US20150369236A1 - System and method for health determination of a machine component - Google Patents
System and method for health determination of a machine component Download PDFInfo
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- US20150369236A1 US20150369236A1 US14/307,657 US201414307657A US2015369236A1 US 20150369236 A1 US20150369236 A1 US 20150369236A1 US 201414307657 A US201414307657 A US 201414307657A US 2015369236 A1 US2015369236 A1 US 2015369236A1
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- component
- operating parameter
- controller
- health
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B51/00—Testing machines, pumps, or pumping installations
Definitions
- the present disclosure relates to a diagnostic system, and more specifically to a system and method for determining health of a machine component.
- a machine component such as a fuel pump, has an operating life during which the component may provide satisfactory performance. Beyond the operating life, the component may fail or efficiency may reduce due to wear and tear and/or other factors.
- diagnosis techniques for predicting a failure of the component monitor an operating temperature of components connected in parallel to the said machine component, in order to predict failure of the machine component.
- U.S. Pat. No. 5,566,091 discloses a method for diagnosing degradation and predicting failure of similar machine components operated in parallel.
- the method includes providing a plurality of similar components with sensor means for producing signals indicative of a level of an operating parameter common to the components.
- the method includes periodically determining from the signals a difference between the operating parameter level of a first component and the operating parameter level of a second component to generate a differential value.
- the method also includes averaging one or more differential values over a predefined trend period to generate a corresponding trend value for that period.
- the method further includes generating a trend based on a plurality of trend values to provide an indication of component performance useful in diagnosing component health.
- the method disclosed in the '091 patent may provide inaccurate or erroneous results during exceptional behavior characteristics of the machine component such as, for example, a sudden spike in the operating temperature, variation in ambient conditions of operation of the machine component, and so on.
- a system for determining health of a component includes an operational parameter module associated with the component.
- the operational parameter module is configured to generate an operating parameter signal indicative of an operating parameter of the component.
- the system also includes a controller in communication with the operational parameter module.
- the controller is configured to receive the operating parameter signal from the operational parameter module.
- the controller is configured to monitor a change of the operating parameter over a predetermined time period.
- the controller is configured to compare the monitored operating parameter with a first predetermined threshold.
- the controller is configured to determine a rate of change of the monitored operating parameter over the predetermined time period.
- the controller is also configured to compare the determined rate of change with a second predetermined threshold.
- the controller is further configured to determine the health of the component based, at least in part, on the comparisons with the first and second predetermined thresholds respectively and one or more additional parameters associated with the component.
- a method for determining health of a component includes receiving an operating parameter signal indicative of an operating parameter of the component.
- the method includes monitoring a change of the operating parameter over a predetermined time period.
- the method includes comparing the monitored operating parameter with a first predetermined threshold.
- the method includes determining a rate of change of the monitored operating parameter over the predetermined time period.
- the method also includes comparing the determined rate of change with a second predetermined threshold.
- the method further includes determining the health of the component based, at least in part, on the comparisons with the first and second predetermined thresholds respectively and one or more additional parameters associated with the component.
- system for determining health of a component includes a means for generating an operating parameter signal indicative of an operating parameter of the component.
- the system includes a means for receiving the operating parameter signal from an operational parameter module.
- the system includes a means for monitoring a change of the operating parameter over a predetermined time period.
- the system includes a means for comparing the monitored operating parameter with a first predetermined threshold.
- the system includes a means for determining a rate of change of the monitored operating parameter over the predetermined time period.
- the system also includes a means for comparing the determined rate of change with a second predetermined threshold.
- the system further includes a means for determining the health of the component based, at least in part, on the comparisons with the first and second predetermined thresholds respectively and one or more additional parameters associated with the component.
- FIG. 1 is a block diagram of an exemplary health determination system, according to one embodiment of the present disclosure
- FIGS. 2 to 4 are graphs showing exemplary variations of an operating temperature of a component over a predetermined time period, according to various embodiments of the present disclosure.
- FIG. 5 is a flowchart of a method of working of the health determination system.
- the health determination system 100 is associated with one or more components 102 of a machine (not shown). More specifically, the component 102 may be a fuel pump. The component 102 may be associated with an engine (not shown) of the machine.
- the machine may be any machine known in the art associated with industries including, but not limited to, construction, transportation, mining, agriculture, forestry, material handling, power generation and waste management. Accordingly, the machine may be a wheel loader, an excavator, a dozer, a paving machine, a mining truck, a generator set and so on.
- the health determination system 100 includes a means for generating an operating parameter signal, such as an operational parameter module.
- the operational parameter module may be a single sensor, a combination of sensors, one or more virtual sensors or a module configured to derive or computationally estimate the operating parameter signal from one or more other signals.
- the operating parameter signal may be at least one of a temperature signal, a pressure signal, a velocity signal and a load signal indicative of the respective operating parameter of the component 102 .
- the operating parameter considered herein is a temperature signal “TS” and the operational parameter module is a temperature sensor 104 .
- the operating parameter signal may include the pressure signal, the velocity signal or the load signal and/or a combination thereof without limiting the scope of the disclosure.
- the operational parameter module may be a pressure sensor, a velocity sensor, or a load sensor respectively.
- the health determination system 100 includes the means for generating the temperature signal “TS” such as, the temperature sensor 104 .
- the means for generating the temperature signal “TS” may include any temperature sensing device such as, for example, a thermocouple, a thermistor, a resistive temperature device, an infrared sensor, a bimetallic device, and so on.
- the temperature signal “TS” may be derived or computationally estimated from one or more other signals, virtual sensors or engine related parameters such as, but not limited to, engine speed, engine load, and so on.
- the temperature sensor 104 is communicably coupled to the component 102 .
- the temperature signal “TS” is indicative of an operating temperature “OT” of the component 102 .
- the means for generating the temperature signal “TS” may include a first temperature sensor (not shown) and a second temperature sensor (not shown).
- the first temperature sensor is configured to generate a first temperature signal (not shown) indicative of an operating temperature of an inlet of the component 102 .
