Systems and methods for vehicle brake and wheel HUB monitoring

Abstract

A vehicle brake and wheel hub monitoring system includes at least one vehicle brake stroke sensor assembly and at least one wheel hub sensor assembly. The vehicle brake stroke sensor assembly is configured to be coupled with a vehicle's brake chamber pushrod to monitor length of a brake stroke of the vehicle's brake chamber pushrod. The wheel hub sensor assembly is configured to be coupled with a wheel hub of the vehicle to monitor for presence of metal indicative of a bearing failure and monitor temperature of the wheel hub. At least one communication module is configured to be operable for wirelessly transmitting alert(s) to a digital receiver or other remote device when: the brake chamber pushrod reaches a predetermined length triggering an alert, the wheel hub sensor assembly detects an undesired wheel hub condition triggering an alert, and / or temperature of the wheel hub has exceeded a predetermined value.

Description

SYSTEMS AND METHODS FORVEHICLE BRAKE AND WHEEL HUB MONITORINGCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a PCT International Application of U.S. Provisional Patent Application No. 63 / 538,336 filed September 14, 2023. The entire disclosure of the above application is incorporated herein by reference.FIELD

[0002] This disclosure relates to systems and methods for vehicle brake and wheel hub monitoring, and in particular for monitoring the state of a vehicle’s braking system (e.g., vehicle brake stroke, disc brakes, drum brakes, brake pads going bad causing an overtravel, etc. wheel hub temperature, metal in the wheel hub, and providing an alert(s) when pre-determined undesirable conditions are detected.BACKGROUND

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Brake systems and wheel hubs are critical components in vehicular safety, ensuring effective deceleration and stopping of vehicles along with safe wheel / hub conditions. In the context of heavy-duty vehicles such as trucks and commercial buses, reliable brake systems are of paramount importance to prevent accidents, reduce wear and tear on braking components, and optimize operational efficiency. Monitoring the brake systems and wheel hubs of such vehicles is an essential aspect of maintaining their braking performance and overall safety.

[0005] Traditional methods of brake stroke monitoring in heavy-duty trucks and commercial buses often involve mechanical linkages and sensors that measure the distance between the brake chamber pushrod and the brake chamber housing. Traditional methods of wheel hub monitoring often involve the installation of a specialized wheel hub with pre-integrated sensors. These traditional methods, while functional, come with inherent complexities, requiring intricate arrangements and periodic maintenance. Moreover, these traditional systems aresusceptible to environmental factors such as dirt, moisture, and vibration, which can degrade their accuracy and reliability over time.

[0006] Further, many monitoring systems require components to power the brake sensors, either individually or as a wired system. This requires occasional replacement of such parts often resulting in periods where the system is inoperative until a user notices the problem and a replacement of a part is performed.

[0007] Various applications have attempted to solve this problem, such as by using devices that rely on direct physical contact or intricate mechanical linkages. But these solutions are susceptible to issues associated with wear, mechanical fatigue, environmental contamination, and human error. As recognized herein, there exists a need for a robust, reliable, and easily maintainable vehicle brake and wheel hub monitoring system that is absent of the requirements of frequent maintenance and calibration.DRAWINGS

[0008] The drawings described herein are for illustrative purposes only of selected example embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0009] FIG. 1 illustrates an exemplary system for vehicle brake and wheel hub monitoring applied to a trailer according to an exemplary embodiment of the present disclosure in which a digital receiver is on the trailer.

[0010] FIG. 2 illustrates the exemplary system for vehicle brake and wheel hub monitoring shown in FIG. 1 and generally illustrating the digital receiver’s ability to wirelessly transmit data to a server / dashboard (broadly, a remote device) according to an exemplary embodiment of the present disclosure.

[0011] FIG. 3 illustrates an exemplary system for vehicle brake and wheel hub monitoring applied to a trailer according to another exemplary embodiment of the present disclosure in which a digital receiver mounted on the truck (e.g., in the cab of the truck, etc.) instead of the trailer. This would be a typical installation of the system for a truck that will be used with the same trailer.

[0012] FIG. 4 illustrates an exemplary system for vehicle brake and wheel hub monitoring applied to a droppable trailer according to another exemplary embodiment of the present disclosure in which digital receivers are on the droppable trailer and mounted on the truck. In this exemplary system, both the truck and the trailer are each provided with its own digital receiver.

[0013] FIG. 5 illustrates an example configuration of a slack adjuster sensor assembly that may be used in a system for vehicle brake and wheel hub monitoring according to an exemplary embodiment of the present disclosure.

[0014] FIG. 6 illustrates the slack adjuster sensor of the assembly shown in FIG. 5 that may be used in a system for vehicle brake and wheel hub monitoring according to an exemplary embodiment of the present disclosure.

[0015] FIG. 7 illustrates an example configuration of a disc brake sensor assembly that may be used in a system for vehicle brake and wheel hub monitoring according to an exemplary embodiment of the present disclosure.

[0016] FIG. 8 illustrates the disc brake sensor of the assembly shown in FIG. 7 that may be used in a system for vehicle brake and wheel hub monitoring according to an exemplary embodiment of the present disclosure.

[0017] FIG. 9 illustrates an example configuration of a hub assembly including a hub sensor that may be used in a system for vehicle brake and wheel hub monitoring according to an exemplary embodiment of the present disclosure.

[0018] FIG. 10 illustrates the hub sensor of the assembly shown in FIG. 9 that may be used in a system for vehicle brake and wheel hub monitoring according to an exemplary embodiment of the present disclosure.

[0019] FIG. 11 illustrates an oil sensor that may be used in a system for vehicle brake and wheel hub monitoring according to an exemplary embodiment of the present disclosure.

[0020] FIG. 12 illustrates the oil sensor shown in FIG. 11 with a gearbox assembly to an exemplary embodiment of the present disclosure.

[0021] FIG. 13 illustrates the oil sensor shown in FIG. 11 with an oil pan according to an exemplary embodiment of the present disclosure.

[0022] FIG. 14 illustrates a standalone magnetic switch according to an exemplary embodiment of the present disclosure.

[0023] FIG. 15 shows an example label for an interface keypad that may be used in a system for vehicle brake and wheel hub monitoring according to an exemplary embodiment of the present disclosure.DETAILED DESCRIPTION

[0024] Some example embodiments will now be described more fully with reference to the accompanying drawings.

[0025] Exemplary embodiments are disclosed of systems and methods for vehicle brake and wheel hub monitoring, and in particular for monitoring the state of a vehicle’s braking system (e.g., vehicle brake stroke, disc brakes, drum brakes, brake pads going bad causing an overtravel, etc. , wheel hub temperature, metal in the wheel hub, and providing an alert(s) when predetermined undesirable conditions are detected.

[0026] In exemplary embodiments, the system includes magnetic elements to monitor the brake stroke of a vehicle’ s brake chamber pushrod and a set of sensors to monitor a vehicle’s wheel hub. When a brake chamber pushrod reaches a predetermined length, its magnetic element engages with a complementary sensor, triggering an alert that is transmitted via a communication module. When a wheel hub sensor detects an undesired condition, an alert is transmitted via a communication module. An alert may be transmitted to a digital receiver, server / dashboard, dispatch, and / or remote device, such as a smartphone, tablet, vehicle dashboard display, etc. Advantageously, the brake and wheel hub monitoring system may enhance vehicle safety by providing real-time information about brake conditions, wheel hub conditions, and axle conditions to driver(s) and maintenance personnel.

[0027] With reference to the figures, FIG. 1 illustrates a vehicle brake and wheel hub monitoring system applied to a trailer according to an exemplary embodiment of the present disclosure in which a digital receiver is mounted on the trailer . In this exemplary embodiment, the system may be operated on the trailer of the vehicle , such as a truck or commercial vehicle, to monitor a braking system and wheel hub of an individual wheel, as indicated by RO1, RO2, LO1, and LO2 for the right and left wheels, respectively. In other exemplary embodiments, more sensors per axle may be added for the trailer / tractor / truck than what is shown in FIG. 1.

