A control unit for a mining vehicle

Abstract

A control unit for a mining vehicle, the control unit including a processing module this is mountable to the mining vehicle and the control unit having a braking mode that is operable to actuate a braking system of the mining vehicle, wherein the braking mode is actuated upon detection, by the processing module, of either one of a breakaway condition in which the mining vehicle becomes decoupled from a haul vehicle during operation and a rollaway condition in which there is independent movement of the mining vehicle in absence of the haul vehicle.

Description

A CONTROL UNIT FOR A MINING VEHICLERELATED APPLICATION

[0001] The content of Australian provisional patent application no. 2024902378 as filed is hereby incorporated herein in its entirety by reference.TECHNICAL FIELD

[0002] The invention relates to a control unit for a mining vehicle, and more specifically, but not exclusively, to a control unit that operates as a braking device for a towed vehicle such as a mining trailer.BACKGROUND

[0003] Trailers are used frequently in commercial environments, such as in the construction and mining industries, to facilitate the transport of loads / goods such as: raw material; lighting towers; and plant or other miscellaneous equipment. Trailers are towed (typically behind) a prime mover such as a car, truck or mining machinery / equipment. Often, the trailer may itself be a truck or mining machine / piece of equipment, where that truck or mining machine / piece of equipment is required to be transported to another location, such as somewhere else within the mining site. Such trailers include trailer braking systems, the systems being required when towing heavy loads, like those found in mining applications, to meet legal requirements and ensure safe operation.

[0004] Currently, trailers used in the mining industry conventionally operate using 'overrun' or 'override' braking systems. Generally, overrun braking systems operate using the inertia of the trailer when the prime mover decelerates to compress a (typically hydraulic or cable-driven) actuator which actuates the trailer’s braking system. Overrun brake systems are subject to numerous shortcomings. In particular, overrun brake systems are not operable by user selection, owing to their reliance on inertial forces as described. This reliance can cause potentially dangerous delays in braking actuation, and continuous and unnecessary actuation of the brakes when the trailer descends gradients. Use of such overrun braking systems can lead to decreased braking performance, unnecessary additional wear on the braking components, and, consequently, the unsafe transportation of heavy mining loads. Furthermore, overrun braking systems provide no adjustment to braking parameters, and are less durable than their electrical counterparts. This is a particularly salient point when considering the suitability for use with heavy- duty and large weight mining equipment.

[0005] In consumer towing applications, such a general light-duty towing, the adoption of electrical brake controllers has attempted to remedy these shortcomings. Known brake controllers allow for electrical actuation of the trailer braking system. Traditionally, such brake controllers must be connected to a vehicle in order to actuate the braking system of the trailer, the vehicle providing the source of electric power and electric signal therefor. This is problematic when attempting to utilize known electric brake controllers in mining and construction applications, where the trailers are commonly carrying extremely large / heavy loads, and the uneven terrain and environment on which the trailers traverse and are stored is hazardous. Control over the braking system of the trailer, even when decoupled from its prime mover, is therefore paramount.

[0006] Furthermore, there exists the issue of managing trailer braking systems when the trailer is not coupled to a towing vehicle. For example, breakaway has been known to occur in both consumer and mining towing applications. The term breakaway describes the decoupling of the towed vehicle from the towing vehicle during movement. This can be extremely dangerous in consumer towing applications, and is only exacerbated by the typically large size and weights of mining machinery and vehicles. Convention methods for managing trailer braking systems when decoupled from a towing vehicle are extremely limited. 'Breakaway devices' allow for sudden and permanent application of the trailer braking system where a separate, physical connection between the vehicle and trailer is broken (such as when the decoupled trailer and vehicle become distanced from one another). However, such a device can: typically, only be used once before replacement of the physical connection (wires) is required; does not provide control over the braking actuation; and only provides for actuation of the braking system where a breakaway event has occured, and where the vehicles, subsequently, have become spaced far enough away from one another.

[0007] The present invention was conceived with the above shortcomings in mind, and aims to provide the public with a useful alternative to existing mining brake controllers.SUMMARY

[0008] According to a first aspect of the present invention, there is provided a control unit for a mining vehicle, the control unit including a processing module which is mountable to the mining vehicle and the control unit having a braking mode that is operable to actuate a braking system of the mining vehicle, wherein the braking mode is actuated upon detection, by the processing module, of either one of a breakaway condition in which the mining vehicle becomes decoupled from a haul vehicle during operation and a rollaway condition in which there is independent movement of the mining vehicle in absence of the haul vehicle.

[0009] In some embodiments, the rollaway condition may be triggered during hitching of the mining vehicle to the hail vehicle, prior to the coupling of the haul vehicle to the mining vehicle. The control unit may latch in the braking mode until at least one of: the mining vehicle becomes stationary; coupling with the haul vehicle is (re)established; or a set period of time elapses. The control unit may be operable in a passive mode in which the processing module monitors for the rollaway condition. The control unit may be operable in an active mode in which the processing module monitors for the breakaway condition. In the active mode, the processing module may also monitor for a braking event of the haul vehicle and, upon detection, by the processing module, of a braking event, actuates the braking system of the mining vehicle. The control unit may be provided in the form of a portable brake controller that is removably mountable to the mining vehicle. The mining vehicle may be provided in the form of a mining trailer or the like.

