WO2014143824A2 - Multi-modal fluid condition sensor platform and system thereof - Google Patents
Multi-modal fluid condition sensor platform and system thereof Download PDFInfo
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- WO2014143824A2 WO2014143824A2 PCT/US2014/027963 US2014027963W WO2014143824A2 WO 2014143824 A2 WO2014143824 A2 WO 2014143824A2 US 2014027963 W US2014027963 W US 2014027963W WO 2014143824 A2 WO2014143824 A2 WO 2014143824A2
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Classifications
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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- G01N21/84—Systems specially adapted for particular applications
- G01N21/85—Investigating moving fluids or granular solids
Definitions
- This invention encompasses embodiments for multi-modal integrated simultaneous measurement of various aspects of fluids contained in circulating systems such as automotive reciprocating engines and vehicle transmissions. These circulating systems perform constant internal lubrication, and beat and contaminant removal to protect the interna! moving parts from the inherent friction and damage in normal operation. Most commonly this is achieved with fluids based on hydrocarbon and/or related synthetics, which, over time, can lose their protective properties, and vary in their performance or breakdown decay due to internal and external events. Several components within the lubricant fluid can be measured and can provide insight into the efficacy of the system to perform its designed mission. Described herein is a real-time, simultaneous, integrated, multi-modal sensor system for early warning notification,
- the field relates to mechanical engines and large-scale mechanical devices that utilize motile lubricating fluids operating in high temperature environments.
- these lubricants it would be beneficial to monitor in real-time the changing fluid properties, the levels of contaminants, and changes in performance to ensure safe and reliable operation of the equipment being protected by the lubricating system.
- This approach applies to automotive vehicles, aircraft or spacecraft, industrial equipment, wind-turbines, life-saving medical machinery and other critical devices.
- the conditions of fluids are often detected using a static, periodic approach, typically requiring removing fluid from the system, often by extracting a sample of the fluid to send to testing laboratories around the world, which have established procedures and methods to measure a number of aspects of the lubricating fluid, including historical time-series of various parameters, it is common practice to apply such time-based longitudinal monitoring of the fluid to detect changes over time to gain an understanding of the changes in performance within the closed environment. For example, the presence of specific particles at increasing concentrations can indicate levels of wear and performance of certain underlying components within the system being lubricated.
- This testing typically measures changes in characteristics of the fluid over time, including detecting changes and deterioration of under lying lubricating fluid and additives and the detection of normal (expected) and abnormal (unexpected) "wear" of the mo ving parts due to normal operation, Static samples are usually sent to a facility that performs a number of tests, including detecting the presence of foreign materials and objects.
- the lubrication filter is commonly sent as well as the oil for testing and detailed analysis, For both the sample and the filter, this is a destructive "tear down" analysis - such that the filter and the sample are not returned to service, hut evaluated and subsequently removed.
- Tests typically performed in the laboratory include detection of metallic and non-metallic particles, presence of water or other non-lubricant liquids, carbon sooi and other components, and in some cases, verification that the underlying chemistry of the lubricant is still intact.
- a written (or electronic) report is generated and transmitted to the stakeholder upon completion of the testing.
- Results typically take days or weeks from extraction to stakeholder review, 31
- a number of low-cost lubricating fluid measurement products and techniques are emerging onto the market ⁇ - including a consumer static "check" of a motor oil sample (see lubricheck.com) which measures the changes in electrical impedance characteristics (electrical capacitance and resistance when a small electrical source is applied across the sensor where a sufficient sample size of the lubricant bridges the sensor electrode across to the detector).
- This approach performs a single-dimensional measurement of oil sump fluid properties at a point in time in the evolution of the oil (i.e. a static measurement), providing insight only when the operator manually extracts a sample of oil to be tested and only indicates changes in the electrical properties should the data be appropriately logged and tracked over time.
- Lubricating fluids have to accommodate a wide range of operating conditions - including variances in temperature, pressure, parity, and state change.
- Lubricants are often optimized for a specific operating environment and temperature range and are expressed, in viscosity. Some lubricants are designed to operate with multiple viscosities (e.g., 10W-30 multi-grade viscosity motor oil).
- measurement of the fluid condition and properties is static and performed externally outside this operating environment via sampling when in a static/non-operating state, Static sampling does not necessarily validate the condition of the fluid in the operating state - either within or outside the normal/typical operating range.
