WO2022184318A1 - Remote monitoring of an ignition system of a combustion engine - Google Patents

Remote monitoring of an ignition system of a combustion engine Download PDF

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Publication number
WO2022184318A1
WO2022184318A1 PCT/EP2022/025068 EP2022025068W WO2022184318A1 WO 2022184318 A1 WO2022184318 A1 WO 2022184318A1 EP 2022025068 W EP2022025068 W EP 2022025068W WO 2022184318 A1 WO2022184318 A1 WO 2022184318A1
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WO
WIPO (PCT)
Prior art keywords
ignition system
data
board
evaluation unit
engine
Prior art date
Application number
PCT/EP2022/025068
Other languages
French (fr)
Inventor
Darshit SHAH
Original Assignee
Caterpillar Energy Solutions Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Caterpillar Energy Solutions Gmbh filed Critical Caterpillar Energy Solutions Gmbh
Priority to EP22708034.8A priority Critical patent/EP4301978A1/en
Publication of WO2022184318A1 publication Critical patent/WO2022184318A1/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02P—IGNITION, OTHER THAN COMPRESSION IGNITION, FOR INTERNAL-COMBUSTION ENGINES; TESTING OF IGNITION TIMING IN COMPRESSION-IGNITION ENGINES
    • F02P11/00—Safety means for electric spark ignition, not otherwise provided for
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02P—IGNITION, OTHER THAN COMPRESSION IGNITION, FOR INTERNAL-COMBUSTION ENGINES; TESTING OF IGNITION TIMING IN COMPRESSION-IGNITION ENGINES
    • F02P17/00—Testing of ignition installations, e.g. in combination with adjusting; Testing of ignition timing in compression-ignition engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D41/00—Electrical control of supply of combustible mixture or its constituents
    • F02D41/22—Safety or indicating devices for abnormal conditions
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D41/00—Electrical control of supply of combustible mixture or its constituents
    • F02D41/24—Electrical control of supply of combustible mixture or its constituents characterised by the use of digital means
    • F02D41/26—Electrical control of supply of combustible mixture or its constituents characterised by the use of digital means using computer, e.g. microprocessor
    • F02D41/266—Electrical control of supply of combustible mixture or its constituents characterised by the use of digital means using computer, e.g. microprocessor the computer being backed-up or assisted by another circuit, e.g. analogue
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M15/00—Testing of engines
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M15/00—Testing of engines
    • G01M15/04—Testing internal-combustion engines
    • G01M15/11—Testing internal-combustion engines by detecting misfire

Definitions

  • the present invention pertains to a method for monitoring an ignition system of a combustion engine as well as a corresponding system and computer program product, in particular to facilitate long-term functioning of the ignition system and to improve the operating life.
  • the ignition system is a vital part of an engine and also one of the most critical, when it comes to operational robustness. With an ever increasing demand of operational flexibility and higher uptimes of the engine, it is of utmost importance to make the ignition system more robust and advanced in terms of their diagnostic and prognostics capability.
  • a method for monitoring an ignition system of a combustion engine comprising the steps of: by an on-board control unit for controlling the ignition system, receiving at least one measurement of a parameter related to the ignition system, determining an operational state of the ignition system based on said at least one parameter measurement, and controlling the ignition system based on the determined operational state; by an off-board evaluation unit, receiving the at least one parameter measurement and/or the determined operational state from the on board control unit via a data link; and by the off-board evaluation unit, receiving data from a plurality of on-board control units, comparing the at least one parameter measurement and/or determined operational state with said received data, and outputting a signal based on said comparison.
  • an ignition system for a combustion engine comprising an on-board control unit for controlling the ignition system and an off-board evaluation unit communicatively coupleable to the on-board control unit via a data link, the ignition system being configured to perform the method according to the invention.
  • a computer program product is suggested, which is embodied on a computer readable storage medium and is configured to, when executed on a processor, perform operations of the method according to the invention.
  • Fig. 1 shows a schematic view of an ignition system of a combustion engine and a corresponding method for monitoring such ignition system according to the invention
  • Fig. 2 shows a schematic view of the ignition system and method according to Fig. 1 according to a preferred embodiment.
  • FIG. 1 an ignition system 100 of a combustion engine and a corresponding method for monitoring such ignition system 100 according to the invention are schematically depicted.
  • the ignition system 100 comprises an on-board control unit 10 and an off-board evaluation unit 12, wherein the on-board control unit 10 is arranged in proximity of the combustion engine and provides a direct monitoring and adjustment of operating parameters of the ignition system, e.g. the ignition driver and/or directly of one or more sparkplugs.
  • the on-board control unit 10 may hence be considered as an on-engine control unit, which may be primarily directed to ignition timing, ignition energy, and the proper functioning of the one or more sparkplugs.
  • the off-board evaluation unit 12 may be part of a decentral unit, i.e. not being on-board or on-engine.
  • the off-board evaluation unit 12 may be provided e.g. at a server end of a computer system or computational network, which may optionally be part of a decentral monitoring and/or plant management center.
  • the off-board evaluation unit 12 may also be cloud-based or may include, at least in part, an edge-computing system.
  • the system 100 furthermore comprises a data link 14 providing a communication between the on-board control unit 10 and the off-board evaluation unit 12.
  • the on-board control unit 10 is configured to provide at least one parameter measurement 16 and/or a determined operational state 17 corresponding to the at least one parameter measurement 16 related to the ignition system 100 and to receive a signal 18 outputted by the off-board evaluation unit 12.
  • the off-board evaluation unit 12 is configured to receive the at least one parameter measurement 16 and/or operational state 17 from the on-board control unit 10 and to output the signal 18.
  • the off-board evaluation unit 12 is furthermore configured to compare the received data from the respective, i.e. present or actual, on-board control unit 10 with corresponding data received from a plurality of on-board control units 20, which may either be actively retrieved, e.g. from a server, or may be provided in a data storage communicatively coupled to or internally connected to the off-board evaluation unit 12. Such data storage is preferably continuously or periodically updated. Based on said comparison, the signal 18 may be generated as output.
  • the data comparison is preferably performed with data from corresponding on-board control units, wherein several factors or attributes may be compared in order to improve the relevance of the respective data and the validity of the data comparison.
  • Such data comparison may furthermore take a trend analysis into account, wherein the performance of the ignition system (or engine as a whole) as well as long-term prognostics, e.g. the potential remaining lifetime of one or more sparkplugs, are assessed.
  • statistical data e.g. from previous sparkplugs and corresponding parameter values and wear states for a large or predefined number of corresponding on-board control units may be considered and the signal 18 that is output may be based on said assessment in order to ensure that an optimal performance and longevity are provided.
  • an optimum ignition energy and waveform shaping may be required to assure minimum wear rate and thereby maximum operating life. All the activities relevant to driver controls may be performed in real-time, are work cycle based and are adapted with high responsiveness to changing operating conditions. Such algorithms may be realized on-board to assure the expected functionalities. Also, relevant or essential enablers and diagnostic means may be implemented on the electronic control module software.
  • Such enablers and feedback indicators from the respective algorithms may be provided to the data link 14, which enables their usage e.g. for engine operation, plant control and further transmits this data to the off-board evaluation unit 12 so as to enable a long-term trend analysis.
  • the data received from the plurality of on-board control units 20 may comprise data from multiple engines, which may be of various configuration, may be operating in various applications, and/or are used at various site locations.
  • the combination of the on-board control unit 10 and the off-board evaluation unit 12 thereby provides an ignition system 100 as a whole, wherein different tasks are performed at a respective end, i.e. short-term functionality being assured at the end of the on-board control unit 10 and long term prognostics and data comparison being performed at the off-board evaluation unit 12.
