Patent Publication Number: US-9834235-B2

Title: System for remotely overriding locomotive controls

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to a locomotive control system and, more particularly, to a system for remotely overriding controls of a locomotive. 
     BACKGROUND 
     Large mobile machines, for example locomotives, can operate in many different applications and many different climates. For example locomotives can operate in conditions of extreme temperature. When operating in certain conditions, if the locomotive is shut down for an extended period of time, it may be difficult to restart and/or components of the locomotive could fail. For example, if a locomotive is shut down in extremely cold conditions for an extended period of time, an engine of the locomotive may not restart easily and/or components of the engine could crack when fluids inside the engine freeze. When this happens, the locomotive can become stranded away from assistance. 
     One attempt to improve locomotive operation in cold extremes is disclosed in U.S. Pat. No. 2,914,644 of Hillig that issued on Dec. 1, 1959 (“the &#39;644 patent”). In particular, the &#39;644 patent discloses a system that can be used to remotely start the diesel engine of a locomotive when fluid temperatures inside the engine fall below a threshold temperature. The system includes a wayside station, at which the locomotive is pared, and wires connected to the locomotive that extend from the wayside station to a remote office. When a water temperature of the engine drops, a contact is closed that energizes a cold relay causing an indicator and a buzzer to sound in the remote office. At the same time, another contact is closed that causes a fuel pump of the engine and a starter motor to actuate. During and after startup, telephone lines are energized and used by personnel at the remote office to listen to the startup process and to the engine after startup to confirm successful operation of the engine. When the water temperature of the engine rises above the threshold temperature, the fuel pump is deactivated to shut down the engine. 
     Although perhaps somewhat successful in maintaining a desired engine temperature of a remote locomotive, the system of the &#39;644 patent may be limited. In particular, there may be times when the locomotive is shutdown away from the wayside station, and temperatures should still be maintained in these situations. Further, there may be reasons why the engine was originally shutdown or reasons why the engine should not be restarted, and the &#39;644 patent does not provide a way to communicate these reasons from the wayside station to the remote office. Further, the engine of the &#39;644 patent must be specially prepared at the wayside station for remote startup (e.g., connected to the wires that extend to the office) or remote startup may not be possible. Finally, it may be possible for startup of the engine to initiate without sufficient warning onboard the locomotive, creating a potentially hazardous situation. 
     The present disclosure is directed at overcoming one or more of the shortcomings set forth above and/or other problems of the prior art. 
     SUMMARY 
     In one aspect, the present disclosure is directed to a control system for a machine. The control system may include a component located onboard the machine, the component having a first state and a second state. The control system may also include an operator input device located onboard the machine and used to manually toggle operation of the component between the first and second states, and at least one sensor located onboard the machine and configured to generate a signal associated with a condition of the machine. The control system may also include an offboard controller located remotely from the machine and being configured to selectively override the operator input device and toggle operation of the component between the first and second states based on the signal. 
     In another aspect, the present disclosure is directed to another control system for a locomotive. This control system may include an engine located onboard the locomotive, and a switch located onboard the locomotive and manually moveable between a run state allowing startup of the engine from onboard the locomotive, and an isolation state inhibiting startup of the engine from onboard the locomotive. The control system may also include a temperature sensor configured to generate a signal associated with a coolant temperature of the engine, a warning device located onboard the locomotive, and an offboard controller located remotely from the locomotive. The offboard controller may be configured to selectively activate the warning device, override the switch, and allow startup of the engine when the coolant temperature is below a threshold temperature. The control system may further include a lockout switch located onboard the locomotive and selectively activated by an operator of the locomotive to inhibit the offboard controller from starting the engine. 
     In yet another aspect, the present disclosure is related to a method of controlling a machine. The method may include receiving input from onboard the machine regarding an operator desire to toggle operation of a component between first and second states, and sensing a condition of the machine and generating a corresponding signal. The method may also include generating a command from offboard the machine to selectively override the input and toggling operation of the component between the first and second states based on the signal. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIG. 1  is an isometric illustration of a locomotive equipped with an exemplary disclosed control system. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a mobile machine  10  equipped with an exemplary control system  12 . In the disclosed example, machine  10  is a locomotive. However, it is contemplated that machine  10  may embody another type of machine, if desired. For example, machine  10  may embody an on- or off-highway haul truck, a construction machine, a vocational machine, or another type of machine. Alternatively, machine  10  could be a stationary machine, such as a genset, a pump, or a drill that requires continuous attention from an operator. Other types of machines may also be possible. 
