Method for operating a diaphragm valve, system and reading device

Abstract

A method for operating a diaphragm valve including the step of reading out data, which characterize at least one property of a diaphragm of the diaphragm valve, from at least one data memory integrated into the diaphragm valve, by a reading device. The method further includes the steps of: (a) transmitting the read-out data to a processing device which is arranged remote from the reading device and the diaphragm valve and (b) synchronizing the transmitted data with data present in the processing device.

Claims

1. Method for operating a diaphragm valve, which comprises the step of reading out data, from at least one data memory integrated into the diaphragm valve, by means of a reading device, characterized in that the method further comprises the steps of: a. transmitting the read-out data to a processing device which is arranged remote from the reading device and the diaphragm valve; b. providing access to data present in the processing device that is characterized by at least one of: at least one property of the diaphragm of the diaphragm valve; at least one property of a component of the diaphragm valve that is not the diaphragm; and at least one property of the diaphragm valve; and c. synchronizing the transmitted data with data present in the processing device.

2. Method according to claim 1, characterized in that in step a, the data are transmitted to a processing device which is at the premises of the manufacturer or supplier of the diaphragm valve.

3. Method according to claim 1, characterized in that the data are read out by means of a mobile reading device, in particular by means of at least one of a smartphone, tablet PC and smart tablet.

4. Method according to claim 1, characterized in that the data are read out wirelessly.

5. Method according to claim 1, characterized in that the data present in the processing device characterize at least one property of the diaphragm of the diaphragm valve and at least one property of a component of the diaphragm valve that is not the diaphragm, and at least one property of the diaphragm valve.

6. Method according to claim 1, characterized in that data which characterize at least one property of a component that is not the diaphragm and one operational property of the diaphragm valve are read out from the integrated data memory.

7. Method according to claim 5, characterized in that the data which characterize at least one property of the diaphragm of the diaphragm valve and at least one property of the component of the diaphragm valve that is not the diaphragm and-at least one property of the diaphragm valve at least one item of data from the following group: type, material, valve drive, manufacture date, manufacture location, production batch, quality test values, supplier, delivery route, storage location, storage duration, date into storage, date out of storage, installation date, installation location, name of installer, name of operator.

8. Method according to claim 6, characterized in that the data which characterize an operational property of the diaphragm valve comprise an item of data from the following group: fluid type, fluid pressure, fluid temperature, number of switching cycles, operating time.

9. Method according to claim 1, characterized in that, at the time of an initialization of a valve drive, the current diaphragm thickness is determined and, together with the date said thickness was determined, stored in the data memory and transmitted to the processing device.

10. Method according to claim 1, characterized in that, during maintenance of the diaphragm valve, at least one variable which characterizes the current state of the diaphragm is determined and stored in the data memory and transmitted to the processing device.

11. Method according to claim 1, characterized in that it further comprises the following steps: c. processing the synchronized data in the processing device; d. determining an action by means of the processing device depending on the result of the processing.

12. Method according to claim 11, characterized in that in step c, the processing device determines a probable state of wear, in particular of the diaphragm.

13. Method according to claim 11, characterized in that the action in step d comprises at least one action from the following group: automatic creation and/or transmission of status information, automatic creation and/or transmission of a replacement part request, automatic creation and/or transmission of warning information.

14. Method according to claim 13, characterized in that at least one of the status information and warning information is transmitted to the reading device and displayed thereon.

15. Method according to claim 13, characterized in that the status information comprises at least one of a probable remaining service life and the warning information comprises an indication of imminent valve failure.

16. System which comprises: a diaphragm valve comprising at least one data memory integrated into the diaphragm valve; a reading device for reading out data stored in the data memory; a transmission device for transmitting the read-out data to a processing device which is arranged remote from the reading device and the diaphragm valve; wherein the data memory, the reading device, the transmission device and the processing device are designed and programmed to carry out a method comprising the steps of a. means for transmitting the read-out data to a processing device which is arranged remote from the reading device and the diaphragm valve; b. means for providing access to data present in the processing device that is characterized by at least one of: at least one property of the diaphragm of the diaphragm valve; at least one property of a component of the diaphragm valve that is not the diaphragm; and at least one property of the diaphragm valve; and c. means for synchronizing the transmitted data with data present in the processing device.

