WO2020159680A1

WO2020159680A1 - Monitoring and reporting operational performance of machinery

Info

Publication number: WO2020159680A1
Application number: PCT/US2020/012722
Authority: WO
Inventors: Christopher J. VANDER NEUT
Original assignee: Exxonmobil Research And Engineering Company
Priority date: 2019-01-31
Filing date: 2020-01-08
Publication date: 2020-08-06

Abstract

A method of monitoring operational performance of machinery includes obtaining samples of two or more of oil, grease, and a filter from the machinery, and receiving and analyzing the samples at a testing facility for a presence of one or more standard indicators of fluid and filter performance and thereby obtaining testing data. The testing data is processed with a computer system to obtain test results, and a report is generated with the computer system based on the test results, wherein the report provides a current health of the machinery in view of a condition of the two or more of the oil, the grease, and the filter.

Description

MONITORING AND REPORTING

OPERATIONAL PERFORMANCE OT MACHINERY

BACKGROUND

[0001] A variety of industries and applications employ machines and equipment that require lubrication and filtration means to ensure proper operation and prolonged useful life of the equipment. Mechanical problems with machinery relying on lubrication and filtration tend to be insidious. There is often only a minor degradation of a lubricating fluid at the beginning, but continued operation of the machine can result in heat generation and accelerated degradation of the lubricating fluids. Left untreated, vital component parts of the machinery can fail, thus leading to substantial machinery damage. Unfortunately, many machinery problems are only recognized after irreparable destruction has transpired. Accordingly, early diagnosis and cure of such problems can be extremely beneficial in reducing machine downtime, repair cost, inconvenience, and even hazardous situations.

[0002] Operators and owners of machinery attempt to monitor the condition of machinery through varied channels, and often through multiple test facilities and data streams. Such monitoring is commonly achieved through analyzing used oil, and operation of the machinery is often adjusted based on the tested condition of the oil. In rare cases, machinery operators may also evaluate greases used in the equipment, or possibly analyze a used filter on an as-needed or one- off basis. Tests of the oil, the grease, and the filter, however, are typically run at different testing facilities that provide different data streams with divergent recommendations directed solely to the condition of the media (i.e., the lubricants and the filter). Consequently, the machinery operators are provided with an incomplete picture of the overall condition of the equipment.

[0003] What is needed is a system and method that provides a combined analysis of machinery oil, grease, and filters, to provide a single indicator of equipment performance and health.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The following figures are included to illustrate certain aspects of the present disclosure, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure.

[0005] FIG. 1 is a schematic diagram of an example system of monitoring and reporting operational performance of machinery, according to one or more embodiments.

[0006] FIG. 2 is a schematic flowchart of an example method of monitoring and reporting operational performance of machinery, according to embodiments of the present disclosure.

[0007] FIG. 3 illustrates an example embodiment of the computer system of FIG. 1. SUMMARY

[0008] According to one aspect, the present disclosure provides a method of monitoring operational performance of machinery comprising the obtaining of samples of two or more of oil, grease, and a filter from the machinery; receiving and analyzing the samples at a testing facility for a presence of one or more standard indicators of fluid and filter performance and thereby obtaining testing data; processing the testing data with a computer system to obtain test results; and generating a report with the computer system based on the test results, wherein the report provides a current health of the machinery in view of a condition of the two or more of the oil, the grease, and the filter.

DETAILED DESCRIPTION

[0009] The present disclosure is related to maintaining machinery and, more particularly, to systems and methods of providing a machine fluid performance indicator from the combined analysis of used oil, used grease, and used filters associated with machinery.

[0010] The equipment that a user maintains is the heart of any operation. In many facilities, several machines operate in concert and are often integral components of large interdependent processes. Effective lubricant and filter analysis on such machines can be used to determine the causes of various machinery problems that may be encountered. Effective lubricant and filter analysis programs can be useful in diagnosing machine problems and trends in order to determine machine malfunctions that can be corrected early, through minor maintenance and with minimal cost, before the malfunction becomes progressively worse. The ultimate goal of monitoring machinery is to optimize lubricant and filter life, optimize machinery life, and minimize maintenance costs.

