Wheel end monitoring device, fastener and method

Abstract

In one aspect, a wheel end monitoring device includes a wheel hub configured to receive a wheel rim and be clamped therewith. The wheel end monitoring device also includes a power source, at least one sensor, and a communication circuit rotatable with the wheel hub. The at least one sensor is configured to detect at least one characteristic of the clamped wheel hub and wheel rim. The at least one characteristic is indicative of the clamping of the clamped wheel hub and wheel rim. The communication circuit is configured to wirelessly communicate data associated with the at least one characteristic to an external device.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 62 / 912,955, filed October 9, 2019, which is hereby incorporated by reference in its entirety. Technical Field

[0003] The present disclosure relates to vehicle wheel ends, and more particularly, to monitoring the clamping components of wheel ends. Background Art

[0004] Fasteners, such as screws, bolts, and studs, are used to create connections between objects. The objects are held together by tension generated within the fastener. If the tension is released (for example, if the nut on the stud becomes loose), the objects may separate and the connection may fail. For example, in commercial trucking, studs are used to connect a wheel (including a wheel rim and one or more tires) to the wheel hub. Specifically, the wheel is positioned on the stud of the hub, where the lug nut engages the stud, and the lug nut is torqued down to secure the wheel to the hub. The process of applying torque to the nut tensions the stud and causes the shank, or body, of the stud to elongate slightly.

[0005] The torque applied to commercial truck lug nuts, and the resulting tension in the studs, is crucial to providing a durable wheel and hub structure. If the tension is too low, the wheel may disconnect, or progressive failure may occur, such as wear of mating surfaces, wear of the hub pilot, and / or stud fatigue. If the tension is too high, the hub studs may yield and / or break. Furthermore, excessive stud tension may cause undesirable stresses in the hub.

[0006] The tension in the studs of commercial vehicle hubs can be too high or too low due to the initial torque applied when the wheel is mounted on the hub. In other cases, the tension in the studs can change over time despite the lug nuts being tightened to the correct amount of torque. A number of environmental factors can cause the tension in the studs to release over time, including vibration, shock, and temperature fluctuations.

[0007] Stud tension indicator systems allow drivers and fleet operators to monitor stud tension. For example, in the case of heavy truck wheel ends, some systems include a nut rotation indicator that allows the driver to visually identify a change in the rotational direction of the wheel hub's nut, which would indicate a loss of stud tension. More specifically, if any nut on the wheel is loose, the nut rotation indicator will be noticeably misaligned with the other nut rotation indicators on the wheel. This alerts the driver to a possible loss of tension in the stud due to a loose nut on the stud. However, these nut rotation indicators do not provide real-time tension information to the driver or fleet operator during vehicle operation. These nut rotation indicators do not indicate a specific tension value. Furthermore, if the wheel hub's stud has yielded and begun to plastically deform (which can occur due to overtightening of the associated nut), these nut rotation indicators cannot alert the driver. Summary of the Invention

[0008] According to one aspect of the present disclosure, a wheel end monitoring device for a vehicle is provided. The wheel end monitoring device includes a wheel hub configured to receive and be clamped together with a wheel rim. The wheel hub may include, for example, a wheel hub body, a stud, and a nut. The wheel end monitoring device also includes a power source, at least one sensor, and a communication circuit, which are rotatable together with the clamped wheel hub and wheel rim. The at least one sensor is configured to detect at least one characteristic of the clamped wheel hub and wheel rim. The at least one characteristic indicates clamping of the clamped wheel hub and wheel rim. The communication circuit is configured to wirelessly communicate data associated with the at least one characteristic to an external device. The data communicated by the communication circuit may include, for example, a signal (e.g., a voltage) output from a transducer of the at least one sensor, at least one characteristic of the clamped wheel hub and wheel rim, an alarm, and / or a conclusion drawn from the at least one characteristic (e.g., an expected lifespan of a wheel hub component). In this way, the wheel end monitoring device can facilitate real-time monitoring of a clamped wheel hub and wheel rim during vehicle operation when the wheel hub and wheel rim are stationary or rotating via an onboard system and / or a remote cloud-based computing system.

[0009] Furthermore, the external device may include a gateway for the vehicle. The wireless communication from the communication circuit to the external device may be short-range wireless communication requiring limited energy consumption. The gateway may be connected to the vehicle's electrical system and utilize power from the vehicle to power long-range wireless communication to a wide-area wireless network (e.g., a cellular telephone network). Thus, the gateway allows for minimization of the power provided by the power source by receiving data from the communication circuit via a short-range wireless signal and transmitting the data to the wide-area wireless network using power from the vehicle.

[0010] In one embodiment, a power supply is configured to harvest electricity from the rotation of a wheel hub. For example, a vehicle spindle may have a magnet mounted thereon, and the power supply includes a coil mounted on the wheel hub. As the wheel hub rotates about the vehicle spindle, the coil rotates through the magnet's magnetic field. The changing magnetic field acting on the coil induces electrical energy to flow in the coil. The power supply may include a battery for storing the harvested electrical energy, as well as power circuitry for supplying power to sensors and communication circuitry. Thus, the power supply provides power to the wheel hub for use by at least one sensor and communication circuitry.