[0010] According to a second aspect of the present invention, there is provided a brake controller for a mining vehicle, the brake controller being mountable to the mining vehicle and including a processing module that is operable to actuate a braking system of the mining vehicle upon detection of either one of a braking condition of the mining vehicle or of a braking event of a haul vehicle coupled to the mining vehicle.

[0011] In some embodiments, braking conditions of the mining vehicle include: a breakaway condition in which the mining vehicle becomes decoupled from a haul vehicle during operation; and a rollaway condition in which there is independent movement of the mining vehicle in absence of the haul vehicle. The processing module is configured to actuate the braking system of the mining vehicle upon detection of a braking condition, or of a braking event, in absence of an electrical connection between the brake controller and the haul vehicle. The processing module may be configured to actuate the braking system of the mining vehicle in absence of power from the haul vehicle 18. The mining vehicle may be provided in the form of a mining trailer or the like.

[0012] In some embodiments of the first aspect and / or the second aspect of the present invention, the processing module includes an inertial sensor configured to sense movement of the mining vehicle. The inertial sensor may be configured to measure both forward and lateral acceleration of the mining vehicle. Power for the braking system of the mining vehicle may be supplied by a power module carried on-board the mining vehicle. The on-board power module may include an auxiliary battery that is arranged to actuate the braking system. The control unit and / or brake controller may further comprise a communications module that is configured to transmit an alert to an operator of the mining vehicle. The control unit and / or brake controller may further comprise a remote controller configured to allow a user to adjust or override automatic actuation of the braking system of the mining vehicle by the control unit or brake controller. Theremote controller may include permission settings configured to limit adjustment and / or override of the automatic actuation of the braking system by the remote controller to authorized users.

[0013] According to a third aspect of the present invention, there is provided a method of operating a mining vehicle, including the steps of: mounting a control unit to the mining vehicle; electrically connecting the control unit to a haul vehicle; coupling the mining vehicle to a haul vehicle; and automatically actuating a braking system of the mining vehicle upon detection, by the control unit, of a braking condition of the mining vehicle or a braking event of the haul vehicle.

[0014] According to a fourth aspect of the present invention, there is provided a method of operating a mining vehicle, including the steps of: monitoring for movement of the mining vehicle; listening for an electrical connection of the mining vehicle with a haul vehicle; and permitting operation of the mining vehicle only when the electrical connection with the haul vehicle is established.

[0015] According to a further aspect of the present invention, there is provided a method of towing a mining vehicle with a haul vehicle, including the steps of: mounting a control unit to the mining vehicle, the control unit operable to actuate a braking system of the mining vehicle upon detection of movement of the mining vehicle in absence of the haul vehicle; and electrically connecting the mounted control unit to the haul vehicle such that the control unit recognises the presence of the haul vehicle to permit movement of the mining vehicle.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:Figure 1 is a perspective view drawing of a control unit and a remote controller in accordance with an embodiment of the present invention;Figure 2 is a side view drawing of the control unit of Figure 1 , the control unit being mounted to a mining vehicle;Figure 3 is a side view drawing of the control unit of Figure 1 , the control unit being mounted to a mining vehicle coupled to a haul vehicle and shown within a mining site;Figure 4 is a side view drawing of the control unit of Figure 3, the control unit, mining vehicle and haul vehicle being shown in isolation;Figure 5 is a flowchart showing operation of a control unit in accordance with an embodiment of the present invention;Figure 6 is the flowchart of Figure 5, including example logic operations for each condition;Figure 7 is a flowchart showing a method of operating a mining vehicle in accordance with an embodiment of the present invention;Figure 8 is a flowchart showing another method of operating a mining vehicle in accordance with an embodiment of the present invention; andFigure 9 is a flowchart showing a method of towing a mining vehicle with a haul vehicle in accordance with an embodiment of the present invention.DETAILED DESCRIPTION

[0017] In the following detailed description, reference is made to accompanying drawings which form a part of the detailed description. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings may be arranged, substituted, combined, separated and designed in a wide variety of different configurations, all of which are contemplated in this disclosure.

[0018] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the example methods and materials are described herein.

[0019] In general terms, the invention shown in the Figures comprises a control unit 10 for a mining vehicle 14, the control unit 10 including a processing module 12 this is mountable to the mining vehicle 14 and the control unit 10 having a braking mode X that is operable to actuate a braking system 20 of the mining vehicle 14, wherein the braking mode X is actuated upon detection, by the processing module 12, of either one of a breakaway condition B in which the mining vehicle 14 becomes decoupled from a haul vehicle 18 during operation of the mining vehicle 14 and a rollaway condition R in which there is independent movement of the mining vehicle 14 in absence of the haul vehicle 18.

