CN113756948A

CN113756948A - Engine alternator health estimation

Info

Publication number: CN113756948A
Application number: CN202010489086.4A
Authority: CN
Inventors: 任杰; 王学伟; 李勇; 孙帅
Original assignee: Cummins Inc
Current assignee: Cummins Inc
Priority date: 2020-06-02
Filing date: 2020-06-02
Publication date: 2021-12-07

Abstract

The engine alternator health estimation is performed by the telematics system using the operational data provided to the telematics control unit. A health anomaly of an alternator may be determined in response to an actual or observed charge time of a battery connected to the alternator exceeding a predicted charge time.

Description

Engine alternator health estimation

Background

The present disclosure relates to engine health estimation devices, methods, systems, processes, and techniques. Engine health estimation aims to estimate the health of an engine and/or one or more engine components to determine malfunctioning, malfunctioning or improperly operating engine systems or components, and to provide for maintenance, repair or replacement before the failure occurs. Some proposals have been made for engine health estimation; however, existing methods have many drawbacks, deficiencies, and unrealized potentials. There remains a substantial need for the unique devices, methods, systems, and techniques disclosed herein.

Disclosure of illustrative embodiments

For the purposes of clearly, concisely and accurately describing illustrative embodiments of the present disclosure, the manner and process of making and using the same, and to enable the practice, manufacture and use of the same, reference will now be made to certain exemplary embodiments, including those illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, and such alterations, modifications, and further applications of the exemplary embodiments as would occur to one skilled in the art are intended to be embraced therein.

Disclosure of Invention

One embodiment is a unique engine alternator health estimation process. Another embodiment is a unique engine alternator health assessment system. Other embodiments include unique methods, techniques, and apparatus for engine alternator health estimation. Engine alternator health estimation in accordance with the present disclosure may include system features and process operations related to data collection, data preparation, data analysis, and health estimation of the engine alternator under evaluation. Other embodiments, forms, objects, features, advantages, aspects, and benefits shall become apparent from the following description and drawings.

Drawings

FIG. 1 is a schematic diagram illustrating certain aspects of an exemplary engine alternator health estimation system.

FIG. 2 is a schematic diagram illustrating certain aspects of an exemplary engine alternator health estimation system.

FIG. 3 is a flow chart illustrating certain aspects of an exemplary engine alternator health estimation process.

Fig. 4 is a graph showing engine speed and battery voltage over time after a successful engine start.

Detailed Description

Referring to FIG. 1, certain aspects of an alternator health estimation system 100 are illustrated, according to an exemplary embodiment. The system 100 includes a combination of components including an internal combustion engine 102 coupled to a starter 104 and an alternator 106. The starter 104 and the alternator 106 are connected to an energy storage device 108, such as a battery. The components of system 100 may be disposed on vehicle 110; however, non-vehicular applications for the system 100 are also contemplated.

The system 100 also includes a telematics control unit 115 that receives data 112 from the operation of the engine 102. The telematics control unit 115 includes a telematics device 114 and an edge computing system 116, the edge computing system 116 being operable to receive the data 112 and pre-process the data in real time. The telematics control unit 115 is connected to the remote processing system 118 and is operable to provide at least a subset of the pre-processed data 112' to the remote processing system 118. The pre-processed data 112' includes values and/or subsets of values that quantify the health of the alternator 106 for analysis by the remote processing system 118 to determine an estimate of the health of the alternator 106.

Each of telematics control unit 115 and remote processing system 118, as well as other components of system 100, may be implemented in one or more computer systems including one or more computers specifically configured according to the techniques of this disclosure to provide the configurations and functions described herein. In certain embodiments, the telematics control unit 115 may be disposed on the vehicle 110. In some forms, one or more of these telematics control unit 115 and remote processing system 118, as well as other components of system 100, may include a network-accessible cloud computing platform.

Referring to fig. 2, a plurality of

sensors

120, 122, 124 are provided for collecting various types of data 112. For example, the engine sensors 120 may collect engine data such as engine speed, time of successful engine start, and/or time of completion of a full charge of the battery 108 after a successful start. The environmental sensor 122 may collect environmental data such as ambient air temperature, ambient air pressure, coolant temperature, and oil temperature. The voltage sensor 124 may collect voltage data, such as alternator voltage from the time the engine is successfully started to the time the battery 108 is fully charged.

