KR20150132848A - Multi-modal fluid condition sensor platform and system thereof - Google Patents

Abstract

The present invention includes embodiments that simultaneously measure various situations of fluid contained in a circulation system such as a motor vehicle engine and a vehicle transmission in a multimode integrated manner. These circulating systems perform constant internal lubrication and remove heat and contaminants to prevent inherent friction and damage of internal moving parts during normal operation. Most commonly, lubrication is accomplished by fluids based on hydrocarbons and / or related compounds, fluids may lose their protective properties over time, their performance may change, internal and external events Resulting in degradation and corrosion. Some of the ingredients in the lubricant can be measured to perform their own tasks as designed, and can provide insight into the efficiency of the system. The mass and level of the fluid can also be monitored on an ongoing basis. This document describes a real-time, simultaneous integrated multimode sensor system for early warning and notification.

Description

TECHNICAL FIELD [0001] The present invention relates to a multi-mode fluid state detection sensor platform,

The present invention relates to a sensor platform for sensing a multimode fluid state and a system therefor and more particularly to a multimode fluid system for simultaneously measuring multimodal integration of various situations of fluid contained in a circulation system such as an automotive reciprocating engine and a vehicle transmission. A sensor platform for state detection, and a system thereof.

The field of the invention relates to, but is not limited to, the automotive industry. In particular, fluids relate to machine engines and large machinery using kinetic lubricants that operate in high temperature environments. In the case of these lubricants, it is advantageous to monitor changes in fluid properties, contamination levels, and performance in real time in order to ensure safe and reliable operation of the equipment protected by the lubricating system. This approach applies to automotive, aircraft or spacecraft, industrial equipment, wind turbines, life-saving medical devices and other critical devices. The state of the fluid is often measured using a static and periodic approach, which typically requires removing fluid from the system. Extracted fluid samples are often sent to test laboratories around the world, with historical time series of various parameters, as well as procedures and methods for measuring various situations of lubricants. At this time, it is common practice to apply such time-based long-term monitoring in order to detect changes over time and to gain an understanding of the performance changes in an enclosed environment. For example, when high concentrations of special particles are present, they can indicate wear and performance of some basic components in the lubricated system. This test typically involves detecting changes and deterioration of the basic lubricant and additives and detecting normal (anticipated) and abnormal (unexpected) "wear" of the moving parts due to normal operation, Measure the change of the characteristic. Static samples are usually sent to the agency performing a number of tests, including detection of the presence of foreign objects and objects. In some cases, such as when changing lubricants, it is common to send lubricant filters as well as oil for testing and detailed analysis. For both the sample and the filter, this is a destructive "decommissioning" analysis whereby the filter and sample are not returned for use, but are removed after evaluation. Tests generally performed in the laboratory include the detection of the presence of metal and non-metallic particles, water or other non-lubricating liquids, carbon soot and other components, and in some cases verification of the basic chemical nature of the lubricant . After the test is completed, a written (or electronic) report is created and sent to the interested party. Extraction to review of the results of stakeholders typically takes several days to weeks.

"Static" check of the engine oil sample to detect changes in electrical impedance characteristics (capacitance and resistance when weak power is applied across a sensor with a sufficiently large sample lubricant placed over the sensor electrode across the detector). com), as well as a number of low-cost lubricant measurement products and technologies are emerging on the market. This approach requires that the operator manually extract the oil samples to be tested by performing one-dimensional measurements (i.e., static measurements) in the fluid in the oil sump at the time of oil release, and data should be properly recorded and tracked over time But only if it shows only a change in the electrical characteristics of the device. This approach has a number of drawbacks, including the possibility of offsetting the force and concealing the actual situation / state of the lubricant due to the presence of various contaminants introduced into the fluid, as well as interval sampling (only when the operator makes the measurements). For example, in the case of a car engine, normal operation of the combustion engine will produce an elastic by-product as a result of operating the engine (which will discolor the oil). If the vehicle only produces this carbon "soot", the resistance will change due to the introduction of soot. At the same time, if the " wear "goes against the engine such that small metal particles are produced in an abnormal state over the inner moving part, these particles reduce the resistance because the metal is a better conductor than the basic lubricant. If soot and metal particles are all produced at the same time, they can provide false information about the actual situation of the lubricant and basic engine by partially or completely nullifying some or all of the measurable results. Test by comparison The laboratory analysis independently detects the presence of two substances in the base lubricant and implements a number of tests that can provide an accurate report of the fluid and consequently the condition of the system.

Lubricants must accommodate a wide range of operating conditions, including temperature, pressure, purity, and changes in conditions. Lubricants are often optimized for specific operating conditions and the temperature range is indicated by viscosity. Some lubricants are designed to operate in multiple viscosities (e.g. 10W-30 multi-grade viscosity engine oil). Typically, the measurement of the state and characteristics of the fluid is static and is externally performed outside of this operating environment through sampling in static / non-operating conditions. Static sampling does not need to check the state of the fluid in an operating situation within or outside the normal / typical operating range. There are expensive and complex sensors developed for real-time measurement of lubricants and other liquids for use in laboratory environments and conditions, or for very expensive machines that place immediate attention on sensor lubrication information. Companies such as Voelker Sensors offer products for the machine tool industry that measure a number of parameters in real time, including oil level oxidation (pH change), temperature, and so on. This sensor element is not MEMS-based, has a wide receive range and is not suitable for size / form factor to operate in an automotive oil / lubricant system (" Continuous Oil Condition Monitoring for Machine and Industrial Processing Equipment," Practicing Oil Analysis (9/2003).

In the field of integrated circuit multimode sensor systems, there is no single-vector analysis (electricity) or oil status (7,835,875, 6,922,064, 7,362,110), Freese et al (5,604,441), Ismail et al (6,557,396), Steininger (4,224,154), Marszalek There are a variety of mechanisms for continuously measuring electrical properties, as is performed by other documents that have been published to begin a time series measurement of electrical properties to derive an understanding of electrical properties. As with the Lubricheck approach, there remains a challenge to overcome the interdependent actual measurement cancellation effects that can report inaccurate oil conditions. It is accurate to apply a test that determines the content of metals and other contaminants in the oil sample, as well as the multidimensional tests, including the fluid test protocol and spectrum analysis in the laboratory.