[0020] In this specification, the terms "haul vehicle" and "mining vehicle" are taken to refer, respectively, to a machine for transport such as a car, utility vehicle, tractor, machinery or a truck, and to a machine for mining, being powered or unpowered, such as a trailer, machinery or a truckthat is towed or towable by a haul vehicle. Whilst the description will refer specifically to haul vehicles and mining vehicles, it is understood that application of the invention is not so limited, and that the invention may also be used with other mining-related vehicles, including those with tracks (such as, for example, continuous tracks or tracked treads) rather than wheels, immobile machinery or equipment, and / or other prime movers, being sources of motive power.

[0021] Aspects and / or embodiments of the control unit 10 and / or brake controller 22 disclosed herein are understood to be particularly suitable for use with a haul and mining vehicle. However, aspects and / or embodiments of the control unit 10 and / or brake controller 22 disclosed herein may also be suitable for use with conventional construction (and related industry) vehicles and equipment. Further still, aspects and / or embodiments of the control unit 10 and / or brake controller 22 disclosed herein may be suitable for use with conventional passenger / consumer vehicles and equipment, such as, for example, caravans and other light(er)-duty vehicles and equipment.

[0022] In this specification, the terms "electrical" and "electronic" are taken to refer, respectively, to the flow of power between two interconnected devices and the flow of signals between two interconnected devices. It is also understood that such connections are not mutually exclusive, that is that two interconnected devices may be both electrically and electronically connected simultaneously, however this is not necessarily the case.

[0023] Turning now to Figure 1 , a control unit 10 is shown. The control unit 10 includes a processing module 12, which is mountable to the mining vehicle 14. The module 12 may be mountable to the mining vehicle 14 in a variety of locations, including within or proximate other electronic components thereof. In the case of a trailer or similar unpowered mining vehicle 14, the module 12 is preferably mounted proximate a draw bar or coupling 16 of the mining vehicle to which a haul vehicle 18 is able to be coupled (as shown in Figure 2).

[0024] The control unit 10 is primarily for use with mining vehicles 14 that are being, or require being, towed by haul vehicles 18. Accordingly, the mining vehicles 14 described herein are ones which include a coupling 16 for coupling with such a haul vehicle 18. It is contemplated that the mining vehicle 14, therefore, is preferably in the form of a mining trailer or the like. Such mining vehicles 14, and therefore also the control unit 10 disclosed herein, are particularly suited to mining sites 40 as shown in Figure 3. A mining site 40 is a work site or work area, and its surrounds, wherein mining operations occur. Put differently, a mining site 40 may take the form of a surface mine or an underground mine, as well as the working roads, infrastructure and facilities surrounding the mine.

[0025] Turning to Figure 4, a mining vehicle 14 can be seen coupled to a haul vehicle 18. The coupling 16 may be any coupling provided it couples the mining vehicle 14 to the haul vehicle 18 such that the haul vehicle can tow or pull the mining vehicle in use. Accordingly, it is contemplated that the coupling 16 could be, for example, a conventional ball hitch, a pintle hitch, or a gooseneck coupling. Further still, the coupling 16 may be simply recovery chain or similar towing chain, rope or strap connected to opposing ends of the mining vehicle 14 and haul vehicle 18 for towing purposes.

[0026] The connection between the control unit 10 and the haul vehicle 18 describes an electrical (and electronic) connection, rather than the physical coupling between the haul vehicle 18 and mining vehicle 14 provided by the coupling 12. Accordingly, it is understood that the haul vehicle 18 includes a wiring harness or powered system, and that the mining vehicle can tap into this system, and be provided movement and braking information, among other things, by this system, through the electrical connection therebetween. While unimportant to the inventive aspects of the present invention, it is contemplated that an electrical plug or the like is used to provide this electronic connection. In preferred embodiments, the electrical connection is provided as part of, adjacent to or at least proximate the physical coupling 12.

[0027] The processing module 12 has a braking mode X that is operable to actuate a braking system 20 of the mining vehicle 14. What is meant by this is that, when operated, the module 12 is configured to activate the brakes of the mining vehicle 14. In this way, the braking mode X can be thought of as an 'actuating' mode, being the time or circumstance within which the brakes of the mining vehicle 14 are actively being applied to brake / slow the vehicle 14. In the case of electric braking systems, the module 12 simply provides the power, or electronically triggers a separate unit which provides the power, to operate the brake calipers, drums or other braking component, and cause braking to occur. The control unit 10, however, is suitable for use with a wide range of braking systems. Including any system which utilises electronic or electric triggers to actuate the brakes, or which can be modified to do so. Accordingly, the unit 10 is suitable, at least, for any system with electric or electronic actuation of either of a drum or caliper braking components. The braking mode X is triggered when any one of a plurality of predefined conditions is met and detected by the module 10. The conditions include a breakaway condition B and a rollaway condition R. When the requirements of at least one of these conditions is met, the processing module 12 activates the braking system 20 of the mining vehicle 14 to which it is mounted.

