Systems and methods for determining wear of a ground-engaging tool

• US 10,190,289 B2
• Filed: 08/02/2016
• Issued: 01/29/2019
• Est. Priority Date: 08/02/2016
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Reyes-Rodriguez, Solimar, Herrera De Kontz, Maria Cristina, Mascarenhas, Aloke Jude
• Primary Examiner(s): Holwerda, Stephen
• Application Number:
  US15/226,617
• Publication Number:
  US 20180038083A1
• Time in Patent Office: 910 Days
• CPC Class Codes: E02F 9/267 Diagnosing or detecting failure of vehicles
• CPC Class Codes: E02F 9/28 Small metalwork for digging elements, e.g. teeth scraper bits ploughs for agriculture A01B15/00; teeth of harrows A01B23/02
• CPC Class Codes: G07C 5/006 Indicating maintenance
• CPC Class Codes: G07C 5/008 communicating information to a remotely located station transmission systems for measured values G08C
• CPC Class Codes: G07C 5/0808 Diagnosing performance data testing of vehicles G01M17/00; testing of electrical installation on vehicles G01R31/005
• CPC Class Codes: G07C 5/0825 using optical means
• CPC Class Codes: G07C 5/0841 Registering performance data recording measured values G01D; information storage G11B
• CPC Class Codes: G07C 5/085 using electronic data carriers

Abstract

A method for monitoring wear of a ground-engaging tool associated with a machine in relation to productivity of the machine is disclosed. The ground-engaging tool defines an inner cavity and a first wall. The method includes receiving a first characteristic signal associated with the first wall from a first sensor, the first sensor operatively associated with the first wall. The method further includes receiving one or more productivity metrics associated with the machine from a performance monitoring system, the performance monitoring system operatively associated with the machine. The method further includes determining a first dimension of the ground-engaging tool based on the first characteristic signal, determining a first wear metric of the ground-engaging tool based on the first dimension, and correlating the first wear metric and the one or more productivity metrics.

Claims

1. A system for monitoring wear of a ground-engaging tool of a machine in relation to productivity of the machine, the ground-engaging tool defining an inner cavity and a first wall, the first wall extending in a first direction having an inner surface and an outer surface, the system comprising:

a first ultrasonic sensor configured to;

transmit a first ultrasonic signal in the inner cavity and towards the inner surface, the first ultrasonic signal configured to travel through the first wall, from the inner surface, and reflect off the outer surface, at least in part, back towards the inner surface;

receive the first ultrasonic signal upon reflection off of the outer surface; and

transmit first signal trip characteristics associated with the first ultrasonic signal and based upon the transmission and subsequent receipt of the first ultrasonic signal;

a wireless receiver for receiving the first signal trip characteristics transmitted by the first ultrasonic sensor;

a performance monitoring system sensor configured to sense a machine efficiency characteristic of the machine during operation of the machine;

a performance monitoring system operatively associated with the machine and configured to determine one or more productivity metrics associated with a productivity or an efficiency of the machine based on the machine efficiency characteristic sensed by the performance monitoring system sensor; and

a controller, including a processor, operatively associated with the wireless receiver and configured to;

receive the first signal trip characteristics;

receive the one or more productivity metrics associated with the machine;

determine a first dimension of the ground-engaging tool based on the first signal trip characteristics;

determine a first wear metric of the ground-engaging tool based on the first dimension; and

correlate the first wear metric and the one or more productivity metrics to determine a relationship between wear on the ground-engaging tool and efficiency losses in the operation of the machine.

2. The system of claim 1, wherein the controller is further configured to determine an optimal time for replacing the ground-engaging tool based on the correlation of the first wear metric and the one or more productivity metrics.

3. The system of claim 2, further comprising an output device configured to output an alert to an operator of the machine based on input from the controller and wherein the controller is further configured to transmit an output signal to the output device when it is the optimal time for replacing the ground-engaging tool.

4. The system of claim 1, wherein the performance monitoring system sensor comprises, at least, a payload sensor operatively associated with the machine and wherein the one or more performance metrics includes payload information determined by the payload sensor over a period of time.

5. The system of claim 4, wherein correlating the first wear metric and the one or more productivity metrics by the controller includes correlating the first wear metric and the payload information over the period of time.

6. The system of claim 1, wherein the performance monitoring system includes, at least, a machine monitoring system operatively associated with the machine and wherein the one or more performance metrics includes machine efficiency information determined by the performance monitoring system over a period of time.

7. The system of claim 6, wherein correlating the first wear metric and the one or more productivity metrics by the controller includes correlating the first wear metric and the machine efficiency information over the period of time.

8. The system of claim 1, wherein the first signal trip characteristics include one or more of a time of flight of the first ultrasonic signal, a speed of the first ultrasonic signal as it travels through the first wall, and any combinations thereof.