17. Reading device for reading out data stored in a data memory, characterized in that said reading device is designed and programmed to carry out a method comprising the steps of: a. means for transmitting the read-out data to a processing device which is arranged remote from the reading device and the diaphragm valve; b. means for providing access to data present in the processing device that is characterized by at least one of: at least one property of the diaphragm of the diaphragm valve; at least one property of a component of the diaphragm valve that is not the diaphragm; and at least one property of the diaphragm valve; and c. means for synchronizing the transmitted data with data present in the processing device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the following, an embodiment of the present invention will be described by way of example with reference to the accompanying drawings, in which:

(2) FIG. 1 is an exploded perspective view of a diaphragm valve comprising a diaphragm and two data memories, and shows, symbolically, a process installation in which the diaphragm valve is installed;

(3) FIG. 2 is a schematic view of a system comprising the diaphragm valve, a reading device, a transmission device and a processing device; and

(4) FIG. 3 is a flow diagram of a method for operating the diaphragm valve from FIG. 1.

DETAILED DESCRIPTION

(5) In FIG. 1, a diaphragm valve is overall denoted by reference sign 10. Said valve comprises a valve body 12 having a seat geometry 13, a diaphragm 14, a pressure element 16 and an intermediate element 18. The diaphragm 14 is clamped between the valve body 12 and the intermediate element 18. The pressure element 16 is used to connect the diaphragm 14 to a valve drive 20, which is merely indicated by a dot-dash line in FIG. 1, and is also used for the form-fitting sealing function.

(6) A tab 22 is provided on the edge of the diaphragm 14 to the rear in FIG. 1, into which tab a data memory 24 in the form of an RFID chip is integrated. The valve body 12 comprises an inlet port 26 and an outlet port 28. A data memory 30 in the form of an RFID chip is also arranged on the outlet port 28. In an embodiment not shown here, data memories are also provided on the valve body and/or on the inlet port. The valve bodies may, for example, differ in terms of the seat geometry. In this case, each valve body may comprise a data memory that is assigned to the specific seat geometry.

(7) The diaphragm valve 10 is installed in a process installation 32, which is indicated merely symbolically by a sketched box 32 in the present case. The process installation may for example be an installation used in the pharmaceutical industry for preparing medication.

(8) In FIG. 2, a system, which, inter alia, also comprises the diaphragm valve 10 from FIG. 1, is overall denoted by reference sign 34. The system 34 further comprises a reading device 36 for reading out data stored in the data memory 24 and the data memory 30, a transmission device 38 for transmitting the read-out data to a processing device 40, which is arranged remote from the reading device 36 and the diaphragm valve 10 and which is also part of the system 34. The data memory 24, the data memory 30, the reading device 36, the transmission device 38 and the processing device 40 are designed and programmed to carry out a method which will be described in detail below.

(9) As can be seen in FIG. 2, the diaphragm valve 10 and the reading device 36 are arranged at the premises of a company 42 that operates the process installation 32. The processing device 40, on the other hand, is arranged at the premises of a manufacturer 44 (or at least a supplier) of the diaphragm valve 10. However, in principle, said processing device may also be arranged at the premises of another service provider.

(10) The reading device 36 is designed and programmed to read out data from the RFID chips 24 and 30 wirelessly, which is indicated by an arrow 46. Said reading device has a display 48, which can be used to display read-out data but also to display commands or data which are intended to be transmitted from the reading device 36 to one of the RFID chips 24 and 30 or to both RFID chips 24 and 30. In the embodiment shown here, the reading device 36 is thus not only designed and programmed to read out data, but also to transmit data to the RFID chips 24 and 30 such that said data can be stored on said chips.

(11) The reading device 36 may be a specific apparatus which is exclusively provided for use in conjunction with the diaphragm valve 10. In this case, the display 48 may simply be an LED display. However, it is also possible for the reading device 36 to be a commercially available smartphone or a commercially available tablet PC or smart tablet, and for the display 48 to be the display of the smartphone. NFC technology, for example, or another form of wireless technology may be used for the data communication between the RFID chips 24 and 30 and the reading device 36, and the conventional interfaces required for this purpose that allow data communication of this kind may be used.

