GB2546600A

GB2546600A - Fluid expulsion detection system for a transmission system

Info

Publication number: GB2546600A
Application number: GB1620662.5A
Authority: GB
Inventors: Wood-Gee Jake; Manss Leonard; Tello David; Oliver Robert
Original assignee: DRIVE SYSTEM DESIGN
Current assignee: DRIVE SYSTEM DESIGN
Priority date: 2015-12-04
Filing date: 2016-12-05
Publication date: 2017-07-26
Anticipated expiration: 2036-12-05
Also published as: GB2545021A; GB2546600B; GB201521458D0; GB201620662D0

Abstract

An apparatus for detecting expulsion or ejection of fluid from a test component (20, Fig. 1), comprising a housing 12 having walls forming an interior chamber 13 and an orifice A for receiving a fluid receiving tube (22, Fig. 1) mounted to the test component. It also comprises a fluid detection system having at least one sensor for detecting the presence of fluid within the receiving tube. The apparatus may be mounted to a drive train component, such as a transmission or gearbox, about a breather system with the fluid receiving tube being a breather tube. The detection system may comprise a camera 14 for capturing an image or recording video of the receiving tube upon detection of fluid. Alternatively it could be an electromagnetic radiation sensor 34 for detecting light from a light source 38. Preferably, there is an additional sensor for monitoring the condition of the automotive component to enable correlation with fluid expulsion events. Also claimed is a method of detection comprising: predefining a reference value of a fluid sensor; sensing the value of an electrical characteristic of a fluid sensor; and determining the expulsion of fluid by comparing the sensed and reference values.

Description

FLUID EXPULSION DETECTION SYSTEM FOR A TRANSMISSION SYSTEM TECHNICAL FIELD

The present invention relates to a fluid expulsion detection system from an apparatus such as a transmission system or axle or a method of monitoring fluid expulsion from an apparatus; particularly but not exclusively to an automated method of monitoring fluid expulsion from an apparatus.

BACKGROUND

It is known to provide vehicles with a drivetrain. Drivetrains may include one or more of the following components: a transmission, also known as a gearbox, for providing speed and torque conversions between a rotating power source, engine or motor; an axle, a differential, a transfer box or a transfer case. Such components typically comprise a fluid such as oil which may serve as a lubricant or coolant or both.

It is necessary to make provision in drivetrain components for breathing. Breathing is characterised as air flow into and out of a drivetrain component’s housing through a vent or a breather tube during operation. Drivetrain components therefore are provided with a breather system.

For example in a transmission system, when temperatures in the transmission housing increase, the air and operating fluid in the transmission housing expand and air flows freely out of the vent into the atmosphere. Without a provision for breathing, pressure would increase within the transmission housing; this may become sufficiently high to force transmission fluid past the transmission seals. Alternatively, when the temperatures in the transmission housing decrease, for example when a vehicle with a hot transmission is driven through high water, air flows freely into the transmission housing through the vent. Without a provision for breathing, reduced pressure or vacuum within the transmission housing may cause contaminants to be drawn into the transmission through the transmission seals.

Further, it is a requirement of transmission systems and other drivetrain components that the transmission fluid is not ejected from the transmission through the transmission breather system.

During the development of a transmission or axle significant time and effort is expended to ensure that transmission fluid is not ejected from the transmission breather system.

Current methods of testing of transmission components in situ on a vehicle require an operator to either observe directly the breather system (if possible) or to record a video of the test. This may require an operator to view hundreds of hours of video recordings. Additionally, it may be difficult or impossible for the operator to determine the precise operating conditions of the vehicle during the test at the point of ejection of transmission fluid. When testing a transmission component in a laboratory on a test rig it is necessary for an operator to watch the device under test either directly or from a video recording of the test.

It is an object of the present invention to provide a system which allows a significant saving in time and manpower during testing of transmission components by automating the detection process and recording the operating conditions where oil leakage (if any) occurs.

SUMMARY

The present invention seeks to overcome or at least mitigate the problems of the prior art.

