Method and system for identifying a health state of a vibrating system

Abstract

The present disclosure relates to a system for monitoring a vibration system of a vibratory compactor. The system for monitoring includes a vibration system associated with a roller of the vibratory compactor and a sensor associated with the vibration system. The system also includes a controller in electrical communication with the sensor. The controller is configured to receive sensor data from the sensor, compare the sensor data to a standard, and identify a health status of the vibration system based on the sensor data meeting the standard over a period of time. In some examples, the system for monitoring can also send an alert to an operator or a remote office indicating that the vibratory compactor is operating in a manner that reduces a useful life of one or more components on the vibratory compactor.

Description

Technical Field

[0001] This disclosure relates to vibration compaction equipment, and more specifically, to methods and systems for predicting wear using the pressure of a vibration system. Background Technology

[0002] A compactor is a machine used to compact initially loose materials, such as bitumen, soil, gravel, etc., into a denser and more rigid mass or surface. For example, soil compactors are used to compact soil on construction sites and landscaping projects to create foundations on which other structures can be built. Most soil compactors include rotating rollers that roll over a surface to compress the material underneath. In addition to using the weight of the rollers to provide compressive force to the compacted material, some compactors include a vibration system configured to also induce vibrational forces on the surface. A description of a vibration system that can be used with a compactor can be found in U.S. Patent Application Publication No. 2022 / 0127797.

[0003] Some vibration systems are configured to operate in two or more modes. For example, a vibration system may generate a first vibration force amplitude in a first mode and a second vibration force amplitude in a second mode. The first vibration force amplitude can produce a higher vibration force to increase the compressive force on the material at the work site. Additionally, for construction sites or soil that are already compacted or at least partially compacted, the second vibration force amplitude may be smaller than the first. Therefore, the machine operator can adjust the operation of the compactor based on the conditions of the work site or the needs of the project. Summary of the Invention

[0004] This document discloses a system for monitoring the vibration system of a vibratory compactor. The monitoring system includes: a vibration system associated with the rollers of the vibratory compactor; sensors associated with the vibration system; and a controller electrically communicating with the sensors. The controller is configured to receive sensor data from the sensors and compare the sensor data with a standard. The controller also identifies the health status of the vibration system based on the sensor data meeting the standard over a time period. In some instances, the monitoring system may additionally or alternatively alert operators in a back office.

[0005] This document also discloses a vibratory compactor. The vibratory compactor includes a vibratory compactor. The vibratory compactor includes a frame, a motor fixed to the frame, and rollers rotatable relative to the frame and operatively coupled to the motor. The vibratory compactor also includes a vibration system. The vibration system includes a mounting indirectly fixed to the rollers, a motor fixedly fixed to the mounting, and an eccentric counterweight operatively coupled to the motor. The vibratory compactor also includes sensors associated with the vibration system and a controller electrically communicating with the sensors. The controller is configured to receive sensor data from the sensors, compare the sensor data with a standard, and identify the health status of the vibration system. The controller identifies the health status of the vibration system based on the sensor data meeting the standard over a time period.

[0006] This document also discloses a method. The method includes activating a motor of a vibration system. The vibration system includes at least one mounting member, a shaft rotatably coupled to the mounting member, and an eccentric counterweight disposed on the shaft. According to the method, activation of the motor causes the eccentric counterweight to rotate about or with the shaft. The method further includes receiving sensor data generated by sensors operatively coupled to the vibration system at a controller. Furthermore, the method includes identifying, via the controller, that the sensor data meets a criterion. Additionally, the method includes predicting the health status of the vibration system via the controller based on the sensor data meeting the criterion. Attached Figure Description

[0007] In accompanying drawings that are not necessarily drawn to scale, similar numbers may describe similar parts in different views. Similar numbers with different letter suffixes may represent different instances of similar parts. The accompanying drawings illustrate, by way of example and not limitation, the various embodiments discussed in this document.

[0008] Figure 1 It is a side view of a vibratory compactor according to one or more embodiments of the disclosed subject matter.

[0009] Figure 2 It is a schematic diagram of a vibratory compactor according to one or more embodiments of the disclosed subject matter.

[0010] Figure 3 It is a perspective view of the vibration system of a compactor according to one or more embodiments of the disclosed subject matter.