[0028] Each monitoring system may comprise a monitoring device attached to the vehicle’s axle, a brake chamber pushrod removably securable with a magnetic element, a set of sensors (e.g., a second pair of sensors, etc.) on the vehicle’s wheel hub with a complementary magnetic element, and a temperature sensor on the vehicle’s wheel hub. Each sensor system may comprise an integrated communication module for transmitting alerts indicative of the system state.

[0029] In the illustrated embodiment shown in FIG. 1, the digital receiver is located on the trailer . The digital receiver is configured to receive alerts from the communication module of the brake and wheel hub monitoring systems.

[0030] FIG. 2 generally illustrates the digital receiver’s ability to wirelessly transmit data to another device , such as a server / dashboard, dispatch, smartphone, tablet, vehicle dashboard display, other remote device, etc.

[0031] FIG. 3 illustrates another example embodiment of a vehicle brake and wheel hub monitoring system . In this example embodiment, the system may be operated on a trailer of a vehicle , such as a truck or commercial vehicle, to monitor a braking system and wheel hub of an individual wheel, as indicated by RO1, RO2, RO3, RO4, LO1, LO2, LO3, and LO4 for the right and left wheels, respectively. In other exemplary embodiments, more sensors per axle may be added for the trailer / tractor / truck than what is shown in FIG. 3.

[0032] Each monitoring system may comprise a monitoring device attached to the vehicle’s axle, a brake chamber pushrod removably securable with a magnetic element, a set of sensors (e.g.. a second pair of sensors, etc.) on the vehicle’s wheel hub with a complementary magnetic element, and a temperature sensor on the vehicle’s wheel hub. Each sensor system may comprise an integrated communication module for transmitting alerts indicative of the system state.

[0033] In the illustrated embodiment shown in FIG. 3, the digital receiver is mounted on the truck instead of the trailer . This would be a typical installation of the system for a truck that will be used with the same trailer. The digital receiver is configured to receive alerts from the communication module of the brake monitoring and wheel hub systems. By way of example, the digital receiver may be located in the cab of the truck . But the digital receiver preferably has a weatherproof housing such that the digital receiver is mountable at an external location on the truck .

[0034] FIG. 4 illustrates an exemplary system for vehicle brake and wheel hub monitoring applied to a droppable trailer according to another exemplary embodiment of the present disclosure. In this exemplary embodiment, first and second digital receivers are respectively located on a droppable trailer and the truck . Accordingly, both the trailer and the truck are each provided with its own digital receiver.

[0035] In this example embodiment, the system may be operable to monitor a braking system and wheel hub of an individual wheel, as indicated by RO1, RO2, RO3, RO4, RO5, LO1, LO2, LO3, LO4, and LO5 for the right and left wheels, respectively. In other exemplary embodiments, more sensors per axle may be added for the trailer / tractor / truck than what is shown in FIG. 4.

[0036] Each monitoring system may comprise a monitoring device attached to the vehicle’s axle, a brake chamber pushrod removably securable with a magnetic element, a set of sensors (e.g., a second pair of sensors, etc.) on the vehicle’s wheel hub with a complementary magnetic element, and a temperature sensor on the vehicle’s wheel hub. Each sensor system may comprise an integrated communication module for transmitting alerts indicative of the system state.

[0037] In response to receiving alerts from the communication module of the brake monitoring and wheel hub systems, the digital receiver whether on the trailer (FIGS. 1, 2, and 4) or on the truck (FIGS. 3 and 4) may be configured to transmit alerts to dispatch, a server / dashboard, remote device, smartphone, tablet, other user handheld device, vehicle dashboard display, other device, etc.

[0038] By way of example, the digital receiver may be located in the cab of the truck . But the digital receiver preferably has a weatherproof housing such that the digital receiver 408 is mountable at an external location on the truck .

[0039] FIG. 5 illustrates an example configuration of a slack adjuster sensor assembly that may be used in a system (e.g., a system shown in any one of FIGS. 1-4, etc.) for vehicle brake and wheel hub monitoring according to an exemplary embodiment of the present disclosure. As shown in FIG. 5, the sensor is removably securable to a brake assembly on a truck axle. The brake sensor housing is secured to a mounting bracket that is further secured to the mount on the brake chamber. The movable adaptor clip is attached to the brake push rod using attachments (e.g., mounting brackets, clips, fasteners, etc.) that ensure the magnet element remains in position during the vehicle’s operation.

[0040] FIG. 6 illustrates the slack adjuster sensor of the assembly shown in FIG. 5. As shown in FIG. 6, the slack adjuster sensor comprises a communication module for transmitting alerts, a magnetic element(s), a spring(s), a contact point(s) (e.g., one or more contact pin(s), etc.), and a magnetic contact element (e.g., copper washer, etc.) within a holder above the magneticelement(s). The slack adjuster sensor also includes a pairing button, a board to board connection, a battery holder, and an outer housing. The board to board connection is between first and second electronic circuit boards, which are configured to be operable as the communication module. The pairing button is usable for pairing the slack adjuster sensor with a digital receiver (e.g., digital receiver shown in FIGS. 1-4, etc.). An O-ring and a removable cap are used to close the housing and seal (e.g., weatherproof, etc.) the internal slack adjuster sensor components within the housing.

[0041] In this exemplary embodiment, the slack adjuster sensor includes one or more contact point(s) e.g., contact pin(s), etc.) that extend outwardly from the second or lower electronic circuit board. The sensor’s magnetic element is configured to pull the contact element (e.g., copper washer, etc.) downwardly via magnetic attraction onto the contact point(s). The slack adjuster sensor is configured to generate an alert when the sensor’s magnetic element comes in close proximity with another component (e.g., a metal bracket on a push rod, etc.) such that the sensor’s magnetic element pulls, via magnetic attraction, the contact element (e.g., a copper washer, etc.) onto the contact point(s) of the sensor. The proximity distance may be pre-determined and programmed.

[0042] FIG. 7 illustrates an example configuration of a disc brake sensor assembly that may be used in a system (e.g., a system shown in any one of FIGS. 1-4, etc.) for vehicle brake and wheel hub monitoring according to an exemplary embodiment of the present disclosure. As shown in FIG. 7, the disc brake sensor assembly is removably securable to a disc brake housing. The disc brake sensor includes a pull switch for detecting brake pad fault. For example, the pull switch is in a relaxed and / or slack condition when no break pad fault is present. But the pull switch elongates from the relaxed / slack condition to a taut and / or elongated condition when a brake pad fault is present, e.g., due to wear and tear on the brake pad, rotor, etc.

[0043] FIG. 8 illustrates the disc brake sensor of the assembly shown in FIG. 7. As shown in FIG. 8, the disc brake sensor comprises a communication module for transmitting alerts, a snap ring, a spring, a mounting plug, a cable connection, a contact point(s) (e.g., one or more contact pin(s), etc.), and a contact element (e.g., copper washer, etc.) within a holder above the contact point(s). The disc brake sensor also includes a pairing button, a board to board connection, a battery holder, and an outer housing. The board to board connection is between first and second electronic circuit boards, which are configured to be operable as the communication module. The pairing button is usable for pairing the disc brake sensor with a digital receiver (e. ., digital receiver shownin FIGS. 1-4, etc.). An O-ring and a removable cap are used to close the housing and seal (e.g., weatherproof, etc.) the internal disc brake senor components within the housing. The disc brake sensor also includes a magnet usable for attaching the pull cable to the head of the bolt inside the disc brake assembly.

