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, making it difficult to monitor and manage valve performance effectively.
Innovation Solution
An apparatus with an integrated electronics module within the valve stem, featuring a microprocessor and sensors, which provides direct measurement of key metrics by embedding the electronics module inside the valve stem and using a primary conductor for power and data communication, allowing for direct access to the control element and flow control elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are placed on the valve stem to directly measure torque, then measurement precision is improved, but device complexity increases due to the need to integrate electronics within the constrained valve stem space
Solution Approach 1:
The electronics module is nested within the hollow interior of the valve stem, with sensors positioned inside the stem bore and connected to the control element. This nesting approach allows direct torque measurement while containing all electronic components within the existing valve stem structure, avoiding external additions that would increase overall device complexity
Solution Approach 2:
The valve stem is designed with multi-functionality by incorporating both its traditional mechanical function (transmitting actuator force to the control element) and a new sensing function (housing electronics and measuring torque). The hollow stem structure serves simultaneously as a mechanical transmission component and as a protective enclosure for the electronics module and sensors
2Ease of operation
If a hollow valve stem is used to house electronics, then ease of operation is improved by enabling direct measurement, but manufacturing precision requirements increase
Solution Approach 1:
The electronics module is nested within the hollow interior of the valve stem, with sensors positioned inside the stem bore and connected to the control element. This nesting approach allows direct torque measurement while containing all electronic components within the existing valve stem structure, avoiding external additions that would increase overall device complexity
Solution Approach 2:
The valve stem design parameters are modified to include a hollow interior cavity of specific dimensions that can accommodate the electronics module. The stem wall thickness and bore dimensions are optimized to provide sufficient structural strength for torque transmission while creating adequate space for housing sensors and electronic components
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The embodiments disclosed herein relate to an apparatus for monitoring a valve having a control element (13), wherein the control element is actuated by an actuator (15), including a valve stem (11) having a bore (12) 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 (20) within the bore of the valve stem, wherein the electronics module further includes one or more sensors (30) within the valve stem.