- Lubricants are designed to perform beyond their stated range and are further
- lubricants can operate for significantly longer intervals, or in the case of specific equipment operating in harsh environments (e.g. military equipment used on the battlefield or in mining operations, etc.) may require a more aggressive replacement cycle. It is important to determine when the lubricating fluid cannot continue to perform according to specifications determined by the equipment/system manufacturers. As long as the lubricating fluid is within the safe margin of operation, it may operate indefinitely and not need to be exchanged or replaced with fresh lubricating fluid.
- an integrated system is provided for continuous monitoring of
- the system is an in- motor lubrication monitoring system and the monitoring is real-time.
- the system is built into the form factor of a standard size and shaped oil drain plug found within a reciprocating engine oil drain pan, wherein said system is remotely located from a receiver by wired o wireless data telemetry.
- the system farther comprises a remotely located receiver.
- the systems further comprises engineered nanoparticles, which when bound to target contaminants, provide a unique and measureable signature and can be captured and removed from circulation by a filtration device.
- engineered nanoparticles which when bound to target contaminants, provide a unique and measureable signature and can be captured and removed from circulation by a filtration device.
- nanoparticles change state when one or more target environmental conditions are met.
- the nanoparticles enable the detection of temperature excursions beyond designed operating specifications (i.e., temperatures higher or lower than the operating specification).
- the nanoparticles enable the detection of pressure excursions beyond designed operating specifications (i.e., pressures higher or lower than the operating specification), in additional embodiments ; the nanoparticles enable the assessment of the performance of said filtration device.
- the sensor modalities comprise at least two of electrical,
- the sensor modalities suitably at least one of the sensor modalities comprises an inductor.
- the sensor modalities compri e at least magnetic and optical sensors and in other embodiments the sensor modalities comprise at least electrical, magnetic and optical sensors.
- the system is contained within an epoxy encapsulation that can support high temperature, high pressure, and high vibration environments contained within the oil drain ping mechanical design.
- the system further comprises a limited lifetime power source that provides electrical energy to the electrical components of the sensor platform.
- the system further comprises an energy scavenger/harvester that provides electrical power to a rechargeable power source for extended lifetime.
- the system further comprises multiple digital signal
- processor modules for detection of both single and multiple related fluid characteristics
- the systems further comprise multi-stage output signal generation selected from the group consisting of error indication, specific data signature detection signal, specific data signature signal detection strength level, and Fast Fourier Transform (FFT) data output.
- FFT Fast Fourier Transform
- the sensor modality measurements are analyzed using Kalman Filtering techniques, Baysian analytic techniques, hidden-Markov Filtering techniques, fuzzy logic analysis techniques or neural network analysis techniques.
- the sensor modality measurements comprise at least one of the following: differential temperature comparison, differential magnetic sensor comparison, differential inductive sensor comparison, differential electrical impedance comparison, differential optical absorption comparison, multi-axis accelerometer
- any combination and integrated comparison consisting of at least a set of two sensors, dat comparison of each sensor vector versus time and temperature, data comparison of an integrated vector consisting of a set of at least two sensors combined, inductive data comparison versus time and temperature, optical data comparison versus time and temperature, optical data comparison versus temperature and pressure, temperature data comparison versus time and pressure to detect peak heat, pressure data comparison versus multi-axis accelerometer data, and other sensor combinations.
- the methods further comprise tracking the condition of the fluid by calculating the time series expected rates of change versus observed rates of change of any single or multiple conditions, In additional embodiments, the methods further comprise calculating the expected divergence or convergence across multiple sensor time-d data of anticipated and expected measured value changes versus unexpected changes.
- Figure 1 is a representation of an exemplary real-time multi-modal fluid sensing
- Figure 2 is a representation of an exemplary major in-engine sensor source
- Figure 3 is a block representation of an exemplary major electronic and firmware elements of the system presented within this application.
- Figure 4 is an inset diagram of exemplary optical sensors.
- FIGS. 5a and 5b are block diagram of illustrative, exemplary processing electrical and/or firmware elements comprising the Digital Signal Processing modules incorporated within the processing portion of the system presented within this application for integrated multi-modal sensor calculations,
- Figure 6 is a representative framework of discrete wavelengths for the various optical properties detection
- Figure 7 is a block representation of an exemplary power unit for the system
- Figure 8 is a representation of an exemplary real-time multi-modal fluid sensing
- an integrated system for continuous monitoring of multiple, properties of a fluid derived from measurements from a plurality of sensor modalities within a fluid-based closed-system environment Suitable embodiments utilize a combination of advanced icro-Eleetro-Mechameal Systems (MEMS) and semiconductor techniques to place the laboratory tests directly into the fluid to continuously and concurrently measure multiple aspects of the fluid and report these parameters individually to a programmable computer to provide parallel and integrated real-time analysis of the fluid condition.
