Patent Publication Number: US-6985803-B2

Title: System and method for monitoring the condition of a vehicle

Description:
This application claims priority of Provisional Patent Application Ser. No. 60/294,330, filed on May 30, 2001. 

   BACKGROUND OF THE INVENTION 
   The present invention relates, in general, to methods and systems for monitoring the condition of vehicles. More specifically, the present invention pertains systems for the wireless transmission of data during the operation of the vehicle, and the non-contact or non-intrusive detection of phenomena emanating from a vehicle, that is relative to the operation of the vehicle. 
   The management of remote operating assets, such as vehicles, including but not limited to, trucks, ships, and railway locomotives, is a challenging logistical effort. The owners and/or leasors of such assets continually attempt to improve the efficiency of operations of these assets. For example, railroads must manage their fleets of locomotives to maximize the on-rail time in order to remain competitive with alternative modes of transportation. Such management systems typically incorporate maintenance services, in which vehicle condition-related data is continuously monitored and updated. 
   Operations of mobile assets may be burdened by overspending on maintenance, both in direct costs and in loss of productivity of the assets due to down time for maintenance of the vehicles. Unplanned down time of the mobile assets may not correspond to scheduled maintenance of vehicles; thereby, increasing operating costs. Timely delivery of information concerning the condition of component parts, and condition of vehicles, presents a substantial opportunity for productivity enhancement of these mobile assets. Accordingly, an inline system for monitoring vehicles is needed to determine the condition of certain components and an overall condition of the vehicle. With this information, maintenance schedules may be updated, reducing the downtime of a mobile asset and enhancing the productivity of the mobile assets in general. 
   Some systems are adapted for on-board analysis to provide real-time condition of the vehicle condition or health. Systems exist which include on-board sensors for detecting certain phenomena relative operating parameters of the vehicle. Data obtained from these sensors is stored on the vehicle computer systems. Typical monitoring systems require that data, relative to the operating parameters of the vehicle, and other information concerning the vehicle, is periodically downloaded from the vehicle computer systems when the vehicle is stopped for servicing. In addition, some systems are adapted for wireless transmission via satellite transmission and data links. However, such systems permit transmissions only at limited locations. In addition, systems do not presently exist that provide detection capabilities that are “off-board”, and transmit data during the online operation of a vehicle, in a non-intrusive manner. 
   BRIEF SUMMARY OF THE INVENTION 
   Accordingly, a system and method are described herein for monitoring the condition of a vehicle, and/or its component parts, during operation of the vehicle, comprising the wireless transmission of data from the vehicle to at least one off-board wireless receiver positioned proximal to a path of travel followed by the vehicle. Similarly, the invention may comprise the non-contact and non-intrusive detecting of phenomena associated with at least one operating parameter of the vehicle. 
   In an exemplary embodiment, the system comprises at least one wireless transmitter, disposed on the vehicle for transmitting data stored on the vehicle and the data is relative to the operation of the vehicle. In addition, at least one wireless receiver is positioned proximal to a path of travel of the vehicle for receiving the data transmitted from the vehicle as the vehicle passes the receiver. A processor is preferably provided in communication with the receiver for receiving and storing the data from the receiver. 
   The system may comprise a structure for supporting at least a portion of the monitoring system, and the receiver may be mounted to the structure. The structure may be positioned at various locations where the vehicle may travel at a reduced speed. For example the structure may positioned adjacent a vehicle servicing station. 
   The system may also comprise at least one sensor secured to the structure, enabling the sensor to detect at least one phenomena emanating from the vehicle and/or its component parts. As the vehicle approaches a service station, the vehicle travels at a slow rate of speed, and the sensor is capable of detecting phenomena, e.g. heat, vibration and/or sounds generated by components that are associated with one or more operating parameters of the components. 
