Patent Description:
Process control systems, such as distributed or scalable process control systems like those used in chemical, petroleum or other processes, typically include one or more process controllers communicatively coupled to at least one host or user workstation and to one or more field devices via analog, digital, or combined analog/digital buses. The field devices, which may include, for example, control valves, valve positioners, switches, and transmitters (for example, temperature, pressure, and flow rate sensors), perform functions within the process such as opening or closing valves and measuring process parameters. The process controller receives signals indicative of process measurements made by the field devices and/or other information pertaining to the field devices, and uses this information to implement a control routine to generate control signals that are sent over the buses to the field devices to control the operation of the process. Information from each of the field devices and the controller is typically made available to one or more applications executed by the user workstation to enable operator personnel to perform any desired function regarding the process, such as viewing the current state of the process and/or modifying the operation of the process. In the event that a field device fails, the operational state of the entire process control system can be jeopardized.

<CIT> discloses a monitoring system for a valve device comprising a semiconductor single crystalline substrate including a bridged circuit and the bridged circuit comprising impurity-diffused resistors. The semiconductor single crystalline substrate is mounted to any of a valve device's valve stem, valve yoke, drive shaft, or elastic body disposed at the end of the drive shaft. Thrust and torque of the valve device are measured by the semiconductor single crystalline substrate and then the measured values are used for monitoring the valve device.

<CIT> discloses an adaptable self-powered sensor node and methods of operation providing real-time monitoring and management of node operation. The adaptable self-powered sensor node incorporates an adaptable generator and a radio transmitter to operate remotely without the need for power or communication wiring. Data analysis capabilities provide for maximizing information extracted from sensors and analysis and providing control or reporting information utilizing a strategy to minimize energy usage while reducing information entropy.

One aspect of the present invention is directed to a system for controlling a field device, for example, a valve, in a controlled process. The system includes a control valve assembly including a stem, an actuator, and a stem connector coupling the stem to the actuator, the stem connector configured to transmit a mechanical actuator output to an input of the control valve assembly. The system further includes a communication module integrated within the stem connector, and one or more sensors integrated within the stem connector and communicably coupled to the communication module, the one or more sensors configured to measure one or more parameters indicative of the health and/or remaining service life of the control valve assembly and/or one or more components of the control valve assembly, wherein the communication module is configured to transmit the measured one or more parameters to a controller via a communication link, and wherein the one or more sensors includes an acoustic emission sensor disposed near or against a flat end of the stem.

Another aspect of the disclosure (not encompassed by the wording of the claims but considered as useful for understanding the invention) is directed to a valve coupler including a first portion configured to couple to an actuator rod of an actuator, a second portion configured to couple to a movable component of a control valve, and one or more sensors measuring one or more parameters indicative of the health and/or remaining service life of the control valve assembly and/or one or more components of the control valve assembly.

A further aspect of the invention is directed to a method for measuring the health and/or remaining service life of a control valve assembly. The method includes measuring one or more parameters, and transmitting the measured one or more parameters to a module configured to collect and process the one or more parameters to determine the health and/or remaining service life of the control valve assembly and/or one or more components of the control valve assembly.

Referring now to <FIG>, an example process plant <NUM> in which a fault detection and isolation system may be implemented includes a number of control and maintenance systems interconnected together with supporting equipment via one or more communication networks. In particular, the process plant <NUM> includes one or more field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> in communication with a process controller <NUM>. The process controller <NUM> is communicably coupled to a data historian <NUM> and one or more user workstations <NUM>. The data historian <NUM> may be any desired type of data collection unit having any desired type of memory and any desired or known software, hardware, or firmware for storing data. Moreover, while the data historian <NUM> is illustrated as a separate device in <FIG>, it may instead or in addition be part of one of the workstations <NUM> or another computing device, such as a server. Each workstation <NUM> includes a user interface <NUM> to facilitate communication with the process system <NUM>. The user interface <NUM> may include a user interface module and one or more devices, such as a display screen, touch-screen, keyboard, and a mouse, for example.

