Caterpillar Inc.

Michael J Campagna

Andrew W Billing

Scott A Thompson

Anthony T Petrou

Austin P Roe

James John Callas

Joseph Lee Kennedy

Dereck Glenn Heffron

David James Lin

Brian Wheeler

Kurt Hopf

Kevin L Martin

Dongming Tan

Matthew Jordan Engfehr

Neil Alan Terry

Robert J Moffat

Joshua Thomas Perko

Sravan K Karri

Jianlong Xu

Anthony L Deluca

Tyler P Jewell

Steven C Zoz

David Krenek

Balasubramanian Ramachandran

Doug A Long

Rohit K Paramatmuni

Ben McAuley

Ben Mcauley

Systems and methods for lubricant dilution detection are disclosed. A method for detecting lubricant dilution for a lubrication system includes detecting a low idle condition. The method includes receiving sensed values indicative of lubricant pressure and lubricant temperature during the low idle condition. The method also includes determining a lubricant pressure threshold based on the sensed value indicative of lubricant temperature. The method further includes determining lubricant dilution based on the sensed value indicative of lubricant pressure and the determined lubricant pressure threshold during the low idle condition. In accordance with a determination that there is lubricant dilution, the method includes outputting an indication of the lubricant dilution.

Systems and methods for lubricant dilution detection

A fuel level measurement system and method for liquified natural gas (LNG) powered machines is disclosed. An engine control module (ECM) receives fuel line pressure levels at a first time (e.g., a key-off event) and, again, at a second time (e.g., a key-on event). The ECM predicts an expected change in pressure from the key-off event to the key-on event based on various factors. If the change in pressure detected is greater than a threshold level different from the predicted change in pressure, the ECM determines a fill event and resets a current fuel level. The ECM tracks mass flow commands used to provide fuel to the engine to determine the consumption of fuel from the fuel tank and to determine a new current fuel level based on the amount of fuel consumed. The current fuel level is displayed on a fuel gauge.

Fuel level measurement system for a machine

Lubricant dilution detection systems and methods are disclosed. A method for detecting lubricant dilution for a lubrication system includes detecting a shutdown event of the lubrication system. The method includes measuring lubricant pressure during the shutdown event. The method further includes determining lubricant dilution based on the measured lubricant pressure during the shutdown event. In accordance with a determination that there is lubricant dilution, the method includes outputting an indication of the lubricant dilution.

Lubricant dilution detection system

A failure detection device is disclosed. The failure detection device may receive operations data related to operations of a set of parts of a machine. The failure detection device may process the operations data using a condition-based processing technique. The condition-based processing technique may be associated with mapping initial values of data elements of the operations data to binary values based on satisfaction of a first set of conditions by the initial values. The failure detection device may detect a presence of a possible issue with the operations of the set of parts based on a second set of conditions, associated with the binary values and the initial values, being satisfied during a time period. The failure detection device may perform, after detecting the presence of the possible issue, a set of actions related to addressing the possible issue.

Failure detection device for detecting an issue with a part of a machine

A system for detecting a fault condition in a valvetrain of an engine is configured to measure one or more operating parameters associated with the engine and determine if the operating parameters satisfy pre-defined corresponding boundary conditions. If so, a pair of values of at least one performance parameter is measured corresponding to measurement on a first and second bank of cylinders present on the engine. The difference between the pair of values is determined and used to compute at least one measure of variation for the at least one performance parameter in a time segment. If the at least one measure of variation for the at least one performance parameter exceeds a pre-defined limit for the engine, the valvetrain is flagged as faulty.

System and method for detecting a fault condition associated with a valvetrain of an engine

A system for determining a remaining useful life of a cooling component operatively connected to a prime mover. A controller performs a thermal strain analysis that includes determining the power output of the prime mover based upon sensor signals, determining a temperature output of the prime mover based upon the power output, determining a temperature at each of the plurality of analysis locations based upon the temperature output, determining a temperature difference based upon the temperature at each respective one of the plurality of analysis locations, and determining a thermal strain based upon the temperature difference. The controller repeats the thermal strain analysis at time intervals over a period of time, determines an accumulated damage for the cooling component based upon the thermal strain from each thermal strain analysis, and determines a remaining useful life of the cooling component based upon the material characteristics and the accumulated damage.

