Patent Application
20220099217
Not Applicable.
Not Applicable.
Not Applicable.
The subject matter generally relates to apparatus and techniques for observing and calculating torque for industrial process control systems, in particular for valves.
Current commercially available devices of calculating the torque of a valve system involves torque cells or transducers as mounted on a cylindrical body (e.g. the torque cell or transducer is mounted on a round bar, or a tube). For these currently available configurations, the conversion from strain to torque is relatively simple and straightforward. The conversion from strain to torque relies on known equations using Diameter, Young's Modulus, Poisson's Ratio that can be applied to a round body for the conversion of micro-strain to torque. However, the measurement of strain on a non-cylindrical body or feature of a valve and subsequent conversion to a usable torque value is not currently available in the field of industrial process control systems. Accordingly there is a need for the ability to measure strain on a non-cylindrical body and accurately and reliably calculate the torque value from the measured strain values.
The embodiments disclosed herein relate to a bracket for a valve system, having an actuator side of the bracket, defining a first set of one or more holes; a valve side of the bracket, wherein the valve side is opposite the actuator side, and further wherein the valve side defines a second set of one or more holes; a wall (or walls) connecting the actuator side and the valve side; and a strain gauge mounted to the wall (or walls).
The embodiments may be better understood, and numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings. These drawings are used to illustrate only typical embodiments of this disclosure, and are not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
The description that follows includes exemplary apparatus, methods, techniques, and instruction sequences that embody techniques of the inventive subject matter. However, it is understood that the described embodiments may be practiced without these specific details.
Enlarged views of the exemplary embodiments of the bracket 40 are depicted in
A gland ring 22 may surround the stem 13 and may also be housed and located at least partially within the interior or inside of the bracket 40. The interior or inside of the bracket 40 may be the area as defined within the walls 47, actuator side/end 41, and the valve side/end 42. A gland retainer 20 is mounted above the gland ring 22. The gland retainer 20 may be secured to the valve body 11 (as illustrated in
In further alternative exemplary embodiments, the bracket 40 may be fully enclosed, without openings 48a, to prevent water and dirt ingress, or fully enclosed with other means of access (by way of example only, a door panel connected to the mounting support or bracket 40 which may be opened or closed). The stem 13 may extend through the top side or end 41 of the bracket 40 via a valve stem hole 45 defined through the top side 41, and through the bottom side or end 42 of the bracket 40 via the bracket slot or opening 48b. The gland ring 22, in certain exemplary embodiments, may be inserted or fitted within the bottom bracket slot or opening 48b. The actuator 70 may engage the stem 13 at the free end of the stem 13 (opposite where the stem 13 is connected to the flow element or obturator 12), above the bracket 40, and actuate or control the flow element or obturator 12 between an open and a closed position.
Further, one or more actuator side or actuator connection holes or ports 44 are drilled or defined in a pattern through the top side 41 of the bracket 40 to allow or enable the fastening or mounting of the actuator 70 to the bracket 40, via fasteners 18. Similarly, one or more valve side holes or ports 49 are drilled or defined in a pattern through the bottom side 42 (e.g. the extensions 42a) of the bracket 40 to allow or enable the fastening, mounting, or direct coupling of the valve body 11 to the bracket 40 via fasteners 18. Fasteners 18 as described within this disclosure may be any type of fastening, connecting, or mounting mechanism or device as is known to one of ordinary skill in the art.
In the exemplary embodiments as depicted in
The strain gauge 50 may detect or sense stress or strain on the wall surfaces 47 (or the recess 43 of a wall 47) during operation of the valve system 10. In particular, the strain gauges 50 may detect the stress or strain as experienced between the valve body 11 and the actuator 70. The strain gauge 50 may be a shear, linear, rosette, or any other type of strain gauge as known to one of ordinary skill in the art. The strain gauge 50 may be a commercially available metal foil type of strain gauge. Moreover, more than one strain gauge 50 may be mounted onto the bracket 40, and strain gauges 50 may be mounted on either or both of the interior surface 47a or the exterior surface 47b of the walls 47 (see e.g.
