Valve Stem Electronics for Direct Torque Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current industrial process control systems face challenges in directly measuring key metrics such as valve torque due to physical constraints, including the placement and power supply of sensors, as well as data communication and processing within control valves.
Innovation Solution
An apparatus with an integrated electronics module housed within the valve stem, which includes sensors and provides a power and data communication pathway through a primary conductor, enabling direct measurement and predictive analysis of valve performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are placed externally on the valve stem to measure torque directly, then measurement precision is improved, but device complexity and installation difficulty increase due to coupling requirements
Solution Approach 1:
The patent combines the sensor, electronics module, and power supply into an integrated assembly that is embedded within the valve stem itself. This merging eliminates the need for external sensor coupling and complex installation, while maintaining direct torque measurement capability through the integrated strain gauge sensors positioned within the stem structure.
Solution Approach 2:
The electronics module and sensors are nested within the hollow interior of the valve stem. The stem is designed with a hollow bore that accommodates the electronic components, power supply, and sensor assemblies. This nesting approach allows direct measurement integration without adding external complexity, as all measurement components are contained within the existing stem structure.
2Measurement precision
If external sensors are used to monitor valve metrics, then measurement capability is improved, but ease of operation deteriorates due to power supply and data communication requirements
Solution Approach 1:
The patent merges the power supply, data processing, and communication capabilities into the integrated electronics module embedded in the valve stem. This consolidation eliminates the need for separate external power and data connections, simplifying installation and operation while enabling comprehensive valve performance monitoring through the integrated sensor system.
3Reliability
If direct torque measurement is implemented through external devices, then reliability is improved, but ease of manufacture decreases due to installation complexity
Solution Approach 1:
The integrated electronics module and sensors are manufactured as a nested assembly within the hollow valve stem structure. The stem is designed with internal cavities and mounting features that accommodate the electronic components during manufacturing. This nested manufacturing approach enables direct torque measurement integration as part of the valve assembly process, improving reliability while maintaining ease of manufacture through standardized integration procedures.
Data Source
AI summary
The embodiments disclosed herein relate to an apparatus for monitoring a valve having a control element, wherein the control element is actuated by an actuator, including a valve stem having a bore therethrough, wherein the bore is defined by a wall of the valve stem, and further wherein the valve stem is connected at a first end to the actuator and at a second end to the control element; and an electronics module within the bore of the valve stem, wherein the electronics module further includes one or more sensors within the valve stem.