[0011] In another aspect, a wheel end monitoring device is provided that includes a wheel hub having a mounting portion and a plurality of studs of the wheel hub, the studs protruding from the mounting portion for mounting a wheel rim to the wheel hub. The wheel end monitoring device includes a nut of the wheel hub configured to threadably engage the studs and clamp the wheel rim and the wheel hub mounting portion together. The studs have a sensor operably coupled to a power source of the wheel hub, the sensor configured to detect at least one characteristic of the studs that is indicative of clamping of the wheel rim and the wheel hub. Because the studs are under tension during clamping of the wheel rim and the wheel hub, the at least one characteristic of the studs can be a highly accurate source of one or more characteristics of the clamping between the wheel rim and the wheel hub. The wheel end monitoring device also includes a communication circuit configured to communicate data associated with the at least one characteristic to an external device (e.g., a gateway of the vehicle).

[0012] A fastener is also provided that includes a fastener housing having a head and a body. The body of the fastener housing extends when the body is tensioned. The fastener housing has an internal compartment and a displacement member located in the internal compartment. The displacement member moves when the body is tensioned. The fastener also includes a capacitive sensor located in the internal compartment, the capacitive sensor configured to detect capacitance between the capacitive sensor and the displacement member. The capacitance changes as the displacement member moves when the body is tensioned. The fastener also includes a communication circuit that is operably connected to the capacitive sensor and is configured to communicate data associated with the capacitance to a remote device. The fastener can be used in a variety of applications, such as a stud for a wheel hub, a fastener for securing a brake rotor to a wheel hub, or a fastener for connecting a drive shaft to a wheel hub.

[0013] According to another aspect, a method for monitoring a wheel end component of a vehicle is provided. The wheel end component includes a wheel hub and a wheel rim that are clamped together. The method includes powering at least one sensor associated with the wheel end component via a power supply. The at least one sensor and the power supply are rotatable with the wheel end component. The method also includes detecting at least one characteristic indicative of clamping between the clamped wheel hub and wheel rim via the at least one sensor. The method also includes wirelessly communicating data associated with the at least one characteristic to at least one external device via a communication circuit associated with the wheel end component and rotatable therewith. In this manner, the method facilitates monitoring at least one characteristic of a rotatable, clamped component of the wheel end using the sensor, power supply, and communication circuitry on the clamped component. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 A wheel hub is shown having a plurality of studs.

[0015] Figure 2 A stud is shown with a nut at one end.

[0016] Figure 3 Shown in Figure 2 An air gap is created between the printed circuit board and the displacement pin of the stud.

[0017] Figure 4 It shows Figure 3 A block diagram of an embodiment of a printed circuit board having a capacitive sensor and a separate processor.

[0018] Figure 5 It shows Figure 3 A block diagram of an embodiment of a printed circuit board having a capacitive sensor without a separate processor.

[0019] Figure 6 、 Figure 7 and Figure 8 An example printed circuit board architecture is shown.

[0020] Figure 9 is realized Figure 2 System diagram of the stud monitoring system.

[0021] Figure 10 is a cross-sectional view of a stud having an internal displacement pin and an electrical circuit received in an internal compartment of the stud.

[0022] Figure 11 yes Figure 10 An exploded view of the stud showing the clamping Figure 10 The battery is between the sensor circuit board and the data communication circuit board.

[0023] Figure 12 is a schematic diagram of a wheel hub having studs, each stud having a sensor to detect tension in the stud, the wheel hub also including a central power supply and communication circuitry that supplies power to the studs and communicates data from the studs to a device external to the wheel hub.

[0024] Figure 13 is a schematic diagram of a wheel hub having a stud with a sensor and a stud without a sensor. DETAILED DESCRIPTION

[0025] According to one aspect of the present disclosure, a fastener monitoring device is provided that allows for the determination of one or more characteristics of one or more fasteners, such as those in a connection between a wheel hub and a wheel, and wirelessly transmits data regarding the one or more fastener characteristics to a user. The one or more fastener characteristics may include, for example, tension, strain, torque, and / or length. The fastener monitoring device can simplify pre-trip inspections and verification of installation quality.

[0026] The fastener monitoring device can utilize one or more characteristics of one or more fasteners to determine, or facilitate remote computer determination of, current or predicted failure mechanisms for the configuration of a wheel and wheel hub. For example, the fastener monitoring device can detect a yielding stud failure mode, in which the material of the stud has yielded due to excessive stud stretching. As another example, the fastener monitoring device can detect under- or over-tensioned studs and provide an early warning system for wheel fall-off, progressive failure of fasteners, broken fasteners, and high hub stress. The fastener monitoring device allows one or more characteristics of a fastener to be determined at the associated vehicle or remotely, including during vehicle operation, thereby improving maintenance planning and helping to avoid unplanned downtime.

[0027] In one embodiment, a fastener monitoring device includes a stud with embedded electronics designed to measure the tension in the stud. This measurement can be wirelessly communicated to a local device, such as a handheld device or a vehicle electronic control unit (ECU), or to a remote computer. This communication can be direct, indirect via a local mesh network, and / or indirect via a wide area network, as some examples.

[0028] In one embodiment, the fastener monitoring device includes a plurality of studs of a commercial truck's wheel hubs and can communicate with the vehicle driver and / or fleet manager through one or more other devices. For example, in an 8x vehicle, or any private or fleet truck, the studs can replace traditional wheel studs. In other embodiments, the fastener monitoring device can be used in place of traditional fasteners in various applications. For example, the fastener monitoring device can be used in heavy equipment, power generation and distribution equipment, wind turbine equipment, and / or mining equipment. The fastener monitoring device can also be used in different components of commercial vehicles, such as studs used to connect brake rotors to wheel hubs and / or studs used to connect drive shafts to wheel hubs.

