Systems and Methods For Analyzing Machine Performance

• US 20130245883A1
• Filed: 03/15/2012
• Published: 09/19/2013
• Est. Priority Date: 03/15/2012
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Humphrey, James D.
• Granted Patent: US 8,626,385 B2
• Time in Patent Office: Days
• US Class Current: 701/36
• CPC Class Codes: G07C 5/006 Indicating maintenance
• CPC Class Codes: G07C 5/0841 Registering performance data recording measured values G01D; information storage G11B

Abstract

A system for analyzing machine performance is disclosed. The system may have one or more processors and a memory. The memory may store instructions that, when executed, enable the one or more processors to identify an event for a machine that includes a desired output parameter value and send a command to a component of the machine. A command value associated with the command may be determined based on the desired output parameter value, one or more machine state parameter values, and a feedback control loop. The instructions may further enable the one or more processors to determine whether the machine requires maintenance by comparing the command value to one or more historical command values each determined based on a historical desired output parameter value and one or more historical machine state parameter values.

Claims

1. A computer-implemented method for analyzing machine performance comprising:

identifying an event for a machine that includes a desired output parameter value;

sending a command to a component of the machine, the command having a command value determined based on the desired output parameter value, one or more machine state parameter values, and a feedback control loop; and

determining that the machine requires maintenance by comparing the command value to one or more historical command values each determined based on a historical desired output parameter value and one or more historical machine state parameter values, the historical desired output parameter value and the one or more historical machine state parameter values each corresponding to the desired output parameter value and the one or more machine state parameter values.

2. The computer-implemented method according to claim 1, wherein the event is a braking event and the desired output parameter value is a desired deceleration value, the computer-implemented method further including:

sending a braking command to a braking mechanism of the machine, the braking command having a braking command value determined based on the desired deceleration value, a velocity value, an elevation value, a payload value, and the feedback control loop; and

determining that the machine requires maintenance by comparing the braking command value to a historical braking command value determined based on a historical desired deceleration value, a historical velocity value, a historical pitch value, and a historical payload value.

3. The computer-implemented method according to claim 1, wherein the event is an acceleration event and the desired output parameter value is a desired acceleration value, the computer-implemented method further including:

sending a fuel injection command to a fuel injection mechanism of the machine, the fuel injection command having a fuel injection command value determined based on the desired acceleration value, a velocity value, an elevation value, a payload value, and the feedback control loop; and

determining that the machine requires maintenance by comparing the fuel injection command value to a historical fuel injection command value determined based on a historical desired acceleration value, a historical velocity value, a historical elevation value, and a historical payload value.

4. The computer-implemented method according to claim 1, wherein determining that the machine requires maintenance includes:

determining that the command value determined based on the desired output parameter value and the one or more machine state parameter values exceeds a threshold command value.

5. The computer-implemented method according to claim 1, wherein determining that the machine requires maintenance includes:

determining a command value trend by comparing the command value to the one or more historical command values, the one or more historical command values each corresponding to a previous execution of the event by the machine; and

identifying a projected machine maintenance date based on the command value trend.

6. The computer-implemented method according to claim 5, wherein determining the projected machine maintenance date includes:

generating an equation that represents the command value trend by applying one or more curve fitting algorithms to the command value and the one or more historical command values; and

identifying the projected machine maintenance date as a date when the equation representing the command value trend exceeds a threshold command value.

7. The computer-implemented method according to claim 5, wherein determining the projected machine maintenance date includes:

generating an equation that represents the command value trend by applying one or more curve fitting algorithms to the command value and the one or more historical command values;

comparing a rate of change of the equation representing the command value trend to a command value trend expected rate of change; and

identifying the projected machine maintenance date as a date when the rate of change of the equation representing the command value trend exceeds the command value trend expected rate of change by a threshold rate of change value.

