Internal combustion engine monitoring system

Abstract

An internal combustion engine monitoring system may include a fluid filter disposed between at least one fluid inlet of the internal combustion engine and at least one of a fluid source or an ambient fluid environment. The at least one fluid sensor may be arranged to detect a plurality of indications of respective fluid pressures on the first side and the second side of the fluid filter under a plurality of respective engine operating conditions. The indication may be compared to its corresponding operating condition to assess the condition of the fluid filter and estimate its life.

Description

Technical Field

[0001] The present disclosure relates to internal combustion engines, such as those used for vehicle or stationary power generation. More specifically, the present disclosure relates to internal combustion engines for use with work machines such as excavators, crawler drills, crawler tractors, cold planers, pavers, graders, compactors, tractors, and stationary power generation systems or "gensets." The internal combustion engine may include a fluid filter to prevent contaminants from entering the engine. Background Art

[0002] Power for machinery, such as agriculture, industry, construction or other heavy machinery can be generated by an internal combustion engine. An internal combustion engine burns a mixture of air and fuel in a cylinder, and thereby generates a driving torque and power. Typically, an internal combustion engine may include an intake system that allows a certain volume of air to enter the engine cylinder. The fuel system can then supply a specified portion of fuel to the cylinder, which generates a driving torque and power when burned. A control system can be used to adjust the air-fuel mixture to help promote the desired combustion. An internal combustion engine may include a fluid filter to prevent contaminants from entering the engine. It is usually necessary to replace such a fluid filter to maintain the desired engine function and protect other parts of the engine from damage. Summary of the invention

[0003] This document describes an internal combustion engine monitoring system. The system can monitor the operating conditions of the engine to help predict the life or expected clogging events of a fluid filter, such as an air or fuel filter. For example, the system can include or use at least one fluid filter disposed between at least one fluid inlet of the internal combustion engine and at least one of a fluid source or an ambient fluid environment. The system can include a first fluid sensor arranged to receive a first indication of corresponding fluid pressures on a first side and a second side of the fluid filter under a first engine operating condition. For example, the first indication and the second indication of corresponding fluid pressures each include a plurality of corresponding fluid pressure measurements on the first side and the second side of the fluid filter over time.

[0004] In an example, the system may include a second fluid sensor, the second fluid sensor being arranged to receive a second indication of a corresponding fluid pressure on a first side and a second side of a fluid filter under a second engine operating condition. The system may include a processing circuit system, the processing circuit system being used to receive sensor data from the first fluid sensor and the second fluid sensor. The processing circuit system may determine a pressure differential across the first side and the second side of the fluid filter over time to estimate the fluid flow on the fluid filter. The processing circuit system may also adjust at least one parameter of the received first indication and the second indication of the corresponding fluid pressure to mitigate the difference attributable to the difference between the first engine operating condition and the second engine operating condition. The processing circuit system may then compare the adjusted first corresponding indication of the fluid pressure with the adjusted second corresponding indication of the fluid pressure. For example, the processing circuit system may estimate a time period during which the fluid pressure differential will exceed a threshold.

[0005] The system may include a user interface to display an alert indicating a condition of an engine fluid filter based on the monitored pressure differential, the alert being triggered by the processing circuitry based on a determination that the pressure differential exceeds a specified threshold differential. For example, a user interface may be included to display an alert including instructions to replace or clean the fluid filter when a plugging event of the fluid filter is anticipated.

[0006] In an example, the first engine operating condition and the second engine operating condition may include a first engine boost pressure and a second engine boost pressure, respectively. For example, the first engine boost pressure may be in the range of 0 kilopascals (kPa) to 50 kPa, and the second engine boost pressure may be greater than 100 kPa. In an example, the processing circuit system triggers an alarm, including generating an indication to replace or clean the fluid filter based on the differential slope exceeding a specified threshold. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In the accompanying drawings, which are not necessarily drawn to scale, like numbers may describe like components in different views. Like numbers with different letter suffixes may represent different examples of similar components. The accompanying drawings generally illustrate various embodiments discussed in this document by way of example and not limitation.

[0008] Figure 1 A work machine coupled to an internal combustion engine monitoring system is depicted according to one or more examples.

[0009] Figure 2 is a block diagram of an example of an internal combustion engine monitoring system for running an algorithm to estimate the condition of a fluid filter or predict a change date for a fluid filter.

[0010] Figure 3is a block diagram illustrating components of a computing machine for performing operations to estimate a condition of a fluid filter or predict replacement of a fluid filter.

[0011] Figure 4 is a diagram depicting a method for detecting a condition of a fluid filter of an internal combustion engine.

[0012] Figure 5A is a graph depicting measured air filter restriction versus boost pressure.

[0013] Figure 5B is a graph depicting measured air filter restriction versus time.

[0014] Fig. 6A is a graph depicting operations for predicting an estimated replacement date for a fluid filter.

[0015] Figure 6B is a graph depicting operations for predicting an estimated replacement date for a fluid filter.

