Operational parameter recording device and method comprising at least a sensor attached to an assembly

Abstract

An operating parameter recording device comprises at least sensors, a central control unit and a remote server, each sensor comprising at least a measuring device determining an operating parameter, at least a power supply, a communication device, a memory and a processing device, the memory comprising at least a sensor identifier, the processing device commanding the communication device to send the sensor identifier to the central control unit, a start time of the assembly being determined within the processing device of the sensor and sent to the central control unit together with the sensor identifier or determined within the processing device of the central control unit, the determination of the start time being based on the operating parameter and on a predetermined threshold value for the operating parameter, the central control unit storing the start time together with the sensor identifier in a data table for each sensor identifier, the central control unit determining the operating duration for each assembly from the recorded start time for each sensor identifier and from paired data recorded on the remote server.

Description

Technical Field

[0001] This invention relates to an apparatus for determining operating parameters of a machine or system. Background Technology

[0002] Most complex systems contain a large number of components that may require maintenance at different times based on their respective mean time before failure (MTBF).

[0003] To gain a comprehensive understanding of the system and its maintenance, it is necessary to record the replacement of each component of the system. Such records should include the identifier of the replaced component (such as part number or serial number) and the start time of the operation.

[0004] Replacement components are typically identified using QR codes or etched or embossed numbers on each component.

[0005] To date, it is not possible to record the precise start time of operation for each component in a complex system. Furthermore, tracking maintenance requires input from maintenance personnel, which is prone to errors.

[0006] Therefore, there is a need for a recording device configured to track the start time of operation of each component and its replacement history. Summary of the Invention

[0007] The present invention provides an operating parameter recording device, which includes at least a sensor, a central control unit, and a remote server. The sensor is attached to a component, and the remote server is connected to the central control unit.

[0008] Each sensor includes a measuring device, at least a power supply, a communication device, a memory, and a processing device. The measuring device is configured to determine at least operating parameters.

[0009] The memory includes at least sensor identifiers, and the processing unit commands the communication unit to send the sensor identifiers to the central control unit.

[0010] The start time of a component is determined within the sensor processing unit and sent to the central control unit along with the sensor identifier, or the start time of a component is determined within the processing unit of the central control unit. The determination of the start time is based on at least one measured operating parameter and at least a predetermined threshold for the at least one measured operating parameter. The central control unit stores the start time along with the sensor identifier in a data table for each sensor identifier.

[0011] Then, the central control unit determines the operating duration for each component based on the recorded start time for each sensor identifier and the pairing data recorded on the remote server. The remote server links the sensor identifier to the component identifier that identifies the component to which the sensor is attached.

[0012] At least one operating parameter of the measurement can be sent to the central control unit along with the sensor identifier.

[0013] The operating parameters can be selected from position, velocity, acceleration, angle, rotational speed, rotational acceleration, rotational direction, elongation, temperature, presence of compound, resistance, current, voltage, or magnetic field.

[0014] A component can be part of a system, a complete system, or a device that includes multiple systems.

[0015] Component identifiers and sensor identifiers can be read and recorded in pairs on a remote server.

[0016] Component identifiers can be obtained from the component housing or surface via optical reading.

[0017] The component identifier can be obtained directly from the laser engraving unit's memory, or it can be set to be etched onto the component surface.

[0018] The sensor identifier can be obtained from the sensor housing via optical reading.

[0019] The sensor identifier can be obtained from the sensor's memory.

[0020] During component maintenance, the component identifier of the replacement component and the sensor identifier of the sensor fixed to the replacement component can be recorded as replacing the previous component identifier and sensor identifier.

[0021] Sensors, like sensor labels, can be essentially flat.

[0022] The sensor power source can be a power harvesting means that can be located in various places.

[0023] The component can be a bearing.

[0024] Another aspect of the present invention is an operation parameter recording method, which is used to record at least the operation parameters of a component using the operation parameter recording device described above.

[0025] The method includes the following steps:

[0026] -At least determine the operating parameters;

[0027] - The start time of the component is determined based on at least one measured operating parameter and at least a predetermined threshold for the at least one measured operating parameter;

[0028] - For each sensor identifier, store the component's start time along with the sensor identifier stored in the sensor's memory in the data table; and

[0029] - The duration of operation for each component is determined based on the start time recorded for each sensor identifier and the pairing data recorded on a remote server that links the sensor identifier to the component identifier that is attached to (or fixed to) the sensor.

