Diagnostic and response systems and methods for fluid power systems

• US 10,359,774 B2
• Filed: 10/28/2008
• Issued: 07/23/2019
• Est. Priority Date: 10/28/2008
• Status: Expired due to Fees

• Current Assignee: Gates Corporation The
• Original Assignee: Gates Corporation (Air System Components)
• Inventors: Keast, Geoffrey Richard, Ellis, Michael H., Swift, Jonathan Clark, Railsback, Layne, Gilbreath, Donald R.
• Primary Examiner(s): Ngon, Ricky
• Application Number:
  US12/290,173
• Publication Number:
  US 20100106461A1
• Time in Patent Office: 3,920 Days
• Field of Search: 702183, 702 33- 36, 702182, 702185, 702 40, 702 57- 60, 702 64, 702 65, 324539, 324512, 324541-543, 324544
• CPC Class Codes: G05B 2219/24053 Diagnostic of controlled machine
• CPC Class Codes: G05B 2219/24065 Real time diagnostics
• CPC Class Codes: G05B 2219/24075 Predict control element state changes, event changes
• CPC Class Codes: G05B 2219/24077 Module detects wear, changes of controlled device, statistical evaluation
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06

Abstract

Diagnostic and response systems and methods for a fluid power system acquire data from pressure and temperature sensors disposed in the fluid power system, analyze the data in a failure algorithm to build a history of cumulative damage to hoses in the fluid power system, communicates an indication of potential imminent hose failure to a central location when a level of the cumulative damage indicates imminent failure of a hose, analyze the information at the central location to determine an appropriate response, and transmit information about the fluid power system, including location, and identification of the hose about to fail to a response unit. The response unit responds to the location and replaces the component prior to failure, or the communication might include information that the hose has failed, such that the response unit replaces the failed hose to return the fluid power system to normal operation.

Claims

1. A fluid power component diagnostic and response system comprising:

ECU means implementing a predictive algorithm determining based on real-time inputs from one or more pressure and temperature sensors when a fluid power system component is nearing an end of its useful life and when it has failed;

GPS means for determining ground position of equipment mounting said fluid power system; and

means for transmitting information about said fluid power system component together with fluid power system component specifications, fluid power system details, and said ground position to a central location; and

means for responding to said information to replace said fluid power system component prior to failure of said fluid power system component;

wherein said fluid power system component is a fluid power hose, and said predictive algorithm is a cumulative hose damage algorithm.

2. The system of claim 1, further comprising:

means for communicating said information from said central location, through a pre-determined communication channel to said means for responding.

3. The system of claim 2, wherein said means for communicating comprises means for communicating said information and said position to a fluid power component supplier through said pre-determined communication channel.

4. The system of claim 2, wherein said means for communicating comprises means for communicating said information and said position to a fluid power component supplier through said pre-determined communication channel and said means for responding comprises a response vehicle equipped with replacement fluid power components supplied by said fluid power component supplier and repair or maintenance personnel.

5. The system of claim 1, wherein said means for responding comprises a response unit equipped with replacement fluid power components and repair or maintenance personnel, responding to said location and maintaining said fluid power system by replacing said component prior to failure of said fluid power system due to failure of said component.

6. The system of claim 1 further comprising:

a plurality of said pressure and temperature sensors, each of said sensors disposed in a different area of a fluid power system and providing said real-time inputs to said predictive algorithm.

7. The system of claim 6 wherein said algorithm employs at least one variable for each hose.

8. The system of claim 7 wherein said variable for each hose is at least one of a burst pressure for that hose, an operating pressure and cycle life at that pressure for that hose, a normal operating temperature for that hose, and an alarm temperature for that hose.

9. The system of claim 6, wherein said algorithm calculates damage to the hose caused by each measured pressure peak, based at least in part on the relative level of the pressure peak, and the temperature of fluid in the hose.

10. The system of claim 6, wherein said algorithm is continuously applied using the real-time input pressures and temperatures to estimate life used of a subject hose, and said information includes a warning when a hose is nearing the end of its life expectancy in accordance with said algorithm.

11. The system of claim 6, wherein said algorithm varies according to information identifying a hose being monitored.

12. The system of claim 11, wherein said information identifying a hose being monitored includes said hose'"'"'s location in said fluid power system.