[0016] Figure 7 Included are graphs of certain data parameters over time related to clogging of a fluid filter. DETAILED DESCRIPTION

[0017] Figure 1 A work machine connected to an internal combustion engine monitoring system according to one or more examples is depicted. The monitoring system 100 may include or be communicatively coupled to, for example, one or more internal combustion engines 104 (e.g., Figure 2 ). The internal combustion engine 104 may be used to generate electricity, such as for propulsion of a vehicle or other machine and / or for powering auxiliary equipment of a work machine such as a hydraulic system. For example, the internal combustion engine 104 may include one of several piston cylinder arrangements and configurations, including, for example, V-shaped engines, in-line engines, and horizontal opposed engines, as well as overhead cam and integral cam configurations. In examples, the internal combustion engine 104 may be used in stationary applications and with vehicles and / or machines, including those associated with various industries, including, for example, power generation (e.g., generators), oil exploration, construction, agriculture, forestry, transportation, material handling, waste management, and the like.

[0018] like Figure 1 As depicted in , the monitoring system 100 may include or be communicatively coupled to one or more work machines, such as an excavator 102. Examples of work machines 102 for use with the monitoring system 100 may include excavators, tractors, bulldozers, haulers, balers, pavers, mixer trucks, asphalt spreaders, off-highway trucks, wheel loaders, separators, compactors or rollers, stabilizer mixers, generators, and the like.

[0019] Monitoring system 100 may also include processing circuitry 106 for receiving data from one or more internal combustion engines. For example, individual work machines 102 may include a transceiver 108 that is communicatively coupled to one or more sensors of internal combustion engines 104 to transmit data to a remotely located processing circuitry 106. In another example, processing circuitry 106 may be located on individual work machines 102.

[0020] In an example, the work machine 102 may include a frame 110. The frame 110 may be supported on a plurality of wheels 112, and the wheels 112 may enable the work machine 102 to move across the surface of the terrain or operate in the environment. The work machine 102 may also include a control room 114 or an operator station, which may be located on the frame 110 for accommodating a transportation or propulsion system 118. The transportation or propulsion system 118 may be configured to enable the work machine 102 to move across the surface of the terrain or move in the environment. The propulsion system 118 may include an internal combustion engine 104, which may include one or more filters coupled to the internal combustion engine, such as a fuel filter, an air filter, or an oil filter. The combustion engine may have a power output component for providing power to other auxiliary systems (such as a hydraulic system) on the work machine, which may be operably coupled to one or more implements or other systems. In an example, the work machine 102 may include at least one power output (PTO), such as an electric motor or a generator, for providing power to the hydraulic system or other auxiliary energy absorbers. The PTO may be mechanically coupled to and operably engaged with the internal combustion engine 104 of the work machine 102. When the PTO is engaged and powered by the internal combustion engine 104, the PTO may be used to transfer energy (e.g., in the form of torque) from the internal combustion engine 104 to, for example, a hydraulic system and / or a ground engaging system 120. For example, the PTO may be used to power a hydraulic system, and the hydraulic system may be used to operate an implement attached thereto.

[0021] The work machine may include a ground engaging propulsion system 120. The ground engaging propulsion system 120 may be associated with the frame 110 and the wheels 112 and configured to interact with the terrain or environment in which the work machine 102 is operating. For example, the ground engaging ETC system 120 may include tires, treads, and tracks that interact with the surface. The ground engaging system 120 may be arranged to affect the movement capabilities of the work machine 102, for example, the ground engaging system 120 may be configured to provide traction, braking, and steering functions.

[0022] In an example, the work machine 102 may include a hydraulic system 122. The hydraulic system 122 may be powered by the internal combustion engine 104 of the work machine 102 and used to actuate any number of hydraulic implements, such as hydraulic actuators and hydraulic accessories. The hydraulic system 122 may be mechanically coupled to the internal combustion engine 104, for example, via a PTO and operably engaged therewith. The hydraulic system 122 may have a source of hydraulic fluid driven by a hydraulic pump powered by the PTO or otherwise powered by the internal combustion engine 104. The hydraulic system 122 may include one or more fluid filters for filtering or removing contaminants from the hydraulic fluid. The hydraulic system 122 may also include a hydraulic reservoir for storing hydraulic fluid.

[0023] In an example, the work machine 102 may include at least one work implement 124. The work implement 124 may be mechanically coupled and operably engaged with the frame 110 of the work machine 102, for example, near the control room 114 or operator station. The work implement 124 may include, for example, attachments, tools, or task-specific implements. For example, the work implement 124 may include attachments, such as pavers, saws, drills, booms, mowers, trenchers, etc., which are used to perform specific tasks associated with the work machine 102. The work implement 124 may also include any attachments or tools that can be used for building or construction applications, such as reaction compaction, vibratory compaction, compaction wheels, etc. The work implement 124 may also include various paddock and / or agricultural applications, such as rakes, tillage components, seeders, mowers, harvesters, brush mowers, etc.