[0044] FIG. 9 illustrates an example configuration of a hub assembly including a hub sensor that may be used in a system (e.g., a system shown in any one of FIGS. 1-4, etc.) for vehicle brake and wheel hub monitoring according to an exemplary embodiment of the present disclosure. As shown in FIG. 9, the hub assembly is removably securable to a truck axle hub.

[0045] FIG. 10 illustrates the hub sensor of the assembly shown in FIG. 9. As shown in FIG. 10, the hub sensor comprises a communication module for transmitting alerts, a pairing button, a board to board connection, a battery holder, and an outer housing. The board to board connection is between first and second electronic circuit boards, which are configured to be operable as the communication module. The pairing button is usable for pairing the disc brake sensor with a digital receiver (e.g., digital receiver shown in FIGS. 1-4, etc.). An O-ring and a removable cap are used to close the housing and seal (e.g., weatherproof, etc.) the internal disc brake senor components within the housing.

[0046] With continued reference to FIG. 10, the hub sensor also includes a temperature / thermal switch, magnets, and a ventilation opening (e.g., vent hole, etc.). The thermal switch is configured to activate the alert when a pre-determined temperature threshold is passed. The magnets are configured to be usable for attracting magnetic materials suspended in the oil that is used to lubricate the bearings. When enough magnetic materials is collected by the magnets, the collected magnetic material will complete a circuit across the magnets (e.g., two spaced apart magnets, etc.) to send an alert.

[0047] FIG. 11 illustrates an oil sensor that may be used in a system (e.g., a system shown in any one of FIGS. 1-4, etc.) for vehicle brake and wheel hub monitoring according to an exemplary embodiment of the present disclosure. As disclosed herein, the oil sensor may be configured to send a resistive value for the temperature and across the two magnets, e.g., instead of using a digital signal and a communication module, etc. This, in turn, enables the oil sensor to be usable with more generic controllers instead of or in addition to a digital receiver.

[0048] FIGS. 12 and 13 respectively illustrate the oil sensor with a gearbox assembly and an oil pan. As shown in FIG. 11, the oil sensor includes a resistor, magnets, and thermistor.

[0049] The oil sensor uses the thermistor and two magnets across which the resistance is measured. The static resistor is used by a controller to detect when the oil sensor is not connected. The oil sensor may be used in any device that has internal magnetic metal components that can wear down or fail and inside a non-conductive lubricant like oil. Examples of these are engine oil pans, transmissions, gearboxes, differentials, wheel hubs, etc.

[0050] The oil sensor has the internal thermistor that changes resistance across two of the M12 pins of the M12 connector. Alternatively, the oil sensor may include a different connection option instead of the M12 connector.

[0051] The oil sensor includes two magnets to collect magnetic material caused by internal wear and tear or component failure of bearings, gears, or other magnetic components. The resistance can be monitored between the two magnets through two of the M12 pins. As magnetic particles accumulate across the two magnets the resistance will decrease. There is also a static resistance across the magnets for a baseline resistance, which can be used by the monitoring controller to determine if the oil sensor is connected.

[0052] FIG. 14 illustrates a standalone magnetic switch according to an exemplary embodiment of the present disclosure. As disclosed herein, the magnetic switch may be configured to be a normally open switch going to a connector (e.g., M12 connector, other connection options, etc.), e.g., instead of using a digital signal and a communication module, etc. This, in turn, enables the magnetic switch to be usable with more generic controllers instead of or in addition to a digital receiver.

[0053] As shown in FIG. 14, the magnetic switch comprises a magnetic element(s), a spring(s), a contact point(s) (e.g., one or more contact pin(s), etc.), and a magnetic contact element (e.g., copper washer, etc.) within a holder above the magnetic element(s). The magnetic switch also includes a pairing button, a board to board connection, and an outer housing. The pairing button may be usable for pairing the magnetic switch with another device. An O-ring and a removable cap are used to close the housing and seal (e. ., weatherproof, etc.) the internal magnetic switch components within the housing.

[0054] In this exemplary embodiment, the magnetic switch includes one or more contact point(s) (e.g., contact pin(s), etc.) that extend outwardly from an electronic circuit board. The magnetic element is configured to pull the contact element (e.g., copper washer, etc.) downwardly via magnetic attraction onto the contact point(s). The magnetic switch is normally open but closeswhen the magnetic element(s) is within a proximity distance from another component such that the magnetic element(s) pulls, via magnetic attraction, the contact element (e.g., a copper washer, etc.) onto the contact point(s) of the magnetic switch. The proximity distance may be predetermined and programmed.

[0055] Exemplary embodiments may include a brake sensor removably securable to a brake sensor mount to monitor the brake stroke of a braking system. Such a sensor may comprise a magnetic element. See, for example, the brake sensor shown in FIGS. 4 and 5 of U.S. Provisional Patent Application No. 63 / 538,336, which is incorporated herein by reference.

[0056] Exemplary embodiments may include sensors that include electronic components (e.g., circuit board(s), power component(s), etc.) configured to function as a communication module for transmitting an alert upon detection of a pre-determined undesired condition. An undesired condition may include long brake stroke, above optimal temperature, and metal in the wheel hub. See, for example, the electronic board of a brake sensor shown in FIGS. 6A and 6B of U.S. Provisional Patent Application No. 63 / 538,336, which is incorporated herein by reference.

[0057] In exemplary embodiments, the vehicle brake and wheel hub monitoring system may include a digital receiver having an interface. See, for example, the digital receiver interface shown in FIG. 7 of U.S. Provisional Patent Application No. 63 / 538,336, which is incorporated herein by reference.

[0058] In exemplary embodiments, the digital receiver is configured to receive alerts from a sensor communication module. The digital receiver interface is configured to display for user viewing of an alert and monitoring the state of the brake monitoring system. The digital receiver indicates, via a light source, if the brake monitoring system is “on”, if a sensor is in a fault battery condition (e.g., not powered “on”), if there is a “lost sensor,” if there is a “brake fault,” or if the system is currently “pairing” with a sensor. A “lost sensor” notification may indicate that a sensor is not communicating with the receiver, e.g., the sensor may have fallen off the brake or has been damaged, etc. A “brake fault” notification may indicate that the brake stroke of an individual braking system on a trailer wheel has reached or surpassed a pre-determined length. In response to a notification, the user may use (e.g., the arrow buttons on, etc.) the digital receiver interface to scroll through listed options and select an illuminated notification and act or dismiss the alert accordingly.

[0059] In exemplary embodiments, the digital receiver with the user interface component may be generally placed over an electronic circuit board. By way of example, FIG. 15 shows an example label for an interface keypad that may be used in a system for vehicle brake and wheel hub monitoring according to an exemplary embodiment of the present disclosure. Accordingly, the unit is configured to use a label with a display instead of a window. The display shows numbers and has an LED to pick between Driver Side and Passenger Side instead of L, R in front of the number. A housing apparatus may be configured to hold the digital receiver. The user interface component may be a touch keypad and may be located on the front portion of the housing for the digital receiver. See, for example, the digital receiver with interface keypad shown in FIGS. 8 A and 8B of U.S. Provisional Patent Application No. 63 / 538,336, which is incorporated herein by reference.

[0060] In exemplary embodiments, the housing for the digital receiver may be transparent, clear, or opaque. See, for example, the digital receiver housings shown in FIGS. 9A and 9B of U.S. Provisional Patent Application No. 63 / 538,336, which is incorporated herein by reference.

