Life estimation device for engine and machine having heat source

• US 6,542,853 B1
• Filed: 05/15/2000
• Issued: 04/01/2003
• Est. Priority Date: 11/17/1997
• Status: Expired due to Term

• Current Assignee: Komatsu Ltd.
• Original Assignee: Komatsu Ltd.
• Inventors: Hashimoto, Haruo, Iijima, Koji, Ohkawa, Hiroshi, Ichikawa, Ichio, Murakami, Taku, Sato, Fumihide
• Primary Examiner(s): Hoff, Marc S.
• Assistant Examiner(s): Desta, Elias
• Application Number:
  US09/554,450
• Time in Patent Office: 1,051 Days
• Field of Search: 702/33-36, 702/42, 702/44, 702/75-79, 702/113-115, 702/130, 702/132, 702/136, 702/141, 702/142, 702/145-148, 702/177-178, 702/182-185, 702/188, 73/10.8, 73/10.9, 73/11.4, 73/16.8, 73/18.4, 73/18.7, 73/644.9, 731/19, 374/40-41, 374/45-49, 374/55-56, 374/101-104, 374/119, 700/39-42, 700/46, 700/67, 700/78, 700/93, 700/103, 700/252, 700/256, 701/15, 701/30, 701/33, 701/35, 701/102, 701/115, 123/41.05, 123/179.15, 123/339-5-3
• US Class Current: 702/183
• CPC Class Codes: F02B 77/08 Safety, indicating or supervising devices thermal insulation F02B77/11; rendering engines inoperative or idling F02D17/04; dependent on lubricating conditions F01M1/22; dependent on cooling F01P11/14
• CPC Class Codes: F02D 2200/1012 Engine speed gradient
• CPC Class Codes: F02D 2200/1015 Engines misfires
• CPC Class Codes: F02D 41/1498 measuring engine roughness
• CPC Class Codes: F02D 41/221 relating to the failure of actuators or electrically driven elements
• CPC Class Codes: F02D 41/407 of the in-line type
• CPC Class Codes: G07C 3/00 Registering or indicating the condition or the working of machines or other apparatus, other than vehicles
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

A life estimation device which numerically measures the damage to a machine such as an engine accurately to estimate, the life of the machine accurately without requiring skill. A load map (B) of the two-dimensional distribution of the operation parameters of an engine is made. In accordance with the weighted integration time αi·ki at each level (Bi) of the load map (B), the actual damage δ=Σαi·ki to the engine for a certain lapse of time τ is calculated. By operating the engine beforehand, a correspondence relation L2 between the magnitude of the damage δ and the life H is predetermined. The life H1 corresponding to the calculated actual damage δ1 is determined in accordance with the predetermined correspondence relation L2 and the H1 is outputted as the estimated life of the engine.

Claims

1. A life estimation device for an engine which collects data of operation parameters which values change when the engine is operating and estimates a life of the engine based on the data of the operation parameters, comprising:

load map setting means for selecting one operation parameter or two or more operation parameters indicative of a load exerted on the engine, and dividing a value of the one operation parameter or combinations of values of the two or more operation parameters into a plurality of levels, so as to set a one-dimensional or two- or more dimensional load map for indicating a distribution of magnitude of the load exerted on the engine;

operation parameter detection means for detecting the values of the operation parameters;

time integration means, by detecting, the operation parameters by the operation parameter detection means until a predetermined time elapses, for integrating a time during which operation parameter values belonging to the respective level are detected for each level of the load map;

weight setting means for setting a weight in accordance with the load of the respective level for each level of the load map;

damage quantity calculation means for determining the weighted integration time for each level of the load map by weighting the integration time integrated by the time integration means in accordance with the weight set by the weight setting means, and calculating an actual damage quantity exerted on the engine until the predetermined time elapses based on the integration time weighted for each level of the load map;

correspondence relationship setting means for presetting a correspondence relationship between a magnitude of the damage quantity and a length of life by pre-operating the engine; and

life estimation means for determining a life corresponding to the actual damage quantity calculated by the damage quantity calculation means from the correspondence relationship preset by the correspondence relationship setting means, and outputting the determined life as the estimated life of the engine.