  • a more detailed depiction of the various preferred or optional functions of the on-board control unit 10 and the off-board evaluation unit 12 is schematically shown in Figure 2.
  • one or more parameters may be received by the off- board evaluation unit 12, wherein the parameters may include at least one usage-specific parameter 22, at least one engine application parameter 24, at least one engine performance parameter 26, and/or at least one engine profile parameter 28.
  • the present embodiment is primarily directed to the functionality of the at least one sparkplug (not shown) of the ignition system 100, such that the off-board evaluation unit 12 is configured to calculate or determine a sparkplug life statistic 30 based on the received one or more parameter measurements 16 and/or operational state 17.
  • Such sparkplug life statistic 30 may also be calculated based additionally on previously received data from the on-board control unit 10 and from statistical data from a data pool.
  • the sparkplug life statistic 30 may e.g. be a remaining useful life in hours, as a percentage, and/or as a fraction.
  • the data comparison 31 is performed between the calculated sparkplug life statistic and the received data from a plurality of on board control units 20, as indicated with the double-sided arrowheads.
  • the at least one usage-specific parameter 22, engine application parameter 24, engine performance parameter 26, and/or engine profile parameter 28 provide that the comparison may be selective and that data only from relevant or corresponding on-board control units is considered in the comparison 31.
  • Such data does not need to correspond entirely as the actual data for each on-board control unit, may be to a large extent essentially unique. Accordingly, a multi-dimensional clustering may be provided, wherein only data within (or, alternatively, outside of) such clusters is considered in the comparison 31. This provides that a more exact long-term prognostic may be provided.
  • the comparison 31 may also include data encompassing a larger or broader extent of e.g. usages or applications, such that the comparison 31 may be e.g. based on data for a particular batch, type of engine, or type of cylinder, etc. This ensures that a large amount of data is available for the comparison and that a tolerance range for the comparison 31 may be adaptable.
  • the signal 18 that is output by the off-board evaluation unit 12, according to the present embodiment, is a control signal 18, which is directly transmitted to the on-board control unit 10 and may, optionally, overrule or directly provide corresponding parameter settings at the on-board control unit level.
  • control signal 18 is understood to be optional.
  • a warning signal or maintenance signal 32 is output, which may be transmitted to a decentral monitoring server, plant monitoring facility, and/or to a central control system of the combustion engine or appliance.
  • one or more engine operating parameters 34 are monitored, preferably continuously and at working-cycle basis.
  • the density at the time point of ignition may be a parameter to assess the proper functioning and performance of the ignition system 100.
  • a corresponding ignition energy control 38 is provided to ensure that a correct amount of current is provided and that the ignition energy is provided according to a calculated or predefined duration.
  • a sparkplug operational state 40 such as a wear state may be determined and this may be performed based on the corresponding data for the operating history of the respective sparkplug, for example. Accordingly, feedback may be provided regarding the sparkplug condition.
  • the on-board control unit 10 may determine whether an anomaly 44 is detected and may e.g. determine that a misfiring has occurred. If this is the case, the on-board control unit 10 then performs a sparkplug validation 46 to assess whether an overall ignitability or sparkability is still present. One or more of these indications or determined states may then be fed back to the engine operating monitor 34 and/or may be directly transmitted to the off-board evaluation unit 12 via the data link 14. As described above, the off- board evaluation unit 12 performs a data comparison 31 and/or long-term prognostics to assess whether any detected or determined abnormalities indeed may result in a critical state and the parameter settings of the on-board control unit 10 or ignition energy control 38 need adjustments.
  • Such adjustment may be provided directly by means of the control signal 18, which may e.g. cause a limp- off mode to be activated, wherein the power may be reduced and/or an ignition angle may be altered.
  • a limp-off mode may be beneficial to avoid downtime while improving the longevity of the respective sparkplug and the ignition system 100 as a whole.
  • the short-term control and assessment of the sparkplug operational state 40 ensures functionality of the on-board ignition system 10, yet may only provide a limited prognosis and is essentially based on predefined (historic) parameter values associated with the operation history of the sparkplug.
  • Long-term prognostics are not possible due to the lack of computational capacity and the amount of data that needs to be considered for such assessment.
  • the off-board evaluation unit 12 provides such functionality and may ensure e.g. in cases of a detected abnormality that servicing is only performed when actually required based on comparison 31 with a large data set of corresponding on-board control units. At the same time, said comparison 31 enables that adjustments of parameter settings may be provided to further improve the performance and achieve a maximum operating life.
  • a method for monitoring an ignition system of a combustion engine is provided.
  • Such method comprises the steps of: by an on-board control unit for controlling the ignition system, receiving at least one measurement of a parameter related to the ignition system, determining an operational state of the ignition system based on said at least one parameter measurement, and controlling the ignition system based on the determined operational state; by an off-board evaluation unit, receiving the at least one parameter measurement and/or the determined operational state from the on board control unit via a data link; and by the off-board evaluation unit, receiving data from a plurality of on-board control units, comparing the at least one parameter measurement and/or determined operational state with said received data, and outputting a signal based on said comparison.
  • the on-board control unit may e.g. comprise or essentially consists of one or more electronic control modules and/or engine control modules (ECM), wherein in particular a present state of the ignition system may be monitored. Such monitoring may be provided based on driving cycles and/or working cycles, which may hence be in a millisecond or nanosecond domain.
  • the on-board control unit may hence monitor an operational state, e.g. of the ignition driver and/or of the spark plug(s) and may accordingly adapt the control of the corresponding components based on the determined operational state and/or one or more operational parameters.
  • the on-board control unit may adapt the control based on a detected waveform anomaly or may adapt the control according to a determined wear state, which may be based on the operation time and/or one or more detected operational parameters.
  • the on-board control unit is not capable to provide long-term prognostics, since the corresponding requirements exceed the computational effort and data storage capacity that may potentially be available on-board. In particular, larger capacities may be required for heavy-duty engines due to their corresponding complexity.
  • the off-board evaluation unit is provided to enable such prognostics or trends, e.g. by determining a remaining operational lifetime for one or more components.
  • the off-board evaluation unit is provided with data from a plurality of on-board control units, i.e. from different combustion engines, and compares the at least one parameter measurement and/or determined operational state with said received data.
  • the data received from the plurality of on-board control units may at least in part comprise previously obtained data and is hence not required to comprise only presently received data, although such present data may also be taken into account. Based on the comparison, the off- board evaluation unit outputs a signal.
  • the signal outputted by the off-board evaluation unit may hence be an indication whether an anomaly that is determined or detected by the on board control unit is of particular relevance or whether based on the comparison with the received data such anomaly may be, at least for the time being, be ignored or requires no immediate adjustment of the on-board control and/or maintenance of the corresponding components of the ignition system.
  • the on-board control unit may provide a short-term control mode and may indicate potential errors
  • the off-board evaluation unit may provide a long-term prognostic, wherein data from multiple on-board control units is factored in.
  • Such trends provided by the off-board evaluation unit may hence provide feedback to the on-board control unit and/or indicate the necessity of further adjustments to improve the (long-term) performance of the ignition system as a whole or particular components thereof.
  • the ignition system may be a stand-alone system that may be coupled to corresponding components of a combustion engine or may be integrated in a combustion engine.
  • the ignition system may e.g. comprise, in addition to the on-board control unit and the off-board evaluation unit, an ignition driver and/or one or more sparkplugs or coils for the combustion engine.
  • the comparison and/or the outputting of the signal is performed by the evaluation unit in real-time or periodically.
  • a direct feedback to the on-board control unit may be provided or at least at predefined time intervals.
  • the outputting in real-time may further improve the efficiency and longevity of the ignition system, such outputting may also be provided depending on the type of parameter measurement and/or determined operational state received from the on-board control unit.
