Patent Description:
<CIT> discloses a valve assembly in a building management system with a processing circuit configured to detect a fault condition based on a flow rate. <CIT> discloses a test platform for an embedded control system. <CIT> discloses an aircraft environmental control system. <CIT> discloses an interface for a gas valve. <NPL> discloses an algorithm to detect valve stiction.

A method for performing valve testing is provided. The method includes receiving, by a pressure controller including a data processor, data characterizing an air flow through a valve coupled to the pressure controller and data characterizing a rate of pressure change through the valve. The method also includes determining, by the data processor, valve operation data associated with the valve. The method further includes providing, by the data processor, the valve operation data in a display coupled to the pressure controller.

A variety of embodiments can be provided. In another embodiment, determining the valve operation data can include determining an opening point of the valve and providing the valve operation data includes providing the opening point of the valve. In another embodiment, determining the valve operation data can include determining a closing point of the valve and providing the valve operation data includes providing the closing point of the valve. In another embodiment, determining the valve operation data can include determining an indication of stiction of the valve and providing the valve operation data includes providing an indication of stiction of the valve.

In another embodiment, the valve can be a pneumatic valve. In another embodiment, the pneumatic valve can be a cabin pressure valve configured in an aircraft. In another embodiment, the valve operation data can be determined based on a control pressure received at the pressure controller. According to the invention, providing the valve operation data includes providing a first plot in the display. The first plot indicates an amount of air flow through the valve with respect to a constant rate of pressure change. In another embodiment, providing the valve operation data can include providing a second plot in the display. The second plot can indicate valve operation with respect to a fixed flow demand of the valve.

In another aspect a system for valve testing is provided. The system includes a valve, a pressure controller coupled to the valve, a pressure and vacuum source coupled to the pressure controller and a computing device coupled to the pressure controller. The computing device includes a memory, a data processor and a display. The data processor is configured to execute instructions stored in the memory, which when executed cause the data processor to perform operations including receiving, by the pressure controller, flow data characterizing an air flow through a valve coupled to the pressure controller and pressure data characterizing a rate of pressure change supplied to the valve via the pressure and vacuum source. The operations also include determining valve operation data associated with the valve based on the received data. The operations further include providing the valve operation data in the display.

A variety of embodiments can be provided. In another embodiment, determining the valve operation data can include determining, by the data processor, an opening point of the valve and providing, by the data processor the valve operation data can include providing the opening point of the valve. In another embodiment, determining the valve operation data can include determining, by the data processor, a closing point of the valve and providing, by the data processor, the valve operation data can include providing the closing point of the valve. In another embodiment, determining the valve operation data can include determining, by the data processor, an indication of stiction of the valve and providing, by the data processor, the valve operation data can include providing an indication of stiction of the valve.

In another embodiment, the valve can be a pneumatic valve. In another embodiment, the pneumatic valve is a cabin pressure valve configured in an aircraft. In another embodiment, pressure controller can be a pitot static tester. According to the invention, providing the valve operation data includes providing, by the data processor, a first plot in the display indicating an amount of air flow through the valve with respect to a constant rate of pressure change.

Non-transitory computer program products (i.e., physically embodied computer program products) are also described herein that store instructions, which when executed by one or more data processors of one or more computing systems, causes at least one data processor to perform operations herein. Similarly, computer systems are also described herein that may include one or more data processors and memory coupled to the one or more data processors. Such computing systems can be connected and can exchange data and/or commands or other instructions or the like via one or more connections, including a connection over a network (e.g. the Internet, a wireless wide area network, a local area network, a wide area network, a wired network, or the like), via a direct connection between one or more of the multiple computing systems, a radio link, or the like.

Valves, such as pneumatic valves can be configured to mitigate pressure differences in a variety of industrial applications. Pneumatic valves are commonly used in aircraft with pressurized cabins. Control valves and safety valves can regulate the amount of pressure within the aircraft to prevent over pressurization of the interior of the aircraft.