(12) At the processing device 40 at the premises of the manufacturer 44 of the diaphragm valve 10, there is another data memory 50, which is coupled to the processing device 40. Furthermore, specific action modules are connected to the processing device 40, of which two are shown in FIG. 2 by way of example, specifically an action module 52, by means of which an automatic replacement part request can be generated, and an action module 54, by means of which an automatic maintenance request can be generated. Other action modules (not shown), which are connected to the processing device 40, may be used to automatically generate status information relating to the diaphragm valve 10 and/or to automatically generate warning information, also relating to the diaphragm valve 10.

(13) The data which is stored in the data memory 50 at the processing device 40 are preferably those generated during manufacture of the diaphragm valve 10. Said data may relate to the diaphragm 14, a component other than the diaphragm 14, or the diaphragm valve 10 as a whole. The stored data may characterize any property, for example the type of the diaphragm valve 10, the type of the diaphragm 14, the type of the valve drive 20, the material of the valve body 12, the material of the diaphragm 14, the manufacture date of the valve body 12, the manufacture date of the diaphragm 14, the manufacture date of the valve drive 20, the assembly date of the valve body 12, diaphragm 14, pressure element 16, intermediate element 18 and valve drive 20, the manufacture location of the subcomponents or of the entire diaphragm valve 10, the production batch, for example of the diaphragm 14, specific quality test values such as tolerances, surface roughness, dimensions, results from visual inspections, etc.

(14) The data stored in the processing device 40 may also include data relating to or defining a maintenance plan, a workflow in a particular operational situation or in a particular maintenance case, an error catalogue, image documentation of the diaphragm valve 10, and other similarly stored information.

(15) Other properties which may be characterized by the stored data include the name of sub-suppliers, information relating to the delivery route, information relating to a storage location and storage duration, preferably also relating to the date into storage and the date out of storage, all of which relates both to subcomponents and to the entire diaphragm valve 10. Said properties may also include the date on which the diaphragm valve 10 was installed in the process installation 32, the name of the installer that installed the diaphragm valve 10 and the name of the operator, and similar information.

(16) At least some of the above-mentioned data may also characterize a property of the diaphragm 14 and be stored in the integrated data memory 24 of the diaphragm 14. Furthermore, the data stored in the integrated data memory 24 of the diaphragm 14 may also characterize an operational property of the diaphragm valve 10. An operational property of this kind is, for example, the type and/or composition of the fluid that is flowing through the diaphragm valve 10 or is switched thereby, the temperature of said fluid, the number and frequency of switching cycles, the cumulative operation time, etc.

(17) Said data may be either saved in the data memory 24 manually by an operator by means of the reading device 36, or recorded at least in part by sensors integrated into the diaphragm valve 10 and/or process installation 32 and automatically transmitted to the data memory 24 and stored therein. Sensors of this kind are indicated in FIG. 2 and are provided with the reference sign 56 (temperature), 58 (pressure), 60 (operation time) and 62 (number of switching cycles and frequency of actuations).

(18) Certain properties may also be determined at any point during operation of the diaphragm valve 10 in a different manner. For example, it is possible for the current thickness of the diaphragm 14 to be determined at the time of an initialization of the valve drive 20. This can be done, for example, by slowly closing the valve drive 20 as far as is sufficient for the diaphragm 14 to come into contact with a valve seat of the valve body 12, and by recording the corresponding path of the valve drive 20. The determined current diaphragm thickness may then also be saved manually or automatically in the data memory 24, for example.

(19) It is also possible for an operator to determine the current state of the diaphragm 14 during maintenance of the diaphragm valve 10, for example during a visual inspection. To do this, the operator may, for example, have at their disposal a catalogue of possible standardized visual appearances on the diaphragm 10, such that the operator can compare the appearance of the diaphragm 14 at the time with the standardized visual appearances shown and thereby deduce that the diaphragm 14 in question corresponds most closely to a particular standardized appearance. A code number corresponding to the appearance can then, for example, be transmitted to the data memory 24 for storage via the reading device 36.

