Connecting rod fault detection system and method

Abstract

Embodiments are disclosed herein for detecting deterioration of a connecting rod large end bearing within an internal combustion engine including a crankshaft and an exhaust manifold, the internal combustion engine incorporated on a vehicle. A method includes providing an electronic control unit coupled to an engine, a first set of sensors positioned adjacent to a crankshaft for detecting crankshaft acceleration, a second set of sensors positioned adjacent to an engine exhaust manifold for detecting engine exhaust manifold pressure, and a display component and an auditory component coupled to the electronic control unit. The display component and / or the hearing component is activated when the first set of sensors detects that the crankshaft acceleration during the power stroke is reduced compared to a previous acceleration of the crankshaft during the power stroke, and the second set of sensors detects that the exhaust manifold pressure does not statistically differ from the expected exhaust manifold pressure.

Description

Citation of Related Applications

[0001] This patent application claims the benefit of U.S. Patent Application No. 17 / 889,721, filed on August 17, 2022. That patent application is hereby incorporated by reference in its entirety. Technical Field

[0002] The present disclosure relates to systems and methods for detecting connecting rod faults in an internal combustion engine. Background Art

[0003] Deterioration of the connecting rod big end bearing in internal combustion engines such as spark ignition engines, compression ignition engines, etc. may lead to engine failure. For example, such engine failure may be dangerous to the driver of an internal combustion engine vehicle and the passengers in the vehicle. This is especially true when the driver does not have enough time to pull the vehicle out of traffic and shut down the engine.

[0004] The cause of connecting rod big end bearing deterioration and failure is insufficient oil lubrication between the connecting rod big end bearing and the associated crankpin journal.

[0005] Existing ways in which an operator of an apparatus including an internal combustion engine (or other engine) may be forewarned of connecting rod big end degradation include reduced engine power and an audible cue, commonly referred to as a knocking sound. In this case, the knocking sound is due to excessive movement of the connecting rod big end about the associated crankpin journal due to the extra space between the connecting rod big end bearing and the associated crankpin journal.

[0006] However, by the time this knocking sound is heard, the connecting rod may already be severely damaged. The costs associated with repairing a connecting rod damaged in this manner can be high. Furthermore, if a connecting rod damaged in this manner is not detected and addressed promptly, damage to the corresponding crankpin journal and crankshaft, as well as damage to the adjacent connecting rod and piston, may occur. Extensive deterioration of the connecting rod big end bearing of the connecting rod may even lead to catastrophic engine failure if not detected and addressed.

[0007] It would be desirable to provide systems and methods that include adequate detection and operator alerting of connecting rod big end bearing degradation and the risk of associated engine damage and failure. Summary of the invention

[0008] Embodiments of systems and methods for detecting degradation of a connecting rod big end bearing in an internal combustion engine contained on a vehicle, the internal combustion engine including a crankshaft and an exhaust manifold are disclosed herein. According to one embodiment, a system includes an electronic control unit connected to the engine. A first set of sensors for detecting crankshaft acceleration, the first set of sensors connected to the electronic control unit and positioned adjacent to the crankshaft. A second set of sensors connected to the electronic control unit and positioned adjacent to the engine exhaust manifold. A display component disposed on the vehicle and connected to the electronic control unit. An auditory component disposed on the vehicle and connected to the electronic control unit.

[0009] An embodiment of a method for detecting degradation of a connecting rod big end bearing in an internal combustion engine included on a vehicle and including a crankshaft and an exhaust manifold includes providing an electronic control unit connected to an engine disposed on the vehicle. A first set of sensors for detecting crankshaft acceleration is provided, the first set of sensors being connected to the electronic control unit and being positioned adjacent to the crankshaft. A second set of sensors for detecting engine exhaust manifold pressure is provided, the second set of sensors being connected to the electronic control unit and being positioned adjacent to the engine exhaust manifold. A display component and an audible component disposed on the vehicle and connected to the electronic control unit are provided. When the first set of sensors detects a decrease in crankshaft acceleration during a power stroke compared to a previous acceleration of the crankshaft during a power stroke, and the second set of sensors detects an exhaust manifold pressure that is not statistically significantly different from an expected exhaust manifold pressure, the display component and / or the audible component are activated. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a schematic diagram of an internal combustion engine incorporating embodiments of systems and methods for detecting connecting rod degradation as described herein. DETAILED DESCRIPTION

[0011] The following disclosure relates to a vehicle 1, such as a trailer, a truck, an automobile, a motorcycle, a locomotive, a water vehicle (such as a ship, a submarine, etc.), an aircraft, etc., including embodiments of a system and method for detecting degradation of a connecting rod 10 within an internal combustion engine 12 and for providing associated alarms for degradation of the connecting rod 10.

