US-12626543-B1 - System and method for vehicle diagnostics with synchronized vehicle acoustic and vibration data with on-board diagnostic data

Abstract

A diagnostic system for assessing engine wear utilizes data from sensors in a vehicle engine compartment and electronic data from a vehicle communications network to provide a comprehensive diagnostic evaluation. The system includes a sensor device with an audio sensor for capturing engine sound, an accelerometer for detecting vibration, and a near-field communication (NFC) tag for sensor information. The sensor device communicates sound and vibration data to a remote server, while a data acquisition and transfer (DAT) device connected to the vehicle's diagnostic port transmits engine performance metrics. A Dynamic Time Warping (DTW) algorithm aligns time-series data from the sensor and vehicle metrics to identify engine problems. The system supports cloud-based diagnostics and enables optimal sensor placement using geo-location or positional data. Applications include smartphone integration, Wi-Fi 6 communication for high-speed data transfer, and scan modes for varying diagnostic detail levels.

Inventors

• Kaushik Mahida
• Derk Steven Louwerse
• Bruce B. Brunda

Assignees

• INNOVA ELECTRONICS CORPORATION

Dates

Publication Date

20260512

Application Date

20250905

Claims (20)

1. 1 . A diagnostic system for diagnosing engine wear using data derived from at least one sensor in a vehicle engine compartment and electronic data from a vehicle communications network to provide a comprehensive vehicle diagnostic assessment, the device being adapted for use in a cloud-based server environment, the diagnostic system comprising: a sensor device having: an audio sensor configured to capture sound data corresponding to engine sound when the sensor device is disposed in the vehicle engine compartment; an accelerometer configured to output vibration data corresponding to engine operation when the sensor device is disposed in the vehicle engine compartment; and a near-field communication (NFC) tag associated with sensor device information; the sensor device configured to facilitate communication of the sensor device information to a remote device to enable identification of optimal sensor device placement within the engine compartment based on the sensor device information; the sensor device configured to facilitate communication of the sound data, and the vibration data to a remote server; and a data acquisition and transfer (DAT) device connectable with a diagnostic port on the vehicle for receiving vehicle data including event-driven or asynchronous engine performance metrics from an electronic communication network on the vehicle, the DAT configured to facilitate communication of the vehicle data to the remote server to perform diagnostics, wherein a Dynamic Time Warping (DTW) algorithm is applied to align time-series data from one or both the sound data and the vibration data, and the event-driven or asynchronous engine performance metrics prior to identifying engine problems.
2. 2 . The system recited in claim 1 , wherein the remote device is a smartphone.
3. 3 . The system recited in claim 1 , wherein the sensor device information is geo-location information of the sensor device.
4. 4 . The system recited in claim 1 , wherein the sensor device information is positional information of the sensor device relative to a reference point.
5. 5 . The system recited in claim 4 , wherein the reference point is a secondary sensor device.
6. 6 . The system recited in claim 5 , wherein the reference point is a location in the vehicle engine compartment.
7. 7 . The sensor device recited in claim 1 , further comprising a wireless transceiver configured to implement wireless communications via Wi-Fi communication to enable high-speed data transfer and mitigate communication interference by metal-rich vehicle components.
8. 8 . The sensor device recited in claim 1 , wherein the event-driven or asynchronous engine performance metrics are associated with scan modes comprising a rapid scan mode, an intermediate scan mode and an enhanced scan mode, each scan mode corresponding to different levels of data sampling frequency and diagnostic detail.
9. 9 . A diagnostic system for diagnosing engine wear using data derived from at least one sensor in a vehicle engine compartment and electronic data from a vehicle communications network to provide a comprehensive vehicle diagnostic assessment, the device being adapted for use in a cloud-based server environment, the diagnostic system comprising: a sensor device having: at least one sensor configured to output vehicle operation data corresponding to vehicle operational conditions when the sensor device is disposed in the vehicle engine compartment; and a near-field communication (NFC) tag associated with sensor device information; the sensor device configured to facilitate communication of the sensor device information to a remote device to enable identification of optimal sensor device placement within the engine compartment based on the sensor device information; the sensor device configured to facilitate communication of the vehicle operation data to a remote server; and a data acquisition and transfer (DAT) device connectable with a diagnostic port on the vehicle for receiving vehicle data including event-driven or asynchronous engine performance metrics from an electronic communication network on the vehicle, the DAT configured to facilitate communication of the vehicle data to the remote server to perform diagnostics, wherein a Dynamic Time Warping (DTW) algorithm is applied to align time-series data from the vehicle operation data, and the event-driven or asynchronous engine performance metrics prior to identifying engine problems.