Lubricants are designed to run beyond their specified range, and performance is further enhanced by the addition of "additives" to extend fluid life and safety limits. Understanding the lubrication life is important for the safe operation of the system. In order to provide the driver with a wide variety of safety limits, the fluid is typically replaced with a highly conservative (ie, short) recommended gap. In general, lubricants can operate for a very long period of time and may require a more aggressive replacement cycle for specialized equipment that operates in harsh environments (such as military equipment used in field or mining operations). It is important to determine if fluid lubrication can not continue to be carried out according to specifications determined by the equipment / system manufacturer. As long as the lubricant is within safe operating limits, it can operate indefinitely and does not need to be replaced or replaced with fresh lubricant.

Providing a more accurate measurement of the performance of the fluid can maximize the life of both the lubricant and the equipment protected by the lubricant. As the cost of equipment and hydrocarbon lubricants increases, it provides accurate values for a longer and precise lifetime of the lubricant, and early detection of deterioration in ongoing equipment performance (including motors, filters, and other components in the system) Notify. This approach can potentially prolong the life span if a critical instrument defect is detected in advance. Also, since fluid failure necessarily leads to equipment failure, these systems potentially eliminate the resources, time, and cost of repairing / replacing basic / damaged equipment. This approach also avoids the loss of service and resources needed to completely replace the oil more often than is actually needed.

It is an object of the present invention to provide a sensor platform for multimode fluid state sensing and an integrated system thereof for continuously monitoring various characteristics of fluids derived from measurements from multiple sensor forms in a fluid-based closed system environment.

In order to achieve the above object, the present invention provides an integrated system for continuously monitoring various characteristics of fluids derived from measurements from a plurality of sensor forms in a fluid-based closed system environment. Preferably, the system is an in-motor lubrication monitoring system and is monitored in real time.

In a particular embodiment, the system is embedded in a form factor of a standard size and shape of an oil drain plug formed in a reciprocating engine oil drain pan, and the system is connected to a wired or wireless data telemetry Lt; / RTI > Preferably, the system further comprises a remotely located receiver.

In a further embodiment, the system further comprises a processed nanoparticle, which when combined with the target contaminant provides a unique and measurable signature and can be collected and removed via circulation by the filtering device. have. Preferably, when one or more target environmental conditions are met, the nanoparticles are changed in state. In an embodiment, the nanoparticles are capable of detecting deviations in temperature above a designed operating specification (i.e., temperatures above or below the operating specifications). In another embodiment, the nanoparticles enable the detection of temperature deviations (i.e., temperatures above or below the operating specifications) beyond the designed operating specifications, and in a further embodiment the nanoparticles are capable of detecting the performance of the filtering device .

In another embodiment, the sensor configuration includes two or more electrical, temperature, magnetic, optical, temperature, and multi-axis accelerometer sensors, and preferably one or more sensor configurations include inductors. In an embodiment, the sensor form comprises one or more magnetic and optical sensors, and in another embodiment, the sensor form comprises at least an electrical, magnetic and optical sensor.

In certain embodiments, the system is housed within an epoxy capsule that is capable of withstanding the high temperature, high pressure, and high vibration environments included in the oil drain flap mechanical design.

In a particular embodiment, the system further comprises a limited-lifetime power source for providing electrical energy to the electrical components of the sensor platform. In some embodiments, the system further includes an energy scavenger / harvester that supplies power to the rechargeable power source for extended life.

In a particular embodiment, the system includes a plurality of digital signal processor modules for detecting both a signal and a plurality of related fluid properties. In an embodiment, the system includes generating a multi-stage output signal selected from the group consisting of error indication, feature detection signal of special data, feature signal detection intensity level of special data, and Fast Fourier Transform (FFT) data output do.

In another embodiment, the measured values of the sensor format may be determined using Kalman filtering techniques, Bayesian analysis techniques, hidden-Markov filtering techniques, fuzzy logic analysis techniques or neural network analysis techniques. Respectively.

In an exemplary embodiment, the measured values of the sensor style include, but are not limited to, differential temperature comparisons, differential magnetic sensor comparisons, differential inductive sensor comparisons, differential electrical impedance comparisons, differential optical absorption comparisons, , Comparison of data of each sensor vector versus time and temperature, data comparison of integrated vector consisting of two or more sensor sets combined, comparison of inductive data versus time and temperature, optical data comparison versus time and temperature, peak column Optical data comparisons versus temperature and pressure, pressure data versus multi-axis accelerometer data for detecting a temperature, and combinations of other sensors.

There is also provided a method of continuously monitoring a working fluid in a machine, the method comprising: measuring a first state of the fluid using a first sensor form; and measuring a second state of the fluid using a second sensor form, The method comprising the steps of measuring, filtering data from the sensors, integrating data from the sensors, analyzing the data from the sensors, deriving the characteristic of the fluid from the data Transmitting the characteristics of the derived fluid state to a receiver; and repeating the process to thermally accumulate fluid properties tracking changes in the operating state of the fluid. In an embodiment, the method includes tracking the state of the fluid by calculating any one or more of the observed rate of change versus the predicted rate of change in time series. In a further embodiment, the method further comprises calculating a predicted divergence or convergence over a plurality of sensor time series data in the expected and predicted measured value versus unexpected changes.

According to the sensor platform for multimodal fluid state sensing of the present invention and its system, these circulation systems are capable of performing certain internal lubrication and removing heat and contaminants to prevent inherent friction and damage of internal moving parts during normal operation Effect.

In addition, lubrication is generally achieved by fluids based on hydrocarbons and / or related compounds, and since fluids can lose their protective properties over time, their performance may change, internal and external events may occur, So that some of the components in the lubricant have the effect of enabling simultaneous estimation of various conditions of the fluid to perform its own tasks as designed.

