A Complete Analysis of the New Hyper-thin Sensor for Cartridge Valves Predictive Diagnosis
DOI:
https://doi.org/10.13052/ijfp1439-9776.2625Keywords:
Cartridge valve, fatigue breakage, pole tube, strain gauge, valve coilAbstract
Functional Safety asks for diagnose-ability of systems and components in order to check for faults to be recovered in real time to avoid dangerous consequences of the faults themselves. At the same time, new technologies offer new materials and new production processes, which allow the creation of new sensors to meet the requirements of the functional safety certification. In some applications, the diagnosis of failures is not sufficient for safety requirements, because it is necessary to prevent the occurrence of dangerous failures; for that reason predictive diagnosis would be most desirable. Furthermore, diagnostics and predictive diagnosis are not only related to functional safety, but rather to reliability and function availability, which represent two very important aspects of products quality. Cartridge valves are widely used in many hydraulic systems, both in mobile and in industrial applications, and they are often part of systems that must meet high performance level functional safety requirements. Currently available sensors do not contain information on the state of health of the valve itself and its state with respect to the average life and the distance from a dangerous failure. Besides, there are few sensors directly embedded in valves, with the consequence that the diagnosis of valve faults often comes from inference of information from indirect sensors. This contribution deals with describing an innovative sensor and its ability to detect valve failures before they can occur, even with a reasonable time in advance of the moment in which the fault occurs. These hyper-thin strain gauges sensors fit the valve pole tube and their thickness allows installing them between valve body and coil. The innovation is described and both mechanical, electromagnetic, fabrication, signal conditioning and installation aspects are addressed. Burst and Endurance tests on prototypes are shown to demonstrate the efficacy of sensors for valve condition monitoring.
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