     As a locomotive, machine  10  may include a car body  14  supported at opposing ends by a plurality of trucks  16  (only two trucks  16  shown). Each truck  16  may be configured to engage a track  18  via a plurality of wheels  20 , and to support a frame  22  of car body  14 . One or more traction motors  24  may be associated with one or all wheels  20  of a particular truck  16 , and any number of engines  26  may be mounted to frame  22  within car body  14  and drivingly connected to produce power that drives motors  24  to propel wheels  20 . Control over engine operation (e.g., starting, stopping, fueling, etc.) and traction motor operation, as well as other locomotive controls, may be provided by way of a cabin  28  supported by frame  22 . 
     Cabin  28  may house a plurality of input devices  30  input devices  30  may be used by the operator to control machine  10  and embody any type of device known in the art. For example, input devices  30  may include, among other things, a run/isolation device (device)  30   a , a lockout device (device)  30   b , and any number of breakers  30   c . Input devices  30  may be switches, levers, pedals, wheels, knobs, push-pull devices, touch screen displays, etc. 
     In the disclosed embodiment, operation of engine(s)  26  may be at least partially controlled by device  30   a . In particular, device  30   a  may embody a switch that is manually movable between a run or activated state (shown in  FIG. 1 ) and an isolation or deactivated state by an operator of machine  10 . When device  30   a  is in the run state, engine(s)  26  may be allowed to start in response to a command generated from onboard machine  10 . When device  30   a  is in the isolation state, engine(s)  26  may be shutdown (i.e., turned off) and not allowed to restart. In one embodiment, toggling device  30   a  to the run state causes startup of engine(s)  26  and, likewise, toggling device  30   a  to the isolation state causes engine(s)  26  to shut down. In another embodiment, toggling device  30   a  to the run state simply allows subsequent startup of engine(s)  26  using other input devices  30 , and device  30   a  is only toggled to the isolation state after engine shutdown to inhibit restart of engine(s)  26 . In either scenario, engine(s)  26  may not be restarted from onboard machine  10  while device  30   a  is in the isolation state. The operator of machine  10  may move device  30   a  to the run state at the start of a work shift or trip, and move device  30   a  to the isolation position at the end of the work shift or trip. 
     Operation of engine(s)  26  (and many other, if not all, of the functions of machine  10 ) may be at least partially controlled by device  30   b . In particular, device  30   b  may embody a button or switch that is manually movable between an off position and an on position by a service technician of machine  10 . When device  30   b  in the on position, all engine and machine functions may be available to the operator. When device  30   b  is in the off position, engine (and most machine) functions may not be available to the operator. The service technician may use device  30   b  during servicing, to ensure that unexpected and/or unauthorized use of engine(s)  26  and/or other machine components is not possible while the technician is in close contact with normally moving and/or energized equipment. 
     Breakers  30   c  may each be associated with a particular component of machine  10 , and configured to trip when performance parameters associated with the component deviate from expected ranges. For example, a breaker  30   c  may be associated with power directed to individual traction motors  24 , power directed to an HVAC component, power directed to lighting, etc. In this example, when a power draw greater than an expected draw occurs, breaker  30   c  may trip to interrupt the corresponding circuit. After a particular breaker  30   c  trips, the associated component may be disconnected from circuit of machine  10  and remain nonfunctional until the corresponding breaker  30   c  is reset. Breakers  30   c  may be manually tripped or reset and, in some applications, include actuators that can be selectively energized to autonomously or remotely toggle the state of the associated breakers  30   c  in response to a corresponding command. 
     As also shown in  FIG. 1 , control system  12  may further include an onboard controller (OC)  32  that is in communication with traction motors  24 , engines  26 , and input devices  30 , and also with one or more sensors  34 , a warning device  36 , and an offboard worksite controller (OWC)  38  via a communications device  40 . OC  32  may embody a single or multiple microprocessors, field programmable gate arrays (FPGAs), digital signal processors (DSPs), etc., that include a means for controlling operations of machine  10  in response to operator requests, built-in constraints, sensed operational parameters, and/or communicated instructions from OWC  38 . Numerous commercially available microprocessors can be configured to perform the functions of these components. Various known circuits may be associated with these components, including power supply circuitry, signal-conditioning circuitry, actuator driver circuitry (i.e., circuitry powering solenoids, motors, or piezo actuators), and communication circuitry. 