[0029] In one method of using the fastener monitoring device, the driver receives an alert if the tension of any monitored fastener of the vehicle exceeds a specified threshold. For example, when the nut of a stud has loosened, the tension in the stud can exceed a lower threshold. As another example, when the tension is approaching a tension that can cause the stud to yield, the tension in the stud can exceed an upper threshold. The driver can then take steps to correct the problem, such as applying torque to the nut associated with the stud using a wrench. Alternatively, the fasteners of the vehicle can be queried on demand to provide tension data as required by an external system, the driver, and / or a fleet mechanic.

[0030] In one embodiment, the fastener monitoring device includes a wheel stud that measures, digitizes, and transmits data about the elongation of the stud body. The stud includes a displacement pin located within the stud body, with a lower end portion fixed to the stud body. Prior to wheel installation, the displacement pin is located at a predetermined depth in the stud. For example, the displacement pin can directly contact or be adjacent to a printed circuit board located in the head of the stud. The stud body includes threads onto which a nut is threaded. In one embodiment, a flange of the wheel hub and a portion of the wheel rim are clamped between the stud head and the nut threaded into engagement with the stud body.

[0031] As the nut is threaded onto the stud body, the stud body elastically stretches until the nut reaches a predetermined torque, and the stud is subjected to an associated tension. This tension causes the stud body to elongate according to the modulus of elasticity of the stud body material. Because the lower end portion of the displacement pin is fixed to the stud body, the elongation of the stud body moves the displacement pin within the stud body away from the printed circuit board a distance proportional to the applied torque. This separation creates or enlarges a gap between an upper capacitor plate portion of the printed circuit board and a lower capacitor plate portion of the displacement pin. The capacitance C between the upper capacitor plate portion and the lower capacitor plate portion can be estimated using the general parallel plate capacitance formula:

[0032]

[0033] Where ε is the permittivity of the dielectric between the two plates, A is the area of ​​the upper and lower capacitor plate portions, and d is the distance between the upper and lower capacitor plate portions. Air is a medium that can be used for capacitance measurement. Other media can include other dielectrics or combinations of dielectrics.

[0034] The change in capacitance corresponding to the change in air gap is used to determine the change in distance between the upper and lower capacitor plate portions. This change in distance corresponds to an elongation or change in length of the stud body. A processor (which can be a component of the stud or external to the stud) can thus determine the strain in the stud by dividing the change in length of the stud body by the length of the stud body. The processor can also use the determined strain, the Young's modulus of the stud material, and the cross-sectional area of ​​the stud to determine the tension in the stud. As an example, the processor can utilize a lookup table containing experimentally derived strain values ​​for different materials and stud sizes and associated capacitance values. Thus, for a given type of stud and detected capacitance, the processor can look up and / or interpolate the strain from the table.

[0035] As another example, the following general capacitance formula can be used to convert sensed capacitance into a tension value:

[0036]

[0037] in:

[0038] C = capacitance between the two plates

[0039] ε = the permittivity of the material between the two plates

[0040] k = dielectric constant of the material between the two plates

[0041] ε0 = permittivity of free space = 8.854e -12 Fm -1

[0042] A c = overlapping area of ​​capacitor plates

[0043] d = distance between plates

[0044] The general capacitance equation (1) can be rearranged to solve for the distance between the plates:

[0045]

[0046] The Young's modulus of the stud material, E, is defined as,

[0047]

[0048]

[0049] in,

[0050] F = Tension in the stud

[0051] A s = Cross-sectional area of ​​the stud

[0052] Δl = change in stud length

[0053] L = original length of the stud

[0054] The change in stud length causes a change in the gap between the capacitor plates. Assuming the initial gap is zero, Δl = d. Substituting and rearranging the Young's modulus formula yields:

[0055]

[0056] The tension in the stud is given by:

[0057]

[0058] Substituting d from the general capacitance formula (1) above, the tension in the stud (F) can be determined using the following formula:

[0059]

[0060] Rearranging the formula yields the following formula, which can be used to obtain the tension value from the sensed capacitance:

[0061]

[0062] The term in brackets in equation (2) may be a constant for a given application. Thus, the value of the tension in the stud may be determined based on the sensed capacitance and the physical properties of the stud.

[0063] In one embodiment, the printed circuit board is configured to detect and digitize the change in capacitance of the air gap (or other dielectric between the upper and lower capacitor plate portions) created by the stud stretching. The change in stud tension, and the resulting change in the air gap between the printed circuit board and the capacitor plate portions of the displaced pin, manifests as a change in electronic capacitance. This data reading can then be transmitted from the stud to a client, cloud, or end user via the stud's communication circuitry.

[0064] refer to Figure 1 , shows a wheel hub 100, which includes components for connecting a wheel rim to a vehicle spindle. Wheel hub 100 may include a wheel hub body 100A, studs 103, a spindle nut 100B, a roller bearing assembly 100C, and a spacer 100D. Roller bearing assembly 100C may each include an inner ring, an outer ring, and roller bearings that roll along the inner and outer rings as wheel hub 100 rotates.

[0065] The wheel hub 100 is configured to receive a wheel and connect the wheel to the wheel hub using studs 103. Each stud 103 has a head portion (e.g., head 110) and a stem or body portion (e.g., stud body 115). The wheel is placed on the studs 103 and secured in place by threading a nut onto each stud body 115 until the wheel is tightly secured in place between the nut and the front surface 120 of the mounting portion of the wheel hub 100 (e.g., flange 105).