[0012] In order to clearly describe the components, features, and method steps discussed throughout this disclosure, some common terms will now be defined. The term "power stroke" used throughout this disclosure refers to the stroke of a piston in an internal combustion engine during which the associated piston is pushed toward the crankshaft by the pressure generated by the ignition of the fuel-air mixture. The term "normal" used throughout this disclosure means that there is no statistically significant difference from what is expected.

[0013] The cause of the deterioration of the connecting rod bearing is insufficient oil lubrication between the connecting rod big end bearing and the associated crankpin journal.

[0014] Deterioration of the connecting rod big end bearing may cause damage to the connecting rod big end bore, damage to the crankpin journal, and may cause cracking of the connecting rod. If not resolved, deterioration of the connecting rod big end bearing 14 of the connecting rod 10 may even cause engine failure.

[0015] The reduction in engine performance resulting from the degradation of the connecting rod big end bearing 14 may be reflected in the crankshaft engine speed. The degradation of the connecting rod big end bearing 14 may result in a reduction in crankshaft acceleration during the power stroke of the piston connected to the connecting rod 10 including the degraded connecting rod big end bearing 14. The analytical method for detecting fuel injection misfire in the internal combustion engine 12 can be used to detect the reduction in crankshaft acceleration due to degradation of the connecting rod big end bearing 14.

[0016] While misfire and degraded connecting rod big end bearing 14 may be substantially similar in terms of associated reductions in crankshaft acceleration during the power stroke, misfire and degraded connecting rod big end bearing 14 may be distinguished from one another based on data regarding engine exhaust manifold pressure.

[0017] When the deterioration of the connecting rod big end bearing 14 causes a decrease in crankshaft acceleration, the fuel is still burning normally. Therefore, the deterioration of the connecting rod big end bearing 14 does not cause a change in the engine exhaust manifold pressure. In contrast, when the decrease in crankshaft acceleration during the power stroke is caused by a fuel injection misfire, a transient decrease in exhaust manifold pressure may be observed.

[0018] refer to Figure 1 , a vehicle 1 is disclosed herein, which includes a system embodiment and a method embodiment for detecting degradation of a connecting rod big end bearing 14 in an internal combustion engine 12, and for providing a related alarm for degradation of the connecting rod 10. The system implemented by the present disclosure may include an electronic control unit (ECU) 16 operatively connected to the internal combustion engine 12 disposed on the vehicle 1.

[0019] Embodiments include a first set of sensors 20 for detecting acceleration of the crankshaft 18. The first set of sensors 20 may be communicatively coupled and operatively coupled to the ECU 16. The first set of sensors 20 may be positioned adjacent the crankshaft 18 of the internal combustion engine 12.

[0020] Embodiments may include a second set of sensors 22 for detecting engine exhaust manifold pressure. The second set of sensors 22 may be communicatively and operatively connected to the ECU 16. The second set of sensors 22 may be located adjacent to the engine 24.

[0021] Embodiments may include a display component 26 disposed on the vehicle 10 in any location accessible to a driver of the vehicle 10. The display component 26 may be operably connected to the ECU 16. As further described below, the display component 26 may be configured to send a visual alert of degradation of the connecting rod 10 when activated. In some embodiments, the ECU 16 may send a suitable signal by wire or wirelessly to the display component 26 that resides locally, such as to a smartphone used by a driver of the vehicle 1, or to the vehicle 1 remotely, such as to a fleet manager, a maintenance facility, or the like.

[0022] Embodiments may include an auditory component 28, such as a longitudinal wave transmitter, such as a speaker, etc., disposed at a suitable location on the vehicle 1. The auditory component 28 is operably connected to the ECU 16. As further described below, when activated, the auditory component 28 may emit longitudinal waves, such as an auditory signal.

[0023] In an embodiment, the ECU 16 may activate at least one of the display component 26 and the audible component 28 when the ECU 16 receives a signal indicating that the following two conditions are simultaneously met: (i) the first set of sensors 20 detects a reduced acceleration of the crankshaft 18 in a degraded cylinder constituting the internal combustion engine 14 during the power stroke as compared to the acceleration of the same crankshaft 18 of other cylinders constituting the same internal combustion engine 14 at a given internal combustion engine 14 speed during the same power stroke; and (ii) the second set of sensors 22 detects an exhaust manifold pressure that does not deviate from nominal exhaust pressure data previously collected from a nominally operating internal combustion engine similar to the internal combustion engine 14. The deviation of the exhaust manifold pressure measured by the second set of sensors 22 from the nominal exhaust pressure data is statistically significant. In some embodiments, at least one of the display component 26 and the audible component 28 may not be activated unless and until the first two conditions are simultaneously met for one of a period of time including at least 1 minute, 1 minute 30 seconds, and 2 minutes.