[0061] In exemplary embodiments, the user interface component is secured to the receiver housing. Such configuration allows a user to operate the digital receiver using the touch keypad of the user interface located on the receiver housing. See, for example, the digital receiver housing with interface keypad shown in FIGS. 10A and 10B of U.S. Provisional Patent Application No. 63 / 538,336, which is incorporated herein by reference. In such exemplary embodiments, “System On” indicates the device is successfully powered “On” via internal batteries or system power. “Low Battery” indicates if any particular sensor in the system or head unit is in a low battery state. “Sensor Lost” indicates that a sensor is not communicating with the receiver. “Brake Fault” indicates that a sensor has detected a problem with a particular brake unit’ s brake slack adjustment. “Axle Fault” indicates that a sensor has detected a problem with either the axle temperature (via a temperature sensor) or the magnetic fragment switch (via a magnetic sensor). “Pairing” indicates that the system is in pairing mode to pair and calibrate new brake stroke and / or wheel hub sensors. Arrow buttons allow a user to cycle through the active error codes and acknowledge and / or dismiss the present error. When no error is present, the arrow buttons may be used to cycle through each error category to manually determine the system state of each error type. The interface may also include “Charging” to indicate when system power is supplied by the truck. The display sectionof the interface provides visible error codes to a user. The error codes may be numerical, alphabetic, and / or alphanumerical and correspond to the error categories listed on the interface.

[0062] During a “pairing” operation of a new sensor, a user may press and hold the “Pairing” button to turn on and illuminate the LED category indicator. The user may then cycle / scroll up or down to select the correct brake / axle number corresponding to the new sensor to be paired with the system. Upon selecting the correct brake / axle number, the user may press and hold the pairing button on the individual sensor to successfully pair the sensor with the system.

[0063] If more than one sensor has a fault, the user can scroll between sensors that have faults using the arrows. When the user stops at a sensor, the LED will show which fault is active for that sensor.

[0064] To clear all error messages on the display interface, a user may press and hold a “Pair / Reset” button. After a short duration of engaging the “Pair / Reset” button, the illuminated LED(s) indicating an error message will turn off. This clears the fault / error message until the system detects and transmits a new error to the digital receiver. In addition, the display will also turn off after a timeout on button activity.

[0065] In exemplary embodiments, a brake sensor includes magnetic components. See, for example, the magnet board and magnet housing shown in FIG. 11 of U.S. Provisional Patent Application No. 63 / 538,336, which is incorporated herein by reference. In such exemplary embodiments, the brake sensor includes a contact washer holder and a magnetic contact washer above the magnetic element in the housing. The contact washer may be made from copper or other suitable material. Connection pins are between the lower and upper circuit boards of the brake sensor.

[0066] In exemplary embodiments, the sensor configuration includes a sensor housing. See, for example, the sensor configuration in a sensor housing shown in FIG. 12 of U.S. Provisional Patent Application No. 63 / 538,336, which is incorporated herein by reference. In such exemplary embodiments, the magnetic sensor component may comprise “pin” elements to detect undesired conditions, such as detecting the presence of magnetic material (e.g., metal shavings, etc.) indicative of a bearing fault, etc. The sensor configuration may include a second sensor for detecting changes in temperature in the wheel hub of the vehicle braking system.

[0067] In exemplary embodiments, the brake sensors include circuit boards. In the brake sensor, the circuit board may be contained within the brake sensor housing. The circuit boardmaintains or supports the communication module thereon that is configured to transmit alerts indicative of the brake system. See, for example, the electronic printed circuit / chip shown in FIGS. 16A and 16B of U.S. Provisional Patent Application No. 63 / 538,336, which is incorporated herein by reference.

[0068] In exemplary embodiments, the electronic circuit board for a brake system includes a battery holder and programming switch. The programming switch allows for the programming of the chip in which position / unit ID, communication, and other appropriate parameters may be configured. See, for example, the example printed circuit / chip board of a brake sensor and a battery holder and programming switch shown in FIGS. 17A and 17B of U.S. Provisional Patent Application No. 63 / 538,336, which is incorporated herein by reference.

[0069] In exemplary embodiments, an alert is generated when the magnetic element of the brake sensor comes in close proximity with the bracket on the push rod and the magnet pulls a corresponding contact washer downward by magnetic attraction onto the contact point(s) (e.g., contact pin(s), etc.) of the electronic circuit board of the brake sensor system. Such proximity distance is pre-determined and programmed in the system. See, for example, the contact pins located alongside or adjacent an opening in a center of the circuit board shown in shown in FIGS. 18A and 18B of U.S. Provisional Patent Application No. 63 / 538,336, which is incorporated herein by reference

[0070] Exemplary embodiments may include a general circuit layout for the digital receiver in a receiver housing shown in FIG. 19 of U.S. Provisional Patent Application No. 63 / 538,336, which is incorporated herein by reference. The circuit layout may be modified in subsequent design iterations and / or in other exemplary embodiments.

[0071] Exemplary embodiments include a wheel hub sensor configured for detecting a bearing fault. See, for example, the wheel hub sensor shown in FIGS. 20-23 of U.S. Provisional Patent Application No. 63 / 538,336, which is incorporated herein by reference. FIGS. 21 and 22 shows the wheel hub dual sensors on a vehicle wheel hub (FIG. 21) and in the vehicle wheel hub (FIG. 22). FIG. 23 shows the wheel hub dual sensor detecting a bearing fault.

[0072] The various sensors disclosed herein may be used in systems for vehicle brake and wheel hub monitoring according to exemplary embodiments of the present disclosure. But the various sensors disclosed herein are also usable in other types of systems. For example, sensors including magnetic elements, contact points, and temperature sensors as disclosed herein may beused in other types of systems and methods and are not limited to use with only vehicle brake and wheel hub monitoring systems.

[0073] Disclosed herein are exemplary embodiments of vehicle brake and wheel hub monitoring systems that comprise a monitoring device attachable to a vehicle’s axle, a brake chamber pushrod removably securable with a magnetic element, a set of sensors positionable or mountable on a vehicle’s wheel hub with a complementary magnetic element, temperature sensor, and a communication module for transmitting alerts.

[0074] Also disclosed are exemplary methods for monitoring vehicle’s braking system (e.g., vehicle brake stroke, disc brakes, drum brakes, brake pads going bad causing an overtravel, etc.} and wheel hub and for alerting when a pre-defined / certain / undesirable brake stroke or wheel hub condition is detected. In exemplary embodiments, the method comprises attaching monitoring devices to an axle of the vehicle. For brake stroke monitoring, the method comprises removably securing a magnetic element on a brake chamber pushrod extending from a brake assembly of the vehicle, monitoring the proximity of the magnetic element on the brake chamber pushrod and the magnetic element of the sensor using a magnetic sensor within the monitoring device, determining that the brake chamber pushrod’s stroke has reached a predetermined length when the magnetic elements make physical contact, and alerting (e.g., transmitting an alert signal from a communication module integrated into the monitoring device, etc. when the brake chamber pushrod’ s stroke reaches the predetermined length. For wheel hub monitoring, the method includes using a dual sensor system configured with at least two forms of detection including a temperature sensor and a second magnetic switch. When the wheel hub’s temperature as measured via the temperature sensor rises above a safe operating temperature, the method includes transmitting an alert signal (broadly, alerting) from a communication module integrated into the monitoring device. Upon detection of magnetic material (e.g., metal shavings indicative of a bearing failure, etc.} via the second magnetic switch, the method includes transmitting an alert signal (broadly, alerting) from a communication module integrated into the monitoring device.

[0075] In exemplary embodiments, a digital receiver is configured to receive alerts from communication modules of brake sensor and wheel hub sensors. The digital receiver comprises a receiver for wireless communication with the brake sensor and wheel hub sensors, a housing for containing the digital receiver therein (e.g., for protection from the environment, etc.}, aninteractive user interface for displaying alerts received, and a plurality of programmed alerts indicating the state of a brake and wheel hub systems being monitored.