[0066] Figure 2 One such stud 103 is shown. The stud 103 has a stud housing 109 including a head 110 and a stud body 115. When a nut 280 is tightened onto the body 115 of the stud 103, the body 115 has a deformable portion 255 extending along an axis 252 between the head 110 and the nut 280. The stud 103 includes a sensor 201 configured to detect one or more characteristics of the stud 103, such as stress, strain, torque, and / or length. The sensor 201 can include a variety of transducers, such as at least one of a capacitive sensor, a strain gauge, an inductive sensor, a Hall effect sensor, an electrical transducer, and an optical sensor. All studs 103 can include the sensor 201, or a portion of all studs 103 can include the sensor 201.

[0067] For example, the sensor 201 can measure the air gap 310 caused by the elongation of the stud body 115 (see Figure 3 ) is used to detect the distance that the stud 103 (particularly its stud body 115) has been extended by using the capacitance associated with the printed circuit board 230. The stud 103 also includes a printed circuit board 230 and a displacement member (e.g., a displacement pin 240) to measure how far the stud 103 has been stretched. The displacement pin 240 has a distal or lower end portion 242 fixed to the stud body 115. The axial dimension of the air gap 310 between the printed circuit board 230 and the displacement pin 240 is measured to determine the axial extension of the stud body 115. The displacement pin 240 includes a proximal upper head portion 342 with a lower capacitor plate portion 344 adjacent to the printed circuit board 230, which is aligned with the capacitor plate portion (e.g., Figure 6, capacitor plate portions 615 in the stud 103) interact to form a capacitor 311. Thus, as the stud body 115 of the stud 103 stretches, the displacement pin 240 moves axially away from the printed circuit board 230 and the axial length of the air gap 310 increases. When no tension is applied to the stud 103, the displacement pin 240 can be configured to contact or be in close proximity to the printed circuit board 230. The displacement pin 240 can be made of, for example, mild steel, the stud 103 can be made of, for example, cold rolled steel, and the nut 280 can be made of, for example, forged steel. It should be understood that other materials can be used to form the displacement pin 240, the stud 103, and the nut 280. The present disclosure should not be construed as limiting these structures to only the materials described above.

[0068] like Figure 4 and Figure 5 As shown, the printed circuit board 230 can be embodied as printed circuit board 430 or printed circuit board 530. The printed circuit board 430 includes, for example, a processor 410, a capacitance sensor 405, and a communication circuit 420 connected to a memory 415. One or more of the above components are also connected to a battery 425. For example, the capacitance sensor 405 can convert a measured capacitance into a corresponding voltage level that indicates the distance between the displacement pin 240 and the capacitance sensor 405. The capacitance sensor 405 can then communicate the voltage level to at least one of the processor 410 and the communication circuit 420. As will be described in more detail below, the processor 410 can further process the received voltage level and / or store the voltage level in the memory 415. After processing the voltage level, the processor 410 can transmit voltage level data, such as the voltage level itself and / or information based on the voltage level (e.g., strain, stress, and / or alarm), via the communication circuit 420. The communication circuit 420 can be configured to send and receive data based on one or more communication protocols, as some examples, the communication protocol such as Zigbee, Z-wave, 6LowPAN, Thread, WiFi, and / or LoRaWAN.

[0069] The circuit of the printed circuit board 430 can be completely completed within the printed circuit board 430. This approach can reduce electrical interference with the stud 103. In another embodiment, the circuit of the printed circuit board 430 can include the head 110 and / or the body 115 of the stud 103.

[0070] Printed circuit board 530 includes, for example, capacitive sensor 505 coupled to memory 515 and communication circuitry 520. One or more of the aforementioned components is also coupled to battery 525. Printed circuit board 530 is similar to printed circuit board 430, except that there is no separate processor on printed circuit board 530, and capacitive sensor 505 includes an integrated processor for processing voltage level data.

[0071] about Figure 6 、 Figure 7 and Figure 8 , the printed circuit boards 230, 430, 530 may each have one of the configurations of printed circuit boards 600, 700, 800. Figure 6 , printed circuit board 600 includes a ground plane 625, a power plane 620, and an upper capacitor plate portion 615. A capacitor sensor 635 and other circuitry 640 (including, for example, communication circuitry 420 and processor 410) can be mounted to printed circuit board 600. Capacitive sensor 635 and other circuitry 640 can be connected to ground plane 625 and power plane 620. Battery 605 can be coupled between power plane 620 and ground plane 625. Battery 605 can also be connected directly to upper capacitor plate portion 615 of capacitive sensor 635, or indirectly to upper capacitor plate portion 615 of capacitive sensor 635 via power plane 620. In one embodiment, capacitive sensor 635 includes a connector 630 that connects upper capacitor plate portion 615 to one or more other components of capacitive sensor 635, allowing capacitive sensor 635 to measure the capacitance between upper capacitor plate portion 615 and lower capacitor plate portion 344.