- the second temperature sensor is configured to generate a second temperature signal (not shown) indicative of an operating temperature of an outlet of the component 102 .
- the health determination system 100 includes a means for receiving the temperature signal “TS” from the temperature sensor 104 such as, a controller 106 .
- the controller 106 may include a product control module, a commercial or third party data acquisition system, a pyrometer and so on.
- the controller 106 is communicably coupled to the temperature sensor 104 .
- the controller 106 when the health determination system 100 may include the first and second temperature sensors, the controller 106 is communicably coupled to the first and second temperature sensors. In such a situation, the controller 106 may receive the first and second temperature signals from the first and second temperature sensors respectively.
- the controller 106 may embody a single microprocessor or multiple microprocessors configured for receiving signals from the components 102 of the health determination system 100 .
- the signals may be in analog and/or digital format.
- Numerous commercially available microprocessors may be configured to perform the functions of the controller 106 .
- the controller 106 may embody a machine microprocessor capable of controlling numerous machine functions.
- the controller 106 may additionally include other elements and may also perform other functions not described herein. Further, the controller 106 may be located on the component 102 , the machine or at a remote location.
- the health determination system 100 includes a means for monitoring a change of the operating temperature “OT” over a predetermined time period “T” such as, the controller 106 .
- the controller 106 may include the product control module, the commercial or third party data acquisition system, the pyrometer and so on.
- the means for generating the temperature signal “TS” may include the first and second temperature sensors
- the controller 106 may be configured to monitor a difference between the first and second temperature signals over the predetermined time period “T”.
- the predetermined time period “T” may refer to a predefined time period such as, a period from date/time of installation of the component 102 until current date/time, a period from date/time of last service interval of the component 102 until current date/time and/or any other custom dates/times.
- the health determination system 100 includes a means for comparing the monitored operating temperature “OT” with a first predetermined threshold “TH1” such as, the controller 106 .
- the controller 106 may include the product control module, the commercial or third party data acquisition system, the pyrometer and so on.
- the means for generating the temperature signal “TS” may include the first and second temperature sensors
- the controller 106 may be configured to compare the difference between the first and second temperature signals with the first predetermined threshold “TH1”.
- the first predetermined threshold “TH1” may be stored in a database 108 communicably coupled to the controller 106 or a memory (not shown) of the controller 106 .
- the controller 106 may refer to a lookup table stored in the database 108 or the memory of the controller 106 .
- the controller 106 may refer to a reference map stored in the database 108 or the memory of the controller 106 .
- the lookup table and/or the reference map may include values of the first predetermined threshold “TH1” corresponding to one or more additional parameters.
- the additional parameters may include at least one of a level of fuel in a tank (not shown), an ambient temperature and a type of fuel which will be explained later.
- the controller 106 may refer to a predefined relationship stored in the database 108 or the memory of the controller 106 .
- the predefined relationship may be a predetermined mathematical equation.
- the mathematical equation may include a multiple polynomial regression model, a physics based model, a neural network model or any other model or algorithm or a combination thereof known in the art.
- the health determination system 100 includes a means for determining a rate of change of the monitored operating temperature “OT” over the predetermined time period “T” such as, the controller 106 .
- the controller 106 may include the product control module, the commercial or third party data acquisition system, the pyrometer and so on.
- the means for generating the temperature signal “TS” may include the first and second temperature sensors
- the controller 106 may be configured to determine a rate of change of the difference between the first and second temperature signals over the predetermined time period “T”.
- the health determination system 100 includes a means for comparing the determined rate of change with a second predetermined threshold “TH2” such as, the controller 106 .
- the controller 106 may include the product control module, the commercial or third party data acquisition system, the pyrometer and so on.
- the means for generating the temperature signal “TS” may include the first and second temperature sensors
- the controller 106 may be configured to compare the determined rate of change of the difference between the first and second temperature signals with the second predetermined threshold “TH2”.
- the second predetermined threshold “TH2” may be stored in the database 108 communicably coupled to the controller 106 or the memory (not shown) of the controller 106 .
- the controller 106 may refer to the lookup table stored in the database 108 or the memory of the controller 106 . In another embodiment, the controller 106 may refer to the reference map stored in the database 108 or the memory of the controller 106 .
- the lookup table and/or the reference map may include values of the second predetermined threshold “TH2” corresponding to one or more additional parameters.
- the additional parameters may include at least one of the level of fuel in the tank, the ambient temperature and the type of fuel which will be explained later.
- the controller 106 may refer to the predefined relationship stored in the database 108 or the memory of the controller 106 .
- the predefined relationship may be the predetermined mathematical equation.
- the mathematical equation may include the multiple polynomial regression model, the physics based model, the neural network model or any other model or algorithm or a combination thereof known in the art.
- the first and second predetermined thresholds “TH1”, “TH2” are absolute values stored in the database 108 or the memory of the controller 106 . Further, the first and second predetermined thresholds “TH1”, “TH2” may be modified by an operator based on system design and requirements.
- the health determination system 100 also includes a means for determining the health of the component 102 such as, the controller 106 .
- the controller 106 may include the product control module, the commercial or third party data acquisition system, the pyrometer and so on.
- the controller 106 is configured to determine the health of the component 102 based, at least in part, on the comparisons with the first and second predetermined thresholds “TH1”, “TH2” respectively and the one or more additional parameters associated with the component 102 .
- a graph 200 showing an exemplary variation of the operating temperature “OT” of the component 102 over the predetermined time period “T” is illustrated.
- the operating temperature “OT” of the component 102 over the predetermined time period “T” is lower than the first predetermined threshold “TH1”.
- the rate of change of the monitored operating temperature “OT” (not shown) over the predetermined time period “T” is lower than the second predetermined threshold “TH2” (not shown).
- the controller 106 is configured to determine a healthy status of the component 102 .
- a graph 300 showing another exemplary variation of the operating temperature “OT” of the component 102 over the predetermined time period “T” is illustrated.