A common technique for determining valve operation is to manually assess operation of a valve using manual pressure controllers and/or sensors, to visually verify that the valve is opening, and closing as designed without stiction. Stiction is an amount of static friction that must be overcome to enable a valve to open or close as intended. Stiction can be considered a threshold in that an amount of force is required to overcome static friction in order for the valve to open or close. Manual inspection and assessment of valve operation can require an operator to visually monitor the valve and a sensor, such as a mechanical altimeter. Human inspectors may be unfamiliar with the configuration of the valve or valve testing system, which can lengthen the time necessary to perform inspection procedures. Manual inspection is also prone to error. For example, the human inspector may not adequately determine a valve opening point due inability to sufficiently view the valve operation and sensor data simultaneously. Accordingly, manual inspection and monitoring of valves can be time-consuming, error-prone, and cost-prohibitive.

As described herein, a pressure controller can be coupled to a valve, and can be configured to provide a constant flow demand or a constant pressure rate of change. The pressure controller can be configured to monitor the actual flow and/or the pressure rate of change present at the valve. The pressure controller can be further configured to identify an opening point and a closing point of the valve. The valve opening and closing points can be provided to a user via a computing device and/or a display coupled to the pressure controller. The pressure controller described herein can be further configured to provide graphical trend data illustrating irregularities in a flow curve and/or a pressure curve associated with the valve so that potential failure conditions can be identified to a user viewing the display.

The improved valve testing system described herein provides precise and automatic opening and closing point detection for valves without requiring manual testing equipment or personnel. Feedback related to the magnitude of valve stiction can also be provided to enable early detection of valve operating problems, unsafe operational conditions, and/or hazardous conditions in which the valve may configured to operate.

The systems and methods described herein provide a pressure controller configured to automatically detect the start and end of a valve's opening, the start and end of a valve's closing, the linearity and hysteresis associated with the valve movement. In some embodiments, the pressure controller can include a pitot static tester, also known as an Air Data Test Set (ADTS). The ADTS can be configured to provide necessary support functions for measuring the opening and closing points of a valve. The systems, and methods described herein for testing valve operation can provide more accurate, reliable, and reproducible valve test results than can be achieved using manual valve testing.

Embodiments of the present disclosure describe systems and methods for determining an opening point, a closing point, and an indication of stiction in a pneumatic valve, such as a cabin pressure valve configured in an aircraft. However, it can be understood that embodiments of the disclosure can be employed for inspecting and monitoring operational characteristics of any valve where volume changes occur within a pilot side of a system as the valve opens and closes without limit.

<FIG> is a flow diagram illustrating one embodiment of a method for determining a valve opening point, a valve closing point, and/or an indication of stiction associated with a valve as described herein. As shown in <FIG>, the method <NUM> includes operations <NUM>-<NUM>. However, it can be understood that, in alternative embodiments, one or more of these operations can be omitted and/or performed in a different order than illustrated.

In operation <NUM>, data characterizing an air flow and/or a rate of pressure change can be received. The data can be received by a pressure controller coupled to the valve at which the air flow and rate of pressure change are present. The data can include time-series data of current valve operation or can include historical data associated with a past operation of the valve. In some embodiments, the data can be received from a computing device coupled to the pressure controller, such as from a memory or a database configured on a remote computing device.

In operation <NUM>, a valve opening point, a valve closing point, and/or an indication of stiction associated with the valve can be determined. Such valve operation data and measurements can be determined by the pressure controller described herein or via a computing device coupled to the pressure controller. Valve testing can be performed with respect to a constant pressure rate of change, and/or a fixed flow demand. In some embodiments, a pressure signal can be oscillated or varied over time to allow continuous movement of the valve across an entire opening range and an entire closing range. In some embodiments, valve operation testing can be based on the valve type fitted for leak testing.

Opening point can be determined by a user or can be a predefined variable above the standard flow or pressure rate without the movement of the valve. The flow must exceed the threshold to trigger the opening point. For example, for constant pressure rate mode, if the nominal flow rate is <NUM> cc/min and the user threshold is <NUM> cc, the operating point can be calculated as <NUM> cc/min. The opening of the valve can be detected when the flow is greater than 16cc/min. Note the actual change in flow rate may be positive or negative depending on the configuration of the valve under test.

