SYSTEMS AND METHODS FOR MONITORING POWER SYSTEMS

• US 20140168433A1
• Filed: 12/19/2013
• Published: 06/19/2014
• Est. Priority Date: 06/03/2009
• Status: Active Grant

• Current Assignee: Teledyne FLIR LLC (Teledyne Technologies Incorporated)
• Original Assignee: FLIR Systems, Inc. (Teledyne Technologies Incorporated)
• Inventors: Frank, Jeffrey D., Nussmeier, Mark, Kurth, Eric A., Hgasten, Nicholas, Hoelter, Theodore R., Strandemar, Katrin, Boulanger, Pierre, Sharp, Barbara, Jepson, Shawn
• Granted Patent: US 9,756,262 B2
• Time in Patent Office: Days
• US Class Current: 348/143
• CPC Class Codes: B60Q 1/00 Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor for lighting vehicle interior B60Q3/00
• CPC Class Codes: H04N 23/57 Mechanical or electrical details of cameras or camera modules specially adapted for being embedded in other devices
• CPC Class Codes: H04N 5/33 Transforming infrared radiation cameras or camera modules for generating image signals from infrared radiation H04N23/20; circuitry of SSIS for transforming infrared radiation into image signals H04N25/20

Abstract

Techniques are disclosed for systems and methods using small form factor infrared imaging modules to monitor aspects of a power system. A system may include one or more infrared imaging modules, a processor, a memory, a display, a communication module, and modules to control components of a power system. Infrared imaging modules may be mounted on, installed in, or otherwise integrated with a power system having one or more power system components. The infrared imaging modules may be configured to capture thermal images of portions of the power system. Various thermal image analytics and profiling may be performed on the captured thermal images to determine the operating conditions and temperatures of portions of the power system. Monitoring information may be generated based on the determined conditions and temperatures and then presented to a user of the power system.

Claims

1. A system comprising:

an infrared imaging module positioned to view at least a portion of a component of a power system, the infrared imaging module comprising a focal plane array (FPA) configured to capture a thermal image of the portion of the component; and

a processor in communication with the thermal imaging module and configured to process the thermal image to generate monitoring information associated with the power system.

2. The system of claim 1, wherein:

the processor is configured to analyze the thermal image to determine a temperature of the portion of the component; and

the monitoring information comprises a notification based on the determined temperature.

3. The system of claim 1, wherein:

the processor is configured to analyze the thermal image to determine a condition of the power system associated with the portion of the component; and

the monitoring information comprises a notification based on the determined condition.

4. The system of claim 3, wherein:

the determined condition is a clogged or leaking water or oil cooling system condition, a malfunctioning water or oil pump condition, a leaking combustion chamber inlet or exhaust valve condition, a non-optimal air/fuel mixture condition, a failing bearing condition, an overheating combustion engine component or electric motor component condition, an exhaust system leak condition, a build-up of debris on an inner surface of a component condition, a failing high voltage (HV) battery condition, a component or power system load condition, a component wear condition, a component deformation condition, a component crack condition, a carbon monoxide leak condition, or a fuel leak condition.

5. The system of claim 1, wherein:

the system is configured to generate, based on the monitoring information, a control signal to adjust one or more power system components associated with the thermal image.

6. The system of claim 5, wherein:

the control signal adjusts an air/fuel mixture, a combustion chamber ignition state or timing, a turbo wastegate state, a turbo boost pressure, a charge or discharge of a high voltage battery, a charge or discharge rate of a high voltage battery, a crankcase heater voltage, a housing venting, a fan speed, a water or oil cooling system throughput, a transmission ratio, or a combustion or electric motor output power in accordance with the monitoring information.

7. The system of claim 1, wherein:

the infrared imaging module is mounted to or within;

the power system, a housing of the power system, the component of the power system, or the portion of the component.

8. The system of claim 1, wherein:

the power system comprises a combustion engine or an electric motor.

9. The system of claim 1, wherein:

the power system is used to provide mechanical power for a machine; and

the monitoring information is provided to a user of the machine.

