Patent Application
20150337522
The present disclosure relates generally to mobile machines and, more particularly, to a system for monitoring the usage and/or wear of machine components of track-type mobile machines in real-time.
Mobile machines are in widespread use in construction, mining, forestry, and other similar industries. Due to the environment in which they are used, many times mobile machines are track-type machines rather wheel-type machines. The undercarriage of such track-type machines utilizes track assemblies, rather than wheels, to provide ground-engaging propulsion. Such track assemblies may be preferred in environments where creating sufficient traction is problematic, such as the environments identified above. Specifically, rather than rolling across a work surface on wheels, track-type machines utilize one or more track assemblies that include a loop of coupled track links defining exterior surfaces, which may themselves comprise, or may be coupled to components that comprise, ground-engaging track shoes, and interior surfaces that travel about one or more rotatable track-engaging elements, such as, drive sprockets, idlers, tensioners, and rollers, for example, all of which may be considered to comprise the undercarriage of the track-type machine.
The environments in which track-type machines are used, namely the environments of the prior-mentioned construction, mining, forestry, etc. industries, can be extremely harsh and tend to put extreme wear on the undercarriage of track-type machines. Accordingly, it is not uncommon for the undercarriage of a track-type machine (or components thereof) to require replacement from time to time. Specifically, it is known to service or replace a machine component, for example, when the component exceeds its expected lifetime (based on the age of the component or number of hours of use experienced by the component), or based on the results of inspection or evaluation of the component.
In accordance therewith, methods have been developed to monitor potential wear on vehicle equipment for repair and or replacement. For example, known prior art methods of monitoring wear for vehicle components, and in particular undercarriage components on track-type vehicles, has included simple inspection and evaluation by an operator and/or technician. However, such a process has some drawbacks. Specifically, simple inspection and evaluation of a machine component may result in unnecessary costs and machine down-time when it is determined that service or replacement of the component is not required. Still further, inspection and evaluation may require that the machine be evaluated by temporarily installing various sensors throughout the machine, with extensive cabling connecting the sensor to a computer that collects data and other information from the sensors. In such situations, the cabling may prevent the machine from being operated on the worksite, and thus such evaluation does not provide information relating to the actual use of the machine while performing work.
Accordingly, it may be desired for methods to monitor the wear on mobile vehicle equipment for repair and or replacement that may monitor the equipment remotely and/or automatically without need for an operator/technician to physically inspect the equipment or that does not result in equipment down time for such monitoring processes. Consistent therewith, US Pub. No. 2002/0116992 to Rickel discloses a system for monitoring wear of a vehicle component, such as tread wear on the wheel of a vehicle, such as a car. More specifically, the Rickel disclosure describes embedding transponders in the tire tread of a motor vehicle tire in such a way that when the tire wears sufficiently, the transponders are exposed to wear and destroyed, thereby terminating the radio frequency being sent out by the transponders. At that time, a corresponding radio frequency monitor recognizes the cessation of the monitored radio frequency and signals to the vehicle ECU that tire tread wear is beyond desired amount.
However, this known method, and others, for remotely determining when components are to be serviced or replaced suffers from some disadvantages as well. For example, with respect to the Rickel reference, sometimes it may not be practical to embed a transponder in a particular component in order to monitor the wear thereof, or depending on the component, that physical wear capable of destroying the transponder is not a practical indicator of overall wear of that component. With respect to other prior art methods, such as simple service time calculations, a particular machine component may be capable of being used far in excess of its expected lifetime, and thus replacement of the component based solely on service time may be premature and result in unnecessary costs and machine down-time. Conversely, a particular machine component may fail well in advance of its expected lifetime based on service time calculations, and continued operation of the machine with the damaged component may result in damage to other components of the machine.
Thus, there exists a need for an improved sensor system for collecting information related to a mobile machine relevant to servicing equipment thereof. The sensor system and method in accordance with the current disclosure may overcome or avoid the above discussed or other disadvantages resulting from the use of known systems and methods.
