US-12618748-B2 - Cylinder head crack detection system

Abstract

A crack detection system for a cylinder head associated with an internal combustion engine of a locomotive is disclosed. The crack detection system comprises: a closed-loop coolant system for cooling the cylinder head; a sensor assembly including a pressure sensor, and a speed sensor; and a controller in communication with the sensor assembly. The controller is configured to monitor a coolant pressure feedback and an engine duty cycle of the internal combustion engine. The controller is further configured to communicate an alert signal indicative of an existence of a crack in the cylinder head when: coolant pressure signals are greater than or equal to a first threshold and less than a second threshold; a pressure decay is calculated greater than a third threshold.

Inventors

• Adarsh G. NAIR
• Raji Rexavier

Assignees

• PROGRESS RAIL LOCOMOTIVE INC.

Dates

Publication Date

20260505

Application Date

20230914

Claims (20)

1. 1 . A crack detection system for a cylinder head associated with an internal combustion engine of a locomotive, comprising: a closed-loop coolant system for cooling the cylinder head; a sensor assembly including a pressure sensor, and a speed sensor; and a controller in communication with the sensor assembly and configured to monitor a coolant pressure feedback, and an engine duty cycle of the internal combustion engine, the controller further configured to communicate an alert signal indicative of an existence of a crack in the cylinder head when: coolant pressure signals are greater than or equal to a first threshold and less than a second threshold; and a pressure decay is calculated greater than a third threshold.
2. 2 . The crack detection system of claim 1 , wherein the cylinder head is a multi-bank cylinder head and the controller is configured to classify a location of the crack in a right bank of the cylinder head when the controller calculates the pressure decay to be greater than the third threshold and greater than a fourth threshold.
3. 3 . The crack detection system of claim 2 , wherein the controller is configured to classify the location of the crack in a left bank of the cylinder head when the controller calculates the pressure decay to be greater than the third threshold and less than the fourth threshold.
4. 4 . The crack detection system of claim 1 , further comprising an oil quality sensor, wherein the controller is configured to communicate the alert signal when the controller receives signals from the oil quality sensor indicative of a sodium content or a water content above an impurity threshold in an oil in the internal combustion engine.
5. 5 . The crack detection system of claim 1 , wherein the controller is configured to communicate the alert signal to a display interface in a cab of the locomotive, and wherein the controller is further configured to activate a limp-home mode feature upon detection of existence of cracks in the cylinder head.
6. 6 . The crack detection system of claim 1 , the controller is further connected to an off-board network and a remote, whereby the off-board network is a cloud based architecture for online remote monitoring and for updating oil quality data.
7. 7 . The crack detection system of claim 1 , wherein a crack is detectable via hot squeeze if the pressure decay is greater than the third threshold.
8. 8 . A locomotive comprising: a frame; a prime mover mounted on the frame; a ground engaging element supporting the frame; a cab; and a crack detection system for a cylinder head associated with the prime mover, including: a closed-loop coolant system for cooling the cylinder head; a sensor assembly including a pressure sensor, an oil quality sensor, and a speed sensor; and a controller in communication with the sensor assembly and configured to monitor a coolant pressure feedback, an engine duty cycle of the prime mover, and a sodium content in the prime mover, the controller further configured to communicate an alert signal indicative of an existence of a crack in the cylinder head detected when: coolant pressure signals are greater than or equal to a first threshold and less than a second threshold; and a pressure decay is calculated greater than a third threshold.
9. 9 . The locomotive of claim 8 , wherein the cylinder head is a multi-bank cylinder head and the controller classifies a location of the crack in a right bank of the cylinder head when the controller calculates the pressure decay to be greater than the third threshold and greater than a fourth threshold.
10. 10 . The locomotive of claim 9 , wherein the controller is configured to classify the location of the crack in a left bank of the cylinder head when the controller calculates the pressure decay to be greater than the third threshold and less than the fourth threshold.
11. 11 . The locomotive of claim 8 , wherein the controller is further configured to communicate the alert signal when the controller receives signals from the oil quality sensor indicative of a sodium content is above a Na threshold in an oil in the prime mover.
12. 12 . The locomotive of claim 8 , wherein the controller is configured to communicate the alert signal to a display interface in the cab of the locomotive.
13. 13 . The locomotive of claim 8 , wherein the controller is further configured to activate a limp-home mode feature upon detection of existence of cracks in the cylinder head.
14. 14 . The locomotive of claim 8 , wherein the controller is further connected to an off-board network and a remote, whereby the off-board network is a cloud based architecture for online remote monitoring and for updating oil quality data.
15. 15 . The locomotive of claim 8 , wherein a crack is detectable via hot squeeze if the pressure decay is greater than the third threshold.
16. 16 . A method for detecting and classifying cracks in a cylinder head of a prime mover in a locomotive, the method comprising: providing a frame, a ground engaging element supporting the frame, the prime mover mounted in the frame, a controller, a closed-loop coolant system associated with the cylinder head, a sensor assembly in communication with the controller, the sensor assembly including a pressure sensor and a speed sensor; operating the prime mover; cooling the cylinder head using the closed-loop coolant system and monitoring a coolant pressure feedback via the pressure sensor; monitoring, via the controller receiving signals from the sensor assembly, continuously for coolant pressure signals, and an engine duty cycle of the prime mover; identifying existence of cracks in the cylinder head from signals received by the controller when the coolant pressure signals are greater than or equal to a first threshold and less than a second threshold; classifying a location of the cracks in a right bank of the cylinder head when the controller calculates a pressure decay, via the pressure sensor, greater than a third threshold and greater than a fourth threshold; classifying the location of the cracks in a left bank of the cylinder head when the controller calculates the pressure decay, via the pressure sensor, greater than the third threshold and less than the fourth threshold; and alerting existence of cracks to an operator of the locomotive, via communicating an alert signal by the controller.
17. 17 . The method of claim 16 , further comprising: identifying existence of cracks in the cylinder head from signals, received by the controller from an oil quality sensor for monitoring oil quality, indicative of a sodium content in an oil in a combustion chamber associated with the prime mover that is above an impurity threshold.
18. 18 . The method of claim 16 , further comprising: connecting the controller to an off-board network and a remote, whereby the off-board network is a cloud based architecture for online remote monitoring and for updating oil quality data; and communicating the alert signal and location of the cracks to a display interface in the locomotive.
19. 19 . The method of claim 16 , further comprising: removing samples of oil from an oil pan; testing the samples of oil for a sodium content or a water content in the oil; and identifying existence of cracks in the cylinder head when the sodium content or the water content in the oil is above an impurity threshold.
20. 20 . The method of claim 18 , further comprising: communicating sample data, from periodic samples of oil, to the off-board network to update the controller.