[0028] A breakaway condition B refers to a condition in which the mining vehicle 14 becomes decoupled from a haul vehicle 18. In particular, this condition describes a breakaway event, where, at the time of decoupling, both the mining vehicle 14 and the haul vehicle 18 are moving. Typically, breakaway occurs due to a fault in the coupling 16 or way in which the vehicles 14, 18were coupled. Such a condition can be extremely dangerous, as the haul vehicle 18 loses all control over the mining vehicle 14 which it is towing when the decoupling occurs. Accordingly, it is advantageous that there exists a way to, safely and in a controller manner, stop the decoupled mining vehicle 14 from continuing its movement. Operation of the unit 10, in response to a breakaway condition B, achieves this.

[0029] A rollaway condition R is met when there is independent movement of the mining vehicle 14 in absence of the haul vehicle 18. Accordingly, this condition R is met when the mining vehicle 14 is not coupled to a haul vehicle 18. Accordingly, a rollaway condition R typically occurs during a period of storage of the mining vehicle 14. A rollaway condition R, however, might also occur while the mining vehicle 14 has been towed to a location for use, before being towed back or to a further location, by the haul vehicle 18. For example, where the mining vehicle 14 is a wheeled waste receptacle for mining materials, the mining vehicle 14 may be coupled to a haul vehicle 18 and towed to a location for loading mining materials into the mining vehicle 14, during which the haul vehicle 18 is decoupled and used for another unrelated purpose. A rollaway condition R describes unintended and unwanted movement of the mining vehicle 14 separately from the haul vehicle 18, such as, for example, where the mining vehicle 14 is parked on an incline, and due to the incline, begins to roll away unintentionally and under the power provided by the incline alone.

[0030] It is understood that the rollaway condition R may be triggered via detection of movement resulting from the hitching of the mining vehicle 14 to the haul vehicle 18. In such circumstance, (electrical) connection or hitching of the control unit 10 to the haul vehicle 18 may occur prior to (physical) coupling of the haul vehicle 18 to the mining vehicle 14. This processing module 12 monitors for such situation in the time leading up to the mining vehicle 14 being coupled to the haul vehicle 18. By monitoring for such hitching situations, the control unit 10 may provide peace of mind than an incorrect order of operations undertaken during hitching / physical coupling will not cause a roll-away event, activating the brakes of the mining vehicle 14 should movement be caused during the physical coupling with the haul vehicle 18.

[0031] The control unit 10 is configured such that, when at least one of a breakaway B or rollaway R conditions is met, and the processing module 12 has actuated the braking system 20 of the mining vehicle 14, the control unit 10 latches (i.e., via a latching or latch switch which maintains the current state until another input is received) in the braking mode (i.e., continues to actuate the braking system 20), until at least one of: the mining vehicle 14 becomes stationary; coupling the haul vehicle 18 is (re)established; or a set period of time elapses. Accordingly, in a typical breakaway condition, where reestablishment of the coupling to the haul vehicle 18 is unlikely or impossible, the control unit 10 remains in the braking mode until either the miningvehicle 14 becomes stationary, or a set period of time elapses. It is contemplated that this response may be adjusted by a user of the control unit 10, and may be varied dependent on local regulations and laws in the area of operation. For example, use of the control unit 10 in Australia, pursuant to regulations applicable at the time of filing this patent application, deem that, in circumstances of 'breakaway', the mining vehicle 14 should automatically apply its brakes for at least 15 minutes. Similarly, it is contemplated that in circumstances of 'rollaway', the mining vehicle 14 should automatically apply its brakes until such time as the mining vehicle 14 determines that it has become stationary. This response may also be customisable to include more complexly defined periods of time, such as, for example, the brakes may be applied: until the mining vehicle 14 becomes stationary and thirty four seconds has elapsed thereafter; or twice the time spent applying the brakes until the vehicle 14 became stationary. In cases of reestablishment of the coupling to the haul vehicle 18, it is contemplated that such reestablishment may be detected by a return of the taillight or brake light signal / s. To determine that the vehicle 14 has become stationary, the unit 10 may utilise the inertial sensor 28 (described below). In exemplary embodiments, it is contemplated that the control unit 10 will be capable of actuating the braking system 20 of the mining vehicle 14 by an algorithm configured to reduce the power requirements for braking. What is meant by this is that, rather than applying a full force to the braking system 20, the control unit 10 may be configured to slowly increase the braking force, such that the mining vehicle 14 is able to be braked and / or become stationary using a lower amount of power than the aforementioned method. Advantageously, a control unit 10 with an algorithm for reducing power requirements during actuation of the braking system allows that the power module 24 which powers actuation of the braking system 20 (described later in more detail) may be of a lower capacity of smaller size than otherwise required.

[0032] The control unit 10 is operable in a passive mode P. In this mode, the processing module 12 is configured to monitor for independent movement of the mining vehicle 14 (i.e., movement without or separately from the haul vehicle 18, such as a rollaway condition R). Put differently, the passive mode P can be thought of as a 'listening' mode, in which the mode P iteratively 'listens' for movement occurring. The passive mode P is contemplated as being a low power-consuming operation mode, such that it is suitable to retain the unit 10 in the mode P while the mining vehicle 14 is being stored (or otherwise decoupled from the haul vehicle 18), even for long periods of time.