[0011] Figure 4 It is an adjustable eccentric mass block suitable for vibration mechanisms that cause vibration based on the first vibration amplitude. Figure 3 The cross-sectional view of line AA.

[0012] Figure 5 It is an adjustable eccentric mass block suitable for vibration mechanisms that cause vibration based on a second vibration amplitude. Figure 3 The cross-sectional view of line AA.

[0013] Figure 6 yes Figure 2-5 An exemplary histogram of pressure data from an exemplary vibration system.

[0014] Figure 7 yes Figure 2-5 A second exemplary histogram of pressure data from an exemplary vibration system.

[0015] Figure 8 This is a flowchart of a method for identifying the health status of a vibration system according to one or more embodiments of the disclosed subject matter. Detailed Implementation

[0016] Figure 1 An exemplary vibratory compactor 100 is illustrated. The vibratory compactor 100 can be used for applications such as soil compaction, road construction, highway construction, parking lot construction, and other such paving and / or construction applications. The vibratory compactor 100 can perform one or more passes on a work site surface 101 to provide a desired level of compaction. In addition to compacting primarily soil-based materials on the work site surface 101, in other instances, the vibratory compactor 100 can also be configured to compact newly deposited asphalt or other materials set on and / or associated with the work site surface 101.

[0017] according to Figure 1 As illustrated, the vibratory compactor 100 may include rollers 102 and wheels 104. In such an example, rollers 102 compact the work area surface 101, and wheels 104 drive the vibratory compactor 100 forward and backward. In some examples, rollers 102 may also drive the vibratory compactor 100 forward and backward. Although in alternative embodiments, rollers 102 may be a first roller, and wheels 104 may be a second roller. In such alternative embodiments, both the first and second rollers compact the work area surface 101, and at least one of the first and second rollers may push the vibratory compactor 100 forward and backward. Rollers according to embodiments of the disclosed subject matter may be referred to as compacting rollers or compaction rollers.

[0018] The compactor 100 may include a chassis or frame 106, an engine 108 (or electric motor) fixed to the frame 106, and a hydraulic system 110 operatively coupled to rollers 102 and wheels 104. The hydraulic system 110 is operatively coupled to and powered by the engine 108. In this example, the hydraulic system 110 is operatively coupled to the rollers 102, wheels 104, and a steering system to control the movement and orientation of the compactor 100.

[0019] Roller 102 and wheel 104 are fixed to frame 106. For example, roller 102 and wheel 104 are rotatable relative to frame 106 and operatively coupled to engine 108 such that roller 102 can rotate clockwise or counterclockwise depending on the direction of travel of vibratory compactor 100 (i.e., forward or backward, respectively) via a control. The first roller 102 (and in some instances a second roller) may be cylindrical or cylindrical in form, but the rollers according to embodiments of the disclosed subject matter are not geometrically limited thereto. For example, roller(s) 102 may include bump rollers.

[0020] A vibration system 120 may be provided for roller 102. In some instances, when the vibratory compactor 100 includes a first roller and a second roller, the vibration system 120 may be used for both the first roller and the second roller. However, in other instances, the vibratory compactor 100 may include a separate vibration system for each roller.

[0021] In this example, the vibration system 120 is at least partially disposed within the internal volume of the roller 102. As will be discussed in more detail below, the vibration system 120 includes an eccentric counterweight (such as...). Figure 4-5 (As shown in the diagram). During operation of the vibratory compactor 100, the eccentric counterweight of the vibration system 120 induces an oscillating force or vibrational force on the roller 102. The vibrational force is transmitted to the work surface 101 via the roller 102. As will be discussed in more detail below, the eccentric counterweight can be configured to provide two or more vibration amplitudes.

[0022] The vibratory compactor 100 also includes a user interface 130 and a controller 132 or other control circuitry. In various instances, the controller 132 may include two or more controllers or microcontrollers. Furthermore, although shown as being mounted on the vibratory compactor 100, in some instances, the controller 132 is not mounted on the vibratory compactor, or the controller 132 is only partially mounted on the vibratory compactor 100. In some such instances, all or part of the controller 132 is implemented in a local or remote server communicating with the vibratory compactor 100. The user interface 130 includes various controls and displays to allow personnel to control the operation of the vibratory compactor 100. The user interface 130 is operatively coupled to the controller 132, enabling the user interface 130 and the controller 132 to receive and send information to each other. The controller 132 includes a processor (or processing circuitry) and memory for operating the vibratory compactor 100. Therefore, in various instances, the controller 132 controls the operation of the vibratory compactor 100 (including rollers 102, wheels 104 and vibration system 120) in response to receiving commands from the user interface 130.