   As the vehicle passes the structure, the sensor detects the phenomena and generates a signal responsive thereto, which signal is transmitted to a processor. The processor receives the data and is capable of generating a signal indicative of the physical phenomena. In an exemplary embodiment, the processor is capable of identifying a component on the vehicle from which the phenomena emanates and analyzes the data to provide a condition of the component, and/or a recommendation for maintenance of the component on the vehicle. For example, a database may provide at least one geometric configuration of a vehicle that identifies all components and their location on the vehicle, for purposes of identifying the components. The processor may also integrate data concerning the component and provide an overall output or signal indicative of the condition of the operating vehicle. The processor output may also provide a maintenance request to initiate further checks or perform repairs. 
   In this manner, the present invention provides a system and method for monitoring the condition of a vehicle that is capable of providing real-time data that is indicative of current operating conditions of components and the vehicle in a manner to allow for optimum timing of parts maintenance and replacement. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The features and advantages of the present invention will become apparent from the following detailed description of the invention, when read with the accompanying drawings in which: 
       FIG. 1  is a schematic illustration of the system for monitoring the condition of a vehicle. 
       FIG. 2  is a schematic illustration of a second embodiment of the monitoring system. 
       FIG. 3  is a sectional elevational view of the frame structure and sensors for the present invention. 
       FIG. 4  is front sectional elevational view of the frame structure with sensors 
       FIG. 5  is a flowchart illustrating operation of the present invention. 
       FIG. 6  is a schematic of the present invention linked with a communication network. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   In order to effectively manage a vehicle or a fleet of vehicles, it is necessary to minimize the amount of down time and repair activities associated with the operation of the vehicle. In this regard, condition-based monitoring systems have been integrated with automated vehicle management systems, whereby sensors are located proximal different components of the vehicle for monitoring operation thereof. In the present invention, a wireless “on-board” transmitter and wireless “off-board” receiver are used to gather data relative to the operation of the vehicle, that may be stored on the vehicle during the operation of the vehicle. The system may also comprise at least one, or an array of sensors used to detect phenomena emanating from the vehicle and/or components of the vehicle to monitor the condition of the vehicle. Thus, the present invention takes advantage of on-line opportunities to gather data without subjecting the vehicle to down time to obtain such data. 
   Accordingly, an exemplary embodiment of the invention is schematically illustrated in  FIG. 1  for use in monitoring the condition of a vehicle and/or a fleet of vehicles. Although primarily illustrated and described with respect to a mobile asset such as a locomotive or fleet of locomotives, the present invention is not so limited and may be used in connection with for example trucks, heavy operating equipment such as loading cranes, excavation equipment, and shipping equipment such as water-going vessels. 
   With respect to  FIG. 1 , the monitoring system  10  is used in connection with the condition-based monitoring of the vehicle  11 . The vehicle  11  is shown traveling a path of travel  12  along a railroad  13 . The monitoring system  10  may comprise a plurality of sensors (not shown) disposed at various locations on the vehicle for detecting operating parameters of the vehicle  11  and/or its component parts. Such sensors are known in the field and may be mounted at various locations to detect phenomena associated with fuel pressure, oil pressure, water temperature, engine vibration, bearing vibrations, engine combustion performance, radiated noise sources or extreme thermal patterns. 
   The sensors are linked with an on-board computer system  19 , which stores the data. The computer system  19  may also be capable of analyzing the data to provide signals or displays indicative of the condition of the vehicle  11 , and/or its component parts. The data stored in the computer system  19  may contain other data related to the operating condition of vehicle  11  such as ambient conditions, on-board inventory count, vehicle location, etc. 
   A wireless transmitter  15  is disposed on the vehicle  11 , and in communication with the vehicle computer system  19 , for gathering and transmitting the data stored in the computer system  19 . The computer system  19  may periodically or continuously download the data to the transmitter  15  during the operation of the vehicle  11 . In the present invention, the transmitter  15  transmits the data to a wireless “off-board” receiver  16  preferably positioned proximal to the path of travel  12  of the vehicle  11 . The receiver  16  may be located along the path of travel  12  of the vehicle  11  at points where the vehicle  11  will proceed at a low rate of speed for the effective transmission of the data. In addition, the receiver, may be mounted within a structure or housing  17  for protection from ambient conditions. 
