WO2018085875A1

WO2018085875A1 - Dynamic sampling system for machine fluids

Info

Publication number: WO2018085875A1
Application number: PCT/AU2016/051072
Authority: WO
Inventors: John Hardy
Original assignee: Komatsu Australia Pty Ltd
Priority date: 2016-11-09
Filing date: 2016-11-09
Publication date: 2018-05-17

Abstract

A system for sampling fluid under pressure in a fluid line of a machine, comprising: a sampling valve assembly connected in the fluid line and configured to selectively withdraw a fluid sample from the fluid line when the machine is operating; a sample canister removably connected to the sampling valve assembly and configured to receive and hold the fluid sample for removal and analysis when the machine is stopped; a data collection module connected to the machine and configured to collect and store sample data relating to the machine and the fluid sample; and data storage associated with the sample canister and configured to receive and store the sample data from the data collection module.

Description

DYNAMIC SAMPLING SYSTEM FOR MACHINE FLUIDS

Field

[0001 ] The present invention relates to a dynamic sampling system for machine fluids. Background

[0002] Oil analysis is used worldwide as a method of reducing maintenance costs, and improving safety, reliability and productivity of industrial machines in various industries, including mining and construction industries. Oil sampling is the most critical aspect of used oil analysis. Failure to obtain a representative sample impairs all further oil analysis efforts. The procedure by which a sample is drawn is critical to the success of oil analysis.

[0003] The two types of sampling procedures conventionally used in mining and construction operations are manual sampling using sample kits and tooling, and automatic sampling (also referred to as 'live' or 'in-line' sampling) using extraction valves. Both these sampling procedures suffer from various drawbacks.

[0004] Manual sampling involves manually extracting oil that has settled in a sump or reservoir when the machine is stopped. 'Settled' oil generally contains other hydrocarbon by-products and wear particles that may have accumulated over a period of time - the net effect being a contaminated sample that does not reflect or represent the current machine condition. Unrepresentative samples result in misleading reports and unnecessary maintenance, repair costs and machine downtime.

[0005] Samples collected by live sampling are more conclusive as they reflect the oil in operation rather than settled oil that has collected in a sump or reservoir and manually extracted. However, live sampling requires an operator to extract the sample from a sample point, on the machine, often located in hazardous vicinity of moving parts on an active machine. For safety reasons, a team of three or more personnel may be required when live sampling is conducted on an active machine, i.e., one person taking the sample, one person in the operators station ensuring the drive systems are neutralised, and one person spotting and acting as the controller between the operator and service person taking the sample (the sampler is invisible to the operator at this time). The number of personnel required will depend on the type and location of the machine. As a result, live sampling can be very labour intensive and time consuming.

[0006] In this context, there is a need for improved solutions for sampling fluids from machines.

Summary

[0007] According to the present invention, there is provided a system for sampling fluid under pressure in a fluid line of a machine, comprising:

a sampling valve assembly connected in the fluid line and configured to selectively withdraw a fluid sample from the fluid line when the machine is operating; a sample canister removably connected to the sampling valve assembly and configured to receive and hold the fluid sample for removal and analysis when the machine is stopped;

a data collection module connected to the machine and configured to collect and store sample data relating to the machine and the fluid sample; and

data storage associated with the sample canister and configured to receive and store the sample data from the data collection module.

[0008] The sampling valve assembly may comprise:

a valve block comprising inlet and outlet conduits each having inlet and outlet ports, wherein the sample canister has an opening removably connected to both the outlet port of the inlet conduit and the inlet port of the outlet conduit;

a directional valve connected in the inlet port of the inlet conduit and configured to selectively direct fluid flow from an inlet portion of the fluid line to either the inlet port of the inlet conduit or an outlet portion of the fluid line; and

a check valve connected in the outlet port of the outlet conduit and configured to close the outlet port of the outlet conduit when the directional valve connects the inlet and outlet portions of the fluid line to one another.

