• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    trigger predictive system. an actuator system includes a piston-cylinder arrangement including a piston which is movable with respect to a cylinder. a first flow path is in fluid communication with the piston-cylinder arrangement and a second flow path is in fluid communication with the piston-cylinder arrangement. a control system is operable to fluidly connect the first flow path to a source of high pressure fluid and to connect the second flow path to a drain to displace the piston in a first direction. a pressure sensor is fluidly connected to the first flow path and is operable to measure sufficient pressure data during piston movement to generate a pressure versus time curve. the control system is operable to compare the generated pressure versus time curve to a known standard pressure versus time curve stored in the control system to determine the condition of the piston-cylinder arrangement.
    公开号:BR112014026187B1
    申请号:R112014026187-3
    申请日:2013-04-19
    公开日:2021-08-31
    发明作者:Kent Tabor
    申请人:Bimba Manufacturing Company；
    IPC主号:
    专利说明:

    RELATED ORDER DATA
    [001] This application claims priority to provisional application US 61/636,431 filed April 20, 2012, the entire contents of which are incorporated herein by reference. BACKGROUND
    [002] The present invention concerns a system and method for predicting the condition of a cylinder. More specifically, the invention concerns a system and method that uses pressure or another parameter to determine the condition of a pneumatic or hydraulic cylinder.
    [003] Pneumatic and hydraulic cylinders are used throughout industry to operate equipment on manufacturing lines and to provide a driving force for various components. Over time, the operation of these cylinders can degrade. However, often, degradation in performance is not detected until a final cylinder failure occurs. If a user is not prepared for the failure, it can result in substantial downtime or costs. SUMMARY
    [004] In one embodiment, the invention provides a system that uses one or more pressure sensors to monitor the condition of a cylinder. The system includes a microprocessor/controller that compares measured pressure data to a known baseline for a particular cylinder performing a known function to determine if operation is acceptable. The system can be standalone or part of a distributed control system. In some constructions, the system may include position sensors that detect the actual position of a piston within the cylinder.
    [005] In another construction, the invention provides an actuator system that includes a piston-cylinder arrangement including a piston that is movable with respect to a cylinder. A first flow path is in fluid communication with the piston-cylinder arrangement and a second flow path is in fluid communication with the piston-cylinder arrangement. A control system is operable to fluidically connect the first flow path to a source of high pressure fluid and to connect the second flow path to a drain to move the piston in a first direction. A pressure sensor is fluidically connected to the first flow path and is operable to measure enough pressure data during piston movement to generate a pressure versus time curve. The control system is operable to compare the generated pressure versus time curve to a known standard pressure versus time curve stored in the control system to determine the condition of the piston-cylinder arrangement.
    [006] In another construction, the invention provides an actuator system that includes a cylinder defining an internal space and including a first fluid port disposed adjacent a first end of the space and a second fluid port adjacent the second end of the space. A piston is disposed within the internal space and is operable to divide the space into a first side and a second side, the first side in fluid communication with the first fluid port and the second side in fluid communication with the second fluid port. fluid. A working element is coupled to the piston and is operable to perform work in response to piston movement and a control system is operable to selectively fluidically connect the first fluid port to one of a pressure source and a drain and to connect the second fluid port to the other of the drain and pressure source to selectively move the piston away from the first port and toward the first port. A pressure sensor is in fluid communication with the first side and is operable to measure pressure data during piston movement. The control system is operable to compare the measured pressure data to a known standard to determine the condition of the system.
    [007] Also in another construction, the invention provides a method of predicting a failure in a triggering system. The method includes bringing a high pressure fluid to a first side of a piston-cylinder arrangement, draining a low pressure fluid from a second side of the piston-cylinder arrangement to allow the piston to move with respect to the cylinder towards the second side. , and obtaining a plurality of pressure measurements of the fluid adjacent to the first side during the movement of the piston. The method also includes comparing the plurality of pressure measurements to a known set of pressure values and determining whether a failure is likely based on comparing the plurality of pressure measurements to the known set of pressure values.
    [008] Other aspects of the invention will become apparent upon consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS
    [009] Figure 1 is a schematic illustration of a possible arrangement of a system embodying the invention.
    [010] Figure 2 is a graph illustrating measured pressure values versus time for a new actuator in the horizontal position with no load and no damping.
    [011] Figure 3 is a graph illustrating measured pressure values versus time for a trigger in the same arrangement as that of figure 2, where the trigger is known to be damaged.