- MEMS advanced icro-Eleetro-Mechameal Systems
- the term "sensor modalities” include measurement of the magnetic, electrical and optical properties of a fluid as well as measuring the temperature and pressure of the fluid and monitoring the orientation of the fluid and surrounding containment vessel in space by measurement of multi-axis acceleration. These collectively comprise examples of "multi -modal” analysis or tests throughout the present invention. These measurements can he done both individually and combined - to provide an integrated insight into the condition and status of the fluid. As single-dimension tests may "obscure” any single result caused by the interplay between two different contaminants in the fluid (e.g. the combination of both electrical resistance increasing and electrical resistance decreasing foreign matter in the system), the application of simultaneous multi-modal sensing using a plurality (i.e., two or more) sensing modalities improves the fidelity and accuracy of the measurements.
- nanoparticles are introduced, designed to enhance sensing and capture of undesired contaminants in the fluid as well as trigger an irreversible property change upon experiencing adverse conditions within the system.
- Specifically engineered and designed particles are either added to the fluid, or impregnated into the fdter and triggered/released into the fluid flow In the presence of contaminants, including water, anti-freeze, metal particles, carbon soot, etc.
- the nanoparticles are not detected until a triggering event.
- the resulting combined or state-changed particle becomes measurable by the multi-modal sensors (plurality of sensor modalities) and provides a more sensitive and complete understanding of the fluid condition,
- the resulting combined particle is also better collected by specific filter stages or by magnets (e.g.
- the nanoparticles and their surface attachments axe designed to activate in the presence of specific contaminant targets, identified through practice and through an understanding of the various contaminant conditions that a lubrication system may encounter.
- the nanoparticles are introduced into the lubricating system, either as an additive or impregnated into the materials within a filter.
- nanoparticles are activated and subsequently detected by the multi-modal sensor system whilst in the operating environment. Further, the combination of the nanoparticles attached to the contaminant suitably becomes better filtered and removed from active circulation within the lubrication system. Alternatively, continued detection and
- measurement of nanoparticles by the multi-modal sensor may indicate a partial or full failure of the fluid filter
- Nanoparticles can also be released into the fluid during normal operating conditions.
- nanoparticles can be designed to change state if any part of the lubrication system exceeds a target operating condition.
- such nanoparticles can be designed to change state irreversibly if excessive temperatures are experienced anywhere within the engine lubrication system.
- the environmentally induced change in nanopailicle properties can later be measured and recognized to indicate that some part of the machinery may be overheating.
- the surface properties of the nanoparticie can be altered under thermal stress. The changes in surface properties can be recognized by the sensor system, alerting the system of an excessive temperature in a part of the system that otherwise would remain unmeasured.
- the particles can, for example, be designed to change fluorescence, paramagnetism or other physical or chemical property irreversibly above a target temperature.
- the engineered nanopartieles themselves serve as lubricating material, as then inherent precursor is based on a carbon nanostracture that has friction- reducing properties. Nanopartieles as well have the inherent property of increasing the surface area coverage, which improves the sensor detection (e.g. over-temperature condition detection) as well as improve the lubricating coverage within the system.
- the nanopartieles encompass metallic nanopartieles, which are coated with a thin (e.g., about 2 nm) layer of graphitic carbon that allows the eovalent chemical functionalization of this carbon to result in chemically functionaiized magnetic beads.
- the nanopartieles encompass metal magnetic nanopartieles including, for example, cobalt, iron, nickel and alloys.
- the reactive metals are covered by graphene-like carbon layers.
- the inert nature of carbon results in a core-shell magnetic material exhibiting an extremely high thermal and chemical stability.
- the nanobeads can be applied in harsh conditions, such as low pH and high temperatures, without the problem of the oxidation of the metal core
- the nanopartieles include eovalent functionalization of the metal nanornagnets, In certain embodiments s the binding relies on carbon-carbon bonds, so no ligands are lost even under demanding process conditions ⁇ e.g., high functional loading),
- the wide range of functionalization allows the preparation of beads with custom s rfaee functionalities, in particular embodiments, the nanopartieles are magnetic beads with covalently functionaiized aromatic groups, catalysts and protective groups. The highly magnetic properties allow a high recyclahility of the magnetic chemicals for reuse.
