Systems and methods for maintaining load histories

• US 20060243056A1
• Filed: 09/16/2005
• Published: 11/02/2006
• Est. Priority Date: 04/28/2005
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Baskett, Jeffrey Dale, Patel, Nitin R., Sundermeyer, Jeffry Neil, Allgaier, Ryan Paul, Clarke, Burton Roland, Vik, Timothy Allen, Dunn, Daniel Kimsey III, Sit, Don, Kyuba, Hiroko, Truax, Byron Edwin
• Granted Patent: US 7,953,559 B2
• Time in Patent Office: Days
• US Class Current: 73/760
• CPC Class Codes: G01N 2203/0073 Fatigue
• CPC Class Codes: G01N 3/32 by applying repeated or pulsating forces

Abstract

Methods and systems for constructing a load history database for a structure is disclosed. In one embodiment, a method is disclosed that may include detecting a measurable parameter on the structure utilizing a sensor positioned on the structure and determining a value of external loads acting upon the structure based on the detected parameter. Further, the method may include evaluating the value of the external loads against a pre-established factor. Based on the evaluation, the value of the external loads are selectively stored in the load history database.

Claims

1. A method of constructing a load history database for a structure, comprising:

detecting a measurable parameter on the structure utilizing a sensor positioned on the structure;

determining a value of external loads acting upon the structure based on the detected parameter;

evaluating the value of the external loads against a pre-established factor; and

selectively storing the value of the external loads in the load history database based upon the evaluation against the pre-established factor.

2. The method of claim 1, wherein selectively storing the value includes replacing a previously stored value of recorded loads associated with the pre-established factor.

3. The method of claim 1, wherein the pre-established factor includes one of the determined external loads exceeding one of a lifetime maximum load value and a lifetime minimum load value.

4. The method of claim 1, wherein selectively storing the value of the external loads includes storing the value of all loads acting on the structure when the value of the external loads meet a pre-established level.

5. The method of claim 1, wherein selectively storing the value of the external loads includes storing the value of the external loads acting on the structure during a determined period of time.

6. The method of claim 5, wherein the determined period of time is bounded by a first time period corresponding to a triggering start event and a second time period corresponding to a triggering end event.

7. The method of claim 6, including detecting a classifiable operation performed by the structure, wherein the triggering start event corresponds to the beginning of the classifiable operation performed by the structure and the triggering end event corresponds to the ending of the classifiable operation performed by the structure.

8. The method of claim 5, including determining a damage rate of the structure based upon the value of the external loads over the determined period of time.

9. The method of claim 8, including generating a histogram based on the damage rate.

10. The method of claim 5, wherein storing the value of the external loads includes storing the value of external loads associated with percentiles of damage rate severity for the structure.

11. The method of claim 1, wherein the pre-established factor includes a determination that the value of the external loads are within a predetermined threshold value of a desired percentile of damage rate severity for the structure.

12. The method of claim 1, including analyzing the value of the external loads to perform at least one of:

determining a warranty price of the structure;

evaluating damage to the structure in relation to the coverage by the warranty;

tracking operator performance of the structure;

analyzing the structure for abuse; and

redesigning the structure.

13. The method of claim 1, wherein detecting the parameter includes detecting strain acting on the structure using a wireless network.

14. The method of claim 1, wherein the value of the external loads is determined by at least one of:

a neural network, solving the equations of motion, and direct measurement.

15. A system for constructing a loading history database for a structure, comprising:

a plurality of sensors positioned on the structure and configured to detect a measurable parameter of the structure;

a processor; and

a memory component storing program code executable by the processor, the processor executing the program code to;

determine a value of external loads acting upon the structure based upon the detected parameter,

evaluate the value of the loads against a pre-established factor, and

selectively store the value of the loads in the loading history database based upon the evaluation against the pre-established factor.

16. The system of claim 15, wherein the processor executes the program code to replace a previously stored value of recorded loads associated with the pre-established factor.

17. The system of claim 15, wherein the pre-established factor includes one of the determined external loads surpassing one of a lifetime maximum load value and a lifetime minimum load value.

18. The system of claim 15, wherein the processor executes the program code to store the value of the external loads acting on the structure during a determined period of time.

