WO2013034420A1 - Surveillance de l'état d'un système contenant un contrôleur à rétroaction - Google Patents
Surveillance de l'état d'un système contenant un contrôleur à rétroaction Download PDFInfo
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- WO2013034420A1 WO2013034420A1 PCT/EP2012/066100 EP2012066100W WO2013034420A1 WO 2013034420 A1 WO2013034420 A1 WO 2013034420A1 EP 2012066100 W EP2012066100 W EP 2012066100W WO 2013034420 A1 WO2013034420 A1 WO 2013034420A1
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- Prior art keywords
- asset
- condition monitoring
- feedback controller
- data
- condition
- Prior art date
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Classifications
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B11/00—Automatic controllers
- G05B11/01—Automatic controllers electric
- G05B11/36—Automatic controllers electric with provision for obtaining particular characteristics, e.g. proportional, integral, differential
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
- G05B19/0423—Input/output
- G05B19/0425—Safety, monitoring
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0224—Process history based detection method, e.g. whereby history implies the availability of large amounts of data
- G05B23/0227—Qualitative history assessment, whereby the type of data acted upon, e.g. waveforms, images or patterns, is not relevant, e.g. rule based assessment; if-then decisions
- G05B23/0235—Qualitative history assessment, whereby the type of data acted upon, e.g. waveforms, images or patterns, is not relevant, e.g. rule based assessment; if-then decisions based on a comparison with predetermined threshold or range, e.g. "classical methods", carried out during normal operation; threshold adaptation or choice; when or how to compare with the threshold
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0259—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the response to fault detection
- G05B23/0283—Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL]
Definitions
- the present invention relates to asset condition or health monitoring and more particularly to the monitoring of machines in service.
- Asset health monitoring commonly referred to as equipment health monitoring (EHM) is based around the premise of sensing a plurality of operational variables for an asset during use.
- the gathered data can be used to determine an operational state of the asset. Additionally the data can be processed to identify the current condition or health status of the equipment
- the output of the EHM system provides information to an operator which can be used to manage the operation of the equipment, for example by controlling the equipment in a manner which is sympathetic to the condition of the equipment or else by scheduling suitable repair or maintenance work.
- EHM electrostatic multi-reliable multi-reliable multi-reliable and low-power systems
- level of sophistication of an EHM system is often determined by the value or complexity of the asset. More particularly, sophisticated EHM systems are most often implemented where the cost of maintenance work to be carried out on the assets is relatively high. This therefore demands that maintenance schedules are optimised so that maintenance can be carried out effectively at appropriate intervals and with minimal disruption to the asset operation.
- Many asset control systems including gas turbine engine controllers, use feedback control as a means to achieve desired transient and steady-state performance.
- the benefits of such methods of control derive at least in part from the ability to cater for operational disturbances, which may be caused by any of the operating context, environment or equipment condition, including equipment faults.
- a feedback controller typically controls variables for a system to ensure the desired operation in spite of such disturbances.
- control system's compensation for the equipment's condition masks the changes the EHM system is intended to detect, thereby, potentially making the EHM systems less effective or less sensitive, which may delay, or completely mask the EHM systems ability to detect a problem in a timely manner.
- the present invention provides a condition monitoring system for an asset having a feedback controller, wherein the condition monitoring system is arranged to receive one or more internal signals of the feedback controller in order to determine an operational condition of the asset.
- a condition monitoring system for an asset comprising: a plurality of sensors for taking readings of operational variables of the asset; a feedback controller arranged to receive data indicative of the operational variables measured by said sensors and to issue control instructions for controlling operation of the asset; and a condition monitoring device arranged to receive one or more internal signals from the feedback controller so as to allow determination of an operational condition of the asset based there-upon.
- the feedback controller receives the data from the sensors as one or more inputs and processes the data in order to generate one or more outputs.
- the control instructions comprise at least one output.
- the feedback controller processes the received sensor data using one or more algorithms and thereby generates the one or more internal signals.
- control instructions are based upon, derived from or determined from the one or more internal signals.
- control instructions and internal signals are not the same.
- the internal signals may comprise a second or further output of the feedback controller.
- the feedback controller may be arranged to output said internal signal to the condition monitoring device automatically.
- the feedback controller may determine a difference between a current operational state of the asset and a desired operational state.
- the internal signal may comprise a parameter which is proportional to said difference.
