System and method for detecting a fault in a flow path of a fluid system

Description

Field of invention

[0001] The invention relates to systems and methods for detecting a failure in a fluid path of a fluid system. The invention is particularly useful in the transportation sector. Technological background

[0002] Crankcase ventilation systems remove unwanted gases from the crankcase of an internal combustion engine. Unwanted gases (also called "blow-by" gases) are gases that have leaked from the combustion chamber into the crankcase through the engine's piston rings. Blow-by gases must be vented out of the crankcase; otherwise, the gases can combine with engine oil vapor in the crankcase to form sludge, potentially diluting the engine oil with unburned fuel.

[0003] Early internal combustion engines used crankcase ventilation systems to vent blow-by gases into the atmosphere. Newer internal combustion engines use a positive crankcase ventilation (PCV) system to return blow-by gases to the combustion chamber for mixing with the air / fuel mixture and combustion. Currently, it is common for national regulators to require new vehicles to be equipped with a PCV system to prevent blow-by gas emissions and thus reduce vehicle emissions.

[0004] Typical PCV systems consist of a tube, a valve or check valve, and a vacuum source (such as an intake manifold). National regulatory authorities often require that these PCV systems be monitored for failures that would result in blow-by gases escaping. One current means of providing such monitoring is a gas pressure sensor inside the tube. A problem with this arrangement is that gas pressure sensors do not detect all possible failure modes, and gas pressure sensors are often unreliable.

[0005] Recent changes in legislation require that a PCV system malfunction be detected when any conduit, e.g., a pipe, tube, or line that carries crankcase vapors has a cut or break greater than or equal to the smallest internal cross-sectional area of ​​that conduit. CN107676185 A describes a detection system known from the prior art.

[0006] An object of the present invention is to provide an alternative or improved detection system suitable for detecting a failure of a fluid path of a fluid system. Summary of the invention

[0007] The present invention provides a detection system and method according to the appended claims.

[0008] In particular, the present invention relates to a detection system for detecting a fault in a fluid path of a fluid system, the detection system comprising: at least one conduit comprising a conduit wall that defines a fluid path for fluid transfer and at least one electrically conductive element extending along the at least one conduit and that forms an electrical signal path for a first electrical signal that indicates a state of the at least one conduit; and, an electrical terminal electrically connected to the at least one electrically conductive element such that the first electrical signal is transmitted to the electrical terminal via the electrical signal path.

[0009] The detection system further comprises at least one connector connected to the at least one conduit and at least one sensor configured to determine a state of the at least one connector and generate a second electrical signal, said at least one sensor being electrically connected to the at least one electrically conductive element such that the second electrical signal is transmitted to the electrical terminal via the electrical signal path.

[0010] The detection system further comprises a processing unit for receiving the first and second electrical signals and monitoring the first and second electrical signals for an electrical characteristic that indicates a failure of the at least one conduit and / or a failure or disconnection of the at least one connector respectively.

[0011] In a particular embodiment of the present invention, the processing unit is configured to determine that a fault is present in the at least one conduit or that the at least one connector is totally or partially disconnected using the monitored electrical characteristic.

[0012] In a particular embodiment of the present invention, the second electrical signal is a sensor electrical signal encoded with data from the at least one sensor and the first electrical signal is a conduit electrical signal encoded with data relating to the state of the at least one conduit.

[0013] In a particular embodiment of the present invention, the electrical conduit signal is applied to the at least one electrically conductive element independently of the electrical signal from the sensor.

[0014] In a particular embodiment of the present invention, the electrical characteristic is one or more characteristics selected from the group comprising: resistance, conductance, capacitance, inductance, frequency response, amplitude or transit time, or a change thereof.

[0015] In a particular embodiment of the present invention, the at least one electrically conductive element extends over the entire length of the at least one conduit.

[0016] In a particular embodiment of the present invention, the at least one electrically conductive element extends circumferentially around a surface of the conduit wall of the at least one conduit.

[0017] In a particular embodiment of the present invention, the at least one electrically conductive element is at least partially integrated into the conduit wall and / or provides an external or internal surface of the at least one conduit.

[0018] In a particular embodiment of the present invention, the at least one electrically conductive element comprises one or more conductive layer(s), tape(s), film(s), wire(s), braid(s) or a conductive polymer.

[0019] In a particular embodiment of the present invention, the at least one conduit further comprises a plurality of electrically conductive elements.

[0020] In a particular embodiment of the present invention, the plurality of electrically conductive elements comprises two or more separate electrically conductive elements each configured to form parallel sensing portions of the electrical signal path.

[0021] In a particular embodiment of the present invention, at least one of the plurality of electrically conductive elements is configured to form a return portion of the electrical signal path.

[0022] In a particular embodiment of the present invention, the processing unit is configured to monitor the respective first and / or second electrical signal of each of the plurality of electrically conductive elements for a relative change in the electrical characteristics of the respective first and / or second electrical signal.

[0023] In a particular embodiment of the present invention, the detection system comprises a plurality of conduits and a plurality of connectors all connected to a common electrical terminal.

[0024] In a particular embodiment of the present invention, the plurality of conduits extend radially from a common electrical terminal.

[0025] In a particular embodiment of the present invention, the electrical signal path comprises a sensing portion extending from the electrical terminal to a remote end of the at least one electrically conductive element at a first end of the at least one conduit, and, a return portion extending from the remote end of the at least one electrically conductive element towards the electrical terminal.

[0026] In a particular embodiment of the present invention, the electrical signal path comprises an electrical conductor, which is located outside the at least one conduit.

[0027] In a particular embodiment of the present invention, the external electrical conductor is a chassis of a vehicle.

[0028] In a particular embodiment of the present invention, the processing unit comprises a bridge circuit.

[0029] In a particular embodiment of the present invention, the at least one electrically conductive element comprises at least one coil.

[0030] In a particular embodiment of the present invention, the at least one coil provides wireless coupling to couple to the at least one connector and / or the at least one sensor.

[0031] In a particular embodiment of the present invention, the electrical signal path further comprises a radio frequency identification, RFID, chip for transmitting data to or from the electrical terminal and / or the at least one connector.

