Patent Publication Number: US-2023135656-A1

Title: Systems and methods for undercarriage wear prediction

Description:
TECHNICAL FIELD 
     The present technology is directed to systems and methods for wear prediction of undercarriages of machines, vehicles, or other suitable devices. More particularly, systems and methods for wear prediction of components of an undercarriage of a machine or a vehicle based on features derived from a plurality of data objects and/or wear measurements associated with the undercarriage. 
     BACKGROUND 
     Machines are used to perform various operations in different industries, such as construction, mining, and transportation. Some of these machines can include an undercarriage to support an upper frame. The undercarriage includes various components including ground engaging members which provide propulsion to the machine. Operation of the machines results in wear to the components of the undercarriage. Each component of the undercarriage may undergo various types of wear due to contact with other components and/or a ground surface. However, it can be challenging effectively predicting such wear for a plurality of machines. U.S. Patent Publication No. 20170356164 (Recker) discloses disposing ID tags on a plurality of components of a machine. A controller stores a usage threshold for each component, receives signals from an ID tag reader, and associates an identification number from each ID tag with a component of the machine. The controller determines current usage data for each component based upon the extent of usage of the machine and the previous usage data and compares the current usage data for each component to the usage threshold for each component. Japanese Patent No. JP-6333598 is directed to a processing device that displays an evaluation result for excavators based on cumulative damages in parts of the excavators. It is advantageous to have an improved method and system to address the foregoing needs. 
     SUMMARY OF THE INVENTION 
     The present technology is directed to systems and methods for wear prediction of an undercarriage of a machine. In some embodiments, the machine can be an excavator or a machine having an undercarriage. The undercarriage can include a track assembly having various components (see, e.g.,  FIG.  3   ) such as a sprocket segment, a carrier segment, a track chain, a track link, a track roller, a track shoe, etc. These components can have different life spans and replacement schedules. The present technology collects high frequency time series data from the machine, determines physics-based features based on the collected data, and establishes a statistical model to predict wear to each component of the undercarriage. Historical wear measurements collected during field inspection can also be used to facilitate establishing the statistical model. 
     The present technology provides a “feature engineering” process for establishing the foregoing statistical model. The “feature engineering” process can include three steps (1) collecting data from input channels (e.g., high frequency time series data channels that are used to communicate with the machine); (2) deriving features or variables based on “physics formulas” (e.g., using a travel mode of the machine and a pump pressure of the machine to determine a drive torque of the machine; using veridical acceleration of the machine to determine a ground condition, etc.); and (3) establishes the statistical model based on the derived features and corresponding coefficients. The coefficients can be determined based on one or more machine learning or training schemes. In some embodiments, the features can be divided into groups based on the correlations of the derived features (e.g., features related to “travel time” of the machine can be divided in the same group). By grouping and analyzing these features, the present technology can effectively predict wear conditions of the components of undercarriages of a plurality of machines (e.g., a fleet of machines in various working sites), enabling efficient management (replacement, maintenance, repair etc.) of these components. 
     In some embodiments, the present method can be implemented to perform undercarriage wear prediction for a target machine. For example, the method can include (1) receiving wear measurements from a plurality of source machines (e.g., the wear measurements are associated with a first set of components of undercarriages of the plurality of source machines); (2) establishing a statistical model based on the received wear measurements and physic-based features derived from the wear measurements; (3) determining coefficients for the statistical model at least partially based on inspection data of a second set of components of the undercarriage of the target machine; and (4) predicting a wear condition of the undercarriage of the target machine by the statistical model and the coefficients. In some embodiments, the foregoing first and second sets of components can be different sets. In other words, the components that have associated high frequency data (e.g., communicated in various channels) do not have to be the same components as those having inspection data (e.g., from field inspection). Accordingly, the present method can effectively integrate data from different sources (e.g., by the derived features) and provide flexible yet reliable schemes for wear prediction. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Non-limiting and non-exhaustive examples are described with reference to the following figures. 
         FIG.  1    is a schematic diagram illustrating a wear prediction system in accordance with embodiments of the present technology. 
         FIG.  2    is a schematic diagram illustrating wear prediction results in accordance with embodiments of the present technology. 
