Systems for detection of bypass valve actuation using pressure data

The bypass valve monitoring system of any of claims 1 and 3-33, the position of the bypass valve comprising at least one selected from the group consisting of fully open, partially open, and fully closed.

The bypass valve monitoring system of any of claims 1-2 and 4-33, wherein the bypass valve monitoring system is configured to identify changes in patterns of the signal reflecting high speed pressure associated with filter restriction pressure changes.

The bypass valve monitoring system of any of claims 1-3 and 5-33, wherein the bypass valve monitoring system is configured to identify changes in patterns of the signal reflecting high speed pressure associated with filter restriction pressure increases, wherein such changes indicate that a bypass valve has at least partially opened.

The bypass valve monitoring system of any of claims 1-4 and 6-33, the patterns comprising frequency patterns.

The bypass valve monitoring system of any of claims 1-5 and 7-33, the patterns comprising a multi-band frequency pattern.

The bypass valve monitoring system of any of claims 1-6 and 8-33, wherein the bypass valve monitoring system is configured to determine valve opening pressure.

The bypass valve monitoring system of any of claims 1-7 and 9-33, wherein the bypass valve monitoring system is configured to determine that the bypass valve is operating in a bypass mode when the filter restriction pressure is above the determined valve opening pressure.

The bypass valve monitoring system of any of claims 1-8 and 10-33, wherein the bypass valve monitoring system is configured to track changes in valve opening pressure over time.

The bypass valve monitoring system of any of claims 1-9 and 11-33, wherein the bypass valve monitoring system is configured to determine valve opening pressure based on a filter restriction pressure at a time of detected valve opening.

The bypass valve monitoring system of any of claims 1-10 and 12-33, wherein the bypass valve monitoring system is configured to estimate filter remaining useful life based on an amount of time that the bypass valve is in an open position.

The bypass valve monitoring system of any of claims 1-11 and 13-33, further comprising a temperature sensor, wherein the temperature sensor is in electronic communication with the control circuit and/or wherein the bypass valve monitoring system is configured to receive signals reflecting temperature.

The bypass valve monitoring system of any of claims 1-12 and 14-33, wherein the bypass valve monitoring system is configured to distinguish between cold start bypass events and normal operation bypass events based at least in part on a signal from the temperature sensor or a received signal reflecting temperature.

The bypass valve monitoring system of any of claims 1-13 and 15-33, wherein the bypass valve monitoring system is configured to utilize signals from a cold start bypass to train the system to detect valve bypass events.

The bypass valve monitoring system of any of claims 1-14 and 16-33, wherein the bypass valve monitoring system is configured to estimate filter remaining useful life based on normal operation bypass events.

The bypass valve monitoring system of any of claims 1-15 and 17-33, wherein the bypass valve monitoring system is configured to estimate filter remaining useful life based on detected valve opening events.

The bypass valve monitoring system of any of claims 1-16 and 18-33, wherein the sensing unit includes a pressure sensor generating both the signal reflecting high speed pressure and the signal reflecting filter restriction pressure.

The bypass valve monitoring system of any of claims 1-17 and 19-33, wherein at least a portion of the sensing unit is configured to be in direct contact with a fluid inside a fluid line.

The bypass valve monitoring system of any of claims 1-18 and 20-33, wherein the sensing unit is configured to be mounted on a fluid line, but not in direct contact with a fluid inside the fluid line.

The bypass valve monitoring system of any of claims 1-19 and 21-33, wherein the sensing unit is configured to be wrapped around a fluid line.

The bypass valve monitoring system of any of claims 1-20 and 22-33, the sensing unit comprising a flexible substrate.

The bypass valve monitoring system of any of claims 1-21 and 23-33, the sensing unit further comprising two or more sensing elements, wherein the two or more sensing elements are disposed on the flexible substrate.

The bypass valve monitoring system of any of claims 1-22 and 24-33, wherein the two or more sensing elements are positioned to be at different axial and/or radial positions along a fluid line.

The bypass valve monitoring system of any of claims 1-23 and 25-33, the sensing unit comprising:

• a first sensor, wherein the first sensor generates the signal reflecting high speed pressure;
• and
• a second sensor, wherein the second sensor generates the signal reflecting filter restriction pressure.

The bypass valve monitoring system of any of claims 1-24 and 26-33, the first sensor comprising a pressure sensor, wherein the pressure sensor has a sampling rate of at least 8,000 Hz.

The bypass valve monitoring system of any of claims 1-25 and 27-33, the first sensor comprising a microphone.

The bypass valve monitoring system of any of claims 1-26 and 28-33, the second sensor comprising a differential pressure sensor.

The bypass valve monitoring system of any of claims 1-27 and 29-33, the second sensor comprising a first pressure sensing element located on one side of a filter element and a second pressure sensing element located on the other side of the filter element.