- measurements are combined to determine the state (and state changes) for the fluid using software/firmware programming to compare sensor inputs against reference datum and to detect changing fluid conditions across various measnrement dimensions, including time. It is important to set thresholds for detection of foreign contaminants in the oil. For example, a sufficient quantity of water over time can cause corrosion of critical elements normally protected by the lubricating fluid. Based on these thresholds, certain alerts and notices can be provided, either transmitted through an output interface or polled by a wireless interface, optionally using a portable band-held device, such as a smart phone. To validate the ongoing assessment of the fluid condition, a secondary check can be done to verify the measurements through periodic laboratory sampling.
- External validation can be part of the conforming calibration process during initial testing of the multi-modal sensors. External validation can also qualify additional lubricating fluids and operating environments. Once the baseline is understood, the thresholds across all the integrated measurements can be programmed into the semiconductor to provide the alerting functionality over and beyond the integrated measurement data outputs.
- the systems and methods described herein detect use of the wrong fluid or unsuitable lubricating fluid that may be mistakenly introduced into the lubrication system. Operating machinery with the wrong lubricating fluid can cause irreparable harm if not immediately remediated.
- the multi-modal sensor 'expects' lubricating fluid to he conforming, raising an alert when non-conforming fluid is introduced and subsequently detected,
- frameworks incorporating magnetic sensors facilitate the timely
- Magnetic sensing can detect magnetic nanoparticles.
- Other sensors in the framework can distinguish between the two. For example, paramagnetic resonance can character e the nature of the ferrous particles, and potentially their size.
- Integrating optical transmisson eters, opacity measurements or spectral measurements into the framework provides an indication of particular contaminants, for example, soot, water, or antifreeze solution. Integrated with nanoparticle sensing, detection of
- the traditional time delay from fluid sampling to testing may place critical equipment at risk of damage.
- the lubricating fluid is sampled at the time it is being exchanged. While potentially useful for providing insight Into the wear of internal parts, machinery may be operated in a potentially unsafe condition until the results are returned from the laboratory.
- the lubricating fluid may he exposed to extreme temperatures during operating transients, which can he often in excess of ISO degrees €, potentially causing some breakdown of additives in the lubricating fluid. Such problems are not usually deteeted 5 as the equipment often is "turned off during these conditions. Although there is no new heat being generated, residual heat is transferred into the lubricating fluid and can potentially impact its performance.
- Additional detection methods include the use of one or more inductive coils and magnetic sensors to enhance detection of moving metallic particles.
- An optical transmissometer f comprised of an optical light source and optical detector, for example, measures the changes in absorption of optical light at various wavelengths to characterize carbon soot buildup and other potential contaminants and materials in the lubricating fluid. All such measurements should be temperature and pressure compensated (or normalized) to provide an accurate indication of the underlying health of the lubricating fluid. Further, pressure measurements can be qualified for changes in the system orientation.
- Computation of orientation from multi-axis accelero eters is used to determine when a pressure reading may be invalid due to the system being oriented beyond a predetermined standard, or alternatively the pressure reading is compensated for a system orientation within predetermined limits of sueh a standard.
- Viscosity analysis derives a frictional index from multiple sensor readings to
- This invention presents a simple method of deriving viscosity by measuring, for example, two magnetic sensors within the fluidic luhricant in a selected site to measure fluid flow.
- These magnetic sensors such as no-iaiency Hall sensors, are substantially similar and located in close proximity to one another within the lubricant flow, A small turbulence inducer enables measurement near the sensors of slight differences in flow based on induced flow perturbation.
- This measure can be further integrated with optical absorption measurements using the optical transmissometer.
- This integrated measure coupled with temperature or qualified pressure readings, provides a framework for calculating the frictional index.
- the Hall-based sensors are designed to be as similar as possible.
- Temporal and spatial variations not caused by the turbulence inducer are subtracted using the two nearly identical sensors, Further, the shape of the turbulence inducer is designed to create subtle changes related to the fluidic vel city, analogous to aeronautical applications in which fluid molecules travel at slightly different speeds above and below an airfoil Viscosity can be derived from these slight difference measurements along with the local temperature and pressure, using documented lubricant viscosity reference data, providing an indication of real-time lubricant conditions.
- Sensors are suitably designed to withstand high temperatures of the engine lubricant.
- High-temperature thermocouples measure temperature, thick-film resistors enable pressure sensing, and high-temperature magnetic sensors.
- the optical measuring methods are based on proven high-temperature designs.