[0009] The directional valve may comprise a two-way ball valve, and the check valve may comprise a spring-loaded check valve. [0010] A lid may be removably connected to the opening of the sample canister when removed from the sampling valve assembly.

[001 1 ] The lid may comprise a necked opening and a cap removably connected to the necked opening.

[0012] A baffle may be connected to the outlet port of the inlet conduit and configured to project into the sample canister.

[0013] The sample data may comprise data relating to location, operation, condition, service history, and sampling interval of the machine.

[0014] The data collection module may comprise a printed circuit board (PCB) comprising a microcontroller connected to the machine and configured to sense operation of the machine.

[0015] The PCB may further comprise electrically erasable read only memory (EEPROM), a clock, a battery, and a data interface each connected to the microcontroller.

[0016] The data interface may comprise a universal serial bus (USB) port, a radio frequency identification (RFID) read/write module, a RFID antenna, a wireless network interface, and combinations thereof.

[0017] The data storage may comprise a USB drive, a RFID chip, a database server, and combinations thereof.

[0018] The present invention also provides a method for sampling fluid under pressure in a fluid line of a machine using the system described above.

Brief Description of Drawings

[0019] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which: Figure 1 is a photograph of an example dynamic sampling system installed on a mining and construction machine;

Figures 2 are 3 are section views of the dynamic sampling system;

Figures 4 and 5 are section and perspective views, respectively, of an example low pressure (LP) dynamic sampling machine;

Figures 6, 7 and 8 are top, side and perspective views, respectively, of an example LP sample canister of the LP dynamic sampling system;

Figures 9 and 10 are section and perspective views, respectively, of an example high pressure (HP) dynamic sampling machine;

Figures 1 1 , 1 2 and 1 3 are top, side and perspective views, respectively, of an example HP sample canister of the HP dynamic sampling system;

Figures 14, 15 and 1 6 are assembled, exploded and section views, respectively, of an example sample canister; and

Figure 17 is a perspective exploded view of an example manifolded dynamic sampling system for multiple working fluids of a machine.

Description of Embodiments

[0020] Referring to the drawings, a system 1 0 for dynamically sampling fluid under pressure in a fluid line of an industrial machine generally comprises a sampling valve assembly 1 2 connected in the fluid line of, for example, a pressurised fluid circuit of the machine. The machine may comprise, for example, a mining and construction machine, such as a rigid dump truck, an articulated dump truck, an excavator, a wheeled dozer, etc. The pressurised fluid circuit may contain a working fluid of the machine, for example, lubricating oil, coolant fluid, engine oil, etc. The sampling valve assembly 1 2 may be implemented as a (LP) assembly 1 2a and a (HP) assembly 12b respectively fluidly connected to LP and HP fluid circuits of the machine. It will be appreciated that the system 10 may be 'numbered-up' and implemented with three or four sample valve assemblies 1 2 for different machine applications depending on machine configuration and the number of sampling compartment for that particular class of machine The system 10 may be installed by original equipment manufacturers on new machines. Alternatively, the system 10 may be provided as an aftermarket accessory for retrofitting to existing machines. [0021 ] The sampling valve assembly 12 may be configured to selectively capture (or withdraw) a fluid sample from the fluid line when the machine is operating. The fluid sample may be a 'dynamic' sample in the sense that it reflects the dynamic state of the fluid when the machine is operating. Hence, the system 10 may be referred to as a dynamic sampling system 10. The dynamic sampling system 10 may further comprise a sample canister 14 removably connected, for example threadingly connected, to the sampling valve assembly 1 2. The sample canister 14 may be configured to receive and hold the fluid sample for removal and analysis when the machine is stopped. In use, the system 10 enables a portion of the circulating oil to be captured in a sample canister 14 whilst the engine of the machine is running and powering all machine pressure circuits. The sample canister 14 containing the portion of the oil is removed from the machine when the machine is inactive and the engine shut down, terminating the power to the machine. The sample canister 14 may also be implemented as a LP sample canister 14a and a HP sample canister 14b respectively removably, fluidly connected to the LP and HP sampling valve assemblies 12a, 12b. The sample canister 14 may be made of metal, for example aluminium, so that is it reusable and durable. This advantageously replaces plastic sampling kits conventionally used in manual and live sampling to thereby save on cost, labour, inventory and have a significant impact on reducing the sampler's carbon footprint.