10. 10 . The system recited in claim 9 , wherein the remote device is a smartphone.
11. 11 . The system recited in claim 9 , wherein the sensor device information is geo-location information of the sensor device.
12. 12 . The system recited in claim 9 , wherein the sensor device information is positional information of the sensor device relative to a reference point.
13. 13 . The system recited in claim 12 , wherein the reference point is a secondary sensor device.
14. 14 . The system recited in claim 13 , wherein the reference point is a location in the vehicle engine compartment.
15. 15 . The system recited in claim 9 , further comprising a wireless transceiver configured to implement wireless communications via Wi-Fi 6 communication protocol to enable high-speed data transfer and mitigate communication interference by metal-rich vehicle components.
16. 16 . The system recited in claim 9 , wherein the event-driven or asynchronous engine performance metrics are associated with scan modes comprising Quick Scan, Normal Scan, and Deep Scan, each scan mode corresponding to different levels of data sampling frequency and diagnostic detail.
17. 17 . A diagnostic system for diagnosing engine wear using data derived from at least one sensor in a vehicle engine compartment and electronic data from a vehicle communications network to provide a comprehensive vehicle diagnostic assessment, the device being adapted for use in a cloud-based server environment, the diagnostic system comprising: a sensor device having: at least one sensor configured to output vehicle operation data corresponding to vehicle operational conditions when the sensor device is disposed in the vehicle engine compartment; and a near-field communication (NFC) tag associated with sensor device information; the sensor device configured to facilitate communication of the sensor device information to a remote device to enable identification of optimal sensor device placement within the engine compartment based on the sensor device information; the sensor device configured to facilitate communication of the vehicle operation data to a remote server; and a data acquisition and transfer (DAT) device connectable with a diagnostic port on the vehicle for receiving vehicle data including event-driven or asynchronous engine performance metrics from an electronic communication network on the vehicle, the DAT configured to facilitate communication of the vehicle data to the remote server to perform AI-based diagnostics to identify engine wear patterns, wherein a Hidden Markov Model (HMM) is applied to the vehicle operation data, and the event-driven or asynchronous engine performance metrics to analyze temporal sequences for purposes of identifying the engine wear patterns.
18. 18 . A diagnostic server system for diagnosing engine wear based on vehicle engine operation, the diagnostic server system comprising: a communication circuit configured to receive: a vehicle identification number (VIN) of a vehicle; sensor position data associated with a vehicle operation sensor for placement in the engine compartment of the vehicle; time series data corresponding to engine operation captured by the identified vehicle operation sensor, and event-driven or asynchronous engine performance metrics from an OBD-II port of the vehicle; a memory storing: engine compartment layout image data associated with the VIN of the vehicle; and placement data corresponding to one or more optimized placement positions of vehicle operation sensor relative to the engine compartment layout image data; a processor in communication with the communication circuit and the memory, the processor being configured to: communicate the engine compartment layout image data and the placement data to an associated user device for display; apply a Dynamic Time Warping (DTW) algorithm to align the time series data with the event-driven or asynchronous engine performance metrics and identify engine wear conditions based on the aligned data.
19. 19 . The diagnostic server system of claim 18 wherein the processor is further configured to generate augmented reality or virtual reality overlays of an engine compartment layout image on the associated user device, the overlays including visual indications of the optimized placement positions of the vehicle operation sensor.