  • the signal outputting frequency may e.g. be dependent on the transmitting frequency of the on-board control unit and/or be on-demand, based on e.g. a type of parameter measurement and/or determined operational state and/or a result of the comparison.
  • a predefined outputting frequency may be provided while particular detected or determined anomalies in the operational state may cause an intermittent transmission and comparison in the evaluation unit and corresponding outputting, if the comparison indicates that an operational issue needs to be resolved.
  • the at least one parameter measurement may include one or more detected parameters of the ignition system configuration and/or at least one measurement of a spark plug of the ignition system, preferably a detected spark time, a detected ignition coil configuration, a detected misfire, and/or one or more detected spark breakdowns.
  • the off-board evaluation unit may then compare the parameter measurement with corresponding parameter measurements in the data from the plurality of on-board control units and may e.g. determine a particular risk for the proper functioning and/or longevity of the ignition system.
  • the off-board evaluation unit may assess whether the occurring parameter measurement is within a tolerance range, correlates with a potential detrimental operating state, or requires an adjustment for improving the lifetime of the ignition system.
  • the determined operational state includes a measure of wear of a sparkplug of the ignition system and/or a remaining operating life of a spark plug of the ignition system is determined by the evaluation unit as a part of the data comparison.
  • the on-board control unit While the wear state of the sparkplug may indicate that a servicing may be due, the on-board control unit is not capable to perform long-term prognostics and to assess how the operating history and operating conditions may have affected the state of the sparkplug. Accordingly, a corresponding tolerance range to avoid malfunctioning of the sparkplug may be narrow at the end of the on-board control unit, thereby including a variety of actual wear states.
  • the off- board evaluation unit may however determine whether a detected abnormality or wear state is considered critical by comparing the determined wear state with data from the plurality of on-board control units.
  • the off-board evaluation unit may compare the determined wear state for one or more particular batch numbers or may even compare said wear state for a particular type of ignition system. Hence, based on the comparison, a remaining lifetime of the sparkplug or the ignition system as a whole may be determined, which factors in data for similar operational states.
  • the comparison may include data for wear states that are increased up to or by a predefined amount to assess whether the actual wear state may result in a near-future malfunctioning.
  • the signal may comprise a control signal for the on-board control unit of the ignition system of the combustion engine, preferably the ignition driver, wherein the control unit may receive said signal via the data link and preferably controls the ignition system based on said control signal or by factoring in said control signal.
  • a monitoring may be provided, but also a direct feedback in the form of a control signal is provided to the on-board control unit.
  • the control signal may hence overrule or adjust a control parameter set or determined by the on-board control unit or the on-board control unit may use the received control signal to accordingly adjust the parameter settings. This may also be provided depending on the result of the comparison. For example, a severe risk of malfunctioning or reduced lifetime of the ignition system, as calculated by the off-board evaluation unit during the comparison, may result in an overruling of the control parameter set or determined by the on-board control unit.
  • the control signal may e.g. cause the on-board control unit to perform a limp-off mode, wherein performance may be (temporarily) reduced by a predefined amount so as to increase the lifetime of the ignition system or particular components thereof.
  • the control signal preferably includes one or more operating parameter values of the ignition system corresponding to a predefined waveform, an ignition energy, an ignition timing, an ignition duration, and/or an ignition angle.
  • Said one or more operating parameter values may be derived from the comparison performed by the off-board evaluation unit, wherein an optimum has been calculated or resolved based on a predefined algorithm using the corresponding data from the plurality of on-board control units.
  • a respective average operating parameter value may also be calculated by the off-board evaluation unit based on said data, e.g. using operating parameter values for a similar performance or a performance with a predefined offset.
  • the evaluation unit may receive one or more usage-specific parameters from the combustion engine via the data link and include said one or more usage-specific parameters in the data comparison, wherein the usage- specific parameters preferably include one or more ambient conditions and/or a type or composition of a used combustion fuel.
  • the data comparison performed by the evaluation unit may be more specific for on-board control units being operated under similar operating conditions.
  • the performance of the combustion engine and the corresponding operating parameter settings may vary for operations at different altitudes, ambient temperatures, humidity, and air composition.
  • the type or composition of the combustion fuel may differ locally and/or globally and the combustion engine may be operated with different combustion mixtures, which may affect both the performance of the combustion engine and the lifetime of the ignition system components.
  • both the atmospheric air and the combustion fuel may comprise different amounts of fine particles and/or ionized molecules. Providing such usage-specific parameters hence enables that only similar and/or relevant data is compared, thereby improving the validity and accuracy of the outputted signal.
  • the evaluation unit may receive one or more engine profile parameters from the combustion engine via the data link and include said one or more engine profile parameters in the data comparison, said engine profile parameters preferably including an engine operating profile, a cooling circuit profile, and/or a measure for gas quality fluctuation.
  • Such engine profile parameters provide a further restriction of the data comparison to on-board ignition systems having similar engine characteristics and/or operating history, wherein preferably a corresponding trend may be assessed and the signal may be output based on such trend.
  • the evaluation unit may also compare data for particular errors or malfunctioning situations, such that e.g. a remaining lifetime of the ignition system and/or the components thereof may be calculated with higher accuracy. Accordingly, the evaluation unit may receive one or more engine performance parameters from the combustion engine via the data link and includes said one or more engine performance parameters in the data comparison, wherein the engine performance parameters preferably include knocking data, one or more diagnostic trouble codes, engine derating data, and/or engine downtime data.
  • the evaluation unit may also receive one or more engine application parameters from the combustion engine via the data link and include said one or more engine application parameters in the data comparison, wherein the engine application parameters preferably including an application-specific indication number and/or a site-specific indication number.
  • Such application-specific or site-specific indication number may indicate e.g. not only where the engine is used, geographically, but also whether the engine is used e.g. in a grid or for a particular load, whether the engine is implemented for marine or land operations or whether the engine is used for power generation, for example. Furthermore, the number may indicate whether the engine is used as a stand-alone or standby engine. These factors may significantly affect the performance and wear of the combustion engine as a whole and the ignition system, such that factoring in this information in the data comparison performed by the evaluation unit may improve the validity and accuracy of the outputted signal.
  • the evaluation unit performs the comparison based on data clustering for matching parameters from data received from a predefined number of control units.
  • the data clustering may include a data selection and a qualitative statistical analysis of the selected data, wherein the data selection is preferably attribute-based and/or the qualitative statistical analysis is preferably density based, and/or wherein the data clustering is performed in a predefined parameter order.
  • the data clustering may be performed in multiple dimensions according to the respective attributes, e.g. a particular wear state, an operating time of the ignition system, a misfire frequency, and/or a performance of the combustion engine.
  • These corresponding values for these attributes from the data received from the plurality of on-board control units may then be clustered based on a statistical analysis to include only those values within a predefined range and the signal to be output may be based on one or more best- matches for the corresponding attributes of the present on-board control unit.
  • the clustering may also provide data associated with a predefined trend, such that the outputted signal may preferably be adapted to improve the lifetime of the ignition system or one or more components thereof.
  • the density-based clustering provides that either only those attributes are considered that fall within a particular value range for the respective attribute or that, conversely, only those attributes are considered that form statistical outliers.
  • the predefined attribute order may include a particular weighting of the respective attributes, which may accordingly implemented in an algorithm for performing the comparison and indicative for outputting the signal.
  • the evaluation unit determines at least one spark plug life statistic from data received from a predefined number of control units and factors the at least one spark plug life statistic into the signal.
  • the sparkplug life statistic is particularly relevant in determining the overall state of the ignition system and its wear state and (remaining) lifetime may directly relate to a servicing necessity and/or engine performance. While the on-board control unit may determine appropriate parameter settings for the ignition system and the one or more sparkplugs to provide an improved functioning and corresponding performance of the combustion engine and provide an indication of a current wear state of the one or more sparkplugs, the on-board control unit is not capable to provide long-term prognostics, such as a remaining lifetime.