[0072] about Figure 2 and Figure 3 , the lower capacitor plate portion 344 of the displacement pin 240 forms a lower capacitor plate that interacts with the upper capacitor plate portion 615. The surface of the lower capacitor plate portion 344 can be generally circular. The displacement pin 240 tapers downwardly to a cylindrical shaft 260, which includes an end portion 242 embedded in the stud body 115. The end portion 242 of the displacement pin 240 can be attached to the stud body 115 within an internal compartment 264 of the stud 103 by a press-fit joint, welding, adhesive, and / or a fastener (e.g., a transverse pin). In one embodiment, the internal compartment 264 comprises a blind hole formed in the stud 103. The head 110 and body 115 of the stud can be two components connected together, for example by welding, or can have a unitary, one-piece structure. The head 110 can include a head portion 268 of the internal compartment 264, and the body 115 can include a body portion 261 of the internal compartment 264. The head portion 268 may have an inner diameter that is larger than the inner diameter of the body portion 261. The head portion 110 may include a tapered surface, such as a frustoconical surface 270, that provides clearance for the underside of the displacement pin head portion 342 as the displacement pin head portion 342 moves axially away from the printed circuit board 230 as the stud body 115 elongates. In another embodiment, the displacement pin 240 includes a uniform width throughout and does not include the head portion 342.

[0073] Go to Figure 7PCB 700 is similar to PCB 600, except that PCB 700 includes a battery 705 and a battery 710. Battery 705 and other circuitry 740 are connected to power plane 720 of PCB 700. Upper capacitor plate portion 715 of capacitive sensor 735 is connected to battery 710. Capacitive sensor 735, including connector 730 and upper capacitor plate portion 715, thus receives power from a separate battery (battery 710) than the other circuitry 740 (battery 705). These parallel power supplies can reduce noise in capacitance measurements.

[0074] Steering Figure 8 , the structures of the printed circuit board 800 with the same reference numerals are the same as those in the Figure 6 Specifically, the printed circuit board 800 includes a capacitive sensor 835, other circuits 840, a power plane 820, a connector 830, and an upper capacitor plate portion 815. The printed circuit board 800 can be configured with respect to Figure 6 and Figure 7 Connect to the battery in either of the ways described. Figure 8 An electrical isolation plane 870 is also included to isolate any noise generated by components above the isolation plane 870 from components below the isolation plane, and vice versa. The connector 830 extends through the isolation plane 830.

[0075] In some embodiments, the upper capacitor plate portion 615, 715, 815 is formed on the bottom surface of the printed circuit board 600, 700, 800, proximate to the associated displacement pin 240. The shape of the upper capacitor plate 615, 715, 815 corresponds to the shape of the lower capacitor plate portion 344 proximate to the displacement pin 240 of the printed circuit board 600, 700, 800. For example, the upper capacitor plate portion 615, 715, 815 and the lower capacitor plate portion 344 can each have a flat opposing surface, or the opposing surfaces can be concave / convex.

[0076] about Figure 9 , a system 900 implementing studs 103 is provided. Each of wheels 910A, 910B, and 910C has a wheel rim 911 with one or more tires 912. The wheel rim 911 is connected to the wheel hub of the tractor 900 using the wheel hub studs 103. The studs 103 can communicate with external devices such as a gateway 939. The gateway can include a processor 941 and communication circuitry 943. In one embodiment, the gateway 939 includes a local server and computer 940 of the tractor 900. The studs 103 can communicate directly or indirectly, such as through one or more of the other studs 103 or other ECUs of the tractor 900. For example, communication can be performed according to a mesh network topology.

[0077] The stud 103 can rotate with the wheel hub of the tractor 900 and wirelessly transmit data to a gateway 939 that is stationary relative to the tractor 900. The communication circuit of the stud 103 can utilize short-range communication protocols (such as Bluetooth, Bluetooth Low Energy, and Zigbee) to communicate with the gateway 939 while minimizing energy consumption. As some examples, the gateway 939 can communicate with a cloud-based computing network via a wide area network (such as a cellular (e.g., 3G, 4G, 4G LTE, 5G), WiMax, or LoRaWAN network). The gateway 939 can receive power from the electrical system of the tractor 900 so that remote communication from the gateway 939 to the network can be performed continuously and / or intermittently as required by the particular situation. Using the gateway 939 to perform remote communication can preserve the battery life of the stud 103, or can reduce the energy requirements of the stud 103 (if the stud 103 uses an inductive charging system).

[0078] The local server and communication computer 940 can be configured to receive one or more samples or other data (e.g., warnings from the studs 103). The local server and communication computer 940 can display or otherwise inform a user about one or more characteristics of the studs 103, such as the tension of any one of the studs 103. For example, the local server and communication computer 940 can be coupled to a human machine interface (HMI) 942 and provide stud tension information via a GUI and / or a speaker.

[0079] Records associated with one or more studs 103 can be stored in a local maintenance database 945. The local server and communication computer 940 can also communicate any or all data from the studs 103 to the remote server computer 930 via the network 937, where the data can be processed or stored in the remote maintenance database 935. The remote server computer 930 can include a processor 931 and a communication interface 933. The network 937 can include, for example, a cellular network and the internet. The remote server computer 930 can transmit data, such as the current tension and / or warnings regarding any stud 103, to the local server and communication computer 940. The local server and communication computer 940 can notify users (including, for example, the driver) about the condition or status of any stud 103. Although this exemplary system shows a tractor 900 as an example, it should be understood that the system can be implemented in any class of vehicle or in any machine requiring fastener tension monitoring.