20. 20 . The diagnostic server system of claim 19 wherein the augmented reality or virtual reality overlays render engine compartment components as interactive objects that the user can virtually move, rotate, or remove to reveal underlying optimized placement positions for the vehicle operation sensor.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a Continuation-in-Part to co-pending U.S. patent application Ser. No. 19/179,398, filed on Apr. 15, 2025, the contents of which are incorporated herein by reference. STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT Not Applicable BACKGROUND 1. Technical Field The present disclosure relates generally to automotive diagnostics and vehicle health monitoring, encompassing systems designed to evaluate engine performance and identify mechanical issues. More specifically, it pertains to AI-driven diagnostic solutions that synchronize and analyze time-series data from multiple sensor sources, including OBD-II modules and high-frequency sound and vibration sensors placed within an engine bay. Through the integration of dynamic time warping (DTW) and machine learning algorithms, the system provides enhanced detection of wear patterns and early-stage mechanical anomalies, improving the accuracy and effectiveness of predictive maintenance in automotive applications. 2. Description of the Related Art On-board diagnostic (OBD) systems emerged in the late 1960s and early 1970s as automotive manufacturers began experimenting with methods to monitor and regulate vehicle performance, particularly in response to growing environmental and safety concerns. Early prototypes were rudimentary, often proprietary, and intended primarily for internal use by manufacturers to verify compliance with evolving emissions standards. By the 1980s, regulatory bodies such as the California Air Resources Board (CARB) began pushing for more standardized methods of emissions monitoring, leading to the development of OBD-I systems. OBD-I introduced more consistent diagnostic capabilities but lacked uniform data protocols, making it difficult for independent mechanics and consumers to interpret fault codes or implement standardized repair procedures. A push for universal compatibility and more rigorous emissions oversight led to the introduction of OBD-II in the mid-1990s. Mandated for all new vehicles sold in the United States from 1996 onward, OBD-II provided a standardized hardware interface and a set of standardized diagnostic trouble codes (DTCs). This made it possible for any generic OBD-II scanner to read fault codes and observe real-time engine parameters such as RPM, fuel trim, and sensor readings from components like oxygen sensors or the mass airflow sensor. Over time, OBD-II systems evolved to include additional protocols, improved data rates, and enhanced monitoring for increasingly sophisticated engine control units (ECUs). With the advent of more powerful onboard computers, the scope of OBD-II diagnostics expanded, yet it remained largely focused on emissions-related and electronic subsystems. While invaluable for detecting issues like misfires, sensor failures, and catalytic converter effectiveness, traditional OBD-II systems are not designed to address mechanical wear problems, such as belt degradation, bearing faults, or other early-stage physical deteriorations. OBD is reactive rather than predictive. It typically registers faults when sensors detect out-of-spec conditions. Automated vehicle diagnostics based solely on OBD data can miss several potentially dangerous conditions because OBD primarily detects electronic sensor faults and emissions-related issues, rather than mechanical problems that may present as abnormal sounds, vibrations, or physical wear and tear. Some critical vehicle conditions that could go undetected include mechanical failures that don't trigger OBD fault codes. A loose or worn timing belt or chain can lead to catastrophic engine failure, but it may not generate a fault code until the engine misfires or stops running. Similarly, a failing accessory belt or pulley, such as a slipping serpentine belt or worn idler pulley, can cause the alternator or water pump to stop functioning, but unless a related sensor detects a voltage drop or overheating, no OBD warning may be issued. Structural and drive-train issues can also be overlooked. A cracked or weakened motor mount can cause excessive engine movement, leading to driveline misalignment, but unless this causes a sensor to detect abnormal vibrations, it won't be flagged. A failing wheel bearing often produces a humming or grinding noise that could indicate imminent failure and wheel detachment, yet it will not trigger an OBD warning unless the failure affects the ABS sensor. Similarly, driveshaft or CV joint damage can cause vibrations and loss of control, but unless the electronic stability control system detects an anomaly, the driver may receive no warning. Suspension and braking system failures present additional risks. A leaking or failing shock absorber or strut can severely impact handling and braking distance, but OBD does not monitor suspension components unless the vehicle has an adaptive suspension system with sensors. A failing brake rotor or pad may cause vibrations or pulsations wh