Patent Application
20210356926
The present disclosure generally relates to monitoring health status of a machine component. More specifically, the present disclosure relates to monitoring the health status of the machine component on a real time basis.
An important feature in modern work machines (e.g., fixed and mobile commercial machines, such as construction machines, fixed engine systems, marine-based machines, etc.) is detection and diagnosis of faults or errors in such machines. Machine faults may cause discomfort to operators handling the machines and may incur additional costs to business entities that use the machines in their particular commercial industry. Accordingly, systems have evolved to monitor and detect faults in the machines during operation.
Currently, such machines are provided with various systems and sub-systems including various sensors & switches, which help in providing machine health information to engine & machine control units. However, this information may not be readily available to end users, and mostly only a failure notification is provided. For example, in case of air filters for an engine, the information is only available when the filters are in a choked/clogged condition and in need of replacement, resulting in machine downtime. Further, air flow restriction from the air filter can increase engine pumping work and reduce machine fuel economy. To avoid such situations, air filters may have to be replace or cleaned in due time which may require periodic monitoring of a health status of the air filter.
U.S. Pat. No. 10,119,886 describes a filtration monitoring system. The filtration monitoring system is an electronic system control module installed on an internal combustion engine or within a vehicle powered by the internal combustion engine. The filtration monitoring system monitors the health and status of the filtration systems present on the engine. The filtration monitoring system tracks filter loading patterns and predicts remaining service life of the filters by running smart algorithms based on sensor feedback.
Thus, the conventional machine systems lack a maintenance system which may provide information on operating parameters of serviceable components on a real time basis.
In an aspect of the present disclosure, a method of monitoring health status of a machine component on a real time basis is provided. The method includes generating a first signal indicative of an operational characteristic of the machine component by a sensor module at regular predetermined intervals. The method also includes receiving the first signal by an Internet of Things (IoT) module. The method further includes converting the first signal from analog format to digital format by the IoT module to generate a second signal. The method includes transmitting the second signal by the IoT module wirelessly. The method also includes receiving the second signal by a mobile device. The method further includes processing the second signal by the mobile device to determine a real time health status of the machine component. Further, the method includes displaying the real time health status of the machine component on the mobile device.
In another aspect of the present disclosure, a system for monitoring health status of one or more machine components of a machine on a real time basis is provided. Each of the one or more machine components has an associated operational characteristic. The system includes one or more sensor modules communicably coupled to each of the one of more machine components. The sensor module generates a first signal at regular predetermined intervals indicative of the operational characteristic. The system also includes one or more IoT modules communicably coupled to each other either directly or indirectly. Each of the one or more IoT modules is communicably coupled with the one or more sensor modules. Each of the one or more IoT modules receives the first signal and converts the first signal from analog format to digital format to generate a second signal. Each of the one or more IoT modules transmits the second signal wirelessly. The system also includes a mobile device communicably coupled to any one of the one or more IoT modules. The mobile device receives the second signal and processes the second signal to determine a real time health status of the machine component. The mobile device further displays the real time health status of the machine component on the mobile device.
In yet another aspect of the present disclosure, a machine is provided. The machine includes a plurality of ground engaging members. The machine also includes a frame supported over the plurality of ground engaging members. The machine further includes one or more machine components having an associated operational characteristic. The machine includes a system for monitoring health status of the one or more machine components on a real time basis. The system includes one or more sensor modules communicably coupled to the machine component. The sensor module generates a first signal indicative of the operational characteristic at regular pre-determined intervals. The system also includes one or more IoT modules. Each of the one or more IoT modules is communicably coupled with the one or more sensor modules and another IoT module either directly or indirectly. Each of the one or more IoT modules receives the first signal and converts the first signal from analog format to digital format to generate a second signal. Each of the one or more IoT modules transmits the second signal wirelessly. The system further includes a mobile device communicably coupled to each of the one or more IoT modules. The mobile device receives the second signal and processes the second signal to determine a real time health status of the machine component. The mobile device further displays the real time health status of the machine component on the mobile device.
Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.
Wherever possible, the same reference numbers will be used throughout the drawings to refer to same or like parts. Referring to
The machine 102 includes a number of ground engaging members 402 (see
The controller may be a single controller or may include more than one controller disposed to control various functions and/or features of the machine 102. The controller includes an associated memory. The controller may be otherwise connected to an external memory, such as a database or server. The associated memory and/or external memory may include, but are not limited to including, one or more of read only memory (ROM), random access memory (RAM), a portable memory, and the like. The present disclosure may also be envisioned without a controller. It should be contemplated that the present disclosure does not depend upon the controller for critical functional steps. The teachings of the present disclosure may be applied to machines with or without such controllers.
The machine 102 includes various other components which may be required for the machine 102 to perform an intended function. However, such components are not being discussed as the present disclosure is not limited by any such components. The machine 102 includes one or more machine components 106. The machine component 106 is an air filter of the engine 104, a break wear sensor, and/or an implement wear sensor. The one or more machine components 106 have an associated operational characteristic. The operational characteristic may be any operational parameter which indicates about status of functioning of the machine component 106. For example, operational characteristic of an air filter may be considered as an inlet pressure, an outlet pressure, or a pressure difference across the air filter. When the air filter gets clogged, the aforementioned parameters may change and provide values which may be outside of a normal operating range, or greater than threshold values.
The machine 102 includes a system 100 for monitoring health status of the one or more machine components 106 on a real time basis. The system 100 includes the one or more machine components 106. Further, the system 100 includes one or more sensor modules 108. The sensor module 108 is communicably coupled to each of the one or more machine components 106. The sensor module 108 may include one or more sensors which may detect operational characteristic of the machine component 106. The sensor module 108 generates a first signal 110 at regular predetermined intervals indicative of the operational characteristic. The regular predetermined intervals may be defined based on various factors such as, but not limited to, a type of the machine component 106, a current life of the machine component 106, a history of real time health status of the machine component 106, operative criticality of the machine component and the like. In an embodiment, a user may also set the regular predetermined interval based on application requirements. In an embodiment, when the machine 100 includes the controller, the sensor module 108 may also be communicably coupled to the controller. In such an embodiment, the sensor module 108 may send the first signal 110 to the controller. In another embodiment, when the controller is not present, the sensor module 108 may be directly coupled to the engine 104.
The system 100 includes one or more Internet of Things (IoT) module 112. In some examples, the IoT module 112 includes a battery or a cell. The IoT module 112 may be defined as an electronic device embedded in parts that connect to wireless networks for sending and receiving data. Although only one IoT module 112 is illustrated herein, it should be contemplated that the present disclosure may use more than one IoT module 112. Each of the IoT module 112 is communicably coupled to the machine component 106. In an embodiment, the machine component 106 may be associated with more than one IoT module 112. In another embodiment, more than one machine component 106 may be associated with single IoT module 112. Further, each of the IoT modules 112 is communicably coupled with the one or more sensor modules 108 and one other IoT module 112 either directly or indirectly.
The IoT module 112 receives the first signal 110. The IoT module 112 converts the first signal 110 from analog format to digital format to generate a second signal 114. The second signal 114 is a high accuracy signal. In an embodiment, the second signal 114 is indicative of the pressure difference between the inlet pressure and the outlet pressure of the air filter. The IoT module 112 transmits the second signal 114 wirelessly. The IoT module 112 may transmit the second signal 114 through any suitable wireless mode of communication, such as Bluetooth®, Wi-Fi®, internet connectivity, cellular networks, Near Field Communication (NFC), and the like.
The system 100 further includes a mobile device 116. The mobile device 116 may be a cell phone, personal digital assistant, a smartphone, a tablet, a smartwatch, or any other suitable device which may be suitable for application with various aspects of the present disclosure. The mobile device 116 may also facilitate an alert, an audio message, a video message, a vibration alert, or any other such type of an alert to inform a user about a real time health status of the machine component 106. In some examples, the mobile device 116 may be present with an operator of the machine 102.
