Systems and methods for maintaining load histories

• US 7,953,559 B2
• Filed: 09/16/2005
• Issued: 05/31/2011
• Est. Priority Date: 04/28/2005
• Status: Expired due to Fees

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Baskett, Jeffrey Dale, Patel, Nitin R., Sundermeyer, Jeffry Neil, Allgaier, Ryan Paul, Clarke, Burton Roland, Vik, Timothy Allen, Dunn, Daniel Kimsey III, Sit, Don, Kyuba, Hiroko, Truax, Byron Edwin
• Primary Examiner(s): Charioui; Mohamed
• Assistant Examiner(s): Suarez; Felix E
• Application Number:
  US11/227,269
• Publication Number:
  US 20060243056A1
• Time in Patent Office: 2,083 Days
• Field of Search: 702/19, 702/23, 702/55, 702/85, 702/120, 702/121, 702/184, 737/60, 374/14, 701/50
• US Class Current: 702/33
• CPC Class Codes: G01N 2203/0073 Fatigue
• CPC Class Codes: G01N 3/32 by applying repeated or pulsating forces

Abstract

Methods and systems for constructing a load history database for a structure is disclosed. In one embodiment, a method is disclosed that may include detecting a measurable parameter on the structure utilizing a sensor positioned on the structure and determining a value of external loads acting upon the structure based on the detected parameter. Further, the method may include evaluating the value of the external loads against a pre-established factor. Based on the evaluation, the value of the external loads are selectively stored in the load history database.

Claims

1. A method of constructing a load history database for a structure, comprising:

detecting a measurable parameter on the structure utilizing a sensor positioned on the structure;

determining a value of external loads acting upon the structure based on the detected parameter;

evaluating the value of the external loads against a pre-established factor;

selectively storing the value of the external loads in the load history database based upon the evaluation against the pre-established factor, wherein selectively storing the value of the external loads includes storing the value of the external loads acting on the structure during a determined period of time; and

determining a damage rate of the structure based upon the value of the external loads over the determined period of time.

2. A system for constructing a loading history database for a structure, comprising:

a plurality of sensors positioned on the structure and configured to detect a measurable parameter of the structure;

a processor; and

a memory component storing program code executable by the processor, the processor executing the program code to;

determine a value of external loads acting upon the structure based upon the detected parameter,

evaluate the value of the loads against a pre-established factor,

selectively store the value of the loads in the loading history database based upon the evaluation against the pre-established factor;

store the value of the external loads acting on the structure during a determined period of time; and

determine a damage rate of the structure based upon the value of the external loads over the determined period of time.

3. The system of claim 2, wherein the processor executes the program code to generate a histogram showing the damage rate.

4. A system for constructing a loading history database for a structure, comprising:

a plurality of sensors positioned on the structure and configured to detect a measurable parameter associated with the structure;

a memory component configured to maintain data indicative of a previously stored lifetime maximum external load value and a lifetime minimum external load value applied to the structure; and

a processor configured to detect at least one of a new lifetime maximum external load value and a lifetime minimum external load value acting upon the structure, and configured to update the memory component to replace at least one of the previously stored lifetime maximum load value and the minimum load value with the new lifetime maximum load value and minimum load value, respectively.

5. The system of claim 4, wherein the processor is configured to store all the loads acting on the structure in the memory component when the processor detects at least one of the new lifetime maximum and lifetime minimum external load value.

6. A system for constructing a loading history database for a structure, comprising:

a plurality of sensors positioned on the structure and configured to detect a measurable parameter of the structure;

a memory component configured to maintain data indicative of a previously stored loading scenario at a desired percentile of damage rate severity for the structure; and

a processor configured to detect a new loading scenario that has data having a closer data relationship with the desired percentile of damage rate severity for the structure than the previously stored loading scenario, and configured to update the memory component to replace the previously stored loading scenario with the new loading scenario based on the detection.

7. The system of claim 6, wherein the previously stored loading scenario and the new loading scenario include loads applied to the structure over a period of time.

8. The system of claim 6, wherein the processor and memory component are configured to generate a histogram showing the damage rate.

9. A method of constructing a loading history database for a mobile machine, comprising:

detecting a measurable parameter of the mobile machine with a plurality of sensors permanently positioned onboard the mobile machine during operation of the mobile machine;

maintaining stored data reflecting a previously stored lifetime maximum external load and a lifetime minimum external load acting upon the mobile machine that was caused by operation of the mobile machine;

analyzing the measurable parameter to detect a new lifetime maximum external load or a lifetime minimum external load acting upon the mobile machine that is caused by operation of the mobile machine;

updating a memory component to replace the previously stored lifetime maximum or minimum load with the new lifetime maximum or minimum load when the new lifetime maximum or minimum external load acts upon the mobile machine;

maintaining data indicative of a previously stored loading scenario at a desired percentile of damage rate severity for the mobile machine;

monitoring the measurable parameter to detect a new loading scenario that agrees more closely with the desired percentile of damage rate severity for the mobile machine than the previously stored loading scenario; and

updating the memory to replace the previously stored loading scenario with the new loading scenario when the new loading scenario agrees more closely with the desired percentile of damage rate severity for the mobile machine than the previously stored loading scenario.

10. The method of claim 9, wherein updating the memory component to replace the old lifetime maximum or minimum load includes storing instantaneous loads applied on the mobile machine.

11. The method of claim 9, wherein updating the memory component to replace the previously stored loading scenario with the new loading scenario includes storing loads over a period of time.

12. The method of claim 9, including analyzing the value of external loads acting on the mobile machine to perform at least one of:

determining a warranty price of the mobile machine;

evaluating damage to the mobile machine in relation to the coverage by the warranty;

tracking human operator performance of the mobile machine;

analyzing the mobile machine for abuse; and

redesigning the mobile machine.

13. The method of claim 11, wherein the period of time is bounded by a first time period corresponding to a triggering start event and a second time period corresponding to a triggering end event.

14. The method of claim 13, including detecting a classifiable operation performed by the mobile machine, wherein the triggering start event corresponds to the beginning of the classifiable operation performed by the mobile machine and the triggering end event corresponds to the ending of the classifiable operation performed by the mobile machine.

15. A method for managing a load history database for a mobile machine, comprising:

collecting measured data received from sensors positioned onboard the mobile machine during operation of the mobile machine;

determining a current damage rate caused by operation of the mobile machine based on the collected measured data;

determining a first relationship between the current damage rate and a predetermined target damage rate;

comparing the first relationship with a second relationship reflecting a relationship between a previously determined damage rate caused by operation of the mobile machine and the target damage rate, the second relationship being stored in the database; and

replacing in the database the second relationship with the first relationship based on the comparison.

16. The method of claim 15, further including:

populating a first load data structure with load data corresponding to measured data and the current damage rate; and

replacing a second load data structure including load data corresponding to the previously determined damage rate with the first load data structure based on the comparison between the first and second relationships.