[0022] Referring to Figures 2 and 3, the sampling valve assembly 1 2 may comprise a valve block (or manifold) 16 comprising inlet and outlet conduits 1 8, 20, each having inlet and outlet ports 18a, 18b, 20a, 20b. The sample canister 14 may have an upper opening removably connected to both the outlet port 18b of the inlet conduit 18, and the inlet port 20a of the outlet conduit 20. A directional valve 22 may be fluidly connected in the inlet port 18a 1 8 of the inlet conduit 1 8 and configured to selectively direct fluid flow from an inlet portion 24a of the fluid line 24 to either the inlet port 18a of the inlet conduit 18 or an outlet portion 24b of the fluid line 24. A check valve 26 may be connected in the outlet port 20b of the outlet conduit 20 and configured to close the outlet port 20b of the outlet conduit 20 when the directional valve 22 connects the inlet and outlet portions 24a, 24b of the fluid line 24 to one another. The check valve 26 thereby prevents backflow of the fluid out of the sample canister 14 when it is ready for removal. The directional valve 22 may comprise a three-way ball valve 22, and the check valve 26 may comprise a spring-loaded check valve 26. In HP implementations, a baffle 28 may be connected to the outlet port 18b of the inlet conduit 18 configured to project into the sample canister 14 to provide smooth fluid flow into and through the sample canister 14 when the machine is operating. The directional check valve 22 may be connected to the oil circuit, before the manifold inlet port 24a in some machine configurations. This valve receives the oil flow entering the manifold. The directional check valve outlet port 24 receives discharged oil from the manifold after flowing through the canister 14 and exiting the manifold 16 through connection 24b. The outlet portion of the directional check valve 22 contains a spring loaded ball mechanism positioned in the outlet chamber. When the oil is flowing through the outlet, the force from the oil flow will move the ball against a spring to an open position allowing oil flow to be directed to discharge from the valve and returning to the circuit. When the flow ceases and the force removed, the spring will push the ball to the closed position in the valve preventing any backflow of oil to the canister. This valve therefore prevents the canister from overfilling and potentially causing spillage when removed. As illustrated in Figures 1 1 and 13, the HP sample canister 14b may be internally provided with an annular support web configured to slidably receive and support the baffle 28.

[0023] The dynamic sampling system 10 may further comprise a data collection module 30 operatively and electrically connected to the machine. The data collection module 30 may be configured to collect and store sample data relating to the machine and the fluid sample. The sample data may, for example, comprise data relating to location, operation, condition, service history, and sampling interval of the machine. For example, the sample data may comprise machine operator details, operating site, machine model, machine ID and serial number, litres oil replenished between sampling intervals, machine operating hours (age of machine), service meter reading, oil hours (service life of oil since last oil change), machine hours, and engine, hydraulics and transmission oil hours, etc.

[0024] In some implementations, the data collection module 30 may comprise a PCB 32 comprising a microcontroller connected to the machine and configured to sense operation of the machine. The PCB 32 may further comprise EEPROM, a clock, a battery, and a data interface each connected to the microcontroller. The data interface may comprise a USB port 34, a RFID read/write module, a RFID antenna 36, a wireless network interface, and combinations thereof. For example, the microcontroller may run a timer software routine which is initiated when the machine is turned on, to count the hours of operation of the engine. When the engine is turned off, the microcontroller may write the value of the engine running hours to the EEPROM. In some implementations, the data collection module 30 may further comprise a display, for example a LCD screen, and user interfaces such as pushbuttons, LEDs, etc.

