controller.

Plants which handle liquids, such as breweries, dairies and soft drink producers, use pipe networks to transfer various liquids between locations. There is a need to stop or change the various liquid flows for mixing, cleaning or other reasons. This is often accomplished by the use of many switching valves disposed at strategic locations in the pipe networks. For example, a modern brewery might utilize numerous switching valves operated by a remote controller located, for example, in a control room.

Such valves typically are operated by a valve control unit which activates a solenoid for supplying air to a pneumatic cylinder, the ram of which directly switches the valve. It is common practice to hardwire each valve control unit to the controller. This requires the use of a great deal of material in terms of wire and conduit, and a large amount of skilled labor is required to complete the installation. Moreover, revisions and additions result in significant system downtimes and are also expensive in terms of labor and material.

A recently proposed valve control system uses valve control units carried by the air cylinder mounted on each valve. The various valve control units are connected by a common cable to the controller and the cable includes two conductors for transmitting a D.C. voltage superimposed on which is a modulated carrier frequency containing date from the controller for synchronization and valve switching while the valve control units supply data as to the condition of a contact at the valve control unit which is intended to represent the position of the valves. This is a type of frequency shift coding and is somewhat subject to interference which could cause unintended and erroneous valve operation. Furthermore, each valve control unit is required to include electronic circuitry for separating the D.C. voltage, for power, and the modulated carrier frequency for use with encoders, decoders and synchronizers. Reference may be made to U.S. Pat. No. 4,217,647 for a further description of the structure and operation of this system.

Among the several objects of the present invention may be noted the provision of an improved valve control unit and system for switching the position of a valve in a pipe network; the provision of such valve control unit and system which permits low cost installation, because less material and labor is required, and which permits fast and inexpensive system revision and additions; the provision of such valve control unit and system which is fast in operation and reports valve malfunction to a controller; the provision of such valve control unit and system which is relatively free of susceptibility to electrical interference which interference could result in erroneous or unintended valve operation; the provision of such valve control unit and system which can accommodate a great number of valves located at a relatively long distance from the controller; the provision of such valve control unit and system which directly monitors both the open and the closed position of each valve; and the provision of such valve control unit and system which is reliable in operation, has long service life and is simple and economical to manufacture. Other objects and advantages will be in part apparent and in part pointed out hereinafter in the specification and attached claims.

Briefly, the valve control unit of the present invention includes electronic circuit means for communicating with a controller. The unit further includes a first sensor at a monitored valve for providing a signal to the circuit means when the valve is in its first predetermined, e.g., open position. A second sensor is provided for signaling to the circuit means when the valve being monitored is in its second predetermined, e.g., closed position. The electronic circuit means is adapted to report to the controller the conditions of each of the sensors.

FIG. 1 is a simplified diagrammatic layout of a plurality of valves each carrying a valve control unit of the present invention with the units operated by a controller positioned remote from the valves;

FIG. 2 is a block diagram representative of one of the valve control units of FIG. 1;

FIG. 3 is a perspective view of one of the valve units of FIG. 1 with certain components removed;

FIG. 4 is a sectional view of a pneumatic cylinder for attachment to the valve, the operation of the cylinder being controlled by a valve control unit of the present invention carried by the cylinder;

FIG. 5 is a sectional view taken generally along line 5--5 of FIG. 4 showing position sensor means of the valve control unit;

FIG. 6 is a sectional view taken generally along line 6--6 of FIG. 4 further illustrating the sensor means; and

FIG. 7 is a schematic illustration of electrical and electronic components included in the valve control unit of the present invention; and

FIGS. 8, 9 and 10 are together a flow chart of a program for use with the valve control unit of the present invention.

Corresponding reference characters indicate corresponding components throughout the several views of the drawings.

At the end of the specification is set forth a program, in machine language and of which FIGS. 8-10 are a flow chart, of the contents of a memory of a microprocessor included in the valve control unit of the present invention.

Referring now to the drawings, a valve control unit for operating a valve in accordance with instructions from a controller 34 and for reporting the position of its valve to the controller, is generally indicated by reference character 20. A valve control system incorporating valve control units 20 is shown in FIG. 1. Each unit 20 is carried by a pneumatic cylinder 22 which in turn is mounted upon the valve 24 which it shifts to control the valve. The various valve control units are all interconnected with a single cable 26 running from controller 34 located, for example, in a control room remote from the pipe network in which the valves are installed. The cable 26 is shielded and includes a pair of A.C. voltage power conductors L1, L2 and a trio of signal conductors 28, 30, 32 for carrying digital signals. Conductor 28 carries a synchronization signal while conductor 30 carries a "B" signal for reporting to the controller the status of each of the valves 24. Finally, conductor 32 carries an "A" signal emanating from the controller including intelligence directing the switching of the various valves. The cable may also include a common ground conductor 35 for all signal conductors, or the cable could include a separate ground conductor for each signal conductor.