- the operating temperature “OT” of the component 102 includes a single instance of a sudden spike “S” which is higher than the first predetermined threshold “TH1”.
- the operating temperature “OT” of the component 102 is lower than the first predetermined threshold “TH1” for a majority of the predetermined time period “T” prior to as well as after the single instance of the sudden spike “S”.
- the rate of change of the monitored operating temperature “OT” (not shown) over the predetermined time period “T” is lower than the second predetermined threshold “TH2” (not shown).
- the controller 106 is configured to determine the healthy status of the component 102 .
- a graph 400 showing yet another exemplary variation of the operating temperature “OT” of the component 102 over the predetermined time period “T” is illustrated.
- the operating temperature “OT” of the component 102 varies over the predetermined time period “T”. More specifically, the operating temperature “OT” of the component 102 gradually increases over the predetermined time period “T” and crosses the first predetermined threshold “TH1”. Also, the rate of change of the monitored operating temperature “OT” (not shown) over the predetermined time period “T” may be approximately equal or higher than the second predetermined threshold “TH2” (not shown).
- the controller 106 is configured to determine a failure status of the component 102 .
- the operating temperature “OT” of the component 102 over the predetermined time period “T” may vary such that the operating temperature “OT” may gradually increase but may be lower or approximately equal to the first predetermined threshold “TH1”. Also, the rate of change of the monitored operating temperature “OT” over the predetermined time period “T” may be approximately equal to or higher than the second predetermined threshold “TH2”. In such a situation, the controller 106 is configured to determine an impending failure status of the component 102 .
- the operating temperature “OT” of the component 102 over the predetermined time period “T” may be approximately equal to or higher than the first predetermined threshold “TH1”.
- the rate of change of the monitored operating temperature “OT” over the predetermined time period “T” may be approximately zero or negligible and the operating temperature “OT” of the component 102 is maintained higher than the first predetermined threshold “TH1”.
- the controller 106 is configured to determine the failure status of the component 102 .
- the controller 106 is also configured to provide a notification to the operator indicative of the determined status of the health of the component 102 . Accordingly, the controller 106 is communicably coupled to an output device 110 .
- the output device 110 may include a monitor, a screen, a display panel, a speaker, a light source, and so on.
- the output device 110 is configured to provide the notification to the operator.
- the notification may be a text message and/or an email including numerical, alphabetical, alphanumerical and/or special characters.
- the notification may be an audible message, a visual indication in form of glowing of the light source or display of specific icons on the output device 110 or a combination of similar such other notifications.
- the controller 106 may be configured to compensate for changes in the ambient temperature.
- the means for generating the temperature signal “TS” may include the first and second temperature sensors and the ambient temperature may be low
- the first temperature signal may be generally low due to the low ambient temperature.
- the difference between the first and second temperature signals may be higher than the first predetermined threshold “TH1”.
- the controller 106 may be configured to compensate for the lower first temperature signal and/or may increase the first predetermined threshold “TH1” in order to compensate for or take into consideration other factors that may have an affect on the temperature signal “TS”.
- the first temperature signal may be generally high due to the high ambient temperature.
- the difference between the first and second temperature signals may be lower than the first predetermined threshold “TH1”.
- the controller 106 may be configured to compensate for the higher first temperature signal and/or may lower the first predetermined threshold “TH1”.
- the controller 106 may be configured to compensate for changes in the type of fuel. Different fuels may have different physical properties such as viscosity, specific heat and so on. Thus, when the type of fuel may change, the operating temperature “OT” may change accordingly. In one embodiment, the operating temperature “OT” of the component 102 may increase due to the change in the type of fuel. Accordingly, the operating temperature “OT” of the component 102 may be higher than the first predetermined threshold “TH1” even when the component 102 may be healthy.
- the operating temperature “OT” of the component 102 may reduce due to the change in the type of fuel. Accordingly, the operating temperature “OT” of the component 102 may be lower than the first predetermined threshold “TH1” even when the component 102 may have already failed or may be failing.
- the controller 106 may be configured to increase or decrease the first predetermined threshold “TH1” based on the type of fuel.
- the controller 106 may also be configured to compensate for changes in the level of fuel in the tank.
- the tank may receive unused fuel from different components of the machine which may generally be at elevated temperatures. During a low fuel level condition in the tank, the returning unused fuel at elevated temperatures may mix with the fuel present in the tank. This may lead to an overall increase in a temperature of the fuel within the tank.
- the increased temperature of the fuel in the tank may represent the first temperature signal.
- the difference between the first and second temperature signals may be lower than the first predetermined threshold “TH1”.
- the controller 106 may be configured to compensate for the higher first temperature signal and/or may lower the first predetermined threshold “TH1” based on the fuel level condition in the tank.
- the present disclosure relates to a method 500 for determining the health of the component 102 .
- a flowchart of working of the health determination system 100 is illustrated.
- the controller 106 receives the operating parameter signal indicative of the operating parameter of the component 102 . More specifically, the controller 106 receives the temperature signal “TS” indicative of the operating temperature “OT” of the component 102 .
- the controller 106 monitors the change of the operating parameter over the predetermined time period “T”. More specifically, the controller 106 monitors the change of the operating temperature “OT” over the predetermined time period “T”.
- the controller 106 compares the monitored operating parameter with the first predetermined threshold “TH1”.
- the controller 106 compares the monitored operating temperature “OT” with the first predetermined threshold “TH1”. At step 508 , the controller 106 determines the rate of change of the monitored operating parameter over the predetermined time period “T”. More specifically, the controller 106 determines the rate of change of the monitored operating temperature “OT” over the predetermined time period “T”. At step 510 , the controller 106 compares the determined rate of change with the second predetermined threshold “TH2”.
- the controller 106 may receive the first and second temperature signals indicative of the operating temperature “OT” of the inlet and the outlet of the component 102 respectively.
- the controller 106 monitors the difference between the first and second temperature signals over the predetermined time period “T”.
- the controller 106 compares the difference between the first and second temperature signals with the first predetermined threshold “TH1”.