[0033] The control unit 10 is further operable in an active mode A. The active mode A is applicable when the mining vehicle 14 and haul vehicle 18 are coupled, the control unit 10 is electrically connected to the haul vehicle 18 and the haul vehicle 18 is actively towing the mining vehicle 14 (i.e., both vehicles are currently moving). In the active mode A, the processing module is configured to monitor for decoupling of the mining vehicle 14 from the haul vehicle 18 (i.e., abreakaway condition B). In this way, the active mode A can be thought of as an 'interrogating' mode, in which the mode A iteratively interrogates whether the unit 10 is receiving a brake light and / or tail light signal from the haul vehicle 18, and / or whether the / either vehicle is moving.

[0034] The active mode A and passive mode P, together, provide for safer operation of mining and haul vehicles 14, 18. Until such time as the active mode A is entered, the unit will essentially react to any movement of the mining vehicle 18 as movement that is in absence of the haul vehicle 18 (i.e., a rollaway condition R) and thus enter the braking mode X to prevent further movement. Accordingly, until such time as the unit 10 transitions from the passive mode P to the active mode A, the mining vehicle 18 is effectively inoperable. In this way, in use, an operator cannot attempt to tow a mining vehicle 14 using a haul vehicle 18, until the operator has coupled the haul vehicle 18 to the mining vehicle 14, connected the unit 10 to the haul vehicle 18, and applied the brakes lights or the park lights in the haul vehicle 18 to cause the unit 10 to transition from passive mode P to active mode A.

[0035] In some embodiments, when in the active mode A, the processing module 12 also monitors for a braking event of the haul vehicle 18, and, upon detection of such an event 310, actuates the braking system 20 of the mining vehicle 14 (i.e., in conjunction with the braking system of the haul vehicle 18 which triggers the braking event thereof). In this way, the control unit 10 is additionally operable similarly to a brake controller. In some embodiments, the control unit 10 may be provided in the form of a portable brake controller that is removably mountable to the mining vehicle 14. What is meant by this is that the control unit 10, rather than being a standalone control unit 10 as described, may be a combined control unit 10 and brake controller or be provided with (such as together in a kit, within the same housing, or integrally connected to) a brake controller.

[0036] Figures 5 and 6 schematically illustrate operation of the control unit 10 described herein, Figure 6 being a duplicate of Figure 5, but which further includes 'logic' operations behind the various modes and conditions the control unit 10 is capable of utilising during operation. As can be seen, when the unit 10 is mounted to the mining vehicle 14 but before or without coupling of a haul vehicle 18 thereto, the unit 10 is in the passive mode (shown in the Figures by a grey park sign). Here, provided there are no issues, mistakes or incidents resulting in a braking condition / braking mode X being activated (i.e., a rollaway condition R), the haul vehicle 18 can be coupled to the mining vehicle 14, and begin towing it. Once movement is detected, in this scenario, the unit 10 will enter active mode A (shown in the Figures by a 'tick' mark) where braking by the unit 10 occurs when a braking event of the haul vehicle 18 is detected, so to equally / adequately actuate the braking system 20 of the mining vehicle 14 to the brakes of the haul vehicle 18.

[0037] While in the active mode A, and both vehicles 14, 18 are moving, a breakaway may occur, i.e., the mining vehicle 14 may become decoupled from the haul vehicle 18. In such a case, as can be seen in the Figures, the unit 10 enters the breakaway condition B (shown in the Figures by a hazard sign), and operates as described for that condition.

[0038] The roll away condition R occurs prior to the unit 10 being placed into active mode A. In a rollaway condition, the mining vehicle 14 is not coupled to the haul vehicle 18. Shown in the Figures by a red park sign, if, while in the passive mode P, movement of the mining vehicle 14 is detected, the unit 10 will enter the rollaway condition R to prevent further movement thereof. Similarly, if, while in the passive mode P, the unit 10 detects that the mining vehicle 14 has become electrically hitched to the haul vehicle 18 without being physically coupling to said haul vehicle 18 by the coupling 16, the unit 10 will also enter the rollaway condition R should the mining vehicle 18 experience movement during coupling to the haul vehicle 18.

[0039] Also disclosed herein is a brake controller 22 for a mining vehicle 14, the brake controller being mountable to the mining vehicle 14 and including a processing module 12 that is operable to actuate a braking system 20 of the mining vehicle 14 upon detection of either one of a braking condition of the mining vehicle 14 (i.e., any one of a breakaway condition B or rollaway condition R), and of a braking event of a haul vehicle 18 coupled to the mining vehicle 14.

[0040] Advantageously, the processing module 12 of the brake controller 22 is configured to actuate the braking system 20 of the mining vehicle 14 upon detection of a braking condition B, R, H or of a braking event in absence of an electrical connection between the brake controller 22 and the haul vehicle 18. What this means is that the processing module 12 of the brake controller 22 is configured to actuate the braking system 20 of the mining vehicle 14 even in absence of receiving power (for doing so) from the haul vehicle 18.