Useful life prediction system for cooling components

A system for determining health of a component is provided. The system includes an operational parameter module associated with the component and in communication with a controller. The controller is configured to receive an operating parameter signal from the operational parameter module. The controller is configured to monitor a change of the operating parameter over a predetermined time period. The controller is configured to compare the monitored operating parameter with a first predetermined threshold. The controller is configured to determine a rate of change of the monitored operating parameter over the predetermined time period. The controller is also configured to compare the determined rate of change with a second predetermined threshold. The controller is further configured to determine the health of the component based, at least in part, on the comparisons with the first and second predetermined thresholds respectively and one or more additional parameters associated with the component.

System and method for health determination of a machine component

A machine may comprise a memory configured to store liner polish information; and an electronic control module. The electronic control module may be configured to: determine a load factor based on an amount of load on the engine; determine an end of injection factor associated with the engine; determine a liner polish rate based on the load factor and the end of injection factor; obtain, from the liner polish information stored in the memory, information identifying a previous amount of damage to the engine; determine an amount of time between a current time and a time when the previous amount of damage was calculated; calculate a current amount of damage to the engine based on the previous amount of liner polish, the amount of time, and the liner polish rate; and take a remedial action based on the current amount of damage.

System for determining damage based on liner polish

A system for detecting spark plug failures in an engine is provided. The system may include one or more sensor devices coupled to the engine and configured to measure engine data, a controller in communication with the sensor devices, and an output device. The controller may be configured to determine at least a misfire count, a secondary transformer voltage, and an exhaust port temperature based on the engine data, identify a fault condition based on one or more of the misfire count, the secondary transformer voltage, and the exhaust port temperature, and perform a corrective action responsive to the fault condition. The output device may be configured to generate a notification corresponding to the fault condition.

Gas fuel engine spark plug failure detection

A machine may comprise a piston; a memory; and an electronic control module. The electronic control module may be configured to obtain information identifying a previous amount of wear of the piston pin bore and information identifying a wear limit; determine a base piston pin bore wear rate; calculate an effective piston pin bore wear rate based on the base piston pin bore wear rate; determine an amount of time between a current time and a time when the previous amount of wear of the piston pin bore was calculated; and calculate a current amount of wear of the piston pin bore based on the previous amount of wear, the amount of time, and the effective piston pin bore wear rate. The electronic control module may further be configured to calculate an amount of damage to the piston pin bore based on the current amount of wear and the wear limit.

System for determining piston pin bore wear

A process for monitoring turbocharger operation in a machine is disclosed. The machine includes a power source having an intake manifold for supplying the power source with air and a plurality of turbochargers. Each turbocharger includes an air inlet passageway to receive air, a plurality of pressure sensors arranged within the inlet passageway, a compressor configured to pressurize air, an air outlet passageway to direct pressurized air from the compressor to the intake manifold, and an exhaust turbine operably driven by exhaust gas from the power source and coupled to the compressor by a turbine shaft. The process includes monitoring the differential pressure across the air inlet passageway for each turbocharger, comparing the differential pressures for each turbocharger and indicating an anomaly in turbocharger speed when the differential pressure for one turbocharger exceeds the differential pressure for another turbocharger by a threshold amount.

Turbocharger speed anomaly detection

A machine may comprise a piston; a memory; and an electronic control module. The electronic control module may be configured to determine a temperature of a bowl rim of the piston; calculate a temperature of an oil gallery of the piston based on the temperature of the bowl rim; determine a carbon deposit growth rate of the piston based on the temperature of the oil gallery; determine an amount of time between a current time and the time when the previous carbon deposit growth was calculated; calculate a current carbon deposit growth on the piston; and take a remedial action based on the current carbon deposit growth. The current carbon deposit growth may be calculated based on: a previous carbon deposit growth on the piston, an amount of time between a current time and a time when the previous carbon deposit growth was calculated, and the carbon deposit growth rate.

System for determining piston damage based on carbon deposit growth

A machine includes a heat exchanger for an engine having a heat exchanger core and a filtration system. The filtration system includes a flexible filter sheet coupled with at least one take-up roller and a filter cleaner adapted to clean the filter via compressed air. A method of operating a machine cooling system includes rotating a rotatable drive element coupled with a filter, and cleaning the filter by directing compressed air therethrough.

Machine having self-cleaning cooling system and method

A heat exchanger is disclosed. The heat exchanger may have an inlet configured to receive a first fluid and an outlet configured to discharge the first fluid. The heat exchanger may further have at least one passageway configured to conduct the first fluid from the inlet to the outlet. The at least one passageway may be composed of a graphite foam and a layer of graphite material on the exterior of the graphite foam. The layer of graphite material may form at least a partial barrier between the first fluid and a second fluid external to the at least one passageway.

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Chillicothe, IL, United States of America

Michael J Campagna