[0024] Figure 21 is a block diagram of an example of an internal combustion engine monitoring system for running an algorithm to estimate the condition of a fluid filter or predict a replacement date for a fluid filter. In an example, an internal combustion engine 104 may be communicatively coupled to an equipment controller module (ECM) 120, which may be communicatively coupled to the internal combustion engine 104 and configured to receive data from at least one of the work machine 102 or the internal combustion engine 104 to control the operation of the internal combustion engine 104. The ECM 120 may also be communicatively coupled to a user interface located within the control room 114, for example, to issue an on-board diagnostic code, for example, related to a filter of the internal combustion engine 104. The ECM 120 may be connected to systems and components of the work machine 102 and be responsible for certain operations of the work machine, for example, power management, diagnostics, implement control, steering or other machine movement, etc. The ECM 120 may be configured to store on-board diagnostic code data, and the data may be transmitted from the ECM 120 and received by the processing circuit system 106 of the monitoring system 100. Additionally, ECM 120 may be communicatively coupled to one or more sensors (e.g., fluid sensor 126) to receive sensor data related to work machine 102 or internal combustion engine 104. ECM 120 may be communicatively coupled to transceiver circuitry (e.g., transceiver 108) to receive remote data for generating remote diagnostic codes or to assist in generating onboard diagnostic codes.

[0025] The transceiver 108 may be configured to communicate with the processing circuit system 106. The transceiver 108 may include a long-range wireless transceiver, such as a cellular, satellite, or Wi-Fi transceiver, and may receive data from a device communicatively coupled to the transceiver 108 via, for example, a cellular network, a satellite network, or a Wi-Fi network. The transceiver 108 may also include a short-range wireless transceiver, such as a Bluetooth transceiver, which may be used to communicate with other systems and components of the work machine 102 and / or with an external non-onboard transmission. In an example, the processing circuit system 106 may be located away from the work machine 102 and configured to act as a gateway for data transmission via network communication via the transceiver 108. The network may be a local area network, such as a cellular network, or a global communication network, such as the Internet. The network may communicatively couple the processing circuit system 106 with a remote / centralized server, which is operated, for example, by a manufacturing entity, a dealer, a maintenance technician, etc., responsible for the work machine 102. The server may include one or more databases that may store updated machine / component information, diagnostic information, replacement component information, analytical information, and machine / component operational data, among other things.

[0026] Typically, the internal combustion engine 104 can receive fluid from a source 132 (e.g., surrounding environment, reservoir, fuel tank, etc.) at a fluid inlet (e.g., air inlet, oil inlet, fuel inlet, etc.). Fluid can be filtered and / or otherwise adjusted by one or more filter components (e.g., air filter, oil filter, fuel filter, etc.). Fluid can flow from the filter component to the internal combustion engine 104 for combustion, and exhaust emissions can leave via an exhaust port. Therefore, the internal combustion engine 104 can be equipped with at least one fluid filter 134, which is arranged between the fluid inlet of the engine 104 and the source 132 for filtering fluid from the source 132. At least one fluid filter 134 may include a material for filtering or removing pollutants, particles or debris from the fluid. For example, at least one fluid filter 134 may include a mesh material, a porous material, an absorbent material, paper, a woven material, etc., or a combination thereof. In an example, at least one fluid filter 134 may include a replaceable filter element, which may be replaced by a user, an operator of the work machine 102, or a maintenance personnel.

[0027] The monitoring system 100 may include at least one fluid sensor 126 coupled to the internal combustion engine 104. The at least one fluid sensor 126 may be used to detect an indication of a fluid pressure corresponding to the fluid filter 134 under a certain engine operating condition. In an example, the monitoring system 100 may include a plurality of fluid sensors disposed on each side of the fluid filter 134 to jointly detect the indication. The at least one fluid sensor 126 may include, for example, an air filter differential pressure sensor, a fuel filter differential pressure sensor, an engine speed sensor, an engine oil pressure sensor, an engine oil temperature sensor, a fuel pressure sensor, a fuel temperature sensor, an ambient pressure sensor, an ambient temperature sensor, an exhaust gas temperature sensor, or a combination thereof. The at least one fluid sensor 126 may be configured to provide data corresponding to the operating condition of the internal combustion engine 104, and such data may be received by at least one of the processing circuit system 106 and the device controller module (ECM) 120, each of which may be communicatively coupled to the at least one fluid sensor 126.

[0028] In an example, the processing circuit system 106 can determine the pressure difference across the first side and the second side of the fluid filter 134 over time to estimate the fluid flow on the fluid filter 134. For example, the processing circuit system 106 can include a memory 128 coupled to the processor 130. The memory 128 can store software that, when executed by the processor 130, can enable the processing circuit system 106 to track operational information related to the internal combustion engine 104, such as boost pressure, fluid flow, engine speed, normal engine combustion, engine temperature, engine vibration, or any other metric of interest. The processing circuit system 106 can also determine the state of the internal combustion engine 104 related to, for example, the performance of the filter or the wear on the fluid filter 134 based on the data collected from the one or more first fluid sensors 126. The internal combustion engine monitoring system 100 can also include a user interface 138, which is used to display an alarm indicating the condition of the fluid filter 134, and the alarm can be triggered by the processing circuit system 106 based on the determined pressure difference of the fluid filter 134 or its slope exceeding a specified threshold difference. Although the algorithms are shown as being separate from the memory, it is to be understood that the algorithms may include computer-implemented instructions stored in the memory 128 and / or the algorithms may include software, hardware, or a combination of software and hardware configured to perform specific operations.