Signals containing data from the

sensors

120, 122, 124 may be output for direct reception by the telematics control unit 115 and/or may be output to an on-board control computer of the engine 102, such as an Engine Control Module (ECM) 126. At least a subset of the data 112 is pre-processed by the telematics control unit 115 and then transmitted to the remote processing system 118. The remote processing system 118 analyzes at least a subset of the pre-processed data 112' derived from the data 112 collected by the

sensors

120, 122, 124 and uses one or more models and/or algorithms to determine an estimate of the health of the alternator 106. The health estimates may be output by the remote processing system 118 to one or

more output devices

130, 132, 134 of an operator, fleet manager, and/or service technician, respectively.

Referring to FIG. 3, a flow chart illustrating certain aspects of an exemplary engine alternator health estimation process 300 is shown. The process 300 begins when the engine is successfully started and proceeds to operation 302, where the engine 102 is operated to generate the data 112 at operation 302. The data 112 is received at the telematics control unit 115 and the data 112 is preprocessed by the edge computing system 116 at operation 304. At operation 307, at least a subset of the pre-processed data 112' is analyzed by the remote processing system 118, and an estimate of the health of the alternator 106 is determined based on the analysis of the subset of the pre-processed data. At operation 310, the estimate of the health of the alternator 106 determined from the analysis may be output to one or more output devices, such as operators, fleet managers, and service technicians.

In an embodiment, the analysis at operation 307 includes analyzing engine data, environmental data, and voltage data, such as from

sensors

120, 122, 124 discussed above. In one embodiment, a model is used in the analysis to determine the difference in the time for the battery 108 to reach the threshold battery voltage when the engine speed is greater than the threshold engine speed. In one embodiment, the model may be represented by the following equation:

equation 1

In the case of the equation 1, the,

to representΔT(time from engine speed greater than threshold to threshold battery voltage);

；

；

；

(ii) a And is

From an engine speed greater than a threshold speed to an average engine speed that reaches a threshold battery voltage). If expected or predicted time after adjusting or compensating for environmental conditionsΔT，Namely, it is

Out of realityΔTExceeds a threshold amount, it can be determined by estimation that an engine alternator health anomaly exists. An example of an implementation of the model showing equation 1 is shown in fig. 4.

The telematics control unit 115 may include any suitable wireless or wired data transfer mechanism that transfers the data 112, 112' using, for example, electrical wires, optical links, communication lines, power lines, radio signals, ultrasonic signals, infrared signals, or other signals. The telematics control unit 115 may be wireless, hardwired, analog, optical, or digital. Telematics control unit 115 may receive information directly from

sensors

120, 122, 124 and/or from ECM 126.

In one embodiment, telematics control unit 115 includes a Global Positioning (GPS) unit; an external interface for mobile communications, such as global system for mobile communications (GSM), General Packet Radio Service (GPRS), Wi-Fi, WiMax, or Long Term Evolution (LTE); an electronic processing unit; a microcontroller and/or microprocessor; a mobile communication unit; and a certain amount of memory that intelligently stores information about the sensor data of the vehicle.

The telematics control unit 115 may include one or more computer processors and/or servers, for example, outside the cloud and located on the engine 102, the vehicle 110, and/or geographically proximate to the system 100 to support real-time processing of edge computing applications and data 112. Telematics control unit 115 may also include a receiver to receive all or a subset of data 112 from ECM 126, a memory to store data and/or computer program instructions for performing all or a portion of process 300, and a transmitter to transmit a subset of pre-processed data 112' to remote processing system 118 using any suitable wireless or wired communication protocol.

The remote processing system 118 may include, for example, a computer processor and/or server located in a cloud computing service or other location remote from the engine 102 and the telematics control unit 115. The remote processing system 118 may communicate with the telematics control unit 115 via any suitable means, such as via wired and/or wireless communication over the internet using any suitable communication protocol. The telematics system 118 may also include memory for storing the data or a subset of the data transmitted by the telematics control unit 115. The remote processing system 118 may also include computer program instructions for performing all or a portion of the process 300, and a transmitter to transmit the health estimate or the indication of the abnormality of the alternator 106 to the

output devices

130, 132, 134.