    [012] Figure 4 is a graph illustrating measured pressure values versus time for a new actuator in the horizontal position with no load but with damping.
    [013] Figure 5 is a graph illustrating measured pressure values versus time for a trigger in the same arrangement as that of figure 4, where the trigger is known to be damaged.
    [014] Figure 6 is a graph illustrating measured pressure values versus time for a new actuator that has a larger diameter than the actuator of figures 2-5 arranged in the horizontal position with no load but with damping.
    [015] Figure 7 is a graph illustrating measured pressure values versus time for a trigger in the same arrangement as that of figure 6, where it is known that the trigger is damaged.
    [016] Figure 8 is a graph illustrating measured pressure values versus time for a new actuator in the vertical position with a load and with damping.
    [017] Figure 9 is a graph illustrating measured pressure values versus time for a trigger in the same arrangement as that of figure 8, where it is known that the trigger is damaged.
    [018] Figure 10 is a schematic illustration of the arrangement of figure 1 and additionally including a position measurement system.
    [019] Figure 11 is a schematic illustration of a multiple drive system including a distributed control system.
    [020] Figure 12 is a screenshot of a monitoring system for use when monitoring the performance and condition of one or more triggers.
    [021] Figure 13 is another screen shot of the monitoring system of Figure 12 for use when monitoring the performance and condition of one or more triggers.
    [022] Figure 14 is an image of baseline test results for a known trigger.
    [023] Figure 15 is an image of test results for the known driver of Figure 14 with a defective shaft or stem seal.
    [024] Figure 16 is an image of test results for the known driver of Figure 14 with a defective rod-side piston seal.
    [025] Figure 17 is an image of test results for the known actuator of Figure 14 with a defective top side piston seal (opposite the stem). DETAILED DESCRIPTION
    [026] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of components set out in the description below or illustrated in the drawings below. The invention is capable of other modalities and of being practiced or being executed in various ways.
    [027] Figure 1 illustrates a system 10 that is suitable for use when predicting or evaluating the condition of an actuator 15 (eg, pneumatic, hydraulic, etc.) or valve. System 10 includes a cylinder 17, a first pressure sensor 20, a second pressure sensor 25, and a microprocessor 30. The illustrated actuator 15 is a typical double-acting actuator 15 having a port 35 at either end of a cylinder. 17, a piston 40 is disposed between ports 35 and a rod 45 extending from piston 40 and outward from one end of cylinder 17. Piston 40 divides cylinder 17 into a first chamber 50 and a second chamber 55. chambers 50, 55 provide a variable volume that allows movement of the piston 40. As one of ordinary skill in the art will appreciate, the system 10 described in this document can be applied to different types of actuators (e.g., rodless) and can be used with actuators fed with different working fluids (eg hydraulic fluid, oils, water, fuel, air, other gases, other liquids, etc.). Furthermore, although the illustrated actuator is not biased in any direction, this system can also be applied for spring return actuators. In fact, the actual design of the actuator or valve is largely irrelevant as the invention can be adapted to many projects.
    [028] Working fluid is admitted to one port 35 and is allowed to drain or escape through the other port 35 to move piston 40 and rod 45 away from port 35 through which fluid is being admitted. Because there is a large pressure differential during movement of piston 40, a seal 60 is provided between piston 40 and cylinder 17. After some amount of use, this seal 60 can wear or otherwise degrade and create a point where failure can occur. A second seal 65 is provided at the end of cylinder 17 through which rod 45 extends. This second seal 65 reduces the amount of working fluid that escapes at the stem opening. Through use, this seal 65 can wear out or otherwise degrade and create a second point of possible failure.
    [029] Typically, one or more valves 70 are used to direct the working fluid to and from ports 35 as required to produce the desired movement. In a preferred arrangement, a three-way valve 70 allows the first port 35 to be opened to a pressure supply 75 and the second port 35 to be opened to a drain 80 in a first position. In a second position, ports 35 are inverted such that first port 35 is open to drain 80 and second port 35 is open to supply pressure 75. First position and second position produce movement of piston 40 and rod 45 in opposite directions. Valve 70 also provides a third operating position in which both ports 35 are closed, thereby trapping working fluid on both sides of piston 40. The third position allows piston 40 and rod 45 to be positioned and retained. somewhere in between the two extremes. Furthermore, variable flow rate valves or other flow control devices can be employed to control the rate of fluid flow into or out of ports 35 to control the speed, acceleration and exact position of piston 40 and the rod 45 as they are moved.