The controller 34 preferably includes a computer, a master control unit 36 for providing a synchronization signal to maintain overall control timing and a transmitter/receiver unit 38 or input/output device for facilitating movement of the input/output data to the various valve control units. The controller 34 may also include a display panel or annunicator system (not shown) for displaying valve position and warning the attendant of malfunction. The master control unit 36 and the transmitter/receiver unit 38 are of the type commercially available from Control Junctions, Inc. of Schaumburg, Illinois. Furthermore, the control system and apparatus using time division multiplexing for generating a sychronization signal and a common signal are fully shown and described in U.S. Pat. No. 4,156,112, assigned to Control Junctions, Inc., the teachings of which are herein incorporated by reference.

By way of overview, each communication cycle established by the master control unit 36 is divided into a predetermined number of channels, e.g., 256, with each cycle divided into a first half and a second half marked by synchronization pulses from unit 36. Each valve control unit 20 is assigned a different adjacent pair of time channels; accordingly, this particular system can accommodate up to 128 valve control units. A high voltage or "1" in the first channel half followed by a low voltage or "0" in the second channel half is interpreted as an activation signal while "0" followed by a "1" is recognized as a deactivation signal. During the time interval provided by the first of the two channels associated with a particular valve control unit, the valve control unit transmits over the "B" signal conductor 30 telling the controller the status of one of a pair of valve position sensors while concurrently the controller effects a transmission over the "A" signal conductor 32 instructing the valve control unit the position in which the valve should be. During the time interval provided by the second channel associated with the particular valve control unit, data is transmitted from the valve control unit to the controller over the "B" line, informing the controller of the status of a second of a pair of valve position sensors. The controller does not send signals over the "A" line during the second time channel.

The communication cycle commences with an absence of pulses of two clock channel duration on the synchronization signal conductor 28. This cues each valve control unit that a communication cycle is commencing and to start counting time channels with the next synchronization pulse. Upon arrival of its assigned time channels, the particular valve control unit 20 is enabled to communicate with the controller 34.

For example, the valve control unit under consideration is assigned time channels 200 and 201. The controlled valve is deactivated causing the valve control unit 20 to generate the "0", "1" sequence. The controller determines that the valve should be activated and generates the "1", "0" sequence. When the synchronization signal conductor 28 has a period of two clock cycles with no pulses, each valve control unit is cued to reset and start counting. When time channel 200 arrives, the valve control unit is enabled to send data on the valve position over the "B" signal conductor, and receives instructions on the "A" signal conductor. During channel 200, the valve control unit transmits the "0", "1" sequence on the "B" signal conductor informing the controller that the first position sensor detects the valve is closed, and receives the "1", "0" sequence on the "A" signal conductor, being commanded to activate the valve. In channel 201, the valve control unit transmits the "0", " 1" sequence indicating that the second position detector has also detected that the valve is closed. Of course, the valve switching is not instantaneous, and movement has not begun upon the arrival of channel 201.

Referring to FIG. 4, pneumatic cylinder 22 includes a housing 40 defining a piston chamber 42 slidably holding a piston 44 having a rod 46 with a threaded end extending through a lower end wall 48 into a connection chamber 50. The chamber 50 is for reception of an operating stem (not shown) of a valve 24 for attachment of the internally threaded rod end. Extending oppositely from the piston rod 46 is an actuator rod 52 protruding slidably through an upper end wall 54 for indicating the piston position, and thus, the valve position. The rod 52 is attached to the piston by means of a retainer cup 56 holding an enlarged head 58 of the rod with the rod stem 60 extending through an opening in the cup of greater diameter than that of the stem. A compression spring 62 is disposed between the rod head and the piston body to secure the position of the rod while permitting alignment during assembly and operation.

The housing 40 also encloses a large compression spring 64, for working against upper end wall 54 and the piston 44, for biasing piston rod 46 to an extended position causing the valve to impede fluid flow through the valve. The lower end wall 48 has a port 66 for entrance of pressurized air. In the interest of brevity, pneumatic switching valves, the air supply and air supply connections and hardware are not fully shown as those are well known to those skilled in the art. Suffice it to say that application of pressurized air to piston chamber 42 through port 66 causes the piston rod 46 to move to a retracted position opening the valve 24 to fluid flow. The application of air also causes actuator rod 52 to extend through a base plate 68 attached to wall 54, a valve control unit mounting bracket 70 fastened to base plate 68, a valve control unit cover 72 held by the mounting bracket, and into a transparent indicator tube 73 for permitting visual observation of the position of the valve 24. On the other hand, exhaustion of port 66 results in the piston rod extending, under the bias of return spring 64, to close the valve 24. Also it causes the actuator rod 52 to retract.

