Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: MANIFOLD FOR A DIRECTIONAL CONTROL VALVE FOR A VALVE
ACTUATOR
FIELD
[0001] The present subject-matter relates to pneumatic and hydraulic
control
systems for valve actuators of the type used in many industrial processes.
INTRODUCTION
[0002] The flow of fluids and other substances carried in process
transport pipes
is typically controlled using a process valve. It may be necessary in an
industrial
process to close, to open, to lock, or to keep open the process valve, in
response to
specific conditions of the flow and the environment, such as a detected change
in the
flow rate inside the pipe, temperature inside and/or outside of the pipe, flow
pressure,
outside environment pressure, etc.
[0003] Conventional control systems for valve actuators are
generally designed
to respond to changes in the process flow in one of four modes: fail open,
fail close, fail
last, and fail last locked. The process valve is typically configured in one
of the four
modes with tubes leading to the actuator, forming a tube network. Such tube
networks
of the control systems have to be quite circuitous with multiple fittings and
bends to
include components such as filter regulators, speed controllers, and so forth.
The tube
networks also need to be customized for each of the four configurations and
therefore
demand qualified labor during the installation and maintenance.
SUMMARY
[0004] The following summary is intended to introduce the reader to
the more
detailed description that follows, and not to define or limit the claimed
subject matter.
[0005] According to a first aspect, the present subject matter
provides a valve
actuator control system. The control system includes a pneumatic directional
valve
operable to move the actuator, and also a manifold having multiple internal
channels,
each channel having a manifold inlet port and a manifold outlet port.
[0006] The pneumatic directional valve has a valve inlet port and a
valve outlet
port. The manifold is mountable directly to the pneumatic directional valve
and is fluidly
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connectible to it in alternative connections such that the manifold outlet
port and
manifold inlet port of one active internal channel communicate with the valve
inlet port
and valve outlet port, respectively, of the pneumatic directional valve, while
the other,
non-active internal channels are isolated from the pneumatic directional
valve.
[0007] The control system also includes closures that block the manifold
outlet
port and manifold inlet port of the non-active internal channels.
[0008] The multiple internal channels of the manifold are configured
to provide
operability of the actuator control system in at least a plurality of fail
modes.
[0009] In some examples, the multiple internal channels of the
manifold are
configured to provide operability of the actuator control system in any one of
fail-open,
fail-close, or fail-last modes.
[0010] In some examples, the multiple internal channels of the
manifold are
configured to provide operability of the actuator control system in any one of
fail-open,
fail-close, fail-last, or fail-last-locked modes.
[0011] According to another aspect, the present subject matter provides a
pneumatic manifold for a directional valve that operates to move the actuator
of a valve
actuator control system. The manifold is connectable to the directional valve
and
comprises a unitary body having multiple internal channels, each with a
manifold inlet
port and a manifold outlet port. The manifold is connectable to the
directional valve in
alternative connections such that the manifold outlet port and manifold inlet
port of one
active internal channel communicate with the valve inlet port and valve outlet
port,
respectively, of the pneumatic directional valve. The multiple internal
channels of the
manifold are configured to provide operability of the actuator control system
in at least a
plurality of fail modes.
[0012] In some examples, the multiple internal channels of the manifold are
configured to provide operability of the actuator control system in any of
fail-open, fail-
close, or fail-last modes.
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[0013] In some examples, the multiple internal channels of the
manifold are
configured to provide operability of the actuator control system in any of
fail-open, fail-
close, fail-last or fail-last-locked modes.
[0014] According to another aspect, the present subject matter
provides a
manifold block for a directional valve that controls the actuator of a process
valve. The
manifold block is connectable to the directional valve and comprises a
plurality of
manifold valve ports that are adapted to receive a plurality of complementary
ports of
the directional valve. A plurality of manifold channels is located inside the
manifold
block, each of the manifold channels extending between at least two manifold
ports
being adapted to conduct pressurized air between them. The manifold block is
configured to operatively connect the directional valve to a pressurized air
supply in at
least one of fail-open, fail-close, fail-last and fail-last-locked operating
modes.
[0015] In some examples, the manifold block is configured so that
the directional
valve is adapted to control the actuator in at least one operating mode chosen
from fail-
open, fail-close, fail-last, and fail-last-locked.
[0016] In some examples, the directional valve is controlled by at
least one pilot
solenoid valve which is connected to at least two of the input and output
manifold ports.
