Wheel end sensor for heavy-duty vehicles

• US 9,933,337 B2
• Filed: 09/11/2015
• Issued: 04/03/2018
• Est. Priority Date: 09/12/2014
• Status: Active Grant

• Current Assignee: Hendrickson USA LLC (The Boler Company)
• Original Assignee: Hendrickson USA LLC (The Boler Company)
• Inventors: White, Jay D., Morris, Jeffrey S., Ernenwein, Keith M., Karich, Matthew, Zawacki, Jeffrey R.
• Primary Examiner(s): Kirkland, III, Freddie
• Application Number:
  US14/851,080
• Publication Number:
  US 20160076973A1
• Time in Patent Office: 935 Days
• CPC Class Codes: B60B 27/0068 the element being a sensor
• CPC Class Codes: B60B 2900/3312 during regular use
• CPC Class Codes: B60B 2900/5112 against dust or dirt
• CPC Class Codes: B60B 2900/5114 against humidity or water
• CPC Class Codes: B60B 2900/541 Servicing
• CPC Class Codes: B60B 7/0013 Hub caps
• CPC Class Codes: B60C 23/001 Devices for manually or automatically controlling or distributing tyre pressure whilst the vehicle is moving
• CPC Class Codes: B60C 23/00318 on the wheels or the hubs
• CPC Class Codes: B60C 23/00336 on the axles
• CPC Class Codes: B60C 23/00363 Details of sealings
• CPC Class Codes: B60C 23/0406 Alarms noticeable from outside the vehicle, e.g. indication in side mirror, front light or audible alarms B60C23/0403, B60C23/0405 take precedence
• CPC Class Codes: B60C 23/041 Means for supplying power to the signal- transmitting means on the wheel
• CPC Class Codes: B60C 23/0433 Radio signals
• CPC Class Codes: B60T 17/22 Devices for monitoring or checking brake systems; Signal devices
• CPC Class Codes: B60T 8/171 Detecting parameters used in the regulation; Measuring values used in the regulation
• CPC Class Codes: G01C 22/00 Measuring distance traversed on the ground by vehicles, persons, animals or other moving solid bodies, e.g. using odometers, using pedometers
• CPC Class Codes: G01M 17/013 Wheels
• CPC Class Codes: G01P 1/026 for speed measuring devices, e.g. pulse generator

Abstract

A wireless sensor for a wheel end assembly of a heavy-duty vehicle is provided. The wheel end assembly includes a wheel hub and a hub cap mounted on the wheel hub. The sensor includes mounting means disposed in the hub cap. Sensing means are mounted on the mounting means to sense at least one condition of the vehicle. A processor is mounted on the mounting means and is electrically connected to the sensing means to process data from the sensing means. Communication means are mounted on the mounting means and are electrically connected to the processor to communicate the processed data to a user. An electrical energy storage device is mounted on the mounting means and is electrically connected to the sensing means, the processor and the communication means, enabling the sensor to be independent from the vehicle power supply. The sensor also accommodates components of a tire inflation system.

Claims

1. A sensor for a wheel end assembly of a heavy-duty vehicle, said wheel end assembly including a wheel hub and a hub cap removably mounted on said wheel hub, said sensor comprising:

mounting means disposed in said hub cap, said hub cap being mounted on an outboard end of said wheel hub to prevent leakage of lubricant from the wheel hub and to prevent contaminants from entering said wheel hub;

sensing means mounted on said mounting means to sense at least one operational condition of said vehicle;

a processor mounted on said mounting means and electrically connected to said sensing means to process data from said sensing means;

communication means mounted on said mounting means and electrically connected to said processor to communicate said processed data to a user; and

an electrical energy storage device mounted on said mounting means and electrically connected to said sensing means, said processor and said communication means to power said sensor.

2. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 1, wherein said mounting means includes a sensor block.

3. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 2, wherein:

said hub cap includes;

a cylindrical side wall;

an intermediate wall disposed between an inboard end of said side wall and an outboard end of the side wall, said intermediate wall extending generally perpendicular to said side wall; and

an outboard wall extending generally perpendicular to said side wall; and

said sensor block is disposed between said hub cap intermediate wall and said hub cap outboard wall.

4. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 2, wherein said sensing means includes sensor instrumentation, and sensor instrumentation and said processor are mounted on a main circuit board.

5. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 4, wherein said sensor block includes a perimeter ring and a component mounting block disposed inside of said perimeter ring, said component mounting block being formed with a plurality recesses for receiving said main circuit board, said communication means, and said electrical energy storage device.

6. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 1, wherein said communication means includes a radio frequency circuit board.

7. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 6, wherein an outboard wall of said hub cap is at least one of transparent and translucent, whereby radio signals from said radio frequency circuit board pass through said outboard wall.

8. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 6, wherein said radio frequency circuit board communicates emergency conditions to a receiver that is visible to an operator of said vehicle.

9. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 6, wherein said radio frequency circuit board communicates said processed data to a remote receiver for central collection and analysis.

10. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 1, wherein said communication means includes light emitting diode indicators.

11. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 10, wherein an outboard wall of said hub cap is at least one of transparent and translucent, whereby said light emitting diode indicators are visible through said outboard wall.

12. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 1, wherein said communication means includes an audible alert.

13. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 1, wherein said mounting means are formed with slots to enable lubricant in said wheel end assembly to circulate through said hub cap.

14. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 1, wherein said electrical energy storage device is independent from a power supply of said vehicle.

15. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 1, wherein said electrical energy storage device includes at least one of a battery, a capacitor, a super-capacitor, and an ultra-capacitor.

16. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 1, wherein said electrical energy storage device is charged by energy harvesting.

17. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 16, further comprising:

a plurality of magnets mounted on a spindle plug;

said spindle plug being seated in a counterbore of an axle; and

a coil of electrical winding material being formed as a ring and mounted in said hub cap in proximity to said magnets, whereby during vehicle travel, said coil rotates with said wheel hub about said magnets to produce an electrical current that is transmitted to said electrical energy storage device.

18. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 17, wherein said transmission of said electrical current to said electrical energy storage device is by wireless transmission.

19. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 1, wherein said operational conditions of said vehicle includes at least one of a temperature in said wheel end assembly, vibration in the wheel end assembly, humidity in said wheel end assembly, a speed of a wheel of said vehicle, a direction of a wheel of said vehicle, and a revolution count of said wheel hub.

20. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 19, wherein said vibration sensing includes overall detection of a high-frequency band for a broad spectrum review.

21. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 1, wherein said sensor accommodates components of a tire inflation system in said hub cab.

22. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 1, further comprising an anti-lock braking system sensor.

23. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 22, wherein said anti-lock braking system sensor includes:

a sensor unit mounted on a spindle plug that is seated in a counterbore of an axle, said sensor unit mounted in an axially outboardly facing direction; and

a ring formed with a plurality of teeth, said teeth facing in an axially inboard direction, whereby said sensor unit senses the teeth to indicate a direction of rotation and speed of a wheel of said vehicle.

24. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 22, wherein said anti-lock braking system sensor includes:

a sensor unit mounted on a spindle plug that is seated in a counterbore of an axle, said sensor unit mounted in a radially inward facing direction; and

a ring formed with a plurality of teeth, said teeth facing in a radially outward direction, whereby said sensor unit senses the teeth to indicate a direction of rotation and speed of a wheel of said vehicle.

25. The sensor for a wheel end assembly of a heavy-duty vehicle of claim 22, wherein said anti-lock braking system sensor includes:

a sensor unit mounted on a spindle plug that is seated in a counterbore of an axle, said sensor unit mounted in a radially outward facing direction;

a ring formed with a plurality of teeth, said teeth facing in a radially inward direction, whereby said sensor unit senses the teeth to indicate a direction of rotation and speed of a wheel of said vehicle.