System and method for a compressor

• US 9,677,556 B2
• Filed: 04/19/2013
• Issued: 06/13/2017
• Est. Priority Date: 04/20/2012
• Status: Active Grant

• Current Assignee: GE Global Sourcing LLC (Westinghouse Air Brake Technologies Corporation)
• Original Assignee: General Electric Company
• Inventors: Worden, Bret Dwayne, Peoples, Richard C., Peterson, David E., Strode, Jason M., Burkell, Neil W., Karunaratne, Milan
• Primary Examiner(s): KRAMER, DEVON C
• Assistant Examiner(s): Hansen, Kenneth J
• Application Number:
  US13/866,670
• Publication Number:
  US 20130294938A1
• Time in Patent Office: 1,516 Days
• Field of Search: 417 12, 417 13, 417 18, 417 22, 417253, 417255, 417 53, 417252
• CPC Class Codes: F04B 2201/0605 Leakage over a valve
• CPC Class Codes: F04B 2205/063 in a reservoir linked to the pump outlet
• CPC Class Codes: F04B 23/02 having reservoirs
• CPC Class Codes: F04B 25/00 Multi-stage pumps
• CPC Class Codes: F04B 41/02 having reservoirs
• CPC Class Codes: F04B 49/02 Stopping, starting, unloading or idling control
• CPC Class Codes: F04B 49/022 by means of pressure
• CPC Class Codes: F04B 49/065 and making use of computers
• CPC Class Codes: F04B 49/10 Other safety measures
• CPC Class Codes: F04B 51/00 Testing machines, pumps, or pumping installations
• CPC Class Codes: F15B 19/005 Fault detection or monitoring
• CPC Class Codes: F16K 37/0091 by measuring fluid parameters
• CPC Class Codes: G01M 3/2876 for valves G01M3/30 takes precedence

Abstract

Systems and methods of the invention relate to diagnosing a compressor. A method may include operating a compressor to compress air from a first stage compressor into an intermediate stage reservoir, to deliver air from the intermediate stage reservoir to a second stage compressor, and to further compress the air in the second stage compressor into a primary reservoir, monitoring an intermediate stage pressure of the intermediate stage reservoir, and identifying a condition of the compressor through recognition of a change in the monitored intermediate stage pressure during a time period in which the compressor is operated. A vehicle system is also provided including an engine, a compressor operatively connected to the engine, and a controller that is operable to identify a condition of the compressor.

Claims

1. A method for a compressor system, comprising:

operating the compressor system to compress air from a first stage compressor into an intermediate stage reservoir, to deliver air from the intermediate stage reservoir to a second stage compressor, and to further compress the air in the second stage compressor into a primary reservoir;

monitoring an intermediate stage pressure of the intermediate stage reservoir; and

identifying a condition of the compressor system through recognition of a change in the monitored intermediate stage pressure during a time period in which the compressor system is operated relative to a stage of a cycle of the compressor system; and

generating a control signal in response to identifying the condition of the compressor system, wherein the control signal operates the compressor system or generates an alert.

2. The method of claim 1, further comprising filling the primary reservoir with compressed air to a determined pressure value, wherein the primary reservoir is configured to store compressed air to be provided to at least one pneumatic device.

3. The method of claim 1, wherein identifying the condition of the compressor system further comprises correlating the monitored intermediate stage pressure and an indication of a position of a piston in a cylinder of the compressor system.

4. The method of claim 3, wherein identifying the condition of the compressor system further comprises identifying a condition of the cylinder based on the correlation of the intermediate stage pressure and the indication of the position of the piston in the cylinder of the compressor system.

5. The method of claim 1, wherein the change in the monitored intermediate stage pressure is recognized by:

calculating an average of the intermediate stage pressure over the time period; and

comparing the average intermediate stage pressure over the time period to a nominal intermediate stage average pressure.

6. The method of claim 5, further comprising identifying the nominal intermediate stage average pressure from at least one of ambient air temperature or ambient air pressure.

7. The method of claim 5, further comprising identifying the nominal intermediate stage average pressure from at least one of compressor speed, primary reservoir pressure, or oil temperature.

8. The method of claim 1, wherein identifying the condition of the compressor system comprises identifying a faulty exhaust valve of a low pressure cylinder.

9. The method of claim 1, wherein identifying the condition of the compressor system comprises identifying a piston blow-by condition of at least one cylinder of the compressor.

10. The method of claim 1, wherein identifying the condition of the compressor system comprises identifying an intake valve failure of a high pressure cylinder.

11. The method of claim 1, wherein the alert comprises one or more of an audio alarm, a visual alarm, a text message, an email, an instant message, or a phone call.

12. The method of claim 1, wherein the control signal operates the compressor system to reduce a duty cycle of the compressor system.

13. A system comprising:

a compressor system comprising;

a first stage compressor configured to compress air into an intermediate stage reservoir at a first pressure, and a second stage compressor configured to receive air from the intermediate stage reservoir at the first pressure and further compress the air into a primary reservoir of the compressor system at a second pressure, wherein the second pressure is greater than the first pressure; and

a controller configured to;

receive a signal corresponding to a monitored intermediate stage pressure of the intermediate stage reservoir of the compressor system; and

identify a condition of the compressor system through recognition of a change in the monitored intermediate stage pressure during a time period in which the compressor system is operated relative to a stage of a cycle of the compressor system; and

generate a control signal in response to the condition of the compressor system that is identified, wherein the control signal operates the compressor system or generates an alert.

14. The system of claim 13, wherein the compressor system is a two-stage compressor system, and wherein the intermediate stage reservoir is disposed between at least one low pressure cylinder and at least one high pressure cylinder.

15. The system of claim 13, wherein the controller is further configured to recognize the change in the monitored intermediate stage pressure based on the monitored intermediate stage pressure as correlated to an indication of a position of a piston in a cylinder of the compressor system.

16. The system of claim 13, wherein the condition of the compressor system identified is a condition of a cylinder of the compressor system, identified based on a correlation of the intermediate stage pressure to an indication of a position of a piston in the cylinder of the compressor system.

17. The system of claim 13, wherein the controller is further configured to recognize the change in the monitored intermediate stage pressure by:

calculating an average of the intermediate stage pressure over the time period; and

comparing the average intermediate stage pressure over the time period to a nominal intermediate stage average pressure.

18. The system of claim 13, wherein the controller is further configured to communicate with one or more intermediate stage pressure sensors and receive the signal corresponding to the monitored intermediate stage pressure from the one or more intermediate stage pressure sensors.

19. The system of claim 13, wherein the condition of the compressor system is a blow-by condition of at least one cylinder of the compressor system.

20. The system of claim 13, wherein the condition of the compressor system is a cylinder valve failure.

21. The system of claim 13, wherein the intermediate stage reservoir comprises an intercooler.

22. The system of claim 13, wherein the controller is configured to generate the control signal for controlling the compressor system to reduce a duty cycle of the compressor system.

23. The system of claim 13, wherein the controller is configured to generate the control signal for generation of the alert, the alert comprising one or more of an audio alarm, a visual alarm, a text message, an email, an instant message, or a phone call.