[0011] The embodiments of the present disclosure provide a triangulated approach to assessing the status (health) of equipment based on fluid (lubricant) and filter sampling. Currently, most machine analyses rely almost entirely on used oil analysis, without tying in grease and filter analyses on a regular basis. Additionally, current machinery analyses typically focus on the lubricant as the subject of investigation, rather than the machine itself. The inventive concepts discussed herein shift the focus of analysis to the machine and the user (i.e., the customer or machine owner), thus providing a better representation of the current health of the machinery. The embodiments described herein may provide an early warning system that helps avoid major maintenance work and premature machinery overhauls or failures. Users may be provided with a performance indicator that conveys the current health of the machinery, and a recommendation may be simultaneously given on how to evade or circumvent foreseeable machinery problems based on the data results. [0012] Accordingly, the systems and methods provided herein describe a process by which a user (machinery operator or owner) can obtain a higher level of insight into the status (health) of machinery by testing used oil, used grease, and used filters at a common test facility (or multiple facilities working in concert), and combining the corresponding test results into a single report focused on the machine. The data streams are harnessed together and reported back to the user in a logical fashion, where the machine is the focus rather than any individual fluid (oil or grease) or filter. Moreover, the report may include the performance indicator specific to the machine that may represent to the user potential issues with the machinery identified through the combined analysis. Suitable recommendations related to the machinery may then be suggested to avoid further (or any) damage thereto.

[0013] FIG. 1 is a schematic diagram of an example system 100 of monitoring and reporting operational performance of machinery, according to one or more embodiments. As illustrated, the system 100 includes one or more pieces of equipment or machinery 102 that will be assessed. The machinery 102 may be owned or otherwise operable by a user, alternately referred to as a “customer.” In some embodiments, the machinery 102 may comprise a single piece of equipment. In other embodiments, however, the machinery 102 may comprise a plurality of pieces of equipment. In such embodiments, the several pieces of equipment of the machinery 102 may operate in concert to support a larger overall process, or may otherwise operate independently.

[0014] The machinery 102 may include any type of machine or equipment that uses or otherwise relies on the use of a lubricant, such as oil 104a and/or grease 104b, and one or more filters 104b used to filter a fluid and thereby promote prolonged operation of the equipment. Examples of the machinery 102 include, but are not limited to, automotive machinery (e.g., personal vehicles, fleet vehicles, autonomous vehicles, etc.), airplanes, boats, generators, industrial manufacturing equipment (e.g., pharmaceutical, medical products, food products, plastics manufacturing, etc.), power generation equipment (e.g., stationary engines, wind turbines, gas or steam turbines, etc.), construction equipment (e.g., cranes, lifts, etc.), mining and excavation equipment (e.g., haul trucks, excavators, etc.), agricultural equipment (e.g., tractors, etc.), processing equipment (e.g., presses, crushers, grinders, feeders, paper processing machines, material shredders, etc.), pumps, motors, gear boxes, or any combination thereof.

[0015] The oil 104a and the grease 104b used in the machinery 102 may comprise any oil and any grease suitable for proper operation of the particular machinery 102 and capable of being analyzed. Those skilled in the art will appreciate that there are no limits to the types or compositions of the oil 104a and the grease 104b that may be used in the machinery 102. Moreover, some machinery 102 may employ multiple types of oils and/or greases on the same piece of equipment but in different locations (e.g., an automobile that uses engine oil, transmission oil, etc.)

[0016] The filter(s) 104c used in the machinery 102 may comprise any type of fluid filter capable of being analyzed and suitable for use with any of the examples of the machinery 102 mentioned herein. In some embodiments, for example, the filter 104c may comprise an oil filter. In other embodiments, however, the filter 104c may comprise a fuel filter. In yet other embodiments, the filter 104c may comprise an air filter, etc. In even further embodiments, the machinery 102 may employ two or more filters of any of the foregoing examples.

[0017] The system 100 may further include samples 106 of two or more of the oil(s) 104a, the grease(s) 104b, and the filter(s) 104c extracted from the machinery 102. The samples 106 may be obtained from the machinery 102 by any known means or processes commonly used to obtain oil, grease, and/or filter samples for analysis. For the oil 104a and the grease 104b, for example, a portion of the oil 104a and the grease 104b may be captured and sealed for transport. For the filter 104c, the entire filter structure may be removed from the machinery 102 and replaced with a new filter, and the extracted filter 104c may be sealed for transport.

[0018] In some embodiments, the samples 106 of one or more of the oil, the grease, and the filter 104a-c may be extracted (obtained) from the machinery 102 at predetermined intervals. In such embodiments, one or more samples 106 of the oil, the grease, and the filter 104a-c be obtained based on a predetermined schedule in accordance with appropriate sampling times for the particular medium. For instance, oils and greases may be sampled at different times and more often than a filter would be sampled. Sampling times may also depend on the type of lubricant used. More specifically, a synthetic oil might be sampled at larger (longer) intervals in contrast to a non synthetic oil.

[0019] In other embodiments, however, the samples 106 of the oil, the grease, and the filter 104a-c may be extracted (obtained) from the machinery 102 randomly and otherwise at any given time when the user simply desires to conduct analysis on the media. In such embodiments, samples 106 of two or more of the oil, the grease, and the filter 104a-c may be obtained simultaneously for analysis.