[0029] The algorithm 136 may use the data collected from the one or more first fluid sensors 126 to identify or predict a flow restriction of the fluid filter 134. Here, the algorithm 136 may be used to predict an estimated replacement date for the fluid filter 134. The algorithm 136 may be executed by the processor 130 of the processing circuit system 106. The algorithm 136 may include various functions and operations, such as a smoothing operation 202, a normalization operation 204, a slope analysis 206, an estimation operation 208, and a triggering operation 210. In an example, the "steady state" of the filter may be quantified based on, for example, a ~10 second moving variance of a normalized engine load (between about 30% load and about 90% load) and an engine speed (e.g., greater than about 1000 rpm) based on the following equation:

[0030]

[0031] The smoothing operation 202 can improve the results associated with short-term outlier conditions in the raw sensor data, thereby helping to derive more meaningful data related to the condition of a particular filter. The smoothing operation 202 can also reduce the conditioning time of the raw sensor data before the slope analysis 206. In an example, the smoothing operation 202 can take a moving average of the calculated slope over time, such as a time-weighted average, to weight certain data acquired recently. When the data is processed in downstream steps of the algorithm 136, the smoothing operation 202 can help limit the noise in the data.

[0032] In the example, comparing a time-based EWMA (where the moving average "look back" window is a time interval, such as 24 hours) to a sample-based EWMA (e.g., a "look back" window of 24 samples) can help the algorithm perform in situations where data samples are not collected regularly. The main difference between the EWMA and the moving average is that the EWMA may not involve a "real" window size, as in the case of the moving average. For example, in this article, where the EWMA "look back" window is a set time period (e.g., 24 hours), the algorithm can incorporate data beyond 24 hours when calculating the average. Here, the specified window size can be used to determine the weight factor to be used in the weighted average formula, so that the response is similar to a simple moving average that only looks at the past 24 hours. This can help the algorithm avoid the need to store an arbitrary number of samples that may have been acquired within a given 24 time period.

[0033] The normalization operation 204 can receive the smoothed output of the raw sensor data, thereby normalizing the range of values ​​associated with the sensor data. In an example, the normalization operation 204 can determine the maximum peak value of the smoothed output, which can then be normalized to within a predetermined range (e.g., between an upper limit and a lower limit). The normalized value can then be output for use in the slope analysis 206.

[0034] Slope analysis 206 can determine the rate of change of a series of continuous or discrete values ​​(e.g., a first normalized value and a second normalized value) associated with the filtered output of the raw sensor data. In an example, slope analysis 206 can compare a series of continuous or discrete values ​​(e.g., a first normalized value and a second normalized value), for example, within a user-defined "review" window associated with the normalized sensor data. Slope analysis 206 can compare the first normalized value (e.g., differential pressure) with the second normalized value, and determine whether the difference between the first normalized value and the second normalized value is within a given threshold. If so, slope analysis 206 can determine the rate of change associated with the normalized sensor data as being substantially constant, flat, or not increasing. In an example, slope analysis 206 can involve quantifying the limiting measurement value based on the first engine boost pressure and the second engine boost pressure of the corresponding measurement. In an example, the first engine boost pressure can be in the range of 0 kilopascals (kPa) to 50kPa, and the second engine boost pressure can be greater than 100kPa.

[0035] For example, where P0=limit at <20 kPa boost pressure, P1=limit at >about 120 kilopascals (kPa) boost pressure, X0=boost measurement of P0, and X1=boost measurement of P1, the slope analysis 206 may be performed based on the following equation:

[0036]

[0037] In the example, the time rate of change (ROC) can be calculated based on the following equation, where the 12-hour EWMA serves as the historical value:

[0038]

[0039] In another example, the ROC may be calculated based on the following equation, where the 24-hour EWMA serves as the historical value and the 2-hour EWMA serves as the current value:

[0040]

[0041] Subsequently, slope analysis 206 may output a trend indicator indicating that the rate of change of the normalized sensor data is substantially constant. The trend indicator may indicate, for example, that the sensor data indicates that the filter is not yet ready to be replaced.

[0042] Alternatively, if the difference between the first normalized value and the second normalized value is found to be outside a given threshold, the slope analysis 206 can determine the rate of change associated with the normalized sensor data to be substantially non-constant. Subsequently, the slope analysis 206 can output a trend indicator (e.g., a status signal) that can indicate, for example, that the sensor data indicates that the filter is ready to be replaced.

[0043] In an example, the estimation operation 208 may include an estimation algorithm capable of predicting or estimating an estimated rate of change of the normalized sensor data within a given amount of time. The estimation operation 208 may receive the normalized sensor data and may estimate the rate of change of the normalized sensor data at a future point relative to a current point of the normalized sensor data and then output an estimated change in the rate of change. The estimation may involve estimating the time until a threshold differential pressure is reached based on the following equation:

[0044]

[0045] In an example, the threshold differential pressure may be calculated based on the following equation:

[0046]

[0047] In another example, the threshold differential pressure may be determined to be within a range of about 90 kPa to about 110 kPa, such as about 100 kPa.

