Torque sensing system for valve actuator

Abstract

An actuator (100) for a valve (200) may include a torque module (106) and a drive module (104) configured to transfer a rotational force from the torque module to a valve member (e.g., by rotating a flow control element of the valve member to selectively open and close the valve). The torque sensing system may include a sensor element (110, 112) configured to detect a deformation of at least one of the torque module (106) or the drive module (104) to monitor a torque applied to the valve (200) by the actuator (100).

Description

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to U.S. Provisional Patent Application No. 63 / 400,294, filed on August 23, 2022, the entire contents of which are incorporated herein by reference. Background Art

[0004] Various types of actuators may be used to control the movement of a valve, including a ball or other flow control element that moves the valve to control the flow of a fluid or other medium through the valve. Summary of the invention

[0006] Changes in the torque required to operate a valve can indicate problems in the function of the valve (e.g., component wear) or in the overall function of the fluid control system in which the valve is used. Thus, monitoring the pattern of torque demand of a valve during operation of a fluid control system can help provide early warning of maintenance problems that may need to be addressed in the valve or fluid control system.

[0007] Actuators or related sensing devices as described herein can provide torque or other rotational measurements for valve actuators (e.g., in real time during operation of the valve actuator), particularly including torque or other rotational measurements for Scotch yoke actuators. For example, as described in more detail below, the sensing system of the actuator can monitor the deformation of the torque module or drive module of the actuator to determine the torque output by the actuator. Such a system and corresponding monitoring can generally benefit valve operation, including for monitoring the mode of torque demand as described above.

[0008] According to some examples of the present disclosure, an actuator is provided for selectively controlling the movement of an actuatable flow control element between a first configuration and a second configuration to control the flow of fluid through a valve. The actuator may include a torque module, a drive module, and a torque sensing system. The torque module may include: an attachment body that is rotatable relative to a rotation axis and configured to engage a rotatable rod of a flow control element; and a drive engagement component that extends radially outward relative to the attachment body. The drive module may include a drive member and a force transfer element. The force transfer element may be configured to engage the drive engagement component in response to the movement of the drive member to apply torque to the torque module for operating the flow control element. The housing may encapsulate at least one of the torque module or the drive module. The torque sensing system within the housing may include a sensor element, wherein the sensor element is configured to detect deformation of at least one of the torque module or the force transfer element along an axis extending transverse to the central axis during operation of the drive module to apply torque to the torque module through the drive engagement component.

[0009] According to some examples of the present disclosure, an actuator may be configured to selectively control the movement of an actuatable flow control element between a first configuration and a second configuration to control the flow of a fluid through a valve. The actuator may include a torque module, which includes: an attachment body that is rotatable relative to a rotation axis and is configured to engage with a rotatable rod of the flow control element; and a drive engagement component that extends radially outward from the attachment body relative to the rotation axis. The actuator may also include a drive module, which includes: a drive member; and a force transfer element attached to the drive member and engaged with the drive engagement component of the torque module. In response to the movement of the drive member, the force transfer element can apply torque to the torque module through the drive engagement component for operating the flow control element to control the flow of fluid.

[0010] In some examples, the housing may enclose at least one of the torque module or the drive module, and a torque sensing system may be disposed within the housing. The torque sensing system may include a sensor element configured to detect deformation of at least one of the torque module or the force transfer element along an axis extending transverse to the rotational axis in response to operation of the drive module to apply torque to the torque module via the drive engagement component.

[0011] In some examples, the torque module includes a Scotch yoke including an attachment body and a drive engagement component.

[0012] In some examples, the attachment body includes an annular sleeve centered about the axis of rotation.

[0013] In some examples, the sensor element is attached along an outer surface of the annular sleeve.

[0014] In some examples, a fixing structure can be configured to engage a rotatable rod of the flow control element, the fixing structure being positioned along an inner surface of the annular sleeve.The sensor element can be attached adjacent to the fixing structure along an outer surface of the annular sleeve.

[0015] In some examples, the fixing structure may include a keyed engagement member formed along an inner surface of the annular sleeve.The sensor element may be attached along an outer surface of the annular sleeve, wherein the sensor element and the fixing structure are within a common quarter circumference area of ​​the annular sleeve.

[0016] In some examples, the sensor element may include a strain gauge arranged to detect deformation of the attachment body in a circumferential direction.

[0017] In some examples, the sensor element may include a plurality of strain gauges.

[0018] In some examples, the strain gauges may be arranged in a full bridge configuration.

[0019] According to some examples of the present invention, a Scotch yoke for actuation of a valve is provided, the Scotch yoke comprising an attachment body rotatable relative to a central axis. A fixed structure may be provided on the attachment body, the fixed structure being configured to engage a corresponding structure of a rotatable rod of a flow control element. A drive engagement component may extend radially outward relative to the attachment body, the drive engagement component being engageable by a drive module to apply torque to the attachment body. A sensor element is configured to detect deformation of at least one of the attachment body or the drive engagement component along an axis extending transverse to the central axis in response to application of torque to the attachment body.

[0020] According to some examples of the present invention, a Scotch yoke for an actuated valve is provided. The Scotch yoke may include: an attachment body rotatable relative to a central axis; and a fixing structure located on the attachment body, the fixing structure fixing the attachment body to the flow control element of the valve by being attached to a corresponding structure of a rotatable rod of the flow control element. A drive engagement component may extend radially outward from the attachment body relative to the central axis, and the drive engagement component may engage with a drive module of an actuator to apply torque to the attachment body, thereby transferring the torque from the drive module to the flow control element. The sensor element may be configured so that in response to the torque applied to the attachment body, the sensor element detects deformation of at least one of the attachment body or the drive engagement component along an axis extending transverse to the central axis.

[0021] In some examples, the sensor element may comprise a strain gauge, and optionally or preferably wherein the Scotch yoke comprises a plurality of sensor elements formed as a plurality of strain gauges arranged in a Wheatstone bridge configuration.

[0022] In some examples, the sensor element may be disposed on the attachment body.

[0023] In some examples, the drive engagement member may include an arm having a free end and a first end fixed along an exterior of the attachment body. The sensor element may be disposed on the arm.

[0024] In some examples, the slot may extend radially inwardly along the arm from the free end of the arm.The sensor element may be arranged adjacent to the slot.