Closing point can be determined by a user or can be a predefined variable above the standard flow or pressure rate without the movement of the valve. The flow must reduce below the threshold to trigger the closing point. For example, for constant pressure rate mode, if the nominal flow rate is <NUM> cc/min and the user threshold is <NUM> cc, the operating point can be calculated as 16cc/min. The closing of the valve can be detected when the flow is less than <NUM> cc/min. Note the actual change in flow rate may be positive or negative depending on the configuration of the valve under test.

Stiction can be determined by a user or predefined variable above the opening flow or pressure. For example, in constant pressure rate mode, if the opening threshold is <NUM> cc/min and the user stiction threshold is <NUM> cc, the stiction point will be calculated as 19cc/min. Excessive valve stiction can be detected when the flow is greater that 19cc/min. The actual change in flow rate may be positive or negative depending on the configuration of the valve under test. Another parameter that can be used to detect stiction is a user defined or a predefined limit on rate of change of flow or pressure where the valve opens. A combination of both methods can be used.

In operation <NUM>, the valve operation data including the valve opening point, the valve closing points, and/or indications of stiction associated with the valve can be provided. In some embodiments the providing can include storing the valve operation data in a memory of the pressure controller and/or a computing device coupled to the pressure controller, or displaying the valve operation data in a graphical user interface (GUI) configured in a display of the pressure controller and/or a computing device coupled to the pressure controller. The providing can also include automatically triggering or causing execution of alarm, alert, or notification functionality to inform operators of the system that the valve may be operating in a compromised or malfunctioning state. In some embodiments, the valve operation data can be provided in textual reports in addition to, or in place of graphical provisions of the data. The valve data can also be used to determine trends of the valve performance over time, as well as the ability to interface with aircraft onboard diagnostic routines.

<FIG> is a diagram illustrating one embodiment of a system for valve testing as described herein. The system shown in <FIG> includes a valve <NUM>, such as cabin pressure valve <NUM> fluidically coupled to a flow and pressure controller <NUM>. The flow and pressure controller <NUM> can be fluidically and communicatively coupled to a pressure and vacuum source <NUM>. The flow and pressure controller <NUM> can be communicatively coupled to a computing device <NUM>, such as microprocessor <NUM>. The computing device <NUM> can be configured with a display <NUM> to provide valve operation data to an operator of the system and/or to a computing device communicatively coupled to computing device <NUM> via a network, such as a local area network, a virtual private network connected to the internet, or via a radio link. The computing device <NUM> can also include a memory <NUM> storing computer-readable, executable instructions configured to perform the methods described herein. In some embodiments, the memory <NUM> can store received valve operation data, provided valve operation data, and thresholds associated with the valve operation data.

The valve <NUM> can include a cabin pressure valve, such as the valve <NUM> shown in <FIG>. The valve <NUM> can be positioned between an aircraft cabin interior and the ambient atmosphere. For example, as shown in <FIG>, the valve <NUM> can be located within a rear pressure bulkhead. The valve <NUM> can include a pilot valve, such as a maximum differential relief valve, which can receive a pilot supply of ambient air. In response to pilot valve modulation, the seat of the valve <NUM> can open or close to maintain a desired pressure of the cabin air. The valve <NUM> can include an upper or control diaphragm against which control pressure can be exerted. The control pressure can be provided to the flow and pressure controller <NUM>, shown in <FIG>. The valve opening point, closing point, and indications of stiction can be determined by way of the control pressure <NUM> received at the flow and pressure controller <NUM>. This can be applied to any pilot operated valve that has a volume change during opening and closing operation of the valve.