The mobile device 116 is communicably coupled to the one or more of IoT modules 112. The mobile device 116 receives the second signal 114. The mobile device 116 processes the second signal 114 to determine the real time health status of the machine component 106. In an embodiment, processing the second signal 114 includes calculating a remaining useful life of the machine component 106. The mobile device 116 may be equipped with suitable hardware/software components to execute the processing step. Further, the mobile device 116 may display the real time health status on a display (not shown) associated with the mobile device 116, or any other display means such as another mobile device, a display screen coupled to the mobile device 116, and the like.
The real time health status corresponds to an actual condition of operational health of the machine component 106. The real time health status may be defined based on various parameters which may be specific to a type of the machine component 106 being monitored. The real time health status may include one or more of a remaining useful life, a maintenance time period, a service procedure requirement for the machine component 106, and the like. It should be contemplated that the real time health status of the machine component 106 may include any other such parameter as well, and the present disclosure is not limited by any such parameters.
The system 100 further includes a remote server 118. The remote server 118 is communicably coupled to the mobile device 116. The remote server 118 may be any remote facility equipped with capabilities to transmit signals, receive signals, and execute processing steps. The remote server 118 may be a back office, a remote office location, a back-end server, or any other such facility. The remote server 118 receives the second signal 114 from the mobile device 116. The remote server 118 processes the second signal 114 to determine the real time health status of the machine component 106. In an embodiment, processing the second signal 114 includes calculating a remaining useful life of the machine component 106. The remote server 118 may further communicate the processed information to the mobile device 116.
In an embodiment, the mobile device 116 receives the real time health status of the machine component 106 from the remote server 118. The mobile device 116 displays the real time health status of the machine component 106 on the mobile device 116. The real time health status includes one or more of a remaining useful life, a maintenance time period, or a service procedure requirement for the machine component. It should be contemplated that the real time health status of the machine component 106 may include any other such parameter as well, and the present disclosure is not limited by any such parameters.
In an embodiment, the mobile device 116 may store a history of the real time health status of the machine component 106. In another embodiment, the remote server 118 may store the history of the real time health status of the machine component 106. The remote server 118 may provide the mobile device with access to the historical data, if required. In another embodiment, the IoT module 112 may also store the history of the real time health status of the machine component 106. The mobile device 116 may retrieve data from the IoT module 112. The mobile device 116 may use the retrieved data for further processing and analysis. The history of the real time health status of the machine component 106 may include previous failure events, operational data leading up to failure, patterns of operational data indicating potential failure etc. For example, for an air filter, the history may include clogging events, pressure values leading up to clogging event etc.
In another embodiment, the mobile device 116 displays the alert on the mobile device 116 when the real time health status of the machine component 106 is below a pre-determined threshold health status. The mobile device 116 may compare the determined real time health status of the machine component 106 with the pre-determined threshold health status, and display the alert based on the comparison. In an embodiment, the mobile device 116 may display a text message indicating the real time health status of the machine component 106.
In another embodiment, the mobile device 116 suggests the corrective measure to be taken to improve the real time health status of the machine component 106. The mobile device 116 may be suitably provided with the pre-determined threshold health status based on various parameters including operating conditions, historical failure data, specification of the machine component 106, etc. After determining that the real time health status of the machine component 106 is unsatisfactory, or below the pre-determined threshold health status, the mobile device 116 may suggest the corrective measure to be take based on the comparison. The corrective measure may involve a service or maintenance procedure of the machine component 106, replacement of the machine component 106, adjusting operational conditions or parameters of the machine component 106 etc.