[0032] In a particular embodiment of the present invention, the at least one sensor is one or more of: a sealed contact pressure sensor, an alignment sensor; an electrical contact sensor in which electrical contacts are made or broken by the connection of the at least one connector; a magnetic sensor in which a magnetic circuit is completed by the connection of the at least one connector; a wireless sensor or an ultrasonic sensor.

[0033] In a particular embodiment of the present invention, the at least one sensor is integrated into the at least one connector.

[0034] The present invention further relates to a vehicle comprising the detection system as defined above.

[0035] In a particular embodiment of the present invention, the detection system is part of a crankcase gas recycling system.

[0036] The present invention further relates to a method for detecting a state of a fluid system using the detection system as defined above, and comprising the steps of: receiving a first electrical signal and a second electrical signal from at least one electrically conductive element in the at least one conduit; and monitoring the first and second electrical signals for an electrical characteristic that indicates a failure of the at least one conduit and / or a disconnection of the at least one connector.

[0037] In a particular embodiment of the present invention, the method further comprises: determining a fault in the fluid path of the fluid system based on a monitored electrical characteristic.

[0038] In a particular embodiment of the present invention, the electrical characteristic is one or more characteristics selected from the group comprising: resistance, conductance, capacitance, inductance, frequency response, amplitude or transit time, or a change thereof. Brief overview of the figures

[0039] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows an isometric view of a detection system. Figure 2a shows a schematic representation of a first exemplary configuration of the detection system of the invention, in particular, indicating a first configuration of an electrically conductive element and an electrical signal path. Figure 2bshows a schematic representation of a second exemplary configuration of the detection system of the invention, in particular, indicating a second configuration of an electrically conductive element and an electrical signal path. Figure 2c shows a schematic representation of a third exemplary configuration of the detection system of the invention, in particular, indicating a third configuration of an electrically conductive element and an electrical signal path. Figure 2d shows a schematic representation of a fourth exemplary configuration of the detection system of the invention, in particular, indicating a fourth configuration of an electrically conductive element and an electrical signal path. Figure 2e shows a schematic representation of a fifth exemplary configuration of the detection system of the invention, in particular, indicating a fifth configuration of an electrically conductive element and an electrical signal path. Figure 2f shows a schematic representation of a sixth exemplary configuration of the detection system of the invention, in particular, indicating a sixth configuration of an electrically conductive element and an electrical signal path. Figure 2g shows a schematic representation of a seventh example configuration of the detection system of the invention, in particular, indicating a seventh configuration of an electrically conductive element and an electrical signal path. Figure 2h shows a schematic representation of an eighth exemplary configuration of the detection system of the invention, in particular, indicating an eighth configuration of an electrically conductive element and an electrical signal path. Figure 3 shows another schematic representation of an exemplary configuration of the detection system of the invention. Figure 4shows a schematic diagram of an example of a bridge circuit used to detect a change in resistance caused by the deformation of a conductive element of a detection system according to the figure 1 . Figure 5 shows a schematic diagram of another example of a bridge circuit used to detect a change in resistance caused by the deformation of a conductive element of a detection system according to the figure 1 . Figure 6a shows a diagram of a smart connector for detecting a break between two elements of a detection system according to this disclosure. Figure 6b shows a diagram of a smart connector for detecting a connection between two elements of a detection system according to this disclosure. Figure 7 shows a representation of a detection conduit of a detection system according to this disclosure. Figure 8 shows an example of an assembly comprising multiple detection systems according to the figure 1 . Figure 9 is a flowchart showing a method of operating a detection system according to this disclosure. Detailed description General layout

[0040] The present invention and description refer to methods and apparatuses that are used to determine a condition of a fluid path in a fluid system. The condition may be one that may cause or create the risk of fluid leakage from the fluid system. The condition may be a failure in a fluid path defined by one or more conduits or connectors.

[0041] The failure may be mechanical and may include deformation, damage, or severance of the conduit(s) or connector(s). Deformation / damage may include any abnormal shape or thickness of a conduit or conduit wall that is outside normal operating parameters. Deformation / damage may include a change in a cross-section of the conduit or conduit wall at one or more locations caused, for example, by a bulge or other distortion in the conduit wall resulting from a local weakness. Deformation / damage may include a break in the integrity of a conduit wall that would result in fluid loss. The break may be an opening such as a hole, a split, a rupture, or a partial or complete severance or disconnection of the conduit. The failure may be deformation, damage, or the partial or complete disconnection of one or more connectors in the fluid system.

[0042] The failure may result in an opening in the fluid path that is at least as large as the smallest cross-sectional area of ​​the fluid path defined in the fluid system and / or conduit and connectors that are monitored by the detection system.

[0043] Note that the term "fluid" can refer to a liquid, a gas or a vapor.

[0044] Generally, the present invention provides a detection system comprising: a sensor; a conduit configured to transfer a fluid; and, an electrical terminal; wherein the conduit is configured to transmit an electrical signal from the sensor to the electrical terminal.

[0045] More specifically, the present invention may provide a detection system for detecting a failure in a fluid path of the fluid system, the fluid system comprising one or more conduits and one or more connectors for coupling or delimiting the conduits in the fluid system, the detection system comprising: a sensor configured to determine a coupled state of a connector; a conduit connected to the connector and comprising a wall that defines a fluid path for fluid transfer and an electrically conductive element that forms an electrical signal path for a first electrical signal; and, a processing unit configured to receive the first electrical signal and monitor the electrical signal for an electrical characteristic that indicates a failure of the conduit and / or a disconnection of the connector.For example, the processing unit may be configured to determine that a fault is present in the conduit or that the connector has become fully or partially disconnected using the at least one monitored electrical characteristic.

[0046] The electrical signal may be a first electrical signal or a second electrical signal, or either the first or second electrical signal is a sensor electrical signal, and the other of the first and second electrical signals is a conduit electrical signal. The conduit electrical signal may be applied to the electrically conductive element independently of the sensor signal. In one embodiment, the conduit electrical signal may be a voltage that is applied to the at least one electrically conductive element. Monitoring the voltage, e.g., the magnitude of the voltage, may provide information relating to the resistance of the electrically conductive element, which may change in the event of a conduit failure. The sensor signal may be provided separately from this signal and may be monitored separately.