[0023] Figure 2 A schematic diagram of a vibratory compactor 100 is shown, including an engine 108, a hydraulic system 110, a vibration system 120, and a controller 132. As shown, the engine 108 is operatively connected to and powers the hydraulic system 110. In some instances, the engine 108 is an internal combustion engine, but in other instances, the engine 108 may be an electric motor or another engine or motor capable of actuating the hydraulic system 110.

[0024] Hydraulic system 110 includes a first hydraulic pump 210 connected to a first hydraulic line 212 forming a closed loop, a first hydraulic motor 214 connected to the first hydraulic line 212, and a second hydraulic line 216 connected to the first hydraulic pump 210 and the first hydraulic motor 214. Hydraulic system 110 also includes a second hydraulic pump 220 connected to a first hydraulic line 222 forming a closed loop, a second hydraulic motor 224 connected to the first hydraulic line 222, and a second hydraulic line 226 connected to the second hydraulic pump 220 and the second hydraulic motor 224. Hydraulic system 110 also includes a third hydraulic pump 230 connected to a first hydraulic line 232 forming a closed loop, a vibratory motor 234 connected to the first hydraulic line 232, and a second hydraulic line 236 connected to the third hydraulic pump 230 and the vibratory motor 234. In various embodiments, vibratory compactor 100 may include more or fewer hydraulic pumps. Each of the first, second, and third hydraulic pumps 210, 220, and 230 can be operated by motors 214, 224, and 234 in a first direction (firstly pumping through the first hydraulic lines 212, 222, and 232) and in a second direction (firstly pumping through the second hydraulic lines 216, 226, and 236). Therefore, the first and second hydraulic pumps 210 and 220 can cause the roller 102 and wheel 104 to rotate in a forward or backward direction. Furthermore, as described below... Figure 4 and Figure 5 As discussed, the third hydraulic pump 230 can rotate the eccentric counterweight in at least the first and second states. Furthermore, the controller 132 can control the operation of the engine 108 and pumps 210, 220, 230 to selectively operate all or a subset of pumps 210, 220, 230.

[0025] The third hydraulic pump 230 also includes a first pressure sensor 242 on the first hydraulic line 232 and a second pressure sensor 244 on the second hydraulic line. In some instances, the first and second pressure sensors 242, 244 are differential pressure sensors fluidly connected to each of the first and second hydraulic lines 232, 236. Both the first and second pressure sensors 242, 244 are in electrical communication with or otherwise operatively connected to the controller 132. Therefore, the controller 132 can calculate the pressure difference across the third hydraulic motor 234. During normal operation, because the first and second pressure sensors 242, 244 are associated with the vibration system 120, the pressure difference across the hydraulic motor 234 can be used to determine the compaction level of the work site surface 101. For example, after the work site surface 101 is fully compacted, the vibration force applied to the work site surface 101 by the rollers can be reflected back to the vibration system 120 and the vibratory compactor 100, and can also be measured as the differential pressure rise level between the first pressure sensor and the second pressure sensors 242 and 244.

[0026] The hydraulic system 110 can be configured or sized differently according to this disclosure. In some instances, two or more of the hydraulic pumps 210, 220, and 230 can be combined into a single hydraulic pump. In other instances, one or more of the hydraulic pumps 210, 220, and 230 can be connected to a separate engine or power source.

[0027] Additionally, the vibratory compactor 100 may include various other sensors 246 operatively connected to the controller 132. In various instances, the sensors 246 may include a variety of sensors, including accelerometers, GPS, temperature sensors, engine and / or motor speed sensors (e.g., tachometers), position sensors, voltage sensors, current sensors, fuel level sensors, timers, etc. The sensors 246 are configured to generate sensor data and transmit it to the controller 132. In some instances, any one of the sensors 246 may be operatively coupled to the vibration system 120 and functionally replace the first and second pressure sensors 242, 244. For example, if the hydraulic pump 230 and hydraulic motor 234 are replaced by an electric motor, the first and second pressure sensors 242, 244 may be replaced by a current sensor to determine operating data on the electric motor.

