Vehicle Part RUL Estimation Using Sensor Data and Dealer Networks

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional methods for determining the Remaining Useful Life (RUL) of automotive parts are either unreliable due to reliance on predetermined schedules or imprecise because they do not account for actual vehicle usage, especially for parts not communicatively connected with an ECU.

Innovation Solution

A system and method that utilize sensors and statistical data from dealer networks to determine the RUL of vehicle parts by calculating the forecasted useful operation time and subtracting the total operation time, allowing for accurate estimation regardless of ECU connectivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If pre-determined replacement schedules are used, then replacement timing is standardized and easy to manage, but unnecessary premature replacement occurs due to not accounting for actual vehicle usage

Engineering Contradiction:

Improveease of maintenance schedulingVSAvoidaccuracy of replacement timing

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The system changes the parameter basis for replacement scheduling from fixed time intervals to actual usage metrics. By integrating sensors that measure real operational parameters (miles driven, operating hours, load conditions), the system dynamically adjusts replacement timing based on actual part wear and usage patterns, eliminating premature replacements while maintaining standardized management procedures

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system implements continuous feedback loops where sensor data from vehicle parts is constantly monitored and fed back to the maintenance management system. This feedback mechanism enables real-time assessment of part condition and usage intensity, allowing the system to optimize replacement schedules dynamically rather than relying on static pre-determined timelines

Inventive Principle:

Principle #23Feedback

2Loss of information

If on-board diagnostics (OBD) are used for parts connected to ECU, then real-time data is available, but parts not connected with ECU cannot be monitored

Engineering Contradiction:

Improveavailability of operational dataVSAvoidapplicability to all vehicle parts

Core Design Contradiction:

Loss of informationVSAdaptability or versatility

Solution Approach 1:

The system achieves universality by implementing a hybrid monitoring architecture that combines ECU-based OBD for connected parts with standalone sensors for unconnected parts. This multi-functional approach enables comprehensive monitoring across all vehicle parts regardless of their connectivity status, with the system automatically selecting the appropriate monitoring method for each part

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

For parts not connected to the ECU, the system introduces intermediary sensor devices that act as mediators between the unconnected parts and the central monitoring system. These standalone sensors capture operational data from parts like exhaust systems or suspension components and transmit it to the maintenance management platform, bridging the connectivity gap

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If performance based prognostic models are used, then RUL estimates can be generated, but the estimates are imprecise because they do not reflect actual use of specific vehicle parts

Engineering Contradiction:

ImproveRUL estimation capabilityVSAvoidaccuracy of RUL estimation

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The system replaces traditional mechanical/probabilistic RUL estimation models with sensor-based actual usage measurement. Instead of using generic performance metrics or extrapolation models, the system directly measures real operational parameters (temperature, vibration, load, operating hours) from sensors installed on or near the parts, providing precise actual usage data that accurately reflects true part wear and extends RUL estimation accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs preliminary characterization of part behavior during early operational phases by continuously collecting and analyzing sensor data. This preliminary action establishes baseline performance patterns and wear rates specific to each part and vehicle configuration, which are then used to generate more accurate RUL predictions that account for actual usage conditions rather than relying on generic models

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250037516A1Systems for prognosing remaining useful life

Publication Date: 2025.01.30 INT ENGINE INTPROP CO LLC

AI summary

Described herein are embodiments of systems and methods for determining remaining useful life (RUL) of an electro-mechanical device. The systems may include a compiler and an external network communicatively connected with the compiler. The compiler determines forecasted reliability of the part, determines actual reliability of the part, divides forecasted reliability by actual reliability to determine forecasted useful operation time, Tx, and subtracts total operation time T from forecasted useful operation time Tx to determine RUL.