2. The life estimation device for an engine according to claim 1, characterized in that the two operation parameters indicative of the load exerted on the engine are an engine rotational speed and a torque or a horse power of the engine, and the load map setting means sets a two-dimensional map of the engine rotational speed and the torque or the horse power of the engine.

3. The life estimation device for an engine according to claim 1, characterized in that the operation parameter detection means detects the operation parameter values at a predetermined interval, and the time integration means counts the number of times when the operation parameter values belonging to the respective level were detected for each level of the load map until the predetermined time elapses, so as to integrate the time when the operation parameter values belonging to the respective level for each level of the load map.

4. The life estimation device for an engine according to claim 1, characterized in that the integration time integrated by the time integration means is reset each time the predetermined time elapses, so as to re-estimate the life of the engine each time the predetermined time elapses.

5. A life estimation device for an engine which collects data of operation parameters which values change when the engine is operating, and estimates a life of the engine based on the data of the operation parameters, comprising:

operation parameter detection means for selecting one operation parameter or two or more operation parameters indicative of a load exerted on the engine or an engine rotational speed and detecting values of the selected operation parameters at each predetermined interval;

fluctuation quantity calculation means for calculating a fluctuation quantity of the operation parameters per unit time based on the values of the operation parameters detected by the operation parameter detection means at each predetermined interval;

fluctuation quantity map setting means for setting a fluctuation quantity map indicative of a distribution of magnitude of the fluctuation quantity of the operation parameters per the unit time;

frequency measurement means for measuring a frequency of calculating the respective magnitude of the fluctuation quantity until a predetermined time elapses for each magnitude of the fluctuation quantity of the fluctuation quantity map;

weight setting means for setting a weight for each magnitude of the fluctuation quantity of the fluctuation quantity map;

damage quantity calculation means for determining the weighted frequency for each magnitude of the fluctuation quantity of the fluctuation quantity map by weighting the frequency measured by the frequency measurement means in accordance with the weight set by the weight setting means, and calculating an actual damage quantity exerted on the engine until the predetermined time elapses based on the weighted frequency for each magnitude of the fluctuation quantity of the fluctuation quantity map;

correspondence relationship setting means for presetting a correspondence relationship between the magnitude of the damage quantity and a length of life by pre-operating the engine; and

life estimation means for determining the life corresponding to the actual damage quantity calculated by the damage quantity calculation means from the correspondence relationship preset by the correspondence relationship setting means, and outputting the determined life as the estimated life of the engine.

7. The life estimation device for an engine according to claim 5, characterized in that the selected operation parameters are the engine rotational speed or a torque or a horse power of the engine.

9. The life estimation device for an engine according to claim 5, characterized in that the device estimates a life of parts constituting the engine, and that a specified detection range to be excluded from a detection target of the detection means, or a specified level to be excluded from a judgment target of the judgment means is preset in accordance with a type of parts constituting the engine.

10. The life estimation device for an engine according to claim 5, characterized in that the device estimates a life of parts constituting the engine, and that the weight to be set by the weight setting means is changed in accordance with a type of parts constituting the engine.

11. The life estimation device for an engine according to claim 5, characterized in that the frequency measured by the frequency measurement means is reset each time the predetermined time elapses, so that the life of the engine is re-estimated each time the predetermined time elapses.

6. A life estimation device for an engine which collects data of operation parameters which values change when the engine is operating, and estimates a life of the engine based on the data of the operation parameters;

comprising;

a first map setting means for setting one operation parameter or two or more operation parameters indicative of a load exerted on the engine or an engine rotational speed and setting a one-dimensional or two- or more dimensional first map indicative of a distribution of magnitude of the load exerted on the engine or a magnitude of the rotational speed by dividing a value of the one operation parameter or combinations of values of two or more operation parameters into a plurality of levels;

operation parameter detection means for detecting the operation parameter values at each predetermined interval;

judgment means where which level of the first map the operation parameter values, which are detected by the operation parameter detection means at each predetermined interval, belong to, is judged at the predetermined interval;

fluctuation quantity calculation means where based on the level judged sequentially by the judgment means, the fluctuation width between the levels which fluctuated per unit time is calculated as the fluctuation quantity of the operation parameters per unit time;

a second map setting means for setting a second map indicative of the distribution of magnitude of the fluctuation quantity of the operation parameters per the unit time;