[0028] In various instances, controller 132 receives sensor data generated by sensors 242, 244, and 246, which are operatively coupled to vibration system 120 or otherwise disposed on vibratory compactor 100. Controller 132 utilizes the sensor data to operate vibratory compactor 100. In various instances, controller 132 may store the sensor data or transmit the data to a remote data storage device (e.g., a data center) for future review or analysis, or use the sensor data to adjust or update the operation of vibration system 120. Additionally, as will be discussed in more detail below, controller 132 may utilize the sensor data to identify the health status of vibration system 120 and / or vibratory compactor 100. In some instances, the health status of the vibration system further indicates an impending failure of components of vibration system 120.

[0029] like Figure 2 As shown, the vibration system 120 includes a mounting bracket 252 that secures the vibration system 120 and a shaft 254 rotatable relative to a motor 234. The vibration system 120 also includes a third hydraulic pump 230 and a motor 234, the motor being operatively coupled to the shaft 254 and fixedly attached to the mounting bracket 252. The vibration system 120 further includes chambers 256 fixed to rollers 102, each chamber 256 including an eccentric counterweight 260 disposed within the chamber 256 and rotatable with or about the shaft 254. In this example, the motor 234 rotates the shaft 254 and the eccentric counterweight 260 in a first or second direction. In this example, the shaft 254 and the eccentric counterweight 260 are rotatable relative to the rollers 102.

[0030] During operation, the vibration system 120 can rotate the eccentric weight 260 relative to the frame 106 and the roller 102 to induce a vibratory force on the roller 102. Because the eccentric weight 260 can rotate relative to the frame 106 and the roller 102, the eccentric weight 260 can maintain its rotational speed regardless of the rotational speed of the roller 102.

[0031] In addition, such as Figure 2 As shown, the vibratory compactor 100 can communicate electronically with network 270 and indirectly with external computing device 272. In various instances, network 270 can be a local area network (LAN), a controller area network (CAN), or a wide area network (WAN). In some such instances, external computing device 272 can send signals to and receive signals from the controller 132 of the vibratory compactor 100. For example, controller 132 can send alarms to external computing device 272.

[0032] Figure 3 It is set inside the roller 102 Figure 2 A perspective view of a portion of the vibration system 120. Figure 3 A motor 234 is shown attached to a mounting bracket 252, which secures the motor 234 to the frame 106. Figure 3 (Not shown in the image). Additionally... Figure 3 The diagram shows a hull 256 (suitable for accommodating an eccentric counterweight 260), including a means for connecting the hull 256 to rollers 102. Figure 3 Fastener 258 (not shown in the image).

[0033] Mounting member 252 includes a first plate 312 fixed to frame 106 and a second plate 314 separated from the first plate by six ISO mounting members 316. In various embodiments, mounting member 252 may include more or fewer ISO mounting members 316. In a preferred embodiment, the greater the mass of the frame applying downward pressure on the rollers, the more ISO mounting members should be included in mounting member 252. Motor 234 is coupled to the second plate 314. The ISO mounting members 316 are configured to reduce the vibrational forces transmitted from vibration system 120 to frame 106.

[0034] Figure 4 and Figure 5 It shows along Figure 3 The cross-section of the hull, 256, is taken from line AA. (Example) Figure 4 and Figure 5 As shown, the eccentric counterweight 260 may include a body 402 defining an inner cavity 404. The body 402 of the eccentric counterweight 260 may define the inner cavity 404 such that the body 402 completely surrounds the inner cavity 404. The body, except for the inner cavity 404, may be solid and made of metal or a metallic material (e.g., steel or ductile iron). The body 402 may be integrally formed or formed as a unit, including optionally being formed as part of the shaft 254. Thus, the inner cavity 404 may be cut or machined from the body 402, or alternatively, produced using additive manufacturing techniques. Alternatively, according to one or more embodiments, the body 402 may have, include, or otherwise connect to opposing end plates that define end walls of the inner cavity 404 in the longitudinal direction along the longitudinal axis X of the shaft 254.