   As the vehicle  11  approaches the receiver  16 , the transmitter  15  transmits the data to the receiver  16 . The receiver  15  then stores the data and/or transmits the data to a processor  18  where the data is stored and analyzed. The processor  18  may be stationed adjacent to the receiver, or within the nearby service station  14 , so analysis of the data may be performed locally. Alternatively, the receiver  16  is remotely stationed with respect to a processor  18  that may be centrally located as part of a communication network for transmission of data concerning the vehicle  11 , or a fleet of vehicles. 
   The components, e.g. transmitter  15  and receiver  16 , may be typical wireless networking components used in the 802.11b wireless local area networks (WLANs) that transmit data over a predetermined bandwidth or range of bandwidths. Such networks typically transmit data at the unlicensed 2.4 GHz band, and are readily available from manufacturers and suppliers known to those skilled in the art. This bandwidth, or range of bandwidths surrounding it, enables the wireless transmission for a limited distance, but at a high rate of speed. 
   The processor  18  is programmed to analyze the data and generate a signal, or output, that is indicative of a condition of the vehicle  11 , or components of the vehicle. The output may provide recommendations concerning servicing of the vehicle  11  and its various components. A vehicle  21  operation activates the transmitter  15  when the vehicle is within a prescribed distance of the structure  22  and/or transmitter  15 . Activation of the transmitter  15  may be automatic through the vehicular computer system  19 , which can identify the location of the vehicle  11  with respect to the receiver  16  obtained through available global positioning means or other systems that can provide location of the vehicle  11  with respect to the structure  17  and receiver  16 . Given the bandwidth of the center technology, the vehicle  21  should preferably be within a few hundred feet of the receiver  16 . The transmitter is activated for a predetermined timed duration to ensure effective transmission of all data available for transmission. 
   In a second embodiment, the monitoring system  19  comprises a structure  22 , having at least one sensor  23  secured thereon for detection of at least one phenomenon associated with the operation of the vehicle  21 . In an exemplary embodiment, the structure  22  may take the form of a partial enclosure through which the vehicle  21  may pass. The structure  22  is proximally located to a path  30  of travel of the vehicle  21  and disposes sensors  23  sufficiently close to the vehicle  21  to effectively detect physical phenomena emanating from the vehicle  21  and/or component parts thereof. Such a structure may include walls in which sensors  23  are imbedded. In this manner, the structure  22  to some degree can control ambient conditions including wind, temperature and noise that may affect the sensitivity of the sensors  23 . 
   The structure  22  shown herein covers a path of travel  30  of the vehicle  21 , e.g., locomotive traveling along a railroad track  39 . The structure  22  is preferably located adjacent a vehicle servicing area  25 , which provides an opportunity to detect various physical phenomena emanating from the vehicle  21 . As the vehicle  21 , such as a locomotive, approaches a servicing station  25 , the speed of the vehicle  21  may slow to only a few miles per hour. At such a speed, the sensors  23  may effectively detect physical phenomena emanating from the vehicle  21  and or components  24  of the vehicle. The term “component” as used in this disclosure includes the individual parts of a locomotive, such as turbo bearings, water pump assemblies, wheel bearings etc. The term “component” may also include various subsystems such as the gear train, water coolant system, radiator fan, air compressor, fuel injectors, engine power assembly, tractive effort motors, fuel pumps, wheel assemblies, etc., within the vehicle  21  that comprise a plurality of different parts. 
   With respect to  FIG. 3 , the structure  22  may comprise the sensors  23  mounted within an enclosure wherein the sensors  23  are disposed adjacent openings  27  for detection of the physical phenomena. The openings  27  may be covered with a covering (not shown) such as a metallic screen material or a thin Plexiglas for protection of the sensor  23  from interference of ambient conditions. The sensors  23  may be secured directly to the structure  22 , or to an mounting assembly disposed within the enclosure  28 . The sensors  23  may be disposed on the structure over the track  39  and the vehicle  21 , and along the sides of the vehicle  21 . In addition, the sensors  23  may be disposed underneath the track  31  and the vehicle  21  as necessary to detect phenomenon emanating from certain components  24 . 
