Useful life prediction system for cooling components

A controller-implemented method for determining a remaining useful life of a cooling component operatively connected to a prime mover, comprising:

• storing material characteristics of the cooling component;
• storing a plurality of spaced apart locations of the cooling component that define a plurality of analysis locations;
• performing a thermal strain analysis including:
• receiving sensor signals from a power output sensor indicative of a power output of the prime mover;
• determining the power output of the prime mover based upon the sensor signals;
• determining a temperature output of the prime mover based upon the power output;
• determining a temperature at each of the plurality of analysis locations based upon the temperature output;
• determining a temperature difference between at least some of the plurality of analysis locations and another of the plurality of analysis locations based upon the temperature at each respective one of the plurality of analysis locations;
• and
• determining a thermal strain for each of the at least some of the plurality of analysis locations based upon the temperature difference;
• repeating the thermal strain analysis at predetermined time intervals over a predetermined period of time;
• determining an accumulated damage for the cooling component based upon the thermal strain from each thermal strain analysis;
• and
• determining a remaining useful life of the cooling component based upon the material characteristics and the accumulated damage.

A machine, comprising:

• a prime mover;
• a cooling component operatively connected to the prime mover;
• a power output sensor associated with the prime mover and configured to generate sensor signals indicative of a power output of the prime mover;
• and
• a controller configured to:
• store material characteristics of the cooling component;
• store a plurality of spaced apart locations of the cooling component that define a plurality of analysis locations;
• perform a thermal strain analysis including:
• receiving sensor signals from the power output sensor;
• determining the power output of the prime mover based upon the sensor signals;
• determining a temperature output of the prime mover based upon the power output;
• determining a temperature at each of the plurality of analysis locations based upon the temperature output;
• determining a temperature difference between at least some of the plurality of analysis locations and another of the plurality of analysis locations based upon the temperature at each respective one of the plurality of analysis locations;
• and
• determining a thermal strain for each of the at least some of the plurality of analysis locations based upon the temperature difference;
• repeat the thermal strain analysis at predetermined time intervals over a predetermined period of time;
• determine an accumulated damage for the cooling component based upon the thermal strain from each thermal strain analysis;
• and
• determine a remaining useful life of the cooling component based upon the material characteristics and the accumulated damage.