frequency measurement means for measuring a frequency of calculating the respective magnitude of the fluctuation quantity until a predetermined time elapses for each magnitude of the fluctuation quantity of the second map;

weight setting means for setting a weight for each magnitude of the fluctuation quantity of the second map;

damage quantity calculation means for determining the weighted frequency for each magnitude of the fluctuation quantity of the second map by weighting the frequency measured by the frequency measurement means in accordance with the weight set by the weight setting means, and calculating an actual damage quantity exerted on the engine until the predetermined time elapses based on the weighted frequency for each magnitude of the fluctuation quantity of the second map;

corresponding relationship setting means for presetting a correspondence relationship between the magnitude of the damage quantity and a length of life by pre-operating the engine; and

life estimation means for determining the life corresponding to the actual damage quantity calculated by the damage quantity calculation means from the correspondence relationship preset by the correspondence relationship setting means, and outputting the determined life as the estimated life of the engine.

8. The life estimation device for an engine according to claim 6, characterized in that the first map set by the first map setting means is a two-dimensional map of the engine rotational speed and a torque or a horse power of the engine, and the second map set by the second map setting means is a one-dimensional map of the fluctuation quantity of the engine rotational speed or a one-dimensional map of the fluctuation quantity of the engine torque or the engine horse power.

12. A life estimation device for an engine which collects data of operation parameters which values change when the engine is operating and estimates a life of the engine based on the data of the operation parameters, comprising:

a first map setting means for selecting two or more operation parameters indicative of a load exerted on the engine and an engine rotational speed, and setting a first map of two- or more dimensions indicative of a distribution of magnitude of the load exerted on the engine and a magnitude of the rotational speed by dividing combinations of values of the two or more operation parameters into a plurality of levels;

operation parameter detection means for detecting the operation parameter values at each predetermined interval;

judgment means where which level of the first map the operation parameter values, which are detected by the operation parameter detection means at each predetermined interval, belong to, is judged at the predetermined interval;

fluctuation locus calculation means, based on the level judged sequentially by the judgment means, for calculating a fluctuation locus between both levels which fluctuated per unit time;

second map setting means for setting a second map indicative of the distribution of types of the fluctuation locus between both levels per the unit time;

frequency measurement means for measuring a frequency of calculating the respective type of the fluctuation locus until a predetermined time elapses for each type of fluctuation locus of the second map;

weight setting means for setting a weight for each type of fluctuation locus of the second map;

damage quantity calculation means for determining the weighted frequency for each type of fluctuation locus of the second map by weighting the frequency measured by the frequency measurement means in accordance with the weight set by the weight setting means, and calculating an actual damage quantity exerted on the engine until the predetermined time elapses based on the weighted frequency for each type of fluctuation locus of the second map;

correspondence relationship setting means for presetting a correspondence relationship between the magnitude of the damage quantity and a length of the life by pre-operating the engine; and

life estimation means for determining the life corresponding to the actual damage quantity calculated by the damage quantity calculation means from the correspondence relationship preset by the correspondence relationship means, and outputting the determined life as the estimated life of the engine.

13. The life estimation device for an engine according to claim 12, characterized in that the first map set by the first map setting means is a two-dimensional map of the engine rotational speed, and a torque or a horse power of the engine.

14. The life estimation device for an engine according to claim 12, characterized in that the device estimates a life of parts constituting the engine, and that a specified detection range to be excluded from a detection target of the detection means, or a specified level to be excluded from a judgment target of the judgment means is preset in accordance with a type of parts constituting the engine.

15. The life estimation device for an engine according to claim 12, characterized in that the device estimates a life of parts constituting the engine, and that the weight to be set by the weight setting means is changed in accordance with a type of parts constituting the engine.

16. The life estimation device for an engine according to claim 12, characterized in that the frequency measured by the frequency measurement means is reset each time the predetermined time elapses so that the life of the engine is re-estimated each time the predetermined time elapses.