[0025] Some examples provide a method for monitoring the operation of a valve. During the movement of a drive module of an actuator of the valve, the drive module applies a torque to an attachment body of a Scotch yoke of the valve through a drive engagement component extending from the attachment body of the valve, and a strain on the attachment body or the drive engagement component can be detected using a sensor element arranged on the attachment body or the drive engagement component. Based on the detected strain, the torque applied to the Scotch yoke can be determined. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate examples of the disclosed technology and, together with the description, serve to explain the principles of examples of the disclosed technology:

[0027] Figure 1 An actuator mounted on a valve according to an example of the present invention is shown;

[0028] Figure 2 According to an example of the present invention Figure 1 A cross-sectional view of an actuator;

[0029] Figure 3 According to an example of the present invention, Figure 1 A perspective view of a torque module of an actuator of the invention, the torque module having a deformation sensor fixed thereto;

[0030] Figure 4 Representatively showing an example of the present invention Figure 1 During operation of the actuator Figure 3 The engagement of the drive module and the torque module;

[0031] Figure 5A-5G partially schematic top and side views showing mounting arrangements for deformation sensors of a torque module according to various examples of the invention; and

[0032] Figure 6 FIG. 4 is a top view of a mounting arrangement of a deformation sensor for a torque module according to an example of the present invention. DETAILED DESCRIPTION

[0033] Before explaining any examples of the disclosed technology in detail, it should be understood that the disclosed technology is not limited in its application to the details of the construction and arrangement of the components set forth in the following description or shown in the following figures. The disclosed technology can have other examples and can be practiced or executed in various ways. Moreover, it should be understood that the words and terms used here are for descriptive purposes and should not be considered restrictive. The use of "including", "comprising" or "having" and its variants herein means including the items listed thereafter and their equivalents and additional items. Unless otherwise specified or limited, the terms "install", "connect", "support" and "couple" and their variants are widely used and include direct and indirect installation, connection, support and connection. In addition, "connect" and "couple" are not limited to physical or mechanical connections or connections.

[0034] The following discussion is provided to enable those skilled in the art to make and use examples of the disclosed technology. It will be readily apparent to those skilled in the art that various modifications to the illustrated examples will be apparent, and the general principles herein may be applied to other examples and applications without departing from the principles of the disclosed technology. Therefore, the examples of the disclosed technology are not intended to be limited to the examples shown, but to conform to the widest range consistent with the principles and features disclosed herein. The following detailed description will be read with reference to the accompanying drawings, in which the same elements in different drawings have the same reference numerals. The drawings, which are not necessarily drawn to scale, depict selected examples and are not intended to limit the scope of the examples of the disclosed technology. It will be appreciated by those skilled in the art that the examples provided herein have many useful alternatives and fall within the scope of the disclosed technology.

[0035] As discussed above, monitoring the torque used to operate a valve actuator can be useful, including identifying potential problems that may require maintenance or replacement of the actuator, valve, or various components thereof.

[0036] Some existing systems and methods monitor changes in valve torque indirectly, such as by calculating torque based on measurements of the amount of force applied by an actuator during actuation of the valve (e.g., by monitoring the pressure within a pneumatic piston of a linear actuator). However, such measurements generally do not directly reflect the torque actually output by the actuator. Instead, they may rely on assumed ideal operation of the actuator when calculating the relationship between the measured force and the output torque, and therefore may be prone to error. As a result, these conventional methods may not always provide an accurate measurement of torque during operation of the valve.

[0037] Load cells can directly measure the torque applied to a valve. However, existing load cell systems for valve actuators have a number of disadvantages that may prevent them from being effectively used for large-scale use to monitor the health of fluid control systems. For example, the installation requirements of existing load cells may require that the load cell be fixed in position along the length of the valve stem between the valve and the actuator. This can result in a relatively uneconomical process for retrofitting or other installations. In addition, in situations where the actuator is already fixed to the valve stem, the available mounting space along the valve stem may be insufficient to meet the installation requirements of the load cell.

[0038] Even in cases where the valve stem includes sufficient mounting space, or where the actuator to be equipped with the load cell has not yet been mounted to the valve, the use of conventional load cells and load cell arrangements to monitor the health of a fluid control system may still present a number of challenges. For example, the conventional mounting position of the load cell between the valve and the actuator - e.g., as required by conventional valve, actuator or load cell configurations - may result in the load cell being undesirably exposed to the surrounding environment. As a result, such an exposed arrangement of the load cell may limit the feasibility of incorporating existing load cells into fluid control systems that operate in harsh (or other) environments.

[0039] Furthermore, because the load cell is typically provided as a separate component from the actuator, additional time and effort is required to install the load cell relative to the valve in addition to the time and effort required to install the actuator relative to the valve. Thus, in a fluid control system that includes a large number of valves, the additional time, effort, and cost required to incorporate a load cell onto each associated valve of the fluid control system may render conventional use of existing load cells an expensive and impractical solution for monitoring the health of the fluid control system.

[0040] Actuators or associated sensing devices as described herein can provide improved devices (and methods) for measuring torque or other rotational force parameters of valve actuators (e.g., measured in real time during operation of the valve actuator), particularly including for use with Scotch yoke actuators. For example, as described in more detail below, the sensing system of the actuator can monitor deformation of a torque module or drive module of the actuator to determine the torque output of the actuator (e.g., real-time torque output). Compared to the operation of conventional sensing systems, deformations of components of the torque module or drive module measured by the disclosed sensing system can directly reflect changes in the torque demand of the flow control valve. Therefore, in general, the torque measurement provided for the actuator under the disclosed arrangement can reliably reflect the actual torque output by the actuator, and can therefore be reliably used for diagnostic or other purposes.

[0041] In some cases, the actuator may include a housing defining an inner cavity, in which the drive module, the torque module, and the sensing system are housed. In this case, because the sensing system is contained within the housing of the actuator, the sensitive components of the sensing system can be protected from the surrounding environment. Therefore, such a device can be suitable even under harsh operating conditions. In addition, integrating the sensing system into the actuator housing can avoid the need for any additional effort or time to separately provide a flow control valve with actuation and torque measurement functions.