1 is a diagram illustrating an exemplary real-time multi-mode fluid sensing system described herein.
Figure 2 is an illustration of an exemplary primary engine sensor source and receiving element forming a multimode fluid sensor solution.
3 is a block diagram illustrating exemplary primary electronics and firmware elements of the system shown herein.
4 is an insertion of an exemplary photosensor.
5A and 5B are block diagrams illustrating exemplary processing electrical and / or firmware elements comprising a digital signal processing module included within the processing portion of the system shown herein for integrated multimode sensor computation.
6 is a diagram showing a configuration of a discrete wavelength for detecting various optical characteristics.
7 is a block diagram illustrating an exemplary power supply for a system shown herein.
8 is a diagram illustrating an exemplary real-time multimode fluid sensing system shown herein for an exemplary form factor of a standard oil drain plug.

It is to be understood that the particular embodiments shown and described herein are illustrative and not intended to limit the scope of the disclosure in any way.

The disclosure patents, patent applications, websites, company names, and scientific literature referred to herein are hereby incorporated by reference in their entirety to the same extent as if each was specifically and individually indicated to be incorporated by reference. In the event of any conflict between any reference cited herein and the specific teachings herein, the latter shall precede it. Likewise, if there is any conflict between the definitions understood in the industry of words or phrases and the definitions of words or phrases specifically taught in this specification, the latter shall prevail.

As used herein, the singular forms include plural forms of the mentioned terms unless expressly specified otherwise. As used herein, the term " about " means roughly, in the area of, roughly, or about. When the term "about" is used in conjunction with a numerical range, the range is modified by extending the boundary above and below the numerical value mentioned. In general, the term " drug ", as used herein, modifies the degree of dispersion of up to and including 20% of such numerical values.

Unless defined otherwise, the technical and scientific terms used herein have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Various methods and materials known to those skilled in the art are referred to herein.

To provide a more accurate understanding of the fluid, performing the multimodal test at the same time helps to give insight into the actual operating conditions and the condition of the lubricant. In an embodiment, an integrated system is provided for continuously monitoring a plurality of characteristics of a fluid derived from measurements from a plurality of sensor forms in a fluid-based enclosure system environment. The preferred embodiment utilizes a combination of advanced micro-electro-mechanical systems (MEMS) and semiconductor technology to directly introduce laboratory tests into the fluid, And reporting these parameters to an individually programmable computer, providing a parallel, integrated, real-time analysis of fluid conditions. As used herein, the term "sensor modalities" refers to the measurement of the fluid's magnetic, electrical, and optical properties, as well as the measurement of fluid temperature and pressure, and the measurement of fluid and multi- And monitoring the orientation. They collectively encompass examples of "multi-modal" analysis or testing throughout the present invention. These measurements can be performed individually and in combination to provide integrated insight into fluid conditions and conditions. One-dimensional tests can make it difficult to understand any single result caused by the interaction between two different contaminants in the fluid (e.g., both electrical resistance in the system and combination of all of the impurities with reduced electrical resistance) The application of the simultaneous multimode using two (or more than two) sensing schemes improves the fidelity and accuracy of the measurements.

In order to provide a better understanding of the fluid state, it is desirable in embodiments to improve the detection and collection of undesirable contaminants in the fluid, as well as to improve the detection of undesirable contaminants in the fluid, Processed nanoparticles are introduced. Specifically, the engineered particles are added to the fluid, injected into the fluid, and triggered / released into the fluid flow in the presence of contaminants, including water, antifreeze, metal impregnate, carbon soot, and the like. No nanoparticles are detected until triggered. The resulting bonded or state-changed particles are measurable by a multimode sensor (multiple sensor forms) and provide a more precise and complete understanding of fluid conditions. Bonded particles obtained are also better captured by special filter steps or magnets (eg, permanent magnets) than contaminants without nanoparticles. This process involves three main steps. First, the nanoparticles and their surface attachments are designed to be activated by the presence of a specific contaminant target and are identified through the particle and through the understanding of various contamination conditions that the lubrication system may encounter. Second, nanoparticles are introduced into the lubrication system by being added or injected into the material in the filter. Finally, the nanoparticles are activated and then detected by the multi-mode sensor system in the operating environment. Also, the binding of the nanoparticles attached to the contaminants is preferably better filtered and removed by active circulation in the lubrication system. Further, continuous detection and measurement of nanoparticles by multimode sensors may indicate partial or total failure of the fluid filter.

The nanoparticles can be released into the fluid during normal operating conditions. In such an embodiment, when any portion of the lubrication system exceeds the target operating state, the nanoparticles may be designed to change state. For example, if an excessive temperature is applied anywhere in the engine lubrication system, such a nanoparticle can be designed to irreversibly change its state. Changes in the environmentally introduced nanoparticle properties are then measured and recognized, indicating that some of the machine may be overheated. For example, the surface properties of nanoparticles may change under thermal stress. Changes in surface properties can be detected by the sensor system, which can alert the system of excessive temperatures in some of the systems that may remain unmeasured. The particles can be designed to change fluorescence, phase magnetism or other physical or chemical properties irreversibly, for example, above the target temperature. If any part of the system or part exceeds the design temperature, these particles irreversibly change state. The changed state can be measured at a single point in the system, like a multidimensional sensor. This approach enables continuous display of temperature limits at all points in the lubrication system. This is equivalent to a temperature sensor mounted over all internal combustion environments, but it provides less complex advantages with less resources.

In an embodiment, the processed nanoparticles themselves serve as lubricants because their unique precursors are based on carbon nanostructures with friction-reducing properties. Nanoparticles also have inherent properties that increase the surface area range, which improves sensor detection (for example, detection of overheating conditions) and improves the lubrication range within the system. In certain embodiments, the nanoparticles include metal nanoparticles that are coated with a thin layer of graphitic carbon (e.g., about 2 nm) that enables covalent chemical functionalization of the carbon to create chemically functionalized magnetic beads. In another embodiment, the nanoparticles comprise metal magnetic nanoparticles containing, for example, cobalt, iron, nickel and alloys. In certain embodiments, the reactive metal is covered by a graphene-like carbon layer. In certain embodiments, the inert properties of carbon result in core-shell magnetic materials exhibiting very high thermal and chemical stability. In certain embodiments, the nanobeads can be applied in harsh conditions, such as low pH and high temperature, without oxidation problems of the metal core. In another embodiment, the nanoparticles have a covalent functionalization of the metal nanomagnets. In certain embodiments, the bond is dependent on the carbon-carbon bond, so that the ligand is not lost under the required process conditions (e.g., high functional load). A wide range of functionalization enables the production of beads with customized surface function, and in certain embodiments the nanoparticles are magnetic beads having covalently functionalized aromatic groups, catalysts and protecting groups. High magnetic properties allow for high recyclability of magnetochemicals for reuse.