[0017] In some examples, the manifold block is a unitary body.
DRAWINGS
[0018] For a better understanding of the subject matter herein and to show
more
clearly how it may be carried into effect, reference will now be made, by way
of
example, to the accompanying drawings which show at least one exemplary
embodiment, and in which:
[0019] FIG. 1 illustrates a schematic side view of a conventional
control system
for a process valve.
[0020] FIG. 2 illustrates a schematic side view of a conventional
control system
for a process valve.
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[0021] FIG. 3A shows a schematic representation of an example of a
conventional two-position solenoid directional valve for a fail-open
configuration.
[0022] FIG. 3B shows a schematic representation of an example of a
conventional two-position solenoid-operated directional valve for a fail-
closed
configuration.
[0023] FIG. 30 shows a schematic representation of an example of a
conventional two-position solenoid directional valve for a fail-last
configuration.
[0024] FIG. 3D shows a schematic representation of an example of a
conventional three-position solenoid directional valve for a fail-last-locked
configuration.
[0025] FIG. 4A shows a schematic representation of a conventional piloted
two-
position directional valve for a fail-open configuration.
[0026] FIG. 4B shows a schematic representation of a conventional
piloted two-
position directional valve for a fail-closed configuration.
[0027] FIG. 40 shows a schematic representation of a conventional
piloted two-
position directional valve for a fail-last configuration.
[0028] FIG. 4D shows a schematic representation of a conventional
piloted three-
position directional valve for a fail-last-locked configuration.
[0029] FIG. 5 shows a schematic representation of a manifold block
for control of
an actuator, in accordance with at least one embodiment.
[0030] FIG. 6 shows a schematic representation of a manifold block adapted
for
the piloted directional valve, in accordance with at least one embodiment.
[0031] FIG. 7 shows a schematic perspective view of the manifold
block, in
accordance with at least one embodiment.
[0032] FIG. 8 shows a top view, a bottom view, and side views of an
example
embodiment of the manifold.
[0033] FIG. 9A shows a schematic representation of the manifold with
the fail-
open solenoid directional valve, in accordance with at least one embodiment.
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[0034]
FIG. 9B shows a schematic representation of the manifold with the fail-
closed solenoid directional valve, in accordance with at least one embodiment.
[0035]
FIG. 9C shows a schematic representation of the manifold with the fail-
last
solenoid directional valve, in accordance with at least one embodiment.
[0036] FIG.
9D shows a schematic representation of the manifold with the fail-
last-locked solenoid directional valve, in accordance with at least one
embodiment.
[0037]
FIG. 10A shows a schematic representation of the manifold with the fail-
open piloted directional valve, in accordance with at least one embodiment.
[0038]
FIG. 10B shows a schematic representation of the manifold with the fail-
closed piloted directional valve, in accordance with at least one embodiment.
[0039]
FIG. 10C shows a schematic representation of the manifold with the fail-
last piloted directional valve, in accordance with at least one embodiment.
[0040]
FIG. 10D shows a schematic representation of the manifold with the fail-
last-locked piloted directional valve, in accordance with at least one
embodiment.
[0041] FIG. 11 shows a perspective view of an actuator with a pneumatic
manifold control system for the actuator.
DESCRIPTION OF VARIOUS EMBODIMENTS
[0042]
In the following description, specific details are set out to provide
examples of the claimed subject matter. However, the embodiments described
below
are not intended to define or limit the claimed subject matter.
[0043]
It will be appreciated that, for simplicity and clarity of illustration,
where
considered appropriate, reference numerals may be repeated among the figures
to
indicate corresponding or analogous elements or steps. Numerous specific
details are
set forth in order to provide a thorough understanding of the exemplary
embodiments of
the subject matter described herein. However, it will be understood by those
of ordinary
skill in the art that the embodiments described herein may be practiced
without these
specific details. In other instances, well-known methods, procedures and
components
have not been described in detail so as not to obscure the present subject
matter.
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Furthermore, this description is not to be considered as limiting the scope of
the subject
matter in any way but rather as illustrating the various embodiments.
[0044] In addition, as used herein, the wording "and/or" is intended
to represent
an inclusive-or. That is, "X and/or Y" is intended to mean X or Y or both, for
example.
As a further example, "X, Y, and/or Z" is intended to mean X or Y or Z or any
combination thereof.