    [030] Continuing with reference to Figure 1, the first pressure sensor 20 is positioned to measure a pressure within the first chamber 50 and the second sensor 25 is positioned to measure a pressure within the second chamber 55. In the illustrated construction, the first sensor 20 is positioned within a first sensor port 85 which is spaced to the side of the fluid port 35 already provided in the first chamber 50 of the cylinder 17. Similarly, the second sensor 25 is positioned within a second sensor port 90 which is spaced beside the fluid port 35 already provided in the second chamber 55 of the cylinder 17. In other constructions, the pressure sensor 25 may be connected in-line with the fluid lines that are connected to the cylinder 17 and valve 70 or it can be connected to a bypass line extending from the supply line or cylinder chambers 50, 55 as may be desired.
    [031] Pressure sensors 20, 25 preferably have a range of sensed pressures that exceeds 150 psi (1,034.21 kPa) with an accuracy of about 0.01 psi (68.95 Pa) with more or less accurate sensors also being possible. Of course, sensors operating at 250 psi (1,723.69 kPa) or more are also possible. Additionally, sensor 20, 25 is preferably sized to provide a response time that allows for data acquisition at a rate of about 1000 data points per second. Certainly other pressure sensors can be used if desired. For example, in a building, sound pressure sensors, audio sensors or other vibration sensors are employed to measure the desired operating characteristics of the actuator 15.
    [032] In preferred constructions, the pressure sensors 20, 25 are detachably connected to the actuator 15 in such a way that they can be reused with subsequent actuators 15. Alternatively, pressure sensors 20, 25 can be manufactured as part of actuator 15 and replaced with actuator 15.
    [033] The pressure sensors 20, 25 convert the pressures measured within their respective chambers to a pressure signal that is transmitted to the microprocessor/controller 30. In preferred constructions, the microprocessor/controller 30 is dedicated to capture data, data and/or analyze failures or control values. Also, a data logger function can be provided to capture the number of operating cycles, minimum and maximum temperatures, maximum pressures, etc. Each microprocessor/controller 30 can include a unique ID. In the construction illustrated in Figure 1, a wired connection is illustrated. However, wireless connections such as infrared, radio frequency and more are also possible. The microprocessor/controller 30 receives the pressure signals and compares the signals with known signals for the triggers 15 to make decisions regarding the performance and condition of the trigger 15 to which it is connected. The microprocessor/controller 30 can include indicators such as lights or audio devices that can be activated when a particular condition is detected. For example, a red light may be provided and lit when excessive wear or damage to trigger 15 is detected. The microprocessor/controller 30 can have additional inputs (eg ambient temperature, pressure, control signals, etc.) and be provided with multiple output options (eg Ethernet, RS485/422, RS-232, USB, RF , IR, LED flicker code, etc.). As noted the microprocessor/controller 30 can perform the necessary comparisons and make decisions regarding the operation, maintenance or condition of the driver 15 or can transfer the raw data or decision information to a central computer which then displays the information with respect to a or more 15 triggers for a user. Additionally, the microprocessor/controller can perform data logging functions and store data relating to virtually any measured parameter such as, but not limited to, the number of cycles, maximum and minimum pressures or temperatures, number of faults, etc.
    [034] In operation, the present system 10 can be applied to virtually any driver 15 performing any operation. However, as a person of ordinary skill in the art will find, the performance of any given actuator 15 will vary with the load applied, the placement of the actuator 15 and the load, the size of the actuator 15, the distance from the pressure source 75 and any number of other variables. As such, the preferred approach is to measure the performance of a known trigger 15 in the particular application and use this measured data as a baseline. The baseline represents an acceptable motion profile and is compared to the profiles measured by the microprocessor/controller 30. This comparison is then used to determine condition and fault reporting.
    [035] Figure 2 illustrates an example of a baseline measurement like this that is exemplary and includes measured pressure and plotted against time. As can be seen, the pressure ranged from about 10 psi (68.95 kPa) to 95 psi (655.00 kPa) with other pressure ranges being possible. Furthermore, the displacement through the full stroke of the piston 40 in a first direction took about 100 ms with faster or slower displacements being possible. Furthermore, travel in one direction may be faster than travel in the opposite direction because of the reduced piston area caused by rod 45.
