Vehicle monitoring system and method

Abstract

A vehicle monitoring system (190) including a sensor device (191) configured to obtain sensed data relating to at least one of position and movement of a first component of a brake assembly (101, 102), the sensor device (191) being configured to transmit the sensed data to a control device (199) of the monitoring device (190), the control device (199) being configured to monitor a condition of the first component of the brake assembly (101, 102) and / or a second component of the brake assembly (101, 102) based on the sensed data, and to transmit a signal indicative of the monitored condition to at least one of a remote hub (200), and a local device (11), and a method of monitoring a condition of a first component of a brake assembly (101, 102), including sensing at least one of position and movement of the first component and / or sensing at least one of position and movement of a second component of the brake assembly (101, 102), the position and / or movement of the first and / or second component being indicative of the condition of the first component of the brake assembly (101, 102), and the method further including transmitting a signal indicative of the condition of the first component of the brake assembly (101, 102) to at least one of a local device (11) and a remote hub (200).

Description

[0001] VEHICLE MONITORING SYSTEM AND METHOD

[0002] FIELD

[0003] The disclosure relates to a vehicle monitoring system and method of monitoring a vehicle condition, in particular, but not exclusively, to a vehicle monitoring system and method of monitoring a condition of one or more components of vehicle braking system.

[0004] BACKGROUND

[0005] Drum brakes and disc brakes are known in the art of vehicle braking systems. A driver of a vehicle may apply a service brake to slow or stop the vehicle. A park brake may be applied to hold the vehicle still. It is known to incorporate an automatic brake adjuster in a vehicle braking system, for example to maintain a predetermined distance between a drum and brake lining, so as to maintain braking precision, for example as the brake lining wears through use. Knowledge of whether the brakes are in or out of adjustment is important. Manual inspection of whether brakes are in or out of adjustment cannot be carried out whilst the vehicle is moving. Such inspection is timeconsuming and can be a dirty task. Typically, a user of a vehicle, e.g. a driver or mechanic is only able to check one wheel end at a time. Other conditions and / or characteristics of a vehicle braking system also require regular checks - for example the condition of a brake lining or brake pad. Similar limitations of current inspection methods typically apply to these conditions or characteristics, too.

[0006] It is an object of the present invention to provide a vehicle monitoring system and method to ameliorate one or more of the problems associated with current monitoring or inspection methods.

[0007] BRIEF DESCRIPTION OF THE INVENTION

[0008] There is provided a vehicle monitoring system including a sensor device configured to obtain sensed data relating to at least one of position and movement of a first component of a brake assembly, the sensor device being configured to transmit the sensed data to a control device of the monitoring system, the control device being configured to monitor a condition of the first component of the brake assembly and / or a second component of the brake assembly based on the sensed data, and to transmit a signal indicative of the monitored condition to at least one of a remote hub and a local device.

[0009] The vehicle monitoring system may include a plurality of sensor devices. The vehicle monitoring system may be configured to monitor one or more of the following conditions: a brake adjuster condition, a brake lining condition, a brake lining / drum interface surface condition, a drum condition, a cam condition, a brake pad condition, a disc condition, an actuator condition, a disc brake condition.

[0010] The sensor device may be an accelerometer.

[0011] The sensor device may be configured to monitor vibration of the component.

[0012] Data obtained by the sensor device may be compared with calibration data to determine or predict the condition of the component.

[0013] The vehicle monitoring system may be configured to monitor and / or transmit the signal indicative of the condition of the or each component whilst the vehicle is being driven.

[0014] The vehicle monitoring system according to any of the preceding claims may be configured to monitor and / or transmit the signal indicative of the condition of the or each component during a braking operation.

[0015] There is also provided a braking system of a vehicle including a vehicle monitoring system as described herein.

[0016] There is also provided a vehicle including a vehicle monitoring system as described herein.

[0017] There is provided a method of monitoring a condition of a first component of a brake assembly, including obtaining at least one of position data and movement data of the first component and / or obtaining at least one of position data and movement data of a second component of the brake assembly, the position and / or movement data of the first and / or second component being indicative of the condition of the first component of the brake assembly, and the method further including transmitting a signal indicative of the condition to at least one of a local device and a remote hub. The method may include obtaining calibration data indicative of a condition of the first component of the brake assembly, and comparing the position and / or movement data with the calibration data to monitor an in use condition of the first component of the brake assembly.

[0018] The position and / or movement data may be combined with one or more of: other data relating to the first component of the brake assembly, data relating to the second component of the brake assembly data relating to a third component, data relating to a vehicle condition or characteristic.

[0019] The condition of the first component of the brake assembly component may be monitored whilst the vehicle is in use.

[0020] The condition of the first component of the brake assembly may be monitored whilst the vehicle is being driven.

[0021] The condition of the first component of the brake assembly may be monitored whilst a braking operation is being carried out.

[0022] BRIEF DESCRIPTION OF THE FIGURES

[0023] In order that the present disclosure may be more readily understood, preferable embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0024] FIGURE 1 is a schematic illustration of a two-vehicle fleet including a hub;

[0025] FIGURE 2A is a perspective view of part of a vehicle braking system, including a drum brake actuation assembly; FIGURE 2B is a cross sectional view of part of a drum brake actuation assembly;

[0026] FIGURE 3 is a side view of a brake adjuster mechanism, co-operating with a brake actuator;

[0027] FIGURE 4 is an illustrative view of parts of a disc brake actuation assembly and a brake actuator; and

[0028] FIGURE 5 is a cross sectional view of part of a wheel assembly with a drum brake actuation assembly.

