Turbocharger fleet management system

• US 8,364,375 B2
• Filed: 07/24/2009
• Issued: 01/29/2013
• Est. Priority Date: 07/24/2008
• Status: Active Grant

• Current Assignee: Scavengetech I LLC
• Original Assignee: Scavengetech I LLC
• Inventors: Chapman, Kirby Scott, Chapman, Sandra Jane, Dufur, Eric Robert, Figge, Eric Ray
• Primary Examiner(s): Gimie, Mahmoud
• Application Number:
  US12/509,170
• Publication Number:
  US 20100023369A1
• Time in Patent Office: 1,285 Days
• Field of Search: 701/101, 701/99, 701/100, 123/559.1, 606/051, 606/11, 606/12, 606/01, 606/02, 702/2
• US Class Current: 701/100
• CPC Class Codes: G06Q 10/04 Forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or "cutting stock problem" market predictions or forecasting for commercial activities G06Q30/0202

Abstract

A system of monitoring the performance characteristics of a turbocharged engine and forecasting a performance parameter based on measured data include sensor components for measuring various performance parameters such as pressures and temperatures. The measured data may be received by electronic components that forward the data through networking components to computing components. The data may be stored in a database. Methods for forecasting turbocharger performance and indicating turbocharger malfunctions include retrieving measured data, performing calculations to correct at least a portion of the measured data, retrieving input from a user, performing regression analysis to determine a forecasting model used to forecast future values, and determining a time when the future values reach a user-specified level.

Claims

1. A physical computer-readable medium comprising a set of code segments to be executed by computing components to forecast the ability of the turbocharger to achieve a turbocharger air specification according to measured turbocharger performance data, the physical computer-readable medium comprising:

a code segment configured to retrieve a user-specified plurality of ambient temperatures;

a code segment configured to retrieve a user-specified plurality of future times;

a code segment configured to determine a forecasted compressor air flow rate for each ambient temperature and future time combination by extrapolating the forecasted compressor air flow rate from the measured turbocharger performance data; and

a code segment configured to determine whether the turbocharger satisfies the turbocharger air specification at each ambient temperature and future time combination based at least partly on the forecasted compressor air flow rate at each ambient temperature and future time combination.

2. The physical computer-readable medium of claim 1,

wherein the turbocharger is determined as not satisfying the air specification for each ambient temperature and future time combination in which the forecasted compressor air flow rate is below a user-specified level.

3. The physical computer-readable medium of claim 1;

and

a code segment configured to determine a forecasted waste gate margin for each ambient temperature and future time combination,

said forecasted compressor air flow rate based on the forecasted waste gate margin.

4. The physical computer-readable medium of claim 3,

wherein the turbocharger is determined as not satisfying the air specification for each ambient temperature and future time combination in which the compressor air flow rate is above a user-specified level and the waste gate margin is below approximately one percent.

5. The physical computer-readable medium of claim 3,

wherein the turbocharger is determined as satisfying the air specification for each ambient temperature and future time combination in which the compressor air flow rate is above a user-specified level and the waste gate margin is above approximately five percent.

6. The physical computer-readable medium of claim 3,

wherein the turbocharger is determined as being in a condition proximal to the air specification for each ambient temperature and future time combination in which the compressor air flow rate is above a user-specified level and the waste gate margin ranges from approximately one percent to approximately five percent.

7. The physical computer-readable medium of claim 3,

wherein the forecasted waste gate margin is determined using regression analysis.

8. The physical computer-readable medium of claim 3,

wherein the air specification is based at least partly on the forecasted waste gate margin.

9. The physical computer-readable medium of claim 1;

and

a code segment configured to create a graph displaying each ambient temperature and future time combination wherein each ambient temperature and future time combination is assigned an indicia based on whether the turbocharger is determined as satisfying the air specification.

10. The physical computer-readable medium of claim 9,

wherein each ambient temperature and future time combination is assigned a first indicia if the turbocharger is determined as satisfying the air specification, a second indicia if the turbocharger is determined as being in a condition proximal to the air specification, and a third indicia if the turbocharger is determined as not satisfying the air specification.

11. The physical computer-readable medium of claim 1,

wherein the code segments are operable to forecast if a plurality of turbochargers achieve a corresponding turbocharger air specification.

12. A physical computer-readable medium comprising a set of code segments to be executed by computing components to determine the earliest date to overhaul the degraded turbocharger of a turbocharged engine to reduce engine operating cost, the physical computer-readable medium comprising:

a code segment configured to retrieve a user-specified turbocharger overhaul cost and a user-specified payback period;

a code segment configured to calculate a plurality of first engine operating costs associated with the turbocharger in a degraded condition prior to overhaul of the turbocharger for each of a plurality of time periods;

a code segment configured to calculate a plurality of second engine operating costs each associated with the turbocharger in an overhauled condition following the turbocharger overhaul for a combination of the plurality of time periods and one of a corresponding plurality of turbocharger overhaul dates on which the turbocharger is overhauled;

a code segment configured to calculate a savings in operating cost for each time period and overhaul date combination by subtracting the first operating cost from the second operating cost for each overhaul date; and

a code segment configured to identify the earliest payback date associated with the operating cost savings being at least as much as the turbocharger overhaul cost, with the payback date being no later than a respective overhaul date plus the payback period.