10. The system of claim 9, wherein:

the machine is a land, water, or air based vehicle; and

at least a portion of the monitoring information is provided to the user while the user is using the machine.

11. The system of claim 1, further comprising a display configured to present the monitoring information to a user.

12. The system of claim 1, wherein:

the FPA comprises an array of microbolometers adapted to receive a bias voltage selected from a range of approximately 0.2 volts to approximately 0.7 volts.

13. The system of claim 12, wherein:

a size of the array of microbolometers is approximately 80 by 60; and

the infrared imaging module is adapted to be inserted into a socket having a size less than approximately 8.5 mm by 8.5 mm.

14. The system of claim 1, wherein:

the thermal image is an unblurred thermal image of the portion of the component;

the infrared imaging module is configured to capture an intentionally blurred thermal image of the portion of the component; and

the processor is configured to determine a plurality of non-uniform correction (NUC) terms based on the intentionally blurred thermal image and apply the NUC terms to the unblurred thermal image to remove noise from the unblurred thermal image.

15. A method comprising:

capturing, at a focal plane array (FPA) of an infrared imaging module, a thermal image of at least a portion of a component of a power system, the infrared imaging module positioned to view the portion of the component; and

processing the thermal image to generate monitoring information associated with the power system.

16. The method of claim 15, wherein:

the processing comprises analyzing the thermal image to determine a temperature of the portion of the component; and

the monitoring information comprises a notification based on the determined temperature.

17. The method of claim 15, wherein:

the processing comprises analyzing the thermal image to determine a condition of the power system associated with the portion of the component; and

the monitoring information comprises a notification based on the determined condition.

18. The method of claim 17, wherein:

the determined condition is a clogged or leaking water or oil cooling system condition, a malfunctioning water or oil pump condition, a leaking combustion chamber inlet or exhaust valve condition, a non-optimal air/fuel mixture condition, a failing bearing condition, an overheating combustion engine component or electric motor component condition, an exhaust system leak condition, a build-up of debris on an inner surface of a component condition, a failing high voltage (HV) battery condition, a component or power system load condition, a component wear condition, a component deformation condition, a component crack condition, a carbon monoxide leak condition, or a fuel leak condition.

19. The method of claim 15, further comprising:

generating, based on the monitoring information, a control signal to adjust one or more power system components associated with the thermal image.

20. The method of claim 19, further comprising:

adjusting, by the control signal, an air/fuel mixture, a combustion chamber ignition state or timing, a turbo wastegate state, a turbo boost pressure, a charge or discharge of a high voltage battery, a charge or discharge rate of a high voltage battery, a crankcase heater voltage, a housing venting, a fan speed, a water or oil cooling system throughput, a transmission ratio, or an electric motor power in accordance with the monitoring information.

21. The method of claim 15, further comprising:

mounting the infrared imaging module to or within;

the power system, a housing of the power system, the component of the power system, or the portion of the component.

22. The method of claim 15, wherein:

the power system comprises a combustion engine or an electric motor.

23. The method of claim 15, wherein the power system is used to provide mechanical power for a machine, the method further comprising:

providing the monitoring information to a user of the machine.

24. The method of claim 23, wherein the machine is at least one of a land, water, or air based vehicle, the method further comprising:

providing at least a portion of the monitoring information to the user while the user is using the machine.

25. The method of claim 15, further comprising:

displaying the monitoring information to a user.

26. The method of claim 15, wherein the FPA comprises an array of microbolometers, the method further comprising:

providing a bias voltage to the microbolometers selected from a range of approximately 0.2 volts to approximately 0.7 volts.

27. The method of claim 26, wherein:

a size of the array of microbolometers is approximately 80 by 60; and

the infrared imaging module is adapted to be inserted into a socket having a size less than approximately 8.5 mm by 8.5 mm.

28. The method of claim 15, wherein the thermal image is an unblurred thermal image of the portion of the component, the method further comprising:

capturing an intentionally blurred thermal image of the portion of the component;

determining a plurality of non-uniform correction (NUC) terms based on the intentionally blurred thermal image; and

applying the NUC terms to the unblurred thermal image to remove noise from the unblurred thermal image.