[0047] The detection system may be provided as part of a fluid system in which a gas, liquid, or vapor is transported from one location to another in, for example, a vehicle. The fluid system may be hydraulic or pneumatic. The fluid may be a coolant, lubricant, air, oil, fuel, or any other gas, liquid, or vapor. Typical uses of the invention may include a crankcase ventilation system as described in the background section, a battery pack cooling system, an electric motor cooling system, a lubrication system, a fuel system, or a hydrogen vehicle cooling system. The system may be part of a conventional internal combustion engine, a hybrid vehicle, an electric vehicle, a hydrogen vehicle, or a fuel cell vehicle.It will be noted that the detection system may be used in other applications outside of automotive, such as aerospace or marine vessels, or elsewhere. The detection system may be used to detect leaks or mechanical failures during use of a system and / or may be used to test the fluid system assembly to ensure that the system is leak-free before each use or after initial assembly.

[0048] The sensing system may be part of a monitoring system such as an engine health monitoring system or an on-board diagnostic system. Accordingly, the fluid sensing system may monitor the fluid system for leaks, or a risk of leaks, and provide data or a signal indicating a condition of the fluid system to an overall monitoring system. The data and / or signal captured or determined by the sensing system may be used to provide a user with a condition of the fluid system. For example, the sensing system may provide a signal indicating that there is a possible leak and the location of the leak. Conduit

[0049] The conduit may be configured to transfer a fluid from a first location at a first end to a second location at a second end along a fluid path as is well known in the art. The conduit may include a first end and a second end and may be comprised of a single portion or multiple portions connected together using suitable connections. The sections of the conduit may be connected by suitable connectors, for example, the sensed connectors described herein, or they may be joined by adhesion, mechanical retention, or welding, for example.

[0050] The connectors may be two-part connectors, such as a male / female connector in which a first male part is sealingly inserted into a second female part. The connectors may include, for example, compression connectors or push-fit connectors having an interference fit and / or one or more sealing elements as is well known in the prior art.

[0051] The conduit may be rigid or flexible and may have any desired length or cross-section. In many embodiments, the cross-section of the conduit will be circular, with the conduit being generally cylindrical. The conduit may include a wall that defines a fluid path for fluid transfer. Electrically conductive element

[0052] As noted above, the conduit may be configured to transmit a signal from a sensor to an electrical terminal. The signal may be an electrical signal and may be transmitted along one or more conductive electrical signal path(s) provided within, for example as part of, the conduit.

[0053] Accordingly, the conduit may include one or more electrically conductive elements embedded within, on, or in a wall of the conduit. The one or more electrically conductive elements may include multiple distinct electrical signal paths as described in more detail below. The electrically conductive elements may be provided specifically for the purpose of the detection system, or may serve a dual purpose. In some embodiments, the electrically conductive elements may be used for electrostatic discharge or electromagnetic shielding, for example.

[0054] The electrically conductive element may comprise one or more conductive layer(s), film(s), wire(s), braid(s) or a conductive polymer. The electrically conductive element may extend along the entire length of the sensing conduit from a first end to a second end, for example from the sensor to the electrical terminal and / or the processing unit. The electrically conductive element may extend circumferentially around the conduit wall so as to at least partially or completely surround the conduit. Thus, the electrically conductive element may comprise one or more sleeve(s), tube(s) or layer(s) within, on or in the conduit wall. The electrically conductive element may be at least partially embedded in the conduit wall and / or may provide an internal surface of the conduit and / or covers and / or overbraids the conduit.

[0055] There may be a plurality of electrically conductive elements. The plurality of electrically conductive elements may be distributed circumferentially around the conduit and / or may be distributed radially through the thickness of the conduit wall. Thus, there may be one or more conductive elements arranged concentrically and / or one or more separate electrically conductive elements extending longitudinally along the length of the conduit. The longitudinally extending electrically conductive elements may be arranged helically or parallel to the longitudinal axis of the conduit.

[0056] The electrically conductive element may comprise a conductive polymer or a metallic conductive element. The conductive polymer may comprise multiple conductive layers or conductive strips that are part of the conduit wall. The different conductive layers or strips may be used to provide different signal paths that are configured to carry different electrical signals. The conductive polymer may be used, for example, for electromagnetic interference suppression as a primary or secondary function.

[0057] The electrically conductive elements can be wires embedded in the conduit wall and can be coextruded. The wires can be overbraided. The electrically conductive elements can be a metal tape wrapped around the conduit. Electrical characteristics / conduit detection

[0058] The electrically conductive element may include one or more electrical characteristics that may be monitored by the detection system to determine whether the one or more electrical characteristics change over time. A change in the one or more electrical characteristics may indicate a failure of the conduit. The failure may be a change in the shape of the conduit such as expansion (e.g., a bulge caused by a failure of the structural integrity of the conduit wall) or compression (e.g., an unintended or unwanted compression), or a failure in which an opening in the conduit wall occurs. The failure may include a complete rupture or severance of two portions of the conduit at a connector or in a continuous length of the conduit wall.

[0059] Monitoring the electrical characteristics of the conduit may enable the fluid system to detect a complete break in the conduit resulting in a total loss of an electrical signal. Alternatively or additionally, monitoring the conduit may detect damage by a loss of signal in one or more of the signal paths or a change in an electrical characteristic (other than a loss of signal).

[0060] The at least one electrical characteristic may be one or more characteristics selected from the group comprising: resistance, conductance, capacitance, inductance or amplitude, for example. However, other characteristics, known in the prior art, may be used in certain embodiments.

[0061] The electrical characteristic can also be monitored to detect a change in the characteristic over time, rather than just monitoring the instantaneous or absolute value. Electric terminal

[0062] The electrical terminal may be electrically connected to the conduit and / or to an electrically conductive element that passes through or along the conduit to provide the electrical signal from the sensor. The electrical terminal may provide a connection point for connecting the electrically conductive element to a monitoring system via external wiring or a wireless link.

[0063] The external wiring may send or receive electrical signals to or from the sensor via the electrical terminal and the conduit and / or may send a signal that indicates the condition of the conduit. The electrical terminal may include a housing in which one or more electrical terminal(s) or electrical connection(s) is / are provided as is well known in the prior art.