- the controller 106 determines the rate of change of the difference between the first and second temperature signals over the predetermined time period “T”.
- the controller 106 compares the determined rate of change of the difference between the first and second temperature signals with the second predetermined threshold “TH2”.
- the controller 106 determines the health of the component 102 based, at least in part, on the comparisons with the first and second predetermined thresholds “TH1”, “TH2” respectively and the one or more additional parameters associated with the component 102 .
- the one or more additional parameters include at least one of the level of fuel in the tank, the ambient temperature and the type of fuel. Based on the comparison and/or status of exceeding the first and second predetermined thresholds “TH1”, “TH2”, the controller 106 determines the healthy, impending failure or failure status of the component 102 . Further, the controller 106 may provide the notification to the operator indicative of the determined health of the component 102 through the output device 110 .
- the health determination system 100 and the method 500 disclosed herein may be used to determine the impending failure of the component 102 based on the monitoring of the operating temperature “OT” of the component 102 itself Further, the system 100 may also take into consideration, the behavior of the component 102 over the predetermined time period “T” thereby providing an accurate diagnosis wherein an anomalous behavior of the component 102 will not affect the overall health determined by the system 100 . Additionally, the system 100 allows flexibility by considering the other additional parameters, such as, the ambient conditions, and so on, in order to accurately determine the health of the component 102 .
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Abstract
A system for determining health of a component is provided. The system includes an operational parameter module associated with the component and in communication with a controller. The controller is configured to receive an operating parameter signal from the operational parameter module. The controller is configured to monitor a change of the operating parameter over a predetermined time period. The controller is configured to compare the monitored operating parameter with a first predetermined threshold. The controller is configured to determine a rate of change of the monitored operating parameter over the predetermined time period. The controller is also configured to compare the determined rate of change with a second predetermined threshold. The controller is further configured to determine the health of the component based, at least in part, on the comparisons with the first and second predetermined thresholds respectively and one or more additional parameters associated with the component.
Description
- The present disclosure relates to a diagnostic system, and more specifically to a system and method for determining health of a machine component.
- A machine component, such as a fuel pump, has an operating life during which the component may provide satisfactory performance. Beyond the operating life, the component may fail or efficiency may reduce due to wear and tear and/or other factors. Currently used diagnosis techniques for predicting a failure of the component monitor an operating temperature of components connected in parallel to the said machine component, in order to predict failure of the machine component.
- For example, U.S. Pat. No. 5,566,091, hereinafter referred as the '091 patent, discloses a method for diagnosing degradation and predicting failure of similar machine components operated in parallel. The method includes providing a plurality of similar components with sensor means for producing signals indicative of a level of an operating parameter common to the components. The method includes periodically determining from the signals a difference between the operating parameter level of a first component and the operating parameter level of a second component to generate a differential value. The method also includes averaging one or more differential values over a predefined trend period to generate a corresponding trend value for that period. The method further includes generating a trend based on a plurality of trend values to provide an indication of component performance useful in diagnosing component health.
- However, the method disclosed in the '091 patent may provide inaccurate or erroneous results during exceptional behavior characteristics of the machine component such as, for example, a sudden spike in the operating temperature, variation in ambient conditions of operation of the machine component, and so on.
- Hence, there is a need for an improved system and method for determining health of the machine component prior to failure.
- In one aspect of the present disclosure, a system for determining health of a component is provided. The system includes an operational parameter module associated with the component. The operational parameter module is configured to generate an operating parameter signal indicative of an operating parameter of the component. The system also includes a controller in communication with the operational parameter module. The controller is configured to receive the operating parameter signal from the operational parameter module. The controller is configured to monitor a change of the operating parameter over a predetermined time period. The controller is configured to compare the monitored operating parameter with a first predetermined threshold. The controller is configured to determine a rate of change of the monitored operating parameter over the predetermined time period. The controller is also configured to compare the determined rate of change with a second predetermined threshold. The controller is further configured to determine the health of the component based, at least in part, on the comparisons with the first and second predetermined thresholds respectively and one or more additional parameters associated with the component.
- In another aspect of the present disclosure, a method for determining health of a component is provided. The method includes receiving an operating parameter signal indicative of an operating parameter of the component. The method includes monitoring a change of the operating parameter over a predetermined time period. The method includes comparing the monitored operating parameter with a first predetermined threshold. The method includes determining a rate of change of the monitored operating parameter over the predetermined time period. The method also includes comparing the determined rate of change with a second predetermined threshold. The method further includes determining the health of the component based, at least in part, on the comparisons with the first and second predetermined thresholds respectively and one or more additional parameters associated with the component.
- In yet another aspect of the present disclosure, system for determining health of a component is provided. The system includes a means for generating an operating parameter signal indicative of an operating parameter of the component. The system includes a means for receiving the operating parameter signal from an operational parameter module. The system includes a means for monitoring a change of the operating parameter over a predetermined time period. The system includes a means for comparing the monitored operating parameter with a first predetermined threshold. The system includes a means for determining a rate of change of the monitored operating parameter over the predetermined time period. The system also includes a means for comparing the determined rate of change with a second predetermined threshold. The system further includes a means for determining the health of the component based, at least in part, on the comparisons with the first and second predetermined thresholds respectively and one or more additional parameters associated with the component.
- Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.
