Health monitoring systems and techniques for vehicle systems

• US 9,014,918 B2
• Filed: 10/12/2012
• Issued: 04/21/2015
• Est. Priority Date: 10/12/2012
• Status: Active Grant

• Current Assignee: Cummins Incorporated
• Original Assignee: Cummins Incorporated
• Inventors: Hagen, Eric L., Fox, Richard S., Ibekwe, Nkemjika, Smith, Malcolm L.
• Primary Examiner(s): Nguyen, John Q
• Assistant Examiner(s): Stroud, James E
• Application Number:
  US13/650,440
• Publication Number:
  US 20140107885A1
• Time in Patent Office: 921 Days
• Field of Search: 701/29.4, 701/33.8, 701/34.3, 701/117, 701/36, 701/39, 701/44, 701/45, 701/46, 701/47, 701/48, 701/49, 701/70, 701/75, 701/77, 701/79, 701/81, 701/83, 701/84, 701/85, 701/86, 701/90, 701/92, 701/91, 701/93, 701/97, 701/98, 701/99, 701/100, 701/101, 701/102, 701/103, 701/104, 701/105, 701/106, 701/107, 701/108, 701/109, 701/110, 701/111, 701/112, 701/114, 701/115, 701/116, 701/123, 701/29.1, 701/29.2, 701/29.3, 701/29.5, 701/29.6, 701/29.7, 701/29.8, 701/29.9, 701/30.1, 701/30.2, 701/30.3, 701/30.4, 701/30.5, 701/30.6, 701/30.7, 701/30.8, 701/30.9, 701/31.1, 701/31.2, 701/31.3, 701/31.4, 701/31.5, 701/31.6, 701/31.7, 701/31.8, 701/31.9, 701/32.1, 701/32.3, 701/32.4, 701/32.5, 701/32.6, 701/32.7, 701/32.8, 701/32.9, 701/33.1, 701/33.2, 701/33.3, 701/33.4, 701/33.5, 701/33.6, 701/33.7, 701/33.9, 701/34.1, 701/34.2, 701/34.4, 73/350.4, 73/350.6, 73/350.9, 73/351.2, 73/351.3, 73/451, 73/452, 73/458
• US Class Current: 701/42
• CPC Class Codes: G07C 5/006 Indicating maintenance
• CPC Class Codes: G07C 5/008 communicating information to a remotely located station transmission systems for measured values G08C

Abstract

Systems and methods for monitoring health of one or more subsystems of a vehicle system are disclosed. At least one sensor can be operatively coupled to a vehicle subsystem having an operational signature and a control system is coupled to the at least one sensor. Using information provided by the at least one sensor, the control system is structured to generate a reference signature of the subsystem during a learning phase and an operational signature of the subsystem subsequent to the learning phase. Systems and methods for identifying the particular subsystem exhibiting degraded performance are also disclosed.

Claims

1. A system comprising:

a powertrain for a vehicle system including a plurality of associated subsystems;

each of the subsystems including at least one sensor, the sensors being structured to generate operational values associated with the respective subsystem to which each sensor is coupled;

a control system of the vehicle system coupled to each of the sensors, the control system including an engine control module including a signal processing system with an electronic filter, the control system configured to;

initiate a learning phase of powertrain and subsystem operation in response to one or more of a start-up of the vehicle system and a start-up of the respective subsystem;

generate a reference signature for each of the subsystems based on the operational values generated by the associated sensor during the learning phase, wherein each of the reference signatures includes a learned normal average, a learned maximum, and a learned minimum of the operational values of the associated subsystem over the learning phase;

update a learned reference signature for at least one of the subsystems in a second learning phase of subsystem operation initiated in response to a re-set flag input into the engine control module corresponding to a deployment of the powertrain in a different application;

record the reference signatures for each of the subsystems in a memory of the control system;

generate an operational signature for each of the subsystems during operation of the powertrain subsequent to the second learning phase, wherein the operational signatures each include a filtered running average of recent operational values, a maximum of the operational values, and a minimum of the operational values of the subsystem generated by the at least one sensor since the second learning phase;

record the operational signatures for each of the subsystems in the memory; and

output the operational signatures and the reference signatures.

2. The system of claim 1, wherein at least one of the plurality of subsystems is an exhaust gas recirculation subsystem and the at least one sensor operatively coupled thereto is structured to monitor an exhaust gas recirculation flow during operation of the powertrain.