Whilst the present invention has particular application in automotive applications, it is envisaged that the invention may be employed in other applications, for example it is foreseen that the invention may be employed in power generation, in pumping applications, marine applications and industrial applications. A first aspect of the invention provides an apparatus for detecting expulsion of fluid from a test component, the apparatus comprising: a housing comprising a plurality of walls forming an interior chamber; wherein the housing comprises an orifice for receiving a fluid receiver mounted to the test component; a fluid detection system comprising at least one sensor for detecting the presence of fluid in the fluid receiver.

Optionally, the fluid detection system comprises a camera for capturing at least one image of the fluid receiver upon detection of fluid therein by the fluid detection system.

Optionally, the fluid detection system comprises an electromagnetic radiation sensor.

In some embodiments, the electromagnetic radiation sensor is configured for detection of visible light.

Optionally, the fluid detection system further comprises a source of electromagnetic radiation configured to illuminate the fluid receiver.

In some embodiments, the fluid detection system comprises a visible light source.

Optionally, the apparatus comprises at least one second sensor for measuring at least one parameter of the test conditions.

In some embodiments, the at least one second sensor comprises an accelerometer for measuring acceleration of the test component along at least one axis during a test cycle.

Optionally, the apparatus comprises a memory device for recording data.

In some embodiments, the apparatus records video images for a predefined period of time upon detection of expulsion of fluid from the test component.

Optionally, the apparatus is mounted to an automotive vehicle drivetrain component.

Optionally, the apparatus is mounted to the housing of a drivetrain component about a breather system of the drivetrain component.

Optionally, the fluid receiver is a breather tube of an automotive vehicle drivetrain component and is transparent to visible light.

The fluid may be a transmission fluid for lubrication of the test component.

Optionally, the apparatus is mounted to a transmission system.

Optionally, the apparatus further comprises a controller configured to determine a change in an electrical characteristic of the at least one sensor is indicative of the presence of fluid in the fluid receiver.

Optionally, the controller is in communication with a memory device which stores a reference value of an electrical characteristic of the at least one sensor for determination of a fluid expulsion event.

Optionally, the fluid detection system comprises a sensor having an electrical characteristic sensitive to contact with the fluid of the test component.

Optionally, the fluid detection system comprises a sensor for capturing images of the fluid receiver and optical recognition software for recognising the presence of fluid in the fluid receiver. A second aspect of the invention provides a method for detecting expulsion of fluid from a test component comprising: predefining a reference value of an electrical characteristic of the at least one fluid sensor; sensing the value of an electrical characteristic of at least one fluid sensor; determining whether expulsion of fluid from the test component has occurred by comparing a sensed value of the electrical characteristic of at least one fluid sensor with the reference value of an electrical characteristic of the at least one fluid sensor.

Optionally, the method further comprises: measuring at least one characteristic of the test component; detecting expulsion of fluid from the test component; recording the measured characteristic of the test component.

Optionally, the method further comprises: capturing one or more video images of the test component; detecting expulsion of fluid from the test component; recording at least one captured video image of the test component. A third aspect of the invention provides an apparatus for detecting expulsion of fluid from an automotive component, the apparatus comprising: a housing comprising a plurality of walls forming an interior chamber; wherein the housing comprises an orifice for receiving a fluid receiver mounted to a breather system of the automotive component; a fluid detection system comprising at least one sensor for detecting the presence of fluid in the fluid receiver; at least one additional sensor for monitoring at least one parameter indicative of the condition of the automotive component.

Optionally, the apparatus is configured to enable correlation of data from the at least one additional sensor with data from the at least one sensor indicating a fluid expulsion event.

Optionally, the apparatus is configured to enable determination of the condition of the automotive component around the time of fluid expulsion from the breather system.

Within the scope of this application it is envisaged and intended that the various aspects, embodiments, examples, features and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings may be taken independently or in any combination thereof. For example, features described in connection with one embodiment are applicable to all embodiments unless there is incompatibility of features.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: FIGURE 1 schematically illustrates a perspective view of a fluid expulsion detection system according to an embodiment of the present invention mounted to a transmission component system; and FIGURE 2 schematically illustrates a top view of the fluid expulsion detection system of Figure 1, a top wall of the housing has been removed for illustrative purposes.