  • the off-board evaluation unit may provide such prognostics by comparing the data received from the plurality of on-board control units with the data received from the actual or present on-board control unit and may calculate the relevant life statistic.
  • the life statistic may e.g. indicate that a current wear state is not problematic, since, for example, corresponding data from the plurality of on-board control units has shown that for a particular performance the actual lifetime with full functionality or having a performance that is reduced by a predefined amount or percentage, but is sufficient to maintain normal operation of the combustion engine, is extended.
  • the outputted signal may accordingly provide an indication to the on-board control unit that the wear state may be ignored or should be monitored, but provides no direct problem for the operational state.
  • the outputted signal may also include a control signal, which enables or causes the on-board control unit to adjust one or more parameter settings to extend the lifetime of the ignition system or, in particular, the sparkplug.
  • the on-board control unit of the combustion engine may also receive the signal and perform a calibration of the ignition system, preferably of the ignition driver and/or at least one sparkplug, based on the signal.
  • averaged or optimized parameter settings calculated from the plurality of on-board control units may be determined based on the received at least one parameter measurement and/or determined operational state of the present on-board control unit. For example, a wear state determined by the on-board control unit may be provided to the off- board evaluation unit prior to start-up of the combustion engine and parameter settings associated with such wear state may be input or accordingly adjusted to improve the performance and/or lifetime.
  • the ignition system using both the on board control unit and the off-board evaluation unit hence enables that e.g. optimum ignition energy and waveform may be provided to assure minimum wear rate and maximum operating life.
  • usage-specific and/or application-specific parameters may be provided to the off-board evaluation unit prior to first use or operation at a particular site, wherein the parameter settings are provided e.g. for the respective ambient conditions and the application and hence an initial calibration may be performed adapted to the actual conditions of the combustion engine.
  • the signal that is output may comprise an indication whether the current parameter settings and/or the current operational state require particular attention or require adjustment, e.g. to improve the lifetime and/or overall performance of the ignition system.
  • the outputted signal may comprise a maintenance signal and/or warning signal, wherein the evaluation unit transmits the maintenance signal and/or warning signal to a decentral or central unit, preferably a central monitoring system, and/or an on-board control system of the combustion engine, preferably the control unit of the combustion engine.
  • the decentral unit i.e. not directly coupled to the respective combustion engine, may e.g. be an asset monitoring center, a plant management and/or fleet management interface, and/or a decentral on-board monitoring unit whereas the on-board control system may e.g. be an on-engine control system of the respective combustion engine.
  • the transmission to the decentral unit or central unit facilitates monitoring of a variety of ignition systems that may e.g. be operated at the same site and/or for the same application and provides that information relating e.g. to the proper functioning of the ignition system may be provided via a central control system monitoring the operational state of the combustion engine.
  • an ignition system for a combustion engine is provided.
  • Such ignition system comprises an on-board control unit for controlling the ignition system and an off-board evaluation unit communicatively coupleable to the on-board control unit via a data link, wherein the ignition system is configured to perform the method according to the invention.
  • the on-board control unit for controlling the ignition system may hence be configured to receive at least one measurement of a parameter related to the ignition system, to determine an operational state of the ignition system based on said at least one parameter measurement, and to control the ignition system based at least on the determined operational state.
  • the off-board evaluation unit may be configured to receive the at least one parameter measurement and/or the determined operational state from the on-board control unit via the data link, wherein the evaluation unit may furthermore be configured to receive data from a plurality of on-board control units, to compare the at least one parameter measurement and/or the determined operational state with said received data, and to output a signal based on said comparison.
  • the off-board evaluation unit may be provided e.g. at a server end of a computer system or computational network, which may optionally be part of a decentral monitoring and/or plant management center.
  • the off-board evaluation unit may also be cloud-based or may include, at least in part, an edge-computing system.
  • a computer program product embodied on a computer readable storage medium and configured to, when executed on a processor, perform operations of the method according to the invention is provided.
  • a method for monitoring an ignition system of a combustion engine and a corresponding system as well as a computer program product are suggested.
  • the suggested method as mentioned above is applicable in a variety of engines, such as (large) gas engines, which require an ignition system and wherein operational states or wear may vary depending on the operational history and usage. Accordingly replacements and/or adjustments of system components and parameters may be necessary on a frequent basis.
  • the combination of the on-board control unit and the off-board evaluation unit may provide an improvement in the performance of the ignition system and overall combustion engine while simultaneously providing an improved assessment of the actual state and requirements of the ignition system.
  • the method may be implemented by means of hardware and/or software updates in existing ignition systems, e.g. by implementing or updating a communication module. The method may be performed at any stage, prior to use and during operation the engine and may also provide an (auto-)calibration upon first usage.

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Abstract

The present invention pertains to a method for monitoring an ignition system of a combustion engine as well as a corresponding system and computer program product, in particular to facilitate long-term functioning of the ignition system and to improve the operating life. Accordingly, a method for monitoring an ignition system (100) of a combustion engine is suggested, comprising the steps of: by an on-board control unit (10) for controlling the ignition system (100), receiving at least one measurement of a parameter related to the ignition system (16), determining an operational state of the ignition system (17) based on said at least one parameter measurement (16), and controlling the ignition system (100) based on the determined operational state (17); by an off-board evaluation unit (12), receiving the at least one parameter measurement (16) and/or the determined operational state (17) from the on-board control unit (10) via a data link (14); and by the off-board evaluation unit (12), receiving data from a plurality of on-board control units (20), comparing (31) the at least one parameter measurement (16) and/or determined operational state (17) with said received data (20), and outputting a signal (18) based on said comparison (31).

Description

Description
REMOTE MONITORING OF AN IGNITION SYSTEM OF A COMBUSTION ENGINE
Technical Field
The present invention pertains to a method for monitoring an ignition system of a combustion engine as well as a corresponding system and computer program product, in particular to facilitate long-term functioning of the ignition system and to improve the operating life.
Technological Background
The ignition system is a vital part of an engine and also one of the most critical, when it comes to operational robustness. With an ever increasing demand of operational flexibility and higher uptimes of the engine, it is of utmost importance to make the ignition system more robust and advanced in terms of their diagnostic and prognostics capability.
Unfortunately, all the conventional ignition systems are pure on- board systems, wherein the computational capacity, e.g. of the electronic or engine control modules and corresponding processors used in their hardware, is limited. For example, such on-board systems are not capable to perform the data analysis used for advanced diagnostics and integrated service assistance. Accordingly, current performance may be monitored and controlled, but no long- term trends and characterization are possible.
Furthermore, even if off-board monitoring devices and solutions are available, such devices cannot use the information derived from data analysis in real-time to impact the actual operation of the respective ignition system. As a result, current solutions only provide short-term on-board prognostics and control and lack any engine-specific long-term prognostics and corresponding control of the respective ignition system. Therefore, a need exists to ensure long-term proper functioning of the ignition system and to further improve the operating life of the ignition system.
Summary of the Invention
Starting from the prior art, it is an objective to provide an improved monitoring of the operational state of the ignition system of a combustion engine, in particular with regard to long-term functioning.
This objective is solved by means of a method for monitoring an ignition system of a combustion engine with the features of claim 1, the corresponding ignition system with the features of claim 16, and the corresponding computer program product with the features of claim 17. Preferred embodiments are set forth in the present specification, the Figures as well as the dependent claims.