[0030] The pairing data stored on the remote server can be determined using the following steps:

[0031] - Read both component identifiers and sensor identifiers during manufacturing or maintenance; and

[0032] - Record both component identifiers and sensor identifiers in pairs on a remote server.

[0033] Another aspect of the present invention is a bearing comprising at least one of the following elements: an inner ring, an outer ring, at least one row of rolling elements, at least one cage for maintaining the circumferential spacing of the rolling elements, and the bearing further comprising an operating parameter recording device as described above, the operating parameter recording device being attached to (or fixed to) one of the inner ring, the outer ring, the rolling elements, or the cage(s).

[0034] The device and method for recording operating parameters offer the following advantages.

[0035] Identifiers can be used to determine which components are integrated into the system.

[0036] The start time of operation can be identified in warranty agreements and warranty claim events, and maintenance can be tracked.

[0037] Allows invoicing based on data provided by one or more components in a performance-based framework. Attached Figure Description

[0038] The invention will be better understood by studying the detailed description of several embodiments considered in a completely non-limiting manner and illustrated by the accompanying drawings, in which only the appended figures are shown. Figure 1 The main components of the operating parameter recording device according to the present invention are shown. Detailed Implementation

[0039] The accompanying drawing shows an operational parameter recording device 1 according to the present invention, which includes at least a sensor 2, a central control unit 3, and a remote server 4.

[0040] During the production of the components, each sensor 2 is integrated into / at component 5.

[0041] Each component 5 includes a component identifier printed or engraved on the casing of component 5, in particular a serial number or QR code depending on the current state of the technology.

[0042] Each sensor 2 includes a sensor identifier (specifically an coded serial number), which is stored in memory and optionally printed or engraved on the housing of component 5. When each sensor 2 is within range of an authorized reader or central control unit 3, each sensor 2 sends ( / transmits) the sensor identifier stored in memory.

[0043] During the manufacturing of component 5, component identifiers and sensor identifiers are read and recorded in pairs on remote server 4.

[0044] Optical reading can retrieve component identifiers from the component housing or surface. Alternatively, the component identifier can be retrieved directly from the memory of the laser engraving unit, or configured to be etched onto the component housing or surface.

[0045] Similarly, optical reading can retrieve the sensor identifier from the sensor housing. Alternatively, the sensor identifier can be read from the memory of sensor 2 via wireless communication (especially RFID or NFC). The component identifier and sensor identifier are then recorded in pairs on a remote server 4.

[0046] During maintenance, component 5 is swapped with replacement component 5. The component identifier of replacement component 5 is read using an optical scanner. The sensor identifier of sensor 2, which is attached to replacement component 5, is obtained using an optical scanner or from the memory of sensor 2 via wireless communication (especially RFID or NFC).

[0047] The component identifier and sensor identifier are then recorded in pairs on the remote server 4. In a particular implementation, the component identifier and sensor identifier are also recorded to replace the previous component identifier and sensor identifier.

[0048] To facilitate the acquisition and recording of component identifiers for replacement components and their paired sensor identifiers, operators can use handheld sensors. These handheld sensors may include optical sensors, processing units, memory, and communication devices capable of establishing near-field communication (especially RFID or NFC) with sensor 2 and communication with a remote server 4.

[0049] The handheld sensor can acquire both component identifiers and sensor identifiers, pair them, and upload the resulting pairing information to a remote server 4. Because both sensor identifiers and component identifiers can be recorded simultaneously, the handheld sensor 2 reduces the risk of operational errors, especially when acquiring sensor identifiers via close-range wireless communication with the sensor 2 and optically reading component identifiers.

[0050] Once the pairing data is determined, the operation parameter recording device can continue to record at least one operation parameter of component 5.

[0051] As described above, the operating parameter recording device according to the present invention includes at least: a sensor 2, fixed to component 5 for monitoring; a central control unit 3, wirelessly connected to each sensor 2; and a remote server 4, connected to the central control unit 3. Component 5 may be part of a system, a system, or a device comprising several systems.

[0052] In a particular embodiment, sensor 2 is fixed to the bearing, wherein sensor 2 may be integrated into a cavity in the bearing ring or bearing surface, integrated into a cage, integrated into a seal, or integrated into a rolling element.