9. The system of claim 1, wherein the ground-engaging tool further defines a second wall extending in a second direction and having a second inner surface and a second outer surface, the system further comprising a second ultrasonic sensor configured to:

transmit a second ultrasonic signal in the inner cavity and towards the second inner surface, the second ultrasonic signal configured to travel through the second wall, from the second inner surface, and reflect off the second outer surface, at least in part, back towards the second inner surface;

receive the second ultrasonic signal upon reflection off of the second outer surface; and

transmit second signal trip characteristics associated with the second ultrasonic signal upon transmission and subsequent receipt; and

wherein the controller is further configured to;

receive the second signal trip characteristics;

determine a second dimension of the ground-engaging tool based on the second signal trip characteristics;

determine a second wear metric of the ground-engaging tool based on the second dimension; and

correlate the second wear metric and the one or more productivity metrics to determine a relationship between wear on the ground-engaging tool and efficiency losses in the operation of the machine.

10. The system of claim 9, wherein the controller is further configured to:

determine a wear profile for the ground-engaging tool based on the first wear metric and the second wear metric;

correlate the wear profile and the one or more productivity metrics to determine a relationship between wear on the ground-engaging tool and efficiency losses in the operation of the machine; and

determine if the ground-engaging tool needs replacement based on the correlation of the wear profile and the one or more productivity metrics.

11. The system of claim 1, wherein the ground-engaging tool is one or more of a tooth, an adapter, a lip shroud, a wing shroud, a blade segment, and any combinations thereof.

12. A method for monitoring wear of a ground-engaging tool associated with a machine in relation to productivity of the machine, the ground-engaging tool defining an inner cavity and a first wall, the method comprising:

receiving a first characteristic signal associated with the first wall from a first sensor, the first sensor operatively associated with the first wall;

receiving one or more productivity metrics associated with a productivity or an efficiency of the machine from a performance monitoring system, the performance monitoring system operatively associated with the machine, and the productivity metrics being determined by the performance monitoring system based on a machine efficiency characteristic sensed by a performance monitoring system sensor;

determining a first dimension of the ground-engaging tool based on the first characteristic signal;

determining a first wear metric of the ground-engaging tool based on the first dimension; and

correlating the first wear metric and the one or more productivity metrics to determine a relationship between wear on the ground-engaging tool and efficiency losses in the operation of the machine.

13. The method of claim 12, further comprising determining an optimal time for replacing the ground-engaging tool based on the correlation of the first wear metric and the one or more productivity metrics.

14. The method of claim 13, further comprising presenting an alert to an operator of the machine when it is the optimal time for replacing the ground-engaging tool.

15. The method of claim 12, wherein the first wall extends in a first direction and has an inner surface and an outer surface, and wherein the method further comprises:

transmitting, by the sensor, a first ultrasonic signal in the inner cavity and towards the inner surface, the first ultrasonic signal configured to travel through the first wall, from the inner surface, and reflect off the outer surface, at least in part, back towards the inner surface; and

receiving, by the sensor, the first ultrasonic signal upon reflection off of the outer surface;

determining the first characteristic signal based upon the transmission and subsequent receipt of the first ultrasonic signal.

16. The method of claim 12, wherein the ground-engaging tool further defines a second wall extending in a second direction, the method further comprising:

receiving a second characteristic signal associated with the second wall from a second sensor, the second sensor operatively associated with the second wall;

determining a second dimension of the ground-engaging tool based on the second characteristic signal;

correlating the second wear metric and the one or more productivity metrics to determine a relationship between wear on the ground-engaging tool and efficiency losses in the operation of the machine.

17. The method of claim 16, further comprising:

determining a wear profile for the ground-engaging tool based on the first wear metric and the second wear metric; and

correlating the wear profile and the one or more productivity metrics to determine a relationship between wear on the ground-engaging tool and efficiency losses in the operation of the machine.

18. A method for optimizing productivity of a machine based on wear of a ground-engaging tool associated with the machine, the ground-engaging tool defining an inner cavity and a first wall, the method comprising:

receiving a first characteristic signal associated with the first wall from a first sensor, the first sensor operatively associated with the first wall;

determining a first dimension of the ground-engaging tool based on the first characteristic signal;

determining a first wear metric of the ground-engaging tool based on the first dimension;

receiving one or more productivity metrics associated with a productivity or an efficiency of the machine from a performance monitoring system, the performance monitoring system operatively associated with the machine, and the productivity metrics being determined by the performance monitoring system based on a machine efficiency characteristic sensed by a performance monitoring system sensor; and

correlating the first wear metric and the one or more productivity metrics over a period of time to determine a relationship between wear on the ground-engaging tool and efficiency losses in the operation of the machine.

19. The method of claim 18 further comprising replacing the ground-engaging tool with a replacement ground-engaging tool, with respect to the machine, if the productivity changes indicate that wear of the ground-engaging tool contributed to the productivity changes.

20. The method of claim 18, further comprising alerting an operator of the machine of the productivity changes over the period of time via an output device.