[0080] The stud 103 may include a processor (e.g., processor 410) or a capacitive sensor (e.g., capacitive sensors 405, 505) that is operable to sample one or more characteristics of the stud body 115 through a capacitive sensing module and transmit the sampled data (e.g., tension, distance, strain) through a communication interface (e.g., communication circuit 420, 520) at fixed time intervals. The capacitance detected by the capacitive sensor can be determined based on, for example, the parallel plate equation. The sampling interval and the transmission interval do not need to be the same. For example, the sampling interval may be more frequent than the transmission interval, and multiple samples may be sent as a batch during a given transmission. In other embodiments, the processor may average or otherwise statistically process the samples during a given transmission before sending the processed data to reduce the size of the data being transmitted and reduce power usage.

[0081] Stud 103 may include a processor (e.g., processor 410) or a capacitance sensor (e.g., capacitance sensors 405, 505) operable to increase the frequency of checks to improve immediate and short-term accuracy. For example, if the tension detected in stud 103 is changing rapidly or is above / below an upper / lower threshold, processor 410 may increase the rate at which processor 410 samples the capacitance between printed circuit board 430 and displacement pin 240. In this case, stud 103 may also increase the rate at which it transmits data via communication circuit 420. If the tension in stud 103 is changing more slowly, stud 103 may reduce the sampling and transmission intervals. Furthermore, if the tension in stud 103 varies within a given range centered around an ideal tension for a given application, stud 103 may ignore (i.e., not change the sampling interval) these changes in tension because processor 410 recognizes that the changes are normal for the given application. For example, if the samples are normally distributed and all samples are within an acceptable statistical variance from the mean, changes in tension may not cause the processor to adjust the sampling rate.

[0082] The stud 103 can be programmed to transmit an indication that the proper tension has been reached. For example, when the processor determines that the proper tension has been reached, the communication circuit of the stud 103 can send a notification to an external device that the proper tension has been reached. For example, when a maintenance worker has tightened a nut on the stud 103 to the correct torque, the stud 103 can communicate a "correct torque reached" message to the maintenance worker's portable electronic device. In some embodiments, the stud 103 can be configured to automatically pair with a tool used to generate tension (e.g., by applying torque to the nut 280) and send a communication to the tool when the proper tension has been reached. This communication may cause the tool to stop applying torque to the nut 280.

[0083] The sampling and transmission rates of stud 103 can be controlled by an external device via the communication circuitry of stud 103. For example, an external device can be wirelessly connected to stud 103 and cause stud 103 to sample the tension on stud 103. Stud 103 can then report the measurements to the external device separately based on power constraints, via a mesh network topology, or through a combination of both. For example, in the case of a pre-trip inspection, a user of an external device (such as a smartphone, tablet, laptop, or desktop computer) can initiate a pre-trip inspection of the vehicle. The external device can cause a signal to be generated that, when received by stud 103, causes stud 103 to sample its tension. This reporting can save time during pre-trip inspections and reduce delays.

[0084] In the event that the sampled tension in stud 103 exceeds an emergency threshold, an emergency notification may be sent to the user, indicating that immediate action is required. Stud 103 may first attempt to communicate using its lowest power communication mode. Stud 103 will increase the power level of the communication to its maximum capability until confirmation of the emergency communication is received. For example, stud 103 may wait for the local server and communication computer 440 to confirm receipt of the emergency communication, after which stud 103 ceases sending the emergency communication.

[0085] The stud 103 can operate normally in a low-power mode unless the tension in the stud 103 exceeds an emergency threshold. For example, the processor 410 may include a main processor and a secondary processor. The secondary processor determines the tension in the stud 103 at predetermined or random intervals. If the tension exceeds the emergency threshold, the secondary processor wakes up the main processor, and the main processor operates the communication circuit 520 to send an emergency communication.

[0086] about Figure 10 and Figure 11 , another stud 1000 is provided that is similar in many respects to the stud 103 discussed above. The stud 1000 includes a stud housing 1002 having a head 1004 and a stud body 1006. The stud housing 1002 includes an internal compartment 1008 that receives a displacement pin 1010 and circuitry 1012. The head 1004 has an upper opening 1014 (see FIG. Figure 11 ) and a closure member, such as a cap 1016, which is secured to the head 1004 to close the upper opening 1014. In one embodiment, the cap 1016 is an overmold made of epoxy or another selected material to form a suitable seal.

[0087] Circuit 1012 includes a sensor circuit board 1020 having a capacitive sensor that interacts with a head 1022 of displacement pin 1010. When stud 1000 is not under tension, head 1022 can contact a dielectric-coated electrode of sensor circuit board 1020. When stud 1000 is under tension, head 1022 can move away from the electrode of sensor circuit board 1020.

[0088] Circuit 1012 also includes a power source, such as a battery 1024. In one embodiment, battery 1024 includes one or more coin cell batteries. Circuit 1012 also includes a data transmission circuit board 1026, which includes communication circuitry. Battery 1024 is sandwiched between sensor circuit board 1020 and data transmission circuit board 1026. Sensor circuit board 1020 and data transmission circuit board 1026 have one or more electrical contacts that complete an electrical circuit with battery 1024 and allow battery 1024 to power sensor circuit board 1020 and data transmission circuit board 1026. In another embodiment, the power source for stud 1000 may include a coil configured to receive power from an inductive power supply mounted on the wheel hub of an associated vehicle.

[0089] refer to Figure 11 , the displacement pin 1010 includes a shaft 1030 having a distal, lower end portion 1032 that is secured to the stud housing 1002, such as by epoxy or adhesive 1034. Figure 10 , after the stud 1000 is assembled, the head 1022 of the displacement pin 1010 includes a lower capacitor plate portion 1040 adjacent to an upper capacitor plate portion 1042 of the sensor circuit board 1020 .

