Frequency analysis system and method for detecting improper actuation system performance and element operation

• US 7,657,360 B2
• Filed: 10/13/2006
• Issued: 02/02/2010
• Est. Priority Date: 10/13/2006
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Skowron, John
• Primary Examiner(s): Cronin; Stephen K
• Assistant Examiner(s): Hoang; Johnny H
• Application Number:
  US11/549,197
• Publication Number:
  US 20080088850A1
• Time in Patent Office: 1,208 Days
• Field of Search: 123/339.15, 123/436, 123/478, 123/479, 123/568.16, 701 1-105, 701/111, 701/114, 318/561, 251/129.05, 251/129.08, 700/32, 700 37- 39, 700/71, 361/152, 361/153, 361/160, 215/129.05, 215/129.08, 316/152, 316/153, 316/180
• US Class Current: 701/103
• CPC Class Codes: G05B 23/0227 Qualitative history assessment, whereby the type of data acted upon, e.g. waveforms, images or patterns, is not relevant, e.g. rule based assessment; if-then decisions
• CPC Class Codes: G05B 23/0256 injecting test signals and analyzing monitored process response, e.g. injecting the test signal while interrupting the normal operation of the monitored system; superimposing the test signal onto a control signal during normal operation of the monitored system

Abstract

Dither frequency analysis systems include a controller for directing a control signal and a dither frequency to an actuation driver. One or more sensors are used for receiving and relaying a signal downstream from an actuation element, which downstream signal includes the dither frequency. A frequency analysis device receives and analyzes the downstream dither frequency and directs the same to a controller that is configured to evaluate the analyzed downstream dither frequency, and evaluate whether the same indicates proper or improper actuation system operation. The downstream dither frequency is analyzed and evaluated at a frequency of less than about one second, and the frequency analysis device analyzes downstream dither frequencies in the range of from about 50 to 500 hertz. The system can include algorithms and test sequences to address and/or further evaluate improper actuation system operation.

Claims

1. A dither frequency analysis system for use in monitoring an actuation control system for actuating one or more actuation elements, the dither frequency analysis system comprising:

a controller for directing a control signal to an actuation driver, the control signal controlling actuation of at least one of the actuation elements and including a predetermined dither frequency defining a frequency applied to the control signal to overcome mechanical or magnetic effects impairing movement of one or more of the actuation elements;

one or more sensors for receiving and relaying a signal downstream from the one or more actuation elements, the downstream signal including the dither frequency; and

a frequency analysis device for receiving and analyzing the downstream dither frequency or directing analysis of the downstream dither frequency to the controller;

wherein the controller evaluates the analyzed downstream dither frequency and evaluates whether such analyzed downstream dither frequency indicates proper or improper actuation system operation.

2. The dither frequency analysis system as recited in claim 1 further comprising one or more algorithms developed to address a particular type of identified improper actuation system operation, and wherein the system implements the one or more algorithms into the actuation control system in the event that an improper actuation system operation is detected.

3. The dither frequency analysis system as recited in claim 2 wherein the system implements the one or more algorithms into the control system in a manner such that operation of the one or more algorithms is transparent to a user of an apparatus comprising the actuation control system.

4. The dither frequency analysis system as recited in claim 1 further comprising one or more test sequences developed to assist in further evaluating improper actuation system operation as detected by analysis of the downstream dither frequency, and wherein the system implements the one or more test sequences into the control system in the event that such improper actuation system operation is detected.

5. The dither frequency analysis system as recited in claim 4 wherein the system implements the one or more test sequences into the control system in a manner such that operation of the one or more test sequences is transparent to a user of an apparatus comprising the actuation control system.

6. The dither frequency analysis system as recited in claim 1 wherein the actuation control system is used to actuate one or more variable geometry elements within a turbocharger in a turbocharged engine system.

7. The dither frequency analysis system as recited in claim 1 wherein the downstream dither frequency is analyzed and evaluated at a frequency of less than about one second.