In multi-mode sensing, the state of the fluid (and / or the fluid) is determined using software / firmware programmed to combine the measured values to compare the sensor input to the reference data and to detect changes in the fluid state over various measurement dimensions, State change). It is important to set a threshold value to detect foreign matter in the oil. For example, over time, a sufficient amount of water may cause corrosion of critical elements that are normally protected by lubricating oil. Based on these thresholds, certain alarms and notifications can be provided by transmission via an output interface or, optionally, polling by the air interface using a portable hand-held device such as a smart phone. To confirm a continuous evaluation of fluid status, a second check can be run to verify the measurements via periodic lab sampling.

An external test can be part of the calibration process that is identified during initial testing of the multimode sensor. The external test can also acquire additional lubricant and operating environment. Once the reference value is known, a threshold over all integrated measurements can be programmed into the semiconductor to provide a warning function above the integrated measurement data output.

In a further embodiment, the systems and methods described herein detect the use of improper fluids or improper lubricants that can be introduced into the lubricant system by mistake. If the machine is operated with incompatible lubricants, immediate improvement may result in irreversible damage. The multimode sensor is expected to identify and alert the lubricant when unconfirmed fluid is introduced and subsequently detected.

For both immediate measurement and long-term monitoring, you can combine special individual sensors in configurations that provide a more complete understanding of the state of the system. Such a sensor configuration greatly improves the real-time monitoring of the system state and greatly improves the system's ability to recognize and respond to various operational events as operational.

In particular, a configuration with a magnetic sensor facilitates timely recognition of ferrous metal contaminants. Such a magnetic sensor can also detect magnetic nanoparticles. Other sensors in the configuration can distinguish two. For example, paramagnetic resonance can characterize the properties of iron particles, and their potential size.

A light transmittance meter, an unambiguous measurement value, or a spectral measurement value integrated into the configuration provides an indication of a particular contaminant, such as, for example, hum, water, or antifreeze. Detection of contaminants can be improved by an integrated nanoparticle sensor. Further, the present invention can be further improved by having a multi-mode sensing analysis, for example, to include pressure and temperature that can change the optical properties of the fluid. These correction factors can be provided to improve measurement accuracy.

An integrated light transmittance meter in the configuration provides a more complete picture of fluid conditions. These measurements may be detected or provided in an independent manner to distinguish between alternative fluid conditions and condition diagnostics. These measurements can detect nanoparticles and can be provided in an independent manner to distinguish between alternative fluid conditions and condition diagnostics. Nanoparticles can be processed and activated under specific conditions and conditions, such as high temperature intrusion, which irreversibly change their state. This state change can be detected by one or more sensor form sets.

The control system incorporates different sensors, using a sensor state pattern that "recognizes "or" diagnoses "a set of states that may be of further interest. Such analytical mathematical algorithms that have been established include, but are not limited to, Kalman filtering (and highly Kalman filtering), hidden-Marcov filtering, Bayesian analysis, artificial neural network analysis, or fuzzy logic analysis. These control systems can be easily implemented in software, hardware, or a combination thereof. (See " Solutions for MEMS Sensor Fusion, " Esfandyari, J, De Nuccio, Xu, G., Solid State Technology, July 2011, 21, the disclosure of which is incorporated herein by reference in its entirety).

In a further embodiment, different machine operations, including, for example, "at rest" when the system is not operational, or "peak heat" Under the conditions, additional understanding of fluid properties can be obtained. If no cooling fluid circulates, the temperature may rise after stopping. As the fluid is heated and cooled, the fluid properties change. Measuring these changes over short heating or cooling periods can create additional markings and insights into the properties of valuable lubricants. For example, light absorption may vary as the fluid is heated. Also, tracking changes in electrical properties with a temperature chart can provide additional information about the state of the fluid. Deviations can cause the control system to require measurements, for example, during start-up or shutdown, as well as when the machine is operating.

The present application addresses many of the limitations of traditional diagnostics. First, the traditional time delay in fluid sampling for testing can pose a risk of damaging critical equipment. Often the lubricant samples at the point of exchange. While potentially useful in providing insight into the wear of internal parts, the machine can be operated in a potentially unsafe condition until results are returned from the laboratory. Second, the lubricating oil can be exposed to extreme temperatures, often exceeding 150 캜, during short-term operation, potentially causing some failure of the additives in the lubricating oil. Often in this state the equipment is "turned off" so that the above-mentioned problems are usually not detected. Even if no new heat is generated, the residual heat can be transferred into the lubricant, potentially impacting its performance. Such extreme temperatures often require special engineering efforts to design an integrated in-situ sensing system to support reliable operation. In addition, sensors and other electrically active devices need to support this environment. It is equally important to support the various pressures that can be applied to the lubricant during normal and high load operation. The on-site sensor configuration must be designed to withstand peak temperatures and pressures applied to the lubrication system over time.

Several variables provide insight into the nature of the lubricant. Some variables can be measured directly, while other variables can be derived. To achieve a basic understanding of the fluid state, several measurements of the lubricant (sensor form) can be helpful, for example, temperature, absolute pressure, electrical impedance or resistance, pH, light transmission or absorption, and magnetic measurements. Like carbon accumulation through the combined measurement of electricity and light conversion, the measurement can be made directly (for example, through a temperature sensor). Standard techniques such as thermocouples and pressure sensors capable of acquiring some of these data points are now available and in use. The derived measurements (for example, viscosity suitability within the operating range) can be calculated from the direct measurements and can be estimated in the range of temperature and pressure. Additional detection methods include the use of one or more derivation coils and magnetic sensors to enhance the detection of the moving magnetic particles. For example, a light transmittance meter consisting of an optical light source and a photodetector characterizes carbon soot accumulation and other potential contaminants and materials in lubricating oil by measuring changes in optical absorption at various wavelengths. All such measurements should be temperature and pressure corrected (or normalized) to provide an accurate indication of the basic health condition of the lubricant. In addition, pressure measurements can be obtained for changes in system operation. It is possible to use a calculation of the orientation from a multi-axis accelerometer to determine when the pressure reading can be invalidated due to the system being oriented beyond a certain standard, or alternatively to compensate the pressure readings for system orientation within such certain standard limits do.