[0064] The electrical terminal may be mounted on a connector of the fluid system or a surrounding structure. When the electrical terminal is mounted on a connector, it may be referred to as a terminal connector or an interface connector. The connector in which a sensor is provided may be described as a remote connector or a sensing connector. Note that the terminal connector may also include one or more sensors as part of the sensing system. Processing unit

[0065] In some embodiments, the electrical terminal may include a processing unit configured to receive the electrical signal from the sensor. Additionally or alternatively, the processing unit may be configured to monitor at least one electrical characteristic of the conduit. Additionally or alternatively, the processing unit may be configured to determine a condition of the conduit or a connector to which the sensor is mounted. In some embodiments, the processing unit may be located remotely from the electrical terminal. Thus, the processing unit may be part of a different or larger monitoring system such as an on-board diagnostic system. Thus, the electrical signal from the conduit or sensor may be transmitted to the processing unit via the electrical terminal, or the electrical terminal may include the processing unit that outputs either an alert or a signal that indicates the condition of the conduit or connector.

[0066] The processing unit may be configured to determine a leak condition in the conduit using the at least one monitored electrical characteristic. The leak condition may be determined from electrical signals received from the sensor or the conduit. The leak condition may correspond to a failure of the conduit or a (total or partial) disconnection of one or more connectors.

[0067] The processing unit may be configured to process one or more ultrasonic signals (e.g., signals from an ultrasonic transducer) and / or one or more electrical signals and / or one or more electrical characteristics. The ultrasonic signals may be based on conventional sensing technologies such as continuous or pulsed wave excitation or resonance.

[0068] Where multiple electrically conductive elements are part of a conduit, the multiple elements may be assembled such that a break in one or more of the electrically conductive paths provides a step change in an electrical characteristic or electrical signal that is transmitted along the multiple electrically conductive paths. This may make damage detection easier.

[0069] The multiple electrically conductive elements can be monitored separately. The multiple electrically conductive elements can be monitored to determine relative changes in the electrically conductive elements using, for example, a bridge circuit.

[0070] Electrical signals / characteristics may include monitoring of ground resistance measurement using conductors used for ESD (electrostatic discharge) and / or EMI (electromagnetic interference) purposes.

[0071] In addition to the electrically conductive elements provided in the conduit, the detection system may use external conductive paths such as, for example, the chassis of a vehicle for a return path. The multiple electrically conductive elements may include one or more electrically conductive elements for a return path (e.g., ground).

[0072] In various embodiments, the processing unit may comprise: control circuitry; and / or processor circuitry; and / or at least one application-specific integrated circuit (ASIC); and / or at least one field programmable gate array (FPGA); and / or single- or multi-processor architectures; and / or sequential / parallel architectures; and / or at least one programmable logic controller (PLC); and / or at least one microprocessor; and / or at least one microcontroller; and / or a central processing unit (CPU) for executing the methods. The processing unit may be executed in hardware or software, for example.

[0073] The external connector may also include one or more memories. The one or more memories may include a non-transitory computer-readable storage medium including computer-readable instructions that, when read by the processing unit, configure the processing unit to perform the methods described herein. The computer-readable instructions may include executable code relating to monitoring or determining or categorizing the conduit or a leak, for example.The memory(s) may comprise: volatile memory, for example, one or more dynamic random access memory (DRAM) modules and / or static random access memory (SRAM) modules; and / or non-volatile memory, for example, one or more read only memory (ROM) modules, which may for example comprise Flash memory and / or another electrically erasable and programmable read only memory (EEPROM) device. Connectors

[0074] The conduit may terminate in or include one or more connectors that join one end of the conduit to another element in the fluid system, or join two portions of the conduit. The connector may be referred to as a fluid connector because it connects the fluid path, however, the fluid connector may also include electrical elements forming part of the electrical signal path and / or an electrically conductive element used to transmit electrical signals from the sensor to the electrical terminal. As noted above, the connectors may include, for example, compression connectors or push-fit connectors having an interference fit and / or one or more sealing elements as is well known in the prior art.

[0075] There may be a plurality of connectors. Each of the plurality of connectors may be associated with a different conduit. The plurality of conduits may be arranged in series, in parallel, or in a radial arrangement. The plurality of conduits may belong to separate systems that may or may not relate to the same fluid system. Thus, there may be a plurality of conduits and / or connectors that are electrically connected to a common electrical terminal and / or processing unit.

[0076] Providing a single electrical terminal and / or processing unit for a number of sensors or detection conduits can reduce the infrastructure required to implement the detection system.

[0077] The connectors and conduit may include alignment features that only allow mating in a predetermined orientation so that all sensors used to detect mating of the connector may be placed in separate locations to allow alignment of mating parts within the sensor.

[0078] The electrical connection between the conduit sections and / or connectors may be provided by a conductive connection having a low resistance interface to allow efficient transmission of all electrical signals. The electrical connection may include multiple sets of connectors to provide separate electrical paths. As noted above, the paths may include one or more signal paths and one or more return paths.

[0079] The electrical bond and / or sensor may include one or more coils for inductive coupling through the connector. In some embodiments, the electrical bond may be provided by a conductive epoxy or the like in the bonding interface. Other mechanical elements may be included to help bridge the bond, such as conventional electrical contacts that contact an electrically conductive element within or on the conduit, such as an overbraid. Sensor

[0080] The connectors may include one or more sensors for detecting mating of the connectors so that partial or complete disconnection of the connector and / or the risk of leakage associated with the connector may be determined. The sensor may be any suitable sensor known in the prior art and may include, for example, a transducer, electrical contacts or a magnetic sensor.

[0081] The sensor may be configured to determine a sealed contact pressure and / or an alignment of the connector parts (e.g., an alignment along an insertion axis of the connector parts). In the case of a sealed contact pressure, the sensor may include one or more of an ultrasonic sensor and a force measuring sensor. The force measuring sensor may be an ultrasonic sensor in which the ultrasonic response of the connector is measured to determine the contact pressure, or an electrical sensor such as a strain gauge or the like is used to determine the contact pressure.