The strain gauges 50 may include communication mechanisms, connectors or leads 53 which connect to a strain gauge connection board 52 and/or a microprocessing unit 30. In certain exemplary embodiments, the strain gauge connection board 52 may be a flex circuit. As can be best seen in
The strain, micro-strain or stress data or signal 60 as sensed, observed or measured from the strain gauge 50 on the wall(s) 47 corresponds to torque force or strain acting upon the valve system 10 and the bracket 40, such as during actuation or operation of the control element or obturator 12 via the actuator 70. The raw observed data 60 requires conversion, calculation or modification to correspond the raw data 60 to the related torque value, amount, or data 60a. The data 60, 60a may be continuously monitored by and stored within microcontroller 30 as the valve system 10 operates. The data 60 and calculated/converted data 60a regarding the sensed conditions, as monitored and tracked over time, may indicate and alert the operator as to potential problems of the valve system 10, such as excessive torque amount, breakdown of components, valve sealing degradation, or actuator performance issues. The C-shaped bracket 40 and the presence of various actuator side holes 44, valve side holes 49 and mounting holes 46 results in a unique and complex geometry without a currently known or available method of converting the measured or sensed strain 60 from the strain gauges 50 into understandable or usable torque values 60a to determine acceptable levels of strain, stress, and torque on the valve system 10. As the present disclosure utilizes a bracket 40 having a non-cylindrical, asymmetric body on which a strain gauge 50 is mounted, this requires a nonconventional method of converting micro-strain data 60 into torque values or data 60a.
The bracket 40, while depicted as having a C-shape in
A first proposed approach would be to physically apply a known torque value (such as, by way of example, using an output digital torque wrench) to the device or valve system 10, measure the strain or micro-strain data 60 with the strain gauge 50, repeat for various different torque levels or values, record the data to the connection board/microcontroller 52 and determine or map the relationship between micro-strain data 60 and the known torque. Such process may produce a relationship having a linear equation in the following form:
y=mx+b,
or alternatively: (Torque)=(m)(strain)+(b),
wherein y is the calculated and sought after torque value 60a; x is the strain data measurement 60 as obtained from the strain gauge 50; and the variables m and b are numerical values which are experimentally determined from physical testing of each device or valve system 10. The equation, including the variables m and b, may be stored in the microcontroller 52, for converting the raw sensed data 60 to torque values 60a, and storing same, as the strain gauge 50 measures/senses the conditions of the valve system 10. In alternative exemplary embodiments, a polynomial curve fit may be used instead to depict the relationship between the strain data 60 and the known torque, and subsequently used to convert future raw data 60 to calculated torque values 60a.
Alternatively a formula or equation may be developed to provide the relationship between the measured strain or micro-strain data 60 and the torque 60a as based on various dimensions and material properties of the bracket 40, so as to be able to convert the raw data 60 to torque 60a. This may include dimensional properties or the geometry of the bracket 40 including the length, width, height, thickness 40a at the strain gauge 50, strain gauge 50 or bracket 40 orientation, number of openings or holes, and/or bolt or fastener 18 circle or hole diameter(s). The calculation may also take into account the mechanical properties including Young's modulus, Poisson's ratio, amongst others. While equations may already exist for simple shapes, the same cannot be said for a bracket 40 with complex geometry (such as having multiple openings of different sizes, including front and rear side openings 48a, drill patterns including holes 44, 45, 45a, 46, and 49, and varying bracket thicknesses 40a). By way of example only, but not limited to, further geometric dimensions and features like the mounting hole (e.g. 44, 45, 45a, 46, and 49) diameter, number of holes, and hole(s) orientation may be incorporated into the equation.