[0045] Examples of conventional control systems 30 and 60 for a
process valve
32 actuated by actuator 34 are shown schematically at Fig. 1 and Fig. 2. A
conventional control system 30 (or 60) comprises a directional valve 36 (or
62), a filter
(filter-regulator) 38, and a plurality of tubes leading to ports of the
directional valve 36
(or 62). Shown at Fig. 1 and Fig. 2 are five-port directional valves 36 and 62
with ports
40, 42, 44, 46, and 48.
[0046] It should be noted that the control system 30 may be
pneumatic or
hydraulic. Although pneumatic operation using air is described herein, the
same
operation and schematics can be used in a hydraulic control system 30, by
replacing air
with oil.
[0047] Depending on the type of the actuator 34 to be controlled and
other
requirements for the control system for the actuator 34, either a solenoid-
operated
directional valve 36 or a piloted directional valve 62 can be used in the
control system
for the actuator 34.
[0048] Fig. 1 illustrates a schematic side view of a conventional
pneumatic
control system 30 for the process valve 32 using a five-port solenoid-operated
directional valve 36. The solenoid-operated directional valve 36 may be
operated using
at least one solenoid 37. As shown at Fig. 1, a plurality of tubes 50, 52, 54,
56, and 58
form a network of tubes which connects the directional valve 36 to the
actuator 34, an
input air filter 38, and exhaust controls (not shown). The solenoid 37 of the
solenoid-
operated directional valve 36 is electrically connected to the installation
site's control
system. Failure of this source (power failure, initiated emergency-stop of
process
shutdown) deactivates solenoid valve 37 which reverts to a known (lair)
position. A
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five-port directional valve 36 typically has a pressure port (P-port) 40, a
first exhaust
valve port 42, a second exhaust valve port 44, as well as two output ports: A-
port 48
and B-port 46. The P-port 40 is an input port and is operatively connected to
an input
tube 50 which brings air from the filter 38. The output ports A-port 48 and B-
port 46, are
connected to the actuator 34 through the A-tube 54 and B-tube 52. The first
and the
second exhaust valve ports 42, 44 are connected to exhaust tubes 56, 58,
respectively,
which may be connected, for example, to an exhaust flow control device (not
shown at
Fig. 1).
[0049] Fig. 2 illustrates a schematic side view of a conventional
pneumatic
control system 60 for the process valve 32 using a five-port piloted
directional valve 62.
In addition to previously discussed P-port 40, A-port 46, B-port 48, and the
first and the
second exhaust valve ports 42, 44, the piloted directional valve 62 has at
least one pilot
port. At least one pilot solenoid valve can operate the piloted directional
valve 62
through at least one pilot port.
[0050] Shown at Fig. 2 is the piloted directional valve 62 with a first
pilot port 64
and a second pilot port 66. The first pilot port 64 may be operatively
connected through
a first pilot tube 68 to a first pilot solenoid valve 70. The second pilot
port 66 may be
operatively connected through a second pilot tube 72 to a second pilot
solenoid valve
74. The first or the second solenoid pilot valves 70, 74 can operate the five-
port piloted
directional valve 62 using air pushed through the first or the second pilot
tubes 68 and
72 to the first or the second pilot ports 64, 66. When the signal to the pilot
solenoid
valve fails, the corresponding pilot valve, 70 or 74 stops pushing air to the
corresponding pilot port 64, 66 of the piloted directional valve 62.
[0051] Typically, a control system 30 for the actuator 34 of process
valve 32 can
operate in one of four configurations: fail-open, fail-close, fail-last, and
fail-last-locked.
[0052] Each of the four configurations demands a specifically
configured
directional valve 36 or 62. Figures 3A, 3B, 3C, and 3D show conventional five-
port
solenoid directional valves 36a, 36b, 36c, and 36d, each operating in one of
the four
configurations.
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[0053] Figures 3A, 3B, 3C, and 3D also schematically show an
actuator 34
having a moving piston & piston rod 130 which separates the actuator's
cylinder in two
portions: a rod portion 132 and a cap portion 134. The A-port of any one of
the solenoid
directional valves 36a, 36b, 36c, and 36d may be connected via the tube 54 to
the cap
portion 134 of the actuator 34, while the B-port of any one of the solenoid
directional
valves 36a, 36b, 36c, and 36d may be connected via the tube 52 to the rod
portion 132
of the actuator 34.
[0054] The five-port directional valve 36 (or 62) may be a five-port
three- position
directional valve or a five-port two- position directional valve, depending on
the
configuration it is used for.
