Vehicle Prognostics Using Fleet Data for Predictive Maintenance

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Solution Overview

Problem

Current vehicle fleet management relies on reactionary maintenance, leading to unsatisfied riders and undesirable downtime due to unexpected failures, which can be mitigated by implementing a predictive maintenance system.

Innovation Solution

A preventative maintenance interval analysis system and prognostic system using machine learning engines to analyze vehicle and fleet data, determining failure probabilities and generating predictive maintenance schedules based on component health and usage patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If reactionary maintenance is used, then maintenance costs are reduced, but vehicle downtime increases and reliability decreases

Engineering Contradiction:
Improvevehicle reliabilityVSAvoidvehicle downtime
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary actions by predicting component failures before they occur. The machine learning model analyzes current component data and historical failure patterns to forecast future failures, enabling maintenance to be scheduled in advance rather than reacting to actual failures. This preliminary prediction and scheduling reduces both downtime and improves reliability.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system implements feedback by continuously monitoring component data, comparing it against learned failure patterns, and adjusting maintenance schedules based on predicted failure probabilities. The model learns from actual failure outcomes and refines its predictions, creating a closed-loop system that improves reliability while optimizing maintenance timing to minimize downtime.

Inventive Principle:
Principle #23Feedback

2Reliability

If predictive maintenance system is implemented, then vehicle downtime is reduced, but system complexity increases

Engineering Contradiction:
Improvefleet reliabilityVSAvoidmaintenance system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The system achieves universality by creating a multi-functional platform that handles data collection from multiple sources, machine learning model training, failure prediction, maintenance schedule optimization, and fleet-wide analysis. This single integrated system performs what would otherwise require multiple separate tools, managing complexity through consolidation while delivering comprehensive predictive maintenance capabilities.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The machine learning model serves as an intermediary between raw component data and maintenance decisions. Rather than directly complex data processing and decision-making logic, the system introduces a trained model that translates sensor data and historical information into failure probability predictions and maintenance recommendations, simplifying the overall system architecture.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Measurement precision

If component monitoring is enhanced, then failure prediction accuracy is improved, but data processing requirements increase

Engineering Contradiction:
Improvefailure prediction accuracyVSAvoiddata processing energy
Core Design Contradiction:
Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The system extracts only the most relevant features and patterns from component data for analysis. Rather than processing all raw sensor data equally, the machine learning model identifies and extracts key indicators of component health and failure risk, processing only these essential features. This extraction approach maintains high prediction accuracy while significantly reducing computational energy requirements.

Inventive Principle:
Principle #2Taking out (Extraction)

Data Source

PatentUS20240176341A1Vehicle prognostic tool
Publication Date: 2024.05.30 CUMMINS INC
  • US20240176341A1 patent drawing
  • US20240176341A1 patent drawing
  • US20240176341A1 patent drawing

AI summary

Systems and apparatuses include one or more processing circuits comprising one or more memory devices configured to store instructions thereon that cause one or more processors to: receive electronic field performance analytics (eFPA) information related to a component of the vehicle; receive vehicle information including operating conditions and historical vehicle information of the vehicle; receive fleet information including fleet usage and fleet vehicle types of the fleet of vehicles; develop a prognostic model using a machine learning engine that receives the eFPA information, the vehicle information, and the fleet information; determine a failure probability using the prognostic model; compare the failure probability to a predetermined threshold; determine a remaining life of the component when the failure probability is equal to or greater than the threshold; and generate a report identifying the component and the remaining life.