Apparatus and method for vehicle maintenance scheduling and fault monitoring

• US 10,497,185 B2
• Filed: 11/28/2017
• Issued: 12/03/2019
• Est. Priority Date: 11/28/2017
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Hanov, Nile, Ethington, James M., Sturlaugson, Liessman E.
• Primary Examiner(s): Cheung, Calvin
• Application Number:
  US15/824,231
• Publication Number:
  US 20190164358A1
• Time in Patent Office: 735 Days
• CPC Class Codes: B64F 5/60 Testing or inspecting aircraft components or systems
• CPC Class Codes: G05B 23/0245 based on a qualitative model, e.g. rule based; if-then decisions
• 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
• CPC Class Codes: G06Q 10/1097 Task assignment
• CPC Class Codes: G06Q 10/20 Administration of product repair or maintenance
• CPC Class Codes: G07C 2205/02 using a vehicle scan tool
• CPC Class Codes: G07C 5/006 Indicating maintenance
• CPC Class Codes: G07C 5/0808 Diagnosing performance data testing of vehicles G01M17/00; testing of electrical installation on vehicles G01R31/005

Abstract

A vehicle health monitoring system including a rules generation module that receives historical time-stamped vehicle fault data for a vehicle system, determines a correlation between pairs of a precedent historical vehicle fault data, of the historical time-stamped vehicle fault data, and a subsequent different historical vehicle fault data, of the historical time-stamped vehicle fault data, and generates maintenance rules based on the correlation determined for the pairs. A fault detection module of the system monitors faults of the vehicle system, where the vehicle faults include a plurality of time-stamped precedent vehicle fault data, applies the rules to the plurality of time-stamped precedent vehicle fault data, determines an imminent occurrence of a subsequent vehicle fault, and generates a maintenance report corresponding to the imminent occurrence of the subsequent vehicle fault so that proactive maintenance is performed on the vehicle system.

Claims

1. A vehicle health monitoring system comprising:

a vehicle system maintenance rules generation module configured so as to couple with a vehicle, the vehicle system maintenance rules generation module being configured to

receive historical time-stamped vehicle fault data for a vehicle system;

determine a correlation between pairs of a precedent historical vehicle fault data, of the historical time-stamped vehicle fault data, and a subsequent different historical vehicle fault data, of the historical time-stamped vehicle fault data, and

generate vehicle system maintenance rules based on the correlation determined for the pairs of the precedent historical vehicle fault data and the subsequent different historical vehicle fault data; and

a vehicle system fault detection module configured so as to couple with the vehicle to monitor faults of the vehicle system where the vehicle faults include a plurality of time-stamped precedent vehicle fault data, the vehicle system fault detection module being further configured to

apply the vehicle system maintenance rules to the plurality of time-stamped precedent vehicle fault data,

determine an imminent occurrence of a subsequent vehicle fault, based on the application of the vehicle system maintenance rules to the plurality of time-stamped precedent vehicle fault data, and

generate a maintenance report corresponding to the imminent occurrence of the subsequent vehicle fault so that proactive maintenance is performed on the vehicle system;

wherein the plurality of time-stamped precedent vehicle fault data corresponds with the precedent historical vehicle fault data, and the subsequent vehicle fault corresponds with the subsequent different historical vehicle fault data.

2. The vehicle health monitoring system of claim 1, wherein the vehicle system maintenance rules generation module is configured to:

receive historical vehicle usage data; and

combine the historical vehicle usage data with the correlation determined for the pairs of the precedent historical vehicle fault data and the subsequent different historical vehicle fault data to generate the vehicle system maintenance rules.

3. The vehicle health monitoring system of claim 2, wherein the historical vehicle usage data includes one or more of an exclusion date, an excursion time, an excursion location, an age of the vehicle, hours of maintenance performed on the vehicle, excursion type, a type of maintenance performed on the vehicle, and an order of precedence of vehicle fault data.

4. The vehicle health monitoring system of claim 1, wherein the vehicle system maintenance rules generation module is configured to:

determine which pairs of the precedent historical vehicle fault data and the subsequent different historical vehicle fault data exceed a correlation threshold; and

for at least one pan of the precedent historical vehicle fault data and the subsequent different historical vehicle fault data that exceed the correlation threshold,

determine a statistically significant number of occurrences of the precedent historical vehicle fault data that occurred prior to an occurrence of the subsequent different historical vehicle fault data, and

generate a relational matrix including the statistically significant number of occurrences of the precedent historical vehicle fault data that occurred prior to an occurrence of the subsequent different historical vehicle fault data and at least one or more of the precedent historical vehicle fault data, the subsequent different historical vehicle fault data, and historical vehicle usage data.