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FIG. 1 is a block diagram of an exemplary health determination system, according to one embodiment of the present disclosure; -
FIGS. 2 to 4 are graphs showing exemplary variations of an operating temperature of a component over a predetermined time period, according to various embodiments of the present disclosure; and -
FIG. 5 is a flowchart of a method of working of the health determination system. - Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or the like parts. Referring to
FIG. 1 , an exemplary block diagram of ahealth determination system 100 is illustrated. Thehealth determination system 100 is associated with one ormore components 102 of a machine (not shown). More specifically, thecomponent 102 may be a fuel pump. Thecomponent 102 may be associated with an engine (not shown) of the machine. The machine may be any machine known in the art associated with industries including, but not limited to, construction, transportation, mining, agriculture, forestry, material handling, power generation and waste management. Accordingly, the machine may be a wheel loader, an excavator, a dozer, a paving machine, a mining truck, a generator set and so on. - The
health determination system 100 includes a means for generating an operating parameter signal, such as an operational parameter module. The operational parameter module may be a single sensor, a combination of sensors, one or more virtual sensors or a module configured to derive or computationally estimate the operating parameter signal from one or more other signals. The operating parameter signal may be at least one of a temperature signal, a pressure signal, a velocity signal and a load signal indicative of the respective operating parameter of thecomponent 102. - For the purpose of explanation of the disclosure, the operating parameter considered herein is a temperature signal “TS” and the operational parameter module is a
temperature sensor 104. It should be noted that, in other embodiments, the operating parameter signal may include the pressure signal, the velocity signal or the load signal and/or a combination thereof without limiting the scope of the disclosure. Accordingly, the operational parameter module may be a pressure sensor, a velocity sensor, or a load sensor respectively. - The
health determination system 100 includes the means for generating the temperature signal “TS” such as, thetemperature sensor 104. In other embodiments, the means for generating the temperature signal “TS” may include any temperature sensing device such as, for example, a thermocouple, a thermistor, a resistive temperature device, an infrared sensor, a bimetallic device, and so on. In yet other embodiments, the temperature signal “TS” may be derived or computationally estimated from one or more other signals, virtual sensors or engine related parameters such as, but not limited to, engine speed, engine load, and so on. Thetemperature sensor 104 is communicably coupled to thecomponent 102. The temperature signal “TS” is indicative of an operating temperature “OT” of thecomponent 102. - In other embodiments, the means for generating the temperature signal “TS” may include a first temperature sensor (not shown) and a second temperature sensor (not shown). The first temperature sensor is configured to generate a first temperature signal (not shown) indicative of an operating temperature of an inlet of the
component 102. The second temperature sensor is configured to generate a second temperature signal (not shown) indicative of an operating temperature of an outlet of thecomponent 102. - The
health determination system 100 includes a means for receiving the temperature signal “TS” from thetemperature sensor 104 such as, acontroller 106. In other embodiments, thecontroller 106 may include a product control module, a commercial or third party data acquisition system, a pyrometer and so on. Thecontroller 106 is communicably coupled to thetemperature sensor 104. In the embodiment, when thehealth determination system 100 may include the first and second temperature sensors, thecontroller 106 is communicably coupled to the first and second temperature sensors. In such a situation, thecontroller 106 may receive the first and second temperature signals from the first and second temperature sensors respectively. - The
controller 106 may embody a single microprocessor or multiple microprocessors configured for receiving signals from thecomponents 102 of thehealth determination system 100. The signals may be in analog and/or digital format. Numerous commercially available microprocessors may be configured to perform the functions of thecontroller 106. It should be appreciated that thecontroller 106 may embody a machine microprocessor capable of controlling numerous machine functions. A person of ordinary skill in the art will appreciate that thecontroller 106 may additionally include other elements and may also perform other functions not described herein. Further, thecontroller 106 may be located on thecomponent 102, the machine or at a remote location. - The
health determination system 100 includes a means for monitoring a change of the operating temperature “OT” over a predetermined time period “T” such as, thecontroller 106. In other embodiments, thecontroller 106 may include the product control module, the commercial or third party data acquisition system, the pyrometer and so on. In the embodiment, where the means for generating the temperature signal “TS” may include the first and second temperature sensors, thecontroller 106 may be configured to monitor a difference between the first and second temperature signals over the predetermined time period “T”. The predetermined time period “T” may refer to a predefined time period such as, a period from date/time of installation of thecomponent 102 until current date/time, a period from date/time of last service interval of thecomponent 102 until current date/time and/or any other custom dates/times. - The
health determination system 100 includes a means for comparing the monitored operating temperature “OT” with a first predetermined threshold “TH1” such as, thecontroller 106. In other embodiments, thecontroller 106 may include the product control module, the commercial or third party data acquisition system, the pyrometer and so on. In the embodiment, where the means for generating the temperature signal “TS” may include the first and second temperature sensors, thecontroller 106 may be configured to compare the difference between the first and second temperature signals with the first predetermined threshold “TH1”. The first predetermined threshold “TH1” may be stored in adatabase 108 communicably coupled to thecontroller 106 or a memory (not shown) of thecontroller 106. - In one embodiment, the
controller 106 may refer to a lookup table stored in thedatabase 108 or the memory of thecontroller 106. In another embodiment, thecontroller 106 may refer to a reference map stored in thedatabase 108 or the memory of thecontroller 106. The lookup table and/or the reference map may include values of the first predetermined threshold “TH1” corresponding to one or more additional parameters. The additional parameters may include at least one of a level of fuel in a tank (not shown), an ambient temperature and a type of fuel which will be explained later. In yet another embodiment, thecontroller 106 may refer to a predefined relationship stored in thedatabase 108 or the memory of thecontroller 106. The predefined relationship may be a predetermined mathematical equation. The mathematical equation may include a multiple polynomial regression model, a physics based model, a neural network model or any other model or algorithm or a combination thereof known in the art. - The