The controller <NUM>, which may be, by way of example, a DeltaV™ controller sold by Emerson Process Management, is communicatively connected to the workstations <NUM> and to the data historian <NUM> via a communication network <NUM> that may be, for example, an internet or Ethernet connection. So configured, the controller <NUM> may monitor and/or control the field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, by delivering signals to and receiving signals from the field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and the workstations <NUM> to control the process control system. In additional detail, the process controller <NUM> of the process system <NUM> of the version depicted in <FIG> is connected via hardwired communication connections to the field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> via input/output (I/O) cards <NUM> and <NUM>. The field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> are illustrated as being communicatively connected to the controller <NUM> via a hardwired communication scheme, which may include the use of any desired hardware, software, and/or firmware to implement hardwired communications, including, for example, standard <NUM>-<NUM> mA communications, and/or any communications using any smart communication protocol such as the FOUNDATION® Fieldbus communication protocol, the HART® communication protocol, etc..

The field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> may be any types of devices, such as sensors, control valve assemblies, transmitters, positioners, for example, while the I/O cards <NUM>, <NUM> may be any types of I/O devices conforming to any desired communication or controller protocol. In the embodiment illustrated in <FIG>, the field devices <NUM>, <NUM>, <NUM>, <NUM> are standard <NUM>-<NUM> mA devices that communicate over analog lines to the I/O card <NUM>, while the digital field devices <NUM>, <NUM>, <NUM>, <NUM> can be smart devices, such as HART® communicating devices and Fieldbus field devices that communicate over a digital bus to the I/O card <NUM> using Fieldbus protocol communications. Of course, the field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> may conform to any other desired standard(s) or protocols, including any standards or protocols developed in the future.

The process control system <NUM> depicted in <FIG> also includes a number of wireless field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> disposed in the plant to be monitored and/or controlled. The field device <NUM> is depicted as a control valve assembly including, for example, a control valve, while the field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM> are depicted as transmitters, for example, process variable sensors. Wireless communications may be established between the controller <NUM> and the field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> using any desired wireless communication equipment, including hardware, software, firmware, or any combination thereof now known or later developed. In the version illustrated in <FIG>, an antenna <NUM> is coupled to the control valve assembly <NUM> to perform wireless communications for the control valve assembly <NUM>. Likewise, an antenna <NUM> is coupled to and is dedicated to facilitate wireless communications for the transmitter <NUM>, while a wireless router or other module <NUM> having an antenna <NUM> is coupled to collectively coordinate wireless communications for the transmitters <NUM>, <NUM>, <NUM>, <NUM>. The field devices or associated hardware <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> may implement protocol stack operations used by an appropriate wireless communication protocol to receive, decode, route, encode, and send wireless signals via the antennas <NUM>, <NUM>, <NUM> to implement wireless communications between the process controller <NUM> and the control valve assembly <NUM> and the transmitters <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. The transmitters <NUM>, <NUM>, <NUM>, <NUM>, <NUM> may constitute the sole link between various process sensors (transmitters) and the process controller <NUM> and, as such, are relied upon to send accurate signals to the controller <NUM> to ensure that process performance is not compromised. The transmitters <NUM>, <NUM>, <NUM>, <NUM>, <NUM> are often referred to as process variable transmitters (PVTs) and may play a significant role in the control of the overall control process.

One or more I/O devices <NUM>, <NUM> are operatively coupled to the process controller <NUM>. Each I/O device is connected to a respective antenna <NUM>, <NUM> and the I/O devices and antennas operate as transmitters/receivers to perform wireless communications with the wireless field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> via one or more wireless communication networks. The wireless communications with the field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> may be performed using one or more known wireless communication protocols, such as the WirelessHART® protocol, the Ember protocol, a WiFi protocol, an IEEE wireless standard, etc. Still further, the I/O devices <NUM>, <NUM> may implement protocol stack operations used by these communication protocols to receive, decode, route, encode, and send wireless signals via the antennas <NUM>, <NUM> to implement wireless communications between the controller <NUM> and the control valve assembly <NUM> and the transmitters <NUM>, <NUM>, <NUM>, <NUM>, <NUM>.