5. The vehicle health monitoring system of claim 4, wherein the imminent occurrence of the subsequent vehicle fault is based on at least a number of occurrences of the plurality of time-stamped precedent vehicle fault data, where the vehicle system fault detection module is configured to generate the maintenance report when the number of occurrences of the plurality of time-stamped precedent vehicle fault data reaches a first percentage threshold of the statistically significant number of occurrences of the precedent historical vehicle fault data that occurred prior to an occurrence of the subsequent different historical vehicle fault data.

6. The vehicle health monitoring system of claim 4, wherein the vehicle system maintenance rules generation module is configured to, for the at least one pair of the precedent historical vehicle fault data and the subsequent historical different vehicle fault data that exceed the correlation threshold,

determine a statistically significant duration between occurrences of the precedent historical vehicle fault data that occurred prior to an occurrence of the subsequent different historical vehicle fault data, and

populate the relational matrix with the statistically significant duration between occurrences of the precedent historical vehicle fault data that occurred prior to an occurrence of the subsequent historical different vehicle fault data.

7. The vehicle health monitoring system of claim 6, wherein the imminent occurrence of the subsequent vehicle fault is based on at least a duration between occurrences of the plurality of time-stamped precedent vehicle fault data, where the vehicle system fault detection module is configured to generate the maintenance report when the duration between occurrences of the plurality of time-stamped precedent vehicle fault data reaches a second percentage threshold of the statistically significant duration between occurrences of the precedent historical vehicle fault data that occurred prior to an occurrence of the subsequent different historical vehicle fault data.

8. A vehicle maintenance scheduling apparatus comprising:

a records module configured so as to couple with a vehicle to receive historical time-stamped vehicle fault data for a vehicle system;

a vehicle system fault correlation module configured to

determine a correlation between pairs of a precedent historical vehicle fault data, of the historical time-stamped vehicle fault data, and a subsequent different historical vehicle fault data, of the historical time-stamped vehicle fault data, and

generate vehicle system maintenance rules based on the correlation determined for the pairs of the precedent historical vehicle fault data and the subsequent different historical vehicle fault data; and

a vehicle maintenance scheduling engine configured so as to couple with the vehicle to monitor faults of the vehicle system where the vehicle faults include a plurality of time-stamped precedent vehicle fault data, the vehicle maintenance scheduling engine being further configured to

apply the vehicle system maintenance rules to the plurality of time-stamped precedent vehicle fault data,

determine an imminent occurrence of a subsequent vehicle fault, based on the application of the vehicle system maintenance rules to the plurality of time-stamped precedent vehicle fault data, and

generate a maintenance report corresponding to the imminent occurrence of the subsequent vehicle fault so that proactive maintenance is performed on the vehicle system;

wherein plurality of time-stamped precedent vehicle fault data corresponds with the precedent historical vehicle fault data, and the subsequent vehicle fault corresponds with the subsequent different historical vehicle fault data.

9. The vehicle maintenance scheduling apparatus of claim 8, wherein one or more of the historical time-stamped vehicle fault data and the plurality of time-stamped precedent vehicle fault data comprises time-stamped fault code messages.

10. The vehicle maintenance scheduling apparatus of claim 8, wherein one or more of the historical time-stamped vehicle fault data and the plurality of time-stamped precedent vehicle fault data comprises time-stamped component failure reports.

11. The vehicle maintenance scheduling apparatus of claim 8, wherein the records module is configured to receive, after one or more of each determination of the imminent occurrence of the subsequent vehicle fault and the occurrence of the subsequent vehicle fault, at least the plurality of time-stamped precedent vehicle fault data for inclusion in the historical time-stamped vehicle fault data.

12. The vehicle maintenance scheduling apparatus of claim 11, wherein the records module is configured to receive, after each determination of the imminent occurrence of the subsequent vehicle fault or after the occurrence of the subsequent vehicle fault, data corresponding to the subsequent vehicle fault for inclusion in the historical time-stamped vehicle fault data.

13. The vehicle maintenance scheduling apparatus of claim 8, further comprising a user interface coupled to the vehicle maintenance scheduling engine, the vehicle maintenance scheduling engine being configured to cause the maintenance report to be presented on the user interface to effect the proactive maintenance.

