Claims:WE CLAIM:
1. A system (100) for continuous online health monitoring of hydraulic valve (5 &5.1), the system (100) comprising:
a continuous online adopter (3A) communicably coupled to the hydraulic valve (5), the continuous online adopter (3A) being configured to retrieve operational data associated with the hydraulic valve; and
a display unit communicably coupled with the continuous online adopter (3A) for displaying the operational data associated with the hydraulic valve (5).
2. The system (100) as claimed in claim 1, wherein the continuous online adopter (3A) includes a 7-pin connector (4) (A, B, C, D, E, F, G) through which the operational data associated with the hydraulic valve (5) passes.
3. The system as claimed in claim 2, wherein the operational data comprises an enabling voltage between a pin (A &B), a reference command between a pin (D&E), and an LVDT feedback between a pin (C&F) and a grounding voltage between a pin (G and B).
4. The system as claimed in claim 1, wherein the display screen comprises a play and pause button to display the operational data at any instance of time and play button to take it further.
5. The system as claimed in claim 1, wherein a wireless unit communicably coupled to the continuous online adopter (3A), the wireless unit being configured to receive the retrieved operational data associated with the hydraulic valve (5)
6. The system as claimed in claim 5, wherein the wireless unit is configured to process the retrieved operational data to assess deviation from normal course.
7. The system as claimed in claim 6, wherein the wireless unit is configured to raise an alarm in case of deviation.
8. The system (100) as claimed in claim 7, wherein the alarm includes a video signal, and an audio signal.
9. The system as claimed in claim 7, wherein the wireless unit is any of the mobile phone, computer, laptops, etc. The system as claimed in claim 1, wherein a central monitoring system (4A) communicably coupled to the wireless unit and operatively coupled to the hydraulic valve (5), wherein the central monitoring system (4A) is configured for taking a corrective and/or operative alarm based on processing of the operational data associated with the hydraulic valve (5).
10. The system (100) as claimed in claim 1, wherein the communicably coupled includes a wired or wireless network.
11. The system (100) as claimed in claim 1, wherein the hydraulic valve (5) is a proportional or servo valve.
, Description:A SYSTEM FOR CONTINUOUS ONLINE HEALTH MONITORING OF HYDRAULIC VALVE
FIELD OF INVENTION
[001] The present invention relates to hydraulic systems of heavy machines, and more particularly towards, provision of continuous online health monitoring of hydraulic valves associated with the hydraulic systems.

BACKGROUND OF THE INVENTION

[002] In hydraulic systems, current prognostic and health management (PHM) designs collect sensor data and download it for processing at a later time. Sensor data can include performance metrics, including, for example, temperature, voltage, current, pressure, and power. Such downloaded data is then analyzed to assess the operating state of equipment and to predict degraded operation, near failure, and end of useful life of the equipment, including individual components.

[003] Such downloaded data can also be augmented by non-operational data, i.e., data acquired on the ground and when the equipment is not operating, including, for example, induced vibration data. Often such data are supplemented by visual inspections. These PHM systems typically do not provide real-time solutions to an operator. As such, these solutions can increase the down-time between operations, or otherwise delay operations at times. The gathering of sensor data and necessary storage of that data also typically require the installation of a complex computer system on the hydraulic system, typically a ruggedized and embedded computer system.

[004] CN107340438 relates to a hydraulic proportional pressure valve tester. The hydraulic proportional pressure valve tester comprises a housing, an external testing port, a pressure signal collection port, a display and control unit and a circuit board; a rechargeable lithium battery, a power supply conversion module, a central processing unit, a 0-10v output unit and a pressure signal collection unit are installed on the circuit board; the rechargeable lithium battery set is connected to the central processing unit through the power supply conversion module; and the rechargeable lithium battery is connected to the external testing port and the pressure signal collection port. The hydraulic proportional pressure valve tester can output 0-10v signals, can directly control the proportional pressure valve and realizes pressure regulation of the proportional pressure valve. In the meantime, a pressure sensor collects output pressure of the hydraulic proportional pressure valve and the output pressure is displayed on a screen in a form of an instrument or a curve, which make the user see directly.