17. A life estimation device for a machine having a heat source which collects data of operation parameters which values change when the machine is operating, and estimates a life of the machine based on the data of the operation parameters, comprising:

thermal map setting means for selecting one operation parameter or two or more operation parameters indicative of a heat generated in the heat source, and dividing a value of the one operation parameter or combinations of values of two or more operation parameters into a plurality of levels, so as to set a one-dimensional or two- or more dimensional thermal map for indicating a distribution of magnitude of the heat generated in the engine;

operation parameter detection means for detecting the values of the operation parameters;

time integration means, by detecting the operation parameters by the operation parameter detection means until a predetermined time elapses, for integrating a time during which values of the operation parameters belonging to the respective level are detected for each level of the thermal map;

weight setting means for setting a weight in accordance with the magnitude of heat of the respective level for each level of the thermal map;

damage quantity calculation means for determining a weighted integration time for each level of the thermal map by weighting the integration time integrated by the time integration means in accordance with the weight set by the weight setting means, and calculating an actual damage quantity exerted on a composing element, where the heat generated by the heat source is applied, out of the machine until the predetermined time elapses based on the integration time weighted for each level of the thermal map;

correspondence relationship setting means for presetting the magnitude of the damage quantity and a length of the life by pre-operating the machine; and

life estimation means for determining the life corresponding to the actual damage quantity calculated by the damage quantity calculation means from the correspondence relationship preset by the correspondence relationship setting means, and outputting the determined life as the estimated life of the machine.

18. The life estimation device for a machine according to claim 17, characterized in that the operation parameter indicative of the heat generated in the heat source is a temperature, and the thermal map is a one-dimensional map indicative of a magnitude of the temperature.

19. The life estimation device for a machine according to claim 17, characterized in that the heat source is an engine, and the operation parameter indicative of the heat generated in the heat source is a temperature of the engine.

20. The life estimation device for a machine according to claim 19, characterized in that the rotational speed of the engine and the torque of the engine are detected as the operation parameters, and the temperature of the engine is determined from values of the engine rotational speed and the engine torque.

21. The life estimation device for a machine according to claim 17, characterized in that the heat source is an engine, and the composing element where the heat generated by the heat source is applied is a part constituting the engine or a part constituting a power train to which power by the engine is transferred.

22. The life estimation device for a machine according to claim 17, characterized in that the operation parameter detection means detects the operation parameter values at each predetermined interval, and the time integration means counts the number of times when the operation parameter values belonging to the respective level are detected until the predetermined time elapses for each level of the thermal map so as to integrate the time when the operation parameter values belonging to the respective level are detected for each level of the thermal map.

23. The life estimation device for a machine according to claim 17, characterized in that the integration time integrated by the time integration means is reset each time the predetermined time elapses so as to re-estimate the life of the machine each time the predetermined time elapses.

24. A life estimation device for a machine having a heat source which collects data of operation parameters which values change when the machine is operating, and estimates a life of the machine based on the data of the operation parameters, comprising:

operation parameter detection means for selecting one operation parameter or two or more operation parameters indicative of a heat generated in the heat source, and detecting values of the selected operation parameters at each predetermined interval;

fluctuation quantity calculation means for calculating a fluctuation quantity of the operation parameters per unit time based on the values of the operation parameters detected by the operation parameter detection means at each predetermined interval;

fluctuation quantity map setting means for setting a fluctuation quantity map indicative of a distribution of magnitude of the fluctuation quantity of the operation parameters per the unit time;

frequency measurement means for measuring the frequency of calculating the respective magnitude of the fluctuation quantity until a predetermined time elapses for each magnitude of the fluctuation quantity of the fluctuation quantity map;

weight setting means for setting a weight for each magnitude of the fluctuation quantity of the fluctuation quantity map;

damage quantity calculation means for determining the weighted frequency for each magnitude of the fluctuation quantity of the fluctuation quantity map by weighting the frequency measured by the frequency measurement means in accordance with the weight set by the weight setting means, and calculating an actual damage quantity of a composing element, where the heat generated by the heat source is applied, out of the machine until the predetermined time elapses based on the weighted frequency for each magnitude of the fluctuation quantity of the fluctuation quantity map;

correspondence relationship setting means for presetting a correspondence relationship between the magnitude of the damage quantity and a length of life by pre-operating the machine; and

life estimation means for determining a life corresponding to the actual damage quantity calculated by the damage quantity calculation means from the correspondence relationship preset by the correspondence relationship setting means, and outputting the determined life as the estimated life of the machine.