health determination system 100 includes a means for determining a rate of change of the monitored operating temperature “OT” over the predetermined time period “T” such as, thecontroller 106. In other embodiments, thecontroller 106 may include the product control module, the commercial or third party data acquisition system, the pyrometer and so on. In the embodiment, where the means for generating the temperature signal “TS” may include the first and second temperature sensors, thecontroller 106 may be configured to determine a rate of change of the difference between the first and second temperature signals over the predetermined time period “T”. - The
health determination system 100 includes a means for comparing the determined rate of change with a second predetermined threshold “TH2” such as, thecontroller 106. In other embodiments, thecontroller 106 may include the product control module, the commercial or third party data acquisition system, the pyrometer and so on. In the embodiment, where the means for generating the temperature signal “TS” may include the first and second temperature sensors, thecontroller 106 may be configured to compare the determined rate of change of the difference between the first and second temperature signals with the second predetermined threshold “TH2”. The second predetermined threshold “TH2” may be stored in thedatabase 108 communicably coupled to thecontroller 106 or the memory (not shown) of thecontroller 106. - In one embodiment, the
controller 106 may refer to the lookup table stored in thedatabase 108 or the memory of thecontroller 106. In another embodiment, thecontroller 106 may refer to the reference map stored in thedatabase 108 or the memory of thecontroller 106. The lookup table and/or the reference map may include values of the second predetermined threshold “TH2” corresponding to one or more additional parameters. The additional parameters may include at least one of the level of fuel in the tank, the ambient temperature and the type of fuel which will be explained later. In yet another embodiment, thecontroller 106 may refer to the predefined relationship stored in thedatabase 108 or the memory of thecontroller 106. The predefined relationship may be the predetermined mathematical equation. The mathematical equation may include the multiple polynomial regression model, the physics based model, the neural network model or any other model or algorithm or a combination thereof known in the art. It should be noted that the first and second predetermined thresholds “TH1”, “TH2” are absolute values stored in thedatabase 108 or the memory of thecontroller 106. Further, the first and second predetermined thresholds “TH1”, “TH2” may be modified by an operator based on system design and requirements. - The
health determination system 100 also includes a means for determining the health of thecomponent 102 such as, thecontroller 106. In other embodiments, thecontroller 106 may include the product control module, the commercial or third party data acquisition system, the pyrometer and so on. In the illustrated embodiment, thecontroller 106 is configured to determine the health of thecomponent 102 based, at least in part, on the comparisons with the first and second predetermined thresholds “TH1”, “TH2” respectively and the one or more additional parameters associated with thecomponent 102. - Referring to
FIG. 2 , agraph 200 showing an exemplary variation of the operating temperature “OT” of thecomponent 102 over the predetermined time period “T” is illustrated. As shown, the operating temperature “OT” of thecomponent 102 over the predetermined time period “T” is lower than the first predetermined threshold “TH1”. Also, the rate of change of the monitored operating temperature “OT” (not shown) over the predetermined time period “T” is lower than the second predetermined threshold “TH2” (not shown). In such a situation, thecontroller 106 is configured to determine a healthy status of thecomponent 102. - Referring to
FIG. 3 , agraph 300 showing another exemplary variation of the operating temperature “OT” of thecomponent 102 over the predetermined time period “T” is illustrated. As shown, the operating temperature “OT” of thecomponent 102 includes a single instance of a sudden spike “S” which is higher than the first predetermined threshold “TH1”. Further, the operating temperature “OT” of thecomponent 102 is lower than the first predetermined threshold “TH1” for a majority of the predetermined time period “T” prior to as well as after the single instance of the sudden spike “S”. Also, the rate of change of the monitored operating temperature “OT” (not shown) over the predetermined time period “T” is lower than the second predetermined threshold “TH2” (not shown). In such a situation, thecontroller 106 is configured to determine the healthy status of thecomponent 102. - Referring to
FIG. 4 , agraph 400 showing yet another exemplary variation of the operating temperature “OT” of thecomponent 102 over the predetermined time period “T” is illustrated. As shown, the operating temperature “OT” of thecomponent 102 varies over the predetermined time period “T”. More specifically, the operating temperature “OT” of thecomponent 102 gradually increases over the predetermined time period “T” and crosses the first predetermined threshold “TH1”. Also, the rate of change of the monitored operating temperature “OT” (not shown) over the predetermined time period “T” may be approximately equal or higher than the second predetermined threshold “TH2” (not shown). In such a situation, as the operating temperature “OT” and the rate of change of the operating temperature “OT” exceeds the first and second predetermined thresholds “TH1”, “TH2” respectively, thecontroller 106 is configured to determine a failure status of thecomponent 102. - In another embodiment (not shown), the operating temperature “OT” of the
component 102 over the predetermined time period “T” may vary such that the operating temperature “OT” may gradually increase but may be lower or approximately equal to the first predetermined threshold “TH1”. Also, the rate of change of the monitored operating temperature “OT” over the predetermined time period “T” may be approximately equal to or higher than the second predetermined threshold “TH2”. In such a situation, thecontroller 106 is configured to determine an impending failure status of thecomponent 102. - In yet another embodiment (not shown), the operating temperature “OT” of the
component 102 over the predetermined time period “T” may be approximately equal to or higher than the first predetermined threshold “TH1”. However, the rate of change of the monitored operating temperature “OT” over the predetermined time period “T” may be approximately zero or negligible and the operating temperature “OT” of thecomponent 102 is maintained higher than the first predetermined threshold “TH1”. In such a situation, thecontroller 106 is configured to determine the failure status of thecomponent 102. - The
controller 106 is also configured to provide a notification to the operator indicative of the determined status of the health of thecomponent 102. Accordingly, thecontroller 106 is communicably coupled to anoutput device 110. Theoutput device 110 may include a monitor, a screen, a display panel, a speaker, a light source, and so on. Theoutput device 110 is configured to provide the notification to the operator. In one embodiment, the notification may be a text message and/or an email including numerical, alphabetical, alphanumerical and/or special characters. In another embodiment, the notification may be an audible message, a visual indication in form of glowing of the light source or display of specific icons on theoutput device 110 or a combination of similar such other notifications. - The
controller 106 may be configured to compensate for changes in the ambient temperature. For example, in one embodiment, where the means for generating the temperature signal “TS” may include the first and second temperature sensors and the ambient temperature may be low, the first temperature signal may be generally low due to the low ambient temperature. As a result, the difference between the first and second temperature signals may be higher than the first predetermined threshold “TH1”. Accordingly, thecontroller 106 may be configured to compensate for the lower first temperature signal and/or may increase the first predetermined threshold “TH1” in order to compensate for or take into consideration other factors that may have an affect on the temperature signal “TS”. - In another embodiment, where the means for generating the temperature signal “TS” may include the first and second temperature sensors and the ambient temperature may be high, the first temperature signal may be generally high due to the high ambient temperature. As a result, the difference between the first and second temperature signals may be lower than the first predetermined threshold “TH1”. Accordingly, the