- the optical spectrum suitably ranges from UV to mid- IR in which the lubricating fluid is not emitting energy at high temperature, depending on the fluid and the environment and potential contaminants.
- the transmissometer range is measured in millimeters and the distance between the emitting element and the receiving element is precisely controlled using known MEMS manufacturing techniques. This distance between the optical emitting and receiving elements must be very accurate. All of these elements have been implemented and operate individually within these extreme temperature and pressure environment in such a manner as to relay useful data. The design is not limited to these methods. At present, these methods are proven effective and provide a simple solution.
- the systems and methods described throughout provide real-time monitoring of fluids such as those associated, with high-temperature environments present within or associated with internal combustion engines (i.e., monitoring the fluid dining engine activity without the delay of removing a sample).
- the systems and methods monitor oil-based fluid lubricants normally used with internal combustion engines, as well as other fluids such as transmission fluids or glycol-based coolants such as antifreeze, and other fluids in manufacturing environments and critical life-saving medical equipment used in the healthcare industry,
- the systems and methods suitably provide real-time monitoring using multiple sensor modalities to determine the degradation of the monitored fluid, under various operating conditions.
- Another aspect is the ability of the invention to detect the presence of known harmful particulates, such as metal, within the lubricant.
- monitoring fluid with a sensor module ihat is continually submerged within the lubrication flnid.
- Another aspect addressed is the parallel and integrated real-time analysis of the fluid condition.
- Another aspect addressed is the introduction of specifically engineered
- This invention also addresses high temperatures and other conditions experienced in the operating environment of such machinery,
- a real time multi-modal fluid sensing system is in a self- contained embodiment of a single unit comprising an active sensing environment (100) intended to be submerged in the fluid to be monitored.
- the sensors are attached to an assembly that can be placed into the fluid with the electronic and active sensors embedded into a oil drain plug (300) that is held in place via a threaded bolt (200),
- the bolt head accommodates the non-sensor elements of the self-contained system, called the command, control and communications module, C3 module (400) to Include the microcontroller, filters and other elements, Abo suitably contained within the assembly ai'e inductor coils (108) and other methods of signal source to include power to operate the system., such as a power source (1 ⁇ 0),
- the bolt assembly is a self-contained platform that can be installed and removed by a technician.
- Such an environment is typical of an oil drain plug on an automobile or a similar- "low point" in a lubricating return system that may also serve as a reservoir for the fluid.
- the fluid environment may be subject to changes in temperature and pressure through normal and abnormal operations.
- the sensors are designed to operate within the temperature and pressure specifications - as well as customary tolerances beyond the normal operating environment to be able to detect abnormal conditions.
- the system program maiically generates its own local and low energy reference signal sources across multiple sensor modalities including magnetic, optical and electrical, and continuously detects values therein as well as passively receives continuous pressure and temperature measurements.
- the acti ve elements of the sensor platform (100) ai'e intended to be submerged in the fluid under measurement. In the case that the sensor is not submersed, either completely or partially into the fluid, this can be detected and confirmed through multiple sensor confirmation across the optical (106) transmission to optical reception (10?) as well as electrical source (101) to reception (104) of expected value tolerances, In this way the condition of lack of fluid can be detected by multiple approaches, as well as verify that both the electrical and optical, sensors are correctly and collaboratively cross-checked.
- programmable characteristic (102) that has a known fixed reference distance within close proximity to the magnetic sensors (103) that is received and processed by a data acquisition control unit (109) that performs signal amplification, A D conversion and data filtering.
- the sensing can be accomplished by one or more sensors (103) of a type such that provide a response rate commensurate with the signal, that can be the same type or different and provide both direct and differential measurements of the fluid condition.
- the data acquisition control unit (109) performs the steps to filter and analyze the signals, including amplification, noise reduction filtering which is then communicated to the microcontroller (140).
- Nano-particfe activation is independent of the sensors and is triggered upon an exception condition - such as an extreme temperature limit being exceeded j etc. 1]
- One or more optical sensors (107) can be coupled to one or more optical so rce(s)
- optical emitters such as narrow frequency tuned light emitting diodes (LEDs) and optical receivers such as photoreceptors.
- LEDs narrow frequency tuned light emitting diodes
- Today's optical emitters can be configured to emit light in narrow frequency bands. Such wavelengths are dependerit upon the specific types of fluid and contaminants that may accumulate within the fluid.
- Figure 6 shows a representative map over the near infrared region of such.
- the optical sensing can determine a number of characteristics, including but not limited to the presence of fluid, when the LED is emitting. Further the LEDs can be placed at different known and fixed distances from accompanying photoreceptors to provide a distance based profile of the level of absorption across different frequencies.