   As shown in  FIG. 4 , the structure  22  may be sufficiently large to house the processor  26  display or any other equipment necessary for operation of the system. Alternatively, the processor  26  and/or display may be remotely positioned with respect to the sensors  23 , as in wireless communication networks, known to those skilled in the art. In addition, enough room within the enclosure  27  should be available for one or more operators  20  to comfortably move about to operate or maintain the system  19 . 
   However, the invention is not limited by the size or shape of the structure  22 . For example the sensors  23  maybe mounted to an assembly that may comprise a plurality of frame members. Such a structure would not include any large enclosure, but each sensor may have a housing within which it is maintained and mounted on a frame member. 
   The sensors  23  may include ultrasound-based sensing devices, infrared-based sensing devices, vibration sensors, acoustic-based sensing devices or electrical test equipment, etc. The array of sensors  23  is contemplated to detect a variety of physical phenomena including, but not limited to, temperature, vibrational movement, sounds, etc. Such physical phenomena may be attributed to various operating conditions of component parts of the vehicle and/or failure modes such as valve and seal leakage of fluids, liquid or gas from components such as water pump and oil pump assemblies, or air compressors to out-of-balance vibration, which may be attributed to bearing defects, overheated connectors, wheels or bearing in electrical arcing and potential insulation defects. These sensors  23  are commercially available from appropriate suppliers. 
   As shown in  FIGS. 3 and 4 , the sensors  23  are optimally positioned along the frame structure to detect the physical phenomenon. The sensors  23  may be disposed at elevations corresponding to the location of certain components  24  from which these physical phenomena may emanate, or to cover an elevation or defined area of the vehicle  21  in which components are located. Once a sensor  23  is activated, or begins detection of the physical phenomenon, the processor is able to immediately identify the component  24  as generating the signal from the sensor  23 . However the sensors  23  do not have to correspond to any particular component  24 , but may be positioned to optimize detection of physical phenomenon generated from any location on the vehicle  21  as it passes the sensor  23 . And, as will be explained in more detail below, the processor  26  is capable of identifying a particular component  24  from which the physical phenomenon is generated. 
   In an exemplary embodiment, the vehicle  21  may be also be equipped with a wireless transmitter  28  for the wireless transmission of data stored on board within a vehicle computer system  29 . A wireless receiver  38  is mounted to the structure  22  and optimally positioned for receiving data transmitted from the transmitter  28 . The transmitter  28  and receiver  38  operate as described for the wireless transmission of data during the operation of the vehicle  21 . The computer system  29  may periodically or continuously download data to the transmitter  28 , which then transmits data via wireless communication to the wireless receiver  38 , mounted to the structure  22 . 
   The method for the invention is referenced with respect to  FIGS. 1 ,  2  and  5 . With respect to  FIG. 5 , steps  31  and  32 , as the vehicle  21  passes the frame structure  22 , the sensors  23  detect the physical phenomena emanating from the vehicle  21  and generate a signal that is associated with an operating parameter of the vehicle  21 . The signal is transmitted to, and received by, the processor  26 . 
   In step  32 , the processor  26  collects data by digitizing the signals and generates data, usually in a waveform having frequency, amplitude and/or time. In order to analyze collected data, the processor  26  must correspond the data to a particular vehicle component  24 . In steps (Blocks  34  and  35 ), the processor  26  identifies the sensor  23  detecting the physical phenomena, and then identifies the components  24  generating the phenomena. In this manner, the processor  25  is capable of comparing the generated data to historical data representing operating parameters of the components  24  and vehicle  21 . 
   The database  26 B may contain a geometric configuration of the vehicle  21 , including its various components  14 . The geometric configuration may be that of a vehicle  21  representative of a group of vehicles within a fleet of mobile assets, or a configuration may exist for each individual vehicle  21  that passes the structure  22 . The geometric configuration comprises the identification and location of various components  24  on the vehicles  21 . A vehicle  21  may be assigned an identification number, which corresponds to a geometric configuration representative of that vehicle  21 , or a group of vehicles. 
