Switching module for a valve controller

• US 9,541,214 B2
• Filed: 07/31/2014
• Issued: 01/10/2017
• Est. Priority Date: 08/01/2013
• Status: Active Grant

• Current Assignee: General Equipment & Manufacturing Co., Inc. (Emerson Electric Company)
• Original Assignee: General Equipment & Manufacturing Co., Inc. (Emerson Electric Company)
• Inventors: Penning, Bruce R., LaFountain, Robert Lynn, Rigsby, Bruce, Carpenter, Scott
• Primary Examiner(s): Bastianelli, John
• Application Number:
  US14/448,799
• Publication Number:
  US 20150034848A1
• Time in Patent Office: 894 Days
• Field of Search: 251/129.04, 137/1, 137553-554
• US Class Current: 1/1
• CPC Class Codes: F16K 31/06 using a magnet , e.g. diaphragm valves, cutting off by means of a liquid
• CPC Class Codes: F16K 37/0033 using a permanent magnet, e.g. in combination with a reed relays
• CPC Class Codes: G01D 5/145 influenced by the relative movement between the Hall device and magnetic fields see G01R33/06

Abstract

A valve controller assembly includes a first switch that generates a first input signal based on an operational parameter of a control valve, and a docking assembly is communicatively coupled to the first switch. A switching module is removably secured to and communicatively coupled to the docking assembly such that the first switch is communicatively coupled to the switching module when the switching module is secured to the docking member. The switching module includes a first emulation circuit adapted to receive the first input signal, process the first input signal, and output a first output signal that is different than the first input signal.

Claims

1. A method of operating a valve controller assembly, the valve controller assembly including a first switch that generates a first input signal based on an operational parameter of a control valve and a docking assembly communicatively coupled to the first switch, the method comprising:

securing a first switching module to the docking assembly such that the first switching module is communicatively coupled to the docking assembly, the first switching module including a first emulation circuit adapted to receive the first input signal, process the first input signal, and output a first output signal that is different than the first input signal;

removing the first switching module from the docking assembly such that the first switching module is not communicatively coupled to the docking assembly; and

securing a second switching module to the docking assembly such that the second switching module is communicatively coupled to the docking assembly, the second switching module including a second emulation circuit adapted to receive the first input signal, process the first input signal, and output a second output signal that is different than the first input signal and the first output signal;

wherein the first switch and the docking member are each fixed to a printed circuit board.

2. The method of claim 1, further comprising removing all or a portion of a controller enclosure prior to securing the first switching module to the docking assembly.

3. A method of controlling a control valve comprising:

generating a first input signal from a first switch, the first input signal based on an operational parameter of the control valve;

processing the first input signal using a first emulation circuit included in a first switching module, the first switching module being communicatively coupled to a docking assembly that is communicatively coupled to the first switch; and

outputting a first output signal from the first emulation circuit, the first output signal being different than the first input signal;

processing the first input signal using a second emulation circuit included in a second switching module, the second switching module being communicatively coupled to the docking assembly that is communicatively coupled to the first switch; and

outputting a second output signal from the second emulation circuit, the second output signal being different than the first input signal and the first output signal;

wherein the first switch and the docking member are each fixed to a printed circuit board.

4. The method of claim 3, further comprising transmitting the first output signal to a device.

5. The method of claim 3, wherein processing the first input signal using the first emulation circuit includes reducing the voltage of the first input signal such that the first output signal has a lower voltage than the first input signal.

6. The method of claim 3, wherein processing the first input signal using the first emulation circuit includes reducing the current of the first input signal such that the first output signal has a lower current than the first input signal.

7. A valve controller system comprising:

a first switch that generates a first input signal based on an operational parameter of a control valve;

a docking assembly communicatively coupled to the first switch;

a first switching module adapted to be removably secured to and communicatively coupled to the docking assembly such that the first switch is communicatively coupled to the first switching module when the first switching module is secured to the docking assembly, the first switching module including a first emulation circuit adapted to receive the first input signal, process the first input signal, and output a first output signal that is different than the first input signal;

a second switching module adapted to be removably secured to and communicatively coupled to the docking assembly such that the first switch is communicatively coupled to the second switching module when the second switching module is secured to the docking assembly, the second switching module including a second emulation circuit adapted to receive the first input signal, process the first input signal, and output a second output signal that is different than the first input signal and the first output signal;

wherein the first switch and the docking member are each fixed to a printed circuit board.