- the embodiment can he accomplished by a single LED emitter to photoreceptors at known distances as well as multiple LEDs spaced at known distances from the photoreceptor pulsed in a known sequence.
- the controlling logic is managed through software/firmware in the microcontroller (140) and in the data acquisition control unit (109).
- Optical sensing can detect the difference in both the specific wavelength absorption and time series changes in optical characteristics.
- the optical sensing developed operates in both an active and passive mode. In the active mode the optical source pulses light of known strength and wavelengths through the fluid to measure the degree and level of absorption of the light from its source.
- This small scale transrnissometer is configured to detect the specific contaminants and/or changes such as a breakdown in the fluid properties across specific wavelengths, such as shown in Figure 6,
- Another mode of operation is to detect optically activated Nano-partides that have been triggered by an exception event such as a temperature excursion.
- a signal source such as, hut not limited to, a specific wavelength optical trigger as well as an electrical trigger or magnetic trigger
- Optical emitters can be pulsed in a programmatic sequence such that a common photoreceptor can be applied as the sensing receiving point and the software in the microcontroller can associate the emitter frequency to the signal response received by the optical photoreceptor sensor.
- Nano-particle activation is independent from the sensing.
- the triggering method for the Nano-particle if activated can be independent from an optical trigger, e.g, a Mano-particle can be triggered to fluoresce upon a magnetic or electric field source as its trigger, which is provided by the multi -dimensional sensor.
- Sensing changes in the electrical properties is accomplished by an electric source (101) placed at known reference distance from an electric capacitive measuring such as the constant of dielectric of the fluid.
- the strength and frequency of signal and measurement is based on the programmable microcontroller firmware and is based and dependent on the underlying characteristics of the fluid to be continuously monitored which lies between the source and measurement sensing.
- the electric resistance and capacitance can be measured across the gap via the data acquisition control unit (109). Different fluids will have different properties, and thus the ability to prograrnmatically configure and control both the source field and sensor receiving properties is an important aspect of this invention.
- Pressure sensing (11 1 ) and temperature sensing (1 10) are also connected to the data acquisition control unit (109), These sensors can also detect normal and abnormal conditions in heat and pressure levels and provide insight to the operating status of the environment. Fluid condition changes - such as at rest (when the system is not operating) through the peak operating environment - can be evaluated by the programmable microcontroller unit (140). Such applications can be developed in software/firmware to include developing an understanding of both "at rest” and “in operating” conditions, Further, the profile at specific pressures and temperatures can be useful for both determining calculations (offsets due to
- Nano-particles can be triggered by the introduction of an electrical signal of a certain characteristic such as a frequency, which facilitates detection either by magnetic or optical modalities.
- accelerometer 112 may be disposed in the C3 module (400), MEMS sensor platform (100). receiver (170), or other external location.
- the accelerometer sensor (1 12) may be disposed in the MEMS device (100), in the non-sensor elements of the self-contained system, called the command, control and communications module, C3 module (400), or near another processor unit.
- the acceleration of each axis of interest is measured by the data acquisition control unit (109) and used to compute the orientation of the oil drain plug (300), and therefore the orientation of the engine and of the vehicle in space.
- the orientation computation can be used hy the data acquisition control unit (109) to qualify the measurements from the pressure sensors (11 1) and reject certain pressure readings or make adjustment to certain pressure readings to compensate the pressure output, according to predetermined standards of orientation.
- a real time clock (150) provides an accurate time basis to trigger monitoring events by the microcontroller module (1.40) and associate acquired data with a time basis for longitudinal analysis.
- the real time clock provides both time and date information that can be associated with each of the recorded multi-modal sensor measurements,
- the programmable microcontroller (140) also provides both pre and post processing of information including the use of filtering and other algorithms to provide data correction.
- the results are communicated via a communications module (1 0) either via a wired or wireless connection to a receiver (170).
- receiver 170 may optionally comprise a display, a processing unit, or both, receiving data from the integrated system.
- Both the receiver (170) and the microcontroller may possess internal storage (280) to record and evaluate time-series data.
- sensor data is accumulated and subject to additional filtering and integration across the multiple sensors.
- the raw data is subject to processing hy a set of at least one digital signal processor (DSP) for each of the individual sensor modalities such as temperature, pressure, optical absorption, electrical impedance and magnetic signature (203 , 204, 205, 206, 207 and 208).