The data or signals 60 may be further processed, converted and/or analyzed by the microprocessor or computing unit 30 to provide the corresponding torque values 60a of valve system 10, as further described for
The microprocessor 30 and its components are generally implemented as electronic circuitry and processor-based computational components controlled by computer instructions stored in physical data storage components 38, including various types of electronic memory and/or mass-storage devices. It should be noted, at the onset, that computer instructions stored in physical data storage devices 38 and executed within processors or microcontrollers 30 comprise the control components of a wide variety of modern devices, machines, and systems, and are as tangible, physical, and real as any other component of a device, machine, or system. Occasionally, statements are encountered that suggest that computer-instruction-implemented control logic is “merely software” or something abstract and less tangible than physical machine components. Those familiar with modern science and technology understand that this is not the case. Computer instructions executed by processors must be physical entities stored in physical devices. Otherwise, the processors would not be able to access and execute the instructions. The term “software” can be applied to a symbolic representation of a program or routine, such as a printout or displayed list of programming-language statements, but such symbolic representations of computer programs are not executed by processors. Instead, processors fetch and execute computer instructions stored in physical states within physical data storage devices 38. Similarly, computer-readable media are physical data storage media 38, such as disks, memories, and mass-storage devices that store data in a tangible, physical form that can be subsequently retrieved from the physical data storage media 38. Moreover, the physical data storage media 38 may optionally be integral with the microprocessor 30.
The microprocessor 30 may access and use a variety of different types of stored or received information, signals, feedback, data, metrics, measurements or inputs 60, including, user/operator input, in order to generate output controls or commands that may trigger or change processes of the microprocessor 30 or the valve 10a, or otherwise transmit signals and data 60, 60a. Such changed processes may include visual and audible alerts or alarms to the operator of the process system, amongst others. The data 60, 60a may be collected and analyzed both singularly and collectively to provide warnings and alerts (real-time and in a predictive manner), determine faults, predicted faults, comparison to base line readings, and others. The computations may be distributed between the microprocessors 30 and other computing units or electronics within the actuator 70, valve 10a or remotely. Received/measured variables, data, measurements or metrics 60,60a, or input/stored variables, metrics, information or data 60,60a, whether received to the microprocessor 30 by user-input or feedback from any of the strain gauges 50, includes at least the sensed or threshold/limit stress, strain or micro-strain data 60, calculated or derived torque values 60a as well as other sensors that may be monitoring aspects of the valve system 10, including the valve 10a. Additional information used by the microprocessor 30 in its algorithms may include one or more stored control schedules, algorithms, immediate control inputs received through a control or display interface, and data, commands, commissioning, and other information received from other processing systems (including the data communication between other computing units), remote data-processing systems, including cloud-based data-processing systems (not illustrated) and may further include calculations or analysis of data 60 and 60a. Further, in alternative exemplary embodiments, the microprocessor 30 may monitor and coordinate data feedback and/or input 60,60a for the valve 10 or to alert an operator of maintenance or repair needs as based on the measurements/metrics, calculated values, or saved/stored data 60,60a for the valve system 10. Analog and digital interfaces of the microcontroller 30 may process the strain gauge data 60 and torque data 60a and perform real-time analysis of the collected data 60,60a. The microprocessor 30 can extract and deduce from the raw real-time sensor data 60 information or predictions regarding or calculated/converted data 60a. By way of example only, the microprocessor 30 may monitor and record the data 60,60a over several periods of time into the physical data storage component 38, and alert the operator when the sensed data or metric 60,60a exceeds a stored desired data value or set of parameters, range or threshold for the corresponding sensed data or calculated values 60,60a. This history and data 60,60a stored by the physical data storage component 38 may be further used to troubleshoot, maintain, and repair the components (such as the stem 13, strain gauge 50, bracket 40, gland retainer 20, gland ring 22 or fasteners 18, amongst others) of the valve system 10 by the operator or manufacturer of the system. The microprocessor 30 may optionally also provide a LED, graphic, display or analog interface (including a digital or analog interface or alarm system) that allows users/operators to easily input controls and may also provide or transmit output, data, signals and other information to remote entities, other microcontrollers, and to users through an information-output interface. The interface system may be an actuator mounted electronics having the ability to display information and in-turn communicate further information to a process controller or other instrumentation connected to a network for actuator, including, but not limited to, cloud-based network and storage. Digital communication may allow the electronics or computing units within the actuator to directly communicate with the microprocessor unit 30. In this manner, the microprocessor 30 may act as a mechanism to sense or receive feedback for adjusting and correcting the valve 10 system(s).
