Remote Diagnostic Combustion Gas Leak Detection Strategy
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Solution Overview
Problem
Current methods for detecting combustion gas leaks in work machines are time-consuming and costly, often requiring the machine to be out of service during testing, and may not accurately identify leaks until engine damage has occurred.
Innovation Solution
A remote diagnostic system for work machines that includes a controller with a processor, coolant temperature sensor, and pressure sensor, which monitors coolant fluid temperature and pressure during start-up, calculates an expected pressure based on temperature, and generates a failure code if the actual pressure exceeds the expected pressure, indicating a combustion gas leak.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional combustion gas leak detection methods are used, then leak detection capability is achieved, but the detection process is time-consuming and requires the work machine to be out of service
Solution Approach 1:
The system performs preliminary monitoring of coolant pressure and temperature during normal engine operation before actual leak damage occurs. By continuously measuring these parameters and comparing them against expected values calculated from engine operating conditions, the system detects leaks in advance, allowing maintenance to be scheduled during convenient downtime rather than requiring immediate machine shutdown for testing.
Solution Approach 2:
The patent replaces traditional mechanical pressure testing methods with electronic sensing and computational analysis. Instead of using physical test equipment to pressurize and monitor the cooling system, the invention uses coolant pressure and temperature sensors combined with a controller that calculates expected pressure values based on engine operating parameters, enabling non-intrusive detection during normal operation.
2Reliability
If traditional combustion gas leak detection methods are used, then leak detection is possible, but costly testing kits are required
Solution Approach 1:
The system integrates combustion gas leak detection functionality into the existing engine control unit, allowing the same controller to perform multiple functions including engine management, emissions control, and leak detection. This eliminates the need for separate expensive testing kits, as the diagnostic capability is built into the standard engine control system that is already present in modern equipment.
Solution Approach 2:
The engine control system performs self-diagnosis by monitoring its own operating parameters (coolant pressure, temperature, engine load, RPM) and comparing actual values against expected values. This self-monitoring capability eliminates the need for external testing equipment, as the system uses its own sensors and computational resources to detect combustion gas leaks internally.
3Loss of information
If traditional diagnostic systems are used, then coolant flow reduction or low coolant level codes are generated, but the underlying combustion gas leak is not accurately identified
Solution Approach 1:
The system continuously monitors coolant pressure and temperature and provides feedback to the controller, which calculates expected pressure values based on engine operating conditions. When actual pressure deviates from expected pressure beyond a threshold, the system generates a specific combustion gas leak diagnostic code. This closed-loop feedback mechanism provides accurate identification of the underlying leak condition rather than generic coolant system codes.
Solution Approach 2:
The invention detects combustion gas leaks by monitoring changes in coolant pressure and temperature parameters and comparing them against expected parameter values calculated from engine operating conditions. By analyzing deviations in these physical parameters rather than relying on generic coolant level or flow codes, the system achieves precise identification of combustion gas intrusion into the cooling system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system allows for early detection of combustion gas leaks, preventing engine damage and reducing downtime by providing an automated alert for maintenance before catastrophic failure, enabling timely maintenance planning and minimizing productivity loss.
Implementation Method 1
The pressure sensor may be coupled to the inlet of the pump, and may monitor and transmit a coolant fluid pressure at the inlet of the pump
Implementation Method 2
The coolant temperature sensor may be configured to monitor and transmit a coolant fluid temperature
Implementation Method 3
as combustion gas leaks into the engine cooling system of a work machine, the gas can aerate the coolant fluid, causing a typical diagnostic system for the work machine to generate a failure code indicating a reduction in coolant flow
Data Source
AI summary
A work machine with a remote diagnostic system includes a combustion engine, a pump, a coolant temperature sensor to monitor and transmit a coolant fluid temperature, a pressure sensor coupled to an inlet of the pump, and a controller. The pressure sensor is configured to monitor and transmit a coolant fluid pressure. The controller is operatively associated with the engine, the coolant fluid temperature sensor, the pressure sensor and an equipment care advisor module. The equipment care advisor module is configured to monitor the coolant fluid temperature during a start-up of the work machine, monitor the coolant fluid pressure during the start-up of the work machine, calculate an expected coolant fluid pressure based on the monitored coolant fluid temperature and the monitored coolant fluid pressure, and generate a failure code indicating a combustion gas leak when the monitored coolant fluid pressure exceeds the expected coolant fluid pressure.