[0029] DETAILED DESCRIPTION OF THE DISCLOSURE

[0030] A vehicle 10 includes a plurality of wheel end units. The vehicle 10 may include a tractor unit and one or more trailer units, for example. The vehicle 10 includes a braking system for braking one or more wheels of the vehicle. The vehicle 10 may include a monitoring system for monitoring one or more characteristics of the vehicle. The or each monitored characteristic may be used to detect, monitor, analyse or predict a condition of one or more components of the vehicle 10. The vehicle 10 may be part of a fleet (as illustrated in Figure 1 , for example). The fleet may include a plurality of vehicles 10 (two are shown but it will be understood that a fleet may include many more vehicles) 10. A hub 200 is shown, with each vehicle 10 being communicable with the hub 200.

[0031] Referring to Figures 2A and 2B, there is shown a brake assembly 101. The brake assembly 101 may include a brake actuator 140, which is operable in accordance with a braking signal. The braking signal may be provided in accordance with a braking demand, which may be supplied via a user input device 180. The user input device 180 may be a pedal, lever or switch, for example. The braking demand input at the user input device 180 may be transmitted to a brake actuation assembly 110 at or near the wheel end, to apply a braking force.

[0032] The braking demand may be supplied to an electronic controller or supplied pneumatically to the actuator 140. The actuator 140 is configured to transmit the braking demand supplied via the user input device 180 into a braking force at the wheel end.

[0033] In an example, the brake actuation assembly 110 may be a drum brake assembly, including a drum 111 , a brake shoe assembly 112 moveable substantially radially relative to the drum 111 and a brake lining assembly 113. In the example shown the brake shoe assembly 112 includes a first brake shoe member 112a, a second brake shoe member 112b, each of the first and second brake shoe members 112a, 112b being moveable substantially radially relative to the drum 111. In the example shown, the brake lining assembly 113 include a first brake lining member 113a and a second brake lining member 113b, each of which is associated with a corresponding brake shoe member 112a, 112b, and is moveable with the corresponding brake shoe member 112a, 112b substantially radially relative to the brake drum 111. Movement of the brake shoe assembly 112 causes the brake lining assembly 113 to move into and out of contact with the drum 111 in accordance with a braking signal.

[0034] In the example shown, the braking signal is transmitted to the brake actuation assembly 110 via the actuator 140. It will be appreciated that the actuator 140 may take any appropriate form.

[0035] In the example shown the actuator 140 causes substantially linear movement of a rod 150. The rod 150 may be connected to a brake adjuster mechanism 151. The brake adjuster mechanism 151 may be an automatic slack adjuster. The brake adjuster mechanism 151 may be of conventional type. The brake adjuster mechanism 151 may include a worm gear mechanism and a clutch. The brake adjuster mechanism 151 may be configured to automatically adjust into one of a plurality of positions. The positions of the brake adjuster mechanism 151 may be discrete positions, each of which corresponds with a range (C, Ce, E) of rotational movement of the arm 151a, which corresponds with a range of movement of the rod 150. Each range of movement may be defined by a stroke-torque relationship, which may be defined in accordance with one or more regulations. This relationship may be used when calibrating the monitoring device 190, for example. It will be appreciated that whilst a brake adjuster mechanism is a common component of a brake assembly 101 , is not essential and may be omitted.

[0036] In the example shown, linear movement of the rod 150 causes rotational movement of an arm 151a of the brake adjuster mechanism 151 about a first axis A. The brake adjuster mechanism 151 may be coupled to a shaft 152, which extends substantially parallel to the first axis A, and is rotatable about the first axis A. The shaft 152 may be coupled to a cam member 114 that is engageable with the brake shoe assembly 112. The cam member 114 may be an S-cam. The cam member 114 may be rotatable about the first axis A. A first cam surface 114a of the cam member 114 may be engageable with the first brake shoe member 112a and a second cam surface 114b of the cam member 114 may be engageable with the second brake shoe member 112b. Rotational movement of the cam member 114 may cause substantially radial movement of the or each brake shoe member 112a, 112b, and the or each brake lining member 113a, 113b, relative to the drum 111 , so as to engage or disengage the brake lining assembly 113 with or from the drum 111 in accordance with the braking signal. The brake assembly 101 may include an exciter ring 22.

[0037] As the or each brake lining member 113a, 113b wears, the amount of radial movement of the or each brake shoe member 112a, 112b to apply a required braking force to the drum 111 may increase. The brake adjuster mechanism 151 may be operable so as to automatically adjust the range of movement of the rod 150 by controlling the range of movement of the arm 151a of the brake adjuster 151 , to enable consistent, accurate and safe application of a required braking force. The driver experience is maintained - e.g. the range of pedal travel may be maintained substantially constant to apply the same braking force, irrespective of the thickness of the brake lining members 113a, 133.

[0038] Disc brake systems are also known in the art. In Figure 4, there is shown a brake assembly 102, in which the actuator 140 transmits the braking demand to an actuation assembly 120. The actuation assembly 120 may be a disc brake assembly. The disc brake assembly 120 may include a brake pad carrier assembly 121 and a brake pad assembly 122, including a pair of brake pads 122a, 122b and a rotor or disc 123. The disc brake assembly 120 may be of a conventional form, and operate in a conventional manner. It will be appreciated that the actuator 140 of the brake assembly 102 may take any appropriate form. The actuator 140 and the disc brake assembly 120 may be connected together.

[0039] The vehicle 10 may include one or more drum brake assemblies 101 and / or one or more disc brake assemblies 102.

[0040] The vehicle 10 may include a monitoring system 190.