[0082] The alignment sensor may include one or more of an electrical sensor, a magnetic sensor, and an ultrasonic sensor. The alignment sensor may include a wireless sensor such as an induction coil or electrical contacts that mate when the connector is fully inserted.

[0083] The sensor can transmit a signal to the electrical terminal using the conduit, as described above. The sensor can also receive one or more electrical signals via the conduit.

[0084] The sensor may be provided as part of a sensing unit that is separately manufactured and attached to a connector before, during, or after assembly of the fluid system. The sensor may include a sensor housing that is configured to be mated or coupled to a connector by one or more fasteners or connecting portions. For example, the sensor may be a collar in which an outer surface of the connector is received by means of an interference or compression fit. The sensor housing may be secured by one or more fasteners such as a strap, fastener, bolt, adhesive, or clip, for example. Functioning

[0085] As noted above, operation of the detection system may include receiving a signal from a sensor placed in a connector of the conduit. The signal may be monitored to determine an electrical characteristic of the signal (which corresponds to an electrical condition or characteristic of the conduit or sensor) or a change in the signal. The change in the signal may be a change in amplitude or a complete loss of signal due to failure or severance of the conduit or connector. In some embodiments, the frequency content and / or phase and / or timing of the signal may change. In some embodiments, electrical signals may be injected into the conduit and monitored for a change. For example, a voltage may be applied to one or more electrically conductive elements and the voltage is monitored to determine whether the electrical characteristics of the conduit have changed.The injected signal can be separated into a signal transmitted to or received from the sensor.

[0086] When a change in an electrical characteristic is detected, the reason for the change can be determined and an assessment is made as to whether this indicates a leak in the system or, in some embodiments, whether the system has degraded such that the risk of leakage may increase.

[0087] An appropriate alert may be provided to a user of the system or the machine in which the system is installed, for example a vehicle, so that appropriate action can be taken. Specific embodiments

[0088] A number of specific embodiments in relation to the drawings are described below. It will be appreciated that the features of the specific embodiments may be used interchangeably where technically feasible to provide intermediate embodiments.

[0089] In reference to the figure 1 , an improved detection system is provided, which system is suitable for use as a crankcase ventilation (PCV) system 101. The detection system comprises an electrical terminal 102 (which may also be referred to as a communication interface), a conduit 103 and a sensor 104. The electrical terminal and the sensor 104 may be electrically connected via the conduit 103. As can be seen, the electrical connection may be made with one or more conductive element(s) 105 which is / are part of the conduit 103.

[0090] The electrical terminal 102 may be in communication with, or interfaced with, an on-board diagnostic (OBD) system (not shown) of a vehicle, for example. The OBD may be configured to provide a user (e.g., the driver of the vehicle or a mechanic) with an alert relating to one or more systems of the vehicle. The alert may relate to a condition of the fluid system for which the detection system is intended to monitor. The condition may be a change in pressure or a loss of pressure, for example. The condition may indicate a leak in the system. The leak may be caused by a failure of one or more conduits or connectors, such as a rupture of the wall of a conduit and / or a total or partial cut causing a fluid leak.

[0091] The electrical terminal 102 may be electrically connected to the sensor 104 with an electrically conductive element 105. The electrically conductive element 105 may be part of or coupled to a wall 106 of a conduit 103. In one embodiment, the conduit 103 may be suitable for transferring gases from a crankcase (not shown) to a combustion chamber (not shown) of an internal combustion engine (not shown).

[0092] In the example of the figure 1, the sensing conduit 103 is tubular with a circular cross-section. However, the conduit 103 could have any shape suitable for transferring a gas or other fluid. The conduit 103 may be made from any suitable material which may be a conductive material, such as a conductive polymer, or an insulating material to insulate the electrically conductive element 105. The conductive element 105 forms an electrical signal path between the electrical terminal and the sensor.

[0093] The electrical terminal 102 may include one or more processing units configured to inject an electrical signal into the signal path and to monitor a change in the electrical signal caused by a deformation or breakage of the conductive element 105 to indicate damage to the wall of the sensing conduit 103. As will be discussed below, the conductive element 105 may be coupled to the wall 106 so as to undergo a breakage or deformation when there is damage to the wall 106. Such a breakage or deformation of the conductive element 105 may cause a change in the electrical characteristics of the conductive element 105 and / or the signal traveling along the signal path (through the conductive element 105). The change in the electrical characteristic and / or the electrical signal may be detected by the electrical terminal 102, allowing the user to be alerted, via the electrical terminal, of the breakage of the wall 106.

[0094] A break in the wall 106 of the conduit 103 could be detected based on a complete loss of the electrical signal or another change in electrical characteristics in the signal path, for example. The system may be able to detect either a complete break in the conduit or damage such as a hole or thinning of the conduit wall.

[0095] It has been found that this damage / rupture detection mechanism is more reliable and an improvement over conventional PCV systems that use pressure sensors to detect damage / ruptures based on a change in gas pressure. The detection systems according to this disclosure are capable of detecting smaller ruptures than those detectable using pressure sensors. In particular, the present detection system is capable of detecting ruptures that have a size greater than or equal to the smallest internal cross-sectional area of ​​the duct 103.

[0096] The electrically conductive element 105 may be fabricated from a metallic material. In this case, the conductive element 105 may include any of the following: wires, tapes, films, or layers embedded in the wall of the conduit 103 or overlaid or overbraided onto the conduit 103. The conductive element may include, for example, a metal tape wrapped around the conduit 103 or any other alternatives described herein or known in the art. The conductive element 105 may include multiple conductors to provide multiple signal paths. The multiple conductors may be provided as part of a laminated or layered conduit wall in which conductive layers are radially separated through the thickness of the conduit wall, as described in more detail below.

[0097] The electrically conductive element 105 may be fabricated from a conductive polymer. In this case, the electrically conductive element 105 may include any of: multiple conductive layers within the wall 106; and multiple strips of conductive material to provide multiple signal paths. The multiple conductive layers may be configured to provide suppression of electromagnetic interference.

[0098] In the example of the figure 1 , an optional connector 107 is further shown, which connector may be referred to as a smart connector. The connector 107 may include the sensor 104 for determining a connection status of the connector 107. Thus, the sensor 104 may be configured to send a signal to the electrical terminal 102 that indicates the connection status and whether there is a partial or complete disconnection of the connector or a misalignment for example.

