DESC:FORM 2

THE PATENTS ACT 1970
(39 OF 1970)
AND
THE PATENTS RULES 2003

COMPLETE SPECIFICATION
(see Section 10; Rule 13)

A PREDICTIVE MAINTENANCE SYSTEM FOR T90 TANK ENGINES

ENGINE FACTORY AVADI
Unit OF Armoured Vehicles Nigam Limited
Government of India Enterprise
Ministry of Defence
Avadi, Chennai, 600054
Tamil Nadu, India

The following specification particularly describes the invention and the manner in which it is to be performed.
A PREDICTIVE MAINTENANCE SYSTEM FOR T90 TANK ENGINES
TECHNICAL FIELD
[0001] The present invention pertains to, developing, and integrating a data acquisition and predictive maintenance system specifically engineered for high-power diesel engines such as a T90 tank.

BACKGROUND OF THE INVENTION
[0002] The high-power diesel engine for mobility and combat effectiveness. which are integral to the tank's performance. However, a significant challenge has been the lack of real-time monitoring and diagnostic capabilities, which has often left the causes of engine failures undetermined. This uncertainty can be detrimental, especially in combat situations where reliability and readiness are critical.
[0003] Historically, the inability to capture and analyze vital engine parameters at the moment of failure has hindered effective maintenance and timely interventions. Failures often occur due to operational neglect, such as improper handling by the driver or inadequate maintenance, leading to unexpected engine breakdowns. Moreover, the cost and time associated with repairing or replacing these engines place a considerable burden on resources.
[0004] To address these challenges, there is a pressing need for a system that can monitor engine conditions in real-time, predict potential failures, and provide actionable alerts to operators. The development of a predictive maintenance system is a response to this need. Such a system would enhance operational efficiency by providing continuous monitoring and diagnostics, thereby preventing engine failures before they occur. This proactive approach is particularly vital in military applications where equipment reliability is paramount.
[0005] The implementation of this technology is expected to revolutionize maintenance protocols by shifting from reactive to predictive maintenance strategies. By providing early warnings, the system allows for timely interventions, such as cleaning filters, adjusting engine settings, or performing necessary repairs. This not only extends the life of the engine but also ensures that the tank remains operationally ready, thereby safeguarding both equipment and personnel in high-stakes environments.