- the internal signal may comprise a parameter which is based on a rate of change of said difference. Additionally or alternatively, the internal signal may comprise a parameter which is based on a duration of divergence of the current and desired operational states.
- the one or more internal signals comprise any or any combination of a proportional, differential and/or integral parameter value based upon said difference.
- the internal signal preferably relates to a parameter that displays persistence.
- the condition monitoring device is arranged to further receive the data indicative of the operational variables measured by said sensors. That data may be received directly from the sensors, typically over a network, or else may be received via the feedback controller.
- the condition monitoring device may determine an operating condition of the asset based upon a combination of the sensor data and the internal signals of the feedback controller.
- condition monitoring device can provide a greater degree of certainty in its interpretation of the asset condition by monitoring a further system variable, namely the internal signal(s) of the controller.
- a further system variable namely the internal signal(s) of the controller.
- components/devices of an asset can add significant cost and complexity to, not only the asset hardware itself, but also the assembly and maintenance thereof.
- the condition monitoring device may be arranged to receive the control instructions from the controller.
- the condition monitoring device may determine an operating condition of the asset based upon the internal signals of the feedback controller and any, or any combination, of the sensor data and/or the control instructions.
- the condition monitoring device may be included in the feedback controller, for example to improve cost and design simplicity.
- the condition monitoring device may comprise one or more processors which are separate to the control feedback processor(s) but housed within a common unit.
- the condition monitoring device and the control feedback device may exist on common processing means, for example being separated by a soft partition.
- a method of asset condition monitoring comprising: obtaining or receiving readings of asset operational variables from a plurality of sensors; obtaining or receiving an internal signal from an asset feedback controller; and, determining an operational state of the asset based on the combined readings and internal controller signal.
- the method may be undertaken continually or substantially continually during an instance, or period, of asset operation.
- the sampling interval of the data may be varied depending on the know operating state, and/or level of interest in the operating state. For instance, where precursors of a failure have been detected the sampling rate may be increased to provide greater sensitivity.
- condition monitoring methods are many, including, but not limited to, exceedance of thresholds to comparisons of "actual" condition monitoring signals with model based predictions.
- the method may output information or instructions derived from the determination of asset operational state, such as asset operation instructions , asset condition information and/or an asset maintenance instruction.
- a data carrier comprising computer readable instructions for controlling the operation of one or more processors to perform the method of the second aspect.
- a condition monitoring system for an asset having a feedback controller, the condition monitoring system comprising: a plurality of sensors for taking readings of operational variables of the asset; a condition monitoring device arranged to receive data indicative of the operational variables measures by said sensors, wherein the condition monitoring device further receives one or more internal signals from the feedback controller so as to allow determination of an operational condition of the asset based upon both the sensor readings and also the internal signal from the feedback controller.
- Any reference made herein to 'an asset' or 'equipment' may comprise a reference to a sub-assembly or component thereof.
- Figure 1 shows a schematic of a condition monitoring system according to the general principles of the present invention
- Figure 2 shows a flow diagram of exemplary control signals of the controller according to one embodiment of the invention
- Figure 3 is an exemplary plot of a measured variable against time for a machine
- Figure 4 shows an exemplary system of the present invention for gas turbine engines
- FIG. 5 is a schematic showing further details of the flow of data in the system of Figure 4.
- the present invention derives in general from the realisation by the inventor that the processing of data by the controller of an asset and the associated data signals used in the determination of control steps for the asset can be used to gain a greater insight into the health of the asset for condition monitoring purposes.
- An asset as referred to in the description below typically refers to a machine or a number of machines, which are inter-reliant for correct operation thereof.
- Computer control systems are used conventionally to operate machinery according to a control strategy.
- Simple control strategies may be used to control devices having a single, or relatively few, degrees of freedom such as valves, pistons, simple rotating drives and the like.
- more complicated control strategies are put in place where a machine or system has a number of interdependent sub-assemblies or components, each of which having a number of control inputs and outputs.
- controllers applying such control strategies typically receive operation data from, and have control over, a number of different sub-assemblies or components of the asset.
- FIG. 1 there is shown a control system 1 for a generic asset 2, which in this example is shown as a plant.
- the inputs may be, for example, materials, energy and/or operation demands and the outputs may comprise any, or any combination, of products, energy, waste materials or the like.