(20) The transmission device 38 may, as shown in FIG. 2, be a bidirectional transmission device which can thus transmit data or information both from the reading device 36 to the processing device 40 (arrow 64) and from the processing device 40 to the reading device 36 (arrow 66). In principle, however, it is also conceivable for the transmission device 38 to function in a solely unidirectional manner, for example to transmit data only in the direction of the arrow 64 from the reading device 36 to the processing device 40.

(21) Based on the entirety of the available data, i.e. the data read out from the integrated data memory 24 and transmitted and the data synchronized therewith present in the processing device 40, said entirety of available data can then be processed in the processing device 40 and, depending on the result of this processing, an action is then determined. For example, the processing may involve determining the current state of wear of the diaphragm 14.

(22) Depending on such a current state of wear, status information can then be automatically generated as the action and transmitted to the reading device 36 via the transmission device 38 and displayed on the display 48 of said reading device. Depending on the current state of wear and further relevant data, a probable remaining service life can also be determined using a corresponding algorithm. If said determined remaining service life is below a threshold value, valve failure is imminent, and corresponding warning information can be generated and likewise transmitted to the reading device 36 by means of the transmission device 38 and displayed on the display 48 of said reading device. Additionally, in such a case as this, an acoustic signal may also be generated at the reading device 36, which signal indicates to the operator the urgency of a measure.

(23) Depending on such a current state of wear, a maintenance request may also be generated in the action module 54, and in the action module 52, the corresponding replacement part, for example a new diaphragm 14, may be requested immediately.

(24) While data relating to the diaphragm 14 are primarily stored in the RFID chip 24 of the diaphragm 14, data relating to the valve body 12 are rather stored in the RFID chip 30 of the valve body 12. In principle, every essential individual component of the diaphragm valve 10 may be provided with a data memory, for example in the form of an RFID chip, in which the data relating to this specific component are then stored. However, it is also conceivable for the data memory 30 provided on the outlet port 28 of the valve body 12 to store all data relating to components that are not the diaphragm 14.

(25) Finally, it is essential that the individual data be synchronized on an external apparatus, specifically the processing device 40, as a result of which an electronic identity for the diaphragm valve 10 is produced, which may for example be as follows:

(26) Diaphragm valve A=diaphragm B+ valve drive C+ valve body D at timepoint E, assembled on F by G, the diaphragm B having been produced on H by I, etc.

(27) Because the diaphragm 14 is provided with a data memory 24, reliability can be significantly improved during maintenance. Specifically, it can be identified, for example, whether the correct diaphragm 14 has been installed in the diaphragm valve 10 during replacement of the diaphragm 14, or whether, for example, the old and worn diaphragm 14 has been inadvertently re-installed in the diaphragm valve 10. The data memory 24 of the diaphragm 14, together with the other linked or synchronized data, also provides the means for counterfeit protection. This is in particular possible if the data in the data memory 24 of the diaphragm 14 are correspondingly encrypted and/or an individual and unfalsifiable identification code for each individual diaphragm 14 is stored.

(28) By means of the synchronized data, a complete electronic service life record for the diaphragm valve 10 is produced, which record can be used in the context of quality assurance of the operation of the process installation 32 and can be retrieved extremely quickly in order to reduce the liability risks for the operator of the process installation 32. If necessary, it is also possible, using the example of a diaphragm 14, to trace back to the manufacture thereof, to the resources used for manufacture, etc.

(29) A method for operating the diaphragm valve 10 will now be described with reference to FIG. 3: after starting box 68, in box 70 the current thickness of the diaphragm 14 is determined at the time of an initialization of the valve drive 20, and in box 72 said thickness is saved in the data memory 24 together with the time said thickness was determined. In box 74, the state of the diaphragm 14 is assessed by means of a visual inspection during maintenance and stored as a corresponding code in the data memory 24 as well.

(30) In box 76, the data stored in the data memories 24 and 30 are read out. In 78, the read-out data are wirelessly transmitted to the processing device 40 by means of the transmission device 38. In box 80, the transmitted data are synchronized with the data read out from the data memory 50 and the synchronized data are processed. Depending on the result of the processing in box 80, actions are determined in box 82, and in box 84 the determined actions are carried out. The method ends in 86.