The viscosity analysis derives the friction index from a number of sensor readings that determine the net fluid friction of the lubricant. The present invention provides a simple method of deriving viscosity, for example, by measuring by two magnetic sensors in a fluid lubricant in a selected zone. These magnetic sensors, such as a no-latency Hall sensor, are placed closely adjacent to each other within the lubricant flow. A small disturbance trigger enables a slight difference in flow to be measured near the sensor based on the derived flow disturbance. This measurement can be further integrated with the light absorption measurement using a light transmittance meter. An integrated measurement, or acquired pressure reading, associated with this temperature provides a configuration for calculating the friction index. Hall-based sensors are designed to be as similar as possible. The temporal and spatial changes not caused by the turbulence inducer are subtracted using almost the same two sensors. In addition, the shape of the turbulence inducer is designed to create subtle changes related to fluid velocities similar to aerospace applications where fluid molecules travel at slightly different velocities above and below the wing. The viscosity can be derived from these measurements with slight differences with local temperature and pressure using the documented lubricant viscosity reference data to provide an indication of real-time lubrication conditions.

Preferably, the sensor is designed to withstand high temperature engine lubricants. The high temperature thermocouple measures the temperature, the thick film resistor is pressure sensitive, and there is a high temperature magnetic sensor. The optical measurement method is based on a proven high temperature design. Preferably, the light spectrum has a UV to medium-IR range in which the lubricating oil does not emit energy at high temperatures, depending on the fluid, environment and potential contaminants. The transmittance range is measured in mm, and the distance between the light emitting element and the light receiving element is precisely controlled using a known MEMS manufacturing technique. The distance between the light emitting device and the receiving device must be very accurate. These devices are all implementable and operate individually in the extreme temperature and pressure environment described above in a manner that relay useful data. The design is not limited to the above-described method. Currently, these methods have proven to be effective and provide a simple solution.

In an embodiment, the systems and methods described throughout are suitable for use with such fluids in connection with a high temperature environment present in or associated with an internal combustion engine (i.e., without delaying the removal of the sample, monitoring the fluid during engine activation) Provides real-time monitoring. Preferably, the systems and methods are used in conjunction with oil-based lubricants commonly used in internal combustion engines, as well as glycol-based coolants such as other fluids such as transmission fluids or antifreeze fluids, and other fluids of critical life-saving medical equipment used in the manufacturing environment and healthcare industry Lt; / RTI > Preferably, the system and method provide real-time monitoring using a plurality of form sensors to determine the rating of the monitored fluid under various operating conditions. Another aspect resides in the ability of the present invention to detect the presence of known noxious particulates, such as metals, in lubricants. Another aspect described is to monitor the fluid with a sensor module that is continuously impregnated in the lubricant. Another aspect described is the parallel analysis of fluid states in real time. Another aspect described is the introduction of specifically engineered nanoparticles designed to enhance the detection and capture of contaminants and the detection of adverse operating conditions. The present invention also describes high temperatures and other conditions experienced in the operating environment of such a machine.

In an exemplary embodiment, the real-time multimode fluid sensing system is a self-contained embodiment of a single unit that includes an active sensing environment 100 that is immersed in a fluid to be monitored. The sensor is attached to the assembly, which can be placed in fluid with an electronic active sensor embedded in the oil drain plug 300, which is held in place through the threaded bolt (200). The bolt head accepts a non-sensor element of a self-contained system, called a command, control and communication module, C3 module 400, to include a microcontroller, filter and other elements. Also included within the assembly are preferably an induction coil 108 and other sources of signal including power needed to operate the system, such as the power supply 180. The bolt assembly is a self-contained platform that can be installed and removed by an engineer. Such an environment is typical of an oil drain plug on a similar "lowest point" in an automotive or lubrication recovery system that may function as a reservoir for the fluid. The fluid environment is subject to changes in temperature and pressure through normal and abnormal operation. These sensors are designed to operate within the temperature and pressure specifications, and with typical tolerances beyond the normal operating environment to detect abnormal conditions.

Within the sensing environment, the system programmatically generates its local and low energy reference signal sources over a number of sensor forms including magnetic, optical and electrical, and continuously detects the values therein, Manually receive pressure and temperature measurements. The active elements of the sensor platform 100 are allowed to be impregnated into the fluid during the measurement. If the sensor is not fully or partially impregnated in the fluid it is detected through optical sensor 106 to light reception 107 as well as multiple sensor acknowledgments across power source 101 to reception 104 of expected value tolerances. And confirm. In this way, the lack of fluid can be detected in a number of approaches, as well as verifying that both the electrical and optical sensors are correctly co-cross checked.

The magnetic sensing is performed by a predefined programmable characteristic 102 having a predetermined fixed reference distance immediately adjacent to the magnetic sensor 103 that is received and processed by the data acquisition control 109 to perform signal amplification, ≪ / RTI > signal. The detection can be accomplished by one or more sensors 103 of that type, which may be the same type or different and provide a response speed corresponding to a signal that can provide both direct and differential measurements of the fluid state. The data acquisition control unit 109 performs the steps of filtering and analyzing the signals, including amplification and noise reduction filtering, communicated to the microcontroller 140. In connection with other measured dimensions, magnetic measurements permit both the identification of the detected conditions and the vector for detecting exceptional conditions, such as paramagnetic nanoparticles, which develop magnetic characteristics that can be detected during activation. Activation of the nanoparticles is independent of the sensor, triggered by exceptional conditions such as exceeding the extreme temperature limit.