- a number of sensors 5 sense different operational variables, or the same operational variables at different locations, and the sensor readings are fed to an asset controller 6 which runs a series, or nest, of control loop programs in its software in order to generate suitable control signals for operation of the asset 2 to produce the desired output 4.
- internal control signals are generated as will be described by way of example with reference to Figure 3.
- Those internal signals are passed to an asset monitoring unit 7, which in this example may be referred to as a change detection element or unit, to be monitored.
- the change detection element 7 compares data it receives pertaining to an operational state of the asset and compares it to a model which defines a normal or acceptable operational state of the asset. Whilst such functionality represents one implementation for a system according the invention there are other ways of detecting or assessing changes in operational condition, such as for example by comparison of received data with a fault model in addition to, or instead of, a normal model. Any such a model will typically be stored at the change detection element or else be accessible thereby and comprises data pertaining to acceptable or threshold value ranges for the sensor readings and internal signals of the feedback controller.
- the change detection element 7, in different embodiments of the invention, may be provided as a further processing means within the same hardware as the controller 6 or else may be located remotely from the controller and in data communication therewith.
- the change detection element may be co-located with the controller 6; located elsewhere on the same asset and connected therewith over a local network; or else remotely located and in communication with the controller over a wider network.
- PID controller 6 applies a control feedback loop and are used to control a change in a machine from its current state to a currently desired, or reference, state.
- the controller 6 receives a desired reference condition or state and compares it to a current measured state, which is based on the data received from sensors 5, indicative of measurements of operational variables for the asset.
- the controller then aims to rectify the difference between the current and desired states (i.e. the control error) by instructing one or more changes in the operation of the asset 2. This is otherwise described as applying control effort.
- the control effort is controlled based on a combination of: a value proportional to the difference between the current state and the desired state (P), the rate of change between the two states (differential, D) and the duration of the divergence between the current and reference states (integral, I).
- the P, I and D signal elements may be weighted as part of the summation process in order to achieve suitable control of the machine. It will be appreciated that for some types of machine and/or control scenarios, only a simple P signal will be required, whereas in other situations a combination of two or more signals may be needed in order to achieve an optimal or stable control strategy.
- the control output from the controller 6 is then fed to the asset 2 and the resulting change in operation is measured and input to the start of the process as a feedback loop. Accordingly the control loop is repeated based on the changed state (or the new current state) of the asset.
- the control feedback loop typically operates
- a controller Whilst in a conventional system the controller outputs only control instructions, a controller performs a number of internal or intermediate steps or loops in order to arrive at those instructions. Accordingly the present invention seeks to access the internal or intermediate signals of the controller that contribute towards the final set of control instructions in order to glean useful EHM data there-from. Whilst the current example refers to those internal signals as P, I or D signal elements, it will be appreciated that a controller may use any of a number of different control strategies and may generate or handle a multitude of different internal parameter values. The term 'internal signals' is intended to encompass any such data that may otherwise not be available in a control signal output by the feedback controller. For example, a controller may operate a number of different loops depending on the operational context of an asset (e.g.
- FIG 3 an example is shown of a plot of displacement 's' against time 't' for an actuator, such as a hydraulic actuator.
- the dashed line represents a desired hydraulic actuation of a piston within a cylinder, whereas the solid line represents an actual plot of piston motion in a condition where the piston is sticking.
- the controller determines at time T1 that the actuator has not moved sufficiently and increases the actuation load such that the piston is actuated more suddenly to its displaced condition S1 .
- This invention uses the terms of the control system 8A, 8B and 8C as inputs to the condition monitoring function in order to provide greater understanding of the asset operation. Also the condition monitoring function plots/trends the changes in the controller internal signals over time. This allows the changes in controller internal signals to be compared to a standard or desired profile for those signals. This method may be simple (thresholds) or complex (models) depending on the requirement.
- a desired profile is accompanied by threshold values, typically for time and/or magnitude, such that a comparison of the recorded profile against the desired profile for said signals leads to a discrepancy which exceeds one or more of the predetermined thresholds.
- This may require, for example, a form, model or normalisation process so the operating context of the asset or component thereof can be eliminated.
- the proposed implementation of the invention would graph the terms of the control system signals and compare some or all of the sample points with a known good graph and assess its condition. Thereby, using the signals/parameters of the control loop itself, more condition information can be extracted (such as resistance to motion, discontinuities in motion, etc) to give a more accurate condition indicator without the addition of sensors.