    [036] Continuing with reference to Figure 2, there are the two curves 95, 100 where each curve 95, 100 represents data from one of the pressure sensors 20, 25. The first pressure sensor 20 is measuring a pressure slightly greater than 10 psi (68.95 kPa) and for this reason is connected to drain 80. The second pressure sensor 25 is measuring slightly above 90 psi (650.53 kPa) and is connected to the high pressure source 75. Thus, the piston 40 is moved to an end closer to the first pressure sensor 20. In a first time, the control valve 70 is moved to the second position in such a way that the first chamber 50 and for this reason the first pressure sensor 20 remain exposed to the high pressure fluid 75 and the second chamber 55 and for this reason the second pressure sensor 25 are opened to the drain 80. The pressure within the second chamber 55 immediately begins to drop, following a substantially exponential curve. Simultaneously, the pressure within the first chamber 50 increases substantially linearly to a first pressure level. Upon reaching the first pressure level, the force produced by the high-pressure fluid on the piston 40 overcomes the mechanical inertia of the piston and any grip friction and the piston 40 begins to move towards the second pressure sensor 25. The movement of the piston 40 increases the volume in the first chamber 50, thereby causing a drop in pressure to a level below the first pressure. Simultaneously, the volume within the second chamber 55 is reduced and the pressure drops to a lower level at an accelerated rate. Once the piston 40 reaches its end of travel, the pressure within the first chamber 50 increases to a level approximately equal to the pressure of the high pressure source 75 and the pressure within the second chamber 55 drops to a level approximately equal to the pressure of drainage 80.
    [037] As illustrated in figure 2, movement in the opposite direction produces similar curves with slightly different pressure values and durations. Variations in pressures and durations are mainly due to the non-symmetrical configuration of chambers 50, 55. For example, the first pressure required to overcome inertia and adhesion friction is smaller in the direction of figure 2 because the piston area is smaller. slightly larger because of the lack of rod 45 on the second chamber side of piston 40. The total force on piston 40 is approximately the same in both directions. Of course, if a load is applied, this relationship and values will change based at least in part on that load.
    [038] Figure 3 illustrates the same type of trigger 15 performing the same operation as trigger 15 of figure 2. However, it is known that trigger 15 of figure 3 is defective. A comparison of curves 110, 115 of Figure 3 which correspond to curves 95, 100 of Figure 2 illustrates several differences. For example, the magnitude 120 of the first pressure required to initiate movement of the piston 40 is remarkably greater in Figure 3 than it is in Figure 2. Furthermore, once piston movement begins, the pressure within the first chamber 50 drops. more significantly than it falls with the actuator 15 of figure 2. Thus, the pressure variation within the first chamber 50 during piston movement is greater with the damaged actuator 15 of figure 3 as compared to that of the good actuator 15 of figure 2 .
    [039] The curve representing the data measured by the opposite pressure sensor is also different between figure 2 and figure 3. For example, the high pressure value 125 that is held before moving valve 70 is smaller in figure 3 of which it is in figure 2. Furthermore, when opened for drainage, the pressure inside the second chamber 55 falls more quickly in the cylinder of figure 3 as compared to the cylinder of figure 2.
    [040] The differences between the two curves 110, 115 can also be illustrative of possible problems with the cylinder. For example, the difference between the maximum pressure within the second chamber 55 before switching valve 70 and the first pressure required to initiate movement 120 of the piston 40 is significantly different between figure 2 and figure 3. Additionally, the pressure difference between the two chambers 50, 55 during movement of the piston 40 and at the end of the stroke of the piston is much smaller for the actuator 15 of figure 3 when compared to the actuator 15 of figure 2.
    [041] As noted, the loading and placement of trigger 15, along with many other factors, greatly affect the pressure data collected by pressure sensors 20, 25. Figures 4 and 5 illustrate triggers 15 similar to triggers 15 of figures 2 and 3 respectively, but with the addition of damping to slow the movement of the piston 40. Again, there are differences in the curves that are identifiable and that can be used to assess the condition of the actuators 15; however the curves are very different from those in figures 2 and 3.
    [042] Figures 6 and 7 illustrate the same actuator 15 during horizontal operation with no load and no damping. Trigger 15 has a larger diameter than the trigger 15 used to produce figures 2-5. Figure 6 represents data from a new trigger 15 with Figure 7 illustrating data from a trigger 15 that is known to be damaged.