         FIG.  3    is a schematic diagram illustrating components of an undercarriage of a machine in accordance with embodiments of the present technology. 
         FIG.  4    is a schematic diagram illustrating a data structure of jobs performed on parts or components in accordance with embodiments of the present technology. 
         FIG.  5    is a schematic diagram illustrating a data structure of a feature engineering process in accordance with embodiments of the present technology. 
         FIG.  6    is a schematic diagram illustrating components in a computing device in accordance with embodiments of the present technology. 
         FIG.  7    is a flow diagram showing a method in accordance with embodiments of the present technology. 
     
    
    
     DETAILED DESCRIPTION 
     Various aspects of the disclosure are described more fully below with reference to the accompanying drawings, which form a part hereof, and which show specific exemplary aspects. Different aspects of the disclosure may be implemented in many different forms and the scope of protection sought should not be construed as limited to the aspects set forth herein. Rather, these aspects are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the aspects to those skilled in the art. Aspects may be practiced as methods, systems, or devices. Accordingly, aspects may take the form of a hardware implementation, an entirely software implementation, or an implementation combining software and hardware aspects. The following detailed description is, therefore, not to be taken in a limiting sense. 
       FIG.  1    is a schematic diagram illustrating a wear prediction system  100  in accordance with embodiments of the present technology. The system  100  includes inspection data  101  and high frequency time series data  103  (for a group of machines or “source” machines) as input for a statistical model  105 . The inspection data  101  and the high frequency time series data  103  are associated with a plurality of components (e.g.,  FIG.  3   ) of undercarriages of the group of machines. In some embodiments, the inspection data  101  can be from an on-site inspection. In some embodiments, the high frequency time series data  103  can be received from communications channels (e.g., vehicle or machine telematic channels) of the group of machine (e.g., a fleet of machines operated in multiple sites). 
     The statistical model  105  can be established and trained based on the inspection data  101  and high frequency time series data  103 . Various features corresponding to the components of the undercarriage can be derived and identified based on physics-based formulas (e.g., physics-based relationships among the measurements and/or data objects). The statistical model  105  can generate a plurality of coefficients  107  corresponding to the derived features by one or more machine leaning/training processes. These coefficients  107  can be used to perform a wear prediction process for components of a target machine. Embodiments of the derived features are discussed in detail with reference to  FIG.  5   . 
     Referring now to  FIG.  5   ,  FIG.  5    shows a data structure of a feature engineering process  500  in accordance with embodiments of the present technology. The feature engineering process  500  incudes (i) collecting data objects from input channels and/or on-site inspection (block  501 ); (ii) deriving variables and travel states based on the collected data objects (block  503 ); and (iii) determining aggregated, derived features based on the variables and travel states (block  505 ). For each of the derived features, a coefficient can be determined by the statistical model  105 . 
     As shown in  FIG.  5   , examples of the data objects include machine idle state (a), service hours (b), travel state (c), implement levers (d), travel mode state (e), left travel pedal (f), right travel pedal (g), Machine Pitch Angle (h), Machine Roll Angle (i), Swing Angle (j), Body Inertial Measurement Unit (IMU) vertical acceleration (k), implement pump pressure (I), implement pump dispense (m), engine speed (n), etc. 
     As shown in  FIG.  5   , examples of the derived variables (including travel states) can include pedal travel difference (f, g), average pedal travel (f, g), drive torque (e, I), undercarriage pitch angle (h, i, j), vibration level (k), pump flow (m, n), travel hours (b, c), travel speed (e, m, n), steering state (f, g), travel slope (f, g, h, i, j), towing load (e, I), ground condition (k), etc. 
     The annotations of the data objects and the deriving variables show correlations among them. These correlations are determined based on physics formulas. For example, the derived variable “pedal travel difference (f, g)” corelates to data objects “left travel pedal (f)” and “right travel pedal (g).” As another example, the derived variable :undercarriage pitch angle (h, i, j)” corelates to data objects “Machine Pitch Angle (h),” “Machine Roll Angle (i),” and “Swing Angle (j).” 