[0053] Sensor 2 includes a measuring device, at least a power supply, a communication device, a memory, and a processing device. In a particular embodiment, sensor 2, like a sensor tag, is substantially flat to limit encumbrance and avoid altering the operation of component 5 or the system to which component 5 is fixed. More specifically, when sensor 2 is fixed to a moving part, sensor 2 must not alter the physical properties of the part that might change its movement, such as weight, center of gravity, adhesion, etc.

[0054] The measuring device can at least determine the operating parameters of component 5. To determine the start time of operation, the measuring device can be selected from reed contacts, magnetic flowmeters, or Hall effect sensors. The measuring device can also measure other relevant operating parameters of component 5, such as temperature and vibration.

[0055] Both the processing unit and the power supply are connected to the measuring device and the communication device. This configuration enables sensor 2 to determine and record the start time of operation, and transmit this information, along with the sensor identifier, to the central control unit 3 via the communication device.

[0056] Sensor 2 includes its own power source or draws power from an energy source in the product environment (preferably, energy that is ubiquitous (e.g., radio waves of different frequencies)).

[0057] The power supply for sensor 2 can be transmitted from a source (such as Bluetooth, WLAN or mobile phone base station, RFID, Zigbee or radio waves) via central control unit 3.

[0058] The power source can be a ubiquitous power harvesting device (radio waves, RFID, Bluetooth, WLAN), a battery, a local energy harvesting device (piezoelectric, motion power), an electromagnetic power source, or a combination thereof.

[0059] Pervasive power harvesting devices generate electricity when at least partially immersed in an energy field of predetermined characteristics. Examples of pervasive power harvesting devices include inductive power sources that generate electricity from electromagnetic fields (i.e., Zigbee, Bluetooth, Wi-Fi, mobile phone networks, etc.).

[0060] The local energy harvesting device generates electricity by transferring a portion of the energy of component 5 to which the sensor is attached. It can be powered directly by utilizing the electricity tapped into the component or system, or by converting the potential or mechanical energy of the component or system into electricity (i.e., regenerative braking, potential energy conversion).

[0061] The processing device includes an integrated clock and is connected to a memory. The memory stores a sensor identifier and a predetermined threshold, which is compared with at least one operating parameter measured by a measuring device to identify the start time of operation.

[0062] In one embodiment, the processing device is configured to record an operation start time equal to the time stamp given by the integrated clock when the measured value received from the measuring device exceeds a predetermined threshold.

[0063] The processing unit instructs the communication unit to periodically send the operation start time, along with the sensor identifier, to the central control unit 3. Other measured operating parameters may also be periodically sent simultaneously with the transmission of the operation start time, or periodically sent along with the sensor identifier in their own transmissions.

[0064] In another embodiment, the processing device instructs the communication device to periodically send at least one measured operating parameter, along with a sensor identifier, to the central control unit 3. The central control unit 3 includes a memory, a communication device, and a processing device such as a processor or microcontroller.

[0065] In this implementation, the central control unit 3 receives at least a sensor identifier and a start-up time from the sensor 2, and connects to the remote server 4 to obtain pairing information linking each sensor identifier to a component identifier.

[0066] In another embodiment, the central control unit 3 receives at least a sensor identifier and at least one operating parameter. The processing device of the central control unit includes an integrated clock and is configured to record an operation start time equal to a timestamp given by the integrated clock when a measurement received from the sensor exceeds a predetermined threshold stored in memory.

[0067] In any embodiment, for each sensor 2, the central control unit 3 then records at least the start time transmitted by the sensor in a table linked to the component identifier. As described above, at least one operating parameter measured by the measuring device of the sensor 2, together with the component identifier, is recorded in the table or in a separate table on the same remote server 4 or on another server.

[0068] In a particular implementation, the central control unit 3 determines at least one performance value based on a predetermined rule and at least one value measured by the sensor 2. The performance value may be a key performance index (KPI).

[0069] In some implementations, the components and at least one sensor are part of the machine including the housing. It is known that, according to the Faraday effect, a housing (especially a metal housing) blocks all radio waves. Therefore, such a housing is often referred to as a Faraday cage. To allow communication from the sensor to reach the central control unit, an antenna can be connected to the sensor through a hole in the housing. Alternatively, the antenna can be configured as a repeater, which repeats the communication emitted by the sensor inside the housing from outside the housing.

[0070] In some other implementations, the central control unit is also housed within the housing. Communication between the sensors and the central control unit is not attenuated (or affected) by the housing. However, the central control unit's outgoing communication is similarly affected by the housing. Furthermore, openings in the housing allow for the mounting of physical connections or antennas for outbound communication.