The one or more optical sensors 107 may include one or more specific light wavelength emitters, such as narrow band frequency tuned light emitting diodes (LEDs), and one or more specific light source (s) 106, which may consist of an optical receiver, Can be connected. Today's light emitters are capable of emitting light at narrowband frequencies. Such wavelengths depend on the fluid and the particular type of contaminant that can accumulate in the fluid. Fig. 6 shows a representative map over the near infrared region. The optical sensor is not limited, but can determine a number of characteristics including the presence of fluid upon LED emission. Also, the LEDs can be placed at different predetermined fixed distances from the accompanying photoreceptor, thereby providing a distance based on the profile of the absorption over different frequencies. Embodiments can be achieved with a single LED emitter for a photoreceptor at a given distance, as well as by multiple LEDs spaced a predetermined distance from a photoreceptor pulsed in a known sequence. The control logic is managed through the software / firmware in the microcontroller 140 and the data acquisition control unit 109. [ The optical sensor can detect the difference between the absorption of a specific wavelength in the optical characteristic and the time series change. The developed optical sensor operates in both active and passive modes. In the active mode, the light source measures the absorption and level of light from the light source by pulsing light of a predetermined intensity and wavelength through the fluid. As shown in Fig. 6, this small transmissivity meter detects a change in fluid characteristics such as a failure and / or a special contaminant through a special wavelength. Other operating modes detect optically active nanoparticles triggered by exceptional events such as temperature deviations. In this mode, sources such as (but not limited to, a special wavelength light trigger and an electrical trigger or a magnetic trigger) cause the specially processed nanoparticles to fluoresce at a specific frequency so that they can be detected by the optical sensor 107 do. The optical emitter can be pulsed into a programming sequence so that a common photoreceptor can be applied as the sense receiving point and software in the microcontroller can couple the emitter frequency to the signal response received by the photoreceptor sensor. In addition, activation of nanoparticles is independent of detection. The method of triggering the nanoparticle is as long as the activated particle can be independent of the light trigger, for example, if the nanoparticle is triggered and emits a magnetic or electric field source as its trigger, which is provided by the multidimensional sensor.

The change detection of the electrical characteristic is achieved by the power source 101 disposed at a predetermined reference distance obtained from the measured capacitance such as the dielectric constant of the fluid. The strength and frequency of the signal and the measurement are based on the programmable microcontroller firmware and are based on and depend on the basic characteristics of the fluid to be placed and monitored continuously between the source and the measurement sensor. The electrical resistance and capacitance may be measured across the gap through the data acquisition control 109. The ability of different fluids to have different characteristics and thus to control both the source system and the sensor reception characteristics to be programmed is an important aspect of the present invention. The pressure sensor 111 and the temperature sensor 110 are also connected to the data acquisition control unit 109. These sensors can also detect normal and abnormal conditions of the heat and pressure levels and can provide insight into the operating conditions of the environment. A change in the fluid state, such as break through the peak operating environment (if the system is not operating), can be evaluated by the programmable microcontroller unit 140. These applications can be developed with software / firmware to include developing an understanding of both "break" and "on the move". In addition, the profile at a particular pressure and temperature can be used to determine the amount of optical characteristics (e.g., the offset due to temperature / pressure) It can be useful for all of the changes. In addition, the detection of nanoparticles can be triggered by the introduction of electrical signals of any nature, such as frequency, which facilitate detection by magnetic or optical means.

Tracking changes in the orientation of the oil drain plug 300 of FIG. 1 in a three-dimensional space is accomplished by a multi-axis acceleration sensor 112, and in an alternative embodiment by reference, the accelerometer 112 includes a C3 module 400 ), A MEMS sensor platform 100, a receiver 170, or other external location. The accelerometer sensor 112 may be located within the MEMS device 100, within the non-sensor element of the self-contained system, within the C3 module 400, which is referred to as command, control, and communication module, or near other processor units. The acceleration of each axis of interest is measured by the data acquisition control unit 109 and used to calculate the orientation of the oil drain plug 300, that is, the orientation of the vehicle engine in space. The orientation calculation is used in the data acquisition control unit 109 to obtain a measurement value from the pressure sensor 111 and to reject the specific pressure reading value or to calculate a specific pressure reading value .

The real time clock 150 provides an accurate time reference for trigger monitoring events by the microcontroller module 140 and combines the acquired data with a time reference for time series analysis. The real-time clock provides both time and date information that can be combined with the measured values of each recorded multimode sensor.

The programmable microcontroller 140 also provides information both before and after processing, including the use of filtering, and other algorithms for providing data correction. The result is communicated to the receiver 170 via the communication module 160 via a wired or wireless connection. For reference, the receiver 170 may include a display, a processing unit, or both, for receiving data in an integrated system. Both the receiver 170 and the microcontroller may have an internal storage 280 for recording and evaluating time series data.

Sensor data is accumulated in the microcontroller 140, and further filtering and integration are performed through a plurality of sensors. The raw data may be stored in one or more sets of digital signal processors (DSP) for each individual sensor style, such as temperature, pressure, light absorption, electrical resistance and magnetic characteristics 203,204, 205,206, . The resultant parallel output (both before and after data correction filtering 220) provides all of the raw data output 260 that can be communicated via communication module 160.

The configuration module 270 can dynamically set filtering and processing parameters in the advanced filter 220 to include parameters such as baseline and error conditions, as well as other configuration storage, event monitoring, triggers, and the like. The configuration module is connected to the external device through the communication module 160.

The nano-state detector 240 continuously checks for any triggered and activated nanoparticles that exhibit certain characteristics through one or more sensor sets. The detector includes detecting any active features in the microcontroller in a profiled and programmed state. The state detector evaluates the output of the DSP processing from one or more sensor sets and integrates filtered and integrated characteristic data combined with real-time characteristic 230 data. The nano-state detector may also provide outputs to display 260 and storage 280, as well as receive configuration parameters via configuration module 270.