The control valve assembly <NUM> may receive control signals from the controller <NUM> to effect physical parameters, for example, flow, within the overall process. In addition, the control valve assembly <NUM> may provide measurements made by sensors within the control valve assembly <NUM> or may provide other data generated by or computed by the control valve assembly <NUM> to the controller <NUM> as part of its operation. As illustrated in <FIG>, the controller <NUM> conventionally includes a processor <NUM> that implements or oversees one or more process control and/or diagnostic routines <NUM> (or any module, block, or sub-routine thereof) stored in a memory <NUM>. The process control and/or diagnostic routines <NUM> stored in the memory <NUM> may include or be associated with control loops being implemented within the process plant. Generally speaking, and as is generally known, the process controller <NUM> executes one or more control routines <NUM> and communicates with the field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, the user workstations <NUM>, and the data historian <NUM> to control a process in any desired manner.

The health and operability of the field devices <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and ultimately the performance of the process system, may be adversely affected by several factors. For a field device such as a control valve assembly, for example, flow and/or trim looseness may occur due to the valve leaking, straining, and/or vibrating. To monitor the health and/or remaining service life of the control valve assembly and/or one or more components of the control valve assembly, one or more control valve parameters associated with one or more of the adverse factors may be monitored and/or measured. <FIG> depicts one embodiment of a coupler <NUM> utilized to facilitate the monitoring and/or measuring of the control valve health parameters. The coupler <NUM> couples an actuator rod <NUM> to a valve stem or valve shaft <NUM>. That is, depending upon the type of valve being monitored, the coupler <NUM> couples the actuator rod <NUM> with a valve stem of a linear valve type such as a sliding stem valve type or a globe style valve type; and for a rotary valve type, the coupler <NUM> couples the actuator rod <NUM> to a valve shaft.

Valve parameters associated with one or more factors that adversely affect control valve performance, include, and are not limited to, stem force (in a sliding stem or globe style valve) and dynamic torque (in a rotary valve); through-valve leakage; strain; vibration due to flow and/or trim component looseness; and vibration or poor motion control caused by looseness or damage in the drive train components. Sensors included within or near the coupler <NUM> may collect and/or transmit information corresponding to one or more such parameters and provide the information to, for example, a control processor <NUM> similar to controller <NUM> in <FIG>, for processing and/or alerting asset management and/or control personnel. The sensors are communicably coupled to a communication module <NUM> wherein information received from the sensors may be stored, analyzed, and/or transmitted via wired or wireless communication to the controller <NUM> or some other processor based device that is either local or remote. Some example sensors that may be integrated within and/or near the coupler <NUM> and utilized by the controller and/or communication module <NUM> to monitor the health and/or remaining service life of the control valve assembly and/or one or more components of the control valve assembly include a vibration sensor <NUM>, an acoustic emission sensor <NUM>, and/or a stem force or shaft torque sensor <NUM>.

The vibration sensor <NUM> may facilitate the diagnosing of the health and/or remaining service life of the control valve assembly and/or one or more components of the control valve assembly, and/or operating environment by providing a signal to the controller that includes information relating to flow induced vibration and looseness of the valve's internal components. In one embodiment, the vibration sensor <NUM> may be an accelerometer integrated into the coupler <NUM> and communicably connected to the controller <NUM> of the process plant.

