IP Library › Granted Patent US 12,228,089
Granted Patent B2
US 12,228,089 · App. 18/602,931 · Granted Feb 18, 2025

Systems and methods for determining exhibited useful life of sensors in monitored systems

Inventors: Swapnali Gujar (Bargersville, IN); Kapil Rajkumar Dhanwani (Columbus, IN); Kwadwo O. Owusu (Greenwood, IN); Premjee Sasidharan (Columbus, IN); Alan H. Zhao (Columbus, IN); Jinqian Gong (Columbus, IN); Jeffrey Diwakar Abraham (Columbus, IN); Thomas C. Smith, Jr. (Columbus, IN)
Assignee: Cummins Emission Solutions Inc.
F02D41/222F02D41/1401F02D41/1454F02D41/1461F02D41/2474G05B23/0283F02D2041/1433
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Quick Facts
Patent No.
US 12,228,089
App. No.
18/602,931
Granted
Feb 18, 2025
Kind
B2
Abstract

A method executed by at least one server, comprising: receiving, from a first monitored system comprising an internal combustion engine and a first sensor, a first signal associated with a first occurrence and a second occurrence of an internal combustion engine event and first measurement data of the first sensor; determining a first measurement from the first measurement data and a second measurement from the first measurement data based on the first and second occurrences, respectively; determining a reference measurement; determining a first reference deviation; determining a second reference deviation; after determining the first reference deviation is less than a first reference threshold and the second reference deviation is less than a second reference threshold, determining a measurement deviation; comparing the measurement deviation to a measurement threshold; and after determining the measurement deviation satisfies the measurement threshold, determining a first exhibited useful life of the first sensor.

Claims (112)

1. A method comprising:

receiving, by at least one server comprising at least one processor coupled to at least one memory, a first signal from a first monitored system that comprises an internal combustion engine and a first sensor, the first signal associated with a first occurrence of an internal combustion engine event of the first monitored system, a second occurrence of the internal combustion engine event of the first monitored system, and first measurement data of the first sensor;

determining, by the at least one server, a first measurement from the first measurement data based on the first occurrence of the internal combustion engine event;

determining, by the at least one server, a second measurement from the first measurement data based on the second occurrence of the internal combustion engine event;

determining, by the at least one server, a reference measurement from the first measurement data;

determining, by the at least one server, a first reference deviation between the first measurement and the reference measurement;

determining, by the at least one server, a second reference deviation between the second measurement and the reference measurement;

comparing, by the at least one server, the first reference deviation to a stored first reference threshold;

comparing, by the at least one server, the second reference deviation to a stored second reference threshold;

after determining that the first reference deviation is less than the stored first reference threshold and the second reference deviation is less than the stored second reference threshold, determining, by the at least one server, a measurement deviation between the first measurement and the second measurement;

comparing, by the at least one server, the measurement deviation to a stored measurement threshold; and

after determining that the measurement deviation satisfies the stored measurement threshold, determining, by the at least one server, a first exhibited useful life of the first sensor based on the measurement deviation and at least one of the first measurement or the second measurement.

2. The method of claim 1 , wherein the stored first reference threshold is equal to the stored measurement threshold.

3. The method of claim 1 , further comprising:

determining, by the at least one server, the first measurement by applying a first offset to a first data point of the first measurement data; and

determining, by the at least one server, the second measurement by applying a second offset to a second data point of the first measurement data.

4. The method of claim 1 , wherein the first signal is further associated with operation data of the first monitored system, the method further comprising:

determining, by the at least one server, a target operating characteristic associated with the first measurement,

determining, by the at least one server, an exhibited operating characteristic based on the operation data and the first measurement,

determining, by the at least one server, a target deviation between the target operating characteristic and the exhibited operating characteristic,

comparing, by the at least one server, the target deviation to a stored target threshold, and

comparing, by the at least one server, the measurement deviation to the stored measurement threshold after determining that the target deviation is less than the stored target threshold.