controller 106 may be configured to compensate for the higher first temperature signal and/or may lower the first predetermined threshold “TH1”. Thecontroller 106 may be configured to compensate for changes in the type of fuel. Different fuels may have different physical properties such as viscosity, specific heat and so on. Thus, when the type of fuel may change, the operating temperature “OT” may change accordingly. In one embodiment, the operating temperature “OT” of thecomponent 102 may increase due to the change in the type of fuel. Accordingly, the operating temperature “OT” of thecomponent 102 may be higher than the first predetermined threshold “TH1” even when thecomponent 102 may be healthy. - In another embodiment, the operating temperature “OT” of the
component 102 may reduce due to the change in the type of fuel. Accordingly, the operating temperature “OT” of thecomponent 102 may be lower than the first predetermined threshold “TH1” even when thecomponent 102 may have already failed or may be failing. Thecontroller 106 may be configured to increase or decrease the first predetermined threshold “TH1” based on the type of fuel. - The
controller 106 may also be configured to compensate for changes in the level of fuel in the tank. The tank may receive unused fuel from different components of the machine which may generally be at elevated temperatures. During a low fuel level condition in the tank, the returning unused fuel at elevated temperatures may mix with the fuel present in the tank. This may lead to an overall increase in a temperature of the fuel within the tank. - In the embodiment where the means for generating the temperature signal “TS” may include the first and second temperature sensors, the increased temperature of the fuel in the tank may represent the first temperature signal. As a result, the difference between the first and second temperature signals may be lower than the first predetermined threshold “TH1”. Accordingly, the
controller 106 may be configured to compensate for the higher first temperature signal and/or may lower the first predetermined threshold “TH1” based on the fuel level condition in the tank. The above mentioned factors are exemplary and may vary based on thecomponent 102 and/or application. Further, the factors disclosed herein do not limit the scope of the present disclosure. - The present disclosure relates to a
method 500 for determining the health of thecomponent 102. Referring toFIG. 5 , a flowchart of working of thehealth determination system 100 is illustrated. Atstep 502, thecontroller 106 receives the operating parameter signal indicative of the operating parameter of thecomponent 102. More specifically, thecontroller 106 receives the temperature signal “TS” indicative of the operating temperature “OT” of thecomponent 102. Atstep 504, thecontroller 106 monitors the change of the operating parameter over the predetermined time period “T”. More specifically, thecontroller 106 monitors the change of the operating temperature “OT” over the predetermined time period “T”. Atstep 506, thecontroller 106 compares the monitored operating parameter with the first predetermined threshold “TH1”. More specifically, thecontroller 106 compares the monitored operating temperature “OT” with the first predetermined threshold “TH1”. Atstep 508, thecontroller 106 determines the rate of change of the monitored operating parameter over the predetermined time period “T”. More specifically, thecontroller 106 determines the rate of change of the monitored operating temperature “OT” over the predetermined time period “T”. Atstep 510, thecontroller 106 compares the determined rate of change with the second predetermined threshold “TH2”. - In the embodiment where the means for generating the temperature signal “TS” includes the first and second temperature sensors, the
controller 106 may receive the first and second temperature signals indicative of the operating temperature “OT” of the inlet and the outlet of thecomponent 102 respectively. Thecontroller 106 monitors the difference between the first and second temperature signals over the predetermined time period “T”. Thecontroller 106 then compares the difference between the first and second temperature signals with the first predetermined threshold “TH1”. Thecontroller 106 then determines the rate of change of the difference between the first and second temperature signals over the predetermined time period “T”. Thecontroller 106 compares the determined rate of change of the difference between the first and second temperature signals with the second predetermined threshold “TH2”. - At
step 512, thecontroller 106 determines the health of thecomponent 102 based, at least in part, on the comparisons with the first and second predetermined thresholds “TH1”, “TH2” respectively and the one or more additional parameters associated with thecomponent 102. In case of the fuel pump, the one or more additional parameters include at least one of the level of fuel in the tank, the ambient temperature and the type of fuel. Based on the comparison and/or status of exceeding the first and second predetermined thresholds “TH1”, “TH2”, thecontroller 106 determines the healthy, impending failure or failure status of thecomponent 102. Further, thecontroller 106 may provide the notification to the operator indicative of the determined health of thecomponent 102 through theoutput device 110. - The
health determination system 100 and themethod 500 disclosed herein may be used to determine the impending failure of thecomponent 102 based on the monitoring of the operating temperature “OT” of thecomponent 102 itself Further, thesystem 100 may also take into consideration, the behavior of thecomponent 102 over the predetermined time period “T” thereby providing an accurate diagnosis wherein an anomalous behavior of thecomponent 102 will not affect the overall health determined by thesystem 100. Additionally, thesystem 100 allows flexibility by considering the other additional parameters, such as, the ambient conditions, and so on, in order to accurately determine the health of thecomponent 102. - While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.
Claims (20)
1. A system for determining health of a component, the system comprising:
an operational parameter module associated with the component, the operational parameter module configured to generate an operating parameter signal indicative of an operating parameter of the component; and
a controller in communication with the operational parameter module, the controller configured to
receive the operating parameter signal from the operational parameter module;
monitor a change of the operating parameter over a predetermined time period;
compare the monitored operating parameter with a first predetermined threshold;
determine a rate of change of the monitored operating parameter over the predetermined time period;
compare the determined rate of change with a second predetermined threshold; and
determine the health of the component based, at least in part, on the comparisons with the first and second predetermined thresholds respectively and one or more additional parameters associated with the component.
2. The system of claim 1 , wherein the operating parameter is at least one of a temperature, a pressure, a velocity and a load on the component.
3. The system of claim 1 , wherein the controller is further configured to determine a failure of the component based on exceeding the first and second predetermined thresholds respectively.