[0041] The monitoring system 190 may be configured to monitor one or more conditions or characteristics of the vehicle 10. The monitoring system 190 may be configured to directly or indirectly monitor the or each condition or characteristic. The monitoring system 190 may be configured to monitor a condition or characteristic of a component of the brake assembly 101 , 102.

[0042] The monitoring system 190 may include a sensor device 191. The monitoring system 190 may include a plurality of sensor device 191 . The or each sensor device 191 may be an accelerometer or inertial measurement sensor, for example. The or each sensor device 191 may detect movement in one, two or three degrees of movement (denoted x, y and z in Figure 2A). The type and / or position of the or each sensor 191 may be selected dependent on the application, for example the type of brake assembly and / or the type of vehicle 10 and / or the condition(s) / characteristic(s) to be monitored. The sensitivity of the or each sensor 191 may be selected dependent on the application and / or the condition(s) / characteristic(s) to be monitored. In other words the or each sensor 191 may be configured and operable in a manner that is selected and dependent upon the application and / or the condition(s) / characteristic(s) to be monitored. The configuration of the or each sensor 191 may include selecting, designing and / or positioning the most appropriate sensor and / or selecting and positioning the most appropriate combination of sensors 191 dependent upon the application and / or the condition(s) / characteristic(s) to be monitored.

[0043] In an example, a sensor device 191a may be positioned on the rod 150. The sensor device 191 a may be operable (configured) to monitor position and / or movement at least in the x direction, for example. The rod 150 is operable to reciprocate substantially in the x direction. The sensor 191a may be configured to provide data indicative of position and / or movement of the rod 150 to the control device 199.

[0044] A sensor device 191 b may be provided on a part of the brake adjuster mechanism 151. The sensor device 191 b may be provided on the arm 151 a. The sensor device 191 b may be configured to detect movement in the x-direction and / or the y-direction, for example. The sensor device 191 b may be configured to provide data indicative of position / movement of the adjuster mechanism 151 to the control device 199. A sensor device 191 c may be positioned on the shaft 152. The sensor device 191 c may be configured to provide data indicative of position and / or movement of the shaft 152 to the control device 199.

[0045] A sensor device 191 d may be provided on the actuator 140, for example on a body of the actuator 140, and to transmit a signal to the control device 199.

[0046] A sensor device 191 e may be provided on the exciter ring 22. The sensor device 191 e may be configured to detect position and / or movement, for example rotation and / or vibration of the exciter ring 22 and / or one or more other components of the brake assembly 101 , and to transmit a signal to the control device 199.

[0047] A sensor device 191f may be positioned on a part of the disc brake actuation assembly 120, for example on a brake pad carrier assembly 121 . The sensor device 191 f may be configured to detect position and / or movement of a part of the disc brake actuation assembly 120, and to transmit a signal to the control device 199.

[0048] The monitoring system 190 may be configured to monitor the or each characteristic / condition continuously and or substantially continuously. The monitoring system 190 may be configured to monitor the or each condition / characteristic whilst the vehicle 10 is moving. The monitoring system 190 may be configured to monitor the or each condition / characteristic whilst the vehicle 10 is being driven. Additionally or alternatively, the monitoring system 190 may be configured to monitor the or each characteristic or condition whilst the vehicle is stationary.

[0049] The monitoring system 190 may include a control device 199. The control device 199 may be configured to receive signals from the or each sensor 191. The control device 199 may be configured to transmit signals, for example to a remote hub 200 and / or to a local device 11 , for example to provide a signal to a user of the vehicle. The control device may be configured to communicate with the or each sensor by wired and / or wireless communication methods. Wireless communication methods are advantageous, since this simplifies installation, for example.

[0050] The control device 199 may be local to or remote from the or each sensor 191. The control device 199 may be configured to receive, store, and / or analyse signals received from the or each sensor device 191. The control device 199 may be configured to determine and / or predict one or more conditions of one or more components of the brake assembly 101 , 102. The control device 199 may be configured to determine and / or predict one or more conditions of the brake assembly 101 , 102, based upon sensor data (signals) received from the or each sensor device 191. The control device 199 may be configured to determine and / or predict one or more conditions of the brake assembly 101 , 102, by comparing signals from the or each sensor device 191 with other data. The control device 199 may be a vehicle ECU, for example a central ECU, or a system ECU, for example an electronic braking system (EBS) ECU. The control device 199 may be specific to the monitoring system 190.

[0051] The control device 199 may be configured to provide a signal indicative of one or more characteristics or conditions of the brake assembly 101 , 102, or of one or more components of the brake assembly 101 , 102 to a local device 11 , for example to provide a signal to a user, for example a driver or engineer carrying out an inspection and / or maintenance. The local device 11 may be configured to provide a signal in the form of a visible signal, such as an illuminated indicator, and / or an audible signal and / or a haptic signal, for example. The signal provided to a local user may be provided in the cab of the vehicle 10, and / or externally of the vehicle, for example near a wheel end. The position and / or configuration of the local device 11 may be selected in accordance with its application. For example, certain conditions may be best signaled to a driver of the vehicle, when the vehicle is in use, whilst other conditions may be best signaled near to a wheel end unit, so that they can be detected by a mechanic whilst performing an inspection or maintenance. The control device 199 may be configured to provide a signal to a user of the vehicle in real time, or quasi-real time. The control device 199 may be configured to provide a signal, for example a warning signal, to a user of the vehicle 10. For example, if a signal from the monitoring system 190 indicates that a predetermined threshold is approaching or is met, the control device 199 may provide a signal to the user.