OBJECTS OF THE INVENTION
[0006] The primary object of this invention is to provide a predictive maintenance system for high-power diesel engines.
[0007] Another objective is to reduce the frequency and severity of engine failures through proactive maintenance interventions.
[0008] Yet another object is to facilitate a comprehensive data acquisition and analysis capability that allows for detailed monitoring and recording of engine performance.
[0009] Yet another object of the invention is to provide a cost-effective solution for engine maintenance that leverages existing technologies and infrastructure.
SUMMARY OF THE INVENTION
[0010] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
[0011] According to an embodiment of the present invention, a Predictive Maintenance System comprises an Electronic Control Unit (ECU) housed in an enclosure. The ECU includes a microprocessor, a Real-Time Clock (RTC), a power supply, an Analog-to-Digital Converter (ADC), an RPM converter board, and connectors for peripheral circuits. Additionally, the system features a data acquisition system connected to the ECU, equipped with sensors for monitoring various engine parameters. The system also includes a display unit for visualizing data and interacting with the system, a gear position monitoring system using Infrared (IR) transmitter and receiver sensors, a set of pressure transducers for measuring main oil pressure, water inlet pressure, and crankcase pressure, Resistance Temperature Detectors (RTD) probes for measuring water and oil temperatures, an exhaust gas temperature sensor using a K-type thermocouple, limit switches for monitoring radiator fan speeds and shutter positions, an engine RPM monitoring subsystem using a tachogenerator and RPM converter, a system clock-based air filter clog indicator, and a speaker system for delivering audible warnings and alarms.
[0012] According to an embodiment of the present invention, the microprocessor used in the system is a Raspberry Pi-4B running Raspbian OS, equipped with a 128GB memory chip and an RTC unit.
[0013] According to an embodiment of the present invention, the display unit of the system is a 21-inch LED display with HDMI ports, and the system includes an adapter cable for micro HDMI to HDMI connections.
[0014] According to an embodiment of the present invention, the IR sensors for gear position monitoring are configured to detect a gear position including the forward gears, neutral, and reverse.
[0015] According to an embodiment of the present invention, the RTD probes have a temperature measurement range of 0-250°C.
[0016] According to an embodiment of the present invention, the exhaust gas temperature sensor is a K-type thermocouple with a range of 0-1000°C.
[0017] According to an embodiment of the present invention, the system further comprises data processing, analysis, and the triggering of alarms or warnings based on preset thresholds.
[0018] According to an embodiment of the present invention, the data acquisition system is configured to record engine parameters and provide data retrieval for defect investigation and predictive maintenance analysis.
[0019] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating the preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:
[0021] FIG. 1 illustrates a photo image of the predictive maintenance, according to the present invention.
[0022] FIG. 2 illustrates a circuit diagram of the predictive maintenance system, according to the present invention.
[0023] Although the specific features of the present invention are shown in some drawings and not in others. This is done for convenience only as each feature may be combined with any or all of the other features in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[0024] In the following detailed description, a reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practised are shown by way of illustration. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense. The various embodiments of the present invention provide for a predictive maintenance system for high-power diesel engine vehicles.
[0025] According to an embodiment of the present invention, a Predictive Maintenance System comprises an Electronic Control Unit (ECU) housed in an enclosure. The ECU includes a microprocessor, a Real-Time Clock (RTC), a power supply, an Analog-to-Digital Converter (ADC), an RPM converter board, and connectors for peripheral circuits. Additionally, the system features a data acquisition system connected to the ECU, equipped with sensors for monitoring various engine parameters, and a display unit for visualizing data and interacting with the system. It includes a gear position monitoring system using Infrared (IR) transmitter and receiver sensors, a set of pressure transducers for measuring main oil pressure, water inlet pressure, and crankcase pressure, Resistance Temperature Detectors (RTD) probes for measuring water and oil temperatures, an exhaust gas temperature sensor using a K-type thermocouple, limit switches for monitoring radiator fan speeds and shutter positions, an engine RPM monitoring subsystem using a tachogenerator and RPM converter, a system clock-based air filter clog indicator, and a speaker system for delivering audible warnings and alarms.
[0026] According to an embodiment of the present invention, the microprocessor in the system is a Raspberry Pi-4B running Raspbian OS, equipped with a 128GB memory chip and an RTC unit.
[0027] According to an embodiment of the present invention, the display unit of the system is a 21-inch LED display with HDMI ports, and the system includes an adapter cable for micro HDMI to HDMI connections.
[0028] According to an embodiment of the present invention, the IR sensors for gear position monitoring are configured to detect nine gear positions, including seven forward gears, neutral, and reverse.
[0029] According to an embodiment of the present invention, the pressure transducers are specified as follows: Main Oil Pressure with a range of 0-16 Bar, Water Inlet Pressure with a range of 0-6 Bar, and Crankcase Pressure with a range of -500 to 500 mBar.
[0030] According to an embodiment of the present invention, the RTD probes used in the system have a temperature measurement range of 0-250°C.
[0031] According to an embodiment of the present invention, the exhaust gas temperature sensor is a K-type thermocouple with a range of 0-1000°C.
[0032] According to an embodiment of the present invention, the system further comprises a software program developed in Python-3 for data processing, analysis, and triggering of alarms or warnings based on preset thresholds.
[0033] According to an embodiment of the present invention, the data acquisition system is configured to record engine parameters and provide data retrieval for defect investigation and predictive maintenance analysis.
[0034] According to an embodiment of the present invention, a method for predictive maintenance using the system as described in any of the preceding claims involves continuously monitoring engine parameters using the data acquisition system, recording the monitored data in real-time, analyzing the data to predict potential engine failures based on historical and real-time data, issuing warnings and alarms to the vehicle operator when parameters exceed or fall below preset thresholds, and providing data retrieval capabilities for maintenance analysis and troubleshooting.
[0035] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such as specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.
[0036] It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modifications. However, all such modifications are deemed to be within the scope of the claims.
,CLAIMS:We Claim:
1. A Predictive Maintenance System, comprising:
an Electronic Control Unit (ECU) housed in an enclosure, the ECU including, a microprocessor, a Real-Time Clock (RTC), power supply, Analog-to-Digital Converter (ADC), RPM converter board, and connectors for peripheral circuits;
a data acquisition system connected to the ECU, equipped with sensors for monitoring various engine parameters;
a display unit for visualizing data and interacting with the system;
a Gear position monitoring system using Infrared (IR) transmitter and receiver sensors;
a set of pressure transducers for measuring main oil pressure, water inlet pressure, and crankcase pressure;
a Resistance Temperature Detectors (RTD) probes for measuring water and oil temperatures;
an exhaust gas temperature sensor using a K-type thermocouple;
a Limit switches for monitoring radiator fan speeds and shutter positions;
an engine RPM monitoring subsystem using a tachogenerator and RPM converter;
a system clock-based air filter clog indicator; and
a speaker system for delivering audible warnings and alarms.

2. The system as claimed in claim 1, wherein the microprocessor is a Raspberry Pi-4B running Raspbian OS and equipped with a 128GB memory chip and an RTC unit.

3. The system as claimed in claim 1, wherein the display unit is a 21-inch LED display with HDMI ports, and the system includes an adapter cable for micro HDMI to HDMI connections.

4. The system as claimed in claim 1, wherein the IR sensors for gear position monitoring are configured to detect a gear position including the forward gears, neutral, and reverse.

5. The system as claimed in claim 1, wherein the RTD probes have a temperature measurement range of 0-250°C.

6. The system as claimed in claim 1, wherein the exhaust gas temperature sensor is a K-type thermocouple with a range of 0-1000°C.
7. The system as claimed in claim 1, further comprising data processing, analysis, and triggering of alarms or warnings based on preset thresholds.

8. The system as claimed in claim 1, wherein the data acquisition system is configured to record engine parameters and provide data retrieval for defect investigation and predictive maintenance analysis.

Dated this 31st day of January 2025.

Saravanan Gopalan
Registered Patent Agent
(INPA – 3249)