[0042] Typically, the torque module of the actuator includes an attachment body and a drive engagement component. The attachment body is supported within the housing of the actuator in a manner that allows the attachment body to rotate relative to a rotational (e.g., center) axis around which the attachment body extends. In this regard, the attachment body can be used to fix the actuator relative to a rotatable actuating member (e.g., a valve stem) of a flow control valve, thereby allowing the actuating force to be transmitted between the actuator and the actuable member via the attachment body. In this regard, some attachment bodies may be formed to include a sleeve or other similar structure that includes a partial or full circumference, which may engage a rotatable shaft that in turn engages a rotatable flow control element (e.g., a ball element, a butterfly element, etc.). Therefore, during operation of the actuator, rotation of the attachment body may result in a corresponding rotation of the actuable member of the flow control valve. In some examples, the attachment body may include a fixed structure (e.g., a key or keyway, or various other structures) that engages a corresponding structure (e.g., a keyway or key, or various other geometrically complementary structures) of the actuatable member to rotationally fix the attachment body and the actuatable member relative to each other.

[0043] Continuing, the drive engagement component of the torque module may include a body member extending between an attachment end and a force receiving end or free end (e.g., extending radially from an attachment end to which the body is fixedly attached to the body to a distal free force receiving end). An engagement structure may be provided (e.g., near the force receiving end of the body member). The engagement structure may include a separate component (e.g., a pin or other protrusion) fixed to the force receiving end of the body member. Alternatively (or additionally), the engagement structure may be defined by a portion of the force receiving end of the body member. For example, the engagement structure may include a slot formed along the force receiving end of the body member that may receive a corresponding protrusion on the actuator assembly.

[0044] As described above, the attachment end of the body member can be firmly fixed relative to the outer surface of the attachment body, so that rotation of the attachment body relative to the central axis can cause corresponding movement of the body member. In some examples, the body member can therefore extend along an axis that is angled (i.e., not parallel) relative to the central axis. For example, the body member can extend along an axis that is substantially perpendicular to the central axis, or extend radially outward relative to the central axis. Therefore, the force receiving end of the body member (and the engagement structure disposed thereon) can be radially offset from the outer surface of the attachment body.

[0045] The drive module of the actuator may include a force transfer element and a drive member. The drive member is operably connected to a power source so that during operation of the actuator, the power received by the drive member from the power source actuates the movement of the drive member relative to the housing. For example, the drive member can be formed as an integral or assembled rod structure capable of linearly (or otherwise) transmitting force. The force transfer element can be configured to transfer force from the drive member to the body member (as described above) and is therefore supported substantially fixedly relative to the main axis of motion of the drive member. For example, the force transfer element can be a pin or other protrusion that engages a groove on the body member, or can be otherwise configured to transfer force from the drive member to the body member. Therefore, the movement of the drive member in response to the operation of the power source can achieve a corresponding movement of the force transfer element. As discussed further below, this movement of the force transfer element can in turn cause a corresponding movement of the body member.

[0046] Accordingly, the torque module and the force transfer element of the drive module may include various mutually engaging engagement structures to operably connect the torque module to the force transfer element. Typically, the engagement structure and the force transfer element are supported relative to each other within the housing so that the force transfer element operably engages the engagement structure during movement of the force transfer element. During operation of the actuator, this interaction between the force transfer element and the engagement structure may result in movement of the force transfer element being transferred to movement of the force receiving end of the body component.

[0047] Given the generally radially offset arrangement of the force receiving end of the body member relative to the attachment body, and the generally fixed relationship of the attachment body relative to the central axis (e.g., the attachment body is substantially restricted from translational movement relative to the rotational axis), the above-mentioned movement of the force receiving end of the body member achieved by the drive module can cause the attachment body to be subjected to torque. Since the attachment body is rotationally fixed relative to the actuatable member, the torque applied to the attachment body can correspond to the torque applied to the actuatable member and the corresponding rotation of the attachment body and the actuatable member. Therefore, the drive module and torque module of the actuator are able to utilize power from the power source to selectively control the movement of the actuatable member between the first rotational position and the second rotational position to achieve the desired conversion of the flow control valve between the first operating state and the second operating state (e.g., between a flowing state and a non-flowing state, or between flow states that allow different flow rates at a given pressure drop).

[0048] In this arrangement and other arrangements, the sensing system of the actuator may include one or more sensor elements that detect a parameter indicating (e.g., directly measuring) the torque required to operate an actuable component of a flow control valve to which the actuator is fixed. In particular, at least one of the sensor elements of the sensing system may include a strain sensor that is arranged to sense deformation of one or more components of the valve in order to determine the applied torque. For example, during operation of the actuator, the engagement of components of the drive module and the torque module to convert the movement of the force transfer element into the rotation of the actuable component of the flow control valve may cause one or more components of the drive module and the torque module to be subjected to stress / strain (e.g., compression, tension, torsion, shear, etc.), resulting in deformation of various parts of the drive module and the torque module. These deformations can be sensed as strains in the relevant components, and the corresponding torque on the components can then be easily determined based on the sensed strains.

[0049] As will be appreciated, changing the torque requirements of the actuatable member will correspondingly affect the magnitude of the forces to which the components of the drive module and the torque module are subjected during operation of the actuator. Such changes will therefore also affect the degree of deformation experienced by the drive module and the torque module. Thus, by measuring the degree of deformation of the components of the torque module or the drive module, the sensors of the sensing system may allow for direct measurement of the torque to which the actuatable member is subjected during operation of the actuator.

[0050] Typically, one or more deformation sensors of the sensing system can be fixed along one or more torque detection areas on one or both of the drive module or the torque module. Therefore, during operation of the actuator, each deformation sensor can monitor the degree of deformation of the torque detection area to which it is fixed. For example, one or more sensors can be arranged so that each (or some) sensors monitor the degree of deformation in a direction that is not parallel to the relevant rotation axis (e.g., in a radial, circumferential or other similar direction). In this regard, in some examples, any of a variety of known types of strain sensors can be used to measure deformation.

[0051] The torque sensing region along which the deformation sensor is fixed may correspond to multiple locations along the torque module or drive module. In some cases, the deformation sensor can be arranged to maximize or otherwise optimize the magnitude and detection confidence of the detected torque-induced deformation. For example, the degree of deformation experienced along the structure may be greatest at or near the point on the structure that is directly subjected to the stress or strain inducing force. Therefore, in order to improve the accuracy with which the degree of deformation of the torque sensing region can be assessed, the torque sensing region can advantageously correspond to a location adjacent to a contact point at which force is directly applied by / to the torque module or drive module.