- DSP digital signal processor
- a parallel output of the results - both pre and post data correction filtering (220) provides both a raw data output (260) that can be communicated via a communications module (160).
- a configuration module (270) can dynamically set filtering and processing
- a ano-state detector (240) is a continuous check for any triggered and activated Nano-particies that exhibit a signature across a set of at least one of the sensors. This includes the detection of any active signature as profiled and programmed into the microcontroller.
- the state detector evaluates the outputs of the DSP processing from a set of at least one sensor and integrates real time characteristic (230) data and associated filtering and integrated characteristic data.
- the Nano-state detector as well provides output to the display (260) and storage (280) as well as can receive configuration parameters via the configuration module (270),
- Such measurement "cross checking” provides for both inherent value confirmation, improves that data correction (by example alman filtering and other algorithmic techniques) and overall sensor system integrity. For many high value systems when a "fault" is detected, often the failure is not in the environment, but the sensor.
- This invention provides for the cross- correlation and verification of the Inherent sensor platform by continuously validating across a number of the measurement criteria such that expected and anticipated sensor output alues can continuously validate the sensor system performance. In this way the Isolation of the error condition (e.g. the sensor failure) is In itself a valuable operator insight - to identify and replace a faulty sensor as a known failed device.
- the electrical storage comprises a battery that provides power to the system until It Is discharged.
- the electrical storage comprises a rechargeable battery connected to one or more energy harvesters, which extend the lifetime of the electrical storage beyond a single charge.
- the power storage comprises an electrical double layer capacitor, optionally coupled to an energy harvester that extends the life time of the electrical storage beyond a single charge, h !J in one embodiment, the energy harvester comprises a vibration energy harvester (I ⁇ 3) that converts kinetic energy from the environment Into an electrical current.
- the energy harvester comprises an acoustic energy harvester (184) that converts audible or vibrational energy into an electrical current.
- the energy harvester comprises a thermal energy harvester (185) that converts differential temperatures into an electrical current,
- die energy harvester comprises an electromagnetic energy harvester (186). where an antenna (188) collects background electromagnetic radiation, such as F transmissions, for conversion into an electrical current.
- the C3 module (400) communicates with the Receiver (170) using cither wired or wireless protocols, or both. Suitable protocols exist In automotive systems today, such as Controller Area Network bus (CAN) and Local Interconnect Network bus (LIN) for wired communications, and Tire Pressure Monitoring System (TPMS) and Remote Keyless System (RKS) for wireless communications.
- the Receiver (170) in some embodiments could comprise a processing unit. It could also comprise a display for depiction of the monitoring status,
- the mechanical design for sensing changes In fluid parameters ln-situ incorporates unique features to minimize costs and provide an environmentally sound design for long life.
- the concept is to include a pressure sensor device built into the oil drain plug that allows for simple installation for upgrades and replacement on scheduled maintenance schedules.
- the sensor is mounted with an epoxy polymer resin that has an excellent operating temperature range, adherence properties, and resistance to salts and petroleum by products. This is a key to prevent, issues with differential thermal expansion, delamination, and chemical breakdown.
- the bolt has a standard thread size based on the end users specification.
- a hole is drilled through the middle of the bolt to allow for Installation of the integrated system and to provide a path for the oil to reside over the sensor platform (100),
- the outside of the pressure sensor Is open to the atmosphere via an integrated atmospheric pressure pipe (314).
- the head of the bolt is machined down to fit the sensor into the bolt by creating a cavity.
- Fig. 7 depicts a power source comprising energy storage (1 82) and/or an energy
- harvester for adding to the energy storage (182).
- Such energy harvesters could collect vibrational energy (183), especially from the oil pan of an operating engine, or acoustic energy (184).
- harvester (1 5) could comprise a TEC (Thermo-Eleetoc Converter) for the conversion of thermal to electric energy, as Is known to those of skill in the ait.
- Electromagnetic Han'ester (186) could collect energy from any one of electric field, magnetic tteld, inductive, wired or wireless eleeiromagnetic energy, optionally using antenna (188).
- R antenna (310) provides communications and in some
- embodiments performs the energy havesting of antenna (188).
- Printed circuit boards (312) shown in cutaway view provide one or more substrates and electrical coupling for C3 module (400) and MEMS sensor platform (316 or 100).
- Ambient pressure pipe (314) conveys the ambient pressure to a differential pressure sensor disposed in this embodiment on sensor platform (316), Note that other embodiments could use an absolute pressure sensor in place of this differential sensor, with or without an additional ambient pressure sensor to enable an electrical compensation as opposed to mechanical pressure compensation. Temperature compensation is also known to those of skill in the art for these pressure sensors to improve accuracy and repeatability.
