Intermittent Fault Detection via Dynamic Trip Condition Modification

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing diagnostic methods for electrical systems struggle to accurately identify intermittent faults, which are often overlooked or mischaracterized as false errors, leading to unnecessary repairs and potential machine failure, especially in systems where vibrations from testing procedures complicate fault identification.

Innovation Solution

An apparatus and method utilizing an electronic service tool to instruct an electronic control module to disable enable conditions and modify trip conditions, allowing for the identification of intermittent faults by monitoring electrical system data as a user wiggles components, generating and communicating fault codes when modified trip conditions are met, and switching the on-board diagnostics system into a wiggle test mode to enhance sensitivity to intermittent faults.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional diagnostic methods are used to identify hard faults, then hard faults can be detected, but intermittent faults are mischaracterized as false errors and overlooked

Engineering Contradiction:

Improvefault detection accuracyVSAvoidintermittent fault information

Core Design Contradiction:

Measurement precisionVSLoss of information

Solution Approach 1:

The patent changes the diagnostic parameters by disabling enable conditions and modifying trip conditions to be more sensitive to intermittent faults. This allows the system to detect faults that would otherwise be missed or mischaracterized as false errors, thereby improving measurement precision without losing intermittent fault information

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a dynamic testing approach where the system monitors electrical system data in real-time as components are physically manipulated. This dynamic monitoring capability allows the system to capture intermittent faults that occur during the manipulation process, preventing information loss

Inventive Principle:

Principle #15Dynamics

2Reliability

If vibration-based testing procedures are used to provoke intermittent faults, then faults can be made visible, but vibrations cause intermittent faults to appear simultaneously in multiple areas making separate identification difficult

Engineering Contradiction:

Improvefault visibilityVSAvoidfault isolation difficulty

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent extracts the vibration source from the testing procedure by replacing shaking or engine cycling with direct manual manipulation of individual components. This allows intermittent faults to be provoked locally at the specific component being tested rather than system-wide through vibrations, enabling separate identification of each fault

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses an electronic service tool as an intermediary that guides the testing process and correlates fault occurrences with specific component manipulations. This intermediary system helps isolate and identify individual intermittent faults even when multiple components are being tested, by providing structured feedback and fault tracking

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If engine starting and stopping is used to provoke intermittent faults, then faults can be detected, but the process causes vibrations that make separate fault identification more difficult and may cause damage to components

Engineering Contradiction:

Improvefault detection capabilityVSAvoidcomponent stress and damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical testing method of starting and stopping the engine with an electronic diagnostic approach. The electronic service tool monitors electrical system data while components are manually manipulated, eliminating the need for repeated engine cycles and associated mechanical stress on components

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent performs preliminary configuration of the diagnostic system by disabling enable conditions and modifying trip conditions before beginning the fault detection process. This preliminary setup allows the system to be more sensitive to intermittent faults without requiring aggressive testing procedures that could damage components

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS7454298B2Apparatus and method for identifying electrical faults

Publication Date: 2008.11.18 CATERPILLAR INC

AI summary

A method of identifying an electrical fault in an electrical system may include coupling an electronic service tool to an electronic control module. The method may also include instructing the electronic control module to disable an enable condition and modify a trip condition set by the electronic control module. The method may further include monitoring the electrical system as a user wiggles a component of the electrical system. The method may further include providing the electronic control module with electrical system data, and generating a fault code when the electrical system data fulfills the modified trip condition. The method may further include communicating the fault code to the user.