[0020] The system 100 may further include a testing facility 108 that receives and analyzes the extracted samples 106. In some embodiments, the testing facility 108 may comprise a single facility capable of appropriately analyzing all samples 106 of the oil, the grease, and the filter 104a- c. In other embodiments, however, the testing facility 108 may comprise two or more facilities capable of suitably analyzing the oil, the grease, and the filter 104a-c. Example testing facilities 108 include, but are not limited to, MOBIL SERV™ lubricant analysis facilities and ALS oil analysis and testing facilities. In at least one embodiment, the testing facility may be located onsite and otherwise at a user’s (machinery operator or owner) site.

[0021] The testing facility 108 may be configured to analyze the extracted samples 106 for the presence one or more standard indicators (alternately referred to as“criterion”) of fluid and filter performance. In some embodiments, the standard indicators may be related to the specific application in which the machinery 102 operates. For example, standard indicators found (detected) in engine oil would be different from standard indicators found in oil used in a hydraulic system.

[0022] Example standard indicators for the oil 104a include, but are not limited to, metals, fuel dilution, viscosity, oxidation, nitration, particle count, total base number (TBN), acidity, glycol, soot, contamination, and water detection, or any combination thereof. Example standard indicators for the grease 104b include, but are not limited to, penetration, viscosity, wear metals, consistency, contamination, oxidation, or any combination thereof. Example standard indicators for the filter 104c include, but are not limited to, metal particulates, non-metal particulates, filter media degradation, particle counts and characterization, or any combination thereof.

[0023] The testing facility 108 (whether singular or plural) may be in communication with a computer system 110 programmed to receive testing data from the testing facility 108. The computer system 110 may include one or more processors used to process the testing data and one or more databases to store past and present test results. Based on the computed test results, the computer system 110 may also be programmed and otherwise configured to generate a report 112 indicative of the current status (health) of the machinery 102. The report 112 may be delivered and otherwise provided to the user in any form suitable for apprising the user of the details of the report 112. In some embodiments, for example, the report 112 may be provided to the user as a hard copy (e.g., a printout), but could alternatively be provided as a digital copy (e.g., an email, a text, a website-based informative, etc.), or a digital alert from the lab into the machinery control system, without departing from the scope of the disclosure.

[0024] In some embodiments, the report 112 may provide individualized test results for each of the oil 104a, the grease 104b, and the filter 104c. In such embodiments, the user may be apprised of the individual impact each medium may be currently having on the condition of the machinery 102. As an example, if the test results for the oil 104a shows low viscosity, this may lead to increased wear due to a poor film thickness between metal elements in the machinery 102. This increased wear may then lead to higher metal counts in the filter 104c, as well as increased metal in the oil 104a. Each of these conditions individually represent suboptimal performance for each medium, and when reviewed together in concert, the user gains a more holistic and insightful interpretation of their overall machine condition. In such a case, an individualized result for the oil 104a would present the user with an opportunity to improve the condition of the oil 104a or change the oil 104a to prevent the progression of a potential issue in the machinery 102.

[0025] In other embodiments, or in addition thereto, the computer system 110 may be configured and otherwise programmed to combine (aggregate) the test results of two or more of the oil, the grease, and the filter 104a-c, and the report 112 may provide an overall machine performance indicator corresponding to the status (health) of the machinery 102 based on the combined results. The performance indicator may be presented or otherwise conveyed to the user in a manner where the machinery 102 is the focus, rather than individual assessments of the oil 104a, the grease 104b, and/or the filter 104c. Consequently, the report 112 and the associated performance indicator may provide the user insight into the condition of the machinery 102, which would otherwise not be possible by analyzing the used oil, grease, and filter 104a-c individually and unrelated.

[0026] In some embodiments, the performance indicator may be based solely on the current analysis of two or more of the oil, the grease, and the filter 104a-c. In such embodiments, the report 112 may provide the user with a real-time snapshot assessment of the machinery 102 at a single point in time.

[0027] In other embodiments, however, the report 112 may be able to provide the user with a historical analysis of the machinery 102. More specifically, the computer system 110 may be configured and otherwise programmed to query a database or library that includes historical testing data corresponding to the machinery 102. For instance, the oil, the grease, and the filter 104a-c for the machinery 102 may have been previously tested, and the corresponding test results may have been stored in the library for access by the computer system 110. In such embodiments, the performance indicator provided in the report 112 may comprise a combination of the current and historical test results for each of the oil 104a, the grease 104b, and the filter 104c used in conjunction with the machinery 102. This may prove advantageous in apprising the user of historical trends corresponding to the operational performance of the machinery 102 and over a known time period. As will be appreciated, this may also allow a user to observe the historical operation of the machinery 102, which may help the user make intelligent decisions on how to effectively maintain the machinery 102 now and in the future, as well as to monitor and confirm whether changes to the system operation result in a positive change to the oil, grease, and filter 104a-c performance and the machinery 102 performance and condition over time.

