Engine Starter Crank Speed Monitoring for Predictive Failure Alerts

Solution Overview

Problem

Engine starter failures in transport refrigeration units lead to downtime and loss of goods due to the inability to maintain temperature, as existing systems lack predictive maintenance capabilities to anticipate and prevent such failures.

Innovation Solution

An engine starter system that includes a controller programmed with predicted crank speed values based on battery voltage and ambient air temperature, comparing measured crank speed to these values, and triggering an alarm if the actual speed is below a threshold, along with additional sensors for battery voltage and temperature measurement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional engine starter systems are used without predictive maintenance capabilities, then the system structure remains simple, but the reliability of the engine starter decreases due to unexpected failures

Engineering Contradiction:

Improveengine starter reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system performs preliminary diagnostics by measuring crank speed, battery voltage, and temperature before failure occurs. The controller compares actual crank speed against expected values to detect potential starter failures early, enabling maintenance before the starter actually fails and causing downtime.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements feedback by continuously monitoring crank speed sensor signals and comparing them against expected performance thresholds. When the crank speed deviates from expected values, the system generates an alarm signal to alert operators of potential starter failure, creating a closed-loop monitoring system that improves reliability.

Inventive Principle:

Principle #23Feedback

2Loss of time

If no predictive maintenance system is implemented, then the device complexity remains low, but the loss of time due to unexpected failures and downtime increases

Engineering Contradiction:

ImprovedowntimeVSAvoidsystem complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The system performs preliminary diagnostics by measuring crank speed, battery voltage, and temperature before failure occurs. The controller compares actual crank speed against expected values to detect potential starter failures early, enabling maintenance before the starter actually fails and causing downtime.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements feedback by continuously monitoring crank speed sensor signals and comparing them against expected performance thresholds. When the crank speed deviates from expected values, the system generates an alarm signal to alert operators of potential starter failure, creating a closed-loop monitoring system that improves reliability.

Inventive Principle:

Principle #23Feedback

3Difficulty of detecting and measuring

If existing monitoring systems without predictive capabilities are used, then the measurement requirements are minimal, but the ability to detect and measure potential failures is insufficient

Engineering Contradiction:

Improvefailure detection capabilityVSAvoidsensor and controller complexity

Core Design Contradiction:

Difficulty of detecting and measuringVSDevice complexity

Solution Approach 1:

The controller serves multiple functions: it monitors crank speed from the sensor, measures battery voltage, reads temperature data, compares actual versus expected crank speed values, determines whether failure is likely, and generates alarm signals. This multi-functionality consolidates what could be separate complex systems into a single integrated controller.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system detects potential failures by monitoring changes in crank speed parameters and comparing them against expected values that account for varying operating conditions (battery voltage and temperature). This parameter-based approach enables failure detection without requiring complex diagnostic equipment.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system effectively predicts engine starter failures, allowing for timely maintenance and preventing downtime by alerting operators to potential issues before they cause operational disruptions.

Implementation Method 1

a crank speed sensor operable to measure the crank speed of the engine starter

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a voltage sensor operable to measure the voltage of the battery

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS8534082B2Engine starter predictive maintenance system

Publication Date: 2013.09.17 THERMO KING CORP

AI summary

An engine starter system that predicts when starter failure is imminent. The engine starter system monitors engine starter crank speed, battery voltage and ambient air temperature. The crank speed, battery voltage and ambient air temperature are communicated to a controller which compares the crank speed for the measured battery voltage and air temperature to a predicted crank speed for the measured battery voltage and air temperature. If the crank speed is lower than the predicted crank speed, a signal is sent to an alarm.