Hydraulic Event Monitoring for Predictive Maintenance
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Solution Overview
Problem
Current hydraulic system monitoring technologies are inefficient and costly due to the need for extensive domain expertise and resource-intensive solutions, leading to reactive maintenance practices that result in accelerated system wear and high operational costs.
Innovation Solution
A scalable system and method for evaluating hydraulic system events at subcomponent and global levels, utilizing a sensor subsystem with pressure, temperature, flow, and pump demand sensors, and processing subsystem that analyzes signals to generate analyses for improved maintenance and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If distributed sensors and custom algorithms are used for full system monitoring, then measurement precision and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The patent applies universality by using a single set of sensors to monitor multiple hydraulic subcomponents (pump, valve, actuator, hose) through a unified monitoring system that processes signals from all components, thereby reducing overall system complexity while maintaining comprehensive monitoring capability
Solution Approach 2:
The patent introduces a signal processing intermediary that acts as a mediator between the physical hydraulic system and the monitoring system. This intermediary layer processes and interprets sensor signals to extract diagnostic information, simplifying the connection between distributed sensors and the monitoring platform
2Measurement precision
If application-specific domain expertise is required for monitoring system implementation, then measurement precision is improved, but ease of operation deteriorates
Solution Approach 1:
The monitoring system applies self-service by automatically detecting, classifying, and diagnosing hydraulic system events without requiring user expertise. The system autonomously processes sensor data, identifies anomalies, and provides diagnostic information, making the monitoring capability accessible to operators regardless of their domain knowledge
Solution Approach 2:
The patent applies preliminary action by pre-configuring the monitoring system with algorithms and signal processing capabilities that automatically recognize and classify hydraulic events. This preliminary preparation enables the system to immediately diagnose issues upon occurrence without requiring real-time expert analysis
3Loss of energy
If reactive maintenance practices are used to reduce monitoring costs, then loss of substance is reduced, but productivity deteriorates
Solution Approach 1:
The monitoring system applies preliminary action by detecting and diagnosing hydraulic system events before they cause equipment failure. By identifying anomalies early through continuous sensor monitoring and analysis, the system enables proactive maintenance scheduling that prevents unexpected downtime while optimizing maintenance resource allocation
Data Source
AI summary
A system includes sensors for monitoring signals, and a processing system executes one or more methods for identification of system events, from the signals, corresponding to state changes and performance of the system and/or its subcomponents. Event identification is performed with classification and/or other machine learning algorithms, with generation of novel training data sets. The sensor(s) can also be used to determine power consumption information about the system and/or its subcomponents. The system processes event-associated outputs for execution of actions for improving system performance, along with other downstream applications.