It may also be continued or polled at intervals as indicated by the microprocessor and associated programming software during operation and may be further improved by including a real time clock to provide an accurate time reference 150. [ The "crosscheck" of such measurements all provide confirmation of eigenvalues and improve the integrity of data correction (eg, Kalman filtering and other algorithmic techniques) and the overall sensor system. In many high-value systems, when a "fault" is detected, the fault is often in the sensor, not in the environment. The present invention provides for cross comparison and verification of unique sensor platforms by continually checking across multiple measurement criteria and can continuously verify the performance of the sensor system with expected and expected sensor outputs / values. In this way, isolation of an error condition (e.g., sensor failure) provides the operator with useful insight into the recognition and replacement of a faulty sensor as an essentially known faulty device.

A power source 180, including a power storage unit 182 and an optional energy harvester, powers the C3 module 400 and the sensor platform 100. In one embodiment, the power storage includes a battery that powers the system until it is discharged. In another embodiment, the power storage unit includes a rechargeable battery connected to one or more energy harvesters, extending the life of the storage unit over a single charge. In another embodiment, the power storage unit includes an electric double layer capacitor selectively connected to an energy harvester that extends the lifetime of the power storage unit beyond a single charge.

In one embodiment, the energy harvester includes a vibrational energy harvester 183 that converts kinetic energy from the environment into current. In another embodiment, the energy harvester includes an acoustic energy harvester 184 that converts audible or vibrational energy into electrical current. In another embodiment, the energy harvester includes a thermal energy harvester 185 that converts the temperature difference to a current. In another embodiment, the energy harvester includes an electromagnetic energy harvester 186, and the antenna 188 collects background electromagnetic radiation, such as an F transmission for conversion into a current path.

The C3 module 400 communicates with the receiver 170 using a wired or wireless protocol, or both. A suitable protocol is currently used for a controller area network (CAN) bus and a local interconnect network (LIN) bus for wired communications, a tire pressure monitoring system for wireless communication, TPMS) and remote keyless systems (RKS). In some embodiments, the receiver 170 may include a processing unit. The receiver may also include a display for displaying the monitoring status.

Mechanical design for on-site sensing of changes in fluid parameters, including unique features, provides an environmentally sound and robust design for minimal cost and long life. The concept is to include a pressure sensor device built into the oil drain plug which allows the installation and replacement of a simple upgrade according to a scheduled maintenance schedule. The sensor is equipped with an epoxy polymer resin that has excellent operating temperature range, adhesion, and salt and oil resistance due to byproducts. This is important in preventing problems associated with differential thermal expansion, exfoliation, and chemical failure. The bolt has a standard thread size based on end user specifications. The holes enable the installation of the integrated system and are punched through the center of the bolt to provide the oil path present on the sensor platform 100. The pressure sensor is open to the outside through an atmospheric pressure integrated pipe 314. The head of the bolt is machined down so that the sensor can be joined in the bolt by creating a cavity.

7 shows a power source including power storage unit 182 and / or energy harvesters 183-186. Such an energy harvester may collect vibrational energy 183, or acoustic energy 184, from the oil pan of the engine in operation, among others. As is known to those skilled in the art, many embodiments also include a thermal gradient between the fluid fan and the environment, and the harvester 185 includes a TEC (Thermo-Electric Converter) for converting heat to electrical energy . Alternatively, the electromagnetic harvester 186 may selectively use the antenna 188 to collect energy from any one of electric, magnetic, inductive, wired, or wireless electromagnetic energy.

8 shows a particularly preferred embodiment of the present invention in which the C3 module 400, the integrated MEMS sensor platform 316 equivalent to the sensor platform 100, the oil drain plug multi-mode sensor system 316 including the battery 180, Of FIG. The RF antenna 310 provides communication and, in some embodiments, performs the evolution of the antenna 188. The printed circuit board 312 shown in the cutaway view provides electrical connection to one or more substrates and the C3 module 400 and the MEMS sensor platform 316 or 100. The atmospheric pressure integrated pipe 314 transfers the atmospheric pressure to the differential pressure sensor disposed on the sensor platform 316 in the case of the present embodiment. For reference, in another embodiment, an absolute pressure sensor may be used in place of this differential pressure sensor, and, contrary to mechanical pressure compensation, an additional atmospheric pressure sensor may be provided with or without an additional atmospheric pressure sensor to enable electrical compensation. For those skilled in the art, temperature compensation for such pressure sensors is also known to improve accuracy and repeatability. The bolt screw 200, in some preferred embodiments, provides conformal drop-in replacement for a conventional oil drain fan bolt.

In one embodiment, the sensor system measures the pressure near the bottom of the fluid reservoir and optionally compares this pressure to atmospheric pressure. Optionally, measurements may include temperature correction. This approach can measure the mass of a fluid in a column on a sensor corresponding to a static pressure in a gravity (or acceleration) system. For a given temperature, this static pressure is close to the level of fluid at the specific temperature and orientation of the fluid containing vessel.

The foregoing description has been presented for purposes of illustration and with reference to specific embodiments. It should be understood, however, that the foregoing description is not intended to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teachings. The embodiments have been chosen and described in order to explain the principles of the invention and its practical application and, therefore, those skilled in the art will be able to best understand the invention and various embodiments with various modifications as are suited to the particular use contemplated.

Claims (42)