     In  FIG.  5   , examples of the derived features can include, for example, total travel time (X 1 ), estimate Odometer (X 2 ), travel hours per steering (X 3 ), travel hours per slope (X 4 ), travel hours per speed (X 5 ), travel hours per load (X 6 ), and travel hours per ground condition (X 7 ). In some embodiments, the derived features can include sub-features to describe different conditions. 
     For example, the travel hours per steering (X 3 ) can have sub-features such as “straight” “curve” and “spin”, each of which corresponds to a particular steering condition. The travel hours per slope (X 4 ) can have sub-features such as “uphill” “downhill” and “flat” corresponding to different slope conditions. The travel hours per speed (X 5 ) can have sub-features as “fast” and “slow,” which can be defined by an operator in different situations. The travel hours per load (X 6 ) can have sub-features such as “heavy” “moderate” and “light” which can be defined by the operator in different situations. Travel hours per ground condition (X 7 ) can have sub-features such as “rough” “moderate” and “smooth,” which can be defined by the operator in various cases. 
     In some embodiments, the derived features can corelated to one or more derived variables. For example, total travel time (X 1 ) corelates to travel hours (b, c). Estimate Odometer (X 2 ) corelates to travel hours (b, c) and travel speed (e, m, n). Travel hours per steering (X 3 ) corelates to steering state (f, g). Travel hours per slope (X 4 ) corelates to travel slope (f, g, h, i, j). Travel hours per speed (X 5 ) corelates to travel speed (e, m, n). Travel hours per load (X 6 ) corelates to towing load (e, l). Travel hours per ground condition (X 7 ) corelates to ground condition (k). 
     Referring back to  FIG.  1   , based on the foregoing correlations, the statistical model  105  analyzes these correlations and accordingly generates coefficients  107  based on one or more machine learning or training schemes. Once the coefficients  107  are generated, they can be used to perform a wear prediction process of a target machine. The target machine can have an undercarriage that includes at least one common component as the undercarriages of the source machines. The system  100  can retrieve specific machine information  109  (e.g., from field inspection, observation, operator feedback, etc.) and high frequency time series data  111  (e.g., from communication channels) of the target machine, and then generate a wear prediction  113  for the target machine based on the coefficients  107 . In some embodiments, the wear prediction  113  can be for a single machine (e.g., the target machine). In other embodiments, the wear prediction  113  can be for a plurality of machines. Embodiments of the wear prediction  113  are further discussed with reference to  FIG.  2   . 
       FIG.  2    is a schematic diagram illustrating a wear prediction result  200  in accordance with embodiments of the present technology. The wear prediction result  200  includes a percentage wear prediction for components  1 -N of undercarriages of machines M 1 -Mn. As shown in  FIG.  2   , component  1  of M 1  has wear prediction “35%” (and “100%” indicates a new component). Accordingly the present system can send an alert or reminder to an operator for further process (e.g., to perform an onsite inspection or replacement). 
       FIG.  3    is a schematic diagram illustrating components of an undercarriage  300  of a machine in accordance with embodiments of the present technology. The undercarriage  300  includes components such as a sprocket segment  301 , a carrier segment  302 , a track chain  303 , a track link  304 , a track roller  305 , and a track shoe  306 . The present method can perform a wear prediction process for at least the foregoing components  301 - 306 . In some embodiments, the wear prediction process can be performed on other suitable components of the undercarriage. 
       FIG.  4    is a schematic diagram illustrating a data structure of jobs performed on parts or components in accordance with embodiments of the present technology.  FIG.  4    provides a data structure for tracking one or more “jobs” performed on a component. The “jobs” can be tracked with “work orders.” Several types of “work-order” based information can be merged into a component tracking data set  407 . For example, the “work-order” based information can include a work performed record with component description  401  (e.g., Component C 1  has been maintained by process Y; Component C 2  has been installed by technician Z, etc.). The “work-order” based information can include work order with dates  403 . The work order with dates  403  can include time information regarding the component, such as, Component C 1  was inspected on 10:30 a.m. PT, of Date D 1 ; Component C 2  was upgraded on 15:45 p.m. PT of Date D 2 , etc. The “work-order” based information can also include work order with parts information  405 . The work order with parts information  405  can include, for example, “components C 3 -C 6  of machine M 1 -M 5  are scheduled to be replaced,” “recall information has been received for components C 7 ,” “manufacturer of component C 8  suggests a replacement after 500 hours of operation,” etc. By consolidating the “work-order” based information and store it as the component tracking data set  407 , the present technology can effectively manage and then perform the wear prediction process discussed herein. For example, the component tracking data set  407  can serve as inspection data input (e.g., the inspection data  101 ) for establishing the statistical model  105 . 