[005] CN105927612 relates to an intelligent portable multifunction hydraulic pressure control valve failure diagnosis tester, comprising a housing, a display and control unit, a first interface and a circuit board mounted within the housing, the second circuit board, the circuit board is mounted on the first charge lithium batteries, the power conversion unit, and PWM power output unit; central processing unit installed in the second circuit board, respectively, and an output signal of the central processing unit I / O unit connected to the automatic switch, automatic feedback signal acquisition unit.

[006] CN200989852 relates to a testing technology for the performance of a proportion valve. A microcomputer and a display unit are taken as a display control interface of a performance tester for the proportion valve, thus displaying a plurality of tested product datum which are collected by the proportion valve tester in the form of timing dynamic curve and carrying out the qualified estimation to the curve according to the standard; comparing with the traditional type, the utility model has strong real-time, visible data representation type, large information quantity, and can wholly reflect all features of the products. The utility model has the technic proposal of that a pressure input port of a pressure transmitter 1 in front of the valve is connected with a pressure inspecting port in front end of the tested proportion valve 13; an electric signal output port is connected with a simulation quantity input port of an A or D collecting unit 8; a pressure input port of a pressure transmitter 2 at rear of the valve is connected with a pressure inspection port at rear of the tested proportion valve 13; an electric signal output port is connected with a simulation quantity input port of an A or D collecting unit 8; a control input terminal of a programmable power supply 12 is connected with a control output terminal of a programmable power supply drive unit 9 by cables. A video output port of a microcomputer 5 is connected with a video input port of a display unit 6 by cables.

[007] Accordingly, the prior art provides solution implementable after the failure and diagnosis purpose. Further, electrical parameter to valve are neither communicated wirelessly, nor analyzed as predictive major. Also, all parameters require individual testing. All above processing requires highly technical competent person.

OBJECTIVE

[008] The prime objective of the present invention is towards continuous online health monitoring of hydraulic proportional valve associated with hydraulic systems and also enabled with escalation alarm system

[009] Another object of the invention is to propose a new technology to eliminate failures associated with conventional systems. Existing hydraulic system toward digitalization concept.

[0010] Another object of the invention is to reduce the fault-finding time between electrical & mechanical, and further eliminating the high skill level measurement.

[0011] Another object of the invention is to assess all parameter for standalone system and also system which do not configured a spool feedback in HMI.

[0012] Another object of the invention is to compare the data between input vs output, supply voltage and grounding without affecting the process at same time with play and pause button which do not required highly technical person.

SUMMARY OF THE INVENTION

[0013] The present disclosure relates to a system (100) for continuous online health monitoring of hydraulic valve (5 &5.1). The system (100) includes a continuous online adopter (3A) communicably coupled to the hydraulic valve (5), the continuous online adopter (3A) being configured to retrieve operational data associated with the hydraulic valve; and a display unit communicably coupled with the continuous online adopter (3A) for displaying the operational data associated with the hydraulic valve (5).
[0014] This embodiment of the invention is related to the continuous online monitoring/measurement of the hydraulic valve parameter & provide prior information of deviated value against the defined reference. This invention suggests a change in the installation of adopter unit & feedback arrangement of valve at critical / non-critical location. More particularly, the invention relates to an improved condition monitoring on a hydraulic valve parameter with 7 pin arrangements. The present invention is available as adopter; which can locally measure by using multimeter after the failures. The “Online continuous monitoring adopter “of the hydraulic proportional valve is to provide predictive analysis and thus reducing the failure of hydraulic valve. The present invention is a control, test one of the intelligent portable multifunction hydraulic pressure control valve failure diagnosis tester, the output 0- ± 10v, 4-20mA, 0- ± 10mA, 0-10v and 0-20mA of the pulse width modulation (PWM ) signal, servo valves, proportional valves and the general control valve can also be collected servo valve, proportional valve and the hydraulic control valve spool displacement outputs a, B pressure chamber, and on the screen or a curved instrument the form is displayed at a glance.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0015] Further objects and advantages of this invention will be more apparent from the ensuing description when read in conjunction with the accompanying drawings of the exemplary embodiments and wherein:
Fig. 1: Shows a prior art of proportional/servo valve arrangement in hydraulic system
Fig. 2: Shows the prior art of proportional/servo valve arrangement of Fig. 1 having a measuring adopter.
Fig. 3: Shows a system for continuous online health monitoring of hydraulic valve arrangement in accordance with an embodiment of the present disclosure.