The current disclosure may provide a method for collecting information related to a machine component of a mobile machine that is configured to perform work on a worksite. The sensor system may be installed on or within the machine component, and the machine component may be installed with the sensor system on the mobile machine. The information may be collected with the sensor system while the machine is performing work on the worksite, the information relating to a characteristic experienced by the machine component. The information may be transmitted to a network of the mobile machine using the sensor system using either a wired or wireless connection.
The current disclosure may further provide a method for collecting information related to a machine component of an undercarriage of a mobile machine that is configured to perform work on a worksite, utilizing a sensor system on or within the machine component. In accordance therewith, the sensor system may comprise a battery operated BlueTooth Low Energy (BLE) transmitter and a corresponding BLE transceiver. The information may be collected with the BLE sensor system while the machine is performing work on the worksite and the information may be related to at least one of wear, temperature, fluid level, fluid pressure, or load experienced by a machine component of the undercarriage. Specifically, The signal from the BLE transmitter may be received by a BLE transceiver which communicates with a Controller Area Network (CAN) system on the machine.
In accordance with an embodiment of the disclosure, an undercarriage load for a track-type machine (both instantaneous and over time) may be calculated utilizing information received from a sensor system in accordance with the disclosure. More specifically, a BLE transmitter may be located in or on a portion of the track on a track-type machine, such as, for example, located in or on a track pin. The BLE transmitter may then output a signal to a BLE transceiver (and other associated sensor equipment) located on another portion of the machine which can be used to calculate the speed of the track at any given time. Utilizing track speed, in combination with existing monitoring of machine torque converter input and output speeds (as is known in the art), a calculation of instantaneous load and load over time on the undercarriage may be made utilizing a track-type machine Electronic Control Unit (ECU).
Further in accordance with the present disclosure, a sensor indication of certain conditions, including the absence of a signal (indicating that sensor has stopped transmitting or aftermarket parts have been installed not including a sensor), certain actions can be triggered. For example, ECU indication that undercarriage load/speed, either instantaneously, or in the aggregate over time, exceed the capabilities of the undercarriage can trigger an alert to the operator of the condition, an indication to the operator of imminent shutdown if the situation is not rectified in a certain period of time, reduced power sent to the undercarriage to resolve the situation, shutting down of undercarriage related electronics, etc.
For example, sensor system 10 or BLE system 34 may be used with a mobile machine such as a tractor (as shown in and described below with reference to a bulldozer shown in
As shown in
A controller 22, such as a low-power microcontroller, may provide an output in response to the input received from sensing component 12 and/or one or more signals processed by any or all of signal conditioner 14, amplifier 16, multiplexer 18, and converter 20. An on-board memory 24, such as either or both of a random-access memory (RAM) and a read-only memory (ROM), may store information related to one or more of the input received from sensing component 12, one or more processed signals from signal conditioner 14, amplifier 16, multiplexer 18, and/or converter 20, and the output from controller 22. Alternately or additionally, on-board memory 24 may store instructions used by one or more other components of sensor system 10, such as controller 22.
A transceiver 26, such as for example a radio-frequency (RF) transceiver, may wirelessly broadcast the output provided by controller 22, such as at a frequency of 2.4 GHz, 900 MHz, or another frequency. Alternately or additionally, an output port 28, such as for example a USB (universal serial bus) port or similar port, may transmit the output provided by controller 22 through a cable or other connection removably connected to output port 28. A battery 30, such as for example a lithium-ion (Li-ion) battery, may power one or more of the components of sensor system 10. Alternately or in addition to battery 30, an energy source 32, such as a vibration-based energy-harvesting system, may power one or more of the components of sensor system 10, and/or may be used to charge battery 30. Any or all of these components may be located in a sealed housing that sufficiently protects the components from damage due to heat, cold, vibration, weather, exposure to liquids, worksite conditions, and/or any other conditions that may damage the components of the sensor system 10. In aspects of the disclosure, sensor system 10 may be replaced by a BLE system 34 comprising a BLE transmitter 36 and a separate BLE transceiver 38.
Although
Bulldozer 40 may include a tracked undercarriage 42 that is driven by a power source 44. Specifically, power source 44 may drive tracked undercarriage 42 at a range of output speeds and/or torques. Power source 44 may be an engine, such as for example a diesel engine, a gasoline engine, a gaseous fuel-powered engine, or any other suitable engine. Power source 44 may also be a non-combustion source of power, such as for example a fuel cell, a power storage device, or any other source of power known in the art.