[0099] The sensor 104 may include a wireless sensor electrically connected to the signal path. The sensor 104 may be configured to detect an alignment of the conduit 103 with the smart connector 107 and change an electrical property of the signal when the alignment deviates from a default position. The connector 107 may be capable of detecting a break in the conduit 103 from other parts of the system, which would cause a fluid leak. The sensor 104 may use wireless induction coils or detection of electrical contact mating, as will be described in more detail below.

[0100] The sensor 104 may be housed in a sensor housing. The sensor housing may be configured to be separate from the connector 107 and fit around the connector 107 so that the sensor 104 may be located in a suitable location to detect the condition of the connector 107. As can be seen in the figure 1, the sensor housing may include a collar that surrounds an outer surface of the connector 107 so as to receive the connector tightly therein, by an interference fit, for example.

[0101] Various possible configurations of the detection system as described with reference to the figure 1 will now be described with reference to figures 2a to 2h .

[0102] In reference to the Figure 2a , the electrically conductive element 105 is in the form of an inner layer, for example a coating, of a conduit 103. The inner layer may be exposed to or directly in contact with the fluid within the conduit 103 during use, for example. The electrical terminal 102 may be located at one end of the conduit 103 and may be electrically coupled to the electrically conductive element 105 by two local conductive regions 203a, 203b.

[0103] The detection system may include a remote connector 201 (which may be equivalent to connector 107 of the figure 1 ), which is located at an opposite end of the conduit 103 relative to the electrical terminal 102 comprising a processing unit. The remote connector 201 may include a remote conductive region 202. In such an arrangement, the electrical signal path is formed by the two local conductive regions 203a, 203b, the electrically conductive element 105 and the remote conductive region 202. The remote conductive region 202 may include a grounding connection (not shown) to provide static discharge, as is known in the prior art.

[0104] When there is a break in the conduit wall 106, or a break between the remote connector 201 and the conduit 103 or between the electrical terminal 102 and the conduit 103, then there is a change in the signal path causing a change in one or more electrical characteristics that can be detected by the electrical terminal 102. In the particular configurations of the Figures 2a-h , the electrical terminal 102 may include a resistance monitoring device and the detection of a rupture of the conduit wall 106 or an open may be based on a measurement of a change in resistance across the signal path. The configuration of the Figure 2a has been found to be more effective in detecting breaks that are located closer to the electrical terminal 102, as compared to those that are located further from the electrical terminal 102.

[0105] In reference to the Figure 2b , an alternative configuration to the Figure 2ais presented with reference numerals corresponding to the same features described above. There is a single local conductive region 203a connected to the electrically conductive element 105, which is in the form of an inner conductive layer. There are two ground connections 204a and 204b connected to the remote conductive region 202 and the electrical terminal 102 respectively. The signal path is formed by the local conductive region 203a, the electrically conductive element 105, the remote conductive region 202 and the region between the ground connections 204a and 204b. The signal path can be considered to include a sensing portion (in this case, from the electrical terminal 102 to the ground connection 204a), and a return portion (in this case, from the ground connection 204a to the ground connection 204b).

[0106] As used herein, the term “sensing portion” may refer to a portion of the signal path extending through the conduit 103 to an end of the conduit 103 opposite the electrical terminal 102. The term “return portion” may refer to a portion of the signal path “returning” to the electrical terminal 102 from the end of the conduit 103 opposite the electrical terminal 102. The “return portion” of the signal path may or may not be configured to provide sensing capability. In the example of the Figure 2b , the return portion of the signal path is between the ground connections 204a, 204b, and is, therefore, typically on grounding elements such as a chassis of a vehicle. A particular advantage of the configuration of the Figure 2b is that breaks along the entire length of the conduit 103, or cuts at each end of the conduit 103, are detectable substantially equally.

[0107] In reference to the Figure 2c , an alternative configuration to the Figure 2ais presented with reference numerals corresponding to the same features described above. The electrically conductive element comprises two separate electrically conductive elements 105a and 105b. The electrical terminal 102 comprises two local conductive regions 203a, 203b for connection to the corresponding separate electrically conductive elements 105a, 105b. The signal path is formed by the circuit provided by the local conductive region 203a, the electrically conductive element 105a, the remote conductive region 202, the electrically conductive element 105b and the local conductive region 203b. There is a single ground connection 204b connected to the interface connector 102. In this configuration, the sense and return portions of the signal path are both located along the conduit 103, and there is no need for a chassis ground connection for the return portion according to the configuration of the Figure 2bThe electrically conductive elements 105a, 105b may be segmented internal conductive coatings applied to an internal surface of the conduit 103.

[0108] The configuration of the figure 2d is similar to that of the Figure 2c with the inclusion of a ground connection 204a connected to the remote conductive region 202. In this configuration, the ground connection 204a includes a grounding resistor to ensure that the ground connection does not interfere with the return portion of the signal path. The ground connection 204a at this location provides static discharge from the remote conductive region 202.

[0109] The configuration of the figure 2e is similar to that of the Figure 2b, except that there are two electrically conductive elements 105a, 105b in the form of multiple conductive coating layers providing multiple parallel signal paths for the sensing portion of the signal path. In the examples, there are more than two electrically conductive elements.

[0110] The configuration of the Figure 2f is similar to that of the figure 2e, except that each of the two electrically conductive elements is individually connected to a different channel 205a, 205b at the electrical terminal 102 via different local conductive regions 203a, 203b respectively. Therefore, the electrical properties across each of the electrically conductive elements 105a, 105b can be measured separately. For example, when the electrical terminal 102 is configured to measure resistance, then the resistance of each conductive element 105a, 105b can be compared. If only one resistance changes, then it is possible to detect particularly small breaks.