The acoustic emission sensor <NUM> facilitates the diagnosing of the health and/or remaining service life of the control valve assembly and/or one or more components of the control valve assembly, and/or operating environment by providing a signal including information related to monitoring valve leakage, stem and/or shaft integrity, other drivetrain component integrity and internal trim condition. In one embodiment, the acoustic emission sensor <NUM> is positioned near or against a flat end of the valve stem or valve shaft <NUM>. In this configuration, the valve stem/shaft <NUM> and the connected trim element will act as a wave guide for acoustic emissions and facilitate the transmission of the desired signal out of the generally inaccessible cavity of the valve body.

The stem force or shaft torque sensor <NUM> facilitates the diagnosing of the health and/or remaining service life of the control valve assembly and/or one or more components of the control valve assembly, and/or operating environment by enabling measurement of the stem force or shaft torque. Readily available measurements that may be collected at relatively low acquisition levels include, at least, valve seat force, valve seat torque, and friction measurements. Additional diagnostic measurements that may be acquired using higher sample rates include dynamic stem force related to flow stability within the control valve.

Empirical analyses of information attained from one or more sensors <NUM>, <NUM>, <NUM> reveals that dynamic stem force may be a measure of the flow stability within the valve body. For example, dynamic stem force has been measured on a <NUM>-inch valve known to have unstable behavior in some applications. The measured dynamic stem force, as a function of inlet pressure, stem travel, cage type, plug type, and pressure drop ratio; demonstrates a variable presence of instability. The instability is a consequence of pressure on the exposed surfaces of the valve plug.

<FIG> is a graph illustrating the measured stem force for a <NUM>-inch valve having an <NUM>-inch port and long neck with up to <NUM> inches of stem travel. The valve was configured in a flow-up arrangement with <NUM> pound-per-square inch (psi) inlet pressure. The total test time was <NUM> seconds and measurements for the first <NUM> seconds of the test are shown in the graph.

<FIG> is a graph displaying histograms of the force time signals depicted in <FIG>, but over the full <NUM> second test. The histogram is used to determine the scaled probability that, for any time during the test, the stem force will have a specified force value. The histograms shown in <FIG> illustrate that at full stem travel (for example, <NUM>-inches), the force varies widely over a large range and there are two general force values where there are peaks in the probability. For <NUM>% stem travel (<NUM>-inches) and <NUM>% stem travel (<NUM>-inches), the force is stable, although at different mean values.

In <FIG>, additional results attained for <NUM> psi inlet pressure are shown for changes in stem travel and pressure drop ratio. The results show two main stable forces, a first main stable force at approximately -<NUM> to -<NUM> lbf. and a second main stable force at approximately -<NUM> to -<NUM> Ibf. In instances of <NUM>% stem travel (<NUM> inches) and <NUM>% stem travel (<NUM> inches), the force is stable; fluctuating near the mean and at the two different points. For the instance of full <NUM>% stem travel (<NUM> inches) and a pressure drop ratio of <NUM>, the force is centered on the first main stable point, but also includes a large amount of variation compared to the lesser stem travel distances. Then, at the higher pressure drop ratios (<NUM>, <NUM>, and <NUM>), the stem force changes between the two main stable points and has a much wider range of variation. These results illustrate how the static force, as well as stability, are linked and are a function of the valve travel distance (or length) and the pressure drop ratio. In particular, <FIG> shows the stem force histogram data shown in <FIG> with a pressure drop ratio of <NUM> and an inlet pressure of <NUM> psi along with data at inlet pressures of <NUM> psi and <NUM> psi and a pressure drop ratio of <NUM>. The results in <FIG> show that there is a similar pattern of stable and unstable stem force conditions as stem travel is changed at each inlet pressure valve.

Measuring the dynamic stem force requires a means to create a time signal that represents the stem force. A digital form of that time signal is then acquired prior to processing of the time signal. The measurement of the stem force can be accomplished in several ways. For example, one direct technique is to include a force sensor within the valve stem. Another technique includes measuring the strain on the valve stem or actuator rod. Yet another technique includes measuring the pressure difference across the actuator diaphragm or piston. Any measured pressure difference is related to the stem force while also including the dynamics of the gas volumes where the pressure is being measured.