[0048] The trigger operation 210 may determine when to display an alarm or activate other components of the monitoring system 100 based on determining that the time until the threshold differential pressure is reached is less than a predetermined period, such as less than about 48 hours. If so, the trigger operation 210 may output data indicating an executable condition that a replacement of the fluid filter 134 is recommended. In an example, the trigger operation 210 may generate a recommended replacement alarm before activating an ECM diagnostic code indicating that a replacement of the fluid filter 134 is recommended. In an example, the algorithm 136 may calculate a filter replacement interval in the range of three to four weeks up to six months. In an example, for example, to verify the accuracy or precision of the algorithm 136, the algorithm 136 may also receive ECM data from the ECM 120 of the work machine 102 and use the ECM data to help estimate the condition of the filter 134, such as involving using the ECM data as a second indicator of the condition of the filter 134 or comparing the ECM data with the estimate from the trigger operation 210.

[0049] Figure 3 300 according to some exemplary embodiments, the machine is capable of reading instructions 324 from a machine storage medium 322 (e.g., a non-transitory machine storage medium, a machine storage medium, a computer storage medium, or any suitable combination thereof) and performing, in whole or in part, any one or more of the methodologies discussed herein. Specifically, Figure 3 A machine 300 is shown in the exemplary form of a computer system (e.g., a computer) in which instructions 324 (e.g., software, programs, applications, applet, app, or other executable code) for causing the machine 300 to perform any one or more of the methodologies discussed herein may be executed in whole or in part. For example, the instructions 324 may be processor-executable instructions that are executed by a processor of the machine 300 (e.g., included in a processor). Figure 1 and Figure 2 When executed in the processing circuit system 106 of the machine 300, the machine 300 performs the operations summarized above.

[0050] In alternative embodiments, the machine 300 is used as a standalone device, or can be communicatively connected (e.g., networked) to other machines. In a networked deployment, the machine 300 can operate in the capacity of a server machine or a client machine in a server-client network environment, or as a peer machine in a distributed (e.g., peer-to-peer) network environment. The machine 300 can be a server computer, a client computer, a personal computer (PC), a tablet computer, a laptop computer, a netbook, a cellular phone, a smart phone, a set-top box (STB), a personal digital assistant (PDA), a network appliance, a network router, a network switch, a network bridge, or any machine capable of sequentially or otherwise executing instructions 324, the instructions specifying the actions to be taken by the machine. In addition, although only a single machine is shown, the term "machine" should also be understood to include any collection of machines that individually or collectively execute instructions 324 to perform all or part of any one or more methods discussed herein.

[0051] The machine 300 includes a processor 302 (e.g., a central processing unit (CPU), a graphics processing unit (GPU), a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a radio frequency integrated circuit (RFIC), or any suitable combination thereof), a main memory 304, and a static memory 306 configured to communicate with each other via a bus 308. The processor 302 may include microcircuits that may be temporarily or permanently configured by some or all of the instructions 324, such that the processor 302 may be configured to perform, in whole or in part, any one or more of the methods described herein. For example, a set of one or more microcircuits of the processor 302 may be configurable to execute one or more modules (e.g., software modules) described herein.

[0052] The machine 300 may also include a graphics display 310 (e.g., a plasma display panel (PDP), a light emitting diode (LED) display, a liquid crystal display (LCD), a projector, a cathode ray tube (CRT), or any other display capable of displaying graphics or video). The machine 300 may also include an alphanumeric input device 312 (e.g., a keyboard or keypad), a cursor control device 314 (e.g., a mouse, a touch pad, a trackball, a joystick, a motion sensor, an eye tracking device, or other pointing instrument), a storage unit 316, an audio generating device 318 (e.g., a sound card, an amplifier, a speaker, a headphone jack, any suitable combination thereof, or any other suitable signal generating device), and a network interface device 320.

[0053] The storage unit 316 includes a machine storage medium 322 (e.g., a tangible and non-transitory machine storage medium) on which are stored instructions 324 that embody any one or more of the methods or functions described herein. The instructions 324 may also reside completely or at least partially within the main memory 304, within the processor 302 (e.g., within a cache memory of the processor), or both before or during execution by the machine 300. Thus, the main memory 304 and the processor 302 may be considered machine storage media (e.g., a tangible and non-transitory machine storage medium). The instructions 324 may be transmitted or received over a network 326 via the network interface device 320. For example, the network interface device 320 may transmit the instructions 324 using any one or more transmission protocols (e.g., the Hypertext Transfer Protocol (HTTP)).

[0054] In some exemplary embodiments, the machine 300 may be a portable computing device, such as a smartphone or tablet computer, and have one or more additional input components (e.g., sensors 328 or meters). Examples of additional input components include image input components (e.g., one or more cameras), audio input components (e.g., microphones), direction input components (e.g., compasses), position input components (e.g., global positioning system (GPS) receivers), orientation components (e.g., gyroscopes), motion detection components (e.g., one or more accelerometers), height detection components (e.g., altimeters), and gas detection components (e.g., gas sensors). Input collected by any one or more of these input components may be accessible and available for use by any of the modules described herein. Various memories (i.e., 304, 306, and / or memories of the processor 302) and / or storage unit 316 may store one or more sets of instructions and data structures (e.g., software) 324 that embody or are used by any one or more of the methods or functions described herein. These instructions, when executed by the processor 302, cause various operations to implement the disclosed embodiments.

