Patent Description:
Pumps (e.g., centrifugal, positive displacement, etc.) degrade in their performance over time and can benefit from preventative health monitoring. Pump performance for each pump also vary based upon their initial manufacturing dimensions and other manufacturing tolerances (e.g., motor winding characteristics, surface finishes, part rigidity, etc.). Pump monitoring systems are disclosed in <CIT>, <CIT>, <CIT> and <CIT>.

Such conventional systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for pump health monitoring. The present disclosure provides a solution for this need.

A method is provided as defined by claim <NUM>.

In certain embodiments, the method can include outputting a health warning signal if the health of the pump is determined to be less than a predetermined threshold. In certain embodiments, the method can include shutting down the pump and/or removing the pump for maintenance and/or replacement if the health of the pump is determined to be degraded below a predetermined threshold. The method can include any other suitable method(s) and/or portion(s) thereof. The method can be embodied as computer executable instructions on a non-transitory computer readable medium such that a computerized device can execute the method, for example.

In accordance with at least one aspect of this disclosure, a system is provided as defined by claim <NUM>.

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, an illustrative view of an embodiment of a method in accordance with the disclosure is shown in <FIG> and is designated generally by reference character <NUM>.

Other embodiments and/or aspects of this disclosure are shown in <FIG> and <FIG>.

Referring to <FIG>, and additionally to the embodiment of a system <NUM> of <FIG>, a method can include receiving (e.g., at block <NUM>), e.g., at a control module <NUM>, first pump characteristic data from a data source <NUM> associated with a pump <NUM>. The method <NUM> can include sensing (e.g., at block <NUM>) second pump characteristic data (e.g., actual characteristic data) from a flow system <NUM> using one or more sensors <NUM>. The one or more sensors <NUM> can include any suitable type of analog and/or digital senor (e.g., a flow sensor, a pressure sensor, a temperature sensor, a current, voltage, and/or power sensor, etc.) connected to any suitable part of the system (e.g., a flow line, an electrical component of the pump).

The method <NUM> can include comparing (e.g., at block <NUM>) the first pump characteristic data to the second pump characteristic data sensed in the flow system <NUM>. The method <NUM> can also include determining (e.g., at block <NUM>) a health of the pump <NUM> based on the comparison of the first pump characteristic data to the second pump characteristic data.

The first pump characteristic data can include pump performance data, e.g., for when the pump is new. For example the first pump characteristic data can include mass or volumetric flow, flow pressure, and/or flow temperature (e.g., at an inlet and/or outlet of the pump <NUM>) as a function of an input speed command by the control module <NUM> and/or as a function of a pump operating speed, for example. In certain embodiments, the first pump characteristic data can include one or more electrical characteristics (e.g., electrical power consumption, a current at predetermined voltage, etc.). Any other suitable pump characteristic (e.g., performance) data is contemplated herein. The second pump characteristic data can be the same as the first pump characteristic data, measured from the system <NUM> using the one or more sensors <NUM> (e.g., which can be existing flow system sensors). For example, a flow rate and/or pressure at an outlet of the pump <NUM> can be measured and compared to a flow rate and/or pressure of the first pump characteristic data corresponding to the operating conditions (e.g., speed) of the pump <NUM>. Sensing and/or comparison can be continuous, periodic, or otherwise caused to occur in any suitable manner or timing (e.g., only at start up).

Receiving the first pump characteristic data includes receiving the first pump characteristic data only at start-up and/or initialization of the control module <NUM> The method <NUM> includes storing the first pump characteristic data until shut down or reset of the flow system to allow an update of the first pump characteristic data at each start-up to account for a pump change.

In certain embodiments the first pump characteristic data may only be read or otherwise input to the control module (e.g., scanned in from a bar code) once when the pump is replaced.

The data source <NUM> can be or can include a digital memory device (e.g., a hard drive, a removable memory, any suitable non-transitory computer readable medium, etc.) connected (e.g., wirelessly or wired) to the control module <NUM>. Receiving the first pump characteristic data can include reading the first pump characteristic data from the digital memory device, e.g., by the control module <NUM>.

In certain embodiments, the data source <NUM> can be or include a pump label. For example, receiving the first pump characteristic data can include receiving scan data from a scanning device operatively connected to the control module <NUM> (e.g., wirelessly or wired). Any combination of types of data sources <NUM> are contemplated herein.

In certain embodiments, the method <NUM> can include outputting a health warning signal if the health of the pump <NUM> is determined to be less than a predetermined threshold (e.g., the values of the second pump characteristic data deviate from the values of the first pump characteristic data by a selected amount). In certain embodiments, the method <NUM> can include shutting down the pump and/or removing the pump for maintenance and/or replacement <NUM> if the health of the pump is determined to be degraded below a predetermined performance threshold. In certain embodiments, health monitoring can be done to recognize pump degradation before the pump degrades to where it has to be shutdown or before it degrades to where it is no longer able to perform its function, for example. In this regard, maintenance can be scheduled at a convenient time with minimal interruption to the pumps performance. Any combination of outputs is contemplated herein.