[0052] The control device 199 may be configured to transmit a signal indicative of one or more characteristics or conditions of the brake assembly 101 , 102, or one or more components of the brake assembly 101 , 102 to a hub 200. The hub 200 may be remote from the vehicle 10, for example the hub 200 may be a fleet control centre.

[0053] The control device 199 may be configured to transmit information about one or more conditions or characteristics of one or more other vehicle components or systems to the hub 200. Signals) provided by the monitoring system 190 may be transmitted to the hub 200 with, or in a similar manner to, other vehicle telematics data.

[0054] The or each sensor 191 may be operable (configured) to sense data continuously and / or substantially continuously. The or each sensor 191 may be operable (configured) to transmit data continuously and / or substantially continuously to the control device 199. The or each sensor device 191 may be operable (configured) to sense and / or transmit data to the controller while the vehicle is moving, e.g. being driven. The or each sensor device 191 may be operable (configured) to sense and / or transmit data to the control device during a braking operation. The control device 199 may be configured to monitor the or each characteristic / condition continuously and or substantially continuously. The control device 199 may be configured to monitor the or each condition / characteristic whilst the vehicle 10 is moving. The monitoring system 199 may be configured to monitor the or each condition / characteristic whilst the vehicle 10 is being driven. The control device 199 may be configured to monitor the or each condition / characteristic during a braking operation. The control device 199 may be configured to transmit signals indicative of a characteristic or condition of a component of the brake assembly 101 , 102 to the hub 200 in real time, or approximately real time. It will be appreciated that additionally or alternatively, data may be processed and / or transmitted in batches and / or at predetermined time intervals. The control device 199 may be configured to transmit data in response to a data request, for example from the hub 200. Additionally or alternatively, the control device 199 may be configured to transmit data routinely and / or in response to receiving a signal from one or more sensor devices 191 that indicates a predetermined threshold has been met and / or is approaching. The control device 199 may be configured to monitor the or each condition / characteristic whilst the vehicle 10 is moving. The control device 199 may be configured to monitor the or each condition / characteristic whilst the vehicle 10 is being driven.

[0055] The configuration and / or operation of the monitoring system 190 may be dependent upon the condition or characteristic that it is intended to monitor. The location of the monitoring system 190 may be dependent upon the condition or characteristic that it is intended to monitor.

[0056] The monitoring system 190 may be provided as part of the vehicle brake assembly 101 , 102. The or each sensor 191 may be fixed or coupled to a component of the vehicle brake assembly 101 , 102. The or each sensor device 191 may be communicable with the control device 199, for example by a wired or wireless communication method. The control device 199 may be remote from the brake assembly 100. The control device 199 may be a control device that is provided as part of a vehicle braking system, for example an EBS controller, or may be part of a central vehicle control unit (ECU), for example a telematics ECU of the vehicle.

[0057] The monitoring system 190 may be operable (configured) to monitor a condition or characteristic of a component of the brake assembly 101 , 102 by monitoring the position and / or movement of one or more parts of the brake assembly 101 , 102.

[0058] Data provided by the monitoring system 190 may be used in conjunction with and / or modified by data from and / or relating to other components and / or systems of the vehicle 10.

[0059] The control device 199 may be configured to compare data provided by the monitoring system 190 with other data indicative of a condition or characteristic of a component in order to monitor a condition or characteristic of a component of the brake assembly 101 , 102. The monitoring system 190 may be configured to monitor a condition or characteristic of the brake actuator 140. The monitoring system 190 may be configured to monitor a condition or characteristic of a component of the brake actuator 140. The monitoring system 190 may be configured to monitor a position and / or movement of one or more components of the brake actuator 140.

[0060] The monitoring system 190 may be configured to monitor a condition or characteristic of the actuation assembly 110, 120. The monitoring system 190 may be configured to monitor a position or movement of the actuation assembly 110, 120. The monitoring system 190 be configured to monitor a position or movement of a component of the actuation assembly 110, 120.

[0061] The monitoring system 190 may be configured to monitor a condition or characteristic of a drum 111 of the brake assembly 100.

[0062] The monitoring system 190 may be configured to monitor a condition or characteristic of a brake lining member 113a, 113b of the brake assembly 100. The monitoring system 190 may be able to monitor a condition or characteristic of a brake lining member 113a, 113b by monitoring the position and / or movement of a component of the brake assembly 101.

[0063] The monitoring system 190 may be configured to monitor a condition or characteristic of the cam member 114 of the brake actuation assembly 110.

[0064] The monitoring system 190 may be configured to monitor a condition or characteristic of the brake adjuster 151. The monitoring system 190 may be configured to monitor a position and / or movement of the brake adjuster 151. The monitoring system 190 may be operable (configured) to determine a position and / or movement of a brake adjuster mechanism 151 to monitor a condition or characteristic of the brake assembly 100.

[0065] The monitoring system 190 may be configured to monitor a condition or characteristic of a disc brake actuation assembly 120.

[0066] The monitoring system 190 may be configured to monitor one or more conditions or characteristics of a brake caliper assembly. The monitoring system 190 may be configured to monitor one or more conditions or characteristics of one or more brake pad members 122a, 122b. The monitoring system 190 may be configured to monitor one or more conditions or characteristics of a disc 123 of the disc brake actuation assembly 120. The monitoring device 190 may be configured to monitor a condition of a wheel assembly, for example tyre balance.