Fail-open
[0055] In a fail-open configuration, the process valve 32 needs to
open when
there is a failure of the solenoid valve's electrical signal
[0056] Fig. 3A shows a schematic representation of an example of a
conventional
two- position solenoid directional valve 36a for fail-open configuration ("FO
solenoid
directional valve") connected to the actuator 34 through the tubes 52 and 54.
Such a FO
solenoid directional valve 36a can be operated by a solenoid 100a and a spring
102a.
[0057] The FO solenoid directional valve 36a may be in a rest
position 110a (or
home position, or default position), or in an activated position 120a. The A-
port
(represented schematically at Fig. 3A as port 116a in the rest position 110a
and as port
126a in the activated position 120a) of the FO solenoid directional valve 36a
is
connected to the cap portion 134 of the actuator 34, while the B-port
(represented
schematically as 114a and 124a at Fig. 3A) of the FO solenoid directional
valve 36a is
connected to the rod portion 132 of the actuator 34.
[0058] When the FO solenoid valve 36a is in its rest position 110a, the
air,
received from the filter 38 to the P-port 112a, passes from the P-port 112a to
the B-port
114a. From the B-port 114a, the air passes via the tube 52 to the rod portion
132 of the
actuator 34, pushing the piston & piston rod 130 and expanding the rod portion
132.
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The air from the cap portion 134 of the actuator 34 returns through the tube
54 to the A-
port 116a and passes through the directional valve 36a to the exhaust port
119a.
[0059] When the solenoid 100a is activated, the FO solenoid valve
36a is in the
activated position 120a. In this activated position 120a, the air passes from
the P-port
122a to the A-port 126a, the cap portion 134 of the actuator 34 is therefore
filled with
air, and the process valve 32 is closed.
[0060] When the solenoid 100a is deactivated, the FO solenoid valve
36a is
returned to the rest position 110a by means of the spring 102a. In the rest
position
110a, the air is brought from P-port 112a to B-port 114a and returns from the
A-port
116a to the exhaust valve port 119a. In this rest position 110a, the air
pushed from the
B-port 114a via the tube 52 fills the rod portion 132 of the actuator 34 and
the piston &
piston rod 130 retracts in the ¨z direction and opens the process valve 32.
The air from
the cap portion 134 exhausts through the tube 54 via the port 116a and then
through
the port 119a.
Fail-closed
[0061] In a fail-closed configuration, the process valve 32 needs to
close if there
is a failure of the solenoid valve's electrical signal
[0062] Shown at Fig. 3B is a schematic representation of a two-
position
solenoid-operated directional valve 36b for fail-closed ("FC") configuration
("FC solenoid
directional valve"), connected to the actuator 34 through the tubes 52 and 54.
The B-
port (represented schematically as 114b and 124b at Fig. 3B) of the
directional valve
36b is connected to the rod portion 132 of the actuator 34, while the A-port
(represented
schematically as 116b and 126b at Fig. 3B) is connected to the cap portion 134
of the
actuator 34. Such a directional valve 36h can be in a rest position 110b or in
an
activated position 120b.
[0063] The FC solenoid directional valve 36b has a solenoid 100b for
activation
and a spring 102b. The FC solenoid directional valve 36b is in the activated
position
120b when it is activated by the solenoid 100b and the air passes from the P-
port 122b
to the B-port 124b. The B-port 124b is connected to the rod portion 132 of the
actuator
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34, the rod portion 132 is filled with air, the rod is retracted in the ¨z
direction and the
process valve 32 is opened.
[0064] When there is no signal coming from the solenoid 100b, for
example,
when the industrial process has failed, the spring 102b moves the directional
valve 36b
to the rest position 110b. In the rest position 110b, the air passes from the
P-port 112b
to the A-port 116b and fills the cap portion 134 of the actuator 34 with air,
thereby
closing the process valve 32. The air from the rod portion 132 of the actuator
then
returns via the tube 52 to the port 114b and then exhausts through the port
118b.
Fail-last
[0065] Shown at Fig. 3C is an example of a two- position solenoid
directional
valve for the fail-last configuration ("FL solenoid directional valve") 36c.
The FL solenoid
directional valve 36c is activated by a first solenoid 104 or the second
solenoid 105,
and does not have springs. The FL solenoid directional valve 36c can be in a
first
position 140 or in a second position 150.