[0025] The dynamic sampling system 10 may further comprise data storage 40 associated with the sample canister 14 and configured to receive and store the sample data from the data collection module 30. The data storage 40 may comprise a USB drive, a RFID chip, a database server, and combinations thereof. The data storage may be physically or logically associated with the sample canister 14. For example, when the data storage 40 is implemented as a USB drive 40, the sample canister 14 may have a lid 42 that is configured to removably hold the USB drive 40 so that it can be securely sent to a remote laboratory with the sample canister 14 for analysis. Alternatively, when the data storage 40 is a database server 40, the sample canister 14 may have a unique identifier that is logically associated with a database entry. The data communication between the data collection module 30 and the data storage 40 may be via a data communication network, for example, the RFID module, a local area network (LAN) or wide area network (WAN), for example, the Internet, or a combination of networks, any of which may include wireless links. The data collection module 30 may further comprise a web and/or mobile application configured to render interactive graphical user interfaces on a user device, for example, a smartphone, tablet or laptop computer, to provide dynamic sampling services to users.

[0026] Referring to Figures 14 to 16, a lid 42 may be removably, sealingly connected, for example, threadingly connected, to the opening of the sample canister 14 when removed from the sampling valve assembly 12. The lid 42 may comprise a necked opening 44 and a cap 46 removably connected to the necked opening 44. O-rings 48, 50 may be respectively provided between the cap 46 and the necked opening 44, and the lid 42 and the opening of the sample canister 14.

[0027] Figure 17 illustrates an example variant of the dynamic sampling system 10 in which three fluid sampling valve assemblies 12A, 1 2B, 12C are implemented in a common manifold 52. The fluid sampling valve assemblies 1 2A, 1 2B, 12C may be respectively fluidly connected to engine oil, hydraulic oil and coolant circuits of the machine. [0028] A method of operating the dynamic sampling system 10 may start when the machine is parked with engine shut down for fuelling, scheduled inspection, or other reason. The sample canister 14 may then be removed and replaced with a clean sample canister, such that the machine is immediately ready for operation. The sample data may be downloaded to the USB drive. The USB drive may be connected to the PCB and can be used as an optional download port in some applications or circumstances. The fluid sample held by the sample canister 14 may be run directly upon arrival and pre-registered with sample information.

[0029] Embodiments of the present invention provide a dynamic sampling system and related method that are useful for dynamic sampling of working fluids of industrial machines. Dynamic sampling refers to capturing an oil sample from an operating machine rather than stopping a machine to manually extract the sample. Embodiments of the present invention improve safety, reduce prolonged machine down time and labour costs, and eliminate the need for human intervention for sample drawing or extraction. The sample quality is maintained and the integrity of the oil sample has positive flow on effects with data cleanliness and accurate reporting. The tooling mimics an oil filter by design with a continuous flow of oil passing through a canister while the machine is in operation. Unlike the current sampling methods that require the machine to be stood down from operation when the sample is taken, the canister, containing sample oil is removed when the machine is stopped and de-activated. This can be at any time during the day when the machine is at stand still, for example, lunch breaks, fuelling, safety inspections, etc.

[0030] The sample canister containing the dynamic sample of used oil may be capped for despatch to the laboratory, and a replacement canister fitted to the machine compartment - each machine may have two sets of dynamic sampling units assigned to it. Dynamic sampling advantageously eliminates the requirement for the 'human' element for live sample extraction on pressure circuits as the extraction process can be conducted whenever the machine is inactive, i.e. , when the machine is shut down for servicing, maintenance, inspection, refuelling or parked and off for any other reason. A dynamic oil sample may be truly representative, and its analysis can reflect the true component condition as the oil was captured during its working cycle. The integrity of the dynamic sample will greatly reduce unnecessary machine repairs, downtime and associated costs. [0031 ] Dynamic sampling is conducted when the machine is stopped and deactivated. This alleviates the need to have general maintenance personnel attend the sample extraction process. More importantly, with the machine deactivated, there is no risk of injury from rotating components, hot oil splashes and stored energy risk as all components and associated pumps will be at rest. The operator changing the sample canister will not be exposed to risk from stored energy, for example, from an active hydraulic system.