     Machine  10 , including engine(s)  26 , may be outfitted with any number and type of sensors  34  known in the art for generating signals indicative of associated performance parameters. In one example, machine  10  includes a temperature sensor  34  configured to generate a signal indicative of a coolant temperature of engine(s)  26 . Additionally or alternatively, sensors  34  may include a brake temperature sensor; an exhaust sensor; a fuel level, pressure, and/or temperature sensor; a boost temperature or pressure sensor; a knock sensor; a reductant level and/or temperature sensor; an oil level, pressure, and/or temperature sensor; a speed sensor; or any other sensor known in the art. The signals generated by sensor(s)  34  may be directed to OC  32  for further processing. 
     Any number and type of warning devices  36  may be located onboard machine  10 , including an audible warning device and/or a visual warning device. Warning device  36  may be used to alert an operator of machine  10  of an impending operation, for example startup of engine(s)  26 . Warning device  36  may be triggered manually from onboard machine  10  (e.g., in response to movement of device  30   a  to the run state and/or  30   b  to the on position) and/or remotely from offboard machine  10 . When triggered from offboard machine  10 , a corresponding command signal used to initiate operation of warning device  36  may be communicated to OC  32  via communications device  40 . 
     OWC  38  may include any means for monitoring, recording, storing, indexing, processing, and/or communicating various operational aspects of machine  10 . These means may include components such as, for example, a memory, one or more data storage devices, a central processing unit, or any other components that may be used to run an application. Furthermore, although aspects of the present disclosure may be described generally as being stored in memory, one skilled in the art will appreciate that these aspects can be stored on or read from different types of computer program products or computer-readable media such as computer chips and secondary storage devices, including hard disks, floppy disks, optical media, CD-ROM, or other forms of RAM or ROM. 
     OWC  38  may be configured to execute instructions stored on computer readable medium to perform methods of remote control of machine  10 . That is, as will be described in more detail in the following section, onboard control (manual and/or autonomous control) of some operations of machine  10  (e.g., operations of traction motors  24 , engine(s)  26 , breakers  30   c , etc.) may be selectively overridden by OWC  38 . For example, OWC  38  may be configured to selectively override device  30   a  and cause startup of engine(s)  26 , even when device  30   a  is in the isolation position. Similarly, particular traction motors  24  may be selectively turned on/off remotely, and/or breakers  30   c  may be reset or tripped remotely. 
     Remote control of machine  10  between OC  32  and OWC  38  may be facilitated via communications device  40 . Communications device  40  may include hardware and/or software that enables sending and receiving of data messages between  32  and OWC  38 . The data messages may be sent and received via a direct data link and/or a wireless communication link, as desired. The direct data link may include an Ethernet connection, a connected area network (CAN), or another data link known in the art. The wireless communications may include satellite, cellular, infrared, and any other type of wireless communications that enable communications device  40  to exchange information between OWC  38  and the components of OC  32 . 
     Based on information from input devices  30  and sensor(s)  34 , and based on instructions from OWC  38 , OC  32  may be configured to help regulate movements and/or operations of its associated machine  10  (e.g., direct operations of associated traction motors  24 , engines  26 , breakers  30   c , etc.). OC  32  may be configured to autonomously control these movements and operations, OC  32  may also be configured to send operational information associated with components of machine  10  offboard to OWC  38  via communications device  40 , if desired. This information may include, for example, parameters associated with signals generated by sensor(s)  34 , positions of devices  30   a  and  30   b , a state of engine(s)  26 , conditions of traction motors  24 , and other information known in the art. The information may then be displaced at a remote facility housing OWC  38  for use by a remote user in determining operational commands for machine  10 . 
     INDUSTRIAL APPLICABILITY 
     The control system of the present disclosure may be applicable to any machine where remote access to particular functions of the machine may be desirable. These functions may normally be controlled manually from onboard the machine, and remote access to these functions may provide a way to inhibit machine damage and/or reduce the likelihood of the machine from becoming stranded when human operators are not present or available within the machine. Operation of control system  12  will now be described in detail. 
     During normal operation, a human operator may be located onboard machine  10  and within cabin  28 . The human operator may be able to control when engine(s)  26  are started or shut down, which traction motors  24  are used to propel machine  10 , and when and what breakers  30   c  should be reset or tripped. However, there may be times when the human operator is not available to perform these functions, when the human operator is not onboard machine  10 , and/or when the human operator is not sufficiently trained or alert to perform these functions. 