DETAILED DESCRIPTION OF EMBODIMENTS

Detailed descriptions of specific embodiments of the fluid expulsion detection system and method of testing of the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. Indeed, it will be understood that the fluid expulsion detection system and method of testing described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

Figures 1 and 2 illustrate a schematic representation of an apparatus for detecting fluid expulsion referred to hereinafter as a detection system 10. The fluid expulsion detection system 10 is mountable to a device under test, hereinafter referred to as the test component 20, as shown in Figure 1. In the illustrated embodiment the test component 20 is a drivetrain component of an automotive vehicle.

The detection system 10 can be employed on a test rig, for example in a laboratory, or may be mounted on the test component 20 of a vehicle for in situ testing of the component during operation of the vehicle.

The test rig may be adapted to rotate the device under test about one or more axes, optionally three perpendicular axes.

The detection system 10 comprises a fluid receiver in the form of test breathing tube 22. The test breathing tube 22 is mounted to the breather system of the test component 20. The test breathing tube 22 may be transparent or clear. If necessary the test breathing tube 22 replaces an existing breather tube fitted to the test component 20. The test breathing tube 22 may be formed from a plastics material; however, in alternative embodiments other materials may be employed such as, but not limited to, glass.

The detection system 10 comprises a housing 12. The housing 12 comprises a plurality of walls 15a, 15b, 15c, 15d, 15e, 15f defining an interior chamber 13. The housing 12 comprises an aperture A in a lower wall of the housing 12; the test breathing tube 22 is received in the aperture A and passes into the housing 12.

Optionally, the housing 12 comprises a second aperture in an upper wall 15f of the housing 12; an optional collar 24 comprising an aperture is mounted to the upper wall 15f about the test breathing tube 22. The test breathing tube 22 passes through the upper wall 15f of the housing 12. The test breathing tube 22 comprises an optional termination 23. The termination 23 may comprise a valve (not shown) which allows air flow between the test breathing tube 22 and the atmosphere. The termination 23 may comprise a reservoir for the collection of expelled transmission fluid.

The detection system 10 is mounted to the test component 20 by suitable fixings.

The detection system 10 comprises a fluid detection system. The fluid detection system comprises a light source 38 such as, but not limited to, a Light Emitting Diode (LED). The fluid detection system comprises a light sensor 34 such as but not limited to a light dependant resistor (LDR).The light source 38 is placed on a first side of the test breathing tube 22. The light source 38 is secured within the housing 12 by a mount 36. The light sensor 34 is placed on a second side of the test breathing tube 22 facing towards the light source 38. The light sensor 34 is secured within the housing 12 by a mount 32. The detection system 10 comprises a tri-axial accelerometer 30 for measurement of the acceleration of the test component 20 in three defined planes.

The detection system 10 may comprise, or may be in communication with, a power supply.

The accelerometer 30 may be mounted in the housing 12 or, in alternative embodiments, elsewhere on the test component 20, test rig or vehicle.

The accelerometer 30 can take measurements enabling analysis of the movement or motion of the device under test or analysis of vibrations in the device under test.

The detection system 10 may comprise, or may be in communication with, a controller (not shown) such as but not limited to a computer or other data acquisition system. The controller may comprise or be in communication with a memory device (not shown) for recording data from the accelerometer 30.

The presence of transmission fluid in the test breathing tube 22 will effect an electrical characteristic of the light sensor 34. In the illustrated embodiment the electrical resistance of the light sensor 34 is dependent on the intensity of light received at the light sensor 34. In other embodiments an alternative electrical characteristic such as, but not limited to, conductance, capacitance, inductance, voltage, current, electrical charge, reactance and susceptance may be dependent upon the intensity of light received at the light sensor 34. In alternative embodiments, frequency, amplitude or phase of an electrical signal may be dependent upon the intensity of light received at the light sensor 34. Transmission fluid, when present in the test breathing tube 22, will obstruct or otherwise interfere with the transmission of light from the light source 38 to the light sensor 34.