[0035] The cavity 404 may include a first segment 412, a second segment 414, and a third segment 416 disposed between the first segment and the second segments 412, 414. In various embodiments, the cavity 404 may include a portion of... Figure 4 and Figure 5 The cavity 404 may include more or fewer segments as shown. Alternatively, the cavity 404 may include one or more segments that are not connected to any of the first segment 412, the second segment 414, and the third segment 416. Such segments may be provided to provide one or two additional vibration amplitudes for the vibration system 120.

[0036] The filling material 420 may be disposed within the cavity 404. The filling material 420 may be metal or a metal component, such as pellets, steel balls, metal blocks, liquid metal, or sand, or a liquid that can move or flow between the first section 412, the second section 414, and the third section 416. The filling material 420 may be moved in a controlled manner between the first section 412, the second section 414, and the third section 416 based on the rotation of the cavity 404 corresponding to the rotation of the shaft 254 (and the body 402).

[0037] In one operating mode, to generate a first vibration amplitude, the filler material 420 can be disposed in the first section 412, and then the inner cavity 404 is rotated clockwise. Because the filler material 420 is offset from the central axis 422 of the shaft 254 and the body 402, the filler material 420 can cause the eccentric counterweight 260 to vibrate with the first vibration amplitude.

[0038] In another operating mode, to generate a second vibration amplitude, the filler material 420 can be disposed in the second section 414, and then the inner cavity 404 is rotated counterclockwise. Because the filler material 420 is offset from the central axis 422 of the shaft 254 and the body 402, the filler material 420 can cause the eccentric counterweight 260 to vibrate with the second vibration amplitude.

[0039] In various instances, the vibration system 120 may have an eccentric counterweight configured to produce more than two vibration modes. Examples of eccentric counterweights configured to generate multiple vibration modes are described, for example, in U.S. Patent Application Publication No. 2011 / 0158745 (incorporated herein by reference). In such instances, the control scheme for the eccentric counterweight can achieve three or more different vibration amplitudes by controlling the position of the counterweight (e.g., the degree of offset between a movable mass and a fixed mass when rotating about a rotatable axis), the rotational speed, or other operating characteristics of the eccentric counterweight.

[0040] Figure 6 It shows the corresponding Figure 1-3 An exemplary histogram 600 of the differential pressure data 602 of the non-vibration pressure data 604 and the operating pressure data 606 of the vibration system 120. (See also...) Figure 6As shown, the histogram includes a median of 612 and a standard deviation of 614 and 616. In the example shown, the X-axis of the differential pressure data 600 represents pressure. In various examples, the X-axis may correspond to different pressure scales (e.g., 0 bar to 250 bar, 400 bar, 600 bar, etc.). Additionally, in the example shown, the Y-axis of the histogram 600 measures the data points in each cell of the histogram 600. In the example shown, the differential pressure data 602 includes more than 500,000 data points. In other examples, the differential pressure data 602 may be measured over longer or shorter time periods (e.g., daily, weekly, monthly, quarterly, yearly) and within different differential pressure ranges.

[0041] Figure 7 It shows the corresponding Figure 1-3 An exemplary histogram 700 of the differential pressure data 702 of the non-vibration pressure data 704 and the operating pressure data 706 of the vibration system 120. (See also...) Figure 7 As shown, the histogram includes a median of 712 and a standard deviation of 714, 716. In the example shown, the X-axis of the differential pressure data 700 represents pressure. In various examples, the X-axis may correspond to different pressure scales (e.g., 0 bar to 250 bar, 400 bar, 600 bar, etc.). Additionally, in the example shown, the Y-axis of the histogram 700 measures the data points in each cell of the histogram 700. In the example shown, the differential pressure data 702 includes over 400,000 data points. In other examples, the differential pressure data 702 may be measured over longer or shorter time periods and within different differential pressure ranges.

[0042] like Figure 6 As shown, most differential pressure data 602 are within one standard deviation of the median 612, 614, 616. In contrast, as... Figure 7 As shown, approximately half of the operating pressure data 706 deviates from the median 712 by more than one standard deviation 716. In some instances, a large amount of differential pressure data deviating from the median (e.g., median 612, 712) by more than the standard deviation can indicate pressures that may damage components and parts of the vibratory compactor 100 or unnecessarily increase their wear.