Tracked undercarriage 42 may include tracks 46 (only one shown in
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Referring to
As is well known in the art, the components of the track pin joint assembly 100 can define a plurality of annular seal cavities 112 that extend around the track pin 108 and are each adapted for housing therein a seal assembly suitable for sealingly engaging rotating components of the track pin joint assembly 100. For purposes of illustration, the left-side insert 104 can be considered a first member, and the bushing 102 can be considered a second member. The first member 104 and the second member 102 are both coaxial with the pin 108 about the longitudinal axis 109. The first member 104 is pivotable with respect to the second member 102 about a rotational axis that coincides with the longitudinal axis 109 of the track pin 108. The first member 104 includes an end and a load ring engagement surface defining, at least in part, an axially-extending seal cavity 112 disposed in proximal relationship to the second member 102. A seal assembly can be disposed within the seal cavity 112 to sealingly engage the first member 104 and the second member 102 while allowing relative rotation therebetween. In accordance with the disclosure, the sensor system 10 or BLE transmitter 36 may be located on or in the track pin 108 including, but not limited to, for example, in the seal cavity 112, or in portions of the track that are used to seal oil in the cavity, etc.
In accordance with an embodiment of the disclosure, an undercarriage 42 load for a track-type machine 40 (both instantaneous and over time) may be calculated utilizing information received from the sensor system 10 or BLE system 34. More specifically, the sensor system 10 or BLE system 34 may be located in or on a portion of the track 46, such as, for example, located in or on the track pin 108 or, in the case of the BLE system 34, the BLE transmitter 36 may be placed in or on the track pin 108 and the BLE transceiver 38 may be located remotely on the machine 40. In either embodiments, the sensor system 10 or BLE transmitter 36 may output a signal which can be used to calculate the speed of the track 46 at any given time. Utilizing track 46 speed, in combination with existing monitoring of machine torque converter input and output speeds (as is known in the art), a calculation of instantaneous load and load over time on the undercarriage 42 may be made utilizing the machine ECU (not shown).
Further in accordance with the present disclosure, the sensor system 10 or BLE system 34 indication of certain conditions, including the absence of a signal (indicating that sensor system 10 or BLE system 34 has stopped transmitting or aftermarket parts have been installed not including sensor system 10 or BLE system 34/BLE transmitter 36), or absence of a pre-programmed machine serial number and/or track part number (that may be programmed into sensor system 10 or BLE transmitter 36), certain actions can be triggered. For example, ECU (not shown) indication that undercarriage 42 load/speed, either instantaneously, or in the aggregate over time, exceed the capabilities of the undercarriage 42 can trigger an alert to the operator of the condition, an indication to the operator of imminent shutdown if the situation is not rectified in a certain period of time, reduced power sent to the undercarriage 42 to resolve the situation, etc.
Thus, the foregoing description describes an exemplary configuration of sensor system 10 and BLE system 34, as well as examples of particular mobile machines (e.g., bulldozer 40) with which sensor system 10 or BLE system 34 may be used, and particular locations on a track-type machine 40 where the sensor system 10 or BLE transmitter 36 may be located.
For example, when sensor system 10 or BLE system 34 is to measure load on a track 46, sensor system 10 or BLE transmitter 36 may be installed directly on or within an interior of the track link, including on or in a track pin 108. In accordance with the disclosure, sensor system 10 or BLE system 34 or BLE transmitter 36 may be installed during manufacture of the machine component, and may be installed in such as way as to impede or prevent removal, replacement, or servicing of sensor system 10 or BLE system 34, such that the machine component and sensor system 10 or BLE system 34 may be provided as a single unit. As further shown in
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In accordance with the disclosure, a single sensor system 10 or BLE system 34 may measure a plurality of the above-discussed characteristics (e.g., may measure at least two of wear, temperature, fluid level, fluid pressure, or load), and/or may measure other characteristics. Alternately or additionally, a mobile machine or other structure may include multiple sensor systems 10 or BLE systems 34, each measuring one or more of the above characteristics and/or other characteristics. Thus, although the foregoing description provides specific examples, sensor system 10 or BLE system 34 is not limited to the particular uses described above. Rather, sensor system 10 or BLE system 34 may measure any characteristic of a machine on and/or within which it is installed, characteristic of a component of the machine, operating condition of the machine, environmental condition, ambient condition, or any other information. By way of non-limiting examples, sensor system 10 or BLE system 34 may measure or determine stress, relative distance between components, velocity, angular velocity, acceleration, angular acceleration, position, bolt clamp load, joint clamp load, crack initiation, crack propagation, torque, whether a part is attached properly, whether a part is attached tightly, whether a part is loose, whether a part is missing, whether a part is rotating, or whether a part is not rotating, among others.