[0067] Brake adjuster condition

[0068] It may be desirable for a condition or characteristic of a brake adjuster of a vehicle to be monitored. It may be desirable for an indication of a condition of a brake adjuster mechanism to be provided to a local device 11 , e.g. to a user of the vehicle 10, and / or remotely, for example to a hub 200. The remote location may be a control centre, for example a fleet operator control centre. Vehicles 10 are regularly inspected, for example four times per year. However, if a brake adjuster mechanism fails, is out of adjustment, or is otherwise not operating as desired or as expected, it is advantageous for this to be rectified as quickly as possible. The monitoring system 190 may enable data indicative of a condition / characteristic of the brake adjuster mechanism 151 to be provided to a local user, e.g. a driver of the vehicle 10 and / or to a remote “user”, for example a fleet operator. This may enable inspection and / or maintenance to be carried out / scheduled as appropriate. It will be appreciated that the brake adjuster mechanism 151 shown and described herein is an example, and the methods and apparatuses described herein may be used to provide an indication of a condition or characteristic of any type of brake adjuster.

[0069] One or more sensors 191a, 191 b, 191c may be provided, for example positioned as described above.

[0070] Signals provided by the or each sensor 191a, 191 b, 191c may be indicative of the position and / or movement of the brake adjuster mechanism 151 , such that the monitoring system 190 may be configured / operable to determine whether the brake assembly 101 is in or out of adjustment and / or a condition of the brake adjuster mechanism (for example whether the adjuster mechanism 151 is worn / has failed / is about to fail. The monitoring system 190 may be configured to determine an extent to which the brake assembly 101 is in or out of adjustment and / or is worn. The adjuster mechanism 151 shown includes a worm mechanism and a clutch. The monitoring system may be configured to monitor whether the clutch and / or the worm mechanism is worn and / or has failed.

[0071] Calibration may be carried out, with the brake adjuster mechanism in a known position, for example in adjustment or fully out of adjustment. The monitoring system 190 may transmit signals from the or each sensor 191 a, 191 b, 191 c to the control device 199. The signals may be associated with or compared with the known position, such that the in use position and / or movement of the brake adjuster mechanism 151 may be determined, so as to determine a condition / characteristic of the brake adjuster mechanism 151. The signals provided by the monitoring system 190 may be compared with, combined with and / or modified by other vehicle data. Brake lining condition

[0072] It may be desirable to provide an indication of the condition or characteristic of the brake lining of a drum bake assembly 110 to a local or remote user. The condition or characteristic of the brake lining 113 may be a thickness of the or each lining member 113a, 113b, and / or the roughness (or smoothness) of an interface surface of the lining which engages with the drum 111 , for example.

[0073] One or more of sensors 191a, 191 b, 191 c, may be provided in the positions as described above. The monitoring system 190 may be configured to determine one or more conditions / characteristics of the or each brake lining member 113a, 113b.

[0074] Signals provided by the or each sensor 191a, 191 b, 191 c may be indicative of a condition, e.g. the thickness of either or both of the brake lining member 113a 113b.

[0075] Position or movement data provided by the or each sensor 191a, 191 b, 191c may be used to determine a value indicative of the distance between the / or each brake lining member 113a, 113b, which may be used to determine the thickness of the or each brake lining member 113a, 113b.

[0076] The monitoring system 190 may be configured such that a signal indicative of a predetermined position and / or movement may be indicative of failure or imminent failure of a component of the brake assembly 100, for example this may be an indication that the or each lining member 113a, 113b has worn to a level where replacement is necessary or advisable.

[0077] Calibration data, including position and / or movement data may be obtained, for example when the brake lining members 113a, 113b are new. A change in movement or position data compared with the calibration data may indicate wear of the brake lining members 113a, 113b. Calibration data may be obtained in a plurality of conditions, for example at different brake temperatures, braking demands, pressure, loads, etc..

[0078] Drum / brake lining surface / interface condition

[0079] Movement data including vibration data provided by the or each sensor 191a, 191 b, 191c may be used to determine the roughness / smoothness of the or each brake lining interface surface that engages with the drum 111. It is known for the interface surfaces of the drum 111 and / or the lining members 113a, 113b to become glazed over time - reducing the friction value of the interface, and reducing the efficacy of the brakes. Vibration data of a new drum 111 and / or new brake lining member 113a, 113b when the brake is applied may be obtained as calibration data. A vibration profile or signature of a drum / lining combination may depend on the roughness / smoothness of the drum 111 and / or the or each brake lining member 113a, 113b. Calibration data may be compared with in use data, to determine changes in the texture of the lining and / or drum surface over time / following use. Multiple calibration profiles may be obtained, for example at different temperatures and different brake pressures, loads, etc., to improve the accuracy of “in use” monitoring. Calibration data (for example one or more vibration profiles) may be obtained / updated each time maintenance and / or inspection is carried out.

[0080] Calibration may include storing a vibration “signature” or profile of the brake assembly when the brake is applied, i.e. when the or each brake lining member 113a, 113b is brought into contact with the drum 111. The vibration signature will be dependent on the smoothness of the surface of the drum 111 and the surface of the or each lining member 113a, 113b. One or more sensors 194 may be used to obtain the vibration signature of the brake assembly. The vibration signature may be obtained / updated each time the brake linings are replaced for example, and / or when inspections and / or maintenance are carried out.

[0081] The interface between the drum 111 and the or each brake lining member 113a, 113b may become glazed over time, meaning that the required braking force may not be applied. The brake adjuster monitoring system 190 may be configured to indicate that glazing has occurred.

[0082] The surface of the drum 111 may become smoother, such that an in use signal from the or each sensor 191 is different from an expected vibration signature, for example the calibration data, when the brake is applied.

[0083] Figure 5 shows a wheel assembly 20. The wheel assembly 20 includes a hub assembly 21 and an exciter ring 22, provided to enable wheel data to be obtained and transferred to the control device. A sensor 191e may be associated with the exciter ring 22, to obtain movement data, for example vibration data of the wheel assembly. The sensor 191e may be configured / operable to obtain data whilst the vehicle is in operation, for example while driving, and whilst being braked. The data from the sensor 191e may be used in conjunction with ABS data.