[0028] The performance indicator may be presented to the user in the report 112 in a variety of formats or styles, without departing from the scope of the disclosure. In some embodiments, for example, the performance indicator may be presented as a numerical score. In such embodiments, a numerical score lying in the range of 81-100, for example, may indicate that no dangerous levels were detected during analysis and that the machinery 102 is operating in satisfactory condition. A numerical score of 61-80 may indicate that the machinery 102 is operating currently and historically in less than ideal condition and action may need to be taken. A numerical score of 41-60 may indicate that the machinery 102 is likely in need of repair, and a numerical score less than 40 may indicate that a major malfunction of the machinery 102 has occurred or is otherwise imminent, thus requiring immediate action to remedy the problem. As will be appreciated, a similar system may be implemented using letter grades A, B, C, D, etc. to convey the same meaning.

[0029] In other embodiments, the performance indicator may be presented graphically in the report 112. In such embodiments, the performance indicator may comprise, for example, an image such as a gauge or a generic machine, and the image may be color-coded to indicate the current condition of the machinery 102. A green color, for example, may indicate that no dangerous levels were detected and the machinery 102 is operating in satisfactory condition. A yellow color, however, may indicate a warning that the machinery 102 is operating in less than ideal conditions and that action may need to be taken. Lastly, a red color may indicate that a major malfunction of the machinery 102 has occurred or is otherwise imminent, thus requiring immediate action to remedy the problem. As will be appreciated, different colors or additional numbers of colors may also be used to graphically represent the performance indicator in the report 112 in varying gradations of severity and warning.

[0030] In at least one embodiment, the graphic included on the report 112 may have a similar form or design as the actual piece of machinery 102 under analysis. In such embodiments, it is further contemplated that the graphic of the machinery 102 may include individual smaller graphics corresponding to each of the oil 104a, the grease 104b, and the filter 104c, where each smaller graphic is super-imposed on the larger graphic where that associated medium would generally be located. Each smaller graphic may be color-coded based on the corresponding test results obtained at the testing facility 108. In one example, for instance, the color of the smaller graphics for the grease 104b and the filter 104c may be green, thus indicating that no dangerous levels were detected in the corresponding analysis undertaken at the testing facility 108. The color of the smaller graphic for the oil 104a, however, may be red, thus indicating a serious problem needing to be addressed with the machinery 102 as related to the oil 104a. Moreover, in such embodiments, the combined colors of the oil 104a, the grease 104b, and the filter 104c may dictate the color of the overall larger graphic of the machinery 102, thereby providing the user with a graphical representation of the overall health of the machinery 102.

[0031] In some embodiments, the user may be provided with a recommendation 114 based on the results compiled or otherwise presented in the report 112. In at least one embodiment, the recommendation 114 may be provided by a skilled technician 116, such as a field engineer who has application expertise related to the particular machinery 102. In such embodiments, the technician 116 may review the test results presented in the report 112 and, relying on industry knowledge and skill, interpret the test results provided by the report 112. The technician 116 may then provide the user with a reasoned recommendation as to what action(s) should (or should not) be taken on the machinery 102 to maintain or improve the health of the machinery 102.

[0032] In other embodiments, however, the recommendation 114 may be provided automatically 118 by the computer system 110 as part of the report 112. In such embodiments, a particular recommendation 114 may be automated based on similar test results obtained from equipment similar to the machinery 102. More particularly, the computer system 1 10 may be configured and otherwise programmed to query the library for datasets and test results obtained from similar types of machinery and apply those results to one or more common (e.g., preferred or probable) recommended courses of action. In such embodiments, the computer system 110 may be programmed to provide one or more prior recommendations given based on prior test results obtained from similar types of machinery.

[0033] It is contemplated herein to incorporate artificial intelligence technology and neural networks in providing the recommendation 114 via the computer system 110. More specifically, the interpretation and recommendations provided by the computer system 110 may be improved through machine learning based on both a breadth of results from other users with similar equipment, as well as from the norm of operating the machinery 102 and the typical results the user experiences. Over time, and with the compilation of large amounts of data and data sets accessible by the computer system 110, it is expected that the automatic recommendation 118 provided by the computer system 110 may be just as accurate as a recommendation from the skilled technician 116, but provided in real-time.