The method can include any other suitable method(s) and/or portion(s) thereof. The method can be embodied as computer executable instructions on a non-transitory computer readable medium such that a computerized device can execute the method, for example.

In accordance with at least one aspect of this disclosure, a system <NUM> can include a control module <NUM> for a flow system <NUM>. The control module <NUM> can be configured to perform a control module method. The control module method can include any suitable method(s) and/or portion(s) thereof as disclosed herein, e.g., as described above. In certain embodiments, the system <NUM> can include the pump <NUM> operatively connected to the control module <NUM> and having the data source <NUM> mounted to the pump <NUM>. The control module <NUM> can include any suitable hardware and/or software module(s).

The control module <NUM> can be a dedicated pump control module, or any other suitable module (e.g., an engine control module for controlling fuel flow with the pump). In this regard, the pump <NUM> can be for any suitable application (e.g., a fuel pump).

Referring additionally to <FIG>, in accordance with at least one aspect of this disclosure, a pump <NUM> can include a pump housing 305a containing one or more pump components (not shown; e.g., a centrifugal impeller or positive displacement pump such as a gear pump, a motor, etc.) and a data source <NUM> mounted on or in the pump housing 305a. The pump <NUM> (and/or pump <NUM>) can be any suitable type of pump, e.g., a centrifugal pump or a positive displacement pump. Certain embodiments of a pump can be driven by an electric motor, or can be otherwise driven. For example, certain embodiments can be a fuel pump (e.g., for a gas turbine engine) driven by the engine through a gearbox, and the pump can spin in proportion to rotor speed. In this regard, the first pump characteristic data can include a correlation between engine speed and performance characteristics (e.g., pressure, flow rate upstream and/or downstream, etc.). The control module <NUM> can compare the actual pump performance at a rotational speed, for example, to determine if the actual pump performance is within a predetermined range of performance criteria.

The data source <NUM> can at least include first pump characteristic data configured to be read from the data source <NUM> to provide a control module <NUM> with the first pump characteristic data. The first pump characteristic data can be standard pump performance data detailing performance when the pump is new, for example. In certain embodiments, e.g., as shown, the data source <NUM> can include at least one of a 2D barcode or a 3D barcode disposed on or formed on a surface (e.g., an outside surface, a pump face, an interior accessible surface) of the pump housing 305a. Any other suitable data source (e.g., a digital memory) and/or type of first pump characteristic data is contemplated herein.

In accordance with certain embodiments disclosed herein, pump specific performance characteristics identified, e.g., by original equipment manufacturer (OEM) testing can be stored on a suitable data storage medium (e.g., a USB type memory device) attached to the pump, on a 3D name plate attached to the pump, or in any other suitable storage medium attached to the pump. Such characteristics can provide a control module (e.g., an engine controller such as a FADEC/EEC) with pump performance data which can allow for monitoring of the pump for degradation to provide preventative health monitoring, for example. Characterization and storage of the specific operating characteristics on the pump and/or the engine controller can allow for preventative health monitoring of the pump and removal prior to a failure. Onboard storage or ID plate printing of performance characteristics specific to each pump can aid the electronic fuel controls or electronic engine controller to monitor the pump's performance over time and establish criteria for removal of the pump prior to its failure, for example.

Aspects of the this disclosure may be described above with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of this disclosure. It will be understood that each block of any flowchart illustrations and/or block diagrams, and combinations of blocks in any flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in any flowchart and/or block diagram block or blocks.

Only terms clearly indicated to the contrary, such as "only one of or "exactly one of," or, when used in the claims, "consisting of," will refer to the inclusion of exactly one element of a number or list of elements.

Any suitable combination(s) of any disclosed embodiments and/or any suitable portion(s) thereof are contemplated herein as appreciated by those having ordinary skill in the art in view of this disclosure.

Claim 1:
A non-transitory computer readable medium comprising computer executable instructions to cause a computerized device to perform a method, the method comprising:
receiving, at a control module (<NUM>) , first pump characteristic data from a data source (<NUM>) associated with a pump (<NUM>);
sensing second pump characteristic data from a flow system (<NUM>) using one or more sensors (<NUM>);
comparing the first pump characteristic data to second pump characteristic data; and
determining a health of the pump based on the comparison of the first pump characteristic data to the second pump characteristic data;
wherein receiving the first pump characteristic data includes receiving the first pump characteristic data only at start-up and/or initialization of the control module; and
wherein the method further comprises storing the first pump characteristic data until shut down or reset of the flow system.