[0090] about Figure 12 , a wheel hub 1200 is provided that includes studs 1202 similar to the studs 103 discussed above. Each stud 1202 includes a sensor configured to detect, for example, tension in the stud 1202. The studs 1202 receive power from a power source 1204 (such as a battery, an inductive power source, and / or a solar power source). The wheel hub 1200 includes a communication circuit 1206 that is configured to communicate data from the studs 1202 to a device external to the wheel hub 1200 (e.g., a gateway mounted on the vehicle). The communication circuit 1206 may include a processor that performs pre-processing on the data before communicating the data to the external device. In some embodiments, the wheel hub 1200 includes a processor operably coupled to the communication circuit 1206 and the studs 1202, the processor performing operations on signals from the studs 1202 and operating the communication circuit 1206. In some embodiments, the communication circuit 1206 may be capable of receiving communications from a gateway.

[0091] about Figure 13 , a wheel hub 1300 is provided that includes studs 1301, each stud 1301 having a sensor 1301A, a communication circuit 1301B, and an integrated power source 1301C (such as a battery). The wheel hub 1300 also includes conventional studs 1301. The wheel hub 1300 includes a power source 1304. In one embodiment, the power source 1304 includes a non-rechargeable battery. In another embodiment, the power source 1304 collects energy from the rotation of the wheel hub 1300 and provides electrical energy to the battery of the power source 1304. The wheel hub 1300 includes a processor 1306 that communicates with one or more peripheral sensors 1308 of the wheel hub 1300 (such as temperature, vibration, speed, and / or acceleration). The wheel hub 1300 also includes a central communication circuit 1310 operably coupled to the power source 1304 and the processor 1306. The central communication circuit 1310 can receive wireless communications from the communication circuit 1301B of the stud 1301, and the processor 1306 controls the communication circuit 1310 to wirelessly communicate data from the stud 1301 to an external device (such as a vehicle gateway). The central communication circuit 1310 can thus operate as an active repeater that uses harvested power to minimize the signal strength used by the communication circuit 1301B of the stud 1301 to maximize the life of the battery of the power supply 1301C of the stud 1301.

[0092] Unless otherwise indicated herein or clearly contradicted by context, use of singular terms such as "a," "an," and the like is intended to encompass both the singular and the plural. The terms "including," "having," "comprising," and "containing" are to be construed as open-ended terms. The phrase "at least one of" as used herein is intended to be interpreted in a disjunctive sense. For example, the phrase "at least one of A and B" is intended to encompass A, B, or both.

[0093] While particular embodiments of the present invention have been illustrated and described, it will be understood that numerous changes and modifications will occur to those skilled in the art, and the present invention is intended to cover all such changes and modifications that fall within the scope of the appended claims.

Claims

1. A wheel end monitoring device for a vehicle, characterized in that: The wheel end monitoring device comprises: a wheel hub configured to receive and be clamped together with a wheel rim; a power source, at least one sensor, and communication circuitry operably coupled; wherein the power source, at least one of the sensors, and the communication circuit are capable of rotating with the clamped wheel hub and wheel rim; at least one of the sensors is configured to detect at least one characteristic of the clamped wheel hub and wheel rim, the at least one characteristic being indicative of clamping of the clamped wheel hub and wheel rim; and the communication circuitry being configured to wirelessly communicate data associated with at least one of the characteristics to an external device; Wherein, the wheel end monitoring device further includes: a stud of a wheel hub and a nut, the nut being operatively threadably engaged with the stud and clamping the wheel hub and the wheel rim together, thereby extending the stud; internal compartments for studs; At least one of the sensors includes a capacitive sensor in an interior compartment of the stud, and the stud includes a displacement member in the interior compartment of the stud, the displacement member moving relative to the capacitive sensor when the wheel hub and the wheel rim are clamped, the capacitive sensor detecting at least one of the characteristics based on capacitance between the capacitive sensor and the displacement member.

2. The wheel end monitoring device according to claim 1, characterized in that: At least one of the sensors is configured to detect at least one of the following: stud stress, stud strain, stud length, and nut torque.

3. The wheel end monitoring device according to claim 1, characterized in that: The power source, at least one of the sensors, and the communication circuitry are embedded in the wheel hub.

4. The wheel end monitoring device according to claim 3, characterized in that: The power source, at least one of the sensors, and the communication circuit are embedded in the stud.

5. The wheel end monitoring device according to claim 1, characterized in that: Also included is a processor configured to utilize the at least one characteristic of the clamped wheel hub and wheel rim to determine at least one of the following: a failure mechanism of one or more of the wheel hub and wheel rim; The wheel hub fasteners are under-tensioned or over-tensioned; elongation of one or more components of the wheel hub exceeds a threshold value; stress in one or more components of the wheel hub exceeds an upper threshold or is less than a lower threshold; the stress in one or more components of the wheel rim exceeds an upper threshold or is less than a lower threshold, and The stress pattern of one or more of the components of the wheel hub and the components of the wheel rim corresponds to a predetermined pattern.

6. The wheel end monitoring device according to claim 1, characterized in that: The power source is configured to harvest energy from rotation of the wheel hub.

7. The wheel end monitoring device according to claim 1, characterized in that: Also comprising at least one processor operatively coupled to at least one of the sensors, the power source, and the communication circuitry, the at least one processor rotatable with the clamped wheel hub and wheel rim; At least one of the processors is configured to receive a signal from at least one of the sensors and determine at least one of the characteristics based on the signal received from at least one of the sensors.