3. The system of claim 2, wherein the at least one sensor comprises a flow meter.

4. The system of claim 1, wherein the control system comprises:

a diagnostic monitor structured to receive inputs of the operational values of the subsystems from the sensors; and

a health monitoring system coupled to the diagnostic monitor structured to receive the operational values of the subsystems from the diagnostic monitor, generate the reference signature and the operational signature for each of the subsystems, and output the reference signatures and the operational signatures to the memory.

5. The system of claim 1, wherein the plurality of subsystems include two or more subsystems selected from the group consisting of:

an exhaust subsystem, an exhaust aftertreatment subsystem, an exhaust reductant dosing subsystem, an exhaust gas recirculation subsystem, a turbocharger subsystem, a fuel injection subsystem, a cooling subsystem, an accessory drive subsystem, a power generation subsystem, a power storage subsystem, a compressed air subsystem, and a lubrication subsystem.

6. A method, comprising:

receiving with an engine control module sensor information from at least one sensor operatively coupled to at least one subsystem of a vehicle system including a powertrain, the engine control module including a signal processing system with an electronic filter;

initiating a learning base of powertrain and subsystem operation with the engine control module in response to one or more of a start-up of the vehicle system and a start-up of the subsystem;

generating with the engine control module a reference signature for the at least one subsystem based on the sensor information output during the learning phase of operation, wherein the reference signature includes a minimum operational value, a maximum operational value and an average operational value of the at least one subsystem during the learning phase of powertrain operation;

updating with the engine control module at least one reference signature to replace a learned reference signature for the at least one subsystem in a second learning phase of subsystem operation, the second learning phase being initiated in response to a re-set flag input into the engine control module corresponding to deployment of the powertrain in a different application; and

recording with the engine control module, subsequent to the second learning phase, an operational signature of the at least one subsystem during powertrain operation of the vehicle system, wherein the operational signature includes a minimum operational value, maximum operational value, and a filtered running average of operational values of the at least one subsystem generated by the at least one sensor since the second learning phase.

7. The method of claim 6, further comprising:

comparing the operational signature with the reference signature; and

determining whether the operational signature indicates a subsystem service event by a deviation of the operational signature from the reference signature.

8. The method of claim 7, wherein the deviation includes at least one of the maximum operational values and the minimum operational values of the operational signature being greater than or less than, respectively, the maximum operational value and the minimum operational value of the reference signature.

9. The method of claim 7, wherein the deviation includes the filtered running average of operational values of the operational signature deviating from the average operational value of the reference signature, and the maximum operational values of the operational signature being less than the maximum operational value of the reference signature and the minimum operational values of the operational signature being greater than the minimum operational value of the reference signature.

10. The method of claim 6, wherein the reference signature is generated after a predetermined number of iterations of operation of the subsystem during the corresponding one of the learning phase and second learning phase.

11. A method, comprising:

powering operation of a vehicle system with a powertrain and a plurality of subsystems associated with the powertrain, the vehicle system including an engine control module that includes a signal processing system with an electronic filter, the signal processing system being operable to receive operational signals from the plurality of subsystems;

initiating a learn in phase of powertrain and subsystem operation with the engine control module in response to one or more of a start-up of the vehicle system and a start-up of the subsystem;

during the learning phase, learning a reference signature with the engine control module for each of the subsystems from the operational signals, wherein the reference signatures each include a minimum operational value, a maximum operational value, and an average operational value of the associated subsystem during the learning phase;

updating with the engine control module at least one reference signature to replace a learned reference signature for at least one of the plurality of subsystems in a second learning phase of subsystem operation, the second learning phase being initiated in response to a re-set flag input into the engine control module corresponding to deployment of the powertrain in a different application;

recording the reference signatures in a memory of the engine control module;

generating with the engine control module an operational signature for each of the subsystems during operation of the powertrain subsequent to the second learning phase, wherein the operational signatures each include a minimum operational value, a maximum operational value, and a filtered running average of operational values of the associated subsystem;

recording the operational signatures in the memory of the engine control module; and

identifying at least one of the subsystems for service by comparing the operational signature with the reference signature of each of the subsystems.

12. The method of claim 11, which includes updating the reference signature of the identified subsystem after servicing the subsystem.