Accordingly, a method for monitoring an ignition system of a combustion engine is suggested, comprising the steps of: by an on-board control unit for controlling the ignition system, receiving at least one measurement of a parameter related to the ignition system, determining an operational state of the ignition system based on said at least one parameter measurement, and controlling the ignition system based on the determined operational state; by an off-board evaluation unit, receiving the at least one parameter measurement and/or the determined operational state from the on board control unit via a data link; and by the off-board evaluation unit, receiving data from a plurality of on-board control units, comparing the at least one parameter measurement and/or determined operational state with said received data, and outputting a signal based on said comparison.
Furthermore, an ignition system for a combustion engine is suggested, comprising an on-board control unit for controlling the ignition system and an off-board evaluation unit communicatively coupleable to the on-board control unit via a data link, the ignition system being configured to perform the method according to the invention.
Furthermore, a computer program product is suggested, which is embodied on a computer readable storage medium and is configured to, when executed on a processor, perform operations of the method according to the invention.
Brief Description of the Drawings
The present disclosure will be more readily appreciated by reference to the following detailed description when being considered in connection with the accompanying drawings in which:
Fig. 1 shows a schematic view of an ignition system of a combustion engine and a corresponding method for monitoring such ignition system according to the invention; and
Fig. 2 shows a schematic view of the ignition system and method according to Fig. 1 according to a preferred embodiment.
Detailed Description of Preferred Embodiments
In the following, the invention will be explained in more detail with reference to the accompanying figures. In the Figures, like elements are denoted by identical reference numerals and repeated description thereof may be omitted in order to avoid redundancies.
In Figure 1, an ignition system 100 of a combustion engine and a corresponding method for monitoring such ignition system 100 according to the invention are schematically depicted.
The ignition system 100 comprises an on-board control unit 10 and an off-board evaluation unit 12, wherein the on-board control unit 10 is arranged in proximity of the combustion engine and provides a direct monitoring and adjustment of operating parameters of the ignition system, e.g. the ignition driver and/or directly of one or more sparkplugs. The on-board control unit 10 may hence be considered as an on-engine control unit, which may be primarily directed to ignition timing, ignition energy, and the proper functioning of the one or more sparkplugs.
The off-board evaluation unit 12 may be part of a decentral unit, i.e. not being on-board or on-engine. In particular, the off-board evaluation unit 12 may be provided e.g. at a server end of a computer system or computational network, which may optionally be part of a decentral monitoring and/or plant management center. The off-board evaluation unit 12 may also be cloud-based or may include, at least in part, an edge-computing system.
As indicated with the arrowheads between the on-board control unit 10 and the off-board evaluation unit 12, the system 100 furthermore comprises a data link 14 providing a communication between the on-board control unit 10 and the off-board evaluation unit 12. Accordingly, the on-board control unit 10 is configured to provide at least one parameter measurement 16 and/or a determined operational state 17 corresponding to the at least one parameter measurement 16 related to the ignition system 100 and to receive a signal 18 outputted by the off-board evaluation unit 12. By the same token, the off-board evaluation unit 12 is configured to receive the at least one parameter measurement 16 and/or operational state 17 from the on-board control unit 10 and to output the signal 18.
The off-board evaluation unit 12 is furthermore configured to compare the received data from the respective, i.e. present or actual, on-board control unit 10 with corresponding data received from a plurality of on-board control units 20, which may either be actively retrieved, e.g. from a server, or may be provided in a data storage communicatively coupled to or internally connected to the off-board evaluation unit 12. Such data storage is preferably continuously or periodically updated. Based on said comparison, the signal 18 may be generated as output.
The data comparison is preferably performed with data from corresponding on-board control units, wherein several factors or attributes may be compared in order to improve the relevance of the respective data and the validity of the data comparison. Such data comparison may furthermore take a trend analysis into account, wherein the performance of the ignition system (or engine as a whole) as well as long-term prognostics, e.g. the potential remaining lifetime of one or more sparkplugs, are assessed. In other words, statistical data e.g. from previous sparkplugs and corresponding parameter values and wear states for a large or predefined number of corresponding on-board control units may be considered and the signal 18 that is output may be based on said assessment in order to ensure that an optimal performance and longevity are provided.
More particular, depending on the configuration of the ignition system 100 and its wear state, an optimum ignition energy and waveform shaping may be required to assure minimum wear rate and thereby maximum operating life. All the activities relevant to driver controls may be performed in real-time, are work cycle based and are adapted with high responsiveness to changing operating conditions. Such algorithms may be realized on-board to assure the expected functionalities. Also, relevant or essential enablers and diagnostic means may be implemented on the electronic control module software.
Such enablers and feedback indicators from the respective algorithms may be provided to the data link 14, which enables their usage e.g. for engine operation, plant control and further transmits this data to the off-board evaluation unit 12 so as to enable a long-term trend analysis.
The data received from the plurality of on-board control units 20 may comprise data from multiple engines, which may be of various configuration, may be operating in various applications, and/or are used at various site locations. The combination of the on-board control unit 10 and the off-board evaluation unit 12 thereby provides an ignition system 100 as a whole, wherein different tasks are performed at a respective end, i.e. short-term functionality being assured at the end of the on-board control unit 10 and long term prognostics and data comparison being performed at the off-board evaluation unit 12. A more detailed depiction of the various preferred or optional functions of the on-board control unit 10 and the off-board evaluation unit 12 is schematically shown in Figure 2.
Accordingly, one or more parameters may be received by the off- board evaluation unit 12, wherein the parameters may include at least one usage- specific parameter 22, at least one engine application parameter 24, at least one engine performance parameter 26, and/or at least one engine profile parameter 28.
By means of example, the present embodiment is primarily directed to the functionality of the at least one sparkplug (not shown) of the ignition system 100, such that the off-board evaluation unit 12 is configured to calculate or determine a sparkplug life statistic 30 based on the received one or more parameter measurements 16 and/or operational state 17. Such sparkplug life statistic 30 may also be calculated based additionally on previously received data from the on-board control unit 10 and from statistical data from a data pool. The sparkplug life statistic 30 may e.g. be a remaining useful life in hours, as a percentage, and/or as a fraction.
Accordingly, the data comparison 31 is performed between the calculated sparkplug life statistic and the received data from a plurality of on board control units 20, as indicated with the double-sided arrowheads. The at least one usage-specific parameter 22, engine application parameter 24, engine performance parameter 26, and/or engine profile parameter 28 provide that the comparison may be selective and that data only from relevant or corresponding on-board control units is considered in the comparison 31.
Such data, however, does not need to correspond entirely as the actual data for each on-board control unit, may be to a large extent essentially unique. Accordingly, a multi-dimensional clustering may be provided, wherein only data within (or, alternatively, outside of) such clusters is considered in the comparison 31. This provides that a more exact long-term prognostic may be provided. On the other hand, the comparison 31 may also include data encompassing a larger or broader extent of e.g. usages or applications, such that the comparison 31 may be e.g. based on data for a particular batch, type of engine, or type of cylinder, etc. This ensures that a large amount of data is available for the comparison and that a tolerance range for the comparison 31 may be adaptable.
The signal 18 that is output by the off-board evaluation unit 12, according to the present embodiment, is a control signal 18, which is directly transmitted to the on-board control unit 10 and may, optionally, overrule or directly provide corresponding parameter settings at the on-board control unit level. However, such control signal 18 is understood to be optional. In addition, a warning signal or maintenance signal 32 is output, which may be transmitted to a decentral monitoring server, plant monitoring facility, and/or to a central control system of the combustion engine or appliance.
At the on-board control unit 10 end of the ignition system 100 one or more engine operating parameters 34 are monitored, preferably continuously and at working-cycle basis. For example, the density at the time point of ignition may be a parameter to assess the proper functioning and performance of the ignition system 100. Based on information regarding to the ignition system configuration 36, e.g. the type of coil, electronic control module, and/or sparkplug type or number, a corresponding ignition energy control 38 is provided to ensure that a correct amount of current is provided and that the ignition energy is provided according to a calculated or predefined duration.