The

output devices

130, 132, 134 may include, for example, one or more of the following: computers, laptops, tablets, smart phones, applications, dashboard displays, terminals, screens, printers, speakers, lights, or other visual indicators and trouble codes. The

output devices

130, 132, 134 include a receiver to receive an indication of the health estimate and/or the anomaly of the alternator 106 from the remote processing system 118.

Various aspects of the disclosure are contemplated. According to one aspect, a method for alternator health estimation includes: operating an engine, the engine comprising an alternator and a battery charged by the alternator; transmitting data from the operation of the engine to a telematics control unit including a telematics device and an edge computing system for pre-processing the data; performing, with a remote processing system connected to the edge computing system, an analysis of at least a subset of the pre-processed data; estimating a health of the alternator in response to the analysis of the subset of the preprocessed data; and outputting the estimate of the health of the alternator from the remote processing system.

In one embodiment, the estimate of the health is output to at least one of an operator, a fleet manager, and a service technician. In one embodiment, the method includes inputting at least the subset of the pre-processed data from the operation of the engine from the telematics control unit to the telematics system; and performing the analysis on the remote processing system.

In one embodiment of the method, the subset of the preprocessed data includes a voltage of the alternator from engine start to the battery being fully charged, an average engine speed from the engine start to the battery being fully charged, and a time from the engine start to the battery being fully charged. The subset of the preprocessed data may include environmental data, engine operating data, and voltage data associated with the battery. The environmental data may include ambient air temperature, ambient air pressure, coolant temperature, and oil temperature.

In one embodiment of the method, the estimate of the health of the alternator is determined based on the data in response to an actual time to charge the battery to a threshold voltage by the alternator. The estimation of the health of the alternator may include determining an anomaly of the alternator in response to a portion of the actual time exceeding a predicted time determined by the analysis of the subset of the data exceeding a threshold amount.

In one embodiment of the method, the remote processing system is a cloud computing service. The cloud computing service may be connected to the telematics control unit via an internet connection.

In another aspect, a distributed engine health estimation system includes an internal combustion engine including an alternator and a battery chargeable by the alternator. The system also includes a telematics control unit configured to receive and transmit data associated with the internal combustion engine, the alternator, and the battery during operation of the internal combustion engine. The telematics control unit includes a telematics device and an edge computing system configured to pre-process the data. The system also includes a remote processing system distinct and remote from the engine and the telematics control unit. The remote processing system includes a server and/or a computing device. The remote processing system is configured to analyze at least a subset of the pre-processed data and estimate a health of the alternator in response to the analysis.

In one embodiment, the telematics system includes a cloud computing service configured to receive the subset of the preprocessed data from the telematics control unit. In one embodiment, the internal combustion engine is disposed on a vehicle.

In one embodiment, the remote processing system is configured to output the estimate of the health of the alternator. The remote processing system may be connected to output the estimate of the health of the alternator to an output device of at least one of an operator, a fleet manager, and a service technician.

In one embodiment, the subset of the preprocessed data includes a voltage of the alternator from engine start to the battery being fully charged, an average engine speed from the engine start to the battery being fully charged, and a time from the engine start to the battery being fully charged. The subset of the preprocessed data may include environmental data and engine data. The environmental data may include an ambient air temperature and an ambient air pressure, and the engine data includes a coolant temperature and an oil temperature.

In one embodiment, the processor and/or server is configured to estimate the health of the alternator based on the subset of the pre-processed data in response to an actual time to charge the battery to a threshold voltage by the alternator. The processor and/or server may be configured to determine the estimated abnormality in the health of the alternator in response to a portion of the actual time to charge the battery to the threshold voltage exceeding a predicted time exceeding a threshold amount.