[0076] In exemplary embodiments, a sensor assembly includes one or more contact point(s), e.g., one or more contact pin(s) extending outwardly from an electronic circuit board. The sensor assembly includes a magnetic element configured to pull a contact element (e.g., a magnetic contact washer within a holder above the magnetic element, etc.) downwardly via magnetic attraction onto the contact point(s). The sensor assembly is configured to generate an alert when the magnetic element of the sensor assembly comes in close proximity with another component (e.g., a metal bracket on a push rod, eta) such that the magnetic element of the sensor assembly pulls, via magnetic attraction, the contact element (e.g., a contact washer, etc.) onto the contact points of the electronic circuit board of the sensor assembly. The proximity distance may be predetermined and programmed. In some exemplary embodiments, the sensor assembly may also include a temperature sensor and / or a metal detection capability (e.g., for detecting a presence of metal shavings or other magnetic material indicative of a bearing failure, etc.). The sensor assembly may be used in a system for vehicle brake and wheel hub monitoring or other types of systems.

[0077] In exemplary embodiments, the head unit specifications may include one or more of Optional Internal Rechargeable Battery, Reverse Battery Protection and Reverse Input Voltage Connection Protection, Internal Resettable Fuses, 7-32 DC Input Voltage Range, Support for Larger External Signal Lights (Wamings / Faults), and / or IP67 Waterproof Rating (Slightly Submersible).

[0078] In exemplary embodiments, a vehicle brake and wheel hub monitoring system comprises at least one vehicle brake stroke sensor assembly and at least one wheel hub sensor assembly. The vehicle brake stroke sensor assembly is configured to be coupled with a vehicle’s brake chamber pushrod to monitor a length of a brake stroke of the vehicle’s brake chamber pushrod. The wheel hub sensor assembly is configured to be coupled with a wheel hub of the vehicle to monitor for a presence of metal indicative of a bearing failure and to monitor temperature of the wheel hub. At least one communication module is configured to be operable for wirelessly transmitting alert(s) to a digital receiver or other remote device: when the brake chamber pushrod reaches a predetermined length triggering an alert; and / or when the wheel hub sensor assembly detects an undesired wheel hub condition triggering an alert, such as magnetic material (e.g., metalshavings, etc.) indicative of a bearing failure and / or the temperature of the wheel hub has exceeded a predetermined value.

[0079] In exemplary embodiments, the vehicle brake and wheel hub monitoring system is configured to provide real-time information about brake, wheel hub, and axle conditions to a driver(s) of the vehicle and / or to maintenance personnel.

[0080] In exemplary embodiments, the communication module is configured to transmit alerts via a short-range wireless communication protocol, such as BLUETOOTH short-range wireless communication protocol, etc.

[0081] In exemplary embodiments, the vehicle brake and wheel hub monitoring system includes a digital receiver that is positioned in a cab of a truck or on a trailer. The communication module is configured to transmit alerts via a short-range wireless communication protocol to the digital receiver.

[0082] In exemplary embodiments, the vehicle brake and wheel hub monitoring system includes the digital receiver that is configured to be operable for wirelessly transmitting alert(s) to dispatch, a smartphone, a tablet, a vehicle dashboard display, and / or a remote device.

[0083] In exemplary embodiments, the vehicle brake and wheel hub monitoring is configured such that the alert may include information regarding the state of the brake stroke, temperature of the axle, detection of metal indicative of a bearing failure, and / or sensor battery level.

[0084] In exemplary embodiments, the vehicle brake and wheel hub monitoring system is configured such that when the brake chamber pushrod reaches the predetermined length its magnetic element engages with a complementary magnetic element triggering an alert.

[0085] In exemplary embodiments, the communication module comprises: a first communication module integrated or associated with the vehicle brake stroke sensor assembly, and a second communication module integrated within or associated with the wheel hub sensor assembly. The first communication module is configured to be operable for wirelessly transmitting alert(s) to a digital receiver for wireless transmission to a remote device when the brake chamber pushrod reaches a predetermined length triggering an alert. The second communication module is configured to be operable for wirelessly transmitting alert(s) to a digital receiver for wireless transmission to a remote device when the wheel hub sensor assembly detects an undesired wheelhub condition triggering an alert, such as magnetic material (e.g., metal shavings, etc.) indicative of a bearing failure and / or the temperature of the wheel hub has exceeded a predetermined value.

[0086] Also disclosed are exemplary methods for monitoring a vehicle’s braking system (e.g., vehicle brake stroke, disc brakes, drum brakes, brake pads going bad causing an overtravel, etc.) and wheel hub and for alerting when a pre-defined condition is detected. In exemplary embodiments, the method comprises monitoring a length of a brake stroke of a vehicle’s brake chamber pushrod via at least one vehicle brake stroke sensor assembly; monitoring the vehicle’s wheel hub, via at least one wheel hub sensor assembly, including monitoring for a metal presence indicative of a bearing failure and monitoring temperature of the wheel hub; and wirelessly transmitting, via at least one communication module integrated or associated with the vehicle brake stroke sensor assembly and / or with the wheel hub sensor assembly, alert(s) to a digital receiver or other remote device: when the brake chamber pushrod reaches a predetermined length triggering an alert; and / or when the wheel hub sensor assembly detects an undesired wheel hub condition triggering an alert, such as magnetic material (e.g., metal shavings, etc.) indicative of a bearing failure and / or the temperature of the wheel hub has exceeded a predetermined value.

[0087] In exemplary embodiments, the vehicle brake stroke sensor assembly includes one or more magnetic elements. And the wheel hub sensor assembly includes one or more magnetic elements and a temperature sensor.

[0088] In exemplary embodiments, the method includes providing real-time information about brake, wheel hub, and axle conditions to a driver(s) of the vehicle and / or to maintenance personnel.

[0089] In exemplary embodiments, the method includes wirelessly transmitting alert(s) via a short-range wireless communication protocol, such as BLUETOOTH short-range wireless communication protocol, etc.

[0090] In exemplary embodiments, the method includes: mounting the vehicle brake stroke sensor assembly on a brake chamber pushrod of a trailer to monitor a length of the brake stroke of the trailer’ s brake chamber pushrod; mounting the wheel hub sensor assembly on a wheel hub of the trailer; and positioning the digital receiver in a cab of a truck or on a trailer.

[0091] In exemplary embodiments, the method includes: mounting a vehicle brake stroke sensor assembly on each brake chamber pushrod of the vehicle; and mounting a wheel hub sensor assembly on each wheel hub of the vehicle.

[0092] In exemplary embodiments, the method includes wirelessly transmitting the alert(s), via the digital receiver, to dispatch, a smartphone, a tablet, a vehicle dashboard display, and / or a remote device.

[0093] In exemplary embodiments, the method includes wirelessly transmitting alert(s) that may include information regarding the state of the brake stroke, temperature of the axle, detection of metal indicative of a bearing failure, and / or sensor battery level.

[0094] In exemplary embodiments, the method includes triggering an alert when the brake chamber pushrod reaches the predetermined length and its magnetic element engages with a complementary magnetic element.

[0095] In exemplary embodiments, the method includes: wirelessly transmitting, via a first communication module integrated or associated with the vehicle brake stroke sensor assembly, alert(s) to a digital receiver for wireless transmission to a remote device when the brake chamber pushrod reaches a predetermined length triggering an alert; and wirelessly transmitting, via a second communication module integrated or associated with the wheel hub sensor assembly, alert(s) to a digital receiver for wireless transmission to a remote device when the wheel hub sensor assembly detects an undesired wheel hub condition triggering an alert, such as magnetic material (e.g., metal shavings, etc.) indicative of a bearing failure and / or the temperature of the wheel hub has exceeded a predetermined value.