[0052] However, in some cases, some spacing may be provided between the contact point and the placement of the sensor. For example, selecting a torque sensing region adjacent to but slightly offset from the force contact point (i.e., as opposed to being immediately adjacent to the force contact point) may advantageously provide an active surface along which the deformation caused by the force may be amplified. This in turn may improve the resolution of the deformation measurement signal obtained by the deformation sensor.

[0053] According to various examples, at least one torque sensing region along which a deformation sensor is fixed can correspond to a position along an attachment body that can provide force transfer between a valve (e.g., a valve stem) and an actuator. In some cases, such a position along the attachment body can correspond to a portion of the attachment body adjacent to the fixed structure. As described above, torque transfer between the attachment body and the actuatable member is possible due to the rotationally fixed engagement provided by the mutual engagement of the fixed structure and the corresponding structure of the actuatable member. During operation of the actuator, such mutual engagement between the fixed structure and the corresponding structure of the actuatable member can cause the actuatable member to apply a reaction force to the fixed structure, which in turn can cause deformation of a portion of the attachment body adjacent to the position where the fixed structure extends. Therefore, positioning the deformation sensor along a portion of the attachment body near the position of the fixed structure can increase the resolution of the deformation signal obtained by the deformation sensor.

[0054] In addition to (or as an alternative to) at least one deformation sensor, according to some examples, the sensing system may include at least one sensor capable of detecting the speed and direction of movement of the torque module or drive module. Thus, for example, a controller of the sensing system may sometimes utilize readings from sensor elements (e.g., deformation sensors and motion sensors) to fully determine the torque vector applied to the actuatable member. Such a controller may also monitor patterns of torque measurements over time (e.g., based on signals from deformation sensors alone, or signals from deformation and speed / direction sensors), and may analyze these patterns to diagnose (e.g., historically evaluate, or predict future operation) the operation of the flow control valve. Thus, in some cases, actuators according to the present invention (and associated sensing devices, etc.) may provide reliable early warnings of maintenance issues (e.g., potential stuck valves or valve failure conditions) that may need to be addressed in a flow control system.

[0055] Typically, the controller may include a processor device (e.g., a general or special purpose computer, or various well-known industrial controllers) and onboard memory (e.g., various well-known types of memory modules) capable of storing sensor element measurements or other data. Additionally or alternatively, the controller may include a wireless (or other) communication interface via which the sensor element readings or related data may be sent to an external computing system for processing. Thus, the controller may allow real-time torque and rotation monitoring.

[0056] In general, the controller may thus implement a variety of methods by which torque values ​​are determined based on deformation measurements obtained by the deformation sensor (e.g., by known correlations between sensed parameters and actual strain, correlations between actual strain and applied torque, etc.). For example, in some cases, the controller may be configured to obtain baseline measurements associated with the operation of the actuator upon initial installation of the actuator relative to the flow control valve. These baseline measurements may be stored by the controller and used as a reference state to which subsequent measurements obtained during normal use of the actuator may be compared. In some examples, the controller may additionally or alternatively store reference data that associates various measured parameter values ​​with corresponding torque measurements (generated during calibration testing of the actuator before the actuator is used with the flow control valve), and the controller may compare measurements obtained by the sensor element during use of the actuator with the corresponding torque measurements to determine the torque output.

[0057] As described above, changes in the operating characteristics of the flow control valve can indicate changes in the overall operation of the fluid control system using the flow control valve. Therefore, in some examples, torque data from the controller can be provided to the control system of the fluid control system, in which the flow control valve is incorporated. The control system of the fluid control system can then use this data to monitor the operation of the fluid control system to diagnose or predict various problems, or can use this data as part of a closed-loop (or other) algorithm by which the operation of the fluid control system is controlled.

[0058] Turning to the specific examples of the drawings, a Scotch yoke torque module 106 (see, e.g., FIG. 1 ) is shown and described according to various example configurations. Figure 2 ) of the actuator 100 (see, for example, Figure 1 ). Specifically, Figure 2 As shown, the actuator 100 includes a housing 102, and a drive module 104 and a torque module 106 are housed within the housing 102. The housing 102 may have a separate compartment (or sub-housing) enclosing the drive module 104 or other components, and may include an opening 108 (or other features) that provides an interface for sensor elements of the actuator 100 (e.g., strain gauges 110 and gyroscopes 112 (see, e.g., Figure 4 ), or other inertial sensors) can be connected to a controller (not shown) of the actuator 100 via the interface (eg, the controller forms part of the actuator 100, is externally attached to the housing 102, etc.).

[0059] The exemplary actuator 100 shown in the figure is a pneumatic piston actuator according to a generally known design, although other configurations are possible using generally known actuators to provide an actuation force to a torque module to actuate a valve. In particular, in the example shown, the drive module 104 of the actuator 100 includes a drive member including a push rod 114 and a force transfer element including a pin 116 fixed along the length of the push rod 114. Figure 2 As shown, a first end of the push rod 114 is fixed to a piston 118. The piston 118 is slidably disposed within a fluid chamber 120 defined by the housing 102.

[0060] The interior or fluid chamber is fluidly attached to a power source (not shown), such as one of various known pneumatic pressure / flow sources. During operation of the actuator 100 to control the operation of the flow control valve 200, the power source (not shown) can be operated to selectively fill the fluid chamber 120 with a fluid (e.g., air, liquid, etc.). When the fluid chamber 120 is filled with fluid, the piston 118 can be moved from a first, unactuated position (not shown) to a second, actuated position (e.g., see Figure 2 ). The displacement of the piston 118 between the first position and the second position causes the push rod 114 to move along Figure 2 The corresponding linear motion is in the direction indicated by the arrow.