Returning to <FIG>, the system <NUM> includes a pressure and vacuum source <NUM>. The pressure and vacuum source <NUM> can be configured to provide the flow and pressure controller <NUM> with a constant pressure ramp so that the pressure and rate of pressure change caused by movement of the valve can be measured. In this way, the valve opening point, the valve closing point, and any indication of stiction can be observed and measured by the flow and pressure controller <NUM>. In some embodiments, the pressure controller can include a pitot static tester, also known as an Air Data Test Set (ADTS). The ADTS can be configured to provide necessary support functions for measuring the opening and closing points of a valve. The valve operation data, such as the valve opening point, the valve closing point, and any indication of stiction can be transmitted to the microprocessor <NUM> for further processing, and/or storage. The valve operation can be provided via the display <NUM>.

<FIG> is a plot <NUM> illustrating valve opening detection with constant rate of change of pressure via the systems and methods described herein. The plot <NUM> can be provided in the display <NUM> and can include the valve operation data. As shown in <FIG>, the amount of air flow in the valve can be indicative of valve movement and can be plotted with respect to a constant pressure rate of change. The plot <NUM> can include indications of normal operation <NUM> and stiction <NUM>. At <NUM>, the valve starts to open as flow increases due to volume changes. At <NUM>, the valve has fully opened. Indication of stiction can be observed at <NUM>, where there is no change in flow at the expected opening point followed by a larger flow observed at a higher pressure than the expected pressure at which the valve opens under normal operation.

<FIG> is a plot <NUM> illustrating valve opening detection with fixed flow demand via the systems and methods described herein. The plot <NUM> can be provided in the display <NUM> and can include the valve operation data. In some embodiments, a constant flow demand can be used to determine valve operation data with respect to a threshold <NUM>. For example, if the flow is too large to test the valve under a constant pressure rate of change, then the pressure change can be observed with respect to a constant flow demand. As shown in <FIG>, indications of normal valve operation <NUM> and stiction <NUM> can be plotted. At <NUM>, the valve starts to open as rate of change of pressure decreases due to volume changes. At <NUM>, the valve has fully opened. Indication of stiction can be observed at <NUM>, where there is no change in rate of change of pressure at the expected opening point <NUM> followed by a larger rate of change of pressure observed at a higher pressure than the expected pressure at which the valve opens under normal operation.

Exemplary technical effects of the methods, systems, and devices described herein include, by way of non-limiting example improved monitoring and detection of valve operation, such as valve opening, valve closing, and stiction present within the valve. The methods, systems, and devices described herein can automatically determine valve operation data in real-time and reduce the need for manual inspection and testing of valves. As a result, valve testing can be performed more reliably tracked over time providing increased testing accuracy, and improved valve maintenance and repair planning. The methods, systems, and devices described herein enable creation of a digital history of valve operation for use in diagnosing valve failures and predicting the occurrence of new failures. The methods, systems, and devices described herein enable automated data collection and more accurate analysis of valve operation data compared to manual testing systems and methods. In addition, the methods, systems, and devices described herein provide improved graphical user interfaces for displaying valve operation data in a dynamic, real-time, streaming manner thereby enhancing operator assessment and interpretation of valve testing results.

Certain exemplary embodiments have been described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the systems, devices, and methods disclosed herein. One or more examples of these embodiments have been illustrated in the accompanying drawings. Those skilled in the art will understand that the systems, devices, and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments and that the scope of the present invention is defined solely by the claims. The features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of the present invention.

Claim 1:
A method (<NUM>) comprising:
receiving (<NUM>), by a pressure controller (<NUM>) including a data processor, data characterizing an air flow through a valve (<NUM>) coupled to the pressure controller (<NUM>);
determining (<NUM>), by the data processor, valve operation data associated with the valve (<NUM>); and
providing (<NUM>), by the data processor, the valve operation data in a display (<NUM>) coupled to the pressure controller (<NUM>);
characterized by further comprising receiving data characterizing a rate of pressure change through the valve (<NUM>); and
wherein providing the valve operation data includes providing a first plot in the display (<NUM>), the first plot indicating an amount of air flow through the valve (<NUM>) with respect to a constant rate of pressure change.