13. A method comprising:

employing a predictive algorithm, by a processor and based on real-time inputs from one or more pressure and temperature sensors, to determine when a fluid power component in a fluid power system is nearing the end of its useful life;

determining the location of equipment mounting said fluid power system by GPS means;

transmitting from said location, via a communication device, information that the fluid power component is nearing the end of its useful life together with fluid power system information and said location;

responding to said location; and

maintaining said fluid power system by replacing said fluid power component;

wherein said fluid power system component is a fluid power hose and said predictive algorithm is a cumulative hose damage algorithm.

14. The method of claim 13 wherein said maintaining is carried out prior to failure of said fluid power system due to failure of said fluid power component.

15. The method of claim 13 where said transmitting includes transmitting information that the fluid power component has failed and said maintaining comprises replacing said fluid power component to return said fluid power system to normal operation.

16. The method of claim 13, wherein said transmitting comprises communicating the information and location to a fluid power component supplier.

17. The method of claim 16, wherein said responding and said maintaining are carried out by said fluid power component supplier.

18. The method of claim 16, wherein said responding and said maintaining is carried out by a repair service provider, using a replacement fluid power component supplied by said fluid power component supplier.

19. The method of claim 13, wherein said fluid power system component is a fluid power hose.

20. The method of claim 13, wherein said fluid power system information comprises fluid power system specifications.

21. The method of claim 13 wherein said algorithm employs said real-time inputs from a plurality of pressure and temperature sensors, each of said sensors disposed in a different area of said fluid power system.

22. The method of claim 21 wherein said algorithm employs at least one variable for each hose.

23. The method of claim 22 wherein said variable for each hose is at least one of a burst pressure for that hose, an operating pressure and cycle life at that pressure for that hose, a normal operating temperature for that hose, and an alarm temperature for that hose.

24. The method of claim 21, wherein said algorithm calculates damage to the hose caused by each measured pressure peak, based at least in part on the relative level of the pressure peak, and the real-time temperature of fluid in the hose.

25. The method of claim 21, wherein said algorithm varies according to information identifying a hose being monitored.

26. The method of claim 25, wherein said information identifying a hose being monitored includes said hose'"'"'s location in said fluid power system.

27. A method comprising:

acquiring real-time data from pressure and temperature sensors disposed in a fluid power system;

determining location of equipment mounting said fluid power system;

analyzing said real-time data in a failure algorithm to build a history of cumulative damage to hoses in said fluid power system;

communicating said location and an indication of potential imminent hose failure from said location to a central location when a level of said cumulative damage indicates imminent failure of a hose in said fluid power system;

analyzing information at the central location to determine an appropriate response; and

transmitting, via a response network, information about said fluid power system including the location of said fluid power system and identification of the hose indicated as subject to imminent failure to a response unit; and

said response unit responding to said location and maintaining said fluid power system by replacing said component prior to failure of said fluid power system due to failure of the hose that is about to fail.

28. The method of claim 27 where said communicating includes transmitting information that the hose has failed and method further comprises replacing the failed hose to return said fluid power system to normal operation.

29. The method of claim 27, wherein said transmitting comprises communicating the information and location to a fluid power component supplier, which in turn communicates with said response unit.

30. The method of claim 29, further comprising said fluid power component supplier supplying a replacement hose to said response unit.

31. The method of claim 27 wherein said algorithm employs at least one variable for each hose in said fluid power system.

32. The method of claim 31 wherein said variable for each hose is at least one of a burst pressure for that hose, an operating pressure and cycle life at that pressure for that hose, a normal operating temperature for that hose, and an alarm temperature for that hose.

33. The method of claim 27, wherein said algorithm calculates damage to the hose caused by each measured pressure peak in the real-time pressure data, based at least in part on the relative level of the pressure peak, and the real-time temperature of fluid in the hose.

34. The method of claim 27, wherein said algorithm varies according to information identifying a hose being monitored.

35. The method of claim 34, wherein said information identifying a hose being monitored includes said hose'"'"'s location in said fluid power system.

36. The method of claim 27 wherein said equipment mounting said fluid power system is mobile.