Embodiments of the technology may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, embodiments of the disclosed subject matter may take the form of a computer program product embodied in any tangible medium of expression having computer usable program code embodied in the medium. The described embodiments may be provided as a computer program product, or software, that may include a machine-readable medium having stored thereon instructions, which may be used to program a computer system (or other electronic device(s)) to perform a process according to embodiments, whether presently described or not, since every conceivable variation is not enumerated herein. A machine readable medium includes any mechanism for storing or transmitting information in a form (e.g., software, processing application) readable by a machine (e.g., a computer). The machine-readable medium may include, but is not limited to, magnetic storage medium; optical storage medium; magneto-optical storage medium; read only memory; random access memory; erasable programmable memory; flash memory; or other types of medium suitable for storing electronic instructions. In addition, the various embodiments may be embodied in an electrical, optical, acoustical, or other form of propagated signal (e.g., carrier waves, infrared signals, digital signals, etc.), or wire line, wireless, or other communications/telemetry medium.
Computer program code for carrying out operations of the embodiments may be written in any combination of one or more programming languages. The program code may execute entirely on a user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN), a personal area network (PAN), or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
The storage device 38 may be any suitable storage device for storing data. The data collection unit 31 may collect, gather, manipulate, and/or categorize the data 60, 60a about the valve system 10. If using multiple strain gauges 50, each strain gauge 50 may contribute metrics or data 60, 60a which lead to a partial view of the underlying valve system 10 condition regarding the torque 60a experienced by the valve system 10. When combining the metrics 60,60a of a group of strain gauges 50 using real-time analytical techniques, an accurate evaluation of the valve 10a and actuator 70 or valve system 10 condition may be obtained. The data collection unit 31 may manipulate the collected data 60,60a into a format that allows the operator and/or the microprocessor 30 to take appropriate action during the operations. The risk assessment or analysis unit 32 may receive the categorized data 60,60a from the data collection unit 31 in order to determine if there is any present or future risk likely at the valve system 10 and may make predictions not limited to remaining valve system 10 life, remaining actuator 70 life, and potential trend of torque values 60a. The risk may be based on real time events that are taking place in the operations and/or based on predictive events that are likely to occur. The risk assessment or analysis unit 33 may classify the risks for the microprocessor 30 and/or the operator (such as whether to create an alert or alarm). By way of example only, the operator can input a threshold limit or range of the strain or stress sensed by the strain gauge(s) 50 (or a threshold limit or range of the torque values 60a, i.e. a threshold torque value), which, if the sensed metrics 60,60a are above the input or desired threshold, can be identified by the microprocessor 30 via the risk assessment analysis unit 32 or other components of the microprocessor 30 (such as the comparative analysis unit 34) and optionally issue an alarm via notification unit 35.