The bypass valve monitoring system of any of claims 1-28 and 30-33, the second sensor comprising a first pressure sensing element located upstream of a filter element and a second pressure sensing element located downstream of the filter element.

The bypass valve monitoring system of any of claims 1-29 and 31-33, wherein the bypass valve monitoring system is a liquid filtration bypass valve monitoring system.

The bypass valve monitoring system of any of claims 1-30 and 32-33, wherein the bypass valve monitoring system is a hydraulic fluid filtration bypass valve monitoring system.

The bypass valve monitoring system of any of claims 1-31 and 33, wherein the bypass valve monitoring system is a gas filtration bypass valve monitoring system.

The method of any of claims 34 and 36-44, further comprising identifying changes in signal patterns of the signal reflecting high speed pressure associated with filter restriction pressure changes.

The method of any of claims 34-35 and 37-44, further comprising identifying changes in signal patterns of the signal reflecting high speed pressure associated with filter restriction pressure increases, wherein such changes indicate that a bypass valve has at least partially opened.

The method of any of claims 34-36 and 38-44, further comprising determining valve opening pressure.

The method of any of claims 34-37 and 39-44, further comprising determining that the bypass valve is operating in a bypass mode when the filter restriction pressure is above the determined valve opening pressure.

The method of any of claims 34-38 and 40-44, further comprising tracking changes in valve opening pressure over time.

The method of any of claims 34-39 and 41-44, further comprising determining valve opening pressure based on a filter restriction pressure at a time of detected valve opening.

The method of any of claims 34-40 and 42-44, further comprising distinguishing between a cold start bypass event and a normal operation bypass event based at least in part on a signal from a temperature sensor.

The method of any of claims 34-41 and 43-44, further comprising estimating filter remaining useful life based on detected normal operation bypass events.

The method of any of claims 34-42 and 44, further comprising estimating filter remaining useful life based on an amount of time that the bypass valve is in an open position during normal operation bypass events.

The bypass valve monitoring system of any of claims 45 and 47-59, wherein the bypass valve monitoring system is configured to identify patterns in the time domain differential pressure associated with pressure changes indicating that a bypass valve is at least partially open.

The bypass valve monitoring system of any of claims 45-46 and 48-59, wherein the bypass valve monitoring system is configured to identify changes in time domain differential pressure signal patterns occurring as differential pressure increases, wherein such changes indicate that a bypass valve has at least partially opened.

The bypass valve monitoring system of any of claims 45-47 and 49-59, the patterns comprising frequency domain patterns.

The bypass valve monitoring system of any of claims 45-48 and 50-59, wherein the bypass valve monitoring system is configured to estimate bypass valve opening pressure.

The bypass valve monitoring system of any of claims 45-49 and 51-59, further comprising a temperature sensor, wherein the temperature sensor is in electronic communication with the control circuit and/or wherein the bypass valve monitoring system is configured to receive a signal reflecting temperature.

The bypass valve monitoring system of any of claims 45-50 and 52-59, wherein the bypass valve monitoring system is configured to distinguish between cold start bypass events and normal operation bypass events based at least in part on a signal from the temperature sensor or a received signal reflecting temperature.

The bypass valve monitoring system of any of claims 45-51 and 53-59, wherein the control circuit is configured to utilize signals from a cold start bypass event to train the system to detect a valve bypass event.

The bypass valve monitoring system of any of claims 45-52 and 54-59, wherein the bypass valve monitoring system is configured to estimate filter remaining useful life based on normal operation bypass events.

The bypass valve monitoring system of any of claims 45-53 and 55-59, wherein the bypass valve monitoring system is configured to estimate filter remaining useful life based on an amount of time that the bypass valve is in an open position during normal operation bypass events.

The bypass valve monitoring system of any of claims 45-54 and 56-59, wherein the first pressure sensor has a sampling rate of at least 8,000 Hz.

The bypass valve monitoring system of any of claims 45-55 and 57-59, wherein the second pressure sensor has a sampling rate of at least 8,000 Hz.

The bypass valve monitoring system of any of claims 45-56 and 58-59, wherein at least a portion of the first pressure sensor or the second pressure sensor is configured to be in direct contact with a fluid inside a fluid line.

The bypass valve monitoring system of any of claims 45-57 and 59, wherein the first pressure sensor and the second pressure sensor are configured to be mounted on a fluid line, but not in direct contact with a fluid inside the fluid line.

The bypass valve monitoring system of any of claims 60 and 62-82, wherein the bypass valve monitoring system is configured to identify patterns of the signal reflecting acoustics and/or vibrations indicating valve chatter associated with strain changes.