5. The method of claim 1 , further comprising:

receiving, by the at least one server, a second signal from the first monitored system, the second signal associated with an indication of a replacement of the first sensor with a second sensor.

6. The method of claim 1 , wherein the first signal is further associated with a third occurrence of the internal combustion engine event of the first monitored system, and the method further comprising:

determining, by the at least one server, a third measurement from the first measurement data based on the third occurrence of the internal combustion engine event,

determining, by the at least one server, a rate of change between the first measurement, the second measurement, and the third measurement,

comparing, by the at least one server, the rate of change to a stored rate threshold, and

after determining that the rate of change satisfies the stored rate threshold, determining, by the at least one server, a second exhibited useful life of the first sensor based on the rate of change and at least one of the first measurement, the second measurement, or the third measurement.

7. The method of claim 1 , wherein the first measurement data is indicative of an amount of an exhaust byproduct associated with the first monitored system, wherein the stored measurement threshold is associated with the exhaust byproduct, and the method further comprising:

selecting, by the at least one server, the stored measurement threshold based on the exhaust byproduct.

8. The method of claim 1 , further comprising:

comparing, by the at least one server, the first exhibited useful life to a stored exhibited useful life threshold;

comparing, by the at least one server, based on the first exhibited useful life satisfying the stored exhibited useful life threshold, the first measurement data to second measurement data associated with a second monitored system; and

determining, by the at least one server, a failure mode of the first sensor based on the first exhibited useful life, the first measurement data, and the second measurement data, the failure mode comprising at least one of a degradation of a heater of the first monitored system, a platinum peel-off event of the first sensor, or a poisoning of the first sensor.

9. The method of claim 1 , further comprising:

comparing, by the at least one server, the first exhibited useful life to a stored exhibited useful life threshold; and

transmitting, by the at least one server, a second signal to the first monitored system, the second signal associated with a notification to replace the first sensor.

10. A method comprising:

receiving, by at least one server comprising at least one processor coupled to at least one memory, a first signal from a first monitored system that comprises an internal combustion engine and a first sensor, the first signal associated with a first occurrence of an internal combustion engine event of the first monitored system, operation data of the first monitored system, a second occurrence of the internal combustion engine event of the first monitored system, and first measurement data of the first sensor;

determining, by the at least one server, a first measurement from the first measurement data based on the first occurrence of the internal combustion engine event;

determining, by the at least one server, a second measurement from the first measurement data based on the second occurrence of the internal combustion engine event;

determining, by the at least one server, a measurement deviation between the first measurement and the second measurement;

determining, by the at least one server, a target operating characteristic associated with the first measurement;

determining, by the at least one server, an exhibited operating characteristic based on the operation data and the first measurement;

determining, by the at least one server, a target deviation between the target operating characteristic and the exhibited operating characteristic;

comparing, by the at least one server, the target deviation to a stored target threshold;

comparing, by the at least one server, the measurement deviation to a stored measurement threshold after determining that the target deviation is less than the stored target threshold; and

after determining that the measurement deviation satisfies the stored measurement threshold, determining, by the at least one server, a first exhibited useful life of the first sensor based on the measurement deviation and at least one of the first measurement or the second measurement.

11. The method of claim 10 , further comprising:

determining, by the at least one server, the first measurement by applying a first offset to a first data point of the first measurement data; and

determining, by the at least one server, the second measurement by applying a second offset to a second data point of the first measurement data.