[0066] The B-port (represented schematically as 144 and 154 at Fig. 3C) of
the
directional valve 36c is connected to the rod portion 132 of the actuator 34,
while the A-
port (represented schematically as 146 and 156 at Fig. 3C) is connected to the
cap
portion 134 of the actuator 34.
[0067] The first solenoid 104 can move the FL solenoid directional
valve 36c into
a first position 140, where the air passes from the P-port 142 to the A-port
146, filling
the cap portion 134 with air,. As the cap portion 134 is filled with air, the
process valve
32 is closed. When the solenoid 104 is deactivated, the directional valve 36c
remains in
the first position 140.
[0068] When the second solenoid 105 is activated, it can move the FL
solenoid
directional valve 36c into a second position 150, where the air passes from
the P-port
152 to the B-port 154, filling the rod portion 132 of the actuator 34 with
air. As the rod
portion 132 is filled with air, the process valve 32 is opened. When the
solenoid 105 is
deactivated, the directional valve 36c remains in the second position 150.
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Fail-last-locked
[0069] Fig. 3D shows an example of a three- position solenoid
directional valve
for the fail-last-locked configuration ("FLL solenoid directional valve") 36d.
The FLL
solenoid directional valve 36d has a first solenoid 106, a second solenoid
107, and a
first spring 108 and a second spring 109. The FLL solenoid directional valve
can be in a
first position 160, a second position 170, or a third (middle) position 180.
[0070] When the first solenoid 106 is activated, the directional
valve 36d is in the
first position 160 and the air passes from the P-port 162 to the A-port 166.
The cap
portion 134 of the actuator 34 is filled with air and the process valve 32 is
closed. The
air from the rod portion 132 returns (exhausts) through the B-port 164 to the
exhaust
valve port 168.
[0071] When the first solenoid 106 is deactivated, the first and the
second springs
108 and 109 move the FLL solenoid directional valve 36d into the third
(middle) position
180. In the third position 180, the FLL solenoid directional valve 36d is
closed and no air
passes from the P-port 182 to either the A-port 186 or the B-port 184.
[0072] When the second solenoid 107 is activated, the directional
valve 36d is in
the second position 170 and the air passes from the P-port 172 to the B-port
174. In this
case, the rod portion 132 of the actuator 34 is filled with air and the
process valve 32 is
opened. The air from the cap portion 134 exhausts through the A-port 176 to
the
exhaust valve port 179.
[0073] When the second solenoid 107 is deactivated, the first and the
second
springs 108 and 109 move the FLL solenoid directional valve 36d into the third
(middle)
position 180, closing the FLL solenoid directional valve 36d such that no air
passes from
the P-port to either the A-port or the B-port.
[0074] Referring back to Fig. 2, the directional valve can be piloted by
one or two
pilot valves. The pilot valve or valves (70 and/or 74) can control the piloted
directional
valve 62 by means of the airflow. When the system fails, the pilot valve or
valves stop
sending air to the piloted directional valve 62, sending therefore a "failure"
signal to the
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piloted directional valve 62. It should be noted that, typically, the solenoid
directional
valves 36 and the piloted directional valves 62 have different physical
dimensions.
[0075] Figures 4A, 4B, 40 and 4D show piloted directional valves
62a, 62b, 62c,
and 62d, each adapted to operate in one of four configurations: fail-open,
fail-closed,
fail-last or fail-last-locked.
[0076] Fig. 4A shows a piloted directional valve for a fail-open
configuration ("FO
piloted directional valve") 62a. The FO piloted directional valve 62a operates
in a similar
manner to the FO solenoid directional valve 36a discussed above, except that
the
piloted valve 62a is activated by a pilot valve 70a. The pilot valve 70a
controls the FO
piloted directional valve 62a by the flow of the air.
[0077] When the pilot valve 70a pushes the air to the FO piloted
directional valve
62a, the FO piloted directional valve 62a is in the activated position 120a.
In the
activated position 120a, the air received by the P-port 122a is transmitted to
the A-port
126a, and then through the pipe 54 to the cap-portion 134 of the actuator 34,
thereby
closing the process valve 32.
[0078] On failure of pilot valve 70a, it stops sending/transmitting
air to the piloted
directional valve 62a .With the absence of air from the pilot valve 70a, the
spring 102a
moves the directional valve 62a into its rest position 110a. In this rest
position 110a, the
input air from the P-port 112a is transmitted to the B-port 114a, and then,
via tube 52, to
the rod portion 132 of the actuator 34, thereby forcing the piston & piston
rod 130 to
move in the ¨z direction, opening the process valve 32.