   In an exemplary embodiment, the processor  26  comprises historical spectral data relating to a specific areas or components  24  on the vehicle  21 . A spatial map may be generated from the historical spectral data of the vehicle which map provides a spatial coordinate, including the location of parts along longitudinal and elevational axes of the vehicle. The spectral data comprises coordinates of frequency and spatial coordinates (x, y). The spectral data also includes waveforms, which similarly provide a print of the vehicle and its components  14 . 
   As represented in steps  36  and  37 , the data received from sensors is compared to the historical data and/or geometric configuration to identify the components  24  associated with the detected phenomena. 
   In another embodiment, the processor  26  may integrate an algorithm by which a location of component or subsystem may be calculated within the vehicle  21 , using the rate of speed by which the vehicle  21  passes a certain sensor. For example, a vehicle traveling a rate of 5 miles per hour may activate a locating sensor (not shown), which corresponds to a location on the vehicle  21  at the front of the vehicle  21 . When a sensor  23  detects a physical phenomenon 2 seconds after the location sensor is activated, a vehicle  11  that is 100 feet long traveling at 5 miles per hour places the subsystem  24  from which physical phenomena is emanated at approximately 16 feet from the front of the vehicle. 
   In an exemplary embodiment, the processor  26  is linked with a database  26 B that comprises historical data regarding the operating condition of the vehicle  21  and its components  24 , from which physical phenomena have been detected. In another exemplary embodiment, the database  26 B may comprise historical data representing various operating conditions of the vehicle  21  and/or its components  24 , which historical data is obtained from a population of like component parts or vehicles. 
   The database may contain various operating parameters within which components effectively operate, including providing data representative of normal operation of a component, incipient failure conditions, or condemning limits at which limits may indicate failure of the component parts. The processor  26  is programmed to implement at least one or more algorithms that compare data obtained from the sensors  23  to the historical data within the database  26 B of the processor  26 . Based on a comparison of the collected data to the historical data, the processor  25  generates a signal that is indicative of a condition of the vehicle  21  and/or a component  24 . The results of this analysis may be presented or placed in a variety of forms, including a general health indicator of the different vehicle components or subsystems; flagging certain components with impending or imminent failures; and recommending corrective actions. The display  26 A of the recommended actions can be displayed on a link with the processor  26  and/or sensor  23  as part of the structure  22  or on a repair kiosk at the fueling or service stations  25  Similarly, remote displays may be available through an information communication network, so that users at various remote locations may review information or data made available on a particular vehicle passing by or through the frame structure and sensors. 
   With respect to  FIG. 6 , an exemplary embodiment of the invention is shown integrated with an information communication network, so that a variety of users remote locations  46  may review data obtained from a vehicle  41  passing by the frame structure  42 . As shown in  FIG. 5 , the monitoring system  40  comprises the frame structure  42  having sensors  43  mounted therein for detecting physical phenomena emanating from the vehicle  41  as it passes the frame structure  42 . 
   The data obtained from the sensors  43  and generated by the processor  45  may be analyzed locally at the monitoring system  40  locations, and/or transmitted to remote locations for analysis. Signals generated by the sensors  43  are digitized for transmission to a processor  45  which may be integrated with the sensor  43 , or provided as a separate component. The processor  45  may comprise a server for integration with the network communication system. Similarly the analysis results determined locally may be transmitted via the network for analysis and storage at remote locations. For example, data and/or analysis results may be transmitted to a data center  47 , which conduct analysis on raw data and/or integrate data results into its own central database. Remote locations may gain access to the data and/or analytical results via an Internet or Intranet communication system. Accordingly, such a system may comprise available technologies for transmission of information via the Internet and/or an Intranet, which are known to those skilled in the art. Such a communication system may be particularly advantageous for operation and maintenance for a fleet of vehicles. 
   While the preferred embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only and not of limitation. Numerous variations, changes and substitutions will occur to those of skilled in the art without departing from the teaching of the present invention. Accordingly, it is intended that the invention be interpreted within the full spirit and scope of the appended claims.