8. The dither frequency analysis system as recited in claim 1 wherein the frequency analysis device is configured to analyzes downstream dither frequencies in the range of from about 50 to 500 hertz.

9. The dither frequency analysis system as recited in claim 8 further comprising a filter device that filters out downstream dither frequencies that are outside of the frequency range.

10. A dither frequency analysis system used with an actuation control system for controlling one or more movable elements in a turbocharger engine system comprising:

a turbocharger assembly comprising a center housing comprising a shaft rotatably disposed therein, a compressor housing attached to one end of the center housing and including a compressor impeller disposed therein and attached to one end of the shaft, a turbine housing attached to an opposite end of the center housing and including a turbine wheel disposed therein and attached to an opposite end of the shaft, and one or more movable members disposed within the turbocharger assembly;

an actuator that is connected to the one or more movable members;

a controller for directing a control signal to an actuation driver that operates the actuator, the control signal controlling actuation of at least one of the moveable elements and including a predetermined dither frequency defining a frequency applied to the control signal to overcome mechanical or magnetic effects impairing movement of one or more of the moveable elements;

one or more sensors for receiving and relaying a signal downstream from the actuator and one or more movable members, the downstream signal including the dither frequency; and

a frequency analysis device for receiving and analyzing the downstream dither frequency and directing analysis of the downstream dither frequency to the controller;

wherein at least one of the controller or frequency analysis device evaluates the analyzed downstream dither frequency and evaluates whether such analyzed downstream dither frequency indicates proper or improper operation of the actuation control system or the one or more movable members.

11. The dither frequency analysis system as recited in claim 10 further comprising one or more cleaning algorithms that are each tailored to address a respective improper operation of the actuation control system or the one or more movable members as evaluated by the analyzed dither frequency.

12. The dither frequency analysis system as recited in claim 11 wherein the controller is configured to implement the one or more cleaning algorithms by introducing the one or more cleaning algorithms to the control system actuation driver.

13. The dither frequency analysis system as recited in claim 12 wherein the controller is configured to implement the one or more cleaning algorithms in a manner that is transparent to a user of the turbocharged engine system.

14. The dither frequency analysis system as recited in claim 10 further comprising one or more test sequences that are each tailored to further evaluate a respective improper operation of the actuation control system or the one or more movable members as evaluated by the analyzed dither frequency.

15. The dither frequency analysis system as recited in claim 14 wherein the controller is configured to implement the one or more test sequences by introducing the one or more test sequences to the control system actuation driver.

16. The dither frequency analysis system as recited in claim 15 wherein the controller is configured to implement the one or more test sequences in a manner that is transparent to a user of the turbocharged engine system.

17. A method for evaluating the operation of an actuation system and its functional elements by monitoring a dither frequency, the method comprising the steps of:

providing a control signal to an actuation driver in an actuation control system and that is connected to one or more movable members, wherein the control signal controls actuation of at least one of the moveable members and includes a predetermined dither frequency defining a frequency applied to the control signal to overcome mechanical or magnetic effects impairing movement of one or more of the moveable members;

receiving the dither frequency downstream from the actuation driver and one or more movable member; and

analyzing the downstream dither frequency to determine whether the downstream dither frequency indicates proper or improper operation of the actuation control system, or the one or more movable members.

18. The method as recited in claim 17 further comprising the step of introducing a cleaning signal into the actuation control system for the purpose of addressing identified improper operation of the actuation control system or the one or more movable members.

19. The method as recited in claim 17 further comprising the step of introducing a test sequence into the actuation control system for the purpose of further evaluating an identified improper operation of the actuation control system or the one or more movable members.

20. The method as recited in claim 17 further comprising the step of introducing a signal into the actuation system for the purpose of addressing or further evaluating an identified improper operation of the actuation control system of the one or more movable members, wherein the step of introducing is done in a manner that is transparent to a user of the device comprising the actuation system.