    [043] Figures 8 and 9 illustrate an actuator 15 mounted vertically with a load and with damping. Figure 8 represents data from a new trigger 15 with Figure 9 illustrating data from a trigger that is known to be damaged.
    [044] In addition to measuring the pressure in the first chamber 50 and the second chamber 55, the system 10 is also capable of measuring the total stroke time duration and counting the cycles or total strokes of the piston 40. These two values can be used for maintenance cycle purposes or to assess the condition of the driver 15. For example, the microprocessor/controller 30 may illuminate a colored light to indicate that a predetermined number of cycles has occurred and routine maintenance must be performed or the driver 15 must be substituted. System 10 can also measure and monitor at maximum operating pressures and trigger an alarm if one or more of the operating pressures are exceeded.
    [045] Other parameters can be monitored using the first sensor 20 and the second sensor 25 or additional sensors can be provided to monitor other parameters. For example, a temperature sensor can be coupled to actuator 15 to monitor working fluid temperature, cylinder metal temperature, or any other desired temperature. Temperature data can be used to compensate for the effects of temperature on operating pressure.
    [046] In addition to the monitoring functions described above, system 10 can also be used to more directly control the operation of actuator 15. For example, microprocessor/controller 30 can provide control signals to valve 70 or to valves controlling the fluid flow to actuator 15 to control the speed at which piston 40 is displaced or the total force generated by piston 40. Furthermore, the present system 10 is capable of detecting the end of displacement and stopping piston 40 at this point. or before this point if desired.
    [047] Another construction of a system 150 includes a position measurement system 155 that is capable of determining the actual position of piston 40 within cylinder 17. Cylinder 17 schematically illustrated in figure 10 is identical to that of figure 1, but includes position measuring system 155. Position measuring system 155 includes a plurality of magnetic sensors 160 spaced along the length of cylinder 17. Each sensor 160 is capable of measuring exactly the angle 165 between it and another magnet 170 such as a magnet 170 placed inside or coupled to piston 40. A signal indicative of angle 165 is sent from each sensor 160 to microprocessor/controller 30. Microprocessor/controller 30 uses the various angles to triangulate and calculate the precise position of piston 40. This positional data can then be used to control the valves 70 to accurately control the position of piston 40 at any time. This position information can also be used independently or in addition to other sensors for control and/or monitoring purposes.
    [048] The systems 10, 150 described in this document can be used alone to monitor and control the operation of a single driver 15. The system can signal when the condition of driver 15 changes significantly, can signal when maintenance is required, and can signal when a replacement of driver 15 or seal is required. Furthermore, the system can be used to control the operation of the individual trigger 15.
    [049] In another arrangement, the various microprocessors/controllers 30 communicate with a host computer 170 as illustrated in figure 11. The host computer 170 is part of a distributed control system (DCS) that can monitor and control the drivers individual 15 from a location as may be required.
    [050] Figures 14-17 illustrate actual test results for a known good trigger and for the same trigger with three different known defects. Figures 14-17 illustrate a possible way in which the present system can be employed. Other types of triggers may have different failure modes and for this reason may require slightly different analysis. Furthermore, the absolute pressures, times and cycles disclosed in this document are exemplary and may vary depending on many factors including the application or actuator being used. However, figures 14-17 are examples of a possible use for the system.
    [051] Figure 14 illustrates a baseline measurement of a known trigger that is considered to be in good or acceptable condition. The actuator includes a shaft or stem seal, a stem side piston seal and a top side piston seal positioned on the opposite side of the piston with the stem side seal. Any of these seals can fail during trigger use and the present system is able to detect this failure before the trigger becomes unusable. As can be seen, the system generates waveforms (or curves) based on pressure measurements taken on both sides of the piston. As illustrated, the three specific data points 301, 302 and 303 are identified. These three data points will be discussed with reference to Figures 15-17 as these points move in response to particular faults. Furthermore, it should be noted that the maximum pressure on each side of the cylinder is substantially equal. This is typical of a good cylinder, but is a function of any pressure or flow regulator that can be positioned upstream of the fluid ports. Additionally, the low pressure of each waveform is approximately equal to atmospheric pressure as is typical of a good driver.