Based on the provided current and duration, a sparkplug operational state 40 such as a wear state may be determined and this may be performed based on the corresponding data for the operating history of the respective sparkplug, for example. Accordingly, feedback may be provided regarding the sparkplug condition.
In case an abnormal operation 42 is detected, the on-board control unit 10 may determine whether an anomaly 44 is detected and may e.g. determine that a misfiring has occurred. If this is the case, the on-board control unit 10 then performs a sparkplug validation 46 to assess whether an overall ignitability or sparkability is still present. One or more of these indications or determined states may then be fed back to the engine operating monitor 34 and/or may be directly transmitted to the off-board evaluation unit 12 via the data link 14. As described above, the off- board evaluation unit 12 performs a data comparison 31 and/or long-term prognostics to assess whether any detected or determined abnormalities indeed may result in a critical state and the parameter settings of the on-board control unit 10 or ignition energy control 38 need adjustments. Such adjustment may be provided directly by means of the control signal 18, which may e.g. cause a limp- off mode to be activated, wherein the power may be reduced and/or an ignition angle may be altered. Such limp-off mode may be beneficial to avoid downtime while improving the longevity of the respective sparkplug and the ignition system 100 as a whole.
It is to be understood that the short-term control and assessment of the sparkplug operational state 40 ensures functionality of the on-board ignition system 10, yet may only provide a limited prognosis and is essentially based on predefined (historic) parameter values associated with the operation history of the sparkplug. Long-term prognostics, however, are not possible due to the lack of computational capacity and the amount of data that needs to be considered for such assessment. The off-board evaluation unit 12, however, provides such functionality and may ensure e.g. in cases of a detected abnormality that servicing is only performed when actually required based on comparison 31 with a large data set of corresponding on-board control units. At the same time, said comparison 31 enables that adjustments of parameter settings may be provided to further improve the performance and achieve a maximum operating life.
It will be obvious for a person skilled in the art that these embodiments and items only depict examples of a plurality of possibilities.
Hence, the embodiments shown here should not be understood to form a limitation of these features and configurations. Any possible combination and configuration of the described features can be chosen according to the scope of the invention. This is in particular the case with respect to the following optional features which may be combined with some or all embodiments, items and/or features mentioned before in any technically feasible combination.
A method for monitoring an ignition system of a combustion engine is provided.
Such method comprises the steps of: by an on-board control unit for controlling the ignition system, receiving at least one measurement of a parameter related to the ignition system, determining an operational state of the ignition system based on said at least one parameter measurement, and controlling the ignition system based on the determined operational state; by an off-board evaluation unit, receiving the at least one parameter measurement and/or the determined operational state from the on board control unit via a data link; and by the off-board evaluation unit, receiving data from a plurality of on-board control units, comparing the at least one parameter measurement and/or determined operational state with said received data, and outputting a signal based on said comparison.
The on-board control unit may e.g. comprise or essentially consists of one or more electronic control modules and/or engine control modules (ECM), wherein in particular a present state of the ignition system may be monitored. Such monitoring may be provided based on driving cycles and/or working cycles, which may hence be in a millisecond or nanosecond domain. The on-board control unit may hence monitor an operational state, e.g. of the ignition driver and/or of the spark plug(s) and may accordingly adapt the control of the corresponding components based on the determined operational state and/or one or more operational parameters. For example, the on-board control unit may adapt the control based on a detected waveform anomaly or may adapt the control according to a determined wear state, which may be based on the operation time and/or one or more detected operational parameters. The on-board control unit, however, is not capable to provide long-term prognostics, since the corresponding requirements exceed the computational effort and data storage capacity that may potentially be available on-board. In particular, larger capacities may be required for heavy-duty engines due to their corresponding complexity.
Accordingly, the off-board evaluation unit is provided to enable such prognostics or trends, e.g. by determining a remaining operational lifetime for one or more components. The off-board evaluation unit is provided with data from a plurality of on-board control units, i.e. from different combustion engines, and compares the at least one parameter measurement and/or determined operational state with said received data. The data received from the plurality of on-board control units may at least in part comprise previously obtained data and is hence not required to comprise only presently received data, although such present data may also be taken into account. Based on the comparison, the off- board evaluation unit outputs a signal.
The signal outputted by the off-board evaluation unit may hence be an indication whether an anomaly that is determined or detected by the on board control unit is of particular relevance or whether based on the comparison with the received data such anomaly may be, at least for the time being, be ignored or requires no immediate adjustment of the on-board control and/or maintenance of the corresponding components of the ignition system. In other words, while the on-board control unit may provide a short-term control mode and may indicate potential errors, the off-board evaluation unit may provide a long-term prognostic, wherein data from multiple on-board control units is factored in. Such trends provided by the off-board evaluation unit may hence provide feedback to the on-board control unit and/or indicate the necessity of further adjustments to improve the (long-term) performance of the ignition system as a whole or particular components thereof.
The ignition system may be a stand-alone system that may be coupled to corresponding components of a combustion engine or may be integrated in a combustion engine. The ignition system may e.g. comprise, in addition to the on-board control unit and the off-board evaluation unit, an ignition driver and/or one or more sparkplugs or coils for the combustion engine.
Preferably, the comparison and/or the outputting of the signal is performed by the evaluation unit in real-time or periodically. Thereby, a direct feedback to the on-board control unit may be provided or at least at predefined time intervals. Although the outputting in real-time may further improve the efficiency and longevity of the ignition system, such outputting may also be provided depending on the type of parameter measurement and/or determined operational state received from the on-board control unit.
The signal outputting frequency may e.g. be dependent on the transmitting frequency of the on-board control unit and/or be on-demand, based on e.g. a type of parameter measurement and/or determined operational state and/or a result of the comparison. For example, a predefined outputting frequency may be provided while particular detected or determined anomalies in the operational state may cause an intermittent transmission and comparison in the evaluation unit and corresponding outputting, if the comparison indicates that an operational issue needs to be resolved.
The at least one parameter measurement may include one or more detected parameters of the ignition system configuration and/or at least one measurement of a spark plug of the ignition system, preferably a detected spark time, a detected ignition coil configuration, a detected misfire, and/or one or more detected spark breakdowns.
The off-board evaluation unit may then compare the parameter measurement with corresponding parameter measurements in the data from the plurality of on-board control units and may e.g. determine a particular risk for the proper functioning and/or longevity of the ignition system. In other words, the off-board evaluation unit may assess whether the occurring parameter measurement is within a tolerance range, correlates with a potential detrimental operating state, or requires an adjustment for improving the lifetime of the ignition system. Preferably, the determined operational state includes a measure of wear of a sparkplug of the ignition system and/or a remaining operating life of a spark plug of the ignition system is determined by the evaluation unit as a part of the data comparison.
While the wear state of the sparkplug may indicate that a servicing may be due, the on-board control unit is not capable to perform long-term prognostics and to assess how the operating history and operating conditions may have affected the state of the sparkplug. Accordingly, a corresponding tolerance range to avoid malfunctioning of the sparkplug may be narrow at the end of the on-board control unit, thereby including a variety of actual wear states. The off- board evaluation unit may however determine whether a detected abnormality or wear state is considered critical by comparing the determined wear state with data from the plurality of on-board control units.
For example, the off-board evaluation unit may compare the determined wear state for one or more particular batch numbers or may even compare said wear state for a particular type of ignition system. Hence, based on the comparison, a remaining lifetime of the sparkplug or the ignition system as a whole may be determined, which factors in data for similar operational states. By the same token, the comparison may include data for wear states that are increased up to or by a predefined amount to assess whether the actual wear state may result in a near-future malfunctioning.