[0061] like Figure 2 As shown, in some examples, the second end of the push rod 114 is operably attached to the back-biasing element 122. During operation of the power source, the movement of the piston 118 in response to the filling of the fluid chamber 120 (and the corresponding linear movement of the piston rod 114) causes the second end of the push rod 114 to compress the back-biasing element 122. When the power source is deactivated, the energy stored by the compressed back-biasing element 122 pushes the piston 118 (and the push rod 114 fixed thereto) toward its first, non-actuated position. However, in other examples, other configurations are also possible. For example, some examples can include a double-acting actuator that can actively (e.g., pneumatically) provide power for actuation of the valve in both directions.

[0062] like Figure 3 As shown, the torque module 106 of the actuator 100 includes a Scotch yoke. In particular, the Scotch yoke includes an attachment body and a drive engagement component, the attachment body includes an annular sleeve 124, and the drive engagement component includes a yoke 126 (for example, a single-sided two-arm yoke as shown). A fixing structure including an axially extending keyway 128 is formed along the inner surface of the annular sleeve 124. In other examples, other fixing structures are also possible (for example, a key configured to engage a corresponding keyway on the valve stem, a set screw device, etc.).

[0063] During installation of the actuator 100, the keyway 128 is aligned with a corresponding axially extending key formed along the outer surface of the valve stem of the flow control valve 200, the axially extending key (e.g., see Figure 4 The key 160 of the annular sleeve 124 will be controlled by the actuator 100. When the annular sleeve 124 is fixed relative to the valve stem, the interaction between the key and keyway 128 (or other fixing structure) of the valve stem will rotationally fix the annular sleeve 124 and the valve stem relative to each other. Therefore, rotation of the annular sleeve 124 and the Scotch yoke generally results in corresponding rotation of the valve stem.

[0064] As also described above, in other examples, the fixing structure of the attachment body may include a variety of structures or features, including a variety of commonly known mechanical connection structures, via which the torque module can be fixed in a rotationally fixed arrangement relative to the valve stem of the corresponding flow control valve (e.g., valve 200). In this regard, for example, a keyway (e.g., keyway 128) and a corresponding key (e.g., on the valve stem) can both be considered keyed engagement members, and it should be understood that some sleeves or other attachment bodies (e.g., similar to sleeve 124 in other respects) can include keyed engagement members that are variously configured as a keyway or recess, where the corresponding recess or keyway is formed on the corresponding valve stem.

[0065] Still reference Figure 3 In particular, the yoke 126 includes a body member and an engagement structure, the body member including a drive engagement component configured as an arm 130, and the engagement structure includes a slot 132. The arm 130 includes: a first end 134 (i.e., an attachment end) fixed relative to the outer surface of the annular sleeve 124, and a second free end 136 (i.e., a force receiving end), the second free end being radially offset from the outer surface of the annular sleeve 124. Figure 3 As shown, according to various examples, the slot 132 is defined by one or more walls 138 of the arm 130. In other examples, other configurations are possible, including configurations with arms or other different configurations of yoke structures, including yoke structures with other engagement structures (e.g., with force transfer pins instead of slots 32).

[0066] In some examples, the torque module 106 includes a single yoke 126. Alternatively, Figure 3 As shown in the example of FIG. 1 , the torque module 106 may include a plurality of yokes 126 that are axially spaced apart in a parallel arrangement along the height of the annular sleeve 124. Figure 3 As shown in the example of the embodiment of the present invention, the first yoke 126 can extend outward from the upper portion of the annular sleeve 124, and the second yoke 126 can extend outward from the lower portion of the annular sleeve 124. In other examples, as also discussed below, one or more yokes can extend from the body member in each of a plurality of directions (e.g., in opposite directions, such as Fig. 5F as shown).

[0067] The yoke 126 can be defined by a variety of structures. Figure 3 As shown, in some examples, the yoke 126 includes a closed yoke arrangement (ie, where the wall 138 of the arm 130 completely surrounds the slot 132). As a further example, including Figure 5B-5G As shown, slot 132 (or Fig. 5F and 5G The plurality of slots 132 in the example of are only partially enclosed by the wall 138 of the arm 130 (eg, may be open at the free end 136 of the associated arm 130).

[0068] like Figure 3 and 5B -5G, the side edge 140 of the arm 130 may be symmetrical in some examples (e.g., Figure 3 , Figure 5D and Fig. 5F exemplarily shown), while in other examples (e.g. Figure 5B , 5C , 5E and 5G), the side edges 140 of the arms 130 may be inclined (e.g., such that the opposite side edges 140 of the arms 130 extend at different angles relative to the outer surface of the annular sleeve 124). Figure 5C As shown, in some examples, the slot 132 is defined by a nonlinear wall 138 of the arm 130, while in other examples, the slot 132 is defined by a straight wall 138 of the arm 130. In some examples, more than one arm 130 may be provided, including Fig. 5F and 5G The relative arms 130 of the balanced yoke torque module 106 are shown.

[0069] The width of slot 132 is typically sized to be slightly greater than the width of pin 116 carried by push rod 114 (or, for example, the width of the corresponding pin in the case of a multi-slot yoke). Thus, during operation of actuator 100, when piston 118 (and push rod 114 fixed relative thereto) is actuated between the first position and the second position (i.e., when push rod 114 is moved by Figure 4 When moving in the direction indicated by the arrow in FIG. 1 ), the pin 116 can slide along the length of the slot 132. Figure 4 As shown by the dotted line, when the push rod 114 is Figure 4When moving in the direction indicated by the arrow in the middle, the movement of the pin 116 along the length of the slot 132 allows the pin 116 to convert the linear movement of the push rod 114 into the rotational movement of the annular sleeve 124 about the central axis. However, as described above, various other arrangements are possible, including arrangements with slots, pins, etc. having different configurations. For transmitting linear force to the Scotch yoke and converting the linear force into a rotational force on a flow control element (e.g., a ball valve element, a butterfly valve element, or other known rotatable flow element for controlling flow through a valve (not shown)).