    [052] Figure 15 illustrates similar waveforms for a trigger identical to that of Figure 14, but with a known defect. Specifically, it is known that the stem seal is damaged. As can be seen, the two waveforms no longer intersect at the first data point 301. Particularly, there is now a 2 psi (13.79 kPa) difference between the two points 301a and 301b and they have been shifted up to from the original value of 57 psi (393.00 kPa). Furthermore, the second point 302 was moved down from 62 psi (427.47 kPa) to 53 psi (365.42 kPa) and the third point 303 was moved down from 55 psi (379.21 kPa) to 48 psi (330.95 kPa). Furthermore, the maximum pressures of the two waveforms are different as a result of the defect. Any or all of these differences can be used to determine not only that the driver is operating abnormally, but that the cause of the abnormal operation is likely to be a faulty stem seal.
    [053] Figure 16 illustrates similar waveforms for a trigger identical to that of Figure 14, but with a known defect. Specifically, it is known that the rod side piston seal is damaged. As can be seen, the two waveforms now include many differences. For example, the first point 301 was shifted upward by about 3 psi (20.68 kPa). Furthermore, the second point 302 was moved down from 62 psi (427.47 kPa) to 55 psi (379.21 kPa) and the third point 303 was moved down from 55 psi (379.21 kPa) to 49 psi (337.84 kPa). These changes are similar to those discussed with reference to the waveforms in Figure 15. However, the maximum pressure of the two waveforms now has a difference of about 3.5 psi (24.13 kPa). This is a greater difference than that seen as a result of the damaged stem seal. Furthermore, unlike with the damaged stem seal, the waveforms in figure 16 also show a pressure difference between the minimum pressures. Specifically, a difference of 1.5 psi (10.34 kPa) is clearly visible. This difference was not present as a result of the faulty stem seal. Thus, these differences can be used to determine not only that the driver is operating abnormally, but that the cause of the abnormal operation is likely to be a defective rod-side piston seal.
    [054] Figure 17 illustrates similar waveforms for a trigger identical to that of Figure 14, but with a known defect. Specifically, it is known that the top side piston seal is damaged. As can be seen, the two waveforms now include many differences when compared to the waveforms in Figure 14 as well as the waveforms in Figures 15 and 16. For example, the first point 301 was not displaced when compared to the waveforms in figure 14. This is different from what is seen in figures 15 and 16. Similarly, the second point 302 and the third point 303 remained largely unchanged compared to the waveforms in figure 14. So, looking only for these three points one can conclude that the trigger in figure 17 is in good condition. However, the maximum pressure of the two waveforms now has a difference greater than 3 psi (20.68 kPa). This difference is similar in magnitude to that of figure 16, but the direction is reversed (ie, the opposite sensor is larger).
    [055] Also, like the waveforms in Figure 16, the waveforms in Figure 17 show a pressure difference between the minimum pressures. Specifically, a difference of about 2 psi (13.79 kPa) is clearly visible. Like the maximum pressure difference, this difference was present in the waveforms in Figure 16, but again the direction is reversed (ie, the opposite sensor is low). Thus, these differences can be used to determine not only that the driver is operating abnormally, but that the cause of the abnormal operation is likely to be a defective top-side piston seal.
    [056] It should be noted that the triggers used to generate the waveforms in figures 14-17 were unloaded. As such, there was very little variation in cycle times (on the X axis) as a result of the defects. However, on loaded cylinders, the defects discussed above also cause measurable variations in cycle times. These variations can be measured and reported and can also be used to assess trigger status. In addition to using timing variations to determine if potential problems have occurred, some constructions use the area under the curve to assess whether problems are occurring. More specifically, the area between the curves can be used in situations where the actuator is operated at varying pressures or at varying rates. In these situations, it was found that the total area under the curve remains substantially uniform. Thus, an increase in this area is indicative of unwanted leakage or other performance failures. In other applications, variations in the area between curves may be indicative of a particular failure mode alone or in combination with other measured parameters.
    [057] In addition, the start and end of a cycle can be easily detected and reported for use both to control a process and to access the trigger condition. Furthermore, if a cycle time is determined to be faster than necessary, or slower than necessary, the pressure can be adjusted to achieve the desired cycle time, thereby improving process quality and possibly reducing the amount of air or compressed fluid used by the actuator.
    [058] Figures 12 and 13 illustrate images of a possible monitoring system for use with the systems discussed in this document. Figure 12 illustrates a status page for the monitoring system. Although the status page includes the status of a trigger, multiple triggers can be grouped and illustrated together as desired. The illustrated image includes three performance indicators with the first indicator providing a red, yellow, or green status based on the waveform analysis discussed earlier. The second indicator provides an indication that the end of the course has been reached. The third indicator counts trigger cycles and provides an indication of trigger life based on the number of cycles. Life can be the actual life of the driver or can be set to mirror recommended maintenance intervals for a particular sensor.