[0055] As used herein, the terms "machine storage medium," "device storage medium," "computer storage medium" (collectively "machine storage medium 322") mean the same thing and may be used interchangeably in this disclosure. These terms refer to a single or multiple storage devices and / or media (e.g., centralized or distributed databases and / or associated caches and servers) that store executable instructions and / or data, as well as a cloud-based storage system or storage network that includes multiple storage devices or devices. Therefore, these terms should be considered to include, but are not limited to, solid-state memory and optical and magnetic media, including memory internal or external to the processor. Specific examples of machine storage media, computer storage media, and / or device storage media 322 include non-volatile memory, including, for example, semiconductor memory devices (e.g., erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM)), FPGAs, and flash memory devices; disks, such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The terms one or more machine storage media, one or more computer storage media, and one or more device storage media 322 explicitly exclude carrier waves, modulated data signals, and other such media, at least some of which are covered under the term "signal media" discussed below. In this context, machine storage media are non-temporary. The terms "signal media" or "transmission media" should be deemed to include any form of modulated data signals, carrier waves, etc. The term "modulated data signal" means a signal that sets or changes one or more of its characteristics in the transaction of encoding information in the signal. The terms "machine-readable medium", "computer-readable medium", and "device-readable medium" mean the same thing and can be used interchangeably in this disclosure. These terms are defined to include both machine storage media and signal media. Therefore, these terms include both storage devices / media and carrier waves / modulated data signals.

[0056] Industrial Applicability

[0057] This document describes a technique for predicting an estimated replacement date for a fluid filter, such as a fuel filter, an air filter, or an oil filter, included as part of an internal combustion engine of a work machine. In one method of monitoring the condition of a fluid filter, an engine control module (ECM) of an internal combustion engine can be configured to selectively display an onboard diagnostic code related to the fluid filter. Here, the ECM can indicate that the filter should be checked or replaced when a pre-calculated future event of an onboard diagnostic code is reached. The pre-calculated future event can include the filter reaching a fixed number or age of use, such as the number of engine operating hours, the number of engine starts, or a milestone, such as the number of miles driven. Once the engine control module indicates that the fluid filter should be checked or replaced, the operator of the work machine will typically contact a service provider to schedule service. This service will be able to confirm the code displayed by the ECM and assess whether the fluid filter does need to be replaced at the time of service. The challenge of this method is that such diagnostic codes may exhibit false inaccuracies or irrelevant warnings, for example, occurring at a frequency that causes the operator to begin ignoring or delaying scheduling service with a service provider. Such inaccuracies may occur because the pre-calculated future events cannot take into account significant changes in the engine operating conditions, such as those related to the surrounding environment or the mission of a particular work machine.

[0058] The present inventors have recognized a need for a method of dynamically and continuously evaluating a fluid filter and corresponding operating condition over time to provide more meaningful and clearer alerts to an operator or maintainer of a work machine to service the machine.

[0059] The techniques described herein can achieve higher accuracy in the estimation of fluid filter condition and life, for example, using operating engine metric readings and comparing the rate of change with a configurable threshold. For example, sensor data corresponding to a specific fluid filter can be received by an algorithm to generate a normalized value, which can then be used to predict a replacement date. In an example, the algorithm can incorporate at least one engine metric to help "screen out" any irrelevant engine transients, for example, where the metric includes a combination of engine speed and engine variance over a period of time (e.g., about 10 seconds). For operations particularly related to fuel filters, certain raw data can be received by an algorithm, for example, for estimating predictions. For operations particularly related to air filters, the algorithm can alternatively or additionally incorporate one or more additional data processing steps to help extract meaningful metrics before predicting and providing advanced warnings. For example, air filter analysis can involve normalizing raw sensor data due to its dependence on how the engine operates, and estimating the condition and life of the air filter based on the normalized raw sensor data. This method can achieve more precise and accurate filter replacement, thereby avoiding excessive maintenance while preventing engine problems associated with filter clogging or blocking.

[0060] In operation and use, the internal combustion engine monitoring system currently described can be used for monitoring fluid filter and predicting the time until fluid filter should be replaced in order to avoid clogging event.In this article, clogging event can refer to such situation, wherein particle, debris, mud, dirt and other pollutants are accumulated in fluid filter in the mode of limiting the ability of fluid filter operation and / or allowing enough fluid to pass.This clogging event can increase the necessary fluid pressure required to pass therein, or exceed the maximum fluid pressure allowed to pass therein.In either case, it is possible to allow fluid to pass through fluid filter, but not with the required amount or pressure as required.Therefore, by monitoring and replacing fluid filter before allowing any such clogging event to occur, the potential negative effect that may be caused by such clogging event can be avoided.