Description

TECHNICAL FIELD The present disclosure generally relates to engines, and more particularly relates to cylinder heads of combustion engines. BACKGROUND Engines for transportation machines, such as diesel engines for trains and boats, play a critical role in the transportation industry, powering locomotives and marine vessels that haul heavy loads over long distances. These engines consist of numerous components, including cylinder heads, which are essential for the proper functioning of the combustion chambers and valve mechanisms. Cylinder heads serve as critical sealing elements, facilitating efficient combustion and ensuring the integrity of the engine's internal components. Detecting the occurrence of cracks in cylinder heads is critical in maintaining the reliability and safety of the engines for operation. Running a locomotive engine with a cracked cylinder head poses significant risks, including coolant leakage, loss of compression, and potential engine overheating, which can lead to engine damage or failure. Continuing to operate a locomotive engine with a cracked cylinder head can result in costly repairs and extended downtime. Timely detection of these cracks is crucial to prevent costly repairs, minimize downtime, and avoid catastrophic failures during operation with existing cracks. Existing crack detection methods often rely on visual inspections, pressure tests, dye penetrant testing, or non-destructive testing methods such as magnetic particle inspection or ultrasonic testing. While these methods have been utilized to some extent, they suffer from various drawbacks that limit their practicality and reliability to detect small or hidden cracks. Furthermore, the existing crack detection systems may lack integration and automation, requiring manual coordination between different testing methods and modules. This can lead to inefficiencies, errors, and increased complexity in the crack detection process, hindering the overall reliability and productivity of the rail engine maintenance operations. Others have attempted to develop a solution for detecting cracks in cylinder heads. For example, in KR100448123, an apparatus is proposed for crack detection during engine endurance tests in vehicles. KR100448123 relies on a constant pressure method in the cooling water passage and connecting pressure measuring hoses attached to the intake and exhaust manifolds. However, this method falls short in accurately identifying crack positions in the cylinder head and is insufficient for comprehensive crack detection. Hence, there exists a need for a crack detection system that provides enhanced accuracy, efficiency, automation, and integration, enabling early and reliable detection of cracks in cylinder heads while minimizing maintenance costs, and downtime. SUMMARY In accordance with one aspect of the disclosure, a crack detection system for a cylinder head associated with an internal combustion engine of a locomotive is disclosed. The crack detection system comprises: a closed-loop coolant system for cooling the cylinder head; a sensor assembly including a pressure sensor and a speed sensor; and a controller in communication with the sensor assembly. The controller is configured to monitor a coolant pressure feedback, an engine duty cycle of the internal combustion engine. The controller is further configured to communicate an alert signal indicative of an existence of a crack in the cylinder head when: coolant pressure signals are greater than or equal to a first threshold and less than a second threshold; a pressure decay is calculated greater than a third threshold. In accordance with another aspect of the disclosure, a locomotive is disclosed. The locomotive comprises: a frame; a prime mover mounted on the frame; a ground engaging element supporting the frame; a cab; and a crack detection system for a cylinder head associated with the prime mover. The crack detection system includes a closed-loop coolant system for cooling the cylinder head; a sensor assembly including a pressure sensor and a speed sensor; and a controller in communication with the sensor assembly. The controller is configured to monitor a coolant pressure feedback and an engine duty cycle of the internal combustion engine. The controller is further configured to communicate an alert signal indicative of an existence of a crack in the cylinder head when: coolant pressure signals are greater than or equal to a first threshold and less than a second threshold; a pressure decay is calculated greater than a third threshold. In accordance with another aspect of the disclosure, a method for detecting and classifying cracks in a cylinder head of a locomotive engine in a locomotive. The method comprises the steps of: providing a frame, a ground engaging element supporting the frame, the prime mover mounted in the frame, a controller, a closed-loop coolant system associated with the cylinder head, a sensor assembly in communication with the control