[0041] In order to power the braking system 20 of the mining vehicle 14, therefore, the control unit 10 or brake controller 22 are supplied with power by a power module 24. The power module 24 is carried on-board the mining vehicle 14. In preferred embodiments, it is contemplated that the power module 24 comprises an existing power module of the mining vehicle 14. For example, in the case of a mining trailer 14, the power module 24 may comprise an auxiliary battery 26 mounted to or housed within the mining trailer 14. Alternatively, such as in the case of a hydraulically operated mining vehicle braking system 20, the power module 24 may instead, or additionally to the auxiliary battery, comprise a hydraulic power unit (or 'HPU'), as is common in conventional prime movers and large trucks.

[0042] To monitor and detect a braking event of the haul vehicle 18, the control unit 10 and / or brake controller 22 utilise an inertial sensor 16. The sensor 28 is housed on or within the mining vehicle 14, preferably being a component of the control unit 10 or brake controller 22 and therefore within a housing of casing thereof. By result of this housing location, the sensor 28 is configured to sense movement of the mining vehicle 14. The sensor 28 is configured to measure at least forward (and backward) acceleration, whereby it can detect and measure movement occurring forward and backward in the mining vehicle 14. In exemplary control units 10 and brake controllers 2, the sensor 28 is additionally configured to measure lateral acceleration of the mining vehicle 14. The sensor 28 described is in the form of a multi-axis accelerometer. Where the sensor 28 measures no acceleration in any direction, the sensor 28 may therefore be able to detect that the vehicle 14 to which it is mounted is stationary (or has recently become stationary). In exemplary embodiments, the sensor 28 may be configured to utilise a standard deviation of acceleration readings in order to determine a relative stationary where it is not possible to find perfectly stationary measurements (such as, for example, where the vehicle 14 is proximate a mining site and large vibrational forces affect a perfect 'zero' acceleration reading). However, other sensor types, capable of measuring at least a forward acceleration or movement, would also be suitable for use without departure from the present invention.

[0043] Along with the inertial sensor 16, the control unit 10 and brake controller 22 are capable of determining whether or not a haul vehicle 18 is coupled to the mining vehicle 14 by detecting an electrical connection between the unit / controller 1 , 2 and the haul vehicle 18, referred to as connection sensor 38. The connection sensor 38 is preferably a virtual sensor (and is not shown in the Figures), which determines connection by simply looking to see if a parking light or braking light signal of the haul vehicle 18 is being received by the unit / controller 1 , 2. The connection sensor 38, therefore and along with the inertial sensor 16, provides the requisite information to the processing module 12 such that any one of the conditions B, R, H can be detected.

[0044] The control unit 10 and / or brake controller 22 also include a remote controller 32. The remote controller 32 is configured to allow an operator / user of the unit / controller 1 , 2 to adjust and / or override the (automatic) actuation of the braking system 20 of the mining vehicle 14 when one of the aforementioned condition or mode results in actuation. What is meant by this is that the controller 32 allows overriding of the system, such that it does not actuate the brakes, and / or adjustment of braking parameters, such as, for example, adjusting the response of the unit / brake controller 10, 2. For example, adjustments may result in an increase or decrease the braking force, effort, amount of time actuated. For example, different brake responses may be provided for different operator preferences, haul vehicle 18, or loads carried by the mining vehicle 14. It is contemplated that the remote controller 32 is wirelessly connectable to the unit / controller 1 , 2such that an operator can cause the override or adjustment without having to physically interact with the unit / controller 1 , 2. In exemplary embodiments, the controller 32 may be simply provided by way of a smart phone app or the like. Alternatively, the controller 32 may be a hard-wired controller, which is provided proximate a dashboard of the haul vehicle 18.

[0045] In view of the nature in which mining vehicles 14 typically have multiple operators and are used in commercial settings, the controller 32 also include permission settings 34 (not shown in the Figures). The permissions settings 34 provide a limitation on the adjustment and / or override that the controller 32 can provide. It is contemplated that multiple controller 32 may be communicable with a single unit / controller 1 , 2. In such a case, the permissions settings 34 allow a limitation of the adjustment and / or override to be based on individual operators. For example, a site manager may be provided permissions settings 34 which allow total control over the operation of the unit / controller 1 , 2, whilst an employee who is only authorised to drive haul vehicles 18, would be provided permissions settings 34 which allow them to adjust the braking parameters, but not to override the automatic actuation of the braking system 20 entirely. Accordingly, by virtue of the permission settings 34, the unit 10 / controller 22 described herein is particularly useful in commercial mining settings.

[0046] The control unit 10 and / or brake controller 22 additionally comprises a communications module 30. The communications module 30 is configured to transmit an alert 36 (not shown in the Figures) to an operator of the mining vehicle 14 and / or haul vehicle 18. The alert 36 may be transmitted in a variety of methods. In particular, exemplary embodiments which include a remove controller (as described above), include a communications module 30 which transmit the alert 36 to the operator by / via the remote controller. Advantageously, this allows an operator to receive alerts 36 without having the requirements of being within visual and / or audible range of the unit / controller 1 , 2 itself. It is contemplated that the alerts 36 at least include an alert for notifying the operator when a power / voltage level in the auxiliary batter 26 (or otherwise the power module 14) falls below an acceptable (predefined) level. For example, where the mining vehicle 14 is a mining trailer using a conventional twelve-volt auxiliary battery 16, this alert would provide the operator with notification when the voltage level of the auxiliary battery 26 falls to or below nine volts. The alert 36 may also include an alert for notifying the operator of a breakaway condition B. This is particularly advantageous as, especially in very large haul vehicles 18, it can be difficult to immediately ascertain that a breakaway condition B has occurred. Thus, the alert 36 can provide the operator this essentially immediate notification, and the operator can safely brake and stop the haul vehicle 18 while the braking system 20 of the mining vehicle 14 brakes and stops the mining vehicle 14. Such an alert 36, therefore, substantially reduces the potential for damage or injury risk during a breakaway condition B.