[0084] Calibration data may be obtained and used in a similar way as described above. One or more movement (e.g. vibration) profiles may be obtained, for example whilst the vehicle is being braked, for example whilst anti-lock braking is being carried out.

[0085] Drum condition

[0086] The monitoring device 190 may be configured to monitor a condition of the drum 111. The monitoring device 190 may be configured to monitor a shape or cross-section of the drum 111. For example, the drum 111 may become misshapen, for example the drum 111 may not be circular in cross-section. This may occur over time, through use, and / or may occur as a result of an impact or other damage. The drum 111 may be or become substantially oval.

[0087] The monitoring system 190 may include a sensor device 191 e. The sensor device 191 e may be an ABS sensor. Signals from the monitoring system 190 may be compared with data from another sensor. The sensor data with which the monitoring system data is compared may be unaffected by the shape, e.g. ovality, of the drum 111. The other sensor could be a wheel speed sensor, for example. If the drum 111 is not circular, the signal(s) from the monitoring system 190 may exhibit a disturbance or “mismatch” compared with the other signal. The disturbance or mismatch may indicate misshapenness of the drum 111 , for example ovality. The degree of misshapenness determined (e.g. ovality) may be compared with a threshold, and a signal may be provided to the local device 11 and / or to the hub 200.

[0088] Cam condition

[0089] Where a cam member is provided as part of the brake actuation assembly 110, the cam member 114 may become worn over time / with repeated use. Wear of the cam surfaces 114a, 114b may affect the amount of rotation of the cam member 114 and hence of the shaft 152 required to bring the brake lining 113 into contact with the drum 11 1. The monitoring system 190 may be configured to monitor the movement of the shaft 152, for example using a sensor 191 c. The monitoring system 190 may be configured / operable to monitor a wear condition of the or each of the cam surfaces 114a, 114b.

[0090] A bearing provided to facilitate rotation of the shaft 152 may also wear over time / with repeated use, and this may affect a vibration profile, which may be monitored by any or a combination of the sensors 191 a, 191 b, 191 c. Wear of the bearing may also increase the time taken for the actuation assembly 120 to move into / out of the braking condition. The monitoring system 190 may monitor movement of any or all of the shaft 152, the adjuster arm 151 a, the rod 150, to determine a speed of movement. This may be compared with calibration data and / or expected data to determine the condition of the bearing.

[0091] Actuator condition

[0092] The monitoring system 190 may be configured / operable to monitor a condition of the actuator 140. The control device 199 may compare signals from the or each sensor 191 with a measurement of the position and / or movement of the actuator 140, which may be indicative of whether a spring brake of the vehicle 10 is applied and / or whether and to what extent a service brake of the vehicle 10 is applied. If, for example, the signals provided by the monitoring system 190 indicate that the brake assembly 101 , 102 has released, for example that the braking force is removed or reduced, but the actuator 140 is jammed, for example as a result of a broken actuator spring, the controller 199 may be configured / operable to determine that the signals from the monitoring system 199 are not as expected given data from other sensors, for example, which may be indicative of a fault or failure of the actuator.

[0093] Disc brake condition

[0094] The monitoring system 190 may be configured / operable to monitor one or more characteristics / conditions of the disc brake assembly 102.

[0095] A sensor 191 d and / or sensor device 191 f may be provided. The sensor 191 d may be positioned on the actuator 140, for example on an outer surface of the actuator 140. The monitoring system 190 may be operable (configured) to monitor position and / or movement of the actuator 140, which may be indicative of the condition of the brake assembly 120. The actuator 140 may be connected to a caliper of the brake assembly 120, and therefore, the position and / or movement of the actuator 140 may be indicative of position and / or movement of the caliper and / or any other part of the brake actuation assembly 120. The condition may be the thickness or degree of wear of one or both brake pads 122, for example.

[0096] Calibration may be carried out to determine a relationship between the position / movement sensed by the sensor device 191 d and the condition to be monitored.

[0097] The sensor 191 f may be positioned on the brake pad carrier assembly 121 . The monitoring system 190 may be used to monitor the position of a brake caliper on its associated brake torque plate / support bridge mounting frame. Movement, for example, the distance travelled by the or each brake pad 122a, 122b may be monitored to determine the thickness of the or each pad 122a, 122b and or a degree of wear.

[0098] A vibration profile of the disc brake actuation assembly 120 may be monitored, to determine a friction value at the interface between the disc / rotor 123 and the brake pads 122. Polishing of the interface surfaces may occur, reducing the efficacy of the disc brake assembly 120 in slowing the wheel / vehicle 10.

[0099] The monitoring system 190 may be configured to monitor a condition of a disc (rotor) 123 of a disc brake actuation assembly 120. The condition of the disc 123 to be monitored may be “runout” of the disc 123. Runout may occur over time, because of wear or damage, for example, or may be present on installation, because of misalignment of the disc with other components of the disc brake actuation assembly 120. A disc 123 may be installed crookedly, for example not substantially parallel to the wheel hub. Runout means that the distance between the disc 123 and each brake pad member 122 varies as the disc 123 rotates. This fluctuation may be monitored by the monitoring system 190. The condition (e.g. orientation, degree of runout) of the disc 123 may be monitored by monitoring system 190 monitoring the position and / or movement of the actuator 140 and / or movement of the brake pad carrier assembly 121. The condition of the disc 123 as indicated by the monitoring system may be compared with a predetermined threshold or condition, and a signal transmitted to a local device 11 and / or the hub 200 if the predetermined threshold / condition is met or is about to be met.