An integrated system that continuously monitors a number of characteristics of a fluid derived from measurements from multiple sensor forms within a fluid-based enclosure system environment. The integrated system of claim 1, wherein the system is an in-motor lubrication monitoring system. The integrated system of claim 1, wherein the monitoring is in real time. The integrated system of claim 1, further comprising a remotely located receiver unit. 2. A method as claimed in claim 1, characterized in that it is embedded in a form factor of a standard size and shape oil drain plug formed in a reciprocating engine oil drain pan, the system being remotely located from the receiver unit, the system being communicated from the system to the receiver unit by telemetry. 2. The integrated system of claim 1, wherein the sensor configuration includes at least two electrical, temperature, magnetic, optical, acceleration, and pressure sensors. 2. The integrated system of claim 1, wherein the at least one sensor form comprises an inductor. The integrated system of claim 1, wherein the sensor form comprises one or more magnetic and optical sensors. 2. The integrated system of claim 1, wherein the sensor form comprises one or more electrical, magnetic and optical sensors. 2. The integrated system of claim 1 housed in an epoxy capsule capable of withstanding high temperature, high pressure and high vibration environments. The integrated system of claim 1, further comprising a plurality of digital signal processor modules for detecting both a signal and a plurality of associated fluid properties. The method of claim 1, further comprising generating a multi-stage output signal selected from the group consisting of an error indication, a feature detection signal of the special data, a feature signal detection intensity level of the special data, and a Fast Fourier Transform (FFT) Integrated system. The integrated system of claim 1, wherein the measured values of the sensor form are analyzed using Kalman filtering techniques. 2. The integrated system of claim 1, wherein the sensor measurements are analyzed using Bayesian analysis techniques. The integrated system of claim 1, wherein the measured values of the sensor form are analyzed using a hidden-Markov filtering technique. The integrated system of claim 1, wherein the measured values of the sensor form are analyzed using fuzzy logic analysis techniques. The integrated system of claim 1, wherein the measured values of the sensor form are analyzed using neural network analysis techniques. 2. The integrated system of claim 1, wherein the measured values of the sensor form include one or more of the following:
a Differential temperature comparison;
b Differential magnetic sensor comparison;
c Differential inductive sensor comparison;
d Differential electrical impedance comparison;
e Differential light absorption comparison;
f Any combination of two or more sensor sets and integrated comparison;
g Comparison of sensor vector versus time and temperature data;
comparing data of an integrated vector consisting of two or more sets of sensors coupled together;
i Guided data comparison vs. time and temperature;
j Optical data comparison vs. time and temperature;
k optical data comparison vs temperature and pressure;
temperature data comparison for detecting peak heat versus time and pressure; And
m Combination of other sensors. An in-engine lubrication monitoring system for continuously monitoring a plurality of characteristics of fluids derived from measurements from a plurality of sensor configurations in a fluid-based enclosure system environment, comprising: error indication, feature detection signals of special data, A signal detection strength level, and a fast Fourier transform (FFT) data output. 20. The integrated system of claim 19, wherein the in-engine lubrication monitoring system includes an oil plug formed within a reciprocating engine oil drain pan. 20. The system of claim 19, wherein the system is remotely located from a receiver unit by wired or wireless data telemetry. 20. The integrated system of claim 19, further comprising a remotely located receiver unit. A method for periodically monitoring a working fluid of a machine, comprising: measuring a first state of a fluid using a first sensor configuration; Measuring a second state of the fluid using a second sensor configuration; Filtering data from the sensors; integrating data from the sensors; Analyzing data from the sensors; Deriving a characteristic of the fluid from the data; Transmitting the derived characteristics of the fluid state to a receiver; And repeating the process to thermally accumulate fluid properties tracking changes in the operating state of the fluid. 24. The method of claim 23, further comprising tracking the state of the fluid by calculating any one or more of the observed rate of change versus time-series predicted rate of change. 24. The method of claim 23, further comprising calculating a predicted divergence or convergence over a plurality of sensor time series data in expected and predicted measured value versus unexpected. The integrated system of claim 6, wherein the pressure sensor form is obtained by the acceleration sensor form. 24. The method of claim 23, further comprising comparing accelerometer readings over time to determine a standard system orientation for obtaining a pressure reading for changes in system orientation. 2. The integrated system of claim 1, wherein the system is powered by a power supply comprising one or more of the following:
a. Non-rechargeable electric battery;
b. Rechargeable electric battery;
c. Electric double layer capacitor
d. An energy harvester for converting vibrational energy into current;
e. An energy harvester that converts acoustic energy into current;
f. An energy harvester for converting a temperature difference into a current;
g. Energy harvesters that convert electromagnetic energy into current; And
h. Other energy harvesting type. 2. The integrated system of claim 1, wherein the system includes a microcontroller for processing sensor form readings. The integrated system of claim 1, further comprising a communication unit for coupling with one or more of:
a. A wireless link from the system to the receiver unit;
b. A wireless link from the receiver unit to the system;
c. A wire connecting the system to the receiver unit; And
d. And a wired line connecting the receiver unit to the system. 29. The integrated system of claim 28, wherein the communication unit comprises one or more of the following:
a. In-vehicle wireless communication;
b. Tire Pressure Monitoring System (TPMS)
c. Remote Keyless System (RKS);
d. Wired communication within the vehicle;
e. CAN bus; And
f. LIN. The integrated system of claim 1, wherein the integrated system is disposed within an oil drain pan bolt of the engine. 24. The method of claim 23, further comprising charging an energy storage that supplies energy to the sensor platform. 24. The integrated system of claim 23, further comprising refurbishing the drain pan plug after filling the fluid. 2. The integrated system of claim 1, wherein the monitoring of the plurality of properties comprises measuring non-conforming properties of the monitored fluid to detect non-compliance of the fluid introduced into the environment of the fluid based enclosure system. An integrated system comprising a sensor for measuring the pressure of fluid below its surface as compared to atmospheric pressure, one of which is a level of fluid in the closed system. 38. The integrated system of claim 36, further comprising a temperature sensor coupled to the system for compensating for pressure readings to temperature. 2. The integrated system of claim 1, wherein the fluid level in the enclosure system comprises one of the characteristics, and wherein one of the sensor forms comprises a pressure sensor. 2. The integrated system of claim 1, wherein the method of signal source from the battery includes power to operate the system. 40. The integrated system of claim 39, wherein the battery is charged by a current provided by the method of one or more of the following sources to include power to operate the system:
a. A source for converting the vibration energy into a current;
b. A source for converting thermal energy into a current; And
c. A source that converts electromagnetic energy into electrical current. 42. The method of claim 41, wherein the signal source from the capacitor comprises power to operate the system, and wherein the capacitor is charged by the current provided by the method of one or more of the following: Integrated systems:
a. A source for converting the vibration energy into a current;
b. A source for converting thermal energy into a current; And
c. A source that converts electromagnetic energy into electrical current. 42. The integrated system of claim 41, wherein the capacitor is an electrical double layer capacitor.

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