Exceeding a pre-set threshold change in the electrical characteristic of the light sensor 34 indicates that transmission fluid has been ejected from the test component 20 into the test breather tube 22. The controller determines that an expulsion event has occurred if the measured electrical characteristic of the light sensor 34 changes relative to a baseline (normal) value by an amount equal to or greater than a predefined magnitude.

Optionally the detection system 10 may comprise a video image capture device 14, optionally in the form of a low light video camera. In the illustrated embodiment the video image capture device 14 is mounted to the housing 12. The video image capture device 14 is mounted so as to view the test breathing tube 22. The video image capture device 14 is received in an opening in a side wall 15d of the housing 12. The video image capture device 14 is mounted to the housing 12 by a suitable mount 16; the mount 16 may take the form of a gland formed from nylon or other suitable material. In other embodiments the video image capture device 14 may be mounted within the housing 12. The video image capture device 14 may comprise a recording device or be in communication with the memory device (not shown) so as to be capable of recording an expulsion event upon detection of an expulsion event by the detection system 10. Optionally, the recording device is capable of recording images of the test breathing tube 22 for a predefined time period prior to an expulsion event upon instruction from the detection system 10. The detection system 10, upon detection of an expulsion of transmission fluid from the test component 20, may trigger the recording device to record or save video images of the test breathing tube 22 for a predefined period of time about or around the expulsion event.

The detection system 10 is optically triggered to record the expulsion event data. The light source 38 and light sensor 34 may be configured to operate in the visible light spectrum, that is to say the portion of the electromagnetic spectrum that is visible to the human eye. Typically, the visible light spectrum comprises electromagnetic radiation in the wavelengths range of about 390 to about 700 nm.

In embodiments including a video recording of an expulsion event an operator may review a saved video recording of the detected expulsion event to confirm that transmission fluid was ejected into the test breathing tube 22.

One advantage of the present invention is that an operator does not have to review all of a video recording of the entire test cycle, but rather only the predefined time periods surrounding a detected expulsion event. A further advantage of the present invention is that the operator can readily obtain the test conditions, which may include data recorded by the accelerometer 30, at the time of the expulsion event from a database or log of the test cycle.

In other embodiments, the detection system 10 may operate in alternative portions of the electromagnetic spectrum, wherein the intensity of the radiation transmitted between the source 38 and the sensor 34 is measureably affected by the presence of transmission fluid in the test breathing tube 22. For example, but not limited to, the detection system 10 may operate in the ultra-violet or infrared portion of the electromagnetic spectrum.

Optionally, the detection system 10 comprises a calibration system. The calibration system allows the detection system 10 to adjust to changes in ambient light levels within the interior chamber 13. The light level within the interior chamber 13 may alter during the test cycle, in particular during long test cycles. The level of ambient light admitted into the interior chamber 13, for example via the test breathing tube 22 and/or the aperture in the collar 24, may change during the course of a test and may be affected by changes in the intensity of natural light and/ or artificial light outside the housing 12. The calibration system may monitor the intensity of the light level within the housing 12 by monitoring changes in the electrical characteristic of the light sensor 34. If a gradual change in light intensity is detected over a period of time the calibration system may recalibrate the absolute or threshold value of the electrical characteristic of the light sensor 34 indicative of an expulsion event.

The calibration system adjusts the baseline or reference value of the electrical characteristic of the light sensor 34. The baseline value is employed to determine the threshold value of the electrical characteristic which is considered to be indicative of an expulsion event.

The detection system 10 will determine whether an expulsion event has occurred if the electrical characteristic of the light sensor 34 increases or decreases relative to the current baseline value by an amount equal to or greater than a pre-set value.