Besides mounting its valve control unit 20, the base plate 68 also supports a junction box 74 through which cable 26 passes. The junction box 74 encloses an external connection board 76 while mounted on base plate 68 in an internal connection board 78, with the boards 76, 78 interconnecting the cable 26 with the electrical and electronic components (which will be described more fully hereinafter) of the valve control unit 20. The valve control unit mounting bracket 70 supports a solenoid valve 80 (shown in FIGS. 3, 5 and 6) for switching the exhaustion/pressurization of cylinder 22, and electrical/electronic component mounting board 82 and a valve position sensor mounting board 84.

Adjustably attached at spaced positions on actuator rod 52 by means of collars 86, 88 are a pair of flags 90, 92. Each flag is bifurcated, including a pair of parallel guide legs 94 bridged by an interrupter 96 (as shown in FIG. 6) for blocking the radiation flow of an optionally coupled sensing device. More specifically, sensor mounting board 84 carries an upper optically coupled switch OS1 for providing data for transmission to the controller during the first time channel of the two time channels assigned to the particular valve control unit under consideration, on the "B" signal conductor 30, and a lower optically coupled switch OS2 for providing data for transmission to the controller during the second of the two time channels on the "B" signal conductor. They thus cooperate with the flags to indicate the position of actuator rod 52 (and thus indicate whether the valve is open or closed), as best shown in FIGS. 5 and 6. Each switch is identical so only switch OS1 need be described. It includes a light emitting diode LED1 for providing infrared radiation, and a phototransistor T1 spaced therefrom which is responsive to the impingement of radiation on its base to render conductive its collector-emitter circuit. Each flag interrupter 96 is movable between the diode and the transistor of its switch, and the collars 86, 88 and switches OS1, OS2 are positioned so that when the interrupter flag 90 is disposed between the components of switch OS1, the valve 24 is open while when the interrupter of lower flag 92 is between the components of switch OS2 (as shown in FIG. 6), the valve 24 is closed.

The electrical/electronic components included in each valve control unit 20 are best shown in FIG. 7. Power leads L1, L2 are connected to the input of a center-tapped, step down transformer TR the output of which is rectified by a full wave bridge rectifier BR with a capacitor C1 connected across the output of the rectifier and acting as a filter to reduce D.C. ripple. The output thus provided is a nominal 18 volts D.C. for power usage. Interconnected with the transformer center tap and the grounded output of the rectifier are a ripple reduction capacitor C4 and the input of a voltage regulator VR for providing a regulated 5 volts D.C. output (VCC) for a control voltage for the electronic components. A voltage stabilization capacitor C2 is connected across the voltage regulator output and the negative output of the rectifier is grounded by virtue of its connection to common ground conductor 35 of cable 26. The transformer TR, rectifier BR, voltage regulator VR and associated capacitors can be considered to constitute a power supply for the valve control unit.

The heart of the valve control unit is a microprocessor M which includes encoder means, decoder means, memory, logic and clock means. Such a microprocessor is part number 8748 manufactured by Intel Corp., Santa Clara, Calif. This microprocessor includes a programmable read only memory (PROM) which is programmable to cause the microprocessor to respond to various sensors, switches and other inputs as will be described below. Connected to the microprocessor are the output of the voltage regulator and a crystal XTAL to establish, for example, a six megahertz clock rate for the microprocessor. Ports 20 and 22 are connected to ground through the collector-emitter circuits of the transistors of optically coupled switches OS1, OS2, respectively. The light emitting diode of each switch OS1, OS2 is connected from +18 volts D.C. to ground in series with a current limiting resistor R7, R8, respectively.

A dual in-line package (DIP) switch module SW1 has its eight outputs connected to a like number of ports of microprocessor M. Switch module SW1 comprises eight single pole, single throw switches, the inputs of which are grounded. Seven of the eight switches are used to fix the identity of the valve control unit with respect to its assigned channels in the communication cycle provided by master control unit 36. The position of the eighth switch identifies to the microprocessor that state that valve 24 is to go into if there is a signal line malfunction.

Interconnected with microprocessor M is a quad voltage comparator 98 comprising comparators COMP 1 through COMP 4. More specifically, a port DB3 of the microprocessor is connected to the negative input of COMP 1 while the positive input thereof (as well as the positive input of COMP 2) is commonly connected to VCC though a current limiting resistor R4 and to ground through serially connected diodes D3 and D2. The diodes provide a voltage drop so that the reference voltage at the positive input of COMP 1 and that of COMP 2 is about +1 volt D.C. The output of COMP 1 controls switching of a transistor T2, the collector-emitter circuit of which connects to ground from the +18 volts D.C. power voltage the parallel combination of the coil 100 of the solenoid valve 80 in series with resistor R6 and the series combination of a light emitting diode LED2 (for providing visual indication of solenoid coil energization) and a current limiting resistor R9. In order to protect transistor T2 from a deleterious voltage surge due to the collapse of the magnetic field of coil 100 upon turn off of transistor T2, a pull back diode D1 is provided in parallel with coil 100.