8. A system for analyzing machine performance comprising:

one or more processors; and

a memory storing instructions that, when executed, enable the one or more processors to;

identify an event for a machine that includes a desired output parameter value;

send a command to a component of the machine, the command having a command value determined based on the desired output parameter value, one or more machine state parameter values, and a feedback control loop; and

determine that the machine requires maintenance by comparing the command value to one or more historical command values each determined based on a historical desired output parameter value and one or more historical machine state parameter values, the historical desired output parameter value and the one or more historical machine state parameter values each corresponding to the desired output parameter value and the one or more machine state parameter values.

9. The system according to claim 8, wherein the event is a braking event and the desired output parameter value is a desired deceleration value, the instructions further enabling the one or more processors to:

send a braking command to a braking mechanism of the machine, the braking command having a braking command value determined based on the desired deceleration value, a velocity value, an elevation value, a payload value, and the feedback control loop; and

determine that the machine requires maintenance by comparing the braking command value to a historical braking command value determined based on a historical desired deceleration value, a historical velocity value, a historical elevation value, and a historical payload value.

10. The system according to claim 8, wherein the event is an acceleration event and the desired output parameter value is a desired acceleration value, the instructions further enabling the one or more processors to:

send a fuel injection command to a fuel injection mechanism of the machine, the fuel injection command having a fuel injection command value determined based on the desired acceleration value, a velocity value, an elevation value, a payload value, and the feedback control loop; and

determine that the machine requires maintenance by comparing the fuel injection command value to a historical fuel injection command value determined based on a historical desired acceleration value, a historical velocity value, a historical elevation value, and a historical payload value.

11. The system according to claim 8, the instructions further enabling the one or more processors to determine that the machine requires maintenance when the command value determined based on the desired output parameter value and the one or more machine state parameter values exceeds a threshold command value.

12. The system according to claim 8, the instructions further enabling the one or more processors to:

determine a command value trend by comparing the command value to the one or more historical command values, the one or more historical command values each corresponding to a previous execution of the event by the machine; and

identify a projected machine maintenance date based on the command value trend.

13. The system according to claim 12, the instructions further enabling the one or more processors to:

generate an equation that represents the command value trend by applying one or more curve fitting algorithms to the command value and the one or more historical command values; and

identify the projected machine maintenance date as a date when the equation representing the command value trend exceeds a threshold command value.

14. The system according to claim 12, the instructions further enabling the one or more processors to:

generate an equation that represents the command value trend by applying one or more curve fitting algorithms to the command value and the one or more historical command values;

compare a rate of change of the equation representing the command value trend to a command value trend expected rate of change; and

identify the projected machine maintenance date as a date when the rate of change of the equation representing the command value trend exceeds the command value trend expected rate of change by a threshold rate of change value.

15. The system according to claim 8, further including the machine, wherein the machine is an autonomous machine and include the one or more processors and the memory.

16. A computer-implemented method for analyzing machine performance among a plurality of machines, the computer-implemented method comprising:

identifying an event for a machine of the plurality of machines, the event including a desired output parameter value;

receiving a command value of a command sent to a component of the machine, the command value having been determined based on the desired output parameter value, one or more machine state parameter values, and a feedback control loop; and

determining that the machine requires maintenance based on the command value and one or more other command values generated by one or more other machines of the plurality of machines during corresponding events for the one or more other machines, the corresponding events including the desired output parameter value.

17. The computer-implemented method according to claim 16, wherein the event for the machine and each of the corresponding events for the one or more other machines occur at substantially the same time within an autonomous machine event schedule.

18. The computer-implemented method according to claim 16, wherein the event is a braking event or an acceleration event.

19. The computer-implemented method according to claim 16, the computer-implemented method further including:

calculating a command value rate of change of the machine based on historical command values of the machine during past occurrences of the event;

calculating command value rates of change of each of the one or more other machines based on historical command values of each of the one or more other machines during past executions of each of the corresponding events; and

determining that the machine requires maintenance based on a comparison of the command value rate of change of the machine with the command value rates of change of the one or more other machines.

20. The computer-implemented method according to claim 19, the computer-implemented method further including:

determining that the machine requires maintenance when the command value rate of change of the machine exceeds a mean of the command value rates of change of the one or more other machines by a threshold amount.