The output of sensor system 10 or BLE system 34 may be used by various entities. By way of non-limiting example, the output may be used by an operator of the machine, a foreperson of the worksite, a repair person, and/or a customer. Thus, benefits provided by using sensor system 10 or BLE system 34 may include improved machine life, improved machine performance, improved machine maintenance scheduling, improved tracking of the machine by equipment maintenance manager, improved component life, improved component performance, enhanced machine resale value, and/or improved product design and validation.
Of course, sensor system 10 or BLE system 34 is not limited to the particular machines or examples described above, but instead may be used with any machine, such as a machine having any type of ground engaging tool. For example, the machine may be a hydraulic front shovel, cable (rope) shovel, backhoe, mass excavator, hydraulic excavator, dragline, wheel loader, track-type loader, or any other machine.
In accordance with the disclosure, the above-described sensor system 10 or BLE system 34 may measure and/or receive data or other information, and/or may output data or other information, related to a machine with which sensor system 10 or BLE system 34 is used, including a mobile machine such as bulldozer 40. Described herein are specific examples of characteristics, including wear, temperature, fluid level, fluid pressure, and load, which may be measured by sensor system 10 or BLE system 34. More specifically, In accordance with the disclosure, sensor system 10 or BLE system 34 may be used to measure wear (e.g., including but not being limited to a change in a physical size or shape of a component which is caused by use and/or contact with one or more other components). By way of non-limiting example, sensor system 10 or BLE system 34 may measure wear of a component within a tracked or wheeled undercarriage of a mobile machine, such as a track link, a track shoe, a component of a roller assembly, a component of an idler assembly, a sprocket, a bushing, any other roller, and combinations of these or other components. Consistent with the disclosure, sensor system 10 or BLE system 34 may measure wear of a component of a ground engaging tool, such as: a tip, an adapter, an edge, a base edge, a sidecutter, or any other component of a bucket; a tip, a plate, an end bit, or any other component of a compactor; a ripper tip; a cutting edge; a wear bar; a wear plate; and combinations of these or other components. Also consistent with the disclosure, sensor system 10 or BLE system 34 may be used to measure wear of a component of a tunnel boring machine, such as a rock cutter, other components of a cutting head, or combinations of these or other components. Sensor system 10 or BLE system 34 is not limited to measuring wear of only these systems and components, however, but instead may be used to measure wear of any component of the above-discussed systems, or different components of other systems.
When sensor system 10 or BLE system 34 is used to measure wear, a component of sensor system 10 or BLE system 34, such as sensing component 12 or BLE transmitter 36, may be placed in a location where wear is to be measured. For example, sensing component 12 or BLE transmitter 36 may be located on a specific portion of a surface of a machine component, so that as the surface of the machine component is worn, sensing component 12 or BLE transmitter 36 simultaneously experiences a corresponding amount of wear. A characteristic or an output of sensing component 12 or BLE transmitter 36 may change as sensing component 12 wears. In accordance with the disclosure, a circuit might be opened or closed when a component (a wire, a capacitor, a resistor, a diode, a transistor, or another component) of sensing component 12 or BLE transmitter 36 is worn beyond a threshold amount, or an electric characteristic of sensing component 12 or BLE transmitter 36 may progressively change based on and in relation to an amount of wear experienced by sensing component 12 or BLE transmitter 36.
