Electronic controller for a modulating valve

A method of controlling the position of a valve plug in a modulating valve including a bi-directional motor, the modulating valve including a valve plug operable between a completely open and a completely closed position, the method comprising the steps of:

• initially calibrating the valve by counting the number of revolutions of the bi-directional motor required to move the valve plug between the completely closed to the completely open position;
• storing the number of revolutions in a microcontroller as a valve stroke count;
• assigning a current position count based on the current position of the valve plug between the completely open and the completely closed position;
• inputting an upper and a lower setpoint limit to the microcontroller, the upper and lower reference limits defining a setpoint range;
• supplying a setpoint signal to the microcontroller, the setpoint signal being between the upper and lower setpoint limits;
• determining the ratio of the setpoint signal to the setpoint range;
• comparing the current position count to the ratio of the setpoint signal to the setpoint range to generate a position error;
• operating the bi-directional motor to move the valve plug in a direction based on the position error;
• counting the number of revolutions of the bi-directional motor to update the current position count;
• and
• stopping the bi-directional motor when the current position count approximately equals the ratio of the setpoint signal to the setpoint range.

A modulating valve for controlling the flow of fluid therethrough, the modulating valve having a valve plug operable between a completely open and a completely closed position, the modulating valve comprising:

• a bi-directional motor interconnected with the valve plug to move the valve plug between the completely open and closed positions;
• a microcontroller connected to the motor to selectively control operation of the motor to control the position of the valve plug;
• a sensor positioned to monitor the operation of the motor as the motor moves the valve plug, the sensor being in communication with the microcontroller;
• a solenoid clutch assembly positioned between the motor and the valve plug and operable between an activated state and a deactivated state, the motor being able to move the valve plug when the solenoid is in the activated state and being unable to move the valve plug when the solenoid is in the deactivated state;
• and
• a solenoid control circuit connected between the microcontroller and the solenoid clutch assembly such that the microcontroller can control the operation of the solenoid clutch assembly through the solenoid control circuit.

A modulating valve for controlling the flow of fluid therethrough, the modulating valve having a valve plug operable between a completely open and a completely closed position, the modulating valve comprising:

• a bi-directional motor interconnected with the valve plug to move the valve plug between the completely open and closed positions;
• a microcontroller connected to the motor to selectively control operation of the motor to control the position of the valve plug;
• a sensor positioned to monitor the operation of the motor as the motor moves the valve plug, the sensor being in communication with the microcontroller;
• and
• a plurality of indicator lights connected to the microcontroller for providing a visual indication as to operation of the valve, wherein the indicator lights include a first indicator light signaling forward motor operation, a second indicator light indicating reverse motor operation, and a third indicator light indicating calibration status.

A control unit for controlling the flow of fluid through a modulating valve, the modulating valve having a valve plug operable between a completely open and a completely closed position, the control unit comprising:

• a bi-directional motor connected to the valve plug through a motor clutch and a series of gears to move the valve plug between the completely open and closed positions;
• a microcontroller connected to the motor to selectively control the motor to adjust the position of the valve plug;
• an optical sensor interconnected with the microcontroller, the optical sensor monitoring the rotation of the motor clutch for providing input signals to the microcontroller, wherein the optical sensor includes a light emitting diode, a photoreceptor, and a reflective portion associated with the motor and rotatable in response to operation of the motor, such that the light from the light emitting diode is reflected by the reflective portion and received by the photoreceptor;
• and
• a setpoint signal selector in communication with the microcontroller, the setpoint signal selector selectively setting upper and lower limits of a setpoint input signal such that the microcontroller operates the motor based on the value of the setpoint input signal with respect to the upper and lower limits set by the setpoint signal selector.

The control unit for controlling the flow of fluid through a modulating valve, the modulating valve having a valve plug operable between a completely open and a completely closed position, the control unit comprising:

• a bi-directional motor connected to the valve plug through a motor clutch and a series of gears to move the valve plug between the completely open and closed positions;
• a microcontroller connected to the motor to selectively control the motor to adjust the position of the valve plug;
• an optical sensor interconnected with the microcontroller, the optical sensor monitoring the rotation of the motor clutch for providing input signals to the microcontroller;
• a setpoint signal selector in communication with the microcontroller, the setpoint signal selector selectively setting upper and lower limits of a setpoint input signal such that the microcontroller operates the motor based on the value of the setpoint input signal with respect to the upper and lower limits set by the setpoint signal selector;
• a solenoid clutch assembly positioned between the motor and the valve plug and being operable between an activated and a deactivated state, the motor being able to move the valve plug when the solenoid is in the activated state and being unable to move the valve plug when the solenoid is in the deactivated state;
• and a solenoid control circuit connected between the microcontroller and the solenoid clutch assembly such that the microcontroller can control the operation of a solenoid clutch assembly through the solenoid control circuit.

A control unit for controlling the flow of fluid through a modulating valve, the modulating valve having a valve plug operable between a completely open and a completely closed position, the control unit comprising:

• a bi-directional motor connected to the valve plug through a motor clutch and a series of gears to move the valve plug between the completely open and closed positions;
• a microcontroller connected to the motor to selectively control the motor to adjust the position of the valve plug;
• an optical sensor interconnected with the microcontroller, the optical sensor monitoring the rotation of the motor clutch for providing input signals to the microcontroller;
• a setpoint signal selector in communication with the microcontroller, the setpoint signal selector selectively setting upper and lower limits of a setpoint input signal such that the microcontroller operates the motor based on the value of the setpoint input signal with respect to the upper and lower limits set by the setpoint signal selector;
• and
• a supply voltage detector in communication with the microcontroller such that the microcontroller can monitor the value of a supplied voltage used to operate the control unit.

A method of controlling the position of a valve plug in a modulating valve including a bi-directional motor, the modulating valve including a valve plug operable between a completely open and a completely closed position in response to operation of the motor, the method comprising the steps of:

• interconnecting a microcontroller with the motor for controlling operation of the motor;
• providing inputs to the microcontroller indicative of operation of the motor;
• calibrating the valve by counting the number of revolutions of the motor required to move the valve plug from a completely open to a completely closed position;
• storing the number of revolutions in the microcontroller as a valve stroke count;
• assigning a current position count based on the position of the valve plug between the completely open and completely closed position;
• supplying a setpoint signal to the microcontroller;
• comparing the current position count to the setpoint signal to generate a position error;
• operating the motor to move the valve plug based on the position error;
• counting the number of revolutions of the motor to update the current position count;
• and
• stopping the motor when the current position count approximately equals the setpoint signal.