[0043] Alternatively, in some instances, histograms 600 and 700 can be used to measure whether a predetermined number of data points are within or exceed a threshold 620. The threshold 620 can be predetermined to quickly identify when the vibration system 120 is operating in a manner that could lead to damage or increased / accelerated wear. Furthermore, extended operating time within or exceeding the threshold 620 can be used to calculate a reduction in the health or lifespan of one or more components of the vibration system 120. For example, the number of data points within the operating pressure data 706 set within the threshold 620 can be used to calculate a reduction in the number of operating hours that the ISO mount could be expected to operate at its design capacity.

[0044] Industrial applicability

[0045] This vibration system 120 is suitable for a variety of construction and road paving applications to identify the health status of the vibration system 120 and / or the vibratory compactor 100. As used herein, health status typically refers to the condition of the components of the vibration system 120. In some instances, health status can be measured as a percentage or proportion of the effective component life (e.g., 50% of the remaining effective life). Alternatively, health status can be a classification of component operation. In some such instances, health status can identify components as "fully operational," "reduced efficiency," "requiring maintenance," or "recommended replacement."

[0046] Figure 8 An exemplary method for identifying the health status of vibration system 120 or vibratory compactor 100 is illustrated. In various instances, controller 132 identifies the health status of vibration system 120 and / or vibratory compactor 100. Alternatively, a computer located remotely from vibratory compactor 100 may identify the health status of vibration system 120 or vibratory compactor 100. In some instances, the health status may indicate a malfunction condition of components of vibration system 120.

[0047] At box 802, controller 132 activates the vibration system 120 of the vibratory compactor 100. For example, controller 132 activates hydraulic pump 230 to activate hydraulic motor 234. In some instances, activating vibration system 120 includes receiving a command from the operator of vibratory compactor 100. For example, the operator can select whether vibration system 120 is operated in a first state or a second state (as described above). Figure 4 and Figure 5 (Description). In other instances, controller 132 may automatically activate vibration system 120 based on operation within the work area, receiving activation commands from external systems, or detecting the compaction level of work area surface 101.

[0048] At block 804, controller 132 receives or accesses current and / or historical operating data from memory. In various instances, the operating data may include information relating to the number of hours the vibratory compactor 100 has operated at the work site, the number of hours the vibration system 120 has been in a first state and a second state, the average daily operating pressure, the vibration system start-up time, and other sensed conditions related to the operation and condition of the vibratory compactor 100. In some instances, controller 132 receives current sensor data corresponding to the operation of the vibratory compactor 100 and / or the vibration system 120.

[0049] At box 806, controller 132 generates or receives health assessment criteria from local memory or a remote server. In various instances, the health assessment criteria may correspond to wear on roller 102, hydraulic motor 234, ISO mounting bracket 316, and various other parts of vibratory compactor 100 and / or vibration system 120.

[0050] In one instance, when health assessment criteria relate to the health condition of rollers and / or the health condition of bumps on bump rollers, the health assessment criteria are based on the start-up time of vibration system 120. For example, if vibration system 120 has a short start-up time, this may indicate that the bumps on roller 102 have reduced mass due to partial or complete wear. In such instances, health assessment criteria are able to assess the health condition of rollers or bumps on roller 102, and in some instances, calculate or predict the expected timeline for replacing the bumps on roller 102. In some such instances, health status can be identified as a proportion or percentage of remaining lifespan.

[0051] In another example, the health assessment criteria involve material buildup on roller 102. In such an example, if the vibration system 120 exceeds its normalized start-up time, the controller can determine that the mass of roller 102 is higher than expected and may lead to reduced effectiveness of the vibration system 120 and / or damage to the vibratory compactor 100. In such an example, the health assessment criteria can determine that material buildup exceeds a desired threshold, and maintenance activities (e.g., cleaning the roller) can help maintain the lifespan of roller 102.