[0079] Fig. 4B shows a piloted directional valve for a fail-closed
configuration
("FC piloted directional valve") 62b, which operates in a similar manner as
the FC
solenoid directional valve 36b, with the exception that the piloted valve 62b
is activated
by a pilot valve 70b (instead of the solenoid 100b).
[0080] Fig. 4C shows a piloted directional valve for a fail-last
configuration ("FL
piloted directional valve") 62c, which operates in a similar manner as the FL
solenoid
directional valve 36c, with the exception that the FL piloted directional
valve 62c is
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activated by a first pilot valve 70c and a second pilot valve 74c (instead of
the first and
the second solenoids 104 and 105).
[0081]
Fig. 4D shows a piloted directional valve for a fail-last-locked
configuration ("FLL piloted directional valve") 62d, which operates in a
similar manner
as the FLL solenoid directional valve 36d, with the exception that the FLL
piloted valve
62d is activated by the first pilot valve 70d or the second pilot valve 74d
(instead of the
first and the second solenoids 106 and 107).
[0082]
Referring back to the conventional control systems 30 and 60 at Figs. 1-2,
the network of tubes 50, 52, 54, 56, and 58, leading from the directional
valves 36 or 62
to the actuator 34 and to supporting components, should be designed, adapted
and
installed specifically for each control system. Interconnecting tubing is
prone to leakage
because of the numerous connection points, is subject to failure due to
mechanical
damage and/or vibrations, and is not well suited for compact assemblies.
Manifold
[0083] Referring now to Fig. 5, shown therein is a schematic representation
of an
example embodiment of a manifold block 200 for control of an actuator 34. For
example, the manifold 200 may be a parallelepiped. For example, the manifold
may be
a rectangular parallelepiped. Different materials can be used to build the
manifold; steel,
ductile iron, aluminum or stainless-steel.
[0084] The manifold 200 comprises a plurality of manifold ports and a
plurality of
manifold channels. Each manifold channel may have two or more ports and may
permit
the air to pass in the manifold channel from at least one port to at least
another port of
the same manifold channel. Each manifold port may permit the air to enter and
exit one
of the manifold channels at an external surface 201 of the manifold 200. The
manifold
ports may be located at different sides (facets) of the manifold 200.
[0085]
In at least one embodiment, the manifold channels of the manifold 200
may shorten or even replace the conventional tube network of the control
system 30 (or
60). In at least one embodiment, the filter 38, a pressure relief valve, as
well as exhaust
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flow control devices (valve/muffler), and/or other devices, may be operatively
connected
directly to the manifold 200.
[0086] In at least one embodiment, the manifold 200 may be
operatively coupled
to the directional valves 36 or 62. In at least one embodiment, five ports of
the manifold
200 (ports 240, 242, 244, 246, and 248) may be adapted to receive the ports of
the
solenoid directional valve 36. The ports of the manifold 200 may be
complementary to
the ports of the directional valves 36 or 62.
[0087] The solenoid directional valve 36 for any one of the four
configurations
fail-open (36a), fail-closed (36b), fail-last (36c) or fail-last-locked (36d)
as discussed
herein may be operatively connected (coupled) to the manifold 200. The filter
38, at
least one exhaust flow control device, as well as a pressure relief valve may
also be
operatively coupled to the ports of the manifold 200.
[0088] Referring to Fig. 5, the manifold 200 comprises at least one
air input
channel 212, which may have at least one input port 202 and an output port
240. The
output port 240 of the air input channel 212 may be operatively connected to
the P-port
40 of the directional valve 36. The input port 202 may be operatively
connected to the
filter 38.
[0089] Shown at Fig. 5 is an example embodiment with the air input
manifold
channel 212 having three input manifold ports (a first input manifold port
202, a second
input manifold port 204, and a third input manifold port 206) and three
channel portions
207, 208, and 203, merged at a node 210 into the air input manifold channel
212. The
air input manifold channel 212 then leads to the output port 240 of the air
input manifold
channel 212. For example, the air input manifold channel 212 may have further
channel
portions, each merged into the air input manifold channel 212 or into at least
one of its
portions.
[0090] In at least one embodiment, the second input port 204 may be
operatively
connected to the pressure relief valve. In at least one embodiment, one or
more of input
ports may be plugged. Multiples of the internal channels offers the
possibility of
interconnecting different peripheral devices (such as a pressure relief valve
and/or
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piloting solenoid valves) and/or simplifying interconnections on different
faces of the
manifold to optimize compactness of the final assembly. All unused ports, with
the
exception of the exhaust ports 224 and 226, must be plugged with appropriate
plugs.
