Description:Complete Specification:

The following specification describes and ascertains the nature of this invention and the manner in which it is to be performed.
Field of the invention
[0001] This invention is related to a control unit for detecting an operating state of an actuator in a vehicle and a method thereof.

Background of the invention

[0002] Actuator systems include both linear and rotary designs, with different drive mechanisms including electric motors, rotary screws, belt drives, and pneumatic cylinders. Actuator weight, size, and system complexity are typically among the major design considerations. Reliability and service life are also important factors, particularly in robotic welding and other large-scale industrial applications, where unscheduled maintenance and downtime can result in substantial lost productivity and associated costs. As a result, there is a continuing demand for more advanced actuator diagnostic and prognostic techniques Failure of actuators occurs due to excess number of actuations caused due to battery voltage fluctuations, sensor noise (both position sensor voltage & control parameter – pressure/mass) & faulty control calibration. Systems in the market uses the demand value to calculate the total number of actuations.

[0003] A patent US10907722 discloses a system includes one or more sensors configured for acquiring data related to operational conditions of a motor actuator,a processor configured for analyzing the data to determine a status of the motor actuator , and memory for storing data representative of the operational conditions. A status indicator is generated based on the analysis of the operational conditions, for example to represent system capabilities, normal operating modes, and failure modes of the motor actuator . The system can be configured to communicate the status indicator to a user interface or higher-level controller.

Brief description of the accompanying drawings
[0004] Figure 1 illustrates a control unit for detecting an operating state of an actuator in a vehicle in accordance with an embodiment of the invention; and
[0005] Figure 2 illustrates a flowchart of a method for detecting an operating state of an actuator in a vehicle in accordance with this invention.

Detailed description of the embodiments
[0006] Figure 1 illustrates a control unit for detecting an operating state of an actuator in a vehicle in accordance with one embodiment of the invention. The control unit 10 detects a change in a direction of the actuator 12 and determines a summation of movements of the actuation in a single direction. The control unit 10 counts number of actuator movements in different movement intervals. The control unit 10 generates a warning if a rate of increase of the number of actuator movements is more than a predefined threshold.

[0007] Further the control unit and the components of the control unit is explained in detail. The control unit is chosen from a group of control units comprising a microcontroller, a microprocessor, a digital circuit, an integrated chip, and the like. The control unit comprises a counter 16 for incrementing a count a count for every respective movement interval of the actuator. The counting of the number of actuator movements in the different movement intervals is determined when a change in a direction of actuator position is detected from a start. I.e.., a single movement of the actuator 12 is considered as a unidirectional change in the actuator position. This unidirectional change in the actuator movement is considered over multiple discrete measurement intervals without stopping / changing direction.

[0008] When the direction of the movement changes or the movement stalls, the previous movement is assumed to be over and the summation of changes in the actuator position from the beginning of the movement in this direction till the current change is considered as the single movement of the actuator 12. The sum value is used for counting of the number of actuations in different movement intervals.

[0009] The total number of actuations of the actuator in the different movement intervals is continuously calculated based on each unidirectional movement of the actuator. The total number of actuations of the actuator 12 in different movement intervals is continuously calculated by tracking each unidirectional movement of the actuator 12. The control unit 10 then finds the absolute/ average value of these movements and classifies these movements into different movement intervals . The counter 16 increments the counter by one for every respective movement interval.

[0010] The respective movement intervals are incremented by the classification of the movements of the actuator 12 and a rate of change of number of movements in each of the movement interval is calculated. The rate of change of number of movements in each movement intervals with the distance covered is calculated taking the values during the last vehicle service as the reference. The rate of change that is calculated is compared with the allowed rate of change as specified by the supplier. If the rate of change of number of movements increases beyond the predefined threshold, then warnings are generated by the control unit 10.

[0011] Figure 2 illustrates a method for detecting an operating state of an actuator in a vehicle in accordance with this invention. In step S1, a change in a direction of the actuator is detected by a control unit 10 and a summation of movements of the actuation in a single direction is determined. In step S2, a number of actuator movements is counted in different movement intervals by a counter 16. In step S3, a warning is generated if a rate of increase of the number of actuator movements is more than a predefined threshold.

[0012] The method is explained in detail. The actuator 12 is used in any of the industrial machine or vehicle or any other place that is known to a person skilled in the art. The failure or faulty actuator 12 is detected based on the number of actuations it is operated in a predefined amount of time. As discussed above, a change in the direction of the actuator movement is detected and upon detecting the change in the direction of the actuator 12, then a summation of changes in the actuator position from the beginning of the movement in that particular direction till the current change is determined. The sum value that is obtained is used for counting the number of actuations in different movement intervals. If there is no change in the actuator direction, then the control unit 10 adds the previous movement to the summation of the movements in the current direction.

[0013] The control unit 10 compares the unidirectional movement of the actuator 12 with minimum and maximum values of the various ranges/bins of multiple/different actuator movement intervals. The counter 16 is incremented by one and a count is added to the movement bin to the previous unidirectional movement of the actuator 12. I.e.., if the actuator movements are divided into three movement intervals, the counter 16 will add or increment a count by one in the last interval, based on the comparison of the unidirectional movement of the actuator 12 with the minimum and maximum values.

[0014] The rate of change of movements in each movement intervals are calculated and compared with the allowed rate of change that is specified by the customer. I.e.., the rate of change of the movement is compared with the predefined threshold. The control unit 10 generates a warning if the actual rate of change of movements (i.e.., calculated ) is more than the predefined threshold/ allowed rate of change. The warning can be of any kind comprising an audio, a signal, or the like.

[0015] It should be understood that embodiments explained in the description above are only illustrative and do not limit the scope of this invention. Many such embodiments and other modifications and changes in the embodiment explained in the description are envisaged. The scope of the invention is only limited by the scope of the claims , Claims:We Claim:
1. A control unit (10) for detecting an operating state of an actuator (12) in a vehicle (14), said control unit (10) adapted to :
- detect a change in a direction of said actuator (12) and determine a summation of movements of said actuation in a single direction;
- count number of actuator movements in different movement intervals;
- generate a warning if a rate of increase of said number of actuator movements is more than a predefined threshold.

2. The control unit (10) as claimed in claim 1, wherein said counting of said number of actuator movements in said different movement intervals is determined when a change in a direction of actuator position from a start.

3. The control unit (10) as claimed in claim 1, wherein said total number of actuations of said actuator (12) in said different movement intervals is continuously calculated based on an each unidirectional movement of said actuator (12).

4. The control unit (10) as claimed in claim 3, wherein said control unit (10) calculates an absolute value of said movements and classifies said movements into said different movement intervals.

5. The control unit (10) as claimed in claim 4, wherein a count is incremented in a counter (16) for a respective movement interval of said actuator (12).

6. The control unit (12) as claimed in claim 1, wherein said warning is generated if rate of change of number of movements in each of said movement intervals is more than an allowed rate of change / said predefined threshold.

7. A method for detecting an operating state of an actuator (12) in a vehicle (14), said method comprising:
- detecting a change in a direction of said actuator (12) by a control unit (10) and determining a summation of movements of said actuation in a single direction;
- counting number of actuator movements in different movement intervals by a counter (16);
- generating a warning if a rate of increase of said number of actuator movements is more than a predefined threshold.