[0052] In other instances, health assessment criteria relate to the hydraulic system 110 of the vibration system 120. In such instances, the controller 132 can calculate the mechanical and volumetric efficiency of the hydraulic motor 234. A drop in mechanical or volumetric efficiency below a predetermined threshold can indicate wear or failure of one or more components of the hydraulic system 110. In some instances, a prolonged start-up time can also indicate wear or failure of one or more components of the hydraulic system 110. In such instances, health assessment criteria can be configured to identify specific components of the vibration system 120 operating below desired or expected efficiency. Thus, health assessment criteria can determine the health status of the hydraulic system 110 as, for example, "fully operational," "reduced efficiency," "requires maintenance," or "replacement recommended."

[0053] In several other instances, health assessment criteria relate to wear or failure of the ISO mount 316. In various instances, the determination of excessive wear conditions can be based on an increased differential pressure measured across the hydraulic motor 234. Alternatively, health assessment criteria can identify abnormal differential pressures that exceed expected differential pressures for a given operating condition. In one instance, a high differential pressure can indicate an operating condition that accelerates wear on the ISO mount 316. Alternatively, a low differential pressure can indicate that the ISO mount 316 is absorbing more operating stress than normally expected. Additionally or alternatively, wear or failure of the ISO mount 316 can be determined by correlation with a unique hydraulic pressure pattern. In such instances, health assessment criteria may include matching or correlating differential pressure data with a predetermined pressure trace. Similarly, as described above... Figure 6 and Figure 7 The increased differential pressure can be compared to a threshold differential pressure value, significantly exceeding the standard deviation of the median differential pressure value, exceeding a threshold number of data points (e.g., threshold 620), or matching the shape of a histogram associated with damage or wear of the vibratory compactor 100 components. In some such instances, the data points are used to calculate the wear of the ISO mounting component. Alternatively, in other instances, the data points directly indicate the wear of the ISO mounting component. In the foregoing examples, the health status of the ISO mounting component 316 can be identified as a proportion of the remaining life of the ISO mounting component 316, or as a condition category such as "fully operational," "reduced efficiency," or "recommended replacement."

[0054] In some instances, health assessment criteria associated with ISO Installation 316 also evaluate the operating conditions of the vibratory compactor 100 to identify when the differential pressure rises above the expected differential pressure value. For example, the vibratory compactor 100 may include sensors to assess the compaction level of the work site surface 101, as the compaction level affects the differential pressure across the hydraulic motor 234. In such instances, a compacted work site surface 101 would result in a high differential pressure across the hydraulic motor 234. In one instance, the controller 132 may utilize a Machine Drive Power (MDP) assessment or Compactor Value (CMV) determination to determine whether a high differential pressure across the hydraulic motor 234 is necessary for a given operating condition. For example, an MDP assessment involves comparing the operating drive power to a baseline drive power to determine the rolling resistance of the vibratory compactor 100. In various instances, rolling resistance can be used to determine the compaction level. Alternatively, the CMV utilizes accelerometers mounted on the rollers to measure the compaction level of the work site surface. Based on the foregoing, controller 132 can evaluate two or more of the following: differential pressure (described above), machine drive power, and compactor value, to accurately identify when a high differential pressure indicates excessive load applied to ISO mount 316 or wear condition of ISO mount 316. In one such example, differential pressure may indicate that ISO mount 316 is under higher operating pressure, but evaluating machine drive power may limit warnings of accelerated wear conditions based on the necessity of a higher differential pressure for compacting the surface material.

[0055] Additionally, in various instances, health assessment criteria may include two or more of the aforementioned health assessment criteria to identify the overall health condition of the vibratory compactor 100. For example, health assessment criteria may include simultaneous analysis of the hydraulic system, engine, and / or rollers. In some instances, two or more health assessment criteria are evaluated to improve the accuracy of component health condition identification; while in other instances, two or more components of the vibration system 120 are evaluated individually.

[0056] At box 808, controller 132 compares real-time and / or historical sensor data with health assessment criteria. In some instances, controller 132 evaluates a single variable relative to a threshold. In other instances, controller 132 evaluates one or more variables against a set of thresholds or within a health assessment algorithm. During certain operating conditions, controller 132 may determine whether the sensor data is helpful in indicating the health status of one or more components of vibration system 120.

[0057] At box 810, controller 132 identifies the health status of one or more components of the vibratory compactor 100 and / or vibration system 120. Health status identification is based on the controller determining that real-time and / or historical sensor data meet health assessment criteria. In some instances, health status identification is based on meeting health assessment criteria within a measured time period. In some instances, controller 132 further calculates a failure timeline.