     For example, a particular machine  10  may be parked at a remote location for an extended period of time, without an operator. And during extreme conditions, for example during cold ambient conditions, machine  10  may begin to acclimate to the surroundings. In this situation, if machine  10  (particularly engines  26 ) were to cool down too much, engines  26  may be difficult to restart and/or fluids within machine  10  could freeze. For example coolant within of engines  26  could freeze, causing components (e.g., the blocks or pumps) of engines  26  to crack and ail, if an operator were onboard and monitoring conditions of engines  26 , the operator could periodically restart engines  26  before engines  26  cooled too much, and allow engines  26  to warm up to temperatures at which freezing would not be possible. However, in applications where the operator is not present, this may not be possible. 
     When machine  10  is parked for an extended period of time, part of the normal engine shutdown routine may include moving device  30   a  to the isolation state. From this point on, startup of engines  26  may not be possible from onboard machine  10 . In the disclosed embodiment, however, OWC  38  may be capable of selectively overriding device  30   a  and initiating a startup procedure regardless of the position of device  30   a.    
     The overriding of device  30   a  and initiation of the engine startup procedure may be implemented manually or automatically from the remote facility. For example, signals from sensor(s)  34  may be communicated offboard machine  10  via OC  32  and communications device  40  to OWC  38 , even when machine  10  is parked and engines  26  are shutdown. These signals may be displayed to a user (e.g., to office personnel) at the remote facility, and the user may responsively provide input to OWC  38  regarding a desire to initiate startup of engines  26 . This input may be received via an input device (e.g., a keyboard or mouse) connected to or integrally forming a part of OWC  38 , and OWC  38  may generate corresponding command signals directed to OC  32  via communications device  40 . In an alternative embodiment, OWC  38  may automatically implement startup of engines  26  without input from the remote user in response to the monitored parameter deviating from an expected range (e.g., in response to coolant temperatures falling below a threshold temperature). 
     After determining that engines  26  should be started and prior to issuing the command for engine startup, OWC  38  may first generate a warning that engines  26  are about to be started. For example, a command may be generated and directed to warning device  36  via communications device  40  and OC  32 , causing warning device  36  to visually and/or audibly alert any nearby personnel that engines  26  may soon be started. This warning may be provided sufficiently in advance of initiating engine startup to allow an operator of machine  10  to activate device  30   b  and thereby abort the startup sequence, if desired, and/or to make the environment ready for startup (e.g., to move personnel and equipment to a location away from engines  26 ). 
     In some embodiments, remote startup of engines  26  may be inhibited without the use of device  30   b , if desired. For example, particular conditions onboard machine  10  that caused the original shutdown of engines  26  may also inhibit restart of engines  26 . For example, conditions occurring that could cause damage to engines  26  upon restart may be observed by OC  32  and/or OWC  38  (e.g., via sensors  34 ) and used as a basis to inhibit startup. These conditions could include, for example, excessively high engine temperatures, low lubricating fluid levels, etc. Normal startup routines that check for these conditions may block local and remote attempts to restart engines  26 . 
     The operation of traction motors  24  and/or breakers  30   c  may be remotely controlled in a similar manner. Specifically, conditions associated with operation of these components (e.g., conditions detected via sensors  34 ) may be monitored via OWC  38  and/or a remote operator, and corresponding commands may be generated to selectively change the state of breakers  30   c  (e.g., trip or reset breakers  30   c ) or traction motors  24  (e.g., to cut in or cut out particular traction motors  24 ) based on the conditions. In these situations, onboard settings that are manually controlled by the operator of machine  10  may need to be overridden in order for the states (e.g., activated and deactivated states) of traction motors  24  and/or breakers  30   c  to be remotely toggled. 
     Because control system  12  may allow for remote overriding of onboard manual control settings, operation of machine  12  may be simplified. In particular, machine  12  may not need to first be prepared for remote control functionality, allowing for greater protection in unexpected situations and at unexpected locations. In addition, because the disclosed system may provide a warning prior to assuming remote control of machine  12 , operation of machine  12  may be secure. 
     It will be apparent to those skilled in the art that various modifications and variations can be made to the system of the present disclosure without departing from the scope of the disclosure. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the system disclosed herein it is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.