The historical data unit 33 may categorize the historical data, measurements, metrics or calculated values 60,60a collected by the data collection unit 31. The comparative analysis unit 34 may compare the data, measurements or metrics 60,60a collected by the data collection unit 31, the classified risks, and/or the historical data 60,60a in order to determine a course of action for the operator and/or microprocessor 30. The comparative analysis unit 34 may further determine if the sensed metrics, data or measurements 60,60a is within a predetermined set of parameter values as previously input into the microprocessor 30. The valve 10a parameters for the strain gauge 50, may be any suitable parameters set by the manufacturer, operator, the client, or any other suitable source or algorithm. The comparative analysis unit 34 may make a determination of how serious the risk is based on the data 60,60a sensed, collected and/or calculated. The comparative analysis unit 34 may relay information to the notification unit 35 so that the notification unit 35 may alert the operator and/or take action. The notification unit 35 may alert the operator or microprocessor 30 of the real time condition, and/or a predicted condition about the valve system 10. The notification unit 35 may include visual display interface(s), audible sounds or alarms, or automated response, and/or a combination thereof. The transceiver unit, transmitter and/or communication device 36 may be any suitable device configured to communicate, send and/or receive data to the microprocessor 30 (such as, by way of example, in certain exemplary embodiments, wires or cables 53 or wirelessly). The transceiver unit or communication device 36 may be located in the microprocessor 30, control box enclosure 51, or remotely at a separate location. The transceiver unit or communication device 36 may enable the microprocessor 30 to communicate with the strain gauge 50 or further computing units 30 outside of the valve system 10. The implementation unit 37 may be configured create and execute an implementation plan for remediation of the valve system 10 (visual and audible alerts or alarms to the operator of the process system, amongst others). In another example, the operator and/or the microprocessor 30 may update, determine or provide predictions as to the valve system 10 parameters, and/or data as operations are being performed. The operator and/or the microprocessor 30 could notify or update the historical data unit 33 of any conditions, or parameters, that need to be compared in the future. The data 60,60a created by the disclosed valve system 10 and microprocessor or computing unit 30 and the subsequent calculations are utilized to provide valve 10a health monitoring services to end-users which includes and is not limited to: visualizations of the data 60,60a and analytics on a web, online, or remote platform; alarm notifications that recommend the maintenance actions that should be performed based on the analytics of the valve 10a performance; and further the analytics as provided by the valve system 10 and microprocessor 30 enable efficient repair service for the valve system 10 by identifying the specific maintenance that is required to prevent unplanned downtime and achieve normal operations (by way of example, maintenance for critical valve components like the stem packing 14 including the gland retainer 20). The monitoring, visualization of and notifications for maintenance or repair as based on the data 60,60a may be stored, tracked, and analyzed over a period of time.
As depicted, the exemplary embodiments of the bracket 40 may include only or merely a bracket 40 and a strain gauge 50. An alternative exemplary embodiment of the bracket 40 further includes a microprocessor or computing unit 30, either in or on the bracket 40, or in a separate location connected by wires 53 or communicating with the strain gauge 50 wirelessly. Further alternative exemplary embodiments of the bracket 40 may also include a communication device 36, which may communicate to components of the valve system 10 and/or components external to the valve system 10 via wires 53 or wirelessly, and may be located in the enclosure 51 with the microprocessor 30, or located in separately from the valve 10a. A strain gauge connection board 52 is optional to include with any of these bracket 40 embodiments as discussed herein.
While butterfly valves have been illustrated as exemplary embodiments, any type of industrial, control or process valve may be implemented as the valve apparatus or system 10.
The disclosures and teachings of U.S. patent application Ser. No. 17/139,284 filed Dec. 31, 2020 and having as title ‘Valve with Load Cell’, and U.S. patent application Ser. No. 16/706,229 filed Dec. 6, 2019 as titled ‘Smart Valve Adaptor with Integrated Electronics’ are hereby incorporated by reference herein.
While the exemplary embodiments are described with reference to various implementations and exploitations, it will be understood that these exemplary embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible.
Plural instances may be provided for components, operations or structures described herein as a single instance. In general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter.
| Number | Date | Country | |
|---|---|---|---|
| 63123818 | Dec 2020 | US | |
| 62956774 | Jan 2020 | US | |
| 62776033 | Dec 2018 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17139284 | Dec 2020 | US |
| Child | 17547709 | US | |
| Parent | 16706229 | Dec 2019 | US |
| Child | 17139284 | US |