8. The valve controller system of claim 7, further comprising a controller enclosure, the first switch and the docking member being secured within an interior volume of the controller enclosure.

9. The valve controller system of claim 7, wherein the first emulation circuit is disposed within a housing of the first switching module and the second emulation circuit is disposed within a housing of the second switching module.

10. The valve controller system of claim 7, wherein the first switch is a magnetically-triggered proximity switch.

11. The valve controller system of claim 7, further comprising a second switch that generates a second input signal, the docking assembly being communicatively coupled to the second switch such that when the first switching module is coupled to the docking assembly, the second switch is communicatively coupled to the first switching module, the first emulation circuit adapted to receive the second input signal, process the second input signal, and output a third output signal that is different than the second input signal.

12. The valve controller system of claim 7, wherein the first emulation circuit reduces one of the voltage or the current of the first input signal such that the first output signal has a lower voltage or current than the first input signal.

13. A control valve assembly comprising:

a control valve having an inlet, an outlet, and a closure element adapted to displace from a first position in which process fluid flows from the inlet to the outlet to a second position in which process fluid is prevented from flowing from the inlet to the outlet;

an actuator coupled to the closure element to displace the closure element;

a valve controller in communication with the actuator to control the displacement of the closure element, the valve controller comprising;

a first switch that generates a first input signal based on an operational parameter of a control valve;

a docking assembly communicatively coupled to the first switch;

a first switching module adapted to be removably secured to and communicatively coupled to the docking assembly such that the first switch is communicatively coupled to the first switching module when the first switching module is secured to the docking assembly, the first switching module including a first emulation circuit adapted to receive the first input signal, process the first input signal, and output a first output signal that is different than the first input signal;

a second switching module adapted to be removably secured to and communicatively coupled to the docking assembly such that the first switch is communicatively coupled to the second switching module when the second switching module is secured to the docking assembly, the second switching module including a second emulation circuit adapted to receive the first input signal, process the first input signal, and output a second output signal that is different than the first input signal and the first output signal;

wherein the first switch and the docking member are each fixed to a printed circuit board.

14. The control valve assembly of claim 13, further comprising a controller enclosure, the first switch and the docking member being secured within an interior volume of the controller enclosure.

15. The control valve assembly of claim 13, wherein the first emulation circuit is disposed within a housing of the first switching module and the second emulation circuit is disposed within a housing of the second switching module.

16. The control valve assembly of claim 13, wherein the first switch is a magnetically-triggered proximity switch.

17. The control valve assembly of claim 13, further comprising a second switch that generates a second input signal, the docking assembly being communicatively coupled to the second switch such that when the first switching module is coupled to the docking assembly, the second switch is communicatively coupled to the first switching module, the first emulation circuit adapted to receive the second input signal, process the second input signal, and output a third output signal that is different than the second input signal.

18. The control valve assembly of claim 13, wherein the first emulation circuit reduces one of the voltage or the current of the first input signal such that the first output signal has a lower voltage or current than the first input signal.

19. The control valve assembly of claim 13, further comprising a target assembly coupled to the closure element, the target assembly including a first magnet, and the first switch adapted to detect the first magnet when the first magnet comes within a predetermined range of the first switch, wherein the first input signal is outputted by the first switch when the first magnet comes within the predetermined range of the first switch or when the first magnet is outside the predetermined range of the first switch.

20. The control valve assembly of claim 19, further comprising a controller enclosure, the first switch, the docking member, the first switching module, and the target assembly being disposed within an interior volume of the controller enclosure.

21. The control valve assembly of claim 13, further comprising a positioner coupled to the actuator and communicatively coupled to the valve controller such that the controller instructs the positioned to displace the closure element.