[0070] During operation of the actuator 100, reaction forces generated by the mutual engagement between the axially extending key slot 128 formed along the inner surface of the annular sleeve 124 and a corresponding key formed along the exterior of the valve stem (not shown) - or similar interactions between other similar structures - can cause the annular sleeve 125 to experience varying degrees of stress or strain, which in turn can cause deformation of the annular sleeve 124. The reaction forces generated by the mutual engagement between the pin 116 and the slot 132 can cause the pin 116 and the arm 130 to experience varying degrees of stress or strain, which in turn can cause deformation of the arm 130 and the pin 116. Therefore, in various examples, one or more portions along any one or more of the annular sleeve 124, the arm 130, or the pin 116 can define a torque sensing region, and a deformation sensor (e.g., a strain gauge 10) can be advantageously arranged along the torque sensing region. In some examples, including as Figures 2 to 5E As described in detail in , the sensor can be fixed to the outer surface (eg, radial outer surface) of the Scotch yoke or other torque module, including allowing for easy installation or maintenance, as well as effective access to the sensor for transmitting the sensor signal to a separate controller.

[0071] As an example of selection, Figure 3-5G As shown, the torque detection area may correspond to a location along the outer surface of the annular sleeve 124. Figures 5A-5C As shown, in some such examples, the torque detection area can correspond to a position around the circumference of the outer surface of the annular sleeve 124, and a plurality of strain gauges 110a-110d are arranged along the circumference. In this regard, for example, each of the strain gauges 110a-110d can be oriented to measure strain at 45° relative to the central axis. Similarly, the strain gauges 110a and 110d can be positioned radially opposite to each other, as can the strain gauges 110b and 110c. In some cases, the strain gauges 110a-110d can each be located at the same height relative to the annular sleeve 124, which generally corresponds to a position slightly higher than the mid-height of the annular sleeve 124.

[0072] In particular, Figures 5A-5DThe strain gauges 110a-110d in the examples of 5F and 5G incorporate a full Wheatstone bridge (or "full bridge") configuration, inter-strain gauge wiring, and a zero balance network, and have corresponding relative orientations and electrical connections between the strain gauges 110a-110d according to principles generally known in the art. Similarly, the arrangement of strain gauges 110a-110d can also be temperature compensated and insensitive to bending stress or axial stress. However, in other examples, other arrangements of sensors can be used, including other known bridge arrangements (e.g., such as Figure 5E half bridge in the circuit).

[0073] According to some examples, the torque detection area (i.e., the location along which the strain gauges 110 are arranged) may correspond to multiple of one or more other locations around the exterior of the annular sleeve 124. For example, as generally described above, such an arrangement of the strain gauges 110 may correspond to various 1 / 4 bridge configurations, half bridge configurations, and full bridge configurations. In different examples, the arrangement of the strain gauges 110 may be symmetrical or asymmetrical about the exterior of the annular sleeve 124, depending on the needs of a particular system.

[0074] In general, the torque sensing regions may correspond to various appropriately spaced locations around the circumference of the annular sleeve 124. In some examples, the sensors may be arranged at equal circumferential intervals or have a degree of radial or reflection symmetry relative to each other. In some examples, at least one of the strain gauges 110 (e.g., Figure 5D , 5E The sensor device is positioned around the circumference of the annular sleeve 124 at a position adjacent to the position of the axially extending keyway 128 (i.e., within the same half-circumference area, third-circumference area, quarter-circumference area, or smaller circumference area of ​​the annular sleeve 124 as the keyway 128). Therefore, the sensor device can advantageously identify the maximum (or near-maximum) deformation of the annular sleeve 124, so that the applied torque can be more accurately evaluated.

[0075] The strain gauge 110 may also be generally secured to the annular sleeve 124 at one or more different locations along the height of the annular sleeve 124. For example, the strain gauge 110 may be located near the upper end or the lower end of the annular sleeve 124 (e.g., as shown in FIG. Figure 5D ), located at the middle height of the annular sleeve 124 (for example, as Figure 5E In some examples, at least one of the strain gauges 110 may be fixed along the annular sleeve 124 at a height adjacent to a location along the annular sleeve 124 where the arm 130 extends from the annular sleeve (e.g., this may allow the sensor to more accurately detect deformation from the transfer of force between the arm 130 and the sleeve 124).

[0076] The orientation of the strain gauge 110 relative to the axis can also be varied appropriately. For example, the strain gauge 110 can be oriented at an angle of 45°, 90°, etc. relative to the central axis. Figure 5D Representatively shown, in examples including multiple strain gauges 110 , the strain gauges 110 may be arranged at different angles relative to the central axis (eg, to allow for more accurate deformation detection and isolation, which may inform monitoring of associated torque).

[0077] In addition to or as an alternative to arranging strain gauges 110 along the exterior of annulus 124, some examples may include sensors arranged along a Scotch yoke or other drive engagement component of a torque module. Figure 6 As shown, the strain gauge 110 can be fixed along the upper surface (or other surface) of the arm 130 along one or both sides of the slot 132. Similar arrangements are also possible for one or more arms of a multi-arm yoke, including in the construction of a balanced yoke that is otherwise similar to 5F and 5G. According to other examples (not shown), one or more strain gauges 110 can be additionally or alternatively arranged on or near the pin 116 (e.g., along a mounting block by which the pin 116 can be fixed to the push rod 114).

[0078] In examples including multiple strain gauges 110, the deformation signals obtained by different strain gauges 110 can be used by the controller for different purposes in determining the torque output by the actuator 100, including according to commonly known analytical techniques for identifying forces based on measured strain. For example, in the illustrated embodiment, the location of strain gauges 110a and 110b adjacent to keyway 128 can result in the largest (and most appropriately represented) amount of deformation being detected during operation of the actuator 100, so as to provide a sense of the torque output by the actuator 100. Figure 3 Thus, in some examples, the controller may utilize signals received from strain gauges 110a and 110b to determine the degree of deformation, and may utilize deformation measurements received from strain gauges 110c and 110d to provide temperature compensation.

[0079] In some examples, the sensing component of the actuator 100 may also include one or more sensor elements, via which the speed or direction of the movement of the actuator 100 may be monitored. Figure 2 and Figure 3As shown, the actuator 100 also includes a gyroscope 112 or other rotation / angular rate sensor (e.g., a known inertial management unit or other known motion detection system). In general, the gyroscope 112 can be fixed at various locations along the movable portion of the actuator 100. For example, the location where the gyroscope 112 is mounted can be selected to minimize the risk of the gyroscope 112 interfering with other moving parts of the actuator 100 during operation and to facilitate wiring of the gyroscope 112 to a controller (not shown). Figure 2 and Figure 3 As shown, in various examples, the gyroscope 112 can be secured along an upper surface of an arm 130 of the torque assembly 106 .