[0111] The configuration of the figure 2g is similar to that of the Figure 2c, except that there are two parallel electrically conductive elements 105a, 105b forming the detection portion of the signal path. The electrically conductive elements 105a, 105b are connected to the electrical terminal 102 via corresponding channels 205a, 205b. In addition, there is a third electrically conductive element 105c providing the return portion of the signal path, and is connected to a grounding channel 205c. The grounding channel 205c is further electrically connected to the grounding connection 204b. The electrically conductive elements 105a, 105b, 105c may comprise conductive strips of material, and breaks in the conduit wall 106 of a size similar to the width of the strips are detectable. Detection sensitivity is improved by comparing electrical properties (such as resistance) measured for each channel.

[0112] The configuration of the figure 2h is similar to that of the figure 2e, except that there are more than two electrically conductive elements 105a, 105b, 105c in parallel along the sensing portion of the signal path.

[0113] In reference to the figure 3 , a detection system is provided, which system uses a wireless link between the conduit and the electrical terminal and / or the smart connector.

[0114] Thus, a sensing system is shown, which system may include an electrical terminal 102, electrically conductive elements 105a, 105b in the form of coils of wire around a conduit 103, and a remote connector 201. The electrical terminal 102 and the remote connector 201 are located at opposite ends of the conduit 103. The electrically conductive elements 105a, 105b form a coil at regions 301a and 301b near the ends of the conduit 103 to provide wireless transmission via inductive coupling between the conduit 103 and the electrical terminal 102 and / or the remote connector 201.

[0115] The inductive coupling coils provide an electrical communication path for transferring radio frequency identification (RFID) frequency data (and power) between an RFID chip 302 located at the electrical terminal 102 and an RFID tag 303 located at the remote connector 201. The coil is preferably resonant at a frequency generated by the RFID chip.

[0116] A break / rupture of the conduit 103 may cause a defect in the conductive elements provided along the conduit, thereby disabling or modifying the data signal received from the RFID tag 303 by the RFID chip 302, thereby ensuring detection of the break. Furthermore, cutting the conduit from the electrical terminal 102 or the remote connector 201 disables reading of the RFID tag 303, thereby causing an alert.

[0117] The conductive element which forms part of the conduit is shown as being arranged in a helically manner but it will be appreciated that other arrangements of conductive elements as described herein may be possible.

[0118] In reference to the figure 4 , the electrical terminal 102 may comprise a processing unit in the form of an analog-to-digital converter 401. The analog-to-digital converter 401 may comprise a voltage reference output VrefOutput configured to provide a predetermined voltage, a voltage input Vin and a ground signal input SigGnd. The converter 401 is connected via these inputs / outputs to a bridge circuit 402 which is well known in the state of the art.

[0119] The output VrefOutput may be electrically connected to a first branch of the bridge circuit 402 comprising a series resistor RA. The signal SigGnd may be electrically connected, via an electrical ground such as a chassis of a vehicle, to a second branch of the bridge circuit 402 comprising a resistor RB, which corresponds to an electrically conductive element as described above. The input Vin may be connected to a third branch of the bridge circuit 402 which is electrically connected between the ends of the first and second branches. The converter 401 is configured to determine a resistance across the electrically conductive element based on a measurement of the voltage Vin from the third branch of the bridge circuit 402, and the predetermined voltage output VrefOutput. In particular, the input Vin is calculated by the following mathematical equation: Vin = RB / RA + RB × Vref

[0120] There Figure 5shows an example of electrical terminal 102 and circuit construction that is similar to that described in connection with the figure 4 , however there are multiple resistors RB1, RB2, RBN+1, corresponding to multiple electrically conductive elements, which may correspond to multiple conductive elements coupled to the conduit as described above, for example with reference to figures 2g, 2hand described elsewhere. Each electrically conductive element corresponding to the resistors RB1, RB2, RBN+1 is in series with a second leg of a corresponding bridge circuit 402a, 402b, 402c. Each of the bridge circuits has a corresponding series resistor on the respective first leg RA1, RA2, RAN+1. Each of the bridge circuits provides a corresponding voltage input VinA, VinB, VinN to be measured by the converter 401. Therefore, the resistors RB1, RB2, RBN+1 can each be monitored separately providing a high level of accuracy for determining breaks in a conduit as described above.

[0121] In reference to the Figures 6a And 6b, a remote connector 201 is connected to a conduit 103. The connection comprises a wireless interface having first wireless detectors 501a located on the remote connector 201 and second wireless detectors 501b located on the conduit 103. The detectors 501a, 501b may be electrically connected to an electrical terminal as described above (not shown). The detectors 501a, 501b may be connected to the electrical terminal via the electrically conductive elements, and may be part of the signal path described above. With particular reference to the Figure 6a , the wireless sensors 501a, 501b are not aligned and, therefore, an outage condition is detected to generate an alert to a user. With particular reference to the Figure 6b, the wireless detectors 501a, 501b are aligned and therefore no cut condition is detected. The wireless detectors 501a, 501b as shown herein may be applied to any connector attached to the conduit upstream or downstream of the gas flow to detect any cut of the conduit at either end. In some examples, the detectors 501a, 501b include integrated conductive coils, such that when a current is applied to at least one of the detectors, a different electrical signal is returned depending on the alignment of the coils. Alternatively, the detectors 501a, 501b may operate based on the detection of an electrical contact that is disconnected when the detectors become misaligned with respect to each other.

[0122] It will be noted that the sensors used to determine the connection status of the remote connector may be magnetic (such as a reed switch, for example) or may be electrical contacts that are made electrically contact after sufficient insertion of the conduit into the connector or the connector onto a different element. The electrical connection may be achieved by the inserted mating connector 103 moving or deforming an electrically conductive structure or feature.

[0123] A sensing conduit as described herein may be coupled to electrically conductive elements in accordance with the structure shown in FIG. figure 7 . In reference to the figure 7 , there are multiple layers of electrically conductive elements 701a, 701b. An insulating layer 702 is located between the layers of electrically conductive elements 701a, 701b. An outer layer 703 is located outside the detection conduit.

[0124] In reference to the figure 8 , a detection system may include multiple detection conduits (each as described herein) 103a, 103b, 103c that are each coupled to a central electrical terminal 102, as described herein. Each of the detection conduits 103a, 103b, 103c may be connected to a corresponding remote connector 201a, 201b, 201c. The assembly provides a modular assembly that may be adapted to multiple different types of geometry. A break or cut in any detection conduit 103a, 103b, 103c, may be detected by a single electrical terminal 102, thereby reducing the number of links / cables, and reducing installation cost. The assembly shown in the figure 8 is a radial arrangement but others are possible.