In one example of measuring the stem force by using the pressure difference across the actuator, the pressure on each side of the actuator piston was measured on a field valve known to buffet. A standard field system was used to monitor the actuator, data was measured, a pressure difference was calculated, and a histogram was calculated. The resulting histogram is illustrated in <FIG> and shows two stable points similarly observed in the lab stem force measurements. Thus, it is likely that the dynamic stem force measured from the pressure difference across the actuator diaphragm or piston may be used to evaluate the average stem force, as well as evaluate flow stability in the valve.

One embodiment of the present invention directed to measuring the health and/or remaining service life of a control valve assembly and/or one or more components of the control valve assembly is shown in <FIG>. A valve coupler <NUM> for a sliding stem valve assembly, which is partially illustrated in the figure, couples a valve stem <NUM> and an actuator rod <NUM>. The coupler <NUM> may incorporate one or more of the example type sensors described above into a stem connector that transmits actuator output to control the valve stem <NUM>. The coupler <NUM>, which may include a first portion and a second portion, is fixedly attached about an end of the actuator rod <NUM> and about an end of the valve stem <NUM>. The first and second portions of the coupler <NUM> may be affixed to the actuator rod <NUM> and the valve stem <NUM> by a bolt, clamp, or any other affixing mechanism <NUM> capable of operatively attaching the coupler <NUM> to the actuator rod <NUM> and the valve stem <NUM>. Integrated about the interior and/or exterior of the coupler <NUM> is a communication module <NUM> that is communicably coupled to one or more sensors used to monitoring the health, remaining service life, and/or operating environment of the valve assembly and/or one or more components of the valve assembly. The communication module <NUM> may be wired or wirelessly coupled to the control system shown in <FIG>.

One type of sensor that may be integrated within the coupler <NUM> is a stem force sensor <NUM>. The stem force sensor <NUM> may include a piezoelectric force sensor or a strain gauge and is capable of attaining information related to the health and/or remaining service life of the valve assembly and/or one or more components of the valve assembly. Some measurements may include a valve seat force and friction measurements that may be collected at relatively lower acquisition speeds. If higher speed sample rates are used, additional monitoring, measuring and/or diagnosing may be capable, such as the ability to measure dynamic stem force, which may then be related to flow stability within the control valve.

In another embodiment, the piezoelectric sensor used as a stem force sensor in measuring the stem force may be utilized to harvest energy. Application of the energy harvesting may be more applicable to valves that frequently modulate or change positions because the harvested energy would be attained from reversals in the force direction. Energy may also be harvested from the operating environment of the valve assembly such as vibration or heat. The harvested energy may be used to charge batteries used for diagnostic and/or prognostic sensors or to power low level functions within the control valve assembly.

Additional types of sensors that may be integrated within the coupler <NUM> include a vibration sensor <NUM> and an acoustic emission sensor <NUM>. In one embodiment, the vibration sensor <NUM> includes an accelerometer, which may provide information related to flow induced vibration and looseness of the internal valve components. The acoustic emission sensor <NUM> may monitor through-valve leakage, stem shaft integrity, and internal trim condition. The acoustic emission sensor <NUM> may be located proximate the flat end of the valve stem <NUM>. When installed in this configuration, the valve stem and connected trim element act as a wave guide for the acoustic emissions and facilitate the transmitting of the desired signal out of the generally inaccessible cavity of the valve body.