[0100] Calibration data may be obtained, for example a vibration profile and / or a movement range of the disc brake assembly 120, and used to determine a characteristic of the disc brake assembly 120 when the vehicle is in use, for example whilst being driven and / or when braking.

[0101] When used herein, the term “monitor” is intended to include detect, determine, monitor and / or predict.

[0102] Whilst examples of some conditions and characteristics are referred to and / or described herein, it will be understood that the described examples do not form an exhaustive list of conditions or characteristics that may be monitored, detected, determined and / or predicted. Examples of conditions or characteristics may include position, movement, operational status, failure condition, size, texture (e.g. roughness or smoothness), temperature, wear, speed, acceleration, age, etc.. It will be appreciated that this list is also not exhaustive.

[0103] When used herein, the term “movement” may include intended movement, for example an actuated movement, and / or consequential / unintended movement, for example vibration or resonance, unless a specific type of movement is particularly described.

[0104] Whilst a single monitoring system 190 having one or more sensors 191 is described herein, the vehicle 10 may include a plurality of monitoring systems 190, each having one or more sensors 191. Each monitoring system 190 may be configured to monitor a respective condition or characteristic. Each monitoring system 190 may be independently operable or may be operable in co-operation with other monitoring systems 190 where a plurality of monitoring systems 190 is provided.

[0105] The or each sensor 191 of the or each monitoring system 190 may be independent, and provided in addition to or as an alternative to other sensors described herein. The or each sensor 191 and / or the or each monitoring system 190 may be configurable dependent upon its position. For example, the or each sensor 191 and / or monitoring system 190 may be configured after installation into the vehicle, based upon its location relative to another component, for example the control device 199. This means that a small number of types of sensor 191 and / or monitoring system 190 (e.g. one) may be required - thus simplifying stock control. When a sensor 191 and / or monitoring system 190 is installed, and a communication link is established with the control device 199, data relating to the distance from the control device 199 may pass between the control device 199 and the sensor 191. The control device 199 may be configured to determine where in the vehicle the sensor 191 and / or monitoring system 190 is located, and hence may be configured to determine which condition(s) / characteristic(s) the sensor 191 (and / or its associated monitoring system 190) is intended to monitor. The sensor 191 (and / or the monitoring system 190) may then be configured to operate in accordance with its intended function.

[0106] Calibration of the or each monitoring system 190 may be carried out. Calibration may include determining the relationship between data sensed by the or each sensor device 191 a-f, and the or each condition / characteristic to be monitored. Relationships between conditions and characteristics may be determined. For example, a condition of one component may be indicative of a condition of another component. This may reduce the number of monitoring systems 190 and / or sensor devices 191 required. Calibration may take into account known factors / data and / or environmental conditions which may affect in use data, such that signals or indications made by the monitoring system are as accurate as possible.

[0107] Data provided by the monitoring system 190 may be compared with and / or used in conjunction with and / or modified by data received from other sensors, or data that is otherwise available to the control device 199. The signals provided by the monitoring system 190 may be compared with and / or used in conjunction with other vehicle data. For example, the control device 199 may send and / or receive other signals relating to components of the brake assembly 101 , 102. Other vehicle data may include load data, vehicle / wheel speed, acceleration, and / or deceleration, the duration of a braking event, data relating to a trailer, etc..

[0108] Data from other sources may be used to adjust or correct data from the or each sensor 191 and / or the or each monitoring system 190, and / or vice versa. This may improve the accuracy of the monitoring, and / or reduce the likelihood / frequency of false readings / indications. For example, monitoring the temperature of a brake assembly component may enable the data received from a monitoring system 190 to be adjusted accordingly, or an appropriate data profile or mask to be applied. Adjustment of warm, e.g. used, brakes is different from adjustment of cold brakes, for example because a warm drum 111 expands slightly, altering the distance that each shoe 112 is required to travel to reach the drum 111. Therefore, it is advantageous to know whether the signals provided by the monitoring system 190 relate to a cold brake or a warm brake, so that any determination made based on the position or movement of the brake adjuster for example 151 is as accurate as possible. Tolerances may be applied and / or adjustment of data provided by the or each monitoring system 190 may be carried out, to take factors affecting the data into account. Measured data may be used as this may be more accurate than calculated or assumed data.

[0109] The control device 199 may be configured / operable to diagnose a fault based upon data that is not as expected, or which does not support or is not supported by other data. Signals from the monitoring system 190 may be used to provide an indication of a condition / characteristic to a local user, for example a driver or engineer. If maintenance has been carried out, for example the brake assembly 101 , 102 has been inspected or repaired, it is possible for mistakes to be made in the reassembly of the brake assembly 101 , 102. Providing an indication that the brake adjuster mechanism 151 is not in the expected position for newly replaced brake linings, for example, can alert the user that further inspection and / or adjustment may be required. This has the benefit that the vehicle 10 is less likely to be driven in an undesirable or inappropriate condition, and may also improve the reliability of data supplied by the monitoring system 190 in the future.

[0110] The signals provided by the or each monitoring system 190 may be provided in real-time (or near- real-time) to the hub 200. This may enable vehicle maintenance to be scheduled at an appropriate time, rather than relying on driver reporting, or waiting for actual failure of a component of the brake assembly 101 , 102, which may have knock-on effects, for example damage to other vehicle components, and / or an urgent requirement for maintenance which may be inconvenient for example if the vehicle is not near to a service location and / or if the vehicle is scheduled to be in use, but cannot be, whilst it is inspected / maintenance is carried out.