12. A method, comprising:

receiving, by at least one server comprising at least one processor coupled to at least one memory, a first signal from a first monitored system that comprises an internal combustion engine and a first sensor, the first signal associated with a first occurrence of an internal combustion engine event of the first monitored system, a second occurrence of the internal combustion engine event of the first monitored system, and first measurement data of the first sensor;

receiving, by the at least one server, a second signal from the first monitored system, the second signal associated with an indication of a replacement of the first sensor with a second sensor;

determining, by the at least one server, a first measurement from the first measurement data based on the first occurrence of the internal combustion engine event;

determining, by the at least one server, a second measurement from the first measurement data based on the second occurrence of the internal combustion engine event;

determining, by the at least one server, a measurement deviation between the first measurement and the second measurement;

comparing, by the at least one server, the measurement deviation to a stored measurement threshold; and

after determining that the measurement deviation satisfies the stored measurement threshold, determining, by the at least one server, a first exhibited useful life of the first sensor based on the measurement deviation and at least one of the first measurement or the second measurement.

13. The method of claim 12 , further comprising:

receiving, by the at least one server, a third signal from the first monitored system, the third signal associated with second measurement data of the second sensor of the first monitored system.

14. A method comprising:

receiving, by at least one server comprising at least one processor coupled to at least one memory, a first signal from a first monitored system that comprises an internal combustion engine and a first sensor, the first signal associated with a first occurrence of an internal combustion engine event of the first monitored system, a second occurrence of the internal combustion engine event of the first monitored system, a third occurrence of the internal combustion engine event of the first monitored system, and first measurement data of the first sensor;

determining, by the at least one server, a first measurement from the first measurement data based on the first occurrence of the internal combustion engine event;

determining, by the at least one server, a second measurement from the first measurement data based on the second occurrence of the internal combustion engine event;

determining, by the at least one server, a third measurement from the first measurement data based on the third occurrence of the internal combustion engine event;

determining, by the at least one server, a rate of change between the first measurement, the second measurement, and the third measurement;

comparing, by the at least one server, the rate of change to a stored rate threshold;

determining, by the at least one server, a threshold deviation between a first operation measurement associated with the first occurrence of the internal combustion engine event and a second operation measurement associated with the second occurrence of the internal combustion engine event after receiving the first signal;

determining, by the at least one server, a measurement deviation between the first measurement and the second measurement;

comparing, by the at least one server, the measurement deviation to the threshold deviation;

after determining that the measurement deviation satisfies the threshold deviation, determining, by the at least one server, a first exhibited useful life of the first sensor based on the measurement deviation and at least one of the first measurement or the second measurement; and

after determining that the rate of change satisfies the stored rate threshold, determining, by the at least one server, a second exhibited useful life of the first sensor based on the rate of change and at least one of the first measurement, the second measurement, or the third measurement.

15. The method of claim 14 , further comprising:

comparing, by the at least one server, the first exhibited useful life to a stored exhibited useful life threshold; and

transmitting, by the at least one server, a second signal to the first monitored system, the second signal associated with a notification to replace the first sensor.

16. A method, comprising

receiving, by at least one server comprising at least one processor coupled to at least one memory, a first signal from a first monitored system that comprises an internal combustion engine and a first sensor, the first signal associated with a first occurrence of an internal combustion engine event of the first monitored system, a second occurrence of the internal combustion engine event of the first monitored system, and first measurement data of the first sensor, wherein the first measurement data is indicative of an amount of an exhaust byproduct associated with the first monitored system;

determining, by the at least one server, a first measurement from the first measurement data based on the first occurrence of the internal combustion engine event;

determining, by the at least one server, a second measurement from the first measurement data based on the second occurrence of the internal combustion engine event;

determining, by the at least one server, a measurement deviation between the first measurement and the second measurement;

comparing, by the at least one server, the measurement deviation to a stored measurement threshold associated with the exhaust byproduct; and

after determining that the measurement deviation satisfies the stored measurement threshold, determining, by the at least one server, a first exhibited useful life of the first sensor based on the measurement deviation and at least one of the first measurement or the second measurement.