[0047] A method 100 of operating a mining vehicle 14 will now be described with reference to Figure 7. The method refers to use of a control unit 10, however it is understood that the method 100 may instead use any / another control unit, provided that such a unit is capable of undertaking / providing of the steps of the method 100. Furthermore, it is contemplated that the unit used may instead or additionally be a brake controller 22 as described.

[0048] A first or 'mounting' step 110 comprises mounting a control unit 10 to the mining vehicle 14.

[0049] The second or 'connecting' step 120 then provides that the control unit 10 is electrically connected to a haul vehicle 18.

[0050] The third or 'coupling' step 130 then provides that the mining vehicle 14, to which the control unit 10 is mounted, is coupled to the haul vehicle 18. While this step 130 is described as the third step, it is understood that this step 130 is interchangeable in order with step 120 (the 'connecting' step). Furthermore, the control unit 10 may be electrically connected to the haul vehicle 18 at the same time as the mining vehicle 14 being physically coupled to the haul vehicle 18. Accordingly, step 120 and 130 may occur simultaneously or at least at approximately the same time.

[0051] Following the these steps, the control unit 10 can be considered installed onto / to the mining vehicle 14, and the control unit 10, therefore, ready to operate. Accordingly, a next and final 'actuating' step 140 comprises the automatic actuation of a braking system 20 of the mining vehicle 14 upon detection, by the control unit 10, of a braking condition B, R, H of the mining vehicle 14, or of a braking event of the haul vehicle 18.

[0052] A method 200 of towing a mining vehicle 14 with a haul vehicle 18 is also disclosed herein, and will now be described with reference to Figure 8.

[0053] In a first or 'monitoring' step 210, the mining vehicle 14 is monitored for independent movement. During this step, for example, a control unit 10 or brake controller 22 that is mounted to the mining vehicle 10 may monitor for movement of the mining vehicle 14 via the processing module 12 thereof.

[0054] In a second or 'listening' step 220, a presence of an electrical connection between the mining vehicle 14 and a haul vehicle 18 is listened or otherwise tracked. During this step, for example, the control unit 10 or brake controller 22 mounted to the mining vehicle 10 may monitor for an establishment of such electrical connection by way of, for example, detection signals from brake lights or a brake light circuit of the haul vehicle 18.

[0055] In a third or 'permitting' step 330, operation of the mining vehicle 14 is only allowed or otherwise permitted once the electrical connection with the haul vehicle 18 is established and / or maintained. Put differently, in absence of the electrical connection, operation of the mining vehicle 14 is prohibited or otherwise prevented. During this step, for example, the control unit 10 or brake controller 22 mounted to the mining vehicle 10 may, upon detection of movement of the mining vehicle 14, actively apply the brake system 20 thereof (and therefore prohibit operation of the vehicle 14) in absence of such electrical connection.

[0056] A method 300 of towing a mining vehicle 14 with a haul vehicle 18 is also disclosed herein, and will now be described with reference to Figure 9.

[0057] In a first or 'mounting' step 310, a control unit 10 is mounted to the mining vehicle 14. It is contemplated that the control unit 10 is one of the control unit's 10 as previously described. However, it may be another / different control unit 10, provided that it is a control unit 10 which is operable to actuate a braking system 20 of the mining vehicle 14 upon detection of movement of the mining vehicle 14 in absence of the haul vehicle 18.

[0058] In a second or 'electrically connecting' step 320, the mounted control unit 10 (from step 610) is electrically connected to the haul vehicle 18 such that the control unit 10 recognises the presence of the haul vehicle 18.

[0059] In a third or 'movement permitting' step 330, the mounted control unit 10 permits movement of the mining vehicle 14 (i.e., without actuating the braking system thereof). It is contemplated that the method 300 may effectively describe the operation of the control unit 10 when transitioning from the passive mode P to the active mode A. In this way, the method 300 provides for safe towing of a mining vehicle 14, wherein the operator may only begin towing the mining vehicle 14 once this transition from passive mode P to active mode A is complete.