[0034] The following is a simple example of providing a recommendation 114 in a scenario where the machinery 102 comprises a gearbox. In this example, test results for the oil 104a indicated increased viscosity and elevated levels of iron, test results for the grease 104b around a drive shaft bearing indicated increasing thickness and viscosity, and test results for the filter 104c indicated the presence of large iron particles. The report 112 may be generated and indicate these test results and corresponding criterion. Based on the test results, the performance indicator included in the report 112 may represent to the user that there is a potential issue identified through the combination of the oil, grease, and filter 104a-c analyses, and that the machinery 102 unit should be inspected to avoid further damage. Moreover, upon reviewing these test results, the recommendation 1 14 provided by the technician 116 or the computer system 110 (i.e., Auto 118 in FIG. 1) may indicate that there is likely a gear issue or a potential gear tooth failure. More specifically, an issue with a gear may be causing large iron particles to be captured in the oil 104a and the filter 104c, thus resulting in the bearing heating to a higher than normal temperature and putting the machinery 102 at risk of seizure due to thermal stress on the grease 104b.

[0035] In some embodiments, the test results presented in the report 112 may also help determine the general location of a potential issue with the machinery 102. For example, the report 112 may indicate that high levels of a particular metal or metal alloy are found in one or more of the oil, the grease, and the filter 104a-c. It may be known that the identified metal or metal alloy is only found in the machinery 102 at a particular type of bearing. Consequently, the recommendation 1 14 may provide the user with instructions on where the metal originated in the machinery 102 and suggest how to remedy the issue.

[0036] As another example, the report 112 may indicate that high levels of silicon were found in the oil 104a and the filter 104c. It may be known that the machinery 102 is operating in an ambient environment elevated amounts of dust or dirt, such as a natural gas engine operating outdoors in gas compression fields in the mid-west United States. Consequently, the recommendation 114 may provide the user with instructions to evaluate the air filter 104c for failure or to reduce the micron size of the air filter 104c to more effectively reduce the size range of this contaminant allowed to enter the system. The recommendation may also include a suggestion to analyze the air filter 104c as part of the next filter analysis.

[0037] FIG. 2 is a schematic flowchart of an example method 200 of monitoring and reporting operational performance of machinery, according to embodiments of the present disclosure. The method 200 may be used to facilitate monitoring and observation of the total fluid performance of the machinery 102 of FIG. 2, for example, and provide a user with a report and/or a performance indicator corresponding to the status (health) of the machinery 102. The method 200 may include obtaining a sample of two or more of oil, grease, and a filter from the machinery, as at 202. As indicated above, samples of one or more of the oil, the grease, and the filter may be extracted (obtained) from the machinery 102 at predetermined intervals, such as based on a predetermined schedule in accordance with appropriate sampling times for the particular medium. Alternatively, samples of the oil, the grease, and the filter may be obtained simultaneously, without departing from the scope of the disclosure. [0038] The method 200 may further include analyzing the samples of the oil, the grease, and the filter at a testing facility, as at 204. The samples may be shipped to and examined at the testing facility (e.g., the testing facility 108 of FIG. 1) to determine the presence one or more standard indicators of fluid and filter performance applicable to the specific application in which the machinery commonly operates. Resulting testing data may then be processed using a computer system, as at 206, and a report (e.g., the report 112 of FIG. 1) may be generated by the computer system (e.g. the computer system 110 of FIG. 1) based on the testing data, as at 208. The report may provide data on the overall condition of each of the oil, the grease, and the filter, as well as the machinery itself.

[0039] The method 200 may optionally include providing a performance indicator corresponding to the status of the machinery, as at 210. The performance indicator may be derived by combining with the computer system the test results of two or more of the oil, the grease, and the filter. In some embodiments, the performance indicator may be based solely on the current analysis of two or more of the oil, the grease, and the filter, but may alternatively be based in historical usage of the oil, the grease, and the filter in connection with the machinery. The performance indicator may be presented to the user in any of the formats and styles mentioned herein.

[0040] The method 200 may further include providing a recommendation based on the report, as at 212. The recommendation (e.g., the recommendation 114 of FIG. 1) may be provided to the user to guide the user in suggested actions that may be taken to maintain improve the health of the machinery. In some embodiments, the recommendation may be provided by a skilled technician after interpreting the results provided in the report. In other embodiments, however, the recommendation may be provided automatically by the computer system. In at least one embodiment, the computer system may be programmed with artificial intelligence technology and/or neural networks that allow the computer system to learn over time based on test results derived from other users and/or tests corresponding to similar types of machinery. Accordingly, recommendations provided by the computer system may gradually improve as data sets and results become increasingly available to the computer system for processing. As will be appreciated, by combining test results from all three media into the same database, especially when measured at the same testing facility and interpreted by a provider with knowledge of the formulations of the grease and oil, the user will have a much more representative view of their equipment performance and health.

[0041] The systems and methods disclosed herein can largely be implemented using the computer system 110 of FIG. 1. One or more aspects or features of the subject matter described herein can be realized in digital electronic circuitry, integrated circuitry, specially designed application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs) computer hardware, firmware, software, and/or combinations thereof. These various aspects or features can include implementation in one or more computer programs that are executable and/or interpretable on a programmable system including at least one programmable processor, which can be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device. The programmable system or computer system may include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.