[0032] The dynamic sampling system removes the need for machine operators to hold stocks of manual sample kits, bottles, pumps for the pressure lube compartments thereby reducing the customers inventory stock, storage, ordering and handling - all labour intensive and costly duties that become redundant under dynamic sampling methodology.

[0033] Dynamic sampling may also reduce standard sampling intervals by up to 50% for each 1000 hour period, and a further 25% off current sampling methods given that the non-combustion samples are taken only twice in a 1000 hour cycle, i.e., engines (combustion) are taken at every 250 hour interval and other compartments (non- combustion) are sampled every 500 hours.

[0034] Dynamic sampling may also improve the integrity and accuracy of sample data. Current sampling practices require manual handling for sample extraction and sample information card entries. On larger equipment, teams are often involved to cover the requirement of personnel working within the machine footprint on an active machine. Quite often, some of the sample machine information is not available to the sample taker and the sample cards are processed by office workers who have computer access and records but have limited understanding of the requirement. This method of handling has a high potential for incorrect data being reported on cards, and incomprehensible writing and mix ups with the wrong cards attached to the samples. Dynamic sampling eliminates the need for these personnel who are involved in the sampling and card entry processes. The potential reduction in labour costs for the whole process is realised over the labour cost per hour multiplied by samples taken. Samples taken can vary from 1 to 9 samples per machine depending on the service type and machine model. A main feature of the dynamic sampling system is to electronically transfer sample data without any manual entries. This may relieve the sample taker of manually entering data to the sample card (some of this information isn't available when the sample is taken) and it also eliminates the need for data entry at the laboratory. The laboratory in this respect may become more efficient and the transfer of data to other maintenance systems will be greatly improved. The efficiency gains may allow more work to be done without increasing head count.

[0035] As discussed above, one of the most important factors of used oil analysis is the quality of the sample. Dynamic sampling systems are designed to take in-stream (working oil) that can be easily 'read' by the analyst. The quality sample provides the data integrity that leads to accurate reporting and conclusive results. The value of an oil analysis report is dependent on the quality of the sample and the accuracy of the sample information provided. Machine operators use oil analysis as value add component to their operation. The reports are universal and contain critical machine information used to plan daily maintenance and monitor problematic machines. Oil analysis provides the primary data used by an operation from which maintenance schedules and work orders are generated. In addition, machine manufacturers use oil analysis to measure and support their products. To summarise, dynamic sampling has the potential to improve most, if not all, aspects of current oil sampling practices.

[0036] For the purpose of this specification, the word "comprising" means "including but not limited to," and the word "comprises" has a corresponding meaning.

[0037] The above embodiments have been described by way of example only and modifications are possible within the scope of the claims that follow.

Claims

1 . A system for sampling fluid under pressure in a fluid line of a machine, comprising:

2. The system of claim 1 , wherein the sampling valve assembly comprises:

3. The system of claim 2, wherein the directional valve comprises a two-way ball valve, and the check valve may comprise a spring-loaded check valve.

4. The system of claim 2, further comprising a lid removably connected to the opening of the sample canister when removed from the sampling valve assembly.

5. The system of claim 4, wherein the lid comprises a necked opening and a cap removably connected to the necked opening.

6. The system of claim 2, further comprising a baffle connected to the outlet port of the inlet conduit and configured to project into the sample canister.

7. The system of claim 1 , wherein the sample data comprises data relating to location, operation, condition, service history, and sampling interval of the machine.

8. The system of claim 1 , wherein the data collection module comprises a PCB comprising a microcontroller connected to the machine and configured to sense operation of the machine.

9. The system of claim 8, wherein the PCB further comprises EEPROM, a clock, a battery, and a data interface each connected to the microcontroller.

10. The system of claim 9, wherein the data interface comprises a USB port, a RFID read/write module, a RFID antenna, a wireless network interface, and combinations thereof.

1 1 . The system of claim 1 0, wherein the data storage comprises a USB drive, a RFID chip, a database server, and combinations thereof.

12. A method for sampling fluid under pressure in a fluid line of a machine using the system of claim 1 .