System and method for detecting reciprocating device abnormalities utilizing standard quality control techniques

• US 9,803,567 B2
• Filed: 01/07/2015
• Issued: 10/31/2017
• Est. Priority Date: 01/07/2015
• Status: Active Grant

• Current Assignee: Ai Alpine Us Bidco LLC
• Original Assignee: General Electric Company
• Inventors: Bizub, Jeffrey Jacob
• Primary Examiner(s): West, Paul
• Assistant Examiner(s): Shabman, Mark A
• Application Number:
  US14/591,192
• Publication Number:
  US 20160195029A1
• Time in Patent Office: 1,028 Days
• Field of Search: None
• CPC Class Codes: F02D 2041/288 for performing a transformation into the frequency domain, e.g. Fourier transformation
• CPC Class Codes: F02D 35/027 using knock sensors
• CPC Class Codes: F02D 41/22 Safety or indicating devices for abnormal conditions in air/fuel ratio feedback systems F02D41/1495, in electric control linkage F02D11/107, in purge control systems F02M25/0809
• CPC Class Codes: G01L 23/221 for detecting or indicating knocks in internal combustion engines
• CPC Class Codes: G01M 15/042 by monitoring a single specific parameter not covered by groups G01M15/06 - G01M15/12
• CPC Class Codes: Y02T 10/30 Use of alternative fuels, e.g. biofuels
• CPC Class Codes: Y02T 10/40 Engine management systems

Abstract

A system includes a controller configured to receive a signal acquired by the at least one knock sensor coupled to a reciprocating device, to sample the received signal, to analyze the sampled signal, and to utilize standard quality control (SQC) techniques to perform real-time diagnostics on the reciprocating device based on the analyzed signal.

Claims

1. A system, comprising:

a combustion engine;

a controller comprising a memory and a processor and communicatively coupled to the combustion engine, wherein the controller is programmed to receive a signal acquired by at least one knock sensor coupled to the combustion engine, to sample the received signal, to temporal filter the sampled signal, to apply a fast Fourier transform to the temporal filtered signal to generate a Fourier transformed signal, to generate a power spectral density having a plurality of spectral bins from the Fourier transformed signal, to apply a weighted coefficient to each spectral bin of the plurality of spectral bins, to average each weighted spectral bin of the plurality of weighted spectral bins over a plurality of cycles to generate a respective baseline for each weighted spectral bin for use with a control chart, to utilize each weighted spectral bin as input into the control chart, to set 3 sigma threshold levels for each weighted spectral bin relative to the respective baseline for use with the control chart, to compare one or more weighted spectral bins associated with known combustion engine failures from the plurality of weighted spectral bins to their respective baselines and associated 3 sigma threshold levels, and to utilize statistical process control utilizing the control chart to perform real-time diagnostics on the combustion engine based on analysis of the received signal and to alter operation of the combustion engine when one or more weighted spectral bins deviate from their respective baselines by at least the 3 sigma threshold level.

2. The system of claim 1, wherein the controller is configured to temporal filter the sampled signal by utilizing a window function.

3. The system of claim 1, wherein the controller is configured to set 2 sigma threshold levels for each weighted spectral bin relative to its respective baseline.

4. The system of claim 3, wherein the controller is configured to compare one or more weighted spectral bins associated with known combustion engine failures from the plurality of weighted spectral bins to their respective baselines and associated 2 sigma threshold levels.

5. The system of claim 4, wherein the controller is configured to provide an indication if the one or more weighted spectral bins deviate from their respective baselines by at least the 2 sigma threshold level.

6. A method for performing real-time diagnostics on a combustion engine, comprising:

utilizing a controller having a memory and a processor and communicatively coupled to the combustion engine for;

receiving a signal from at least one knock sensor coupled to the combustion engine;

sampling the received signal;

temporal filtering the sampled signal;

applying a fast Fourier transform to the temporal filtered signal to generate a Fourier transformed signal;

applying a weighted coefficient to each spectral bin of the plurality of spectral bins;

averaging each weighted spectral bin of the plurality of weighted spectral bins over a plurality of cycles to generate a respective baseline for each weighted spectral bin for use with a control chart;

utilizing each weighted spectral bin as input into the control chart, to set 3 sigma threshold levels for each weighted spectral bin relative to the respective baseline for use with the control chart;

setting 3 sigma threshold levels for each weighted spectral bin relative to the respective baseline for use with the control chart;

compare one or more weighted spectral bins associated with known combustion engine failures from the plurality of weighted spectral bins to their respective baselines and associated 3 sigma threshold levels; and

utilizing statistical process control utilizing the control chart to perform real-time diagnostics on the combustion engine based on analysis of the received signal and to alter operation of the combustion engine when one or more weighted spectral bins deviate from their respective baselines by at least the 3 sigma threshold level.

7. The method of claim 6, wherein temporal filtering the sampled signal comprises applying a window function to sampled signal.

8. The method of claim 6, comprising setting 2 sigma threshold levels for each weighted spectral bin relative to its respective baseline.

9. The method of claim 8, comprising comparing one or more weighted spectral bins associated with known combustion engine failures from the plurality of weighted spectral bins to their respective baselines and associated 2 sigma threshold levels.

10. The method of claim 9, comprising providing an indication if the one or more weighted spectral bins deviate from their respective baselines by at least the 2 sigma threshold level.