Fluid Power Hose Diagnostics for Predictive Failure Response
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Solution Overview
Problem
Fluid power system failures, particularly hose failures, often go undetected until it's too late, leading to costly downtime, oil spillage, and project delays, as existing diagnostic systems lack real-time failure detection and response capabilities.
Innovation Solution
A predictive algorithm and diagnostic system that monitors fluid power system parameters, calculates cumulative hose damage using pressure and temperature sensors, and communicates potential failures to a central location, triggering a service response before actual failure occurs, including vehicle location and necessary spare parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional service replacement methods are used for fluid power hoses, then components are replaced based on scheduled maintenance or after failure, but this leads to expensive downtime, oil spillage, and lost revenue because failures are not detected in real-time
Solution Approach 1:
The system performs preliminary detection of hose degradation by monitoring pressure impulse exposure and calculating cumulative damage before actual failure occurs. This allows maintenance to be scheduled proactively, preventing unexpected failures and the associated downtime and oil spillage.
Solution Approach 2:
The system continuously monitors pressure impulses and provides real-time feedback on hose condition through cumulative damage calculations. This feedback loop enables dynamic assessment of hose integrity and triggers alerts before failure occurs, allowing timely intervention.
2Measurement precision
If cumulative damage formulae like SAE J1927 are used to estimate hose life, then design selection is improved, but real-time diagnostic capability and response to incremental damage are not provided
Solution Approach 1:
The patent replaces static mechanical life estimation methods with an electronic monitoring system that uses sensors and processors to continuously track pressure impulses and calculate cumulative damage in real-time. This substitution enables both accurate estimation and active diagnostic capability.
Solution Approach 2:
The system introduces an intermediary cumulative damage calculation layer between raw pressure sensor data and hose failure prediction. This intermediary processing layer translates pressure impulse history into meaningful degradation assessments, providing both accurate estimation and real-time diagnostic information.
3Device complexity
If no diagnostic system is implemented for fluid power hoses, then system complexity is minimized, but failure detection and response capabilities are completely absent
Solution Approach 1:
The diagnostic system is designed to be multi-functional, serving both as a design tool (providing cumulative damage estimates for hose selection) and as an operational diagnostic system (monitoring real-time hose condition). This universality justifies the added complexity by delivering multiple value propositions from a single system.
Data Source
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AI summary
Diagnostic and response systems and methods for a fluid power system acquire data from pressure and temperature sensors disposed in the fluid power system, analyze the data in a failure algorithm to build a history of cumulative damage to hoses in the fluid power system, communicates an indication of potential imminent hose failure to a central location when a level of the cumulative damage indicates imminent failure of a hose, analyze the information at the central location to determine an appropriate response, and transmit information about the fluid power system, including location, and identification of the hose about to fail to a response unit The response unit responds to the location and replaces the component prior to failure, or the communication might include information that the hose has failed, such that the response unit replaces the failed hose to return the fluid power system to normal operation.