8. The wheel end monitoring device according to claim 7, characterized in that: At least one of the processors is configured to monitor at least one of the characteristics and, when at least one of the characteristics has a predetermined relationship to at least one threshold, cause the communication circuit to wirelessly communicate at least one of the characteristics to the external device.

9. The wheel end monitoring device according to claim 1, characterized in that: The power source includes at least one battery configured to rotate with the clamped wheel hub and wheel rim.

10. The wheel end monitoring device according to claim 1, characterized in that: Also included is the external device, wherein the external device includes a gateway configured to receive power from the vehicle's electrical system, the gateway configured to communicate with the communication circuit using a short-range wireless protocol and to communicate data to a cloud-based computing system via a wide-area wireless network.

11. The wheel end monitoring device according to claim 1, characterized in that: Also included is a processor configured to transmit an alert in response to at least one of the characteristics of the clamped wheel hub and wheel rim being at least one of: greater than an upper threshold, less than a lower threshold, and outside a predetermined range.

12. A wheel end monitoring device for a vehicle, characterized in that: The wheel end monitoring device comprises: a wheel hub having a mounting portion; a plurality of studs of the wheel hub protruding from the mounting portion for mounting a wheel rim to the wheel hub; a wheel hub nut configured to threadably engage the stud and clamp the wheel rim and the wheel hub mounting portion together; a power source for the wheel hub, which is capable of rotating together with the wheel hub; a sensor for the stud operatively coupled to the power source, the sensor configured to detect at least one characteristic of the stud, the at least one characteristic being indicative of clamping of the wheel rim and the wheel hub mounting portion; and communications circuitry of the wheel hub operatively coupled to the power source and the sensor, the communications circuitry configured to communicate data associated with at least one of the characteristics to an external device; wherein the stud comprises a head fixed to a mounting portion of the wheel hub and a body protruding from the mounting portion; wherein the sensor comprises a capacitive sensor in a head of the stud, and the stud comprises a displacement member in a body of the stud, the displacement member moving relative to the capacitive sensor when the mounting portion of the wheel hub and the wheel rim are clamped, the capacitive sensor detecting at least one of the characteristics based on capacitance between the capacitive sensor and the displacement member.

13. The wheel end monitoring device according to claim 12, characterized in that: said stud including its internal compartment; wherein the power source comprises a battery in the interior compartment; Wherein the communication circuit comprises a communication circuit in the internal compartment.

14. The wheel end monitoring device according to claim 12, characterized in that: The stud includes an internal compartment; and wherein the communication circuitry comprises communication circuitry in the interior compartment, the communication circuitry being configured to wirelessly communicate data associated with at least one of the characteristics of the stud to the external device.

15. The wheel end monitoring device according to claim 12, characterized in that: Also included is a processor configured to use at least one of the characteristics to determine at least one of the following: yielding studs; Over-tensioned studs; and Under-tensioned studs.

16. The wheel end monitoring device according to claim 12, characterized in that: Also included is the external device, the external device comprising a gateway configured to be mounted to the vehicle and receive power from the vehicle's electrical system; as well as wherein the gateway comprises communication circuitry configured to communicate at least one of the characteristics of the stud to a cloud-based computing system via a wide-area wireless network.

17. The wheel end monitoring device according to claim 12, characterized in that: The at least one characteristic comprises at least one of tension, length, strain and stress of the stud.

18. A method for monitoring a wheel end member of a vehicle, characterized in that The wheel end component comprises a wheel hub and a wheel rim clamped together, the method comprising: powering at least one sensor associated with the wheel end member with a power source, the at least one sensor and the power source being rotatable with the wheel end member; detecting, via at least one of said sensors, at least one characteristic indicative of clamping between said wheel hub and wheel rim; and wirelessly communicating data associated with at least one of the characteristics to at least one external device via a communication circuit associated with and rotatable with the wheel end member; wherein at least one of said sensors comprises a capacitive sensor of a fastener of said wheel hub; wherein detecting at least one of the characteristics comprises: detecting at least one of the characteristics based on capacitance measured by the capacitance sensor; The fasteners include: a fastener housing comprising a head and a body that extends when the body is tensioned; an interior compartment of said fastener housing; a displacement member associated with the body in the interior compartment, the displacement member moving upon tensioning of the body; a capacitive sensor in the interior compartment, the capacitive sensor configured to detect capacitance between the capacitive sensor and the displacement member, the capacitance changing as the displacement member moves when the body is tensioned; and A communication circuit is operably coupled to the capacitance sensor and configured to communicate data associated with the capacitance to an external device.

19. The method according to claim 18, characterized in that Also includes: Determining, by a remote computer, a current failure mechanism of the wheel end component, a predicted failure mechanism of the wheel end component, or a combination of the current failure mechanism and the predicted failure mechanism is facilitated.

20. The method according to claim 18, wherein The method also includes determining, by the processor, at least one of the following using at least one of the characteristics: yielding fasteners; Over-tensioned fasteners; and Under-tensioned fasteners.

21. The method according to claim 18, wherein The at least one said characteristic comprises at least one of: stress, strain, torque and size.

22. The method according to claim 18, wherein The detecting comprises: detecting at least one of the characteristics while the wheel end member rotates and at least one of the sensors and the communication circuit rotates with the wheel end member; and Wherein, communicating data associated with at least one of the characteristics to at least one of the external devices includes: communicating at least one of the characteristics to a gateway of the vehicle.

Images