[0042] The computer programs, which can also be referred to as programs, software, software applications, applications, components, or code, include machine instructions for a programmable processor, and can be implemented in a high-level procedural language, an object-oriented programming language, a functional programming language, a logical programming language, and/or in assembly/machine language. As used herein, the term“machine-readable medium” refers to any computer program product, apparatus and/or device, such as for example magnetic discs, optical disks, memory, and programmable logic devices (PLDs), used to provide machine instructions and/or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term“machine-readable signal” refers to any signal used to provide machine instructions and/or data to a programmable processor. The machine-readable medium can store such machine instructions non-transitorily, such as for example as would a non-transient solid-state memory or a magnetic hard drive or any equivalent storage medium. The machine-readable medium can alternatively or additionally store such machine instructions in a transient manner, such as would a processor cache or other random access memory associated with one or more physical processor cores.

[0043] To provide for interaction with a user, one or more aspects or features of the subject matter described herein can be implemented on a computer having a display device, such as for example a tablet computer, a personal digital assistant (PDA), a smart phone, a cathode ray tube (CRT), a liquid crystal display (LCD), or a light emitting diode (LED) monitor for displaying information to the user and a keyboard and a pointing device, e.g., a mouse, a trackball, etc., by which the user may provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well. For example, feedback provided to the user can be any form of sensory feedback, such as for example visual feedback, auditory feedback, or tactile feedback; and input from the user may be received in any form, including, but not limited to, acoustic, speech, or tactile input. Other possible input devices include, but are not limited to, touch screens or other touch-sensitive devices such as single or multi-point resistive or capacitive trackpads, voice recognition hardware and software, optical scanners, optical pointers, digital image capture devices and associated interpretation software, and the like.

[0044] FIG. 3 illustrates an example embodiment of the computer system 110. As shown, the computer system 110 includes one or more processors 302, which can control the operation of the computer system 110. “Processors” are also referred to herein as“controllers.” The processor(s) 302 can include any type of microprocessor or central processing unit (CPU), including programmable general-purpose or special-purpose microprocessors and/or any one of a variety of proprietary or commercially available single or multi-processor systems. The computer system 110 can also include one or more memories 304, which can provide temporary storage for code to be executed by the processor(s) 302 or for data acquired from one or more users, storage devices, and/or databases. The memory 304 can include read-only memory (ROM), flash memory, one or more varieties of random access memory (RAM) (e.g., static RAM (SRAM), dynamic RAM (DRAM), or synchronous DRAM (SDRAM)), and/or a combination of memory technologies.

[0045] The various elements of the computer system 110 can be coupled to a bus system 306. The illustrated bus system 306 is an abstraction that represents any one or more separate physical busses, communication lines/interfaces, and/or multi-drop or point-to-point connections, connected by appropriate bridges, adapters, and/or controllers. The computer system 110 can also include one or more network interface(s) 308, one or more input/output (IO) interface(s) 310, and one or more storage device(s) 312.

[0046] The network interface(s) 308 can enable the computer system 110 to communicate with remote devices, e.g., other computer systems, over a network, and can be, for non-limiting example, remote desktop connection interfaces, Ethernet adapters, and/or other local area network (LAN) adapters. The IO interface(s) 310 can include one or more interface components to connect the computer system 110 with other electronic equipment. For non-limiting example, the IO interface(s) 310 can include high-speed data ports, such as universal serial bus (USB) ports, 1394 ports, Wi-Fi, Bluetooth, etc. Additionally, the computer system 110 can be accessible to a human user, and thus the IO interface(s) 310 can include displays, speakers, keyboards, pointing devices, and/or various other video, audio, or alphanumeric interfaces.

[0047] The storage device(s) 312 (e.g., databases) can include any conventional medium for storing data in a non-volatile and/or non-transient manner. The storage device(s) 312 can thus hold data and/or instructions in a persistent state, i.e., the value(s) are retained despite interruption of power to the computer system 110. The storage device(s) 312 can include one or more hard disk drives, flash drives, USB drives, optical drives, various media cards, diskettes, compact discs, and/or any combination thereof and can be directly connected to the computer system 110 or remotely connected thereto, such as over a network. In an exemplary embodiment, the storage device(s) 312 can include a tangible or non-transitory computer readable medium configured to store data, e.g., a hard disk drive, a flash drive, a USB drive, an optical drive, a media card, a diskette, a compact disc, etc.

[0048] The elements illustrated in FIG. 3 can be some or all of the elements of a single physical machine. In addition, not all of the illustrated elements need to be located on or in the same physical machine. Exemplary computer systems include conventional desktop computers, workstations, minicomputers, laptop computers, tablet computers, personal digital assistants (PDAs), mobile (smart) phones, and the like.

