SYSTEM AND METHOD FOR DETECTING CONNECTING ROD FAILURE

Abstract

Embodiments of a method for detecting deterioration of a connecting rod bearing in an internal combustion engine having a crankshaft and an exhaust manifold in a vehicle are described herein. A method includes providing an electronic control unit connected to the engine, a first set of sensors for sensing crankshaft acceleration disposed adjacent to the crankshaft, a second set of sensors for sensing engine exhaust manifold pressure disposed proximate the engine exhaust manifold, and a display component and an audible component connected to the electronic control unit.The display component and / or the audible component is activated when the first set of sensors detects a reduced 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 the expected exhaust manifold pressure.

Description

TECHNOLOGICAL AREA

[0001] The present disclosure relates to systems and methods for detecting connecting rod failures in an internal combustion engine. BACKGROUND

[0002] Wear of connecting rod bearings in internal combustion engines, such as spark-ignition engines, compression-ignition engines, and the like, can lead to engine failure. Such engine failure can pose a hazard to the driver of a vehicle with an internal combustion engine and to the vehicle's occupants. This is especially true if the driver does not have sufficient time to pull the vehicle out of traffic and turn off the engine.

[0003] One cause of connecting rod bearing deterioration and failure is insufficient oil lubrication between the connecting rod bearing and the associated crankpin bearing.

[0004] Existing means of warning the operator of an internal combustion (or other) engine-powered machine of connecting rod bearing deterioration include reduced engine power and audible cues, namely what is commonly referred to as a knocking noise. The knocking noise in such cases is caused by additional space between the connecting rod bearing and the associated crankpin journal, resulting in excessive movement of the connecting rod bearing around the associated crankpin journal.

[0005] However, by the time this knocking noise becomes audible, the connecting rod may already be significantly damaged. The cost of repairing such a damaged connecting rod can be substantial. Furthermore, if not promptly identified and repaired, a connecting rod damaged in this way can cause damage to the corresponding crankpin and crankshaft, as well as damage to adjacent connecting rods and pistons. If not identified and repaired, significant deterioration of a connecting rod's connecting rod bearings can even lead to catastrophic engine failure.

[0006] It is desirable to provide systems and procedures that enable adequate detection of connecting rod base bearing damage and the associated risk of engine damage and failure, and to adequately alert the operator. SUMMARY

[0007] Embodiments of a system and method for detecting connecting rod end bearing deterioration in an internal combustion engine having a crankshaft and exhaust manifold in a vehicle are described herein. According to one embodiment, a system includes an electronic control unit connected to the engine. A first set of sensors for sensing crankshaft acceleration is connected to the electronic control unit and located adjacent to the crankshaft. A second set of sensors is connected to the electronic control unit and located near the engine exhaust manifold. A display component is disposed on the vehicle and connected to the electronic control unit. An acoustic component is disposed on the vehicle and connected to the electronic control unit.

[0008] One embodiment of a method for detecting deterioration of a connecting rod bearing in an internal combustion engine having a crankshaft and an exhaust manifold included in a vehicle comprises providing an electronic control unit connected to the engine disposed in the vehicle; providing a first set of sensors for detecting crankshaft acceleration, connected to the electronic control unit and disposed adjacent to the crankshaft; providing a second set of sensors for detecting engine exhaust manifold pressure, connected to the electronic control unit and disposed proximate the engine exhaust manifold; and providing a display component and an audible component disposed on the vehicle and connected to the electronic control unit.Activating the display component and / or the audible component when the first set of sensors detects a reduced 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 the expected exhaust manifold pressure. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is an illustration of an internal combustion engine incorporating embodiments of a system and embodiments of a method for detecting connecting rod deterioration described herein. DETAILED DESCRIPTION

[0009] The following disclosure relates to a vehicle 1, such as a semi-trailer, a truck, a car, a motorcycle, a locomotive, a watercraft such as a boat, a submarine, and the like, an aircraft, and the like, with embodiments of a system and embodiments of a method for detecting deterioration of a connecting rod 10 in an internal combustion engine 12 and for issuing a corresponding warning upon deterioration of the connecting rod 10.

[0010] To clearly describe the components, features, and method steps discussed in this disclosure, some frequently used terms are now defined. The term "power stroke," as used in this disclosure, refers to a stroke of a piston in an internal combustion engine during which an associated piston is driven toward a crankshaft by the pressure generated by the ignition of a fuel-air mixture. The term "normal," as used in this disclosure, refers to the absence of a statistically significant deviation from what is expected.