- Bolt threads (200) provide a conformal drop-in replacement for a traditional oil drain pan bolt in some preferred embodiments,
- this sensor system measures the pressure near the bottom of the fluid reservoir, and optionally compares ibis pressure to ambient pressure.
- temperature compensation may be included for this measurement.
- This approach can measure the mass of fluid in a column above the sensor corresponding to the static pressure in a gravitational (or aecelerational) field. For a given temperature, this static pressure approximates the level of the fluid at a particular temperature and orientation of the fluid- con taining vessel.
Abstract
Description
Claims
Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
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KR1020157029619A KR20150132848A (en) | 2013-03-15 | 2014-03-14 | Multi-modal fluid condition sensor platform and system thereof |
CN201480023062.2A CN105143877A (en) | 2013-03-15 | 2014-03-14 | Multi-modal fluid condition sensor platform and system thereof |
EP14762566.9A EP2972305A4 (en) | 2013-03-15 | 2014-03-14 | Multi-modal fluid condition sensor platform and system thereof |
BR112015023375A BR112015023375A2 (en) | 2013-03-15 | 2014-03-14 | Integrated system; lubrication monitoring system within the engine; method of regularly monitoring a machine operating fluid; and communications unit |
JP2016502670A JP2016517522A (en) | 2013-03-15 | 2014-03-14 | Oil drain plug |
CA2907213A CA2907213A1 (en) | 2013-03-15 | 2014-03-14 | Multi-modal fluid condition sensor platform and system thereof |
MX2015012918A MX365760B (en) | 2013-03-15 | 2014-03-14 | Multi-modal fluid condition sensor platform and system thereof. |
HK16108107.5A HK1220010A1 (en) | 2013-03-15 | 2016-07-12 | Multi-modal fluid condition sensor platform and system thereof |
Applications Claiming Priority (2)
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US13/844,139 US9389215B2 (en) | 2011-09-23 | 2013-03-15 | Multi-modal fluid condition sensor platform and system thereof |
US13/844,139 | 2013-03-15 |
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WO2014143824A2 true WO2014143824A2 (en) | 2014-09-18 |
WO2014143824A3 WO2014143824A3 (en) | 2014-12-24 |
WO2014143824A8 WO2014143824A8 (en) | 2015-10-01 |
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EP (1) | EP2972305A4 (en) |
JP (1) | JP2016517522A (en) |
KR (1) | KR20150132848A (en) |
CN (1) | CN105143877A (en) |
BR (1) | BR112015023375A2 (en) |
CA (1) | CA2907213A1 (en) |
HK (1) | HK1220010A1 (en) |
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EP3211417A1 (en) * | 2016-02-23 | 2017-08-30 | C.C. Jensen A/S | System and sensor unit for monitoring and evaluation of the condition of a liquid |
CN105866473B (en) * | 2016-02-24 | 2019-06-04 | 安徽华米信息科技有限公司 | The measurement method and device of motor vibrations acceleration |
CN107505927B (en) * | 2017-03-29 | 2019-08-23 | 华北电力大学 | CFB Boiler cigarette equipment fault monitoring method component-based and device |
WO2018212364A1 (en) * | 2017-05-19 | 2018-11-22 | 株式会社 荏原製作所 | Lubrication oil contamination diagnosis method |
US10504236B2 (en) * | 2018-01-08 | 2019-12-10 | The Boeing Company | Testing a battery |
CN109682953B (en) * | 2019-02-28 | 2021-08-24 | 安徽大学 | Method for judging lubricating grease content of motor bearing by using BP neural network |
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- 2014-03-14 EP EP14762566.9A patent/EP2972305A4/en not_active Withdrawn
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Also Published As
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CA2907213A1 (en) | 2014-09-18 |
EP2972305A2 (en) | 2016-01-20 |
WO2014143824A3 (en) | 2014-12-24 |
KR20150132848A (en) | 2015-11-26 |
MX2015012918A (en) | 2016-04-29 |
BR112015023375A2 (en) | 2017-07-18 |
JP2016517522A (en) | 2016-06-16 |
WO2014143824A8 (en) | 2015-10-01 |
CN105143877A (en) | 2015-12-09 |
MX365760B (en) | 2019-06-13 |
HK1220010A1 (en) | 2017-04-21 |
EP2972305A4 (en) | 2016-10-26 |
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