[0016] The figure(s) depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAIL DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE PRESENT INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS

[0017] The present invention, now be described more specifically with reference to the following specification.

[0018] It should be noted that the description and figures merely illustrate the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present subject matter. It should also be appreciated by those skilled in the art that by devising various arrangements that, although not explicitly described or shown herein, embody the principles of the present subject matter and are included within its spirit and scope. Furthermore, all examples recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the inventor(s) to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. The novel features which are believed to be characteristic of the present subject matter, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures.

[0019] These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.

[0020] Various components described in the foregoing description include the following nomenclature and reference numerals: -

- 1 – Controller
- 1.1 – Analog output cable
- 1.2 – input cable to HMI
- 2 – Junction box (JB)
- 2.1 – Output cable from JB
- 3 – Measuring Adopter
- 3A – Continuous online adopter with display screen
- 3.1 – Input cable to valve from adopter / Continuous online adopter
- 3.2 – Multi meter
- 3.3 – Testing cable of multi meter
- 4 – 7 pin connector
- 4A – Central monitoring system of valve
- 5 – Pilot proportional hydraulic valve
- 5.1 – Main hydraulic valve
- 6 – OBE (on board electronic card)
- 6.1 –LVDT feedback of main valve spool
- 7 – Pressure line
- 8 – A and B outlet line
- 9 – T line
- 10 – x line
- 11 – y line
- 12 – HMI (human machine interface)

[0021] The integration of a human machine interface (HMI) and programmable logic controller (PLC) provides a lean automation solution. Lean manufacturing is a proven, powerful method to boost efficiencies in production processes. In some cases, HMI do not have the facility to capture the data and is not configured during project commissioning. Sometimes standalone system does not have display provision and hence cannot measure any electrical operating parameter of hydraulic valve (s) associated with hydraulic systems. Electrical parameters are required to assesses the life of the hydraulic valve during operation. Further, as mentioned earlier, the conventional solutions provide before and after failure diagnosis.

[0022] Based on the failure history of proportional and servo valve in hydraulic systems, non-availability of valve parameters in HMI leads to higher diagnosis time in resolving hydraulic system failure problem. In many cases, HMI is configured with PLC in parallel mode, hence HMI shows reference command of valve, however reference command available in the HMI may not be a correct value if any fault comes in between PLC to valve. Hence this misguides the trouble shooting or diagnosis process.

[0023] Most of the cases, non-availability of spool feedback and grounding voltage of valve plays a vital role in identifying the root causes, which takes higher diagnosis time. Non-availability of capacity in analog input of PLC and standalone system are the major issues. All of the above cases are the post failure analysis and requires higher technical competency. Further upgradation of PLC leads to huge costing.

[0024] Fig. 1 shows a prior art of proportional/servo valve arrangement in hydraulic system. With reference to Figure-1, the hydraulic system is having pilot operated proportional valve (5) to operate main valve of spool (5.1), whereas both solenoid coil of pilot operated proportional valve (5) is connected and it is operating with outboard electronic OBE (6) via input cable to provide the Input reference command (4-20 mA, 0 to 20V and ± 10 V). Based on the operation, controller (1) of hydraulic system which is providing the variable reference input signal via cable (1.1) and simultaneously parallel signal is displayed on the HMI (12) via cable (1.2).

[0025] Further input variable signal goes to valve Junction box (2) and reach the main valve (5.1) of OBE (6). The cable (2.1) is coupled with the valve connector (4), which is having 7 pin configurations (A, B, C, D, E, F, G). Enable voltage, 0 to 24 V or 0 to 110 V/220V in the pin (A and B) is always active, reference command (D and E) (±10 V, 0 to 20V, and 4-20mA) and LVDT (6.1) feedback according to reference command in (C and F) and G is system ground. Once the reference variable signal is fed to the OBE (6) of valve it provides the control to the pilot proportional valve (5) and this controls the stroke of main valve (5.1). Further LVDT (6.1) of main valve (5.1) provide the actual position feedback via pin (C and F) to HMI (12). However, in some cases, LVDT (6.1) feedback is not configured to HMI (12) or not available.

