Blended service schedule for a power generator

Patent metadata

Field	Value
Publication number	US-2016282231-A1
Application number	US-201514669983-A
Country	US
Kind code	A1
Filing date	Mar 26, 2015
Priority date	Mar 26, 2015
Publication date	Sep 29, 2016
Grant date	—

Abstract

A power generation system includes a power generator operatively connected to a plurality of sensors and a processor. The processor is configured to observe usage-based or event-based data regarding one or more components and consumables of the power generator. A usage-based service schedule is observed for the one or more event-based components and consumables. Operation-based data is received from the plurality of sensors regarding the functioning of the power generation system and one or more operation-based components and consumables of the power generator. An operation-based service schedule is determined for the one or more operation-based components and consumables based on the operation-based data. A blended service schedule is generated, the blended service schedule including the usage-based service schedule and the operation-based service schedule. The blended service schedule is then provided to at least one of a local monitor or a remote monitor.

First claim

What is claimed is:

1 . A power generation system, comprising:
a power generator operatively connected to an engine speed sensor; and a processor configured to:
receive usage-based data regarding at least one usage-based component and consumable of the power generator, the usage-based data including at least one of when to perform maintenance of a charge air piping, a spark plug wire, a battery cable, a coolant filter, a turbocharger, an emergency stop control, an electrical cable, an engine cleaning, a heated oxygen sensor, a cylinder head, a cooling fan and a cooling fan drive belt, a fuel line seal, and a fuel pressure regulator;
determine a usage-based service schedule for the one or more usage-based components and consumables based on the usage-based data;
receive operation-based data regarding at least one of an operation-based component and consumable of the power generator, the at least one operation-based component and consumable including a spark plug, a volume of oil, an oil filter, and an air filter;
determine a predictive operation-based service schedule for the one or more operation-based components and consumables based on the operation-based data;
generate a blended service schedule, the blended service schedule including the usage-based service schedule and the predictive operation-based service schedule; and
provide the blended service schedule;
wherein the operation-based data includes at least one of an indication of a duration of operation, an engine speed, an oil temperature, a fuel consumption rate, an exhaust temperature, a compression ratio of an engine, a spark plug voltage, a brake mean effective pressure, an air-to-fuel ratio, a power output, and an engine temperature, of the power generator.

2 . The system of claim 1 , wherein the when to perform maintenance is based on the duration of operation of the power generator.

3 . The system of claim 1 , wherein the processor is configured to prioritize the one or more usage-based components and consumables and the one or more operation-based components and consumables in the blended service schedule based on at least one of an estimated time to completion, an ability to bundle service events, and an urgency of service due.

4 . The system of claim 1 , wherein the processor is configured to determine that at least one of an operation-based component and consumable is operating or predicted to operate outside of a predefined acceptable operating range based on the operation-based data and include the at least one operation-based component and consumable operating or predicted to operate outside of the predefined acceptable operating range on the predictive operation-based service schedule.

5 . The system of claim 1 , wherein the processor is configured to determine that at least one of an operation-based component and consumable is operating within a predefined acceptable operating range based on the operation-based data and include the at least one operation-based component and consumable operating within the predefined acceptable operating range on the predictive operation-based service schedule.

6 . The system of claim 1 , wherein the processor is configured to receive an input from one or more of an operator, a maintenance provider, or a distributor, the input including a service action taken in regard to a scheduled service event, and wherein the processor is configured to update the blended service schedule in response to the service action taken.

7 . A power generation system, comprising:
a power generator operatively connected to a plurality of sensors; and a processor configured to:
receive usage-based data regarding one or more usage-based components and consumables of the power generator;
determine a usage-based service schedule for the one or more usage-based components and consumables based on the usage-based data, wherein the usage-based components and consumables are replaced or serviced based on hours of operation or calendar time in service;
receive operation-based data from the plurality of sensors regarding one or more operation-based components and consumables of the power generator;
determine a predictive operation-based service schedule for the one or more operation-based components and consumables based on the operation-based data, wherein the operation-based components and consumables are replaced or serviced based on a predefined range of operation of the operation-based component or consumable;
generate a blended service schedule, the blended service schedule including the usage-based service schedule and the predictive operation-based service schedule; and
provide the blended service schedule to at least one of a local monitor and a remote monitor.

8 . The system of claim 7 , wherein the processor is configured to prioritize the one or more usage-based components and consumables and the one or more operation-based components and consumables in the blended service schedule based on at least one of an estimated time to completion, an ability to bundle service events, and an urgency of service due.

9 . The system of claim 7 , wherein the processor is configured to determine that at least one of an operation-based component and consumable is operating or is forecast to operate outside of a predefined acceptable operating range based on the operation-based data and include the at least one operation-based component and consumable operating or forecasted to operate outside of the predefined acceptable operating range on the predictive operation-based service schedule.

10 . The system of claim 7 , wherein the processor is configured to selectively alter scheduled maintenance of one or more operation-based or usage-based components and consumables on the blended service schedule both forward and backward in time in the blended service schedule if within a predetermined threshold range for the component or consumable.

11 . The system of claim 7 , wherein the processor is configured to provide a notification based on the blended service schedule, wherein the notification includes at least one of a reminder regarding an upcoming service event and an alert to order a replacement component in advance of the upcoming service event.

12 . The system of claim 7 , wherein the processor is configured to receive an input from an operator, a maintenance provider, or a distributor, the input including a service action taken in regard to a scheduled service event, and wherein the processor is configured to update the blended service schedule in response to the service action taken.

13 . The system of claim 12 , wherein the service action taken includes at least one of a completion date, a dismissed date, and an extended date.

14 . The system of claim 7 , wherein the processor is configured to generate a combined blended service schedule, wherein the combined blended service schedule combines the blended service schedule of one or more associated power generators if geographically proximate or grouped together by an operator, a maintenance provider, or a distributor.

15 . The system of claim 7 , wherein the power generator includes at least one of a solid oxide fuel cell (SOFC) power generator, a proton exchange membrane (PEM) fuel cell power generator, a hybrid genset with energy storage, a variable speed genset, a fixed speed genset, a combined heat and power generator, and a combined heating, cooling, and power generator.

16 . A monitoring system for a power generator, comprising:
a processor configured to:
receive usage-based data regarding one or more usage-based components and co

Assignees

• Cummins Power Generation Ip

Inventors

• Keene Kevin
• Fuchs Benjamin S

Classifications

• G06Q50/06

  Energy or water supply · CPC title

• G05B23/0283 Primary

  Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] (preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06) · CPC title

• G06Q10/0639

  Performance analysis of employees; Performance analysis of enterprise or organisation operations · CPC title

• G01M15/00

  Testing of engines · CPC title

• G01M99/005 Primary

  Testing of complete machines, e.g. washing-machines or mobile phones (testing of machine parts G01M13/00; testing of electric apparatus or components G01R31/50) · CPC title