The mobile device 116 may connect to one or more IoT modules 112 to access relevant information regarding the machine component 106. For example, as illustrated in
An exemplary application scenario may include the operator sitting inside an operator cabin (not shown). It may be counterproductive for the operator to go outside of the operator cabin to check the real time health status of the machine component 106 during an ongoing work cycle. In such a situation, the IoT module 112 may be provided near the operator cabin such that the IoT module 112 may be within a Bluetooth® connection range of the mobile device 116 being carried by the operator. Thus, the operator may access the real time health status of any machine component 106 located across the machine 102 conveniently.
The mobile device 116 may connect to one of the machines 102 via the respective IoT modules 112 using any suitable wireless connection methods. A user may access information about the real time health status of any machine component 106 coupled with any machine 102 through the mobile device 116 as all the IoT modules 112 are interconnected with each other. Further, the mobile device 116 may be present at the back office or with a personnel in charge of the worksite, without limiting the scope of the present disclosure.
At step 508, the IoT module 112 transmits the second signal 114 wirelessly. In an embodiment, the second signal 114 is indicative of the pressure difference between the inlet pressure and the outlet pressure of the air filter. At step 510, the mobile device 116 receives the second signal 114. At step 512, the mobile device 116 processes the second signal 114 to determine the real time health status of the machine component 106. In an embodiment, processing the second signal 114 includes calculating the remaining useful life of the machine component 106. In another embodiment, the IoT module 112 may also perform the processing step. In such case, the mobile device 116 may be used as a display unit. At step 514, the mobile device 116 displays the real time health status of the machine component 106 on the mobile device 116. In an embodiment, the real time health status may include the remaining useful life, the maintenance time period, and/or the service procedure requirement for the machine component 106.
Further, in some embodiments, the mobile device 116 sends the second signal 114 to the remote server 118. Further, the remote server 118 processes the second signal 114 to determine the real time health status of the machine component 106. In an embodiment, processing the second signal 114 includes calculating a remaining useful life of the machine component 106. The method 500 may further include receiving the real time health status of the machine component 106 from the remote server 118 by the mobile device 116. The method 500 may further include displaying the real time health status of the machine component 106 on the mobile device 116 by the mobile device 116.
The present disclosure provides the system 100 and the method 500 to monitor the health status of the machine component 106 in real time. The real time health status information provided by the system 100 can be used to provide alerts or suggest corrective measures to be taken. The corrective measures may include service requirement, replacement requirement, or any other measure which needs to be taken to improve the functioning health of the machine component 106 or eliminate machine downtime. It should be noted that the system 100 may include any type of sensor which can provide analog, digital, pulse width modulation, or current output signals during operation of machine operation. Further, data collected may be forwarded to back office for behavioral analysis of sensor operation. This analysis may further be used for maintenance/service/repair requirements.
The mobile device 116 may have a mobile application installed therein. Such a mobile application may be used to monitor the real time health status of one or more machine components 106. For example, a machine may have multiple engine air filters. Such air filters may be indexed on the mobile application with respective identifiers. Further, a user may get notified about the real time health status through the mobile device 116 via a text message or any other visual indication techniques, audio alert, vibration alert, or any other such alert. Further, the mobile device 116 may also suggest corrective measures to be taken for maintaining health of the air filters. Numerous such applications of the present disclosure may be extended to various type of machine components. Thus, the present disclosure facilitates proactive approach of monitoring the real time health status of any machine component 106.
The present disclosure further provides ease of installation of the solution described herein. The IoT modules 112 may have complementary connection terminals so that the IoT modules 112 may be connected between the sensor module 108 and the controller. In the embodiments, when there is no controller, the IoT module 112 may have appropriate connection terminals to connect to an intermediate component that is coupled to the sensor module 108. Thus, the IoT module 112 may act as a retrofittable aftermarket solution. In an embodiment, the IoT module 112 may be provided with backup battery arrangement to ensure that even when the time the machine 102 is not operational, the user may access the real time health status of various machine components 106.
While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202011020513 | May 2020 | IN | national |