       FIG.  6    is a schematic diagram illustrating components in a computing device  600  in accordance with embodiments of the present technology. The computing device  600  can be used to implement methods (e.g.,  FIG.  7   ) discussed herein. Note the computing device  600  is only an example of a suitable computing device and is not intended to suggest any limitation as to the scope of use or functionality. Other well-known computing systems, environments, and/or configurations that may be suitable for use include, but are not limited to, personal computers (PCs), server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, programmable consumer electronics such as smart phones, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like. 
     In its most basic configuration, the computing device  600  includes at least one processing unit  602  and a memory  604 . Depending on the exact configuration and the type of computing device, the memory  604  may be volatile (such as a random-access memory or RAM), non-volatile (such as a read-only memory or ROM, a flash memory, etc.), or some combination of the two. This basic configuration is illustrated in  FIG.  6    by dashed line  606 . Further, the computing device  600  may also include storage devices (a removable storage  608  and/or a non-removable storage  610 ) including, but not limited to, magnetic or optical disks or tape. Similarly, the computing device  600  can have an input device  614  such as keyboard, mouse, pen, voice input, etc. and/or an output device  616  such as a display, speakers, printer, etc. Also included in the computing device  600  can be one or more communication components  612 , such as components for connecting via a local area network (LAN), a wide area network (WAN), cellular telecommunication (e.g. 3G, 4G, 5G, etc.), point to point, any other suitable interface, etc. 
     The computing device  600  can include a wear prediction module  601  configured to implement methods for operating the machines based on one or more sets of parameters corresponding to components of the machines in various situations and scenarios. For example, the wear prediction module  601  can be configured to implement the wear prediction process discussed herein. In some embodiments, the wear prediction module  601  can be in form of tangibly-stored instructions, software, firmware, as well as a tangible device. In some embodiments, the output device  616  and the input device  614  can be implemented as the integrated user interface  605 . The integrated user interface  605  is configured to visually present information associated with inputs and outputs of the machines. 
     The computing device  600  includes at least some form of computer readable media. The computer readable media can be any available media that can be accessed by the processing unit  602 . By way of example, the computer readable media can include computer storage media and communication media. The computer storage media can include volatile and nonvolatile, removable and non-removable media (e.g., removable storage  608  and non-removable storage  610 ) implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. The computer storage media can include, an RAM, an ROM, an electrically erasable programmable read-only memory (EEPROM), a flash memory or other suitable memory, a CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other tangible medium which can be used to store the desired information. 
     The computing device  600  includes communication media or component  612 , including non-transitory computer readable instructions, data structures, program modules, or other data. The computer readable instructions can be transported in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, the communication media can include wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, radio frequency (RF), infrared and other wireless media. Combinations of the any of the above should also be included within the scope of the computer readable media. 
     The computing device  600  may be a single computer operating in a networked environment using logical connections to one or more remote computers. The remote computer may be a personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above as well as others not so mentioned. The logical connections can include any method supported by available communications media. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet. 
       FIG.  7    is a flow diagram showing a method  700  in accordance with embodiments of the present technology. The method  700  can be implemented to predict a wear condition of an undercarriage of a machine. The method  700  starts at block  701  by receiving wear measurements from a plurality of source machines. The wear measurements are associated with a first set of components of undercarriages of the plurality of source machines In some embodiments, the wear measurements can include an idle state, service hours, a travel state, a travel mode, a pedal state, a pitch angle, a roll angle, a swing angle, a body inertial measurement unit (IMU) vertical acceleration, a pump pressure, a pump dispensing state, and/or an engine speed. 