[0111] Some vehicles, for example fleet vehicles may include communication systems, to enable two-way communication between the vehicle and a control centre, for example. Signals may be provided to a user of the vehicle from the control centre, for example following processing of data transmitted from the vehicle 10 to the control centre. For example, the hub 200 may provide a signal to the control device 199, to cause the driver of the vehicle 10 to be alerted to the fact that inspection or maintenance is advisable or required, for example by illuminating a warning light, or sounding an audible signal.

[0112] Signals or indications provided by the monitoring system 190 may be stored locally or substantially locally, for example by the control device 199, or remotely, for example at the hub 200. Data may be analysed over time for example by the control unit 199 and / or the hub 200, to provide information about the vehicle 10 and / or its components and / or to make assumptions or predictions about the vehicle 10 or its components. For example, patterns may emerge, which may enable more efficient maintenance planning. For example, it may be possible to predict and / or schedule an appropriate time for one or more components of the vehicle 10 to be inspected / maintained / replaced. Where the vehicle 10 is part of a fleet, this may enable more efficient fleet planning, too, since inspection and maintenance schedules may be devised based on individual vehicle data and / or collective data relating to a plurality of vehicles in the fleet. It may be possible for the or each monitoring system 190, the or each sensor 191 , and / or the or each control device 199 to have a dormant state, for example to preserve battery life. The dormant state may be a routinely adopted state, and / or may be adopted after a period of non-use has elapsed. The dormant state may be exited upon receipt of a “wake” command, e.g. a request for data and / or after a predetermined period of time in the dormant state.

[0113] Vehicle components, for example brake system components, are typically checked as part of regular testing and servicing of vehicles, however, replacing parts too soon, in anticipation of failure before the next routine inspection is disadvantageous from an environmental perspective. The present invention enables inspection and replacement of parts at the most appropriate time - for example before actual failure (but not too soon), and / or when the vehicle is near to a service location and / or when the vehicle can be spared, i.e. is not needed for the time taken to carry out the inspection / maintenance. This may also have the advantage that the vehicle completes fewer unnecessary journeys and / or its routes may be optimised, which may also have an environmental benefit.

[0114] When used in this specification and claims, the terms "comprises" and "comprising" and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.

[0115] The invention may also broadly consist in the parts, elements, steps, examples and / or features referred to or indicated in the specification individually or collectively in any and all combinations of two or more said parts, elements, steps, examples and / or features. In particular, one or more features in any of the embodiments described herein may be combined with one or more features from any other embodiment(s) described herein.

[0116] Protection may be sought for any features disclosed in any one or more published documents referenced herein in combination with the present disclosure.

[0117] Although certain example embodiments of the invention have been described, the scope of the appended claims is not intended to be limited solely to these embodiments. The claims are to be construed literally, purposively, and / or to encompass equivalents.

Claims

CLAIMS1 . A vehicle monitoring system including a sensor device configured to obtain sensed data relating to at least one of position and movement of a first component of a brake assembly, the sensor device being configured to transmit the sensed data to a control device of the monitoring system, the control device being configured to monitor a condition of the first component of the brake assembly and / or a second component of the brake assembly based on the sensed data, and to transmit a signal indicative of the monitored condition to at least one of a remote hub and a local device.

2. A vehicle monitoring system according to claim 1 including a plurality of sensor devices.

3. A vehicle monitoring system according to claim 1 or 2 configured to monitor one or more of the following conditions: a brake adjuster condition a brake lining condition a brake lining / drum interface surface condition a drum condition a cam condition a brake pad condition a disc condition an actuator condition a disc brake condition.

4. A vehicle monitoring system according to any of the preceding claims wherein the sensor device is an accelerometer.

5. A vehicle monitoring system according to any of the preceding claims wherein the sensor device is configured to monitor vibration of the component.

6. A vehicle monitoring system according to any preceding claim wherein data obtained by the sensor device is compared with calibration data to determine or predict the condition of the component.

7. A vehicle monitoring system according to any of the preceding claims that is configured to monitor and / or transmit the signal indicative of the condition of the or each component whilst the vehicle is being driven.

8. A vehicle monitoring system according to any of the preceding claims that is configured to monitor and / or transmit the signal indicative of the condition of the or each component during a braking operation.

9. A braking system of a vehicle including a vehicle monitoring system according to any of the preceding claims.

10. A vehicle including a vehicle monitoring system according to any of the preceding claims.

11. A method of monitoring a condition of a first component of a brake assembly, including obtaining at least one of position data and movement data of the first component and / or obtaining at least one of position data and movement data of a second component of the brake assembly, the position and / or movement data of the first and / or second component being indicative of the condition of the first component of the brake assembly, and the method further including transmitting a signal indicative of the condition to at least one of a local device and a remote hub.

12. A method according to claim 11 , including obtaining calibration data indicative of a condition of the first component of the brake assembly, and comparing the position and / or movement data with the calibration data to monitor an in use condition of the first component of the brake assembly.

13. A method according to claim 11 or 12 wherein the position and / or movement data may be combined with one or more of: other data relating to the first component of the brake assembly, data relating to the second component of the brake assembly, data relating to a third component, data relating to a vehicle condition or characteristic.

14. A method according to any of claims 11 to 13 wherein the condition of the first component of the brake assembly is monitored whilst the vehicle is in use.

15. A method according to any of claims 11 to 14 wherein the condition of the first component of the brake assembly is monitored whilst the vehicle is being driven.

16. A method according to any of claims 11 to 15 wherein the condition of the first component of the brake assembly is monitored whilst a braking operation is being carried out.

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