[0096] Also disclosed are exemplary methods of providing vehicles with brake and wheel hub monitoring. In exemplary embodiments the method comprises mounting at least one vehicle brake stroke sensor assembly on a brake chamber pushrod of a vehicle to monitor a length of the brake stroke of the brake chamber pushrod; mounting at least one wheel hub sensor assembly to a wheel hub of the vehicle to monitor for a presence of metal indicative of a bearing failure and to monitor temperature of the wheel hub; and providing at least one communication module integrated within or associated with the vehicle brake stroke sensor assembly and / or with the wheel hub sensor assembly, the communication module configured to be operable for wirelessly transmitting alert(s) to a digital receiver or other remote device: when the brake chamber pushrod reaches a predetermined length triggering an alert; and / or when the wheel hub sensor assembly detects an undesired wheel hub condition triggering an alert, such as magnetic material e.g., metal shavings, etc.) indicative of a bearing failure and / or the temperature of the wheel hub has exceeded a predetermined value.

[0097] In exemplary embodiments, the vehicle brake stroke sensor assembly includes one or more magnetic elements. And the wheel hub sensor assembly includes one or more magnetic elements and a temperature sensor.

[0098] In exemplary embodiments, the method includes enabling real-time information to be provided about brake, wheel hub, and axle conditions to a driver(s) of the vehicle and / or to maintenance personnel.

[0099] In exemplary embodiments, the method step of providing at least one communication module comprises providing at least one communication module that is operable for wirelessly transmitting alert(s) via a short-range wireless communication protocol.

[0100] In exemplary embodiments, the method step of providing at least one communication module comprises providing at least one communication module that is operable for wirelessly transmitting alert(s) via BLUETOOTH short-range wireless communication protocol.

[0101] In exemplary embodiments, the method includes: mounting the vehicle brake stroke sensor assembly on a brake chamber pushrod of a trailer to monitor a length of the brake stroke of the trailer’ s brake chamber pushrod; mounting the wheel hub sensor assembly on a wheel hub of the trailer; and the method includes positioning the digital receiver in a cab of a truck or on a trailer.

[0102] In exemplary embodiments, the method includes: mounting a vehicle brake stroke sensor assembly on each brake chamber pushrod of the vehicle; and mounting a wheel hub sensor assembly on each wheel hub of the vehicle.

[0103] In exemplary embodiments, the method step of providing at least one communication module comprises providing at least one communication module that is operable for wirelessly transmitting the alert(s), via the digital receiver, to dispatch, a smartphone, a tablet, a vehicle dashboard display, and / or a remote device.

[0104] In exemplary embodiments, the method step of providing at least one communication module comprises providing at least one communication module that is operable for wirelessly transmitting alert(s) that may include information regarding the state of the brake stroke, temperature of the axle, detection of metal indicative of a bearing failure, and / or sensor battery level.

[0105] In exemplary embodiments, the method includes mounting the vehicle brake stroke sensor assembly on the brake chamber pushrod of the vehicle such that an alert is triggered when the brake chamber pushrod reaches the predetermined length and its magnetic element engages with a complementary magnetic element.

[0106] In exemplary embodiments, the method includes: providing a first communication module integrated or associated with the vehicle brake stroke sensor assembly, the first communication module configured to be operable for wirelessly transmitting alert(s) to a digital receiver for wireless transmission to a remote device when the brake chamber pushrod reaches a predetermined length triggering an alert; and providing a second communication module integrated within or associated with the wheel hub sensor assembly, the second communication module configured to be operable for wirelessly transmitting alert(s) to a digital receiver for wireless transmission to a remote device when the wheel hub sensor assembly detects an undesired wheel hub condition triggering an alert, such as magnetic material (e. ., metal shavings, etc.) indicative of a bearing failure and / or the temperature of the wheel hub has exceeded a predetermined value.

[0107] Also disclosed are exemplary embodiments of sensor assemblies that may be used in vehicle brake and wheel hub monitoring systems. In exemplary embodiments, the sensor assembly comprises one or more contact point(s) and one or more magnetic element(s). The one or more magnetic element(s) are configured to pull a contact element downwardly via magnetic attraction onto the one or more contact point(s). The sensor assembly is configured to generate an alert when the one or more magnetic element(s) of the sensor assembly are within a proximity distance from another component such that the one or more magnetic element(s) of the sensor assembly pulls, via magnetic attraction, the contact element onto the one or more contact point(s).

[0108] In exemplary embodiments, the sensor assembly includes a temperature sensor for detecting a temperature of a wheel hub. The sensor assembly is configured to generate an alert when the temperature sensor assembly detects a temperature of the wheel hub that has exceeded a predetermined value. The one or more one or more magnetic element(s) may comprise first and second magnetic element. And the temperature comprises a thermistor disposed between the first and second magnetic elements.

[0109] In exemplary embodiments, the sensor assembly includes metal detection capability. And the sensor assembly is configured to generate an alert when the sensor assembly detects a presence of metal indicative of a bearing failure of a wheel hub.

[0110] In exemplary embodiments, the proximity distance is pre-determined and / or programmed.

[0111] In exemplary embodiments, the sensor assembly includes one or more electric circuit boards configured to be operable for as a communication module for transmitting alerts. The one or more contact point(s) may comprise one or more contact pin(s) that extend outwardly from at least one of the one or more electronic circuit boards.

[0112] In exemplary embodiments, the contact element comprises a magnetic contact washer within a holder above the one or more magnetic element(s) of the sensor assembly. The another component comprises a metal bracket on a push rod. And the sensor assembly is configured to generate an alert when the one or more magnetic element(s) of the sensor assembly are within the proximity distance from the metal bracket on the push rod such that the one or more magnetic element(s) of the sensor assembly pulls, via magnetic attraction, the magnetic contact washer onto the one or more contact point(s).

[0113] Also disclosed are exemplary embodiments of oil sensors that comprise a thermistor, a static resistor, and at least magnets spaced apart from each other. The static resistor is useable to detect when the oil sensor is not connected. A static resistance is across the at least two magnets. Accumulation of magnetic particles across the at least two magnets decreases resistance across the at least two magnets. And the static resistance across the at least two magnets is usable as a baseline resistance to compare to the decreased resistance to determine if the oil sensor is connected. The oil sensor is configured to be operable for sending resistive values for the resistance of the thermistor and the resistance across the at least two magnets.

[0114] In exemplary embodiments, the oil sensor includes an M12 connector, and the thermistor is configured to change resistance across two M12 pins of the M12 connector. In alternative embodiments, the oil sensor may include a different connection option than an M12 connector.

[0115] In exemplary embodiments, the at least two magnets are configured to collect magnetic material caused by internal wear and tear or component failure of bearings, gears, and / or other magnetic components.

[0116] The oil sensor may be used in a vehicle brake and wheel hub monitoring system or elsewhere.

[0117] Also disclosed are exemplary embodiments of magnetic switches that comprise one or more contact point(s) and one or more magnetic element(s) configured to pull a contact element downwardly via magnetic attraction onto the one or more contact point(s). The magnetic switch is normally open but closes when the one or more magnetic element(s) are within a proximity distance from another component such that the one or more magnetic element(s) pulls, via magnetic attraction, the contact element onto the one or more contact point(s).

[0118] In exemplary embodiments of the magnetic switch, the proximity distance is predetermined and / or programmed.

[0119] In exemplary embodiments of the magnetic switch, the one or more contact point(s) comprise one or more contact pin(s) extending outwardly from an electronic circuit board.

[0120] In exemplary embodiments of the magnetic switch, the contact element comprises a magnetic contact washer within a holder above the one or more magnetic elements of the magnetic switch. And the magnetic switch is configured to generate an alert when the one or more magnetic element(s) of the magnetic switch are within the proximity distance from the another component such that the one or more magnetic element(s) of the magnetic switch pulls, via magnetic attraction, the magnetic contact washer onto the one or more contact point(s).