     At block  703 , the method  700  continues by establishing a statistical model based on the received wear measurements and physic-based features derived from the wear measurements. In some embodiments, the physic-based features of the target machine include a total travel time, an estimate odometer state, travel hours per steering, travel hours per slope, travel hours per speed, travel hours per load, and/or travel hours per ground condition. 
     In some embodiments, the physic-based features are determined based on derived variables (e.g.,  FIG.  5   ) from the wear measurements. In some embodiments, the derived variables from the wear measurements can include a pedal travel difference, an average pedal travel distance, a drive torque, an undercarriage pitch angle, a vibration level, a pump flow, and/or a steering state. In some embodiments, the derived variables from the wear measurements include travel hours, a travel speed, a travel slope, and/or a ground condition. 
     At block  705 , the method  700  continues by determining coefficients for the statistical model based on inspection data of a second set of components of the undercarriage of the target machine. In some embodiments, the coefficients include parameters associated with data objects associated with the wear measurements associated with the first set of components. In some embodiments, the data objects associated with the wear measurements include an idle state, service hours, a travel state, a travel mode, a pedal state, a pitch angle, a roll angle, a swing angle, a vertical acceleration, a pump pressure, a pump dispensing state, and an engine speed. 
     In some embodiments, the first set of components of undercarriages is the same as the second set of components of the undercarriage. In such embodiments, the undercarriages of the source machines have the same set of components as the undercarriage of the target machine. In some embodiments, the first set of components of undercarriages is more than the second set of components of the undercarriage. In such embodiments, the undercarriages of the source machines have more components than the undercarriage of the target machine. 
     INDUSTRIAL APPLICABILITY 
     The systems and methods described herein can effectively manage components of an undercarriage by performing reliable wear perdition for the components. The methods enable an operator, experienced or inexperienced, to effectively manage and maintain undercarriage components of machines. The present systems and methods can also be implemented to manage multiple industrial machines, vehicles and/or other suitable devices such as excavators, etc. 
     The above description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. However, in some instances, well-known details are not described in order to avoid obscuring the description. Further, various modifications may be made without deviating from the scope of the embodiments. 
     Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of the phrase “in one embodiment” (or the like) in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not for other embodiments. 
     The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. It will be appreciated that the same thing can be said in more than one way. Consequently, alternative language and synonyms may be used for any one or more of the terms discussed herein, and any special significance is not to be placed upon whether or not a term is elaborated or discussed herein. Synonyms for some terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification, including examples of any term discussed herein, is illustrative only and is not intended to further limit the scope and meaning of the disclosure or of any exemplified term. Likewise, the claims are not to be limited to various embodiments given in this specification. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. In the case of conflict, the present document, including definitions, will control. 
     As used herein, the term “and/or” when used in the phrase “A and/or B” means “A, or B, or both A and B.” A similar manner of interpretation applies to the term “and/or” when used in a list of more than two terms. 
     The above detailed description of embodiments of the technology are not intended to be exhaustive or to limit the technology to the precise forms disclosed above. Although specific embodiments of, and examples for, the technology are described above for illustrative purposes, various equivalent modifications are possible within the scope of the technology as those skilled in the relevant art will recognize. For example, although steps are presented in a given order, alternative embodiments may perform steps in a different order. The various embodiments described herein may also be combined to provide further embodiments. 
     From the foregoing, it will be appreciated that specific embodiments of the technology have been described herein for purposes of illustration, but well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments of the technology. Where the context permits, singular or plural terms may also include the plural or singular term, respectively. 
     As used herein, the terms “connected,” “coupled,” or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling of connection between the elements can be physical, logical, or a combination thereof. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the above Detailed Description using the singular or plural number may also include the plural or singular number respectively. Additionally, the term “comprising” is used throughout to mean including at least the recited feature(s) such that any greater number of the same feature and/or additional types of other features are not precluded, unless context suggests otherwise. It will also be appreciated that specific embodiments have been described herein for purposes of illustration, but that various modifications may be made without deviating from the technology. Further, while advantages associated with some embodiments of the technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology can encompass other embodiments not expressly shown or described herein. Any listing of features in the claims should not be construed as a Markush grouping.