14. A method for proactive vehicle maintenance, the method comprising:

receiving from a vehicle, with a vehicle system maintenance rules generation module, historical time-stamped vehicle fault data for a vehicle system of the vehicle;

determining, with the vehicle system maintenance rules generation module, a correlation between pairs of a precedent historical vehicle fault data, of the historical time-stamped vehicle fault data, and a subsequent different historical vehicle fault data, of the historical time-stamped vehicle fault data;

generating, with the vehicle system maintenance rules generation module, vehicle system maintenance rules based on the correlation determined for the pairs of the precedent historical vehicle fault data and the subsequent different historical vehicle fault data;

monitoring faults of the vehicle system, with a vehicle system fault detection module, where the vehicle faults include a plurality of time-stamped precedent vehicle fault data;

applying, with the vehicle system fault detection module, the vehicle system maintenance rules to the plurality of time-stamped precedent vehicle fault data;

determining, with the vehicle system fault detection module, an imminent occurrence of a subsequent vehicle fault, based on the application of the vehicle system maintenance rules to the plurality of time-stamped precedent vehicle fault data; and

generating, with the vehicle system fault detection module, a maintenance report corresponding to the imminent occurrence of the subsequent vehicle fault so that proactive maintenance is performed on the vehicle system;

wherein the plurality of time-stamped precedent vehicle fault data corresponds with the precedent historical vehicle fault data, and the subsequent vehicle fault corresponds with the subsequent different historical vehicle fault data.

15. The method of claim 14, further comprising:

with the vehicle system maintenance rules generation module,

receiving historical vehicle usage data; and

combining the historical vehicle usage data with the correlation determined for the pairs of the precedent historical vehicle fault data and the subsequent different historical vehicle fault data to generate the vehicle system maintenance rules.

16. The method of claim 15, wherein the historical vehicle usage data includes one or more of an excursion date, an excursion time, an excursion location, an age of the vehicle, hours of maintenance performed on the vehicle, excursion type, a type of maintenance performed on the vehicle, and an order of precedence of vehicle fault data.

17. The method of claim 14, further comprising:

with the vehicle system maintenance rules generation module,

determining which pairs of the precedent historical vehicle fault data and the subsequent different historical vehicle fault data exceed a correlation threshold; and

for at least one pair of the precedent historical vehicle fault data and the subsequent different historical vehicle fault data that exceed the correlation threshold,

determining a statistically significant number of occurrences of the precedent historical vehicle fault data that occurred prior to an occurrence of the subsequent different historical vehicle fault data, and

generating a relational matrix including the statistically significant number of occurrences of the precedent historical vehicle fault data that occurred prior to an occurrence of the subsequent different historical vehicle fault data and at least one or more of the precedent historical vehicle fault data, the subsequent different historical vehicle fault data, and historical vehicle usage data.

18. The method of claim 17, wherein the imminent occurrence of the subsequent vehicle fault is based on at least a number of occurrences of the plurality of time-stamped precedent vehicle fault data, the method further comprising:

generating, with the vehicle system fault detection module, the maintenance report when the number of occurrences of the plurality of time-stamped precedent vehicle fault data reaches a first percentage threshold of the statistically significant number of occurrences of the precedent historical vehicle fault data that occurred prior to an occurrence of the subsequent different historical vehicle fault data.

19. The method of claim 17, further comprising:

with the vehicle system maintenance rules generation module, for the at least one pair of the precedent historical vehicle fault data and the subsequent different historical vehicle fault data that exceed the correlation threshold,

determining a statistically significant duration between occurrences of the precedent historical vehicle fault data that occurred prior to an occurrence of the subsequent different historical vehicle fault data, and

populating the relational matrix with the statistically significant duration between occurrences of the precedent historical vehicle fault data that occurred prior to an occurrence of the subsequent different historical vehicle fault data.

20. The method of claim 19, wherein the imminent occurrence of the subsequent vehicle fault is based on at least a duration between occurrences of the plurality of time-stamped precedent vehicle fault data, the method further comprising:

generating, with the vehicle system fault detection module, the maintenance report when the duration between occurrences of the plurality of time-stamped precedent vehicle fault data reaches a second percentage threshold of the statistically significant duration between occurrences of the precedent historical vehicle fault data that occurred prior to an occurrence of the subsequent different historical vehicle fault data.