[0011] One cause of connecting rod bearing deterioration is insufficient oil lubrication between the connecting rod base bearing and the associated crankpin.

[0012] Damage to the connecting rod bottom bearing can lead to damage to the connecting rod big-bore, damage to the crankpin, and possibly cracks in the connecting rod. If left untreated, damage to the connecting rod bottom bearing 14 of a connecting rod 10 can even lead to engine failure.

[0013] Reduced engine power caused by damage to a connecting rod bearing 14 may be reflected in the engine crankshaft speed. Damage to a connecting rod bearing 14 may result in reduced crankshaft acceleration during the power stroke of a piston connected to the connecting rod 10 having the damaged connecting rod bearing 14. Analytical methods for detecting fuel injection misfire in an internal combustion engine 12 may be used to detect reduced crankshaft acceleration due to deterioration of the connecting rod bearing 14.

[0014] While both a misfire and a defective connecting rod bearing 14 may be substantially similar in terms of the associated reduced crankshaft acceleration during a power stroke, a misfire and a defective connecting rod bearing 14 can be distinguished from one another using data on the engine's exhaust manifold pressure.

[0015] If the reduced crankshaft acceleration is due to damage to the connecting rod bearing 14, the fuel will still be burned normally. Therefore, deterioration of the connecting rod end 14 will not cause changes in engine exhaust manifold pressure. Conversely, if reduced crankshaft acceleration during a power stroke was caused by a fuel injection misfire, a momentary drop in exhaust manifold pressure may be observed.

[0016] Referring to Fig.1, a vehicle 1 is disclosed herein that includes embodiments of a system and embodiments of a method for detecting deterioration of a connecting rod bottom bearing 14 in an internal combustion engine 12 and providing an associated warning upon deterioration of the connecting rod 10. Systems enabled 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.

[0017] One embodiment includes a first set of sensors 20 for detecting the acceleration of the crankshaft 18. This first set of sensors 20 may be communicatively and operatively connected to the ECU 16. This first set of sensors 20 may be disposed proximate the crankshaft 18 of an internal combustion engine 12.

[0018] An embodiment may include a second set of sensors 22 for sensing engine exhaust manifold pressure. This second set of sensors 22 may be communicatively and operatively connected to the ECU 16. The second set of sensors 22 may be located proximate an engine 24.

[0019] An embodiment may include a display component 26 disposed on the vehicle 10 at a location accessible to the driver of the vehicle 10. The display component 26 may be operatively connected to the ECU 16. As described further below, the display component 26 may be configured to provide a visual warning of the deterioration of the connecting rod 10 when activated. In some embodiments, the ECU 16 may send a corresponding signal wired or wirelessly to the display component 26, which may be connected locally to the vehicle 1, for example, to a smartphone used by a driver of the vehicle 1, or remotely, for example, to a fleet manager, a repair shop, and the like.

[0020] One embodiment may include an acoustic component 28, such as a longitudinal wave transmitter, e.g., a loudspeaker, etc., arranged at a suitable location of the vehicle 1. The acoustic component 28 is connected to the controller 16. As described further below, the acoustic component 28 may emit a longitudinal wave, e.g., an acoustic signal, when activated.

[0021] In one embodiment, at least one of the display component 26 and the auditory component 28 may be activated by the ECU 16 when the ECU 16 receives a signal indicating that two conditions are simultaneously met: (i) the first set of sensors 20 detects a reduced acceleration of the crankshaft 18 of a deteriorating cylinder comprising the internal combustion engine 14 during a power stroke of that deteriorating cylinder compared to the acceleration of the same crankshaft 18 of other cylinders comprising the same internal combustion engine 14 during the same power stroke at a given speed of the internal combustion engine 14; and (ii) the second set of sensors 22 detects an exhaust manifold pressure that does not deviate from nominal exhaust pressure data previously detected from nominally running internal combustion engines similar to the internal combustion engine 14.The deviation of the exhaust manifold pressure measured by the second group of sensors 22 is statistically significant from the nominal exhaust pressure data. In some embodiments, at least one of the display components 26 and the audible component 28 may not be activated until both of the aforementioned conditions are met simultaneously for a period of at least one minute, one minute and 30 seconds, or two minutes.

[0022] The visual warning for the deterioration of the connecting rod 10 conveyed by the display component 26, when activated, may comprise an electromagnetic wave emitter, e.g., a red light, a white light, a green light, and a colored light sufficiently conspicuous to be perceived by an operator of the vehicle 1 or other device with an internal combustion engine 12. Such an electromagnetic wave emitter may be activated intermittently, i.e., flash. The frequency of such intermittent activation may increase substantially proportionally to the period of time during which the two aforementioned conditions are simultaneously met.