[0060] Summarily, it is to be understood that the control unit 10 and brake controller 22 described herein both provide several performance advantages and improvements over typical, existing mining brake controllers. For example, the functionality of the control unit 10 allows actuation of a mining vehicle's braking system when either or a breakaway or a rollaway condition occurs. Traditional existing breakaway devices restrict actuation of the braking system to at a time when the vehicles become decoupled due to their reliance on a physical connection therebetween which actuates the braking system when it becomes disconnected. Accordingly, the control unit 10 described not only provides for rollaway braking as well as breakaway braking, but also provides for complex and advanced control over the braking of the mining vehicle due to its use of sensors and logic rather than physical cabled connections. Furthermore, the control unit canbe provided in the form of a brake controller, which simultaneously provides active brake control over the braking of the mining vehicle required in response to braking events of the haul vehicle. As such, the control unit, when in the form of a combined brake controller, allows total and sophisticated control of the braking system of the mining vehicle from a single device which is mountable to the vehicle. Finally, existing breakaway devices and brake controllers are configured for use predominantly with passenger 4WD vehicles, and typically are constrained to use with road going vehicles. The feature of permissions settings, and the structure and form which the unit and controller described herein take, allows them to be particularly and uniquely useful for mining operations, use with mining machinery and vehicles and for use in a mining site.

[0061] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not by way of limitation. It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the present invention should not be limited by any of the above-described exemplary embodiments.

[0062] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

[0063] Throughout this specification and the claims which follow, unless the context requires otherwise, the word ‘comprise’, and variations such as ‘comprises’ and ‘comprising’, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.LIST OF REFERENCES

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:1 . A control unit for a mining vehicle, the control unit including a processing module which is mountable to the mining vehicle and the control unit having a braking mode that is operable to actuate a braking system of the mining vehicle, wherein the braking mode is actuated upon detection, by the processing module, of either one of a breakaway condition in which the mining vehicle becomes decoupled from a haul vehicle during operation and a rollaway condition in which there is independent movement of the mining vehicle in absence of the haul vehicle.

2. The control unit according to claim 1 , wherein the control unit latches in the braking mode until at least one of: the mining vehicle becomes stationary; coupling with the haul vehicle is (re)established; or a set period of time elapses.

3. The control unit according to claim 1 or claim 2, wherein the control unit is operable in a passive mode in which the processing module monitors for the rollaway condition.

4. The control unit according to any one of claims 1 to 3, wherein the control unit is operable in an active mode in which the processing module monitors for the breakaway condition.

5. The control unit according to claim 4, wherein, in the active mode, the processing module also monitors for a braking event of the haul vehicle and, upon detection, by the processing module, of a braking event, actuates the braking system of the mining vehicle.

6. The control unit according to any one of the preceding claims, wherein the control unit is provided in the form of a portable brake controller that is removably mountable to the mining vehicle.

7. The control unit according to any one of the preceding claims, wherein the mining vehicle is provided in the form of a mining trailer or the like.

8. A brake controller for a mining vehicle, the brake controller being mountable to the mining vehicle and including a processing module that is operable to actuate a braking system of the mining vehicle upon detection of either one of a braking condition of the mining vehicle or of a braking event of a haul vehicle coupled to the mining vehicle.

9. The brake controller according to claim 8, wherein braking conditions of the mining vehicle include: a breakaway condition in which the mining vehicle becomes decoupled from ahaul vehicle during operation; and a rollaway condition in which there is independent movement of the mining vehicle in absence of the haul vehicle.

10. The brake controller according to claim 8 or claim 9, wherein the processing module is configured to actuate the braking system of the mining vehicle upon detection of a braking condition, or of a braking event, in absence of an electrical connection between the brake controller and the haul vehicle.1 1. The brake controller according to any one of claims 8 to 10, wherein the processing module is configured to actuate the braking system of the mining vehicle in absence of power from the haul vehicle.

12. The brake controller according to any one of claims 8 to 1 1 , wherein the mining vehicle is provided in the form of a mining trailer or the like.

13. The control unit or brake controller according to any one of the preceding claims, wherein the processing module includes an inertial sensor configured to sense movement of the mining vehicle.

14. The control unit or brake controller according to any one of the preceding claims, wherein power for the braking system of the mining vehicle is supplied by a power module carried onboard the mining vehicle.

15. The control unit or brake controller according to claim 14, wherein the on-board power module includes an auxiliary battery that is arranged to actuate the braking system.

16. The control unit or brake controller according to claim 15, further comprising a communications module that is configured to transmit an alert to an operator of the mining vehicle.

17. The control unit or brake controller according to any one of the preceding claims, further comprising a remote controller configured to allow a user to adjust or override automatic actuation of the braking system of the mining vehicle by the control unit or brake controller.

18. The control unit or brake controller according to claim 15, wherein the remote controller includes permission settings configured to limit adjustment and / or override of the automatic actuation of the braking system by the remote controller to authorized users.

19. A method of operating a mining vehicle, including the steps of:mounting a control unit to the mining vehicle; electrically connecting the control unit to a haul vehicle; coupling the mining vehicle to a haul vehicle; and automatically actuating a braking system of the mining vehicle upon detection, by the control unit, of a braking condition of the mining vehicle and / or a braking event of the haul vehicle.

20. A method of operating a mining vehicle, including the steps of: monitoring for movement of the mining vehicle; listening for an electrical connection of the mining vehicle with a haul vehicle; and permitting operation of the mining vehicle only when the electrical connection with the haul vehicle is established.

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