- the individual signals 8A-8C allow improved fault isolation over simple controller effort monitoring. That is to say, different internal signal profiles create different dynamics and allow fault isolation.
- the derived information can be used to identify a number of different abnormal features in the controller behaviour with greater accuracy than by simply using the control output of the controller 6 to the asset 2.
- deviations in signal 8A alone may imply a different fault or abnormality in behaviour from, for example, a deviation in both signals 8A and 8B.
- deviations in those signals may be used to identify for example, step changes in behaviour as opposed to slower deviations over time, and account for corrective actions taken by the controller to maintain a desired operation of the asset.
- the above-described internal signals are output from the controller 6 to the change detection element 7 where monitoring and analysis of the received data is carried out.
- the change detection element can include multiple data inputs, including both the internal control parameters of the controller and also other external parameters as might exist in a conventional equipment health monitoring system.
- the change detection element 7 may receive measurement data from sensors 5 and/or data concerning the
- Such inputs to the element 7 may be achieved by direct or indirect connection to the sensors themselves or the controller input/outputs.
- the analysis of these signals performed by the change detection element may include mathematical manipulations and equipment health monitoring techniques such as trend monitoring, sequence detection, limits, statistical testing (e.g. student distribution "t” test), control charts techniques (e.g. CUSUM or Shewhart charts, etc.) and model comparison.
- the input to the change detection element may be processed using any existing techniques that may be applied to sensor data received by the change detection element.
- the output of the change detection element commands an action. Such actions might be: to alert the equipment operators to a determined minor fault; to schedule
- shut off means or mechanisms such as a shut off valve, relay or solenoid for example. Any, or any combination, of these actions may be performed either on-board or else remotely from the asset and may relate to the entire asset or any component or sub- assembly thereof.
- FIG. 4 there is shown an overview of a system 10 in which the present invention may be incorporated.
- a plurality of gas turbine engines 12 are depicted which are in service or On wing' for a fleet of aircraft. Whilst an aircraft fleet scenario is referred to below, it will be appreciated that the invention can be applied to other gas turbine engine scenarios, including a single aircraft or engine, or else a gas turbine engine used for other applications, such as power generation, marine
- each engine 12 Data relating to the operation of each engine 12 is collected over the engine operational life using conventional sensors and comprises a measure of the duration of operation of the engine and a variety of other operational measures such as fuel consumption, operation speeds or more detailed reports of performance as are common under conventional equipment health monitoring (EHM) practices.
- EHM equipment health monitoring
- Conventional sensors known to those skilled in the art are located on an engine or aircraft to generate readings of any or any combination of fuel consumption or flow, operating time, cycle time or frequency, operational speeds (such as rotor speeds), temperatures, pressures (such as air pressure), forces and the like, as well as operational context, such as for example Weight on Wheels (WoW) signals, engine operator inputs via manual controls, other engine demands, or the like.
- WoW Weight on Wheels
- the operational data for the engines 12, including the internal controller signals described above, is communicated to a remote or central control and/or monitoring facility, where records for all engines in the fleet are gathered. This is achieved by transmission of operational data, typically at the end of each aircraft flight, from the engine or associated aircraft to a control centre server 14.
- one or more wireless transmitters 16 associated with each engine transmit data signals to a receiver 18, which may comprise a base station, for example within a cellular network.
- the data is transmitted from the receiver 18 to the server 14 via a wide area network (WAN) such as the internet 20.
- WAN wide area network
- operational data may include different wireless data transmission standards or protocols or else a wired connection between an engine, or aircraft, and the internet 20.
- data may be transmitted in flight via satellite to ground.
- operational data may be recorded to a removable data storage device such as a memory stick or laptop for subsequent retrieval by and/or transmission to the server 14.
- the server 14 is associated with a network 22, typically via a secure local area or wide area network, over which the operational data can be disseminated for processing and or analysis using networked work stations 24.
- server 14 and network 22 is generally described herein as a monitoring or control centre and may comprise an asset monitoring service provider or else the asset operator organisation.
- the operational data may be communicated to both a service provider and also the asset operator. This is depicted by another server 14A and secure network 22A. Operational data may be transmitted to both servers 14 and 14A or else to the service provider only.