[0080] As also described above, the position / velocity measurements provided by the gyroscope 112 and the deformation measurements provided by the strain gauge 110 can allow the controller of the actuator 100 to provide real-time torque and motion information. By monitoring the trends of the measurements obtained using the gyroscope 112 and the strain gauge 110, and comparing these measurements to baseline measurements, the controller of the actuator 100 is thus able to measure or calculate relevant metrics for the operation of the flow control valve 200 in which the actuator 100 is installed, including those that may indicate a stuck valve or other valve failure, a lack of torque delivery, or other problems.

[0081] In some examples, the actuator 100 may include an existing actuator that has been retrofitted to provide the existing actuator with the ability to provide real-time torque or motion information (e.g., as generally described with reference to the actuator 100). For example, according to one exemplary method of providing an existing actuator with the improved torque and motion monitoring functionality of the actuator 100 as described herein, the Scotch yoke torque transfer member of the existing actuator may be replaced with a Scotch yoke torque transfer module 106 having one or more strain gauges 110 and gyroscopes 112 affixed thereto. If desired, the strain gauges 110 and gyroscopes 112 may be wired to an existing controller of the actuator (or the existing controller, if any, may be replaced with a controller as described herein), and the firmware of the controller may then be updated to allow for processing of measurements obtained by the strain gauges 110 and gyroscopes 112. In such a retrofit arrangement, the size and configuration of torque module 106 (eg, arrangement of arms 130 , length / width of slots 132 ) may be selected to correspond to the size and configuration of existing torque transmitting components to facilitate replacement of the existing torque transmitting components with torque module 106 .

[0082] Although the actuator disclosed herein has been described according to its specific examples and applications, many modifications and changes may be made to it by those skilled in the art without departing from the scope of the disclosed technology described in the claims. For example, the actuator 100 shown and described with reference to the drawings includes a pneumatic / hydraulic powered drive module 104 and a torque module 106 including a Scotch yoke. However, according to other examples, the actuator 100 may include a drive module or a torque module defined by various other structures. For example, the torque module may include other structures that are similar to the Scotch yoke torque module 106 described above, including a surface that undergoes different degrees of deformation in response to a changing torque output, and a deformation sensor may be fixed along the surface. As an example, the torque module may include a pinion, and the drive module may include a rack (e.g., with a sensor fixed to measure the deformation of the pinion). Similarly, although the drive module has been described as pneumatic / hydraulic driven, in other examples, the drive module may be powered by other types of power sources (e.g., motor driven, manually operated, etc.).

[0083] In some embodiments, the devices or systems disclosed herein may be utilized, manufactured, installed, etc. Methods that embody various aspects of the disclosed technology are used. Accordingly, any description herein of a particular feature, capability, or intended purpose of a device or system is generally intended to include disclosure of methods of using such a device for the intended purpose, methods of otherwise achieving such capabilities, methods of manufacturing related components of such a device or system (or the device or system as a whole), and methods of installing disclosed (or otherwise known) components to support such purposes or capabilities. Similarly, unless otherwise indicated or limited, the description herein of any method of manufacturing or using a particular device or system (including installing the device or system) as an example of the disclosed technology is intended to inherently include disclosure of the utilized features and implemented capabilities of this device or system.

[0084] In some examples, aspects of the disclosed technology, including computerized implementations of methods according to the disclosed technology, can be implemented as systems, methods, devices, or products of manufacture using standard programming or engineering techniques to produce software, firmware, hardware, or any combination thereof to control a processor device (e.g., various combinations of serial or parallel general-purpose or special-purpose processor chips, single-core or multi-core chips, microprocessors, field programmable gate arrays, control units, arithmetic logic units, and processor registers, etc.), a computer (e.g., a processor device operably connected to a memory), or another electronically operated controller to implement the various aspects detailed herein. Thus, for example, various aspects of the disclosed technology can be implemented as an instruction set tangibly embodied on a non-transitory computer-readable medium, such that a processor device can implement instructions based on reading instructions from the computer-readable medium. Some examples of the disclosed technology can include (or utilize) control devices such as automation equipment, special-purpose or general-purpose computers including various computer hardware, software, firmware, etc., consistent with the following discussion. As specific examples, the control device may include a processor, a microcontroller, a field programmable gate array, a programmable logic controller, logic gates, etc., as well as other typical components known in the art for implementing appropriate functions (e.g., memory, communication systems, power supplies, user interfaces and other inputs, etc.). In some examples, the control device may include a centralized wheel hub controller that receives, processes and (re)transmits control signals and other data to and from other distributed control devices (e.g., engine controllers, implement controllers, drive controllers, etc.), including as part of a hub-and-spoke architecture or other architecture.

[0085] The term "article of manufacture" as used herein is intended to include a computer program accessible from any computer-readable device, carrier (e.g., non-transient signal), or medium (e.g., non-transient medium). For example, computer-readable media may include, but are not limited to, magnetic storage devices (e.g., hard disks, floppy disks, magnetic strips, etc.), optical disks (e.g., compact disks (CDs), digital versatile disks (DVDs), etc.), smart cards, and flash memory devices (e.g., cards, sticks, etc.). In addition, it should be understood that carrier waves may be employed to carry computer-readable electronic data, such as those used when sending and receiving e-mail or accessing a network such as the Internet or a local area network (LAN). Those skilled in the art will recognize that many modifications may be made to these configurations without departing from the scope or spirit of the claimed subject matter.

[0086] Certain operations of the methods according to the disclosed technology or certain operations of the systems performing these methods may be schematically represented in the accompanying drawings or otherwise discussed herein. Unless otherwise specified or limited, the representation of specific operations in a specific spatial order in the figure may not necessarily require that these operations be performed in a specific order corresponding to the specific spatial order. Accordingly, certain operations represented in the figure or otherwise disclosed herein may be performed in an order different from the order explicitly shown or described, which is appropriate for specific examples of the disclosed technology. In addition, in some examples, certain operations may be performed in parallel, including by dedicated parallel processing devices or separate computing devices configured to interoperate as part of a larger system.