13. The physical computer-readable medium of claim 12;

and

a code segment configured to notify a user if the earliest payback date corresponding to the overhaul date plus the payback period wherein the savings is equal to or greater than the cost of overhaul occurs outside of a user-specified period of turbocharger operation.

14. The physical computer-readable medium of claim 12,

wherein the first operating cost and the second operating cost are calculated at least partly based on a physical parameter of the engine, the cost of fuel, and a forecasted turbocharger efficiency.

15. The physical computer-readable medium of claim 12,

wherein the turbocharger overhaul cost includes the cost of removing and reinstalling the turbocharger.

16. The physical computer-readable medium of claim 12,

wherein at least one of the first operating costs and the second operating costs is calculated by forecasting the engine fuel consumption.

17. The physical computer-readable medium of claim 16,

wherein the engine fuel consumption is calculated based on at least partly the turbocharger efficiency.

18. The physical computer-readable medium of claim 12,

wherein the first operating costs and the second operating costs are cumulative costs, such that the cost at any given time period is the sum of the costs for all previous time periods.

19. The physical computer-readable medium of claim 12,

wherein the savings is a cumulative savings, such that the savings at any given time period is the sum of the savings for all previous time periods.

20. The physical computer-readable medium of claim 12,

wherein the code segments are operable for a plurality of degraded turbochargers to determine the earliest date to overhaul each of the degraded turbochargers.

21. A physical computer-readable medium comprising a set of code segments to be executed by computing components to determine when to service a turbocharged engine due to a flow restriction, the physical computer-readable medium comprising:

a code segment configured to retrieve measured turbocharger performance data recorded over time;

a code segment configured to calculate flow restriction coefficient based on measured turbocharger performance data;

a code segment configured to perform regression analysis to determine a forecasting model operable to forecast values of the flow restriction coefficient associated with a plurality of future times;

a code segment configured to calculate forecasted engine differential pressure values associated with the future times using forecasted values of flow restriction coefficient; and

a code segment configured to calculate forecasted values of turbocharger minimum required turbine inlet temperature associated with the future times based on forecasted values of engine differential pressure.

22. The physical computer-readable medium of claim 21;

and

a code segment configured to report at least one of the future times when at least one of the forecasted values of the turbocharger minimum required turbine inlet temperature reaches a user-specified level.

23. The physical computer-readable medium of claim 21,

wherein the calculation of forecasted engine differential pressure values is at least partly based on forecasted values of a turbocharger compressor mass air flow rate.

24. The physical computer-readable medium of claim 21,

wherein the calculation of forecasted values of turbocharger minimum required turbine inlet temperature is further based on a turbocharger compressor inlet temperature, an ambient pressure, and a turbocharger efficiency.

25. The physical computer-readable medium of claim 21,

wherein the calculation of flow restriction coefficient is at least partly based on the flow loss through an aftercooler of the turbocharged engine.

26. The physical computer-readable medium of claim 21,

wherein the forecasting model includes an exponential model.

27. The physical computer-readable medium of claim 21,

wherein the code segments are operable for a plurality of turbocharged engines to determine when to service each of the turbocharged engines due to a flow restriction.

28. A physical computer-readable medium comprising a set of code segments to be executed by computing components to determine when to overhaul a turbocharger, the physical computer-readable medium comprising:

a code segment configured to calculate forecasted turbocharger turbine flow rate values associated with a plurality of future times necessary to power a compressor of the turbocharger;

a code segment configured to calculate forecasted waste gate flow rate values associated with the future times by subtracting forecasted values of turbine flow rate from corresponding forecasted values of turbocharger compressor flow rate; and

a code segment configured to calculate forecasted waste gate margin values associated with the future times by determining the ratio of forecasted values of waste gate flow rate to corresponding values of forecasted turbine flow rate.

29. The physical computer-readable medium of claim 28;

and

a code segment configured to report the future time when at least one of the forecasted values of the waste gate margin reaches a user-specified level.

30. The physical computer-readable medium of claim 28,

wherein the calculation of the forecasted turbocharger turbine flow rate is based on forecasted values of engine discharge coefficient.

31. The physical computer-readable medium of claim 30,

wherein the forecasted values of engine discharge coefficient are extrapolated from measured turbocharger performance data recorded over time.

32. The physical computer-readable medium of claim 28,

wherein the code segments are operable for a plurality of turbochargers to determine when to overhaul each of the turbochargers.