26. The life estimation device for a machine according to claim 24, characterized in that the operation parameter indicative of the heat generated in the heat source is a temperature, and the fluctuation quantity map is a map indicative of a distribution of magnitude of the fluctuation quantity of the temperature.

27. The life estimation device for a machine according to claim 24, characterized in that the heat source is an engine, and the operation parameter indicative of the heat generated in the heat source is a temperature of the engine.

28. The life estimation device for a machine according to claim 27, characterized in that an engine rotational speed and an engine torque are detected as the operation parameters, and the temperature of the engine is determined by values of the engine rotational speed and the engine torque.

29. The life estimation device for a machine according to claim 24, characterized in that the heat source is an engine, and the composing element where the heat generated by the heat source is applied is a part constituting the engine or a part constituting a power train to which power by the engine is transferred.

34. The life estimation device for a machine according to claim 24, characterized in that the device estimates the life of parts constituting the machine, and that the weight set by the weight setting means is changed in accordance with a type of the part constituting the machine.

35. The life estimation device for an engine according to claim 24, characterized in that the frequency measured by the frequency measurement means is reset each time the predetermined time elapses so as to re-estimate the life of the engine each time the predetermined time elapses.

25. A life estimation device for a machine having a heat source which collects data of operation parameters which values change when the machine is operating, and estimates a life of the machine based on the data of the operation parameters, comprising:

a thermal map setting means for selecting one operation parameter or two or more operation parameters indicative of a heat generated in the heat source, and setting a one-dimensional or two- or more dimensional thermal map indicative of a distribution of magnitude of the heat generated in the heat source by dividing a value of one operation parameter or combinations of values of two or more operation parameters into a plurality of levels;

operation parameter detection means for detecting the operation parameter values at each predetermined interval;

judgment means where which level of the thermal map the operation parameter values, which are detected by the operation parameter detection means at each predetermined interval, belongs to, is judged at the predetermined interval;

fluctuation quantity calculation means where based on the levels judged sequentially by the judgment means, a fluctuation width between the levels which fluctuated per unit time is calculated as a fluctuation quantity of the operation parameter per unit time;

thermal fluctuation map setting means for setting a thermal fluctuation map indicative of a distribution of magnitude of the fluctuation quantity of the operation parameters per the unit time;

frequency measurement means for measuring the frequency of calculating the respective magnitude of the fluctuation quantity until a predetermined time elapses for each magnitude of the fluctuation quantity of the thermal fluctuation map;

weight setting means for setting a weight for each magnitude of the fluctuation quantity of the thermal fluctuation map;

damage quantity calculation means for determining the weighted frequency for each magnitude of the fluctuation quantity of the thermal fluctuation map by weighting the frequency measured by the frequency measurement means in accordance with the weight set by the weight setting means, and calculating an actual damage quantity of a composing element, where the heat generated by the heat source is applied, out of the machine until the predetermined time elapses based on the weighted frequency for each magnitude of the fluctuation quantity of the thermal fluctuation map;

correspondence relationship setting means for presetting a correspondence relationship between the magnitude of the damage quantity and a length of life by pre-operating the machine; and

life estimation means for determining the life corresponding to the actual damage quantity calculated by the damage quantity calculation means from the correspondence relationship preset by the correspondence relationship setting means, and outputting this determined life as the estimated life of the machine.

30. The life estimation device for an engine according to claim 25, characterized in that the operation parameter indicative of the heat generated in the heat source is a temperature, the thermal map set by the thermal map setting means is a one-dimensional map of the temperature, and the thermal fluctuation map set by the thermal fluctuation map setting means is a one-dimensional map of a fluctuation quantity of the temperature.

31. The life estimation device for a machine according to claim 25, characterized in that the heat source is an engine and the operation parameter indicative of the heat generated in the heat source is a temperature of the engine.

32. The life estimation device for a machine according to claim 31, characterized in that an engine rotational speed and an engine torque are detected as the operation parameters, and the temperature of the engine is determined by values of the engine rotational speed and the engine torque.

33. The life estimation device for a machine according to claim 25, characterized in that the heat source is an engine, and the composing element where the heat generated by the heat source is applied is a part constituting the engine or a part constituting a power train to which power by the engine is transferred.