The signal may comprise a control signal for the on-board control unit of the ignition system of the combustion engine, preferably the ignition driver, wherein the control unit may receive said signal via the data link and preferably controls the ignition system based on said control signal or by factoring in said control signal.
Accordingly, not only a monitoring may be provided, but also a direct feedback in the form of a control signal is provided to the on-board control unit. The control signal may hence overrule or adjust a control parameter set or determined by the on-board control unit or the on-board control unit may use the received control signal to accordingly adjust the parameter settings. This may also be provided depending on the result of the comparison. For example, a severe risk of malfunctioning or reduced lifetime of the ignition system, as calculated by the off-board evaluation unit during the comparison, may result in an overruling of the control parameter set or determined by the on-board control unit. The control signal may e.g. cause the on-board control unit to perform a limp-off mode, wherein performance may be (temporarily) reduced by a predefined amount so as to increase the lifetime of the ignition system or particular components thereof.
The control signal preferably includes one or more operating parameter values of the ignition system corresponding to a predefined waveform, an ignition energy, an ignition timing, an ignition duration, and/or an ignition angle. Said one or more operating parameter values may be derived from the comparison performed by the off-board evaluation unit, wherein an optimum has been calculated or resolved based on a predefined algorithm using the corresponding data from the plurality of on-board control units. By the same token, a respective average operating parameter value may also be calculated by the off-board evaluation unit based on said data, e.g. using operating parameter values for a similar performance or a performance with a predefined offset.
The evaluation unit may receive one or more usage-specific parameters from the combustion engine via the data link and include said one or more usage-specific parameters in the data comparison, wherein the usage- specific parameters preferably include one or more ambient conditions and/or a type or composition of a used combustion fuel.
By doing so, the data comparison performed by the evaluation unit may be more specific for on-board control units being operated under similar operating conditions. For example, the performance of the combustion engine and the corresponding operating parameter settings may vary for operations at different altitudes, ambient temperatures, humidity, and air composition. In addition, the type or composition of the combustion fuel may differ locally and/or globally and the combustion engine may be operated with different combustion mixtures, which may affect both the performance of the combustion engine and the lifetime of the ignition system components. Furthermore, both the atmospheric air and the combustion fuel may comprise different amounts of fine particles and/or ionized molecules. Providing such usage-specific parameters hence enables that only similar and/or relevant data is compared, thereby improving the validity and accuracy of the outputted signal.
By the same token, the evaluation unit may receive one or more engine profile parameters from the combustion engine via the data link and include said one or more engine profile parameters in the data comparison, said engine profile parameters preferably including an engine operating profile, a cooling circuit profile, and/or a measure for gas quality fluctuation.
Such engine profile parameters provide a further restriction of the data comparison to on-board ignition systems having similar engine characteristics and/or operating history, wherein preferably a corresponding trend may be assessed and the signal may be output based on such trend.
The evaluation unit may also compare data for particular errors or malfunctioning situations, such that e.g. a remaining lifetime of the ignition system and/or the components thereof may be calculated with higher accuracy. Accordingly, the evaluation unit may receive one or more engine performance parameters from the combustion engine via the data link and includes said one or more engine performance parameters in the data comparison, wherein the engine performance parameters preferably include knocking data, one or more diagnostic trouble codes, engine derating data, and/or engine downtime data.
The evaluation unit may also receive one or more engine application parameters from the combustion engine via the data link and include said one or more engine application parameters in the data comparison, wherein the engine application parameters preferably including an application-specific indication number and/or a site-specific indication number.
Such application-specific or site-specific indication number may indicate e.g. not only where the engine is used, geographically, but also whether the engine is used e.g. in a grid or for a particular load, whether the engine is implemented for marine or land operations or whether the engine is used for power generation, for example. Furthermore, the number may indicate whether the engine is used as a stand-alone or standby engine. These factors may significantly affect the performance and wear of the combustion engine as a whole and the ignition system, such that factoring in this information in the data comparison performed by the evaluation unit may improve the validity and accuracy of the outputted signal.
Preferably, the evaluation unit performs the comparison based on data clustering for matching parameters from data received from a predefined number of control units.
The data clustering may include a data selection and a qualitative statistical analysis of the selected data, wherein the data selection is preferably attribute-based and/or the qualitative statistical analysis is preferably density based, and/or wherein the data clustering is performed in a predefined parameter order.
For example, the data clustering may be performed in multiple dimensions according to the respective attributes, e.g. a particular wear state, an operating time of the ignition system, a misfire frequency, and/or a performance of the combustion engine. These corresponding values for these attributes from the data received from the plurality of on-board control units may then be clustered based on a statistical analysis to include only those values within a predefined range and the signal to be output may be based on one or more best- matches for the corresponding attributes of the present on-board control unit. The clustering may also provide data associated with a predefined trend, such that the outputted signal may preferably be adapted to improve the lifetime of the ignition system or one or more components thereof.
The density-based clustering provides that either only those attributes are considered that fall within a particular value range for the respective attribute or that, conversely, only those attributes are considered that form statistical outliers. Furthermore, the predefined attribute order may include a particular weighting of the respective attributes, which may accordingly implemented in an algorithm for performing the comparison and indicative for outputting the signal.
Preferably, the evaluation unit determines at least one spark plug life statistic from data received from a predefined number of control units and factors the at least one spark plug life statistic into the signal.
The sparkplug life statistic is particularly relevant in determining the overall state of the ignition system and its wear state and (remaining) lifetime may directly relate to a servicing necessity and/or engine performance. While the on-board control unit may determine appropriate parameter settings for the ignition system and the one or more sparkplugs to provide an improved functioning and corresponding performance of the combustion engine and provide an indication of a current wear state of the one or more sparkplugs, the on-board control unit is not capable to provide long-term prognostics, such as a remaining lifetime.
Accordingly, the off-board evaluation unit may provide such prognostics by comparing the data received from the plurality of on-board control units with the data received from the actual or present on-board control unit and may calculate the relevant life statistic. The life statistic may e.g. indicate that a current wear state is not problematic, since, for example, corresponding data from the plurality of on-board control units has shown that for a particular performance the actual lifetime with full functionality or having a performance that is reduced by a predefined amount or percentage, but is sufficient to maintain normal operation of the combustion engine, is extended. The outputted signal may accordingly provide an indication to the on-board control unit that the wear state may be ignored or should be monitored, but provides no direct problem for the operational state. Furthermore, the outputted signal may also include a control signal, which enables or causes the on-board control unit to adjust one or more parameter settings to extend the lifetime of the ignition system or, in particular, the sparkplug. The on-board control unit of the combustion engine may also receive the signal and perform a calibration of the ignition system, preferably of the ignition driver and/or at least one sparkplug, based on the signal.
By means of the data comparison, averaged or optimized parameter settings calculated from the plurality of on-board control units may be determined based on the received at least one parameter measurement and/or determined operational state of the present on-board control unit. For example, a wear state determined by the on-board control unit may be provided to the off- board evaluation unit prior to start-up of the combustion engine and parameter settings associated with such wear state may be input or accordingly adjusted to improve the performance and/or lifetime. The ignition system using both the on board control unit and the off-board evaluation unit hence enables that e.g. optimum ignition energy and waveform may be provided to assure minimum wear rate and maximum operating life.
By the same token, usage-specific and/or application-specific parameters may be provided to the off-board evaluation unit prior to first use or operation at a particular site, wherein the parameter settings are provided e.g. for the respective ambient conditions and the application and hence an initial calibration may be performed adapted to the actual conditions of the combustion engine.
The signal that is output may comprise an indication whether the current parameter settings and/or the current operational state require particular attention or require adjustment, e.g. to improve the lifetime and/or overall performance of the ignition system. The outputted signal may comprise a maintenance signal and/or warning signal, wherein the evaluation unit transmits the maintenance signal and/or warning signal to a decentral or central unit, preferably a central monitoring system, and/or an on-board control system of the combustion engine, preferably the control unit of the combustion engine.