17. A method comprising:

receiving, by at least one server comprising at least one processor coupled to at least one memory, a first signal from a first monitored system that comprises an internal combustion engine and a first sensor, the first signal associated with a first occurrence of an internal combustion engine event of the first monitored system, a second occurrence of the internal combustion engine event of the first monitored system, and first measurement data of the first sensor;

determining, by the at least one server, a first measurement from the first measurement data based on the first occurrence of the internal combustion engine event;

determining, by the at least one server, a second measurement from the first measurement data based on the second occurrence of the internal combustion engine event;

determining, by the at least one server, a measurement deviation between the first measurement and the second measurement;

comparing, by the at least one server, the measurement deviation to a stored measurement threshold;

after determining that the measurement deviation satisfies the stored measurement threshold, determining, by the at least one server, a first exhibited useful life of the first sensor based on the measurement deviation and at least one of the first measurement or the second measurement;

comparing, by the at least one server, the first exhibited useful life to a stored exhibited useful life threshold;

comparing, by the at least one server, based on the first exhibited useful life satisfying the stored exhibited useful life threshold, the first measurement data to second measurement data associated with a second monitored system; and

determining, by the at least one server, a failure mode of the first sensor based on the first exhibited useful life, the first measurement data, and the second measurement data, the failure mode comprising at least one of a degradation of a heater of the first monitored system, a platinum peel-off event of the first sensor, or a poisoning of the first sensor.

18. The method of claim 17 , further comprising:

receiving, by the at least one server, a second signal from the second monitored system that comprises a second internal combustion engine, a second sensor, and a second engine control unit, the second signal associated with a third occurrence of a second internal combustion engine event of the second monitored system, a fourth occurrence of the second internal combustion engine event, and the second measurement data of the second sensor;

determining, by the at least one server, a third measurement from the second measurement data based on the third occurrence of the second internal combustion engine event;

determining, by the at least one server, a fourth measurement from the second measurement data based on the fourth occurrence of the second internal combustion engine event;

determining, by the at least one server, a second measurement deviation between the third measurement and the fourth measurement;

comparing, by the at least one server, the second measurement deviation to the stored measurement threshold; and

after determining that the second measurement deviation satisfies the stored measurement threshold, determining, by the at least one server, a second exhibited useful life of the second sensor based on the second measurement deviation and at least one of the third measurement or the fourth measurement.

19. The method of claim 18 , further comprising:

utilizing, by the at least one server, the first exhibited useful life and the second exhibited useful life to determine an expected useful life associated with the first sensor and the second sensor.

20. A method comprising:

receiving, by at least one server comprising at least one processor coupled to at least one memory, a first signal from a first monitored system that comprises an internal combustion engine and a first sensor, the first signal associated with a first occurrence of an internal combustion engine event of the first monitored system, a second occurrence of the internal combustion engine event of the first monitored system, and first measurement data of the first sensor;

determining, by the at least one server, a first measurement from the first measurement data based on the first occurrence of the internal combustion engine event;

determining, by the at least one server, a second measurement from the first measurement data based on the second occurrence of the internal combustion engine event;

determining, by the at least one server, a measurement deviation between the first measurement and the second measurement;

comparing, by the at least one server, the measurement deviation to a stored measurement threshold;

after determining that the measurement deviation satisfies the stored measurement threshold, determining, by the at least one server, a first exhibited useful life of the first sensor based on the measurement deviation and at least one of the first measurement or the second measurement;

comparing, by the at least one server, the first exhibited useful life to a stored exhibited useful life threshold; and

transmitting, by the at least one server, a second signal to the first monitored system, the second signal associated with a notification to replace the first sensor.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 13, 2024
From: GUJAR, SWAPNALI; DHANWANI, KAPIL RAJKUMAR; OWUSU, KWADWO O.; ZHAO, ALAN H.; SASIDHARAN, PREMJEE; GONG, JINQIAN; ABRAHAM, JEFFREY DIWAKAR; SMITH, THOMAS C., JR.
To: CUMMINS EMISSION SOLUTIONS INC.
Reel/Frame 066755/0263 →
Continuity (2)
Continuation 17868205 · Jul 19, 2022
Related Publication 20240218841A1 · Jul 4, 2024
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