- the service provider may then process the data and make available a subset of data or else the results of the data processing to the asset operator, either by transmission thereof or else by hosting a web site which is accessible to the asset operator via the internet 20 or other network.
- the operational data including the internal signals from the controller, is processed so as to allow appropriate actions to be undertaken, such as the communication of information, instructions and/or control signals derived from the operational data and by the monitoring facility to the engines or operators thereof. It is also possible that such processing could be carried out onboard an aircraft or else by processing means mounted on an engine 12. Necessary actions could then be taken by the local/on-board monitoring device and/or
- the monitoring function is server- based in order to provide for quality control and continuity.
- the monitoring unit on, or associated with the asset would perform a first stage of data processing to determine the operational condition of the asset. If a normal asset operation is determined, then only summary data or a subset of the data need be transmitted to the monitoring facility. However if an unfavourable condition or else a fault is determined by the monitoring unit, then a larger volume of data pertaining to said condition or fault will be transmitted.
- the system would also allow for a mass offload of operation data from the monitoring unit in certain circumstances.
- the asset comprises both an electronic engine controller (EEC) 26 and an engine monitoring unit (EMU) 28 which are in communication, at least for
- a data bus 30 which is typically a conventional engine or aircraft data bus.
- a bespoke wired connection may also be established for this purpose.
- a suitable connection may be achieved using wireless communication technology, such as Wi-Fi (RTM), Bluetooth (RTM), or similar.
- data from the sensors may be received by a conventional wired arrangement, by way of a so-called harness, or else using suitable wireless transmission means so as to establish a suitable communication network on the engine.
- the EMU 28 gathers the necessary data, including the internal signal data as described above from the data bus 30 and records and conditions the data needed for EHM purposes for secure transmission to the monitoring centre in the manner described above, where the data is received and processed and the necessary resulting actions determined.
- the data may be stored both locally and remotely.
- the data will typically be encrypted for secure transmission.
- the data may also be compressed for
- the embodiments of the invention described below are applied to engines for a fleet of aircraft but may equally be applied to other high value assets which are owned by - or else at the disposal of - an asset operator and which require monitoring to achieve a proposed service life.
- the invention is particularly suited to high value assets and/or assets having a significant number of different failure modes.
- the term 'maintenance' used above refers to any kind of action which may be required to ensure correct functioning of an asset, including asset inspection, checking, testing, servicing, repair, overhaul, recall, adjustment, renovation, cleaning or the like.
- the present invention derives from a system or method for machine management, which may typically be carried out over a network comprising data transmitting and receiving actions, as well as the associated transmitting and receiving devices or hardware. Accordingly the transmitting and receiving ends of the system, as well as the method undertaken thereby, should each be considered to comprise embodiments or aspects of the invention in their own right, in addition to the system as a whole.
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Abstract
La présente invention concerne un système de surveillance de l'état d'un équipement, qui comprend une pluralité de capteurs permettant de lire des variables fonctionnelles de l'équipement et un contrôleur à rétroaction. Ledit contrôleur à rétroaction est conçu pour recevoir des données indiquant les variables fonctionnelles mesurées par lesdits capteurs et pour générer un ou plusieurs signaux internes. Ces signaux internes sont utilisés par le contrôleur à rétroaction pour générer des instructions de commande pour assurer la commande de fonctionnement de l'équipement. Le système comporte également un dispositif de surveillance de l'état de l'équipement, conçu pour recevoir un ou plusieurs des signaux internes provenant du contrôleur à rétroaction et pour déterminer un état fonctionnel de l'équipement sur la base desdits signaux. L'unité de surveillance peut en outre recevoir les instructions de commande provenant du contrôleur à rétroaction et/ou les données fonctionnelles provenant des capteurs.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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GB1115410.1A GB2494416A (en) | 2011-09-07 | 2011-09-07 | Asset Condition Monitoring Using Internal Signals Of The Controller |
GB1115410.1 | 2011-09-07 |
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Publication Number | Publication Date |
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WO2013034420A1 true WO2013034420A1 (fr) | 2013-03-14 |
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Application Number | Title | Priority Date | Filing Date |
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PCT/EP2012/066100 WO2013034420A1 (fr) | 2011-09-07 | 2012-08-17 | Surveillance de l'état d'un système contenant un contrôleur à rétroaction |
Country Status (2)
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GB (1) | GB2494416A (fr) |
WO (1) | WO2013034420A1 (fr) |
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