    [059] The second area of the status page provides numerical data for various trigger operating parameters. Other parameters can be measured and displayed as desired. The third area of the status page provides an efficiency analysis. In this example, efficiency is based on cycle time. The data displayed is a comparison of actual cycle time versus desired cycle time with space provided to indicate recommended corrective action based on the result. In this example, the trigger is traveling faster than desired. Thus, fluid pressure can be reduced to decrease drive speed and potentially lower operating cost.
    [060] Figure 13 illustrates a possible configuration page that provides specific data for the trigger being analyzed. In this example, hole size, stroke length and total cycle count can be added, stored and displayed. Furthermore, the steps required to generate the baseline waveforms (figure 14) can be started from this page. Finally, alarm setpoints for any measured parameters can be set with each having a high alarm, a low alarm and a switch to enable or disable the alarm. Finally, a Firmware update status is provided to alert the user when a firmware update is required.
    [061] It should be noted that the invention has been described as being used with an actuator (sometimes referred to as a cylinder, a pneumatic cylinder or a hydraulic cylinder). However, in other applications, the invention is applied to a valve or any other flow device. A flow device is any device that controls the flow of a fluid or operates in response to a flow of fluid being directed into it. As such, the invention is not to be limited to actuators only.
    [062] Thus, the invention provides a system 10, 150 to measure and control the operation of an actuator 15. The system 10, 150 includes pressure sensors 20, 25 that are capable of collecting data and a capable microprocessor/controller 30 of analyzing the data to determine the condition of the trigger 15.
    权利要求:
    Claims (13)
    [0001]
    1. Actuator system comprising: a piston-cylinder arrangement including a piston (40) that is movable with respect to a cylinder (17); a first flow path in fluid communication with the piston-cylinder arrangement; a second flow path in fluid communication with the piston-cylinder arrangement; a control system (30) operable to fluidly connect the first flow path to a source of high pressure fluid and to connect the second flow path to a drain to move the piston (40) in a first direction; a pressure sensor (20) fluidly connected to the first flow path and operable to measure sufficient pressure data during the movement of the piston (40) to generate a pressure versus time curve, the control system (30) operable to compare the generated pressure versus time curve to a known standard pressure versus time curve stored in the control system to determine the condition of the piston-cylinder arrangement, characterized in that the actuator system further comprises a second pressure sensor (25) in communication of fluid with the second flow path is operable to measure a second set of pressure data during movement of the piston (40), and the control system (30) being operable to compare the second set of measured pressure data to a second standard. known to determine the condition of the system.
    [0002]
    2. Actuator system according to claim 1, characterized in that it further comprises a piston seal (60) coupled to the piston (40) to inhibit fluid flow between the piston (40) and the cylinder (17), the control system (30) operable to predict a failure of the piston seal (60) based on comparing the generated pressure versus time curve to the known standard pressure versus time curve stored in the control system (30).
    [0003]
    3. Actuator system according to claim 1, characterized in that it additionally comprises a shaft (45) coupled to the piston (40) and including a shaft seal (65) that inhibits fluid flow between the shaft (45) and the cylinder (17), the control system (30) operable to predict a shaft seal (65) failure based on comparing the generated pressure versus time curve to the known standard pressure versus time curve stored in the control system. (30).
    [0004]
    4. Actuator system according to claim 1, characterized in that it comprises: a cylinder (17) defining an internal space and including a first fluid port (35) disposed adjacent a first end of the space and a second port (35) of fluid adjacent to the second end of the space; a piston (40) disposed within the internal space and operable to divide the space into a first side (50) and a second side (55), the first side (50) in fluid communication with the first fluid port (35) and defining the first fluid path and the second side (55) in fluid communication with the second fluid port (35) and defining the second fluid path; a working element coupled to the piston (40) and operable to perform work in response to movement of the piston (40); a control system (30) operable to selectively fluidically connect the first fluid port (35) to one of a pressure source (75) and a drain (80) and to connect the second fluid port (35) to the another of the drain (80) and pressure source (75) to selectively move the piston (40) away from the first port (35) and toward the first port (35); and a pressure sensor (20) in fluid communication with the first side (50) and operable to measure pressure data during movement of the piston (40).
