Systems and methods for diagnosing and predicting fluid flow systems using sensors

• US 6,917,891 B2
• Filed: 02/28/2003
• Issued: 07/12/2005
• Est. Priority Date: 02/28/2003
• Status: Expired due to Fees

• Current Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Original Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Inventors: Hanna, Sami S., Depoint, Richard J., Rothfuss, Kevin A., Shehata, Ahmed-Mohsen T.
• Primary Examiner(s): Bui, Bryan
• Assistant Examiner(s): Walling, Meagan S
• Application Number:
  US10/248,913
• Publication Number:
  US 20040172210A1
• Time in Patent Office: 865 Days
• Field of Search: 702/100, 702/45, 702/47, 702/50, 702/51, 738/610.4, 738/613.9, 731/95, 731/96, 731/98
• US Class Current: 702/100
• CPC Class Codes: G05B 23/0235 based on a comparison with predetermined threshold or range, e.g. "classical methods", carried out during normal operation; threshold adaptation or choice; when or how to compare with the threshold
• 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

A fluid flow system for continuously monitoring the flow of fluid including fluid flow conduit with an upstream side and a downstream side, sensors and fluid flow elements, with the method for analyzing the operation of a fluid flow system by determining whether the fluid flow subsystem of the main system is operating properly, inputting a sensor reading of the parameter in the fluid flow of the main system and outputting an error indication of the main system.

Claims

1. A method for analyzing an operation of a fluid flow element of a fluid flow subsystem of a main system, comprising:

inputting at least one sensor reading from at least one sensor of the fluid flow subsystem, the at least one sensor reading indicative of a value of at least one parameter of the fluid flow subsystem;

analyzing the at least one sensor reading to determine a value of at least one of the at least one parameter;

comparing the at least one determined value to at least one corresponding value;

outputting an error indication of the fluid flow subsystem based on the comparison,

wherein the error indication comprises both a warning of a need for service and an indication of a remaining time before the fluid flow subsystem will be shut down.

2. The method of claim 1, further comprising:

determining whether the fluid flow subsystem is operating properly based on the at least one comparison.

3. The method of claim 2, wherein determining whether the fluid flow subsystem of the main system is operating properly comprises determining whether a sensor reading is within a defined parameter value range.

4. The method of claim 2, wherein determining whether the fluid flow subsystem of the main system is operating properly comprises determining whether the sensor reading indicates a low base fluid condition.

5. The method of claim 2, wherein determining whether the fluid flow subsystem of the main system is operating properly comprises determining whether the sensor reading indicate a fluid flow through the fluid flow subsystem is below a given first value.

6. The method of claim 2, wherein determining whether the fluid flow subsystem of the main system is operating properly comprises determining whether the sensor reading indicate a fluid flow through the fluid flow subsystem is above a given first value.

7. The method of claim 1, wherein the warning includes beeps, chimes or flashing displays, and the indication of the remaining time includes an intensity of the beeps, the chimes or the flashing displays.

8. The method of claim 1, wherein the warning includes a display on a monitor, and the indication of the remaining time includes a numerical estimate on the monitor.

9. A method for analyzing an operation of a fluid flow element of a fluid flow subsystem, comprising:

determining a deterioration rate of a reading measured by a sensor of the fluid flow system;

determining a rate of use of a main system;

determining an amount of remaining use of the main system before the sensor reading will drop below a first value; and

providing a warning that includes both an indication of a need for service and

an indication of the remaining time before the main system will be shut down.

10. The method of claim 9, further comprising determining whether the sensor reading is indicative of a low base fluid flow condition.

11. The method of claim 9, further comprising inputting at least one sensor reading of at least one fluid flow parameter of the fluid flow element.

12. The method of claim 9, further comprising determining whether the sensor reading is within at least one corresponding parameter value range.

13. The method of claim 9, further comprising determining whether the sensor reading is indicative if a fluid flow rate above a first given value.

14. A method for analyzing an operation of a fluid flow system, comprising:

polling at least one sensor value;

polling at least one machine metric;

comparing the polled at least one sensor value with the polled at least one machine metric;

determining whether the polled at least one sensor value and the polled at least one machine metric correlate;

tracking down a source of the discrepancy between the polled at least one sensor value and the polled at least one machine metric; and

providing a warning that includes both an indication of a need for service and an indication of a remaining time before the fluid flow system will be shut down.

15. The method of claim 14, further comprising:

determining whether the source of the discrepancy is indicative of a critical problem.

16. The method of claim 14, further comprising:

suggesting a solution to fixing the discrepancy.

17. The method of claim 14, further comprising:

shutting down the main system if the source of the discrepancy is indicative of a critical problem.

18. A fluid flow system for continuously monitoring a flow of fluid, comprising:

a sensor reading analyzing circuit, routine or application that senses a condition of the flow of the fluid;

an indication determining circuit, routine or application that determines whether the sensed condition indicates an error, and if the sensed condition indicates an error, provides a warning that includes both an indication of a need for service and an indication of a remaining time before the fluid flow system will be shut down; and

a main system shut down determining circuit, routine or application that shuts down the fluid flow system when the remaining time is up.

19. The fluid flow system of claim 18, further comprising an input/output interface that outputs the warning.

20. The fluid flow system of claim 18, further comprising a storage location that stores metrics of the fluid flow system to be compared with the sensed condition.

21. The fluid flow system of claim 18, further comprising a controller that compares the sensed condition with a metric of the fluid flow system.

22. The fluid flow system of claim 18, wherein the indication of the need for service includes beeps, chimes or flashing displays, and the remaining time includes an intensity of the beeps, chimes or flashing displays.

23. The fluid flow system of claim 18, wherein the indication of a need for service includes a display on a monitor, and the indication of the remaining time includes numerical estimates on the monitor.