[0121] The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims. In the written description and claims, one or more steps within a method may be executed in a different order (or concurrently) without altering the principles of the present disclosure. Similarly, one or more instructions stored in a non-transitory computer-readable medium may be executed in different order (or concurrently) without altering the principles of the present disclosure. Unless indicated otherwise, numbering or other labeling of instructions or method steps is done for convenient reference, not to indicate a fixed order.

[0122] Although each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of the disclosure canbe implemented in and / or combined with features of any of the other embodiments, even if that combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more embodiments with one another remain within the scope of this disclosure.

[0123] Spatial and functional relationships between elements (for example, between modules) are described using various terms, including “connected,” “engaged,” “interfaced,” and “coupled.” Unless explicitly described as being “direct,” when a relationship between first and second elements is described in the above disclosure, that relationship encompasses a direct relationship where no other intervening elements are present between the first and second elements, and also an indirect relationship where one or more intervening elements are present (either spatially or functionally) between the first and second elements.

Claims

CLAIMSWHAT IS CLAIMED IS:

1. A vehicle brake and wheel hub monitoring system comprising: at least one vehicle brake stroke sensor assembly configured to be coupled with a vehicle’s brake chamber pushrod to monitor a length of a brake stroke of the vehicle’s brake chamber pushrod; at least one wheel hub sensor assembly configured to be coupled with a wheel hub of the vehicle to monitor for a presence of metal indicative of a bearing failure and to monitor temperature of the wheel hub; and at least one communication module integrated within or associated with the vehicle brake stroke sensor assembly and / or with the wheel hub sensor assembly, the communication module configured to be operable for wirelessly transmitting alert(s) to a digital receiver or other remote device: when the brake chamber pushrod reaches a predetermined length triggering an alert; and / or when the wheel hub sensor assembly detects an undesired wheel hub condition triggering an alert, including detection of magnetic material indicative of a bearing failure and / or a detection of a temperature of the wheel hub that has exceeded a predetermined value.

2. The vehicle brake and wheel hub monitoring system of claim 1, wherein: the vehicle brake stroke sensor assembly includes one or more magnetic elements; and the wheel hub sensor assembly includes one or more magnetic elements and a temperature sensor.

3. The vehicle brake and wheel hub monitoring system of any one of the preceding claims, wherein the system is configured to provide real-time information about brake, wheel hub, and axle conditions to a driver(s) of the vehicle and / or to maintenance personnel.

4. The vehicle brake and wheel hub monitoring system of any one of the preceding claims, wherein the communication module is configured to transmit alerts via a short-range wireless communication protocol.

5. The vehicle brake and wheel hub monitoring system of any one of the preceding claims, wherein the communication module is configured to transmit alerts via BLUETOOTH short-range wireless communication protocol.

6. The vehicle brake and wheel hub monitoring system of any one of the preceding claims, wherein: the system includes a digital receiver that is positioned in a cab of a truck or on a trailer; and the communication module is configured to transmit alerts via a short-range wireless communication protocol to the digital receiver.

7. The vehicle brake and wheel hub monitoring system of any one of the preceding claims, wherein the system includes the digital receiver that is configured to be operable for wirelessly transmitting alert(s) to dispatch, a smartphone, a tablet, a vehicle dashboard display, and / or a remote device.

8. The vehicle brake and wheel hub monitoring system of any one of the preceding claims, wherein the system is configured such that the alert may include information regarding the state of the brake stroke, temperature of the axle, detection of metal indicative of a bearing failure, and / or sensor battery level.

9. The vehicle brake and wheel hub monitoring system of any one of the preceding claims, wherein the system is configured such that when the brake chamber pushrod reaches the predetermined length its magnetic element engages with a complementary magnetic element triggering an alert.

10. The vehicle brake and wheel hub monitoring system of any one of the preceding claims, wherein the communication module comprises: a first communication module integrated or associated with the vehicle brake stroke sensor assembly, the first communication module configured to be operable for wirelessly transmitting alert(s) to a digital receiver for wireless transmission to a remote device when the brake chamber pushrod reaches a predetermined length triggering an alert; and a second communication module integrated within or associated with the wheel hub sensor assembly, the second communication module configured to be operable for wirelessly transmitting alert(s) to a digital receiver for wireless transmission to a remote device when the wheel hub sensor assembly detects an undesired wheel hub condition triggering an alert, such as magnetic material indicative of a bearing failure and / or the temperature of the wheel hub has exceeded a predetermined value.

11. A method for monitoring a vehicle’s breaking system and wheel hub and for alerting when a pre-defined condition is detected, the method comprising: monitoring a length of a brake stroke of a vehicle’s brake chamber pushrod via at least one vehicle brake stroke sensor assembly; monitoring the vehicle’s wheel hub, via at least one wheel hub sensor assembly, including monitoring for a metal presence indicative of a bearing failure and monitoring temperature of the wheel hub; and wirelessly transmitting, via at least one communication module integrated or associated with the vehicle brake stroke sensor assembly and / or with the wheel hub sensor assembly, alert(s) to a digital receiver or other remote device: when the brake chamber pushrod reaches a predetermined length triggering an alert; and / or when the wheel hub sensor assembly detects an undesired wheel hub condition triggering an alert, including detection of magnetic material indicative of a bearing failure and / or detection of a temperature of the wheel hub that has exceeded a predetermined value.

12. The method of claim 11, wherein: the vehicle brake stroke sensor assembly includes one or more magnetic elements; and the wheel hub sensor assembly includes one or more magnetic elements and a temperature sensor.

13. The method of claim 11 or 12, wherein the method includes: mounting the vehicle brake stroke sensor assembly on a brake chamber pushrod of a trailer to monitor a length of the brake stroke of the trailer’s brake chamber pushrod; mounting the wheel hub sensor assembly on a wheel hub of the trailer; and positioning the digital receiver in a cab of a truck or on a trailer.

14. The method of claim 11 or 12, wherein the method includes: mounting a vehicle brake stroke sensor assembly on each brake chamber pushrod of the vehicle; andmounting a wheel hub sensor assembly on each wheel hub of the vehicle.

15. The method of any one of claims 11 to 14, wherein the method includes providing real-time information about brake, wheel hub, and axle conditions to a driver(s) of the vehicle and / or to maintenance personnel.

16. The method of any one of claims 11 to 15, wherein the method includes wirelessly transmitting alert(s) via a short-range wireless communication protocol.

17. The method of any one of claims 11 to 16, wherein the method includes wirelessly transmitting alert(s) via BLUETOOTH short-range wireless communication protocol.

18. The method of any one of claims 11 to 17, wherein the method includes wirelessly transmitting the alert(s), via the digital receiver, to dispatch, a smartphone, a tablet, a vehicle dashboard display, and / or a remote device.

19. The method of any one of claims 11 to 18, wherein the method includes wirelessly transmitting alert(s) that may include information regarding the state of the brake stroke, temperature of the axle, detection of metal indicative of a bearing failure, and / or sensor battery level.

20. The method of any one of claims 11 to 19, wherein the method includes triggering an alert when the brake chamber pushrod reaches the predetermined length and its magnetic element engages with a complementary magnetic element.

21. The method of any one of claims 11 to 20, wherein the method includes: wirelessly transmitting, via a first communication module integrated or associated with the vehicle brake stroke sensor assembly, alert(s) to a digital receiver for wireless transmission to a remote device when the brake chamber pushrod reaches a predetermined length triggering an alert; andwirelessly transmitting, via a second communication module integrated or associated with the wheel hub sensor assembly, alert(s) to a digital receiver for wireless transmission to a remote device when the wheel hub sensor assembly detects an undesired wheel hub condition triggering an alert, such as magnetic material indicative of a bearing failure and / or the temperature of the wheel hub has exceeded a predetermined value.