[0091] The manifold 200 may further comprise a first exhaust manifold
channel
256 and a second exhaust manifold channel 258. The first exhaust channel 256
may
have two manifold exhaust ports 242 and 224, and the second exhaust channel
258
may also have two manifold exhaust manifold ports 244 and 226. In at least one
embodiment, the first and the second exhaust manifold ports 258 and 244 may be
adapted to receive the first and the second exhaust valve ports 58 and 44 of
the
directional valve 36, such that the manifold 200 may be operatively connected
to the
directional valve 36.
[0092] The exhaust manifold ports 224 and 226 may be adapted to
receive the
exhaust flow control mufflers. If no accessories are required for the exhaust
function,
these ports are to be left opened.
[0093] The manifold 200 may further comprise an A-channel 254 and a B-
channel 252, each having at least two ports. A first manifold A-port port 248
of the A-
channel 254 may be adapted to connect to the A-port 48 of the directional
valve 36. At
least one exit manifold B-port (for example, port 231 or port 233) of the B-
channel may
be operatively connected to the actuator 34, the unused port is thus
appropriately
plugged.
[0094] A first manifold B-port 246 of the B-channel 252 may be
operatively
connected to the B-port 46 of the directional valve 36. At least one exit
manifold B-port
(for example, port 231 or port 233) of the B-channel 252 may be operatively
connected
to the actuator 34, the unused port is thus appropriately plugged.
[0095] In at least one embodiment, at least one exit manifold A-port may
have
one form and/or dimension and/or standard, and the other exit manifold A-port
may
have another form and/or dimension and/or standard. Similarly, at least one
exit
manifold B-port may have one form and/or dimension and/or standard, and the
other
exit manifold B-port may have another form and/or dimension and/or standard.
For
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example, the exit manifold ports 233 (and/or 235) may have the NAMUR standard,
and
exit manifold ports 231 (and/or 237) may have the National Pipe Thread (NPT)
standard. Having two different ports may allow reducing the number of
components,
such as adapters, to be used in the control system. 'NAMUR' describes a
mechanical
interface pattern used to mate a directional valve onto a flat surface and is
typically
used in pneumatic rotary actuators. Other port types can also be integrated
such as
BSP and SAE.
[0096] For example, when one manifold A-port 237 is used, the other A-
port 235
may be blocked/plugged with an appropriate port plug (plug appropriate for the
type of
port, NPT, BSP, SAE, NAMUR).
[0097] Shown at Fig. 6 is a schematic representation of another
example
embodiment of a manifold block 260 adapted for the piloted directional valve
62. In
addition to the manifold channels and ports discussed herein in reference to
the
manifold block 200, the manifold block 260 may have at least two pilot
manifold
channels: a first pilot channel 268 and a second pilot channel 272, each
having at least
two ports. The first and the second pilot channels 268 and 272 are adapted to
be
operatively connected to the first and the second pilot valves 70 and 74,
respectively.
Channels 214 and 216 forward inlet air to ports 215 and 217 respectively which
can be
used by the externally connected pilot valves 70 and 74 as the air source to
be directed
toward pilots 64 and 66. This feature greatly enhances the compactness and
reliability
of the assembly by eliminating the requirement of external interconnections.
[0098] Shown at Fig. 7 is a schematic perspective view (three-
dimensional view)
of an example embodiment of the manifold 260. It should be noted that the
manifold
channels may be of any form. For example, the manifold channels may have
similar or
different cross-sections. For example, a cross-section of at least one
manifold channel
may have round, elliptical or a convex polygon form. The form and at least one
dimension of the cross-section of at least one manifold channel may be
constant over at
least one portion of the at least one manifold channel and/or may vary along
the length
of the at least one manifold channel.
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[0099] Fig. 8 shows a top view, a bottom view, and side views of an
example
embodiment of the manifold 260.
[00100] Fig. 9A shows a schematic representation of the manifold 200
with the FO
solenoid directional valve 36a. Fig. 9B shows a schematic representation of
the
manifold 200 with the FC solenoid directional valve 36b. Fig. 9C shows a
schematic
representation of the manifold 200 with the FL solenoid directional valve 36c.
