Piston Ring Life Estimation via Optical Profile Alignment
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Solution Overview
Problem
Current methods for evaluating the performance and predicting the lifespan of piston rings in internal combustion engines are costly, time-consuming, and often result in conservative replacement schedules, leading to unnecessary maintenance overhead.
Innovation Solution
A system and method that involves obtaining a reference profile of a piston ring with fiducials, aligning it with measured profiles, determining wear parameters such as wear depth and volume, and generating a wear model to estimate the remaining life of the piston ring, using a processor-based system with data acquisition, profile registration, and life prediction units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If piston ring is replaced based on estimated average life span, then maintenance reliability is ensured, but maintenance overhead increases due to conservative replacement schedules
Solution Approach 1:
The patent replaces mechanical measurement methods with optical measurement technology. A profilometer uses optical sensors and lasers to measure piston ring thickness and wear, eliminating the need for physical contact and mechanical wear during inspection. This substitution enables non-destructive, rapid measurement that does not affect the piston ring's operational life.
Solution Approach 2:
The patent changes the measurement parameter from indirect mechanical assessment to direct optical thickness measurement. By measuring the actual thickness of the piston ring and comparing it to minimum threshold values, the system determines remaining life based on physical dimensions rather than time-based estimates, enabling more accurate maintenance scheduling.
2Measurement precision
If engine tests are conducted for performance evaluation, then accurate performance assessment is achieved, but cost and time consumption increase significantly
Solution Approach 1:
The patent extracts the critical measurement function from complex engine testing. Instead of running full engine tests to assess piston ring performance, the system isolates and measures only the relevant parameter - piston ring thickness - using a profilometer. This extraction eliminates the need for costly and time-consuming engine dynamometer tests while maintaining assessment accuracy.
Solution Approach 2:
The patent creates a digital profile copy of the piston ring's physical dimensions. The profilometer generates a digital representation of the piston ring thickness profile, which can be stored, analyzed, and compared without requiring physical engine testing. This digital copying enables repeated assessments without additional time or cost.
3Measurement precision
If piston ring thickness is measured mechanically, then thickness measurement is obtained, but measurement process causes additional wear and reduces measurement precision
Solution Approach 1:
The patent replaces mechanical measurement methods with optical measurement technology. A profilometer uses optical sensors and lasers to measure piston ring thickness and wear, eliminating the need for physical contact and mechanical wear during inspection. This substitution enables non-destructive, rapid measurement that does not affect the piston ring's operational life.
Data Source
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AI summary
A method (600) for estimating life of a piston ring includes obtaining a reference profile of the piston ring. The reference profile comprises a plurality of reference fiducials. The method further includes receiving (602) a measured profile of the piston ring. The measured profile comprises a plurality of measured fiducials. The method further includes aligning (604) the measured profile with the reference profile based on one or more of the plurality of reference fiducials and one or more of the plurality of measured fiducials. The method also includes determining (606) one or more wear parameters based on the aligned measured profile and the reference profile. The method also includes generating (608) a wear model based on the one or more wear parameters. The method also includes estimating (610) a life of the piston ring based on the wear model.