Advancing Precision and Reliability in Analytical Systems: Leveraging Valve Diagnostics for Optimal Performance

In demanding analytical environments, the ability to maintain precision, ensure reliability, and minimise downtime is paramount. The accuracy of diagnostic results, the efficiency of research processes, and the success of industrial applications all hinge on the seamless operation of fluid control systems. Bürkert Fluid Control Systems, a leading innovator in this field, understands these challenges and offers a sophisticated approach to optimising valve performance through integrated diagnostics.

In laboratory devices, the accurate dosing of the right amount of reagents per sample is crucial to ensure high product quality and reliable analytical results. In this context, time-pressure dosing is the preferred method. The liquid is maintained at a constant pressure. The correct amount of reagents is dispensed by controlling the opening time of a dosing valve and the pressure applied to the liquid in the dosing tank.

A critical advancement is the integration of valve diagnostics, moving beyond simple monitoring to actively assessing and optimising valve function. This capability has significant implications for improving efficiency, reducing errors, and enhancing the reliability of analytical systems.

By integrating valve functionality and diagnostic capabilities, new devices can be more compactly designed. By diagnosing the switching behaviour, changes in other parameters such as temperature or pressure can also be deduced.

To reduce such errors, installing independent diagnostic devices is an option. One option for such a diagnostic device is a flowmeter positioned downstream of the dosing valve to monitor whether the valve operation was successful. Alternatively, a photoelectric sensor can be installed for monitoring purposes. However, independent diagnostic devices come with some drawbacks: they incur additional costs, require more space, and significantly complicate the architecture of the end device.

Diagnostic Capabilities: A Deep Dive

A simpler and more elegant way to detect valve malfunctions is to use the dosing valve itself as a sensor. A valve with an electrodynamic actuator, which operates with a moving coil, is particularly well-suited to this application. Thanks to the innovative Whisper Valve actuator, induction can be directly measured, enabling early detection of valve malfunctions.

This approach enables early detection of valve malfunctions by leveraging electrodynamic actuators, where the actuator itself functions as a sensor. Monitoring the time-dependent current during operation unlocks valuable information about the valve’s parameters and its surrounding environment.

In the example of laboratory devices that dose reagents using time-pressure dosing in analysis processes, it is evident that the system can greatly benefit from intrinsic diagnostics using electrodynamic valves. It is possible to verify the proper functioning of the valve without requiring external sensors. Additionally, the pressure of the medium can be estimated, allowing for the verification of the correct functioning of the pressure controller or pump by using the valve as a sensor.

The hardware for this type of diagnostics is cost-effective compared to adding an additional sensor. The complete information extraction relies on an intelligent algorithm tailored to the specific valve type. To utilise this technology, a time-resolved current measurement and a microcontroller for analysis are required. If the application already has a microcontroller, the analysis can be performed there. No external sensors are needed on the valve.

Through real-time monitoring of the valve’s inrush current, valuable data about the actuator’s movement and the valve stroke is obtained. This data is invaluable for identifying issues that might otherwise go unnoticed.

The Advantages of Integrated Valve Diagnostics

• Increased Process Reliability: Integrated diagnostics ensure accurate dosing and fluid handling, leading to more consistent and reliable analytical results.
• Early Detection of Malfunctions: Identifying deviations from normal operation early on prevents erroneous results and costly sample losses.
• Reduced Downtime: Proactive diagnostics enable timely maintenance and repairs, minimising disruptions to critical analytical processes.
• Cost Savings: By eliminating the need for external sensors and streamlining maintenance, integrated diagnostics provides significant cost advantages.
   

Utilising the advanced ValveInsight concept, this approach transforms the role of valves in analytical processes from simple components to intelligent and adaptive elements within the overall system. This integration not only ensures peak performance and minimises errors, but also represents a forward-looking step toward smarter, more resilient analytical systems.

Read the full whitepaper here: https://www.burkert.com.au/en/landingpage/reliable-analytical-devices-with-valveinsight-diagnostics.