Fig. 9D
shows a schematic representation of the manifold 200 with the FLL solenoid
directional
valve 36d.
[00101] The same manifold 200 may be operatively connected to receive
any of
the directional solenoid valves 36a, 36h, 36c, or 36d, each adapted to a
different
configuration, such as fail-open, fail-close, fail-last, and fail-last-locked.
[00102] Fig. 10A shows a schematic representation of the manifold 260
with the
FO solenoid directional valve 62a. Fig. 10B shows a schematic representation
of the
manifold 260 with the FC solenoid directional valve 62b. Fig. 10C shows a
schematic
representation of the manifold 260 with the FL solenoid directional valve 62c.
Fig. 10D
shows a schematic representation of the manifold 260 with the FLL solenoid
directional
valve 62d.
[00103] The solenoid directional valves 36 and the piloted directional
valves 62
typically have different dimensions. Nevertheless, the manifold 260 may be
adapted to
receive a solenoid direction valve 36, all the unused ports of the manifold
260 are
plugged with the exception of the exhaust ports.
[00104] Fig. 11 shows a perspective view of an actuator 34 with a
pneumatic
manifold control system for the actuator. Shown at Fig. 11 is an example
embodiment of
the manifold 260, operatively connected to the directional valve 62. Two pilot
valves 70
and 74 are operatively connected to the manifold 260.
[00105] The pneumatic manifold control system for an actuator may
comprise the
directional valve 36 or 62, the pressure relief valve 199, the filter 38, and
the manifold
block 260. The manifold block 260 may connect using the manifold channels the
filter
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38, the pressure relief valve 199, and the directional valve 36 or 62, with
each other and
with the actuator 34.
[00106] As shown at Fig. 11, only two tubes 52 and 54 may lead from
the manifold
block 260 to the actuator 34. Comparing Fig. 11 to Fig. 2, the conventional
control
system 60 would need a larger number of tubes in order to connect the
directional valve
36 to the control devices (such as the filter 38, the pressure relief valve
199, and the
exhaust flow control device). The number of tubes in the control system 300
may be
considerably reduced due to the manifold 260. The manifold channels as
described
herein replace the tubes of the conventional control system 60 (or 30).
[00107] The directional valve may be the solenoid directional valve 36 or
the
piloted directional valve 62, piloted by at least one pilot solenoid valve 70
(and/or 74).
The pilot solenoid valves 70 and/or 74, as shown at Fig. 11, may be connected
directly
to the manifold 260, i.e. to the manifold channels 268 and/or 272.
[00108] As described herein, the pneumatic manifold control system for
a valve
actuator may operate in at least one of the control configurations. The
control
configuration of the pneumatic manifold control system may be one of fail-
open, fail-
close, fail-last, and fail-last-locked configurations and is dependent of the
directional
valve used in the system.
[00109] The manifold 260 may be attached to the plate 303, while the
plate 303
may be attached to the actuator 34.
[00110] Different manifold blocks may be provided, each with the
functionality
indicated herein, to suit different size directional valves: a 1/4 size
manifold block to suit
the 1/4 size solenoid operated directional valve 36; a 1/2 size to suit the
1/2 size piloted
directional valve 62; and a size 1 to suit a 1 size piloted directional valve
also depicted
by 62. The physical sizes of these blocks are: 1/4 size - 4 in long x 4 in
wide x 1.5 in high;
1/2 size - 8 in long x 4 in wide x 2.25 in high; and 1 size - 10 in long x
4.25 in wide x 3.5
in high.
[00111] The manifold based control system offers numerous advantages
over the
existing methods used in the industry: increased reliability, compactness and
cost
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effectiveness of the final assembly by eliminating the majority of external
component
interconnections, optimized modularity permits four different control schemes
by
changing a single component (FO, FC, FL, FLL), and simplifies the addition of
numerous accessories, easy physical installation since the block is used as a
mounting
platform for all accessories, cost effective manufacturing of the block since
it can be
mass produced, numerous port options, configurations and physical installation
possibilities permit its use in a wide scope of applications.
[00112] While the above description provides examples of the
embodiments, it will
be appreciated that some features and/or functions of the described
embodiments are
susceptible to modification without departing from the spirit and principles
of operation
of the described embodiments. Accordingly, what has been described above has
been
intended to be illustrative of the invention and non-limiting and it will be
understood by
persons skilled in the art that other variants and modifications may be made
without
departing from the scope of the invention as defined in the claims appended
hereto.
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