[0026] Fig. 2 shows the prior art of proportional/servo valve arrangement of Fig. 1 having a measuring adopter. As shown, Fig. 2, is representing the diagnosis arrangement in the existing hydraulic system in addition to installation of an adopter (3) in between Junction Box (JB) (2) and the valve (5); output cable (2.1) from JB (2) is connected / coupled with the adopter (3), and output cable (3.2) of the adopter (3) is coupled with valve connector (4). In this example, controlling parameter of the valve (5) is to be measured by a multi meter (3.2) which uses the cable (3.3) in the different ports (A, B, C, D, E, F, G) available on the adopter (3). However, such a diagnosis arrangement is more time consuming, and stoppage of the operation of the hydraulic system is required. Further, variable reference cannot be capture for any instances.

[0027] In view of the foregoing, embodiments of the present invention provide for a real-time prognostic and health management system, device, and associated methods. Embodiments of the present invention perform prognostic and health management tasks in real time, and in operation, without requiring a complex computer system to be installed, the removal of equipment from its operational environment, or downloading of sensor data for later processing.

[0028] Embodiments of the present invention include a real-time prognostics and health management system for one or more devices, including electronic, electro-mechanical, and mechanical devices. The prognostics and health management system can include a tangible and non-transitory memory preloaded with prognostics and health management signature data. The prognostics and health management system can also include one or more sensors that are adapted to monitor the one or more devices. The prognostics and health management system can further include a logic device adapted to calculate an address and to access the tangible and non-transitory memory using the calculated address. One or more portions of the calculated address are responsive to one or more parameter values associated with one of the one or more sensors so that sensor parameter data determines the address into the memory. The logic device can also be further adapted to generate a prognostics and health management alert in real time responsive to a value of the prognostics and health management signature data accessed at the address.

[0029] Fig. 3 shows a system (100) for continuous online health monitoring of hydraulic valve arrangement (5 &5.1) in accordance with an embodiment of the present disclosure. Referring to the earlier mentioned components, the system (100) includes a continuous online adopter (3A) communicably coupled with the proportional / servo valve (5), the continuous online adopter (3A) being configured to retrieve operational data associated with the hydraulic valve. In an example, the continuous online adopter (3A) includes a display screen communicably coupled with the continuous online adopter (3A) for displaying the operational data associated with the hydraulic valve (5), and internal circuit configuration based on the valve used at site current and voltage type (±10 V, 0 to 20V, 4-20mA). In an embodiment, the operational data comprises an enabling voltage between a pin (A &B), a reference command between a pin (D&E), and an LVDT feedback between a pin (C&F) and a grounding voltage between a pin (G and B). Further in an embodiment, the communicably coupled includes a wired or wireless network.

[0030] In an embodiment, the continuous online adopter 3A includes display of (A, B, C, D, E, and F) on the display screen and, the display screen comprises a play and pause button to display the operational data at any instance of time and play button to take it further, and to acknowledge the variable parameter for valve (5) at any instance. The continuous online adopter (3A) includes a 7-pin connector (4) (A, B, C, D, E, F, G) through which the operational data associated with the hydraulic valve (5) passes. So, for comparison of the parameters no skilled personal is required; further additional wireless connectivity is available to monitor the continuous or real-time parameter or health of the system (100).

[0031] The Continuous online adopter (3A) is installed after the junction box (2) and is connected by the cable (2.1). The adopter cable (3.1) is connected with valve 7 / seven pin connector (4), and reference value is fed to the OBE (6), and at the same time it provides display on the screen of adopter (3A). The play/pause button on the screen is present to monitor the continuous values without interrupted operation.

[0032] In operation, enabling (0 to 24 V) or (0 to 110 V/220V), to the valve (5) is always active in (A&B) (Live & Neutral), (ground G vs N); further displayed over the screen of adopter (3A); once the variable reference input is provided, controller (1) to valve (5.1) via OBE (6) at the same time input value is displayed in D & E. The main valve (5.1) operates and spool moves to provide LVDT (6.1) feedback over the screen. At any time, all the parameters can be verified and displayed on the screen to compare the reference input vs LVDT output. Also, wireless data connectivity is available with adopter (3A) to monitor the performance in central location.

