An apparatus for in-situ testing of a linear actuator configured to exert an actuation force in an actuation direction by movement of a first part of the actuator relative to a second part of the actuator. The apparatus includes a test device, a test actuator and a measurement device. The test device includes a first surface configured to contact the first part of the actuator, and a second surface configured to contact the second part of the actuator. The second surface is moveable relative to the first surface to alter a distance therebetween. The test actuator is configured to exert a test force in a direction opposite to the actuation direction, the test force being to drive movement of the second surface away from the first surface. The measurement device is for detecting a change in the distance between the first surface and the second surface.

Systems and methods for auto-commissioning first and second valve assemblies associated with an actuator in an electro-hydraulic system are disclosed. In one method, a controller performs an automatic test protocol to determine a bulk modulus over fluid volume parameter used by the controller to control the valve assemblies. In one aspect, the test protocol can include pressurizing each side of the actuator to two different pressures with one of the first and second valve assemblies and blocking the other side of the actuator with the other of the first and second valve assemblies. The bulk modulus over fluid volume parameter for each valve assembly can be calculated based on recorded fluid pressures at the actuator and consumed flow at the first and second valve assemblies.

Systems and methods for controlling valve assemblies associated with an actuator in an electro-hydraulic system are disclosed. In one method, a controller monitors hydraulic fluid flow for an actuator to identify one valve assembly connected to the actuator as a meter-in valve and another valve assembly connected to the actuator as a meter-out valve. In one aspect, the valve assembly most recently identified as the meter-in valve is controlled to maintain a pressure setpoint and the valve assembly most recently identified as the meter-out valve is controlled to maintain a hydraulic fluid flow rate. The method can also include determining whether the actuator is in a passive state or an overrunning state and controlling the valve most recently identified as the meter-in valve to maintain a first pressure setpoint when the actuator is in a passive state and to maintain a second pressure setpoint when the actuator is in an overrunning state.

Systems and methods for estimating the area ratio of an actuator in static and dynamic states are disclosed. In one aspect, a metering valve is connected to each side of the actuator. In one example, one metering valve is held closed while the other metering valve incrementally pressurizes the actuator in discrete steps. The resulting work port pressures can be used to determine the actuator area ratio. Where counterbalance valves are installed in the system, the pressurizing metering valve can be placed in a pressure control mode to obtain the desired pressure values. In one example, the ratio of flows through each metering valve is used to determine the actuator ratio.

This application describes apparatuses, systems, and methods that combines specific configurations of a pneumatic actuation system together with a pressure measurement device to allow for measurement of pressure inside isolated subsystems within the system to thereby provide detection of leaks within the system. In certain exemplary embodiments, the apparatus comprises a directional control valve that employs at least one port connectivity configuration that creates at least one isolated fluid subsystem within the overall system. When the valve is in this isolated subsystem configuration, a given mass of fluid (i.e., compressed gas) can neither enter nor leave the subsystem. The leak detection method consists of momentarily placing the valve in this isolated subsystem configuration when switching between standard configurations, and measuring pressure with at least one pressure sensor in the isolated fluid subsystem while in this configuration, where loss of pressure in this configuration indicates existence of a leak.

Methods and apparatus of testing a solenoid valve of an emergency valve via a positioner are disclosed. An example method includes conducting a solenoid valve test by initiating a pulse duration and a monitoring duration for the solenoid valve test. Conducting the solenoid valve test further includes instructing a solenoid valve to transition from a first state to a second state during the pulse duration. The solenoid valve is in fluid communication with an actuator to enable the actuator to actuate an emergency valve. Conducting the solenoid valve test further includes determining a functionality of the solenoid valve by measuring, via a valve positioner, a maximum pressure change of a pressure chamber of the actuator during the monitoring duration. The example method includes, upon determining the solenoid valve is in a functioning state, conducting a partial stroke test of the emergency valve via the valve positioner.

An integrated diagnostics system utilizes online and offline diagnostics techniques to evaluate control valves found in process plant environments. The integrated diagnostics system improves on existing diagnostic systems, which typically rely exclusively on online diagnostics or offline diagnostics.

Methods and apparatus of assessing a test of a solenoid valve via a positioner are disclosed. An example apparatus includes a solenoid valve to enable an actuator to close an emergency valve and a valve positioner fluidly and communicatively coupled to the solenoid valve. The valve positioner is to instruct the solenoid valve to transition the solenoid valve from a first state to a second state. The valve positioner is to monitor a pressure change of a pressure chamber of the actuator in fluid communication with the solenoid valve relative to an initial pressure for a monitoring duration. The valve positioner is to identify a maximum pressure change during the monitoring duration and determine a ready state of the solenoid valve when the maximum pressure change is greater than a minimum trip value and the pressure change at a monitoring end time is less than a maximum reset value.

An emergency shutdown (ESD) system for a process control system includes an air supply coupled to a solenoid valve used to control a pneumatically-operated emergency isolation valve (ZV) via a switchover kit, a smart valve positioner coupled to the solenoid valve via the switchover kit, and an ESD controller. The ESD controller is configured to: control the supply of air from the air supply by the solenoid valve to open and close the ZV, and control the smart valve positioner so as to perform a partial stroke test on the ZV. The switchover kit includes a manifold having a plurality of valves coupling the air supply, the solenoid valve, and the smart valve positioner such that: based on a first setting of the plurality of valves, a first air flow path through the manifold connects the air supply directly to the solenoid valve, and based on a second setting of the plurality of valves, a second air flow path through the manifold connects the air supply to the solenoid valve through the smart valve positioner.

Provided is a pump diagnostic device and construction machine capable of performing precise and accurate diagnosis. A diagnostic device 40 for a hydraulic pump 1 includes an action instruction section 42 that outputs an action instruction for causing a hydraulic actuator 29 of a hydraulic excavator 200 to perform a specific action, a measurement condition setting section 44 that sets a sampling condition in measurement of a pressure of the hydraulic pump 1 during the specific action, a calculation section 46 that acquires a measured value of the pressure sampled during the specific action under the set sampling condition, and calculates a pressure pulsation amplitude of the hydraulic pump 1, an anomaly determination section 47 that determines whether there is an anomaly in the hydraulic pump 1 based on the calculated pressure pulsation amplitude, and an output section 48 that outputs a determination result obtained by the anomaly determination section 47.