[0024] When activated, the visual warning of the degradation of the connecting rod 10 transmitted by the display component 26 may include an electromagnetic wave transmitter such as red light, white light, green light and colored light, which is sufficiently prominent to be noticed by the operator of the vehicle 1 or other device including the internal combustion engine 12. Such electromagnetic wave transmitters may be activated intermittently, i.e., flashing. The frequency of such intermittent activation may increase in a manner substantially proportional to the time period during which the first two conditions are simultaneously met.

[0025] The embodiments disclosed and described herein may be used in conjunction with a method for mitigating the risk of premature failure of the internal combustion engine 12 .

[0026] According to another embodiment, the auditory component 28 may emit a longitudinal wave having a volume and a pitch. At least one of the volume and the pitch may vary in proportion to the duration for which the first two conditions are simultaneously met.

[0027] When the embodiments disclosed herein are implemented in a pre-existing vehicle 1, such implementation may be implemented by means of a software update to the existing ECU 16. The existing ECU 16 may receive data regarding the acceleration of the crankshaft 18 during the power stroke via signals transmitted by the first set of sensors 20. The existing ECU 16 may also receive data regarding the engine exhaust manifold pressure via signals transmitted by the second set of sensors 22.

[0028] In some embodiments, the vehicle 1 includes an instrument panel 30 controlled by the ECU 16. The instrument panel 30 can receive, analyze, and display data regarding the acceleration of the crankshaft 18 during the power stroke and regarding the engine exhaust manifold pressure. Upon receiving such data, the ECU 16 can analyze whether the acceleration of the crankshaft 18 has decreased during the power stroke. When analyzing whether the crankshaft acceleration has decreased during the power stroke, the ECU 16 can analyze whether there is a decrease in the average acceleration of the substantially intact connecting rod 10 and the connecting rod big end bearing 14 of the substantially intact connecting rod 10 during a defined period of time under substantially similar operating and environmental parameters.

[0029] Upon receiving data from the second set of sensors 22, the ECU 16 may analyze whether the engine exhaust manifold pressure is normal, i.e., the detected exhaust manifold pressure is not statistically significantly different from the expected exhaust manifold pressure. When analyzing whether the engine exhaust manifold pressure is normal, the ECU 16 may analyze whether there are any statistically significant differences in the engine exhaust manifold pressure. Upon receiving data from the first set of sensors 20 and the second set of sensors 22, and after performing the above analysis, the ECU 16 may then analyze whether the crankshaft acceleration during the power stroke and the normal engine exhaust manifold pressure are simultaneously reduced at any point in time. If both conditions are met at the same time, the ECU 16 may send a command signal to at least one of the display component 26 and the auditory component 28 to activate at least one of the display component 26 and the auditory component 28. At least one of the display component 26 and the auditory component 28 may be associated with the instrument panel 30. The ECU 16 may be programmable to send a signal to the display component 26, which may cause the display component 26 to send an alarm such as a light for the degradation of the connecting rod 10. The ECU 16 may be programmable to transmit a signal to the audible component 28 such that the audible component 28 transmits an audible signal.

[0030] The embodiments of the systems and methods described herein can be used in conjunction with not only internal combustion engine vehicles, but also any device or piece of equipment including an internal combustion engine having a crankshaft speed sensor and an exhaust manifold pressure sensor. In addition, the embodiments disclosed herein can also be used in other devices such as electric saws, lawn mowers, generators, etc., sometimes with appropriate modifications. Elements of one embodiment can be combined with elements of another embodiment to obtain additional embodiments.

Claims

1. A method for detecting degradation of a connecting rod big end bearing in an internal combustion engine comprising a crankshaft and an exhaust manifold, the internal combustion engine being incorporated on a vehicle, the method comprising the steps of: providing an electronic control unit operatively connected to the internal combustion engine disposed on the vehicle; providing a first set of sensors for detecting crankshaft acceleration, the first set of sensors being operatively connected to the electronic control unit and positioned adjacent the crankshaft of the internal combustion engine; providing a second set of sensors for detecting engine exhaust manifold pressure, the second set of sensors being operatively connected to the electronic control unit and positioned adjacent the engine exhaust manifold; providing a display component disposed on the vehicle, the display component being operably connected to the electronic control unit; providing an auditory component disposed on the vehicle, the auditory component being operatively connected to the electronic control unit; At least one of the display component and the auditory component is activated when the first group of sensors detects that the crankshaft acceleration during the power stroke is reduced compared to the previous acceleration of the crankshaft during the power stroke, and the second group of sensors detects that the exhaust manifold pressure is not statistically significantly different from the expected exhaust manifold pressure.

2. The method according to claim 1, characterized in that The display component includes an electromagnetic wave transmitter, and further includes the following steps: The electromagnetic wave transmitter is activated intermittently.

3. The method according to claim 1, characterized in that The hearing component includes a longitudinal wave transmitter, and further includes the following steps: At least one of the volume and pitch of the longitudinal waves emitted by the longitudinal wave emitter is changed.

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