Design of Intelligent Valve Electric Actuator Controller

Abstract: This paper presents an intelligent controller designed for electric valve actuators. The system is built around MOTOROLA's 8-bit microprocessor, MC68HC908SR12, as the central control unit, and utilizes power electronics to drive the motor. It integrates automatic control, manual adjustment, and real-time status monitoring into a single intelligent platform. The design is versatile and suitable for a wide range of industrial control valves. Key words: valve electric actuator; intelligent controller; MC68HC908SR12 Introduction Fluids such as water, steam, and oil play a critical role in industrial development, and their movement through piping systems is essential. Valves are indispensable components in these systems. With the advancement of industrial automation, traditional manual methods of adjusting valves have become inadequate for many modern applications. To achieve efficient pipeline management, electric valve systems have become necessary. In some cases, valve control goes beyond simple on/off operations and involves precise opening control and flow regulation, which demands higher intelligence from the actuator. This paper introduces a microprocessor-based control system that enables intelligent operation of electric valve actuators. 1. System Working Principle and Functions In practical applications, the control of a valve often requires it to open or close based on specific needs, adjust to certain positions, or follow dynamic switching patterns. Traditional analog control methods, which use current levels to represent valve position, suffer from synchronization issues due to factors like time delays and variations in current or voltage. As a result, the displayed valve position may not match the actual position, leading to significant errors [3]. Additionally, analog control provides limited information, making system debugging and maintenance challenging. To address these issues, this paper proposes an intelligent control system using digital technology. The system, as shown in Figure 1, employs a MOTOROLA microcontroller along with peripheral circuits to create a digital position control unit. It receives standard DC signals (such as 4–20 mA or 0–5 V), processes them via A/D conversion, and displays the results on a digital screen. The microcontroller generates control signals that drive the AC motor. The system also supports remote digital control via PC commands and offers local manual control through a user-friendly HMI interface. Main functions include: (1) Integrated design supporting various input signals (4–20 mA, 4–12 mA, 12–20 mA, 0–5 V, 1–5 V) and outputting isolated 4–20 mA feedback signals. (2) Simulation run capability based on user-defined flow characteristics. (3) Fault detection for open circuit conditions, with alarm and protection features. (4) Digital display of control signal value, valve position, and fault type. (5) RS485 communication for remote data transmission and configuration. (6) Self-calibration of valve stroke and input/output analog signals. 2. Hardware Components of the Intelligent Controller The system is designed with intelligence, high reliability, strong anti-interference capabilities, and cost-effectiveness in mind. The core control unit uses the 8-bit microprocessor MC68HC908SR12 (SR12). The main motor control circuit is implemented using power electronics technology, ensuring efficient and stable operation. The hardware architecture is optimized to meet the requirements of industrial environments while maintaining simplicity and scalability.

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