While illustrative embodiments of the present disclosure have been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain exemplary embodiments have been shown and described and that all changes and modifications that come within the spirit of the claimed invention are desired to be protected. It is to be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as "a," "an," "at least one," or "at least a portion" are used, unless specifically stated to the contrary in the claims, it is not intended that the claims be limited to only one item. When the language "at least a portion" and/or "a portion" is used, the item can include a portion and/or the entire item unless specifically stated to the contrary.

Claims

1. A method for alternator health estimation, the method comprising:

operating an engine, the engine comprising an alternator and a battery charged by the alternator;

transmitting data from the operation of the engine to a telematics control unit including a telematics device and an edge computing system for pre-processing the data;

performing, with a remote processing system connected to the edge computing system, an analysis of at least a subset of the pre-processed data;

estimating a health of the alternator in response to the analysis of the subset of the preprocessed data; and

outputting the estimate of the health of the alternator from the remote processing system.

2. The method of claim 1, wherein the estimate of the health is output to at least one of an operator, a fleet manager, and a service technician.

3. The method of claim 1, wherein the subset of the preprocessed data includes a voltage of the alternator from engine start to the battery being fully charged, an average engine speed from the engine start to the battery being fully charged, and a time from the engine start to the battery being fully charged.

4. The method of claim 3, wherein the subset of the preprocessed data includes environmental data, engine operating data, and voltage data associated with the battery.

5. The method of claim 4, wherein the environmental data includes ambient air temperature, ambient air pressure, coolant temperature, and oil temperature.

6. The method of claim 1, wherein the estimate of the health of the alternator is determined based on the data in response to an actual time to charge the battery to a threshold voltage by the alternator.

7. The method of claim 6, wherein the estimation of the health of the alternator comprises determining an anomaly of the alternator in response to a portion of the actual time exceeding a predicted time determined by the analysis of the subset of the data exceeding a threshold amount.

8. The method of claim 1, wherein the remote processing system is a cloud computing service.

9. The method of claim 8, wherein the cloud computing service is connected to the telematics control unit via an internet connection.

10. The method of claim 1, further comprising inputting at least the subset of the pre-processed data from operation of the engine from the telematics control unit to the telematics system; and performing the analysis on the remote processing system.

11. A distributed engine health estimation system, the distributed engine health estimation system comprising:

an internal combustion engine including an alternator and a battery that is chargeable by the alternator;

a telematics control unit configured to receive and transmit data associated with the internal combustion engine, the alternator, and the battery during operation of the internal combustion engine, the telematics control unit including a telematics device and an edge computing system configured to pre-process the data; and

a remote processing system, distinct and remote from the engine and the telematics control unit, the remote processing system including a server and/or a computing device, wherein the remote processing system is configured to analyze at least a subset of the pre-processed data and estimate a health of the alternator in response to the analysis.

12. The distributed engine health estimation system of claim 11, wherein the remote processing system includes a cloud computing service configured to receive the subset of the pre-processed data from the telematics control unit.

13. The distributed engine health estimation system of claim 11, wherein the remote processing system is configured to output the estimate of the health of the alternator.

14. The distributed engine health estimation system of claim 13, wherein the remote processing system is connected to output the estimate of the health of the alternator to an output device of at least one of an operator, a fleet manager, and a service technician.

15. The distributed engine health estimation system of claim 11, wherein the internal combustion engine is disposed on a vehicle.

16. The distributed engine health estimation system of claim 11, wherein the subset of the preprocessed data includes a voltage of the alternator from engine start to the battery full, an average engine speed from the engine start to the battery full, and a time from the engine start to the battery full.

17. The distributed engine health estimation system of claim 16, wherein the subset of the pre-processed data includes environmental data and engine data.

18. The distributed engine health estimation system of claim 17, wherein the environmental data includes an ambient air temperature and an ambient air pressure, and the engine data includes a coolant temperature and an oil temperature.

19. The distributed engine health estimation system of claim 11, wherein processor and/or server is configured to estimate the health of the alternator based on the subset of the pre-processed data in response to an actual time to charge the battery to a threshold voltage by the alternator.

20. The distributed engine health estimation system of claim 19, wherein the processor and/or server is configured to determine the estimated abnormality in the health of the alternator in response to a portion of the actual time to charge the battery to the threshold voltage exceeding a predicted time exceeding a threshold amount.