[0071] Depending on the implementation, the component 5 equipped with sensor 2 can be part of a system, a complete system, or a device that includes multiple systems.

[0072] Therefore, the central control unit 3, which accesses the remote server 4, can explicitly assign the identified components one-to-one to the recording of sensor measurements, especially monitoring KPIs for operating time, operating temperature, or other operating conditions.

[0073] A product identifier is defined based on a combination of at least two component identifiers, a matching sensor identifier, and records of associated measurements, for a device used as part of a system, a complete system, or comprising multiple systems. The product identifier, along with the operation start time or operation duration recorded by the sensors, is a technical enabler based on the performance-based business model.

[0074] In other words, it is technically capable of generating invoices based on the actual operating time of component 5, or for products comprising multiple components whose operating times are recorded by sensors. It can also identify the start time of operation, which, among other things, is important for warranty agreements and warranty claims.

[0075] In addition, by linking different components, the maintenance of the system and / or its parts can be documented.

[0076] In a particular implementation, the central control unit 3 provides a pervasive energy field for powering each sensor 2 through its pervasive power collection devices.

Claims

1. An operating parameter recording device (1) comprising at least a sensor (2), a central control unit (3) and a remote server (4), wherein the sensor (2) is attached to a component (5) and the remote server (4) is connected to the central control unit (3). Each sensor (2) includes a measuring device, at least a power supply, a communication device, a memory, and a processing device, said measuring device being configured to at least determine operating parameters. The memory includes at least a sensor identifier, and the processing device commands the communication device to send the sensor identifier to the central control unit (3), wherein... The start time of component (5) is determined within the processing device of the sensor and sent to the central control unit along with the sensor identifier, or the start time of component (5) is determined within the processing device of the central control unit. The determination of the start time is based on at least one measured operating parameter and at least a predetermined threshold for the at least one measured operating parameter. The central control unit (3) stores the start time along with the sensor identifier in a data table for each sensor identifier. The remote server (4) links the sensor identifier to a component identifier that identifies the component (5) to which the sensor (2) is attached. Then, the central control unit (3) determines the operating duration for each component (5) based on the start time recorded for each sensor identifier and the pairing data recorded on the remote server (4).

2. The operating parameter recording apparatus according to claim 1, characterized in that At least one operating parameter of the measurement, together with the sensor identifier, is sent to the central control unit (3).

3. The operating parameter recording apparatus according to claim 1 or 2, characterized in that The operating parameters are selected from position, velocity, acceleration, angle, rotational speed, rotational acceleration, rotational direction, elongation, temperature, presence of a compound, resistance, current, voltage, or magnetic field.

4. The operating parameter recording apparatus according to claim 1 or 2, characterized in that The component (5) is part of the system, the complete system, or an apparatus comprising multiple systems.

5. The operation parameter recording apparatus according to claim 1 or 2, characterized by The component identifier and the sensor identifier are read and recorded in pairs on the remote server (4).

6. The operating parameter recording apparatus according to claim 1 or 2, characterized in that The power source for the sensor is a power collection device that is located in various locations.

7. The operating parameter recording apparatus according to claim 1 or 2, characterized in that The component (5) is a bearing.

8. A method for recording operating parameters, the method being used to record at least the operating parameters of component (5) using an operating parameter recording device according to any one of the preceding claims, the method comprising the following steps: -At least determine the operating parameters; - The start time of the component (5) is determined based on at least one operating parameter of the measurement and at least a predetermined threshold for at least one operating parameter of the measurement; - For each sensor identifier, the start time of the component is stored in a data table together with the sensor identifier stored in the memory of the sensor (2); as well as - The duration of operation for each component (5) is determined based on the start time recorded for each sensor identifier and the pairing data recorded on the remote server (4) that links the sensor identifier to the component (5) with the sensor (2) attached.

9. The operation parameter recording method according to claim 8, wherein The pairing data stored on the remote server (4) is determined by the following steps: - Read both the component identifier and the sensor identifier during manufacturing or maintenance; and - Record the component identifier and the sensor identifier in pairs on the remote server (4).

10. A bearing comprising at least one of the following elements: an inner ring, an outer ring, at least one row of rolling elements, and at least one cage for maintaining circumferential spacing of the rolling elements, the bearing further comprising an operating parameter recording device according to any one of claims 1 to 7, the operating parameter recording device being attached to one of the inner ring, the outer ring, the rolling elements, or the cage.

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