[0049] The computer system 110 can include a web browser for retrieving web pages or other markup language streams, presenting those pages and/or streams (visually, aurally, or otherwise), executing scripts, controls and other code on those pages/streams, accepting user input with respect to those pages/streams (e.g., for purposes of completing input fields), issuing HyperText Transfer Protocol (HTTP) requests with respect to those pages/streams or otherwise (e.g., for submitting to a server information from the completed input fields), and so forth. The web pages or other markup language can be in HyperText Markup Language (HTML) or other conventional forms, including embedded Extensible Markup Language (XML), scripts, controls, and so forth. The computer system 110 can also include a web server for generating and/or delivering the web pages to client computer systems.

[0050] In an exemplary embodiment, the computer system 110 can be provided as a single unit, e.g., as a single server, as a single tower, contained within a single housing, etc. The single unit can be modular such that various aspects thereof can be swapped in and out as needed for, e.g., upgrade, replacement, maintenance, etc., without interrupting functionality of any other aspects of the system. The single unit can thus also be scalable with the ability to be added to as additional modules and/or additional functionality of existing modules are desired and/or improved upon.

[0051] The computer system 110 can also include any of a variety of other software and/or hardware components, including by way of non-limiting example, operating systems and database management systems. Although an exemplary computer system is depicted and described herein, it will be appreciated that this is for sake of generality and convenience. In other embodiments, the computer system may differ in architecture and operation from that shown and described here. [0052] Embodiments disclosed herein include:

[0053] A. A method of monitoring operational performance of machinery, comprising obtaining samples of two or more of oil, grease, and a filter from the machinery, receiving and analyzing the samples at a testing facility for a presence of one or more standard indicators of fluid and filter performance and thereby obtaining testing data, processing the testing data with a computer system to obtain test results, and generating a report with the computer system based on the test results, wherein the report provides a current health of the machinery in view of a condition of the two or more of the oil, the grease, and the filter.

[0054] B. A system of monitoring operational performance of machinery, comprising two or more samples of oil, grease, and a filter extracted from the machinery, a testing facility that receives and analyzes the samples for a presence of one or more standard indicators of fluid and filter performance, a computer system in communication with the testing facility and programmed to process the testing data to obtain test results, and a report generated by the computer system based on the test results, wherein the report provides a current health of the machinery in view of a condition of the two or more of the oil, the grease, and the filter.

[0055] Each of embodiments A and B may have one or more of the following additional elements in any combination: Element 1 : wherein generating the report comprises providing individualized test results for the two or more of the oil, the grease, and the filter. Element 2: wherein generating the report comprises combining the test results of the two or more of the oil, the grease, and the filter and thereby obtaining combined test results, and providing a performance indicator based on the combined test results and corresponding to the current health of the machinery. Element 3 : wherein providing the performance indicator comprises basing the performance indicator on a current analysis of the two or more of the oil, the grease, and the filter. Element 4: wherein providing the performance indicator comprises querying a library with the computer system for historical testing data corresponding to the machinery, and combining current and historical testing data for the two or more of the oil, the grease, and the filter used in conjunction with the machinery. Element 5: further comprising presenting the performance indicator to a user in a form selected from the group consisting of a numerical score, a letter grade, a graphic, a color code, a color-coded graphic, and any combination thereof. Element 6: further comprising providing a recommendation based on the test results included in the report. Element 7: wherein providing the recommendation comprises reviewing the test results by a skilled technician, and interpreting the test results by the skilled technician based on industry knowledge and skill. Element 8: wherein providing the recommendation comprises querying a library with the computer system for test results obtained from machinery similar to the machinery, and providing the recommendation automatically with the computer system based on prior recommendations provided for test results obtained from machinery similar to the machinery. Element 9: further comprising improving the recommendation provided by the computer system based on machine learning and artificial intelligence. Element 10: further comprising obtaining the samples of the two or more of the oil, the grease, and the filter at different times. Element 11 : further comprising obtaining the samples of the two or more of the oil, the grease, and the filter simultaneously.

[0056] Element 12: wherein the machinery is selected from the group consisting of automotive machinery, an airplane, a boat, a generator, industrial manufacturing equipment, construction equipment, mining and excavation equipment, agricultural equipment, processing equipment, pumps, motors, a gear box, and any combination thereof. Element 13 : wherein the report further includes a performance indicator corresponding to the current health of the machinery and resulting from a combination of the test results of the two or more of the oil, the grease, and the filter. Element 14: wherein the performance indicator is based on current and historical testing data corresponding to the machinery. Element 15: further comprising a recommendation provided to a user of the machinery based on the test results included in the report. Element 16: wherein the recommendation is provided by a skilled technician who reviews and interprets the test results to provide the recommendation. Element 17: wherein the recommendation is provided by the computer system based on prior recommendations provided for test results obtained from machinery similar to the machinery. Element 18: wherein the two or more samples of the oil, the grease, and the filter are extracted from the machinery at different times.

