Dynamic Lubricant Drain Interval Prediction Using Condition Monitoring
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Solution Overview
Problem
Current methods for determining lubricant drain intervals in engines are often based on fixed time or distance, which can lead to the continued use of spent lubricant in severe conditions or premature disposal, resulting in poor fuel efficiency, costly maintenance, and premature engine failure, as they do not account for individual engine conditions or operating variability.
Innovation Solution
A system and method that uses a computer program to predict lubricant drain intervals by analyzing a plurality of analysis parameter values from engine lubricant samples over time, employing models such as partial least squares regression, neural networks, and general linear models to determine when lubricant properties degrade, allowing for personalized lubricant discard intervals based on engine-specific conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed time or distance lubricant drain intervals are used, then maintenance scheduling is simple and consistent, but lubricant may be continued to be used in severe conditions leading to engine failure or prematurely disposed of in optimal conditions
Solution Approach 1:
The patent transitions from static fixed intervals to dynamic condition-based intervals. The system continuously monitors lubricant condition parameters (viscosity, contamination levels, acid number) and adjusts drain intervals based on actual lubricant degradation rates, allowing extension in optimal conditions and shortening in severe conditions.
Solution Approach 2:
The system implements feedback by measuring lubricant condition parameters at multiple time points and using this information to predict future lubricant state. The feedback loop compares actual condition against thresholds and adjusts maintenance scheduling accordingly, preventing both premature disposal and continued use of degraded lubricant.
2Productivity
If fixed time or distance lubricant drain intervals are used, then maintenance operations are standardized, but fuel efficiency deteriorates due to premature disposal or continued use of spent lubricant
Solution Approach 1:
The system changes the parameter basis for maintenance scheduling from fixed time/distance to actual lubricant condition parameters. By monitoring viscosity, contamination, and chemical degradation, the system determines drain intervals based on physical-chemical state rather than arbitrary time markers, optimizing both maintenance efficiency and fuel economy.
Solution Approach 2:
The system performs preliminary prediction of lubricant failure using regression models and trend analysis on historical data. This allows proactive scheduling of maintenance before actual failure occurs, avoiding the energy loss from using degraded lubricant while preventing premature maintenance on still-functional lubricant.
3Measurement precision
If individual engine condition monitoring is implemented, then lubricant drain intervals can be optimized for each engine, but system complexity increases
Solution Approach 1:
The patent implements a universal monitoring platform that can assess multiple lubricant parameters (viscosity, contamination, chemical degradation) through a single integrated system. The same hardware and software infrastructure supports various measurement functions, reducing overall system complexity while maintaining comprehensive monitoring capability.
Solution Approach 2:
The system uses regression models and prediction algorithms as intermediaries between raw sensor data and maintenance decisions. These mathematical models process complex multi-parameter data and translate it into simple predictive outcomes and recommended drain intervals, reducing the complexity of interpreting monitoring data.
Data Source
AI summary
A system, a method and a computer program to determine the usability of a lubricant such as, e.g., engine oil, and when to replace the lubricant in a particular engine. The system, method, and computer program are further configured to generate a lubricant discard interval for each engine in, e.g., a company's fleet of vehicles. The system, method, and computer program are configured to generate lubricant discard interval schedule for each of the vehicles in the company's fleet based on the lubricant discard intervals.