[0058] In some instances, controller 132 also sends alerts after: (a) identifying a poor health condition of a component of the vibration system; (b) the vibration system 120 operating at high pressure exceeding a threshold that could cause premature wear of components of the vibration system 120; and / or (c) predicting a failure of components of the vibratory compactor 100 and / or the vibration system 120. Alerts may be sent to the user interface 130 of the vibratory compactor 100 or to an external computing device 272 located, for example, in a workplace office. In various such instances, the external computing device 272 may provide alerts to the seller, owner, maintenance manager, workplace supervisor, and / or operator of the vibratory compactor 100. Alerts may include information about the operating condition of the vibratory compactor 100, the health status of one or more components of the vibratory compactor 100, predicted failures of the vibratory compactor 100, and recommended measures for maintaining or repairing the vibratory compactor 100. In some instances, reports on operating condition, the health status of one or more components, and predicted failures of any component may be generated periodically (e.g., monthly, quarterly, annually).

[0059] Various examples are illustrated in the accompanying drawings and the foregoing description. One or more features from one or more of these examples can be combined to form other examples.

[0060] The detailed description above is intended to be illustrative, not restrictive. Therefore, the scope of this disclosure should be determined by referring to the appended claims and the full scope of their equivalents.

Claims

1. A system for monitoring the vibration of a vibratory compactor, comprising: The vibration system associated with the rollers of the vibratory compactor; Sensors associated with the vibration system; as well as A controller that communicates electrically with the sensor, the controller being configured to: Receive sensor data from the sensor; The sensor data is compared with a standard. The health status of the vibration system is identified based on the sensor data meeting the criteria within a certain time period.

2. The system of claim 1, wherein the vibration system further comprises a hydraulic pump and a hydraulic motor, and the sensor is a pressure sensor associated with the hydraulic pump and the hydraulic motor.

3. The system according to claim 2, wherein the pressure sensor is a differential pressure sensor.

4. The system according to claim 2, wherein the vibration system comprises: At least one mounting component; A shaft rotatably connected to the mounting component; A motor connected to the shaft; as well as An eccentric counterweight is installed on the shaft.

5. The system of claim 1, wherein the standard is a percentage of vibration pressure exceeding the limit within a predetermined time period.

6. The system of claim 1, wherein the criterion includes matching a predetermined pressure trace.

7. A vibratory compactor, comprising: The compactor includes: frame; The engine fixed to the frame; and Rollers, which are rotatable relative to the frame and operably coupled to the engine; Vibration system, the vibration system comprising: A mounting component that is indirectly fixed to the roller; A motor that is fixedly attached to the mounting component; and An eccentric counterweight operably connected to the motor; Sensors associated with the vibration system; and A controller that communicates electrically with the sensor, the controller being configured to: Receive sensor data from the sensor; The sensor data is compared with a standard; and The health status of the vibration system is identified based on the sensor data meeting the criteria.

8. The system of claim 7, wherein the vibration system further comprises a hydraulic pump and a hydraulic motor, and the sensor is a pressure sensor associated with the hydraulic pump and the hydraulic motor.

9. The system according to claim 8, wherein the pressure sensor is a differential pressure sensor.

10. The system of claim 7, wherein the standard is a percentage of vibration pressure conditions within a predetermined time period.

11. The system of claim 7, wherein the criterion includes matching a predetermined pressure trace.

12. A method for predicting the failure of the vibration system of a vibratory compactor, comprising: A motor for activating a vibration system, the vibration system including at least one mounting component, a shaft rotatably coupled to the mounting component, and an eccentric counterweight disposed on the shaft, wherein activation of the motor causes the eccentric counterweight to rotate about the shaft or rotate with the shaft. The controller receives sensor data generated by sensors operatively connected to the vibration system. The controller identifies that the sensor data meets the standard; and The controller identifies the health status of the vibration system based on the sensor data meeting the criteria.

13. The method of claim 12, wherein the sensor data includes differential pressure data.

14. The method of claim 12, wherein the standard is a percentage of vibration pressure conditions within a predetermined time period.

15. The method of claim 12, wherein the criterion is a correlation with the pressure trace.

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