[0061] Generally, the monitoring system described herein can facilitate detection of degraded fluid filter conditions prior to an ECM diagnostic code alarm. The monitoring system described herein can provide reliable analysis of fluid filter conditions over a range of operating conditions (e.g., boost pressures in a range of about 20 kPa to over 100 kPa) and despite various environmental conditions present in the work machine. Such reliable analysis can provide improved timing for recommending replacement of fluid filters compared to pre-scheduled replacements based on mileage, operating hours, or filter age that typically do not take into account changes in engine operating conditions. In an example, the monitoring system can be used to receive data from multiple work machines, for example, each work machine corresponding to one or more fluid filters. For example, the monitoring system can be located remotely from multiple work machines and can be connected to the work machines via a communication interface (e.g., a transceiver on a network).

[0062] Figure 4 is a flow chart describing a method for detecting a condition of a fluid filter of an internal combustion engine. For example, the method may include monitoring a pressure differential across a first side and a second side of a fluid filter over time to estimate fluid flow across the fluid filter.

[0063] In an example, at 410, such monitoring may involve receiving a first indication of a corresponding fluid pressure on a first side and a second side of a fluid filter under a first engine operating condition. Similarly, at 420, the method may include receiving a second indication of a corresponding fluid pressure on a first side and a second side of a fluid filter under a second engine operating condition. For example, the first engine operating condition and the second engine operating condition include a first engine boost pressure and a second engine boost pressure, respectively. The first engine boost pressure may be in the range of 0 kilopascals (kPa) to 50 kPa, and the second engine boost pressure may be greater than 100 kPa. In an example, the received first indication and the second indication of the corresponding fluid pressure may each include receiving a plurality of corresponding fluid pressure measurements on the first side and the second side of the fluid filter over time. For example, a plurality of corresponding fluid pressure measurements may include more than 100 measurements taken per hour.

[0064] In an example, at 430, the method may include (e.g., in executing Figure 2 The invention also provides for adjusting at least one parameter of the received first and second indications of corresponding fluid pressures during smoothing operation 202 to mitigate a difference attributable to a difference between the first engine operating condition and the second engine operating condition (e.g., a difference in engine boost pressure, mass fluid flow rate, mass fluid flow amount, or a combination thereof).

[0065] In an example, the method may include (e.g., in executing Figure 2 The method may receive the adjusted first and second indications of the respective fluid pressures and normalize the range of values ​​associated with the first and second indications during a normalization operation 204. For example, the method may determine a maximum peak value of at least one parameter of the adjusted first and second indications, and then may normalize the maximum peak value to within a predetermined range (e.g., between an upper limit and a lower limit).

[0066] At 440, the method may include (e.g., in executing Figure 2 The method may include comparing the adjusted first corresponding indication of fluid pressure with the adjusted second corresponding indication of fluid pressure when performing a slope detection 206. For example, the method may include calculating a slope based on the adjusted first corresponding indication of fluid pressure and the adjusted second corresponding indication of fluid pressure. In an example, the method may include detecting that the fluid pressure differential slope exceeds a threshold. Additionally, the method may include (for example, when performing a slope detection 206) comparing the adjusted first corresponding indication of fluid pressure with the adjusted second corresponding indication of fluid pressure. Figure 2 The estimation operation 208) estimates the time period during which the fluid pressure difference will exceed the threshold.

[0067] At 450, the comparison may include (e.g., in performing Figure 2The triggering operation 210 of the embodiment of the present invention can be used to trigger an alarm indicating the condition of the engine fluid filter based on the monitored pressure differential. For example, triggering the alarm can include generating an indication to replace or clean the fluid filter based on the differential slope exceeding a threshold value. Triggering the alarm can also include generating an indication to replace or clean the fluid filter when a plugging event of the fluid filter is expected.

[0068] Figure 5A and Figure 5B is a graph depicting measured air filter restriction versus boost pressure and time, respectively. In an example, engine boost pressure of an internal combustion engine may be used as a proxy, for example, for estimating airflow through an air filter. Here, the pressure differential across the air filter may be approximately proportional to the flow through the air filter. In general, the internal combustion engine monitoring system described herein may track the slope over time and minimize certain effects of measuring air filter restriction under varying boost pressure. For example, Figure 5A Different slopes corresponding to different time levels a, b and c are depicted, such as Figure 5B By collecting data points over a range of boost pressures (e.g., a first "low" boost pressure between 0 and about 20 kPa and a second "high" boost pressure greater than about 120 kPa), a statistically significant slope can be calculated. As depicted, such a slope can increase over time as the filter ages.

[0069] Fig. 6A and Figure 6B 6 is a diagram depicting an operation for predicting an estimated replacement date for a fluid filter. At 602, the "steady state" of the fluid filter can be determined, for example, by obtaining a moving variance of an engine load or speed below a predetermined threshold. At 604, boost and limit data or differential pressure data can be aggregated or filtered, for example, involving a threshold level greater than a sample to be obtained within a set time (e.g., >150 samples / hour). At 606, the limit measurements can be grouped, for example, by the measured boost level. At 608, the data can be smoothed, for example, by obtaining the EWMA of certain data parameters. At 610, for example, the slope of the limit change relative to the boost change can be calculated. At 612, the time ROC can be calculated, for example, using the EWMA as a historical data point. At 614, an estimate of the time until the ROC will reach a predetermined threshold can be calculated. At 616, for example, when the time until the threshold reaches less than a predetermined time range (e.g., <48 hours), a warning can be triggered.