Another embodiment of the present invention directed to measuring the health and/or remaining service life of a control valve assembly and/or one or more components of the control valve assembly is shown in <FIG>. A valve coupler <NUM> for a rotary style valve, which is partially illustrated in the figure, couples an actuator rod <NUM> to a valve shaft <NUM>. The coupler <NUM> may incorporate one or more of the example type sensors described above into a lever arm that transmits actuator output to control the valve shaft <NUM>. The coupler <NUM>, which may include a first portion and a second portion, is fixedly attached about an end of the actuator rod <NUM> and about an end of the valve shaft <NUM>. The first and second portions of the coupler <NUM> may be affixed to the actuator rod <NUM> and the valve shaft <NUM> by a bolt, clamp, or any other affixing mechanism <NUM> capable of operatively attaching the coupler <NUM> to the actuator rod <NUM> and the valve shaft <NUM>. Integrated about the interior and/or exterior of the coupler <NUM> is a communication module <NUM> that is communicably coupled to one or more sensors used to monitor the health, remaining service life, and/or operating environment of the valve assembly and/or one or more components of the valve assembly. The communication module <NUM> may be wired or wirelessly coupled to the control system shown in <FIG>.

One type of sensor that may be integrated within the coupler <NUM> is a shaft torque sensor <NUM>. The shaft torque sensor <NUM> may include a piezoelectric torque sensor or a strain gauge and is capable of attaining information related to the health and/or remaining service life of the valve assembly and/or one or more components of the valve assembly. Some measurements may include a valve seat torque and friction measurements that may be collected at relatively lower acquisition speeds. If higher speed sample rates are used, additional monitoring, measuring, and/or diagnosing may be capable, such as the ability to measure dynamic stem torque, which may then be related to flow stability within the control valve.

In another embodiment, the piezoelectric sensor used as a shaft torque sensor for measuring the shaft torque may be utilized to harvest energy. Application of the energy harvesting may be more applicable to valves that frequently modulate or change positions because the harvested energy would be attained from reversals in the force direction. Energy may also be harvested from the operating environment of the valve assembly, such as vibration or heat. The harvested energy may be used to charge batteries used for diagnostic and/or prognostic sensors or to power low level functions within the control valve assembly.

Additional types of sensors that may be integrated within the coupler <NUM> include a vibration sensor <NUM> and an acoustic emission sensor <NUM>. In one embodiment, the vibration sensor <NUM> includes an accelerometer, which may provide information related to flow induced vibration and looseness of the internal valve components. The acoustic emission sensor <NUM> may monitor through-valve leakage, stem shaft integrity, and internal trim condition. The acoustic emission sensor <NUM> may be located proximate the flat end of the valve shaft <NUM>. When installed in this configuration, the rotary valve shaft <NUM> and connected trim element act as a wave guide for the acoustic emissions and facilitate the transmitting of the desired signal out of the generally inaccessible cavity of the valve body.

A flow diagram <NUM> of an example method for measuring the health and/or remaining service life of a field device and/or one or more components of the field device, for example, a control valve assembly, implemented in a process system depicted in <FIG> is shown in <FIG>. The method may be integrated into one or more modules stored in the memory and is capable of being executed on one or more processors of the controller or the coupler of the control valve assembly. One or more valve parameters associated with the health, expected life, and/or operating environment of the control valve assembly are measured (block <NUM>). One or more wired or wireless sensors may be utilized to facilitate measuring of the valve parameters, including, at least: a stem force sensor, a shaft torque sensor, an acoustic sensor, a valve seat force sensor, a valve seat torque sensor, and a vibration sensor. The valve parameter information attained by the one or more sensors may be collected into a memory device and is ultimately transmitted to the controller (block <NUM>). The controller processes one or more of the received valve parameters and determines the health and/or remaining service life of the control valve assembly and/or one or more components of the valve assembly (block <NUM>). The determination of the health and/or remaining service life of the control valve assembly and/or one or more components of the valve assembly may include calculating or equating a score or indicator corresponding to the determined health of the valve and/or valve component. The health and/or remaining service life score or indicator of the valve and/or valve component may be output to a device capable of storing the score or indicator and/or emitting a signal, reflecting the health and/or remaining service life of the control valve assembly and/or one or more components of the control valve assembly (block <NUM>). The emitted signal may include an aural and/or visual component.