4. The system of claim 1 , wherein the controller is further configured to provide a notification indicative of the determined health of the component.
5. The system of claim 1 further comprising:
an output device communicably coupled to the controller.
6. The system of claim 5 , wherein the output device includes at least one of a monitor, a screen, a display panel and a speaker.
7. The system of claim 1 , wherein the component is a fuel pump and the one or more additional parameters include at least one of a level of fuel in a tank, an ambient temperature and a type of fuel.
8. The system of claim 1 , wherein the operational parameter module further comprises:
a first operational parameter module configured to generate a first operating parameter signal indicative of an operating parameter of an inlet of the component; and
a second operational parameter module configured to generate a second operating parameter signal indicative of an operating parameter of an outlet of the component.
9. A method for determining health of a component, the method comprising:
receiving an operating parameter signal indicative of an operating parameter of the component;
monitoring a change of the operating parameter over a predetermined time period;
comparing the monitored operating parameter with a first predetermined threshold;
determining a rate of change of the monitored operating parameter over the predetermined time period;
comparing the determined rate of change with a second predetermined threshold; and
determining the health of the component based, at least in part, on the comparisons with the first and second predetermined thresholds respectively and one or more additional parameters associated with the component.
10. The method of claim 9 , wherein the operating parameter is at least one of a temperature, a pressure, a velocity and a load on the component.
11. The method of claim 9 , wherein the component is a fuel pump and the one or more additional parameters include at least one of a level of fuel in a tank, an ambient temperature and a type of fuel.
12. The method of claim 9 , wherein determining the health of the component further comprises:
determining a failure of the component based on exceeding the first and second predetermined thresholds respectively.
13. The method of claim 9 further comprising:
providing a notification indicative of the determined health of the component.
14. The method of claim 9 , wherein receiving the operating parameter signal further comprises:
receiving a first operating parameter signal indicative of an operating parameter of an inlet of the component; and
receiving a second operating parameter signal indicative of an operating parameter of an outlet of the component.
15. A system for determining health of a component, the system comprising:
a means for generating an operating parameter signal indicative of an operating parameter of the component;
a means for receiving the operating parameter signal from an operational parameter module;
a means for monitoring a change of the operating parameter over a predetermined time period;
a means for comparing the monitored operating parameter with a first predetermined threshold;
a means for determining a rate of change of the monitored operating parameter over the predetermined time period;
a means for comparing the determined rate of change with a second predetermined threshold; and
a means for determining the health of the component based, at least in part, on the comparisons with the first and second predetermined thresholds respectively and one or more additional parameters associated with the component.
16. The system of claim 15 , wherein the operating parameter is at least one of a temperature, a pressure, a velocity and a load on the component.
17. The system of claim 15 , wherein the component is a fuel pump and the one or more additional parameters include at least one of a level of fuel in a tank, an ambient temperature and a type of fuel.
18. The system of claim 15 , wherein the means for determining the health of the component further comprises:
a means for determining a failure of the component based on exceeding the first and second predetermined thresholds respectively.
19. The system of claim 15 further comprising:
a means for providing a notification indicative of the determined health of the component.
20. The system of claim 15 , wherein the means for generating the operating parameter signal further comprises:
a means for generating a first operating parameter signal indicative of an operating parameter of an inlet of the component; and
a means for generating a second operating parameter signal indicative of an operating parameter of an outlet of the component.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US14/307,657 US20150369236A1 (en) | 2014-06-18 | 2014-06-18 | System and method for health determination of a machine component |
US15/591,990 US10371143B2 (en) | 2014-06-18 | 2017-05-10 | System and method for health determination of a machine component |
Applications Claiming Priority (1)
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US14/307,657 US20150369236A1 (en) | 2014-06-18 | 2014-06-18 | System and method for health determination of a machine component |
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US15/591,990 Continuation-In-Part US10371143B2 (en) | 2014-06-18 | 2017-05-10 | System and method for health determination of a machine component |
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US20150369236A1 true US20150369236A1 (en) | 2015-12-24 |
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US14/307,657 Abandoned US20150369236A1 (en) | 2014-06-18 | 2014-06-18 | System and method for health determination of a machine component |
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US20170089258A1 (en) * | 2015-09-30 | 2017-03-30 | Deere & Company | Variable geometry turbocharger prognostics |
US20170341606A1 (en) * | 2016-05-26 | 2017-11-30 | The Boeing Company | Health Evaluation and Prognostic Method for Non-Monotonic Dependent Parameters |
US10217066B1 (en) | 2017-08-28 | 2019-02-26 | Deere & Company | Methods and apparatus to monitor work vehicles and to generate worklists to order the repair of such work vehicles should a machine failure be identified |
CN113676508A (en) * | 2020-05-15 | 2021-11-19 | 卡特彼勒公司 | System and method for real-time health monitoring of machine components |
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Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
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US20170089258A1 (en) * | 2015-09-30 | 2017-03-30 | Deere & Company | Variable geometry turbocharger prognostics |
US9765690B2 (en) * | 2015-09-30 | 2017-09-19 | Deere & Company | Variable geometry turbocharger prognostics |
US20170341606A1 (en) * | 2016-05-26 | 2017-11-30 | The Boeing Company | Health Evaluation and Prognostic Method for Non-Monotonic Dependent Parameters |
US10124752B2 (en) * | 2016-05-26 | 2018-11-13 | The Boeing Company | Health evaluation and prognostic method for non-monotonic dependent parameters |
US10217066B1 (en) | 2017-08-28 | 2019-02-26 | Deere & Company | Methods and apparatus to monitor work vehicles and to generate worklists to order the repair of such work vehicles should a machine failure be identified |
US10540618B2 (en) | 2017-08-28 | 2020-01-21 | Deere & Company | Methods and apparatus to monitor work vehicles and to generate worklists to order the repair of such work vehicles should a machine failure be identified |
CN113676508A (en) * | 2020-05-15 | 2021-11-19 | 卡特彼勒公司 | System and method for real-time health monitoring of machine components |
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