[0087] As used in the context of computer implementation, unless otherwise specified or limited, the terms "component", "system", "module", "block", "device", etc. are intended to include part or all of a computer-related system including hardware, software, a combination of hardware and software, or software in execution. For example, a component can be, but is not limited to, a processor device, a process executed (or executable) by a processor device, an object, an executable, an execution thread, a computer program, or a computer. As an illustration, both an application running on a computer and the computer can be a component. One or more components (or systems, modules, etc.) can reside within a process or thread of execution, can be located on one computer, can be distributed between two or more computers or other processor devices, or can be included in another component (or system, module, etc.).

[0088] Unless otherwise qualified or defined, "or" represents a non-exclusive list of components or operations that can exist in any kind of combination, rather than an exclusive list of components that can only exist as alternatives to each other. For example, a list of "A, B, or C" represents the options: A; B; C; A and B; A and C; B and C; and A, B, and C. Accordingly, the term "or" as used herein represents exclusive alternatives only when preceded by an exclusive term, such as "any one," "one of," "only one of," or "exactly one of." For example, a list of "A, B, or C" represents the options: A, but not B and C; B, but not A and C; and C, but not A and B. A list that begins with "one or more" (and variations thereof, such as "at least one") and includes "or" to separate the listed elements indicates an option of one or more of any or all of the listed elements. For example, the phrases "one or more of A, B, or C" and "at least one of A, B, or C" represent the following options: one or more A; one or more B; one or more C; one or more A and one or more B; one or more B and one or more C; one or more A and one or more C; and one or more A, one or more B, and one or more C. Similarly, a list beginning with "plurality" (and variations thereof) and including "or" to separate the listed elements indicates the option of multiple instances of any or all of the listed elements. For example, the phrases "plurality of A, B, or C" and "two or more of A, B, or C" represent the options: A and B; B and C; A and C; and A, B, and C.

Claims

1. An actuator (100) for selectively controlling movement of an actuatable flow control element between a first configuration and a second configuration to control fluid flow through a valve (200), the actuator comprising: A torque module (106), the torque module comprising: an attachment body (124) rotatable relative to an axis of rotation and configured to engage a rotatable stem of the flow control element; and a drive engagement member (130) extending radially outwardly from the attachment body (124) relative to the rotational axis; A driving module (104), the driving module comprising: A driving member (114); and a force transfer element (116) attached to the drive member (114) and engaged with the drive engagement component of the torque module; wherein, in response to movement of the drive member (114), the force transfer element (116) is configured to apply torque to the torque module (106) through the drive engagement component (130), thereby operating the flow control element to control fluid flow; a housing (102), the housing enclosing at least one of the torque module or the drive module; and A torque sensing system is located within the housing, the torque sensing system including a sensor element (110, 112) configured to detect deformation of at least one of the torque module or the force transfer element along an axis extending transverse to the rotational axis in response to operation of the drive module applying torque to the torque module via the drive engagement component.

2. The actuator according to claim 1, characterized in that The torque module (106) includes a Scotch yoke including the attachment body (124) and the drive engagement component (130).

3. The actuator according to claim 1, wherein: The attachment body includes an annular sleeve (124) centered about the axis of rotation.

4. The actuator according to claim 3, wherein: The sensor element is attached along an outer surface of the annular sleeve (124).

5. The actuator according to claim 4, further comprising: a fixing structure (128) configured to engage with a rotatable stem of the flow control element, the fixing structure being positioned along an inner surface of the annular sleeve (124); in, The sensor element (110, 112) is attached along an outer surface of the annular sleeve (124) adjacent to the fixed structure (128).

6. The actuator according to claim 5, wherein: The securing structure (128) includes a keyed engagement member formed along an inner surface of the annular sleeve (124); and The sensor elements (110, 112) are attached along the outer surface of the annular sleeve (124), and the sensor elements and the fixing structure are located within a common quarter circumference area of ​​the annular sleeve.

7. An actuator according to any one of the preceding claims, wherein: The sensor element comprises a strain gauge (110) arranged to detect deformation of the attachment body (124) in a circumferential direction.

8. The actuator according to claim 7, wherein: The sensor element includes a plurality of strain gauges (110a, 110b, 110c, 110d).

9. The actuator according to claim 8, wherein: The strain gauges (110a, 110b, 110c, 110d) are arranged in a full bridge configuration.

10. A Scotch yoke (106) for an actuating valve (200), the Scotch yoke comprising: an attachment body (124) rotatable relative to a central axis; a fixing structure (128) located on the attachment body to fix the attachment body (124) to the flow control element of the valve via a corresponding structure attached to a rotatable stem of the flow control element; a drive engagement member (130) extending radially outwardly from the attachment body (124) relative to the central axis, the drive engagement member (130) being engageable with a drive module (104) of an actuator to apply torque to the attachment body, thereby transferring torque from the drive module (104) to the flow control element; and A sensor element (110, 112), wherein The sensor element detects deformation of at least one of the attachment body (124) or the drive engagement component (130) along an axis extending transverse to the central axis in response to a torque applied to the attachment body.

11. The Scotch yoke according to claim 10, wherein: The sensor element comprises a strain gauge (110), and optionally or preferably, the Scotch yoke comprises a plurality of sensor elements (110a, 110b, 110c, 110d) formed as a plurality of strain gauges arranged in a Wheatstone bridge configuration.

12. The Scotch yoke according to claim 10 or 11, characterized in that The sensor element (110) is arranged on the attachment body.

13. A Scotch yoke according to claim 10 or 11, wherein: The drive engagement member (130) includes an arm having a free end (136) and a first end (134) fixed along an exterior of the attachment body (124); and Wherein, the sensor element (110) is arranged on the arm (130).

14. The Scotch yoke according to claim 13, characterized in that a slot (132) extending radially inwardly along the arm from the free end (136) of the arm; and Wherein, the sensor element (110, 112) is arranged adjacent to the groove (132).

15. A method of monitoring the operation of a valve (200), the method comprising: During the movement of the drive module (104) of the actuator (100) of the valve (200), the drive module (104) applies torque to the attachment body (124) via a drive engagement component (130) extending from the attachment body (200) of the Scotch yoke (106) of the valve (200), and detects strain on the attachment body (124) or the drive engagement component (130) using a sensor element (110, 112) arranged on the attachment body (124) or the drive engagement component (130); and The torque applied to the Scotch yoke (106) is determined based on the detected strain.

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