Also in accordance with the disclosure, sensor system 10 or BLE system 34 may be used to measure temperature. By way of non-limiting example, sensor system 10 or BLE system 34 may measure temperature of or within a component in a tracked or wheeled undercarriage of a mobile machine, such as a component of a roller assembly, a component of an idler assembly, a bushing, any other roller, and combinations of these or other components. Sensor system 10 or BLE system 34 is not limited to measuring temperature of only these systems and components, but instead may be used to measure temperature of any components of the above-discussed systems, or different components of other systems.
A component of sensor system 10 or BLE system 34, such as sensing component 12 or BLE transmitter 36, may be used to measure temperature. For example, sensing component 12 or BLE transmitter 36 may include a thermocouple. Sensing component 12 or BLE transmitter 36 may or may not be submerged in a fluid, such as a lubricant (e.g. oil), within an interior of a component of the machine. The above-discussed components of sensor system 10 or BLE system 34 may then process one or more signals and transmit an output thereof to a component on-board the machine and/or a component off-board the machine.
Still further in accordance with the disclosure, sensor system 10 or BLE system 34 may be used to measure fluid level or pressure. By way of non-limiting example, sensor system 10 or BLE system 34 may measure a level or a pressure of fluid within a component in a tracked or wheeled undercarriage of a mobile machine, such as one or more hydraulic systems associated with any of a roller assembly, an idler assembly, any other roller assembly, and combinations of these or other components. Consistent with the disclosure, sensor system 10 or BLE system 34 may be used to measure fluid level or pressure within a component of a tunnel boring machine, such as one or more hydraulic systems associated with a rock cutter, other components of one or more hydraulic systems associated with a cutting head or any other component. Sensor system 10 or BLE system 34 is not limited to measuring a level or a pressure of fluid within only these systems and components, but instead may be used to measure fluid level or pressure within any components of the above-discussed systems, or different components of other systems.
A component of sensor system 10 or BLE system 34, such as sensing component 12 or BLE transmitter 36, may be used to measure the fluid level or pressure. Sensing component 12 or BLE transmitter 36 may or may not be submerged in a fluid, such as a lubricant (e.g. oil), within an interior of a component of the machine. For example, sensing component 12 or BLE transmitter 36 may include an optical sensor that optically detects the level of fluid. Alternately or additionally, sensing component 12 or BLE transmitter 36 may include a pressure sensor that measures the pressure of the fluid within the interior of the component. The above-discussed components of sensor system 10 or BLE system 34 may then process one or more signals, and transmit an output thereof to a component on-board the machine and/or a component off-board the machine.
Still further in accordance with the disclosure, sensor system 10 or BLE system 34 may be used to measure load. By way of non-limiting example, sensor system 10 or BLE system 34 may measure load on a component within a tracked or wheeled undercarriage of a mobile machine, such as a track link, a track shoe, a component of a roller assembly, a component of an idler assembly, a sprocket, a bushing, any other roller, and combinations of these or other components. Consistent with the disclosure, sensor system 10 or BLE system 34 may measure load on a component of a ground engaging tool, such as: a tip, an adapter, an edge, a base edge, a sidecutter, or any other component of a bucket; a tip, a plate, an end bit, or any other component of a compactor; a ripper tip; a cutting edge; a wear bar; a wear plate; and combinations of these or other components.
When sensor system 10 or BLE system 34 is used to measure load, a component of sensor system 10 or BLE system 34, such as sensing component 12 or BLE transmitter 36, may be placed in a location where load is to be measured. For example, sensing component 12 or BLE transmitter 36 may be one or more strain gauges. The above-discussed components of sensor system 10 or BLE system 34 may then process one or more signals, and transmit an output thereof to a component on-board the machine and/or a component off-board the machine.
It will be appreciated that the foregoing description provides examples of the disclosed system and technique. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to the disclosure or examples thereof are intended to reference the particular example being discussed at that point and are not intended to imply any limitation as to the scope of the disclosure more generally. All language of distinction and disparagement with respect to certain functions is intended to indicate a lack of preference for those functions, but not to exclude such from the scope of the disclosure entirely unless otherwise indicated. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context.