    [0005]
    5. Actuator system according to any one of claims 1 to 4, characterized in that it additionally comprises a piston seal (60) coupled to the piston (40) to inhibit fluid flow between the piston (40) and the cylinder (17), the control system (30) operable to predict a failure of the piston seal (60) based on comparing the measured pressure data to the known standard.
    [0006]
    6. Actuator system according to claim 4, characterized in that the working element includes a shaft (45) extending through the cylinder (17) and a shaft seal (65) that inhibits fluid flow between the shaft (45) and cylinder (17), the control system (30) operable to predict a failure of the shaft seal (65) based on comparing the measured pressure data to the known standard.
    [0007]
    7. Actuator system according to any one of claims 1 to 4, characterized in that the pressure sensor (20) is operable to measure data at a rate of at least 1,000 data points per second.
    [0008]
    8. Actuator system according to any one of claims 1 to 4, characterized in that the pressure sensor (20) is operable to measure pressure data with an accuracy of plus or minus 0.01 psi (68.95 Pan).
    [0009]
    9. Actuator system, according to any one of claims 1 to 4, characterized in that the piston (40) and cylinder (17) define a pneumatic piston-cylinder arrangement.
    [0010]
    10. Actuator system according to any one of claims 1 to 4, characterized in that the control system (30) includes a microprocessor (30) and a memory device, and in which the known pattern is generated during a or more initial operating cycles and is stored in the memory device.
    [0011]
    11. A method of predicting a failure in an actuator system, the method comprising: bringing a high pressure fluid to a first side (50) of a piston-cylinder arrangement; draining a low pressure fluid from a second side (55) of the piston-cylinder arrangement to allow the piston (40) to move with respect to the cylinder (17) towards the second side (55); obtaining a plurality of fluid pressure measurements adjacent to the first side during movement of the piston (40); obtaining a plurality of measurements of the fluid adjacent to the second side during movement of the piston (40); comparing the plurality of pressure measurements to a known set of pressure values; and determining whether a failure is likely based on comparing the plurality of pressure measurements to the known set of pressure values.
    [0012]
    12. Method according to claim 11, characterized in that it further comprises generating the known set of pressure values during one or more initial operating cycles of the drive system and storing the known set of pressure values in a system of control (30).
    [0013]
    13. Method according to any one of claims 11 to 12, characterized in that it further comprises obtaining the plurality of pressure measurements at a frequency of at least 1,000 data points per second.
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    同族专利:
    公开号 | 公开日
    CN104395615B|2018-01-09|
    MX355298B|2018-04-11|
    EP2839169A4|2016-01-06|
    ES2786076T3|2020-10-08|
    DK2839169T3|2020-04-27|
    IN2014KN02380A|2015-05-01|
    KR20150018793A|2015-02-24|
    KR101729822B1|2017-04-25|
    US20210310504A1|2021-10-07|
    US20130276516A1|2013-10-24|
    RU2600200C2|2016-10-20|
    WO2013159008A1|2013-10-24|
    AU2013249065B2|2015-12-17|
    US20160230789A1|2016-08-11|
    CA2871037A1|2013-10-24|
    JP6158914B2|2017-07-05|
    CN104395615A|2015-03-04|
    CA2871037C|2017-06-27|
    MX2014012703A|2015-06-03|
    BR112014026187A2|2017-06-27|
    US9128008B2|2015-09-08|
    RU2014146622A|2016-06-10|
    ZA201407688B|2015-11-25|
    EP2839169A1|2015-02-25|
    JP2015514947A|2015-05-21|
    AU2013249065A1|2014-11-06|
    EP2839169B1|2020-04-01|
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    法律状态:
    2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2020-02-27| B25A| Requested transfer of rights approved|Owner name: EMBEDTEK, LLC (US) |
    2020-08-11| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-10-27| B25A| Requested transfer of rights approved|Owner name: BIMBA MANUFACTURING COMPANY (US) |
    2021-06-08| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-08-31| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 19/04/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    2022-01-18| B25D| Requested change of name of applicant approved|Owner name: BIMBA LLC (US) |
    优先权:
    申请号 | 申请日 | 专利标题
    US201261636431P| true| 2012-04-20|2012-04-20|
    US61/636,431|2012-04-20|
    US13/838,253|US9128008B2|2012-04-20|2013-03-15|Actuator predictive system|
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    PCT/US2013/037393|WO2013159008A1|2012-04-20|2013-04-19|Actuator predictive system|
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