[0070] Figure 7 Includes a graph of certain data parameters over time related to the clogging of the fluid filter. Figure 7As depicted in , the internal combustion engine monitoring system can monitor at least two similar fluid filters simultaneously, for example, a left air filter and a right air filter or a left fuel filter and a right fuel filter of the internal combustion engine. In the example, dashed line 700 indicates when an ECM diagnostic code will be triggered. Based on performing the operations described herein, the internal combustion engine monitoring system can predict when an ECM diagnostic code will be triggered and foresee the code, for example, more than 24 hours before the ECM code is shown.

[0071] The above detailed description is intended to be illustrative rather than limiting.The scope of the disclosure should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

1. An internal combustion engine monitoring system, the system comprising: a fluid filter disposed between at least one fluid inlet of the internal combustion engine and at least one of a fluid source or an ambient fluid environment; a first fluid sensor arranged to receive a first indication of respective fluid pressures on first and second sides of the fluid filter under a first engine operating condition; a second fluid sensor arranged to receive a second indication of respective fluid pressures on the first and second sides of the fluid filter under a second engine operating condition; processing circuitry configured to determine a pressure differential across a first side and a second side of the fluid filter over time to estimate fluid flow across the fluid filter, the processing circuitry configured to: adjusting at least one parameter of the received first and second indications of respective fluid pressures to mitigate a difference attributable to a difference between the first engine operating condition and the second engine operating condition; as well as comparing the adjusted first corresponding indication of the fluid pressure to the adjusted second corresponding indication of the fluid pressure; as well as A user interface is provided for generating an alarm indicating a condition of an engine fluid filter based on the monitored pressure differential, the alarm being triggered by the processing circuitry based on the determined pressure differential exceeding a specified threshold differential.

2. The system of claim 1, wherein the first engine operating condition and the second engine operating condition include a first engine boost pressure and a second engine boost pressure, respectively, and optionally, wherein the first engine boost pressure is in the range of 0 kilopascals (kPa) to 50 kPa, and the second engine boost pressure is greater than 100 kPa.

3. The system of any one of claims 1 or 2, wherein the processing circuitry is configured to trigger the alarm, including generating an indication to replace or clean the fluid filter based on a differential slope exceeding a specified threshold.

4. A system according to any one of claims 1 to 3, wherein: The processing circuitry is configured to estimate a time period during which the fluid pressure differential will exceed a threshold; and The user interface is configured to display the alert, the alert including instructions to replace or clean the fluid filter in anticipation of a clogging event of the fluid filter.

5. A system according to any one of claims 1 to 4, wherein the received first indication and second indication of corresponding fluid pressure each include a plurality of corresponding fluid pressure measurements on the first side and the second side of the fluid filter over time, and optionally, wherein the plurality of corresponding fluid pressure measurements include excess measurements taken every hour, and optionally, wherein the processing circuit system is configured to normalize the plurality of corresponding fluid pressure measurements, including calculating an exponentially weighted moving average (EWMA) of the plurality of corresponding fluid pressure measurements.

6. A method for detecting a condition of a fluid filter of an internal combustion engine, the method comprising: Monitoring a pressure differential across a first side and a second side of the fluid filter over time to estimate fluid flow through the fluid filter includes: receiving a first indication of respective fluid pressures on a first side and a second side of the fluid filter under a first engine operating condition; receiving a second indication of respective fluid pressures on the first and second sides of the fluid filter under a second engine operating condition; adjusting at least one parameter of the received first and second indications of respective fluid pressures to mitigate a difference attributable to a difference between the first engine operating condition and the second engine operating condition; and comparing the adjusted first corresponding indication of the fluid pressure to the adjusted second corresponding indication of the fluid pressure; and An alarm indicative of a condition of the engine fluid filter is triggered based on the monitored pressure differential.

7. The method of claim 6, wherein the first engine operating condition and the second engine operating condition include a first engine boost pressure and a second engine boost pressure, respectively, and wherein optionally, the first engine boost pressure is in the range of 0 kilopascals (kPa) to 50 kPa, and the second engine boost pressure is greater than 100 kPa.

8. The method according to claim 6 or 7, further comprising: Detecting that the fluid pressure difference slope exceeds a threshold value; wherein triggering the alarm comprises generating an indication to replace or clean the fluid filter based on the differential slope exceeding the threshold, and optionally, further comprising: estimating a time period during which the fluid pressure differential will exceed a threshold value; Wherein triggering the alarm includes generating an instruction to replace or clean the fluid filter in anticipation of a clogging event of the fluid filter.

9. The method of any one of claims 6 to 8, wherein the received first and second indications of respective fluid pressures each comprise receiving a plurality of respective fluid pressure measurements on the first and second sides of the fluid filter over time.

10. A method according to claim 9, wherein the plurality of corresponding fluid pressure measurements include excess measurements taken every hour, and optionally, wherein adjusting the received first indication and second indication of the corresponding fluid pressure on the first side and the second side of the fluid filter includes smoothing the plurality of corresponding fluid pressure measurements, including calculating an exponentially weighted moving average (EWMA) of the plurality of corresponding fluid pressure measurements.

Images