The decentral unit, i.e. not directly coupled to the respective combustion engine, may e.g. be an asset monitoring center, a plant management and/or fleet management interface, and/or a decentral on-board monitoring unit whereas the on-board control system may e.g. be an on-engine control system of the respective combustion engine. The transmission to the decentral unit or central unit facilitates monitoring of a variety of ignition systems that may e.g. be operated at the same site and/or for the same application and provides that information relating e.g. to the proper functioning of the ignition system may be provided via a central control system monitoring the operational state of the combustion engine.
Furthermore, an ignition system for a combustion engine is provided.
Such ignition system comprises an on-board control unit for controlling the ignition system and an off-board evaluation unit communicatively coupleable to the on-board control unit via a data link, wherein the ignition system is configured to perform the method according to the invention.
The on-board control unit for controlling the ignition system may hence be configured to receive at least one measurement of a parameter related to the ignition system, to determine an operational state of the ignition system based on said at least one parameter measurement, and to control the ignition system based at least on the determined operational state. The off-board evaluation unit may be configured to receive the at least one parameter measurement and/or the determined operational state from the on-board control unit via the data link, wherein the evaluation unit may furthermore be configured to receive data from a plurality of on-board control units, to compare the at least one parameter measurement and/or the determined operational state with said received data, and to output a signal based on said comparison.
The off-board evaluation unit may be provided e.g. at a server end of a computer system or computational network, which may optionally be part of a decentral monitoring and/or plant management center. The off-board evaluation unit may also be cloud-based or may include, at least in part, an edge-computing system.
Furthermore, a computer program product embodied on a computer readable storage medium and configured to, when executed on a processor, perform operations of the method according to the invention is provided.
Industrial Applicability
With reference to the Figures, a method for monitoring an ignition system of a combustion engine and a corresponding system as well as a computer program product are suggested. The suggested method as mentioned above is applicable in a variety of engines, such as (large) gas engines, which require an ignition system and wherein operational states or wear may vary depending on the operational history and usage. Accordingly replacements and/or adjustments of system components and parameters may be necessary on a frequent basis. The combination of the on-board control unit and the off-board evaluation unit may provide an improvement in the performance of the ignition system and overall combustion engine while simultaneously providing an improved assessment of the actual state and requirements of the ignition system. The method may be implemented by means of hardware and/or software updates in existing ignition systems, e.g. by implementing or updating a communication module. The method may be performed at any stage, prior to use and during operation the engine and may also provide an (auto-)calibration upon first usage.

Claims

Claims
1. A method for monitoring an ignition system (100) of a combustion engine, comprising the steps of: by an on-board control unit (10) for controlling the ignition system
(100), receiving at least one measurement of a parameter related to the ignition system (16), determining an operational state of the ignition system (17) based on said at least one parameter measurement (16), and controlling the ignition system (100) based on the determined operational state (17); by an off-board evaluation unit (12), receiving the at least one parameter measurement (16) and/or the determined operational state (17) from the on-board control unit (10) via a data link (14); and by the off-board evaluation unit (12), receiving data from a plurality of on-board control units (20), comparing (31) the at least one parameter measurement (16) and/or determined operational state (17) with said received data (20), and outputting a signal (18) based on said comparison (31).
2. The method according to claim 1, wherein the comparison (31) and/or the outputting of the signal (18) is performed by the evaluation unit in real-time or periodically
3. The method according to claim 1 or 2, wherein the at least one parameter measurement (16) includes one or more detected parameters of the ignition system configuration (34) and/or at least one measurement of a spark plug of the ignition system (100), preferably a detected spark time, a detected ignition coil configuration, a detected misfire, and/or one or more detected spark breakdowns.
4. The method according to any of the preceding claims, wherein the determined operational state (17) includes a measure of wear of a sparkplug of the ignition system (100) and/or wherein a remaining operating life of a spark plug (30) of the ignition system (100) is determined by the evaluation unit (12) as a part of the data comparison (31).
5. The method according to any of the preceding claims, wherein the signal (18) comprises a control signal for the on-board control unit (10) of the ignition system (100) of the combustion engine, preferably the ignition driver, and wherein the control unit (10) receives said signal (18) via the data link (14) and preferably controls the ignition system (100) based on said control signal (18) or by factoring in said control signal (18).
6. The method according to claim 5, wherein the control signal (18) includes one or more operating parameter values of the ignition system corresponding to a predefined waveform, an ignition energy, an ignition timing, an ignition duration, and/or an ignition angle.
7. The method according to any of the preceding claims, wherein the evaluation unit (12) receives one or more usage-specific parameters (22) from the combustion engine via the data link (14) and includes said one or more usage-specific parameters (22) in the data comparison (31), said usage- specific parameters (22) preferably including one or more ambient conditions and/or a type or composition of a used combustion fuel.
8. The method according to any of the preceding claims, wherein the evaluation unit (12) receives one or more engine profile parameters (28) from the combustion engine via the data link (14) and includes said one or more engine profile parameters (28) in the data comparison (31), said engine profile parameters (28) preferably including an engine operating profile, a cooling circuit profile, and/or a measure for gas quality fluctuation.
9. The method according to any of the preceding claims, wherein the evaluation unit (12) receives one or more engine performance parameters (26) from the combustion engine via the data link (14) and includes said one or more engine performance parameters (26) in the data comparison (31), said engine performance parameters (26) preferably including knocking data, one or more diagnostic trouble codes, engine derating data, and/or engine downtime data.
10. The method according to any of the preceding claims, wherein the evaluation unit (12) receives one or more engine application parameters (24) from the combustion engine via the data link (14) and includes said one or more engine application parameters (24) in the data comparison (31), said engine application parameters (24) preferably including an application- specific indication number and/or a site-specific indication number.
11. The method according to any of the preceding claims, wherein the evaluation unit (12) performs the comparison (31) based on data clustering for matching parameters from data received from a predefined number of control units.
12. The method according to claim 11, wherein the data clustering includes a data selection and a qualitative statistical analysis of the selected data, the data selection preferably being attribute-based and/or the qualitative statistical analysis preferably being density based, and/or wherein the data clustering is performed in a predefined parameter order.
13. The method according to any of the preceding claims, wherein the evaluation unit (12) determines at least one spark plug life statistic (30) from data received from a predefined number of control units and to factor the at least one spark plug life statistic (30) into the signal (18).
14. The method according to any of the preceding claims, wherein the control unit (10) of the combustion engine receives the signal (18) and performs a calibration of the ignition system (100), preferably of the ignition driver and/or at least one spark plug, based on the signal (18).
15. The method according to any of the preceding claims, wherein the outputted signal (18) comprises a maintenance signal and/or warning signal (32), wherein the evaluation unit (12) transmits the maintenance signal and/or warning signal (32) to a decentral or central unit, preferably a central monitoring system, and/or an on-board control system of the combustion engine, preferably the control unit of the combustion engine.
16. An ignition system (100) for a combustion engine, comprising an on-board control unit (10) for controlling the ignition system (100) and an off-board evaluation unit (12) communicatively coupleable to the on board control unit (10) via a data link (14), the ignition system (100) being configured to perform the method according to any of the preceding claims.
17. A computer program product embodied on a computer readable storage medium and configured to, when executed on a processor, to perform operations of the method according to any of the preceding claims.
PCT/EP2022/025068 2021-03-04 2022-02-25 Remote monitoring of an ignition system of a combustion engine WO2022184318A1 (en)

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GB2103031.7A GB2606686A (en) 2021-03-04 2021-03-04 Control and monitoring of smart ignition system

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