22. A method of providing a vehicle with brake and wheel hub monitoring, the method comprising: mounting at least one vehicle brake stroke sensor assembly on a brake chamber pushrod of a vehicle to monitor a length of the brake stroke of the brake chamber pushrod; mounting at least one wheel hub sensor assembly to a wheel hub of the vehicle to monitor for a presence of metal indicative of a bearing failure and to monitor temperature of the wheel hub; and providing at least one communication module integrated within or associated with the vehicle brake stroke sensor assembly and / or with the wheel hub sensor assembly, the communication module configured to be operable for wirelessly transmitting alert(s) to a digital receiver or other remote device: when the brake chamber pushrod reaches a predetermined length triggering an alert; and / or when the wheel hub sensor assembly detects an undesired wheel hub condition triggering an alert, such as magnetic material indicative of a bearing failure and / or the temperature of the wheel hub has exceeded a predetermined value.

23. The method of claim 22, wherein: the vehicle brake stroke sensor assembly includes one or more magnetic elements; and the wheel hub sensor assembly includes one or more magnetic elements and a temperature sensor.

24. The method of claim 22 or 23, wherein the method includes: mounting the vehicle brake stroke sensor assembly on a brake chamber pushrod of a trailer to monitor a length of the brake stroke of the trailer’s brake chamber pushrod; mounting the wheel hub sensor assembly on a wheel hub of the trailer; and the method includes positioning the digital receiver in a cab of a truck or on a trailer.

25. The method of claim 22 or 23, wherein the method includes: mounting a vehicle brake stroke sensor assembly on each brake chamber pushrod of the vehicle; andmounting a wheel hub sensor assembly on each wheel hub of the vehicle.

26. The method of any one of claims 22 to 25, wherein the method includes enabling real-time information to be provided about brake, wheel hub, and axle conditions to a driver(s) of the vehicle and / or to maintenance personnel.

27. The method of any one of claims 22 to 26, wherein providing at least one communication module comprises providing at least one communication module that is operable for wirelessly transmitting alert(s) via a short-range wireless communication protocol.

28. The method of any one of claims 22 to 27, wherein providing at least one communication module comprises providing at least one communication module that is operable for wirelessly transmitting alert(s) via BLUETOOTH short-range wireless communication protocol.

29. The method of any one of claims 22 to 28, wherein providing at least one communication module comprises providing at least one communication module that is operable for wirelessly transmitting the alert(s), via the digital receiver, to dispatch, a smartphone, a tablet, a vehicle dashboard display, and / or a remote device.

30. The method of any one of claims 22 to 29, wherein providing at least one communication module comprises providing at least one communication module that is operable for wirelessly transmitting alert(s) that may include information regarding the state of the brake stroke, temperature of the axle, detection of metal indicative of a bearing failure, and / or sensor battery level.

31. The method of any one of claims 22 to 30, wherein the method includes mounting the vehicle brake stroke sensor assembly on the brake chamber pushrod of the vehicle such that an alert is triggered when the brake chamber pushrod reaches the predetermined length and its magnetic element engages with a complementary magnetic element.

32. The method of any one of claims 22 to 31 , wherein the method includes: providing a first communication module integrated or associated with the vehicle brake stroke sensor assembly, the first communication module configured to be operable for wirelessly transmitting alert(s) to a digital receiver for wireless transmission to a remote device when the brake chamber pushrod reaches a predetermined length triggering an alert; and providing a second communication module integrated within or associated with the wheel hub sensor assembly, the second communication module configured to be operable for wirelessly transmitting alert(s) to a digital receiver for wireless transmission to a remote device when the wheel hub sensor assembly detects an undesired wheel hub condition triggering an alert, such as magnetic material indicative of a bearing failure and / or the temperature of the wheel hub has exceeded a predetermined value.

33. A sensor assembly for a vehicle brake and wheel hub monitoring system, the sensor assembly comprising: one or more contact point(s); and one or more magnetic element(s) configured to pull a contact element downwardly via magnetic attraction onto the one or more contact point(s); wherein the sensor assembly is configured to generate an alert when the one or more magnetic element(s) of the sensor assembly are within a proximity distance from another component such that the one or more magnetic element(s) of the sensor assembly pulls, via magnetic attraction, the contact element onto the one or more contact point(s).

34. The sensor assembly of claim 33, wherein: the sensor assembly includes a temperature sensor for detecting a temperature of a wheel hub; and the sensor assembly is configured to generate an alert when the temperature sensor assembly detects a temperature of the wheel hub that has exceeded a predetermined value.

35. The sensor assembly of claim 34, wherein: the one or more one or more magnetic element(s) comprise first and second magnetic elements; and the temperature comprises a thermistor disposed between the first and second magnetic elements.

36. The sensor assembly of any one of claims 33 to 35, wherein: the sensor assembly includes metal detection capability; and the sensor assembly is configured to generate an alert when the sensor assembly detects a presence of metal indicative of a bearing failure of a wheel hub.

37. The sensor assembly of any one of claims 33 to 36, wherein the proximity distance is pre-determined and / or programmed.

38. The sensor assembly of any one of claims 33 to 37, wherein the sensor assembly includes one or more electric circuit boards configured to be operable for as a communication module for transmitting alerts.

39. The sensor assembly of claim 38, wherein the one or more contact point(s) comprise one or more contact pin(s) extending outwardly from at least one of the one or more electronic circuit boards.

40. The sensor assembly of any one of claims 33 to 39, wherein: the contact element comprises a magnetic contact washer within a holder above the one or more magnetic element(s) of the sensor assembly; the another component comprises a metal bracket on a push rod; and the sensor assembly is configured to generate an alert when the one or more magnetic element(s) of the sensor assembly are within the proximity distance from the metal bracket on the push rod such that the one or more magnetic element(s) of the sensor assembly pulls, via magnetic attraction, the magnetic contact washer onto the one or more contact point(s).41 . An oil sensor comprising: a thermistor; a static resistor useable by a monitoring controller to detect when the oil sensor is not connected; and at least two magnets spaced apart from each other and having a static resistance across the at least two magnets; wherein accumulation of magnetic particles across the at least two magnets decreases resistance across the at least two magnets, and the static resistance across the at least two magnets is usable as a baseline resistance to compare to the decreased resistance to determine if the oil sensor is connected; and wherein the oil sensor is configured to be operable for sending resistive values for the resistance of the thermistor and the resistance across the at least two magnets.

42. The oil sensor of claim 41, wherein the oil sensor includes an Ml 2 connector, and the thermistor is configured to change resistance across two M12 pins of the M12 connector.

43. The oil sensor of claim 41 or 42, wherein the at least two magnets are configured to collect magnetic material caused by internal wear and tear or component failure of bearings, gears, and / or other magnetic components.

44. A vehicle brake and wheel hub monitoring system comprising the oil sensor of any one of claims 41 to 43.

45. A magnetic switch comprising one or more contact point(s); and one or more magnetic element(s) configured to pull a contact element downwardly via magnetic attraction onto the one or more contact point(s); wherein the magnetic switch is normally open but closes when the one or more magnetic element(s) are within a proximity distance from another component such that the one or more magnetic element(s) pulls, via magnetic attraction, the contact element onto the one or more contact point(s).

46. The magnetic switch of claim 45, wherein the proximity distance is pre-determined and / or programmed.

47. The magnetic switch of claim 45 or 46, wherein the one or more contact point(s) comprise one or more contact pin(s) extending outwardly from an electronic circuit board.

48. The magnetic switch of any one of claims 45 to 47, wherein: the contact element comprises a magnetic contact washer within a holder above the one or more magnetic elements of the magnetic switch; and the magnetic switch is configured to generate an alert when the one or more magnetic element(s) of the magnetic switch are within the proximity distance from the another component such that the one or more magnetic element(s) of the magnetic switch pulls, via magnetic attraction, the magnetic contact washer onto the one or more contact point(s).

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