[0125] In reference to the figure 9, a method of operating a detection system according to this disclosure comprises, in step 901, receiving an electrical signal from at least one electrically conductive element in the conduit. The electrical signal may be a signal provided by a sensor that detects the state of a connector and / or an electrical signal injected into an electrically conductive element of the conduit to monitor the state of the conduit.

[0126] In step 902, the electrical signal is monitored for an electrical characteristic or a change in the electrical signal caused by a deformation of the conductive element. In step 903, a determination may be made as to whether a monitored change indicates a change in the condition of the conduit, such as a deformation of the shape of the conduit (such as a break), or a break in the conduit or a poor connection of a connector.

[0127] At step 904, an alert may be provided to a monitoring system or a user. The alert may correspond to the detected change.

[0128] It will be noted that the processing unit described herein and which is located locally with respect to the connectors and the conduit may simply provide an output signal which represents a change in the monitored state, rather than an alert per se. Thus, the determination of step 903 and the provision of the alert may be performed by a different processing unit which is part of a different system or of an overall system of which the detection system is a part. Detection systems as described herein have been found to operate advantageously, particularly when subjected to external conditions such as conduit flexing, the presence of water and high temperature - for example 80 degrees C.When the electrical property being monitored is resistance across the electrically conductive element, the constructions described above provide a correlation between a conduit break size and a resistance level measured by the electrical terminal. It would therefore be possible for a user to use the present system to determine the severity of any break or other damage to the conduit.

[0129] The detection systems discussed herein are not limited to application with crankcase gas recirculation systems. Other examples of use include the detection, in fluid systems, of fluids critical to battery pack cooling systems, electric motor cooling systems (including system tubing and connectors), hydrogen fuel systems, and hydrogen vehicle cooling systems.

Claims

1. A detection system for detecting a breakdown in a fluid pathway of a fluid system, the detection system comprising: at least one conduit (103) comprising a conduit wall (106) which defines a fluid pathway for the transfer of fluid and at least one electrically conductive element (105) extending along the at least one conduit (103) and which forms an electrical signal path for a first electrical signal which indicates a condition of the at least one conduit (103); and, an electrical terminal (102) electrically connected to the at least one electrically conductive element (105) such that the first electrical signal is transmitted to the electrical terminal (102) via the electrical signal path; at least one connector (107) connected to the at least one conduit (103) and at least one sensor (104) configured to determine a condition of the at least one connector (107) and generate a second electrical signal, said at least one sensor (104) being electrically connected to the at least one electrically conductive element (105) such that the second electrical signal is transmitted to the electrical terminal (102) via the electrical signal pathway; and a processing unit for receiving the first and second electrical signals and monitoring the first and second electrical signals for an electrical characteristic which is indicative of a breakdown of the at least one conduit (103) and / or a breakdown or disconnection of the at least one connector (107), respectively.

2. The detection system according to claim 1, wherein the processing unit is configured to determine that a breakdown is present in the at least one conduit (103) or that the at least one connector (107) is fully or partially disconnected using the monitored electrical characteristic.

3. The detection system according to claim 1 or 2, wherein the second electrical signal is a sensor electrical signal encoded with data from the at least one sensor (104) and the first electrical signal is a conduit electrical signal encoded with data relating to the condition of the at least one conduit (103).

4. The detection system according to claim 3, wherein the conduit electrical signal is applied to the at least one electrically conductive element (105) independently of the sensor electrical signal.

5. The detection system according to any of the preceding claims, wherein the electrical characteristic is one or several characteristics selected from the group comprising: resistance, conductance, capacitance, inductance, frequency response, amplitude or transit time, or a change thereof.

6. The detection system according to any of the preceding claims, wherein the at least one electrically conductive element (105) extends along the entire length of the at least one conduit (103).

7. The detection system according to any of the preceding claims, wherein the at least one electrically conductive element (105) extends circumferentially around a surface of the conduit wall (106) of the at least one conduit (103).

8. The detection system according to any of the preceding claims, wherein the at least one electrically conductive element (105) is at least partially embedded within the conduit wall (106).

9. The detection system according to any of the preceding claims, wherein the at least one conduit (103) further comprises a plurality of electrically conductive elements (105a, 105b).

10. The detection system according to claim 9, wherein the electrical signal path comprises a sensing portion extending from the electrical terminal (102) to a remote end of the at least one electrically conductive element (105) at a first end of the at least one conduit (103), and a return portion extending from the remote end of the at least one electrically conductive element (105) to the electrical terminal (102) and wherein at least one of the plurality of electrically conductive elements (105a, 105b) is configured to form said return portion of the electrical signal path.

11. The detection system according to any of the preceding claims, wherein the at least one electrically conductive element (105) comprises at least one coil.

12. The detection system according to claim 11, wherein the at least one coil provides a wireless coupling for coupling to the at least one connector (107) and / or the at least one sensor (104).

13. The detection system according to any of the preceding claims, wherein the at least one sensor (104) is one or several sensors from among: a seal contact pressure sensor, an alignment sensor; an electrical contact sensor in which electrical contacts are made or broken with the connection of the at least one connector (107); a magnetic sensor in which a magnetic circuit is completed with the connection of the at least one connector (107); a wireless sensor or an ultrasonic sensor.

14. The detection system according to claim 13, wherein the at least one sensor (104) is embedded within the at least one connector (107).

15. A method for detecting a condition of a fluid system using the detection system according to any of the preceding claims, and comprising the steps of: receiving a first electrical signal and a second electrical signal from at least one electrically conductive element (105) in the at least one conduit (103); and monitoring the first and second electrical signals for an electrical characteristic which is indicative of a breakdown of the at least one conduit (103) and / or a disconnection of the at least one connector (107).

16. The method of claim 15, further comprising: determining a breakdown in the fluid pathway of the fluid system based on a monitored electrical characteristic.

17. The method of claim 16, wherein the electrical characteristic is one or several characteristics selected from the group comprising: resistance, conductance, capacitance, inductance, frequency response, amplitude or transit time, or a change thereof.