The negative input of comparator COMP 2 is connected to microprocessor port P21 while its output controls operation of a switching transistor T3 via current limiting resistor R3. The collector-emitter circuit of transistor T3 selectively connects +18 volt D.C. to the signal "B" conductor 30 of cable 26 in accordance with instructions from the microprocessor to report to the controller 34 the position of valve 24 as sensed by optically coupled sensor switches OS1 and OS2.

The synchronization signal conductor 28 of cable 26 is connected to the negative input of comparator COMP 3 through resistor R1 which provides a high impedance input. Both the positive input of comparator COMP 3 and the negative input of comparator COMP 4 are referenced to Vcc. The output of COMP 3 is connected to both Vcc through a current limiting resistor R5 and to the interrupt input INT of the microprocessor. Finally, the positive input of comparator COMP 4 is connnected to "A" signal conductor 32 of cable 26 through a current limiting resistor R2 and the output of COMP 4 goes to microprocessor M port P23. Of course, the general operation of the comparators is that if the voltage applied to the negative input is greater than that applied to the positive input, the output of the comparator will be a low voltage logic level. On the other hand, if the voltage at the negative input is equal to or lower than that at the positive input, a high voltage logic level will be present at the output of the comparator.

Operation of the electronic components of a representative valve control unit 20, as dictated in part by the contents of the PROM of the microprocessor, is as follows: Assume that the valve control unit under consideration is number 100 and that the various switches of DIP switch module SW1 have been set accordingly to enable the microprocessor M to receive and transmit data during channels 200 and 201. Furthermore, assume that the piston rod 46 of a cylinder 22 is retracted so that valve 24 is open, and that actuator rod 52 is extended causing optically coupled switch OS1 to disconnect the port P20 of the microprocessor from ground and causing the phototransistor of switch OS2 to conduct thus connecting microprocessor port P22 to ground. Upon the absence of pulses on the synchronization signal conductor 28 for a predetermined time, e.g., of a duration of two clock channels, comparator COMP 3 provides a high output of sufficient duration to the INT input of the microprocessor cueing it to start counting with the next synchronization pulse.

Communications between the valve control unit 20 designated 100 and the controller 34 begin with the start of channel 200 of the communication cycle and end at the expiration of channel 201. Upon arrival of channel 200, microprocessor output P21 provides a low output during the first channel half and a high output (5 volts) during the second channel half. This results in comparator COMP 1, which acts as a buffer, controlling the switching of PNP transistor T3 so that the "1", "0" sequence is applied to signal "B" conductor 30 informing the controller that sensor switch OS1 has sensed that its valve 24 is open. Also during channel 200, the "0", "1" sequence is provided on signal "A" conductor 32. As the "high" on this conductor exceeds +5 volts, comparator COMP 4 passes the "0", "1" sequence to the microprocessor commanding that valve 24 be deactivated or closed. In response, the microprocessor changes the output of DB3 causing transistor T2 to be rendered non-conductive thus deenergizing the solenoid coil 100 resulting in exhaustion of piston chamber 42 to permit biasing spring 64 to extend piston rod 46 to close the valve 24. Of course, valve switching cannot occur instantaneously. Upon the arrival of time channel 201 of the communication cycle, valve 24 is still open and this is reported to the microprocessor by switch OS2. The microprocessor is responsive to generate at output P21 a low output during the first half of channel 201 and high output during the second channel half. This again results in the comparator COMP 1 controlling transistor T3 so that the "1", "0" sequence is applied to signal "B" conductor 30 informing the controller that switch OS2 has determined that its valve 24 is open. Upon arrival of time channel 202, communication between the valve control unit designated 100 and the controller 34 is disabled and is not again enabled until the arrival of channel 200 of the next communication cycle.

The values of the various resistors (in ohms) and capacitors (in microfarads) are as follows: R1=1M, R2=1M, R3=1K, R4=10K, R5=10K, R6=100, R7=3.3K, R8=3.3K, R9=1K, C1=470, C2=1.5, C4=1000.

The attached program and FIGS. 8-10 regard the contents of the PROM of microprocessor M.

In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

As various changes could be made without departing from the scope of the invention, it is intended that all matter contained in the above description shall be interpreted as illustrative and not in a limiting sense. ##SPC1##