19. The system of claim 18, wherein the processor executes the program code to determine a damage rate of the structure based upon the value of the external loads over the determined period of time.

20. The system of claim 19, wherein the processor executes the program code to generate a histogram showing the damage rate.

21. The system of claim 18, wherein the processor executes the program code to store the value of loads associated with percentiles of damage rate severity for the structure.

22. The system of claim 15, wherein the pre-established factor includes a determination that the value of the loads are within a predetermined threshold of a desired percentile of damage rate severity for the structure.

23. The system of claim 15, including a wireless network, wherein the sensors are strain gauges forming a part of the wireless network.

24. The system of claim 15, wherein the processor executes the program code to process at least one of a neural network, the equations of motion, and direct measurement, to determine the external load values.

25. A system for constructing a loading history database for a structure, comprising:

a plurality of sensors positioned on the structure and configured to detect a measurable parameter associated with the structure;

a memory component configured to maintain data indicative of a previously stored lifetime maximum external load value and a lifetime minimum external load value applied to the structure; and

a processor configured to detect at least one of a new lifetime maximum external load value and a lifetime minimum external load value acting upon the structure, and configured to update the memory component to replace at least one of the previously stored lifetime maximum load value and the minimum load value with the new lifetime maximum load value and minimum load value, respectively.

26. The system of claim 25, wherein the processor is configured to store all the loads acting on the structure in the memory component when the processor detects at least one of the new lifetime maximum and lifetime minimum external load value.

27. A system for constructing a loading history database for a structure, comprising:

a plurality of sensors positioned on the structure and configured to detect a measurable parameter of the structure;

a memory component configured to maintain data indicative of a previously stored loading scenario at a desired percentile of damage rate severity for the structure; and

a processor configured to detect a new loading scenario that has data having a closer data relationship with the desired percentile of damage rate severity for the structure than the previously stored loading scenario, and configured to update the memory component to replace the previously stored loading scenario with the new loading scenario based on the detection.

28. The system of claim 27, wherein the previously stored loading scenario and the new loading scenario include loads applied to the structure over a period of time.

29. The system of claim 27, wherein the processor and memory component are configured to generate a histogram showing the damage rate.

30. A method of constructing a loading history database for a structure on a work machine, comprising:

detecting a measurable parameter of the structure with a plurality of sensors positioned on the work machine;

maintaining stored data reflecting a previously stored lifetime maximum external load and a lifetime minimum external load applied to the structure;

analyzing the measurable parameter to detect a new lifetime maximum external load or a lifetime minimum external load acting upon the structure;

updating the memory component to replace the previously stored lifetime maximum or minimum load with the new lifetime maximum or minimum load when the new lifetime maximum or minimum external load acts upon the structure;

maintaining data indicative of a previously stored loading scenario at a desired percentile of damage rate severity for the structure;

monitoring the measurable parameter to detect a new loading scenario that agrees more closely with the desired percentile of damage rate severity for the structure than the previously stored loading scenario; and

updating the memory component to replace the previously stored loading scenario with the new loading scenario when the new loading scenario agrees more closely with the desired percentile of damage rate severity for the structure than the previously stored loading scenario.

31. The method of claim 30, wherein updating the memory component to replace the old lifetime maximum or minimum load includes storing instantaneous loads applied on the structure.

32. The method of claim 30, wherein updating the memory component to replace the previously stored loading scenario with the new loading scenario includes storing loads over a period of time.

33. A method for managing a load history database for a structure, comprising:

collecting measured data received from sensors positioned on the structure;

determining a current damage rate associated with the structure based on the collected measured data;

determining a first relationship between the current damage rate and a predetermined target damage rate;

comparing the first relationship with a second relationship reflecting a relationship between a previously determined damage rate associated with the structure and the target damage rate, the second relationship being stored in the database; and

replacing in the database the second relationship with the first relationship based on the comparison.

34. The method of claim 35, further including:

populating a first load data structure with load data corresponding to measured data and the current damage rate; and

replacing a second load data structure including load data corresponding to the previously determined damage rate with the first load data structure based on the comparison between the first and second relationships.