It can be appreciated that various changes may be made within the scope of the present invention. For example, in other embodiments of the invention the detection system 10 may be triggered to record an expulsion event by detecting a change in an alternative characteristic of the test breathing tube 22 for example, but not limited to, detecting a change in the capacitance or other electrical characteristic of the test breathing tube 22 or of a sensor mounted thereto or integrally formed therewith as a result of expulsion of transmission fluid into the test breathing tube 22. An electrical characteristic of the test breathing tube 22 or of a sensor may be dependent upon contact with the transmission fluid. The controller may determine that an expulsion event has occurred due to a change in the monitored electrical characteristic of the test breathing tube 22 or sensor as a result of the test breathing tube 22 or sensor coming into contact with the transmission fluid. In such embodiments, an optional light source or other electromagnetic radiation source may or may not be provided; for example, the light source may illuminate the test breathing tube 22 so as to facilitate capture of video images.

In other embodiments, the detection system 10 may be configured to be triggered to record an expulsion event by optical recognition of expulsion of transmission fluid into the test breathing tube 22. In such embodiments a suitable video camera is arranged to monitor the test breathing tube 22. The controller comprises image recognition software. The controller may be configured to compare at least one recorded image of the test breathing tube 22 with at least one live image of the test breathing tube 22. The detection system 10 may be triggered by detecting that the live image differs from the recorded image or alternatively approximates, correlates or matches the recorded image. The recorded image may be a predefined or pre-set reference sample of the detection system 10 or alternatively the recorded image may be updated by the detection system 10. In this way the recorded image may be an image of the test breathing tube 22 previously captured by the camera during the current test cycle. It will be appreciated that the live or most recently captured image may be compared with that image captured by the video camera immediately preceding the most recently captured image. In such embodiments, an optional light source or other electromagnetic radiation source may or may not be provided; for example, the light source may illuminate the test breathing tube 22 so as to facilitate capture of video images.

It will be appreciated that the detection system 10 may be in communication with the controller, recording device and/or memory device via a wired connection or wireless communication system. In the illustrated embodiment, the detection system 10 comprises a second gland 18 mounted to one of the plurality of walls forming the housing 12, the second gland 18 carries one or more wires or cables. The cables may enable electrical power delivery to the components mounted in the housing 12 and/or transmission of data from the components mounted in the housing 12 to the controller.

It will be appreciated that the detection system 10 may comprise one or more additional sensors for measuring other parameters of the test environment, the test conditions, or the operating conditions of the device under test for example but not limited to, a thermometer, a gyroscope, or a pressure sensor. Where the device under test is a transmission system the sensors may be configured to determine the gear ratio at any given time in the test cycle; the sensors may sense one or more parameters indicative of the speed of an input shaft, output shaft or one or more gear wheels in the transmission system.

In the foregoing embodiments it is envisaged that the detection system 10 will only save or record video images for a predefined period of time about a fluid expulsion event. However in alternative embodiments the detection sent may save or record video images of the entire test cycle, the detection system may record in a log, or other database, a timestamp (or other indicia) of an expulsion event to enable an operator to readily find and/or view the video images captured surrounding the detected expulsion event. In some embodiments the detection system may place a marker or chapter into the video recording. The marker is associated with one or more video images captured about the time the detection system 10 determined that an expulsion event occurred.

In this way the apparatus is configured to enable correlation of data indicative of the condition of an automotive component with data from a fluid sensor indicating a fluid expulsion event has taken place.

The apparatus is configured to enable determination of the conditions of the automotive component around the time of fluid expulsion from the breather system. This may include data immediately prior to, during and immediately after a fluid expulsion event.

Claims

1. An apparatus for detecting expulsion of fluid from a test component, the apparatus comprising: a housing comprising a plurality of walls forming an interior chamber; wherein the housing comprises an orifice for receiving a fluid receiver mounted to the test component; a fluid detection system comprising at least one sensor for detecting the presence of fluid in the fluid receiver.

2. The apparatus of claim 1 wherein the fluid detection system comprises a camera for capturing at least one image of the fluid receiver upon detection of fluid therein by the fluid detection system.