In another embodiment of the invention, the method may include harvesting energy from the valve parameter component that is being monitored, sensed, and/or measured. In one configuration, a piezoelectric sensor used as a sensor for stem force or shaft torque measurement may facilitate the harvesting of energy from the valve. Energy may also be harvested from the operating environment of the valve assembly, such as vibration or heat. The harvested energy may be used to power low level functions within the control valve assembly and/or charge batteries used by the sensors.

It is apparent from the description above that the operating environment, health, remaining service life, and operability of a field device and/or component thereof, such as a control valve assembly and/or one or more components of the control valve assembly, may be effectively measured by incorporating one or more sensors with a coupler to monitor valve performance, diagnose valve health, and/or predict the remaining service life of the valve assembly and/or one or more components of the valve assembly as described herein.

Although certain example methods, apparatus, and articles of manufacture have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus, and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.

Although individual operations of one or more methods are illustrated and described as separate operations, one or more of the individual operations may be performed concurrently, and nothing requires that the operations be performed in the order illustrated unless specifically described as such.

Additionally, certain embodiments are described herein as including logic or a number of routines, subroutines, applications, or instructions. These may constitute either software (e.g., code embodied on a machine-readable medium) or hardware. In hardware, the routines, etc., are tangible units capable of performing certain operations and may be configured or arranged in a certain manner. In example embodiments, one or more computer systems (e.g., a standalone client or server computer system) or one or more hardware modules of a computer system (e.g., a processor or a group of processors) may be configured by software (e.g., an application or application portion) as a hardware module that operates to perform certain operations as described herein.

Accordingly, the term "hardware module" should be understood to encompass a tangible entity, be that an entity that is physically constructed, permanently configured (e.g., hardwired), or temporarily configured (e.g., programmed) to operate in a certain manner or to perform certain operations described herein. Considering embodiments in which hardware modules are temporarily configured (e.g., programmed), each of the hardware modules need not be configured or instantiated at any one instance in time. For example, where the hardware modules comprise a general-purpose processor configured using software, the general-purpose processor may be configured as respective different hardware modules at different times. Software may accordingly configure a processor, for example, to constitute a particular hardware module at one instance of time and to constitute a different hardware module at a different instance of time.

Where multiple of such hardware modules exist contemporaneously, communications may be achieved through signal transmission (e.g., over appropriate circuits and buses) that connect the hardware modules. For example, one hardware module may perform an operation and store the output of that operation in a memory product to which it is communicatively coupled. A further hardware module may then, at a later time, access the memory product to retrieve and process the stored output. Hardware modules may also initiate communications with input or output products, and can operate on a resource (e.g., a collection of information).

Similarly, the methods or routines described herein may be at least partially processor-implemented. For example, at least some of the operations of a method may be performed by one or more processors or processor-implemented hardware modules. The performance of particular operations may be distributed among the one or more processors, not only residing within a single machine, but deployed across a number of machines. In some example embodiments, the processor or processors may be located in a single location (e.g., within a home environment, an office environment, a mobile platform, or as a server farm), while in other embodiments the processors may be distributed across a number of locations.

Claim 1:
A system comprising:
a control valve assembly (<NUM>) including a stem (<NUM>);
an actuator;
a stem connector (<NUM>) coupling the stem to the actuator, the stem connector configured to transmit a mechanical actuator output to an input of the control valve assembly;
a communication module (<NUM>) integrated within the stem connector (<NUM>); and
one or more sensors (<NUM>, <NUM>) integrated within the stem connector and communicably coupled to the communication module, the one or more sensors configured to measure one or more parameters indicative of the health and/or remaining service life of the control valve assembly and/or one or more components of the control valve assembly,
wherein the communication module is configured to transmit the measured one or more parameters to a controller (<NUM>) via a communication link, and
wherein the one or more sensors (<NUM>, <NUM>) includes an acoustic emission sensor (<NUM>) disposed near or against a flat end of the stem.