[0057] By way of non-limiting example, exemplary combinations applicable to A, B, and C include: Element 2 with Element 3; Element 2 with Element 4; Element 2 with Element 5; Element 6 with Element 7; Element 6 with Element 8; Element 8 with Element 9; Element 13 with Element 14; Element 15 with Element 16; and Element 15 with Element 17.

[0058] Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of’ or“consist of’ the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form,“from about a to about b,” or, equivalently,“from approximately a to b,” or, equivalently,“from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles“a” or“an,” as used in the claims, are defined herein to mean one or more than one of the elements that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

[0059] As used herein, the phrase“at least one of’ preceding a series of items, with the terms “and” or“or” to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item). The phrase“at least one of’ allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, the phrases“at least one of A, B, and C” or“at least one of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.

Claims

CLAIMS:

1. A method of monitoring operational performance of machinery, comprising:

obtaining samples of two or more of oil, grease, and a filter from the machinery;

receiving and analyzing the samples at a testing facility for a presence of one or more standard indicators of fluid and filter performance and thereby obtaining testing data;

processing the testing data with a computer system to obtain test results; and

generating a report with the computer system based on the test results, wherein the report provides a current health of the machinery in view of a condition of the two or more of the oil, the grease, and the filter.

2. The method of claim 1, wherein generating the report comprises providing individualized test results for the two or more of the oil, the grease, and the filter.

3. The method of any one of claims 1 or 2, wherein generating the report comprises:

combining the test results of the two or more of the oil, the grease, and the filter and thereby obtaining combined test results; and

providing a performance indicator based on the combined test results and corresponding to the current health of the machinery.

4. The method of claim 3, wherein providing the performance indicator comprises basing the performance indicator on a current analysis of the two or more of the oil, the grease, and the filter.

5. The method of any one of claims 3 or 4, wherein providing the performance indicator comprises:

querying a library with the computer system for historical testing data corresponding to the machinery; and

combining current and historical testing data for the two or more of the oil, the grease, and the filter used in conjunction with the machinery.

6. The method of any one of claims 3 to 5, further comprising presenting the performance indicator to a user in a form selected from the group consisting of a numerical score, a letter grade, a graphic, a color code, a color-coded graphic, and any combination thereof.

7. The method of any one of claims 1 to 6, further comprising providing a recommendation based on the test results included in the report.

8. The method of claim 7, wherein providing the recommendation comprises:

reviewing the test results by a skilled technician; and

interpreting the test results by the skilled technician based on industry knowledge and skill.

9. The method of any one of claims 7 or 8, wherein providing the recommendation comprises: querying a library with the computer system for test results obtained from machinery similar to the machinery; and

providing the recommendation automatically with the computer system based on prior recommendations provided for test results obtained from machinery similar to the machinery.

10. The method of claim 9, further comprising improving the recommendation provided by the computer system based on machine learning and artificial intelligence.

11. The method of any one of claims 1 to 10, further comprising obtaining the samples of the two or more of the oil, the grease, and the filter at different times.

12. The method of any one of claims 1 to 10, further comprising obtaining the samples of the two or more of the oil, the grease, and the filter simultaneously.

13. A system of monitoring operational performance of machinery, comprising:

two or more samples of oil, grease, and a filter extracted from the machinery;

a testing facility that receives and analyzes the samples for a presence of one or more standard indicators of fluid and filter performance;

a computer system in communication with the testing facility and programmed to process the testing data to obtain test results; and

a report generated by the computer system based on the test results, wherein the report provides a current health of the machinery in view of a condition of the two or more of the oil, the grease, and the filter.

14. The system of claim 13, wherein the machinery is selected from the group consisting of automotive machinery, an airplane, a boat, a generator, industrial manufacturing equipment, construction equipment, mining and excavation equipment, agricultural equipment, processing equipment, pumps, motors, a gear box, and any combination thereof.

15. The system of any one of claims 13 or 14, wherein the report further includes a performance indicator corresponding to the current health of the machinery and resulting from a combination of the test results of the two or more of the oil, the grease, and the filter.

16. The system of claim 15, wherein the performance indicator is based on current and historical testing data corresponding to the machinery.

17. The system of any one of claims 13 to 16, further comprising a recommendation provided to a user of the machinery based on the test results included in the report.

18. The system of claim 17, wherein the recommendation is provided by a skilled technician who reviews and interprets the test results to provide the recommendation.

19. The system of any one of claims 17 or 18, wherein the recommendation is provided by the computer system based on prior recommendations provided for test results obtained from machinery similar to the machinery.

20. The system of any one of claims 13 to 19, wherein the two or more samples of the oil, the grease, and the filter are extracted from the machinery at different times.