[0033] In an example, the adopter (3A) includes a wireless unit which supplies the parameter to a central monitoring system (4A), the wireless unit being configured to receive the retrieved operational data associated with the hydraulic valve (5). In an example, the wireless unit is any of the mobile phone, computer, laptops, etc. In an example, the central monitoring system (4A) is configured to assess the input signal of the adopter (3A), wherein the wireless unit is configured to process the retrieved operational data to assess deviation from normal course, and subsequently generates an alarmin case of deviation, escalation to owner or any other warning like signal to make an operator aware of a fault detection associated with the hydraulic system in real-time. In an example, the alarm includes a video signal, and an audio signal.

[0034] The embodiments of the invention as described with respect to the aforementioned specification continuously provide the online health monitoring of the hydraulic / proportional / servo valve (5) with 7 pin arrangements with local display along with data storage and wireless data facility. The adopter (3A) is configured to be used in the proportional valve and servo valve hydraulic system at various industries. For continuous assessment of the health of proportional and servo valve in the form of mechanical and electrical abnormality in the hydraulic and the equipment associated with it during operation.

[0035] Further local display unit provide the enabling voltage (supply power), reference command and spool feedback and grounding, moreover includes all 7-pin parameter of the valve (5). The embodiment suggests, an introduction to the adopter (3A) with continues online monitoring of electrical parameter and local display on screen. More particularly, the embodiment provides an advanced predictive monitoring the health of the valve (5) during operation in the hydraulic system. Further, the present embodiment provides diagnosis of proportional / servo valve (5) in failure occurrence or malfunction in the hydraulic system.

[0036] The system (100) provides continuous real-time parameter with local display on adopter screen and it also includes play / pause button on display unit and health status. Further in this embodiment output connector of adopter unit (3A) is coupled to the proportional /servo valve (5) whereas inlet connection of PLC via JB (2) is coupled with input of the adopter (3A) having 7 pin arrangements. This adopter (3A) with display screen provides the enabling voltage (power supply), reference command input to the valve and spool feedback and grounding voltage. The display screen of the adopter (3A) has a continuous display of all the 7 parameters and at any instance it can be paused without affecting the operation of hydraulic system or equipment process.

[0037] By installation of this adopter unit (3A) prior to proportional /servo valve (5) provides continuous display on the screen coupled with adopter unit (3A). The 7 pin (A, B, C, D, E, F, G) adopter (3A) having display unit along with play and pause button which displays (power supply) enabling voltage 0 to 24 V /110 V/220V in the pin (A &B), reference command (D&E) (±10 V, 0 to 20V, 4 to 20mA) and LVDT feedback (spool feedback) according to reference command in (C&F) and G is system ground. All the above parameter will be available on the screen at one glance and monitoring of parameter will be done by less skilled personal. Further, play & pause button facilitates to compare the reference data vs spool feedback during the running process. Further all parameter of the valve (5) will be wirelessly transmitted to the central monitoring system for continuous online monitoring.

[0038] It is important to note that while embodiments of the present invention have been described in the context of a fully functional system, those skilled in the art will appreciate that the mechanism of at least portions of the present invention and/or aspects thereof are capable of being distributed in the form of a computer readable medium of instructions in a variety of forms for execution on a processor, processors, or the like, and that the present invention applies equally regardless of the particular type of signal bearing media used to actually carry out the distribution. Examples of computer readable media include but are not limited to: nonvolatile, hard-coded type media such as read only memories (ROMs), CD-ROMs, and DVD-ROMs, or erasable, electrically programmable read only memories (EEPROMs), recordable type media such as floppy disks, hard disk drives, CD-R/RWs, DVD-RAMs, DVD-R/RWs, DVD+R/RWs, flash drives, and other newer types of memories, and transmission type media such as digital and analog communication links. For example, such media can include both operating instructions and operations instructions related to the design and evaluation program product and the method steps, described above.

[0039] It is to be noted that the present invention is susceptible to modifications, adaptations and changes by those skilled in the art. Such variant embodiments employing the concepts and features of this invention are intended to be within the scope of the present invention, which is further set forth under the following claims.