3. The apparatus of claim 1 wherein the fluid detection system comprises an electromagnetic radiation sensor.

4. The apparatus of claim 3 wherein the electromagnetic radiation sensor is configured for detection of visible light.

5. The apparatus of claim 1 wherein the fluid detection system further comprises a source of electromagnetic radiation configured to illuminate the fluid receiver.

6. The apparatus of claim 5 wherein the fluid detection system comprises a visible light source.

7. The apparatus of claim 1 wherein the test apparatus comprises at least one second sensor for measuring at least one parameter of the test conditions.

8. The apparatus of claim 7 wherein the at least one second sensor comprises an accelerometer for measuring acceleration of the test component along at least one axis during a test cycle.

9. The apparatus of claim 1 wherein the apparatus comprises a memory device for recording data.

10. The apparatus of claim 2 wherein the apparatus records video images for a predefined period of time upon detection of expulsion of fluid from the test component.

11. The apparatus of claim 1 wherein the apparatus is mounted to an automotive vehicle drivetrain component.

12. The apparatus of claim 11 wherein the apparatus is mounted to the housing of a drivetrain component about a breather system of the drivetrain component.

13. The apparatus of claim 1 wherein the fluid receiver is a breather tube of an automotive vehicle drivetrain component and is transparent to visible light.

14. The apparatus of claim 1 wherein the fluid is a transmission fluid for lubrication of the test component.

15. The apparatus of claim 2 wherein the apparatus is mounted to a transmission system.

16. The apparatus of claim 1 further comprising a controller configured to determine a change in an electrical characteristic of the at least one sensor which is indicative of the presence of fluid in the fluid receiver.

17. The apparatus of claim 15 wherein the controller is in communication with a memory device which stores a reference value of an electrical characteristic of the at least one sensor for determination of a fluid expulsion event.

18. The apparatus of claim 1 wherein the fluid detection system comprises a sensor wherein the fluid detection system comprises a sensor having an electrical characteristic sensitive to contact with the fluid of the test component.

19. The apparatus of claim 1 wherein the fluid detection system comprises a sensor for capturing images of the fluid receiver and optical recognition software for recognising the presence of fluid in the fluid receiver.

20. A method for detecting expulsion of fluid from a test component comprising: predefining a reference value of an electrical characteristic of the at least one fluid sensor; sensing the value of an electrical characteristic of at least one fluid sensor; determining whether expulsion of fluid from the test component has occurred by comparing a sensed value of the electrical characteristic of at least one fluid sensor with the reference value of an electrical characteristic of the at least one fluid sensor.

21. The method of claim 19 wherein the method further comprises: measuring at least one characteristic of the test component; detecting expulsion of fluid from the test component; recording the measured characteristic of the test component.

22. The method of claim 19 wherein the method further comprises: capturing one or more video images of the test component; detecting expulsion of fluid from the test component; recording at least one captured video image of the test component.

23. An apparatus for detecting expulsion of fluid from an automotive component, the apparatus comprising: a housing comprising a plurality of walls forming an interior chamber; wherein the housing comprises an orifice for receiving a fluid receiver mounted to a breather system of the automotive component; a fluid detection system comprising at least one sensor for detecting the presence of fluid in the fluid receiver; at least one additional sensor for monitoring at least one parameter indicative of the condition of the automotive component.

24. The apparatus of claim 23 wherein the apparatus is configured to enable correlation of data from the at least one additional sensor with data from the at least one sensor indicating a fluid expulsion event.

25. The apparatus of claim 23 or 24 wherein the apparatus is configured to enable determination of the condition of the automotive component around the time of fluid expulsion from the breather system.

26. An apparatus for detecting expulsion of fluid from a test component substantially as described herein with reference to and/or as illustrated by the accompanying Figures.

27. A method substantially as described herein with reference to and/or as illustrated by the accompanying Figures.

27. A transmission system, drivetrain component or vehicle comprising an apparatus for detecting expulsion of fluid through a breather system substantially as described herein with reference to and/or as illustrated by the accompanying Figures.