[0023] The embodiments disclosed and described herein may be used in connection with methods for reducing the risk of premature failure of an internal combustion engine 12.

[0024] According to another embodiment, the acoustic component 28 can emit a longitudinal wave with a volume and a pitch. The volume and / or pitch can vary proportionally to the duration during which the two aforementioned conditions are simultaneously met.

[0025] If an embodiment disclosed herein is implemented in an existing vehicle 1, such implementation may be accomplished through a software update to an existing control unit 16. The existing control unit 16 may receive data about the acceleration of the crankshaft 18 during a power stroke through a signal transmitted from the first group of sensors 20. The existing control unit 16 may further receive data about the engine's exhaust manifold pressure through signals transmitted from the second group of sensors 22.

[0026] In some embodiments, the vehicle 1 includes an instrument cluster 30 controlled by the ECU 16. The instrument cluster 30 may receive, analyze, and display data about the acceleration of the crankshaft 18 during a power stroke and about the exhaust manifold pressure of the engine. Upon receiving this data, the ECU 16 may analyze whether the acceleration of the crankshaft 18 has decreased during a power stroke. In analyzing whether the crankshaft acceleration has decreased during a power stroke, the ECU 16 may analyze whether there has been a decrease in the average acceleration that occurred during a defined period of time for a substantially intact connecting rod 10 and the connecting rod bottom bearing 14 of that substantially intact connecting rod 10 under substantially similar operating and environmental parameters.

[0027] After receiving the data from the second group of sensors 22, the ECU 16 can analyze whether the engine exhaust manifold pressure is normal, i.e., the sensed exhaust manifold pressure does not deviate statistically significantly from the expected exhaust manifold pressure. When analyzing whether the engine exhaust manifold pressure is normal, the ECU 16 can analyze whether there has been a statistically significant deviation in the engine exhaust manifold pressure. After receiving the data from the first group of sensors 20 and the second set of sensors 22 and after performing the analyses described above, the control unit 16 can then analyze whether, at any time, both a reduction in crankshaft acceleration during a power stroke and normal engine exhaust manifold pressure occurred simultaneously.If these two conditions are met simultaneously, the ECU 16 may send a command signal to at least one of the display components 26 and the audible component 28 to activate at least one of the display components 26 and the audible component 28. At least one of the display component 26 and the audible component 28 may be connected to the instrument cluster 30. The ECU 16 may be programmed to send a signal to the display component 26, which may cause the display component 26 to send an alarm, such as a light and the like, to the connecting rod 10 to indicate deterioration. The ECU 16 may be programmed to send a signal to the audible component 28 such that the audible component 28 sends an audible signal.

[0028] The embodiments of systems and methods described herein may be used not only in connection with internal combustion engine vehicles, but with any device or piece of equipment that includes an internal combustion engine with a crankshaft speed sensor and an exhaust manifold pressure sensor. Furthermore, an embodiment disclosed herein, sometimes with appropriate modifications, may be used with other equipment, such as a chainsaw, a lawnmower, a generator, and the like. An element of one embodiment may be combined with an element of another embodiment to obtain another embodiment.

Claims

A system for detecting the deterioration of a connecting rod bearing in an internal combustion engine having a crankshaft and an exhaust manifold in a vehicle, the system comprising: an electronic control unit operatively connected to the internal combustion engine arranged in the vehicle; a method for detecting the deterioration of a connecting rod bearing in an internal combustion engine having a crankshaft and an exhaust manifold in a vehicle, the method comprising the following steps: providing an electronic control unit operatively connected to the internal combustion engine arranged in the vehicle; providing a first set of crankshaft acceleration sensors connected to the electronic control unit and located near the crankshaft of the internal combustion engine;Providing a second set of sensors for sensing pressure in the engine exhaust manifold, operatively connected to the electronic control unit and located near the engine exhaust manifold; Providing an indicator component located on the vehicle and operatively connected to the electronic control unit; Providing an audible component in the vehicle and connected to the electronic control unit; Activating the indicator component and / or the audible component when the first set of sensors detects a reduced 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 the expected exhaust manifold pressure. The method of claim 1, wherein the display component comprises an electromagnetic wave transmitter, and further comprising the step of:intermittently activating the electromagnetic wave transmitter. The method of claim 1, wherein the acoustic component comprises a longitudinal wave emitter, and further comprising the step of:changing the volume and / or pitch of a longitudinal wave emitted by the longitudinal wave emitter.

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