The bypass valve monitoring system of any of claims 60-61 and 63-82, wherein the bypass valve monitoring system is configured to identify patterns of the signal reflecting acoustics and/or vibrations indicating valve chatter associated with strain increases, wherein such occurrences indicate that a bypass valve has at least partially opened.

The bypass valve monitoring system of any of claims 60-62 and 64-82, wherein the bypass valve monitoring system is configured to estimate filter remaining useful life based on an amount of time that the bypass valve is in an open position.

The bypass valve monitoring system of any of claims 60-63 and 65-82, the sensing unit comprising a temperature sensor, wherein the temperature sensor is in electronic communication with the control circuit and/or wherein the bypass valve monitoring system is configured to receive signals reflecting temperature.

The bypass valve monitoring system of any of claims 60-64 and 66-82, wherein the bypass valve monitoring system is configured to distinguish between cold start bypass events and normal operation bypass events based at least in part on a signal from the temperature sensor or a received signal reflecting temperature.

The bypass valve monitoring system of any of claims 60-65 and 67-82, wherein the bypass valve monitoring system is configured to estimate filter remaining useful life based on normal operation bypass events.

The bypass valve monitoring system of any of claims 60-66 and 68-82, wherein the bypass valve monitoring system is configured to estimate filter remaining useful life based on detected valve opening events.

The bypass valve monitoring system of any of claims 60-67 and 69-82, wherein the sensing unit includes a strain sensing element generating the signal reflecting strain.

The bypass valve monitoring system of any of claims 60-68 and 70-82, wherein the sensing unit includes a strain sensing element generating both the signal reflecting strain and the signal reflecting acoustics and/or vibrations.

The bypass valve monitoring system of any of claims 60-69 and 71-82, wherein the sensing unit includes a first strain sensing element and a second strain sensing element generating the signal reflecting strain.

The bypass valve monitoring system of any of claims 60-70 and 72-82, wherein the signal reflecting strain reflects differential strain at two points along a fluid line.

The bypass valve monitoring system of any of claims 60-71 and 73-82, wherein the sensing unit includes an acoustic and/or vibration sensing element generating the signal reflecting acoustics and/or vibrations.

The bypass valve monitoring system of any of claims 60-72 and 74-82, wherein at least a portion of the sensing unit is configured to be in direct contact with a fluid inside a fluid line.

The bypass valve monitoring system of any of claims 60-73 and 75-82, wherein the sensing unit is configured to be mounted on a fluid line, but not in direct contact with a fluid inside the fluid line.

The bypass valve monitoring system of any of claims 60-74 and 76-82, wherein at least part of the sensing unit is configured to be wrapped around a fluid line.

The bypass valve monitoring system of any of claims 60-75 and 77-82, the sensing unit comprising a flexible substrate.

The bypass valve monitoring system of any of claims 60-76 and 78-82, the sensing unit further comprising two or more sensing elements, wherein the two or more sensing elements are disposed on the flexible substrate.

The bypass valve monitoring system of any of claims 60-77 and 79-82, wherein the two or more sensing elements are positioned to be at different axial and/or radial positions along a fluid line.

The bypass valve monitoring system of any of claims 60-78 and 80-82, wherein the bypass valve monitoring system is a liquid filtration bypass valve monitoring system.

The bypass valve monitoring system of any of claims 60-79 and 81-82, wherein the bypass valve monitoring system is a hydraulic fluid filtration bypass valve monitoring system.

The bypass valve monitoring system of any of claims 60-80 and 82, wherein the bypass valve monitoring system is a gas filtration bypass valve monitoring system.

The method of any of claims 83 and 85-92, further comprising identifying changes in signal patterns of the signal reflecting acoustics and/or vibrations associated with strain value changes.

The method of any of claims 83-84 and 86-92, further comprising identifying changes in signal patterns of the signal reflecting acoustics and/or vibrations associated with strain value increases, wherein such changes indicate that a bypass valve has at least partially opened.

The method of any of claims 83-85 and 87-92, further comprising determining that the bypass valve is operating in a bypass mode when the signals from the acoustic or vibration sensor is consistent with valve chatter and the strain value is above a threshold value.

The method of any of claims 83-86 and 88-92, further comprising distinguishing between a cold start bypass event and a normal operation bypass event based at least in part on a signal from a temperature sensor.

The method of any of claims 83-87 and 89-92, further comprising estimating filter remaining useful life based on detected normal operation bypass events.

The method of any of claims 83-88 and 90-92, further comprising estimating filter remaining useful life based on an amount of time that the bypass valve is in an open position during normal operation bypass events.

The method of any of claims 83-89 and 91-92, wherein the sensing unit includes a first sensing element to generate the signal reflecting acoustics and/or vibrations and a second sensing element to generate the signal reflecting strain.

The method of any of claims 83-90 and 92, further comprising wrapping the sensing unit around a fluid line.