Measurement system for individual wheel alignment of four wheeled vehicles

Abstract

A method of measuring and adjusting the toe of a wheel of a vehicle incudes mounting an alignment plate below the vehicle in parallel with a vehicle centerline. Measuring a first distance from a first reference location of the alignment plate to a first portion of a toe plate disposed against the wheel. Measuring a second distance from a second reference location of the alignment plate to a second portion of the toe plate. Comparing the first distance to the second distance and adjusting a toe of the wheel based upon a difference between the first distance and the second distance.

Description

MEASUREMENT SYSTEM FOR INDIVIDUAL WHEEL ALIGNMENT OF FOUR WHEELED VEHICLESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 698106, filed on September 24, 2024. The entire disclosure of the above application is incorporated herein by reference.FIELD

[0002] The present invention pertains to the field of automobiles and other multiwheeled vehicles. More specifically, it involves a tool designed to align the wheels according to the user's desired direction.BACKGROUND

[0003] In the automotive world, proper wheel alignment is essential for a vehicle to perform correctly. Misalignment can lead to uneven tire wear, tracking problems, and reduced control over the vehicle. Camber, Caster, and Toe are the three primary angles used to align a vehicle’s wheels (See FIG.1 ). Camber refers to the angle of the wheel relative to the vertical plane when viewed from the front (FIG. 1 a illustrates negative and positive camber). Caster refers to the forward or rearward tilt of the steering axis (the pivot line around which the front wheels turn) when viewed from the side of the vehicle (FIG. 1 c illustrates negative and positive caster). Toe refers to the angle of the wheel in relation to the vehicle’s centerline when viewed from above (FIG. 1 b illustrates toe-in and toe-out).

[0004] Current vehicle wheel alignment systems are often bulky, costly, and timeconsuming to set up.

[0005] Professional wheel alignment racks can cost thousands of dollars and are not easily transportable. In racing, alignment strings are often hung off the side of the vehicle to fine-tune toe alignment, but setting them up correctly for a car is time-intensive. A quick method available on the market involves using two plates pressed against opposite wheels on the vehicle, with measurements taken between the front and back of these plates to determine the total toe across an axle. While this method is quick and efficient, it only provides the total toe for the axle and does not allow for measuring theindividual toe of each wheel. What is needed is a tool or system that can address these limitations while remaining quick, inexpensive and efficient.SUMMARY

[0006] This invention utilizes sections of a four-wheeled vehicle to mount one or multiple components to dimensionally reference relative to the wheel alignment. The mounted component / components create one or multiple planes that can be referenced relative to the wheel position. These planes can be positioned either parallel to the vehicle’s centerline or at a predetermined angle, with the primary purpose of measuring and aligning the vehicle's wheel suspension. This measurement plane can be structurally integrated into the vehicle's underbody or designed as a detachable component that securely mounts to the underside of the vehicle. If necessary, the plane can be mounted using various methods, including but not limited to bolts, straps, adhesive, magnets, welds, or any other suitable means. The measurement plane may consist of a single component or an assembly of multiple components. The mount brackets can also be one or multiple components. This assembly can be attached to the vehicle's underbody at one or multiple locations, and these components can also be mounted independently of each other.

[0007] The primary function of the present disclosure is to serve as a reference for accurately determining the individual wheel angles (Camber, Caster, Toe) for one or multiple wheels on the vehicle while the vehicle is in motion or at standstill and under different suspension loads. This component is adaptable to function across all vehicle types and alignment scenarios, ensuring broad applicability and effectiveness.

[0008] This is a design that could be heavily used in Automotive Suspension Engineering to analyze the position of each tire in different dynamic vehicle states, at different ride heights, and on different road surfaces to compare vehicle performance to the measured wheel positions. This design is also beneficial to motorsports racers to understand tire and suspension performance at the racetrack or to prevent accidents through early warnings of failed suspension components.

[0009] One potential use case of this invention utilizes one or more sensors, which may include but are not limited to laser distance sensors, ultrasonic sensors, optical sensors, string potentiometers, rotational angle sensors, or other digital or analog devices, to measure the distance, angle, or positional relationship between the wheel, suspension knuckle, tire, or chassis at one or more locations. These measurement points may be referenced from any portion of the vehicle, including the knuckle, tire, chassis, ora dedicated measurement surface or plate installed within the wheel well, beneath the vehicle, or at another suitable location. The measurement devices may be mounted on either the vehicle chassis, the wheel assembly, or any other suitable structural component.

[0010] By digitally or manually deriving values from these measurements, one or more suspension alignment angles and geometric parameters can be determined. These may include, but are not limited to, camber, caster, toe, Ackerman angle, scrub radius, bump steer, and other related suspension or steering geometries. This type of system may be employed while the vehicle is stationary, in motion, under load, or in varying dynamic conditions, and may operate independently of or in conjunction with vehicle systems.

[0011] In one exemplary implementation, multiple sensors may be positioned to measure distances from the chassis to one or more tire surfaces or suspension components. Variations in measured values between forward and rearward points, upper and lower points, or additional positions can be used to calculate changes in steering angle, camber, toe, or other suspension characteristics. These measurements may also be compared across multiple wheels simultaneously to evaluate system-wide geometry under different operating conditions. Additional sensors or sensor orientations may be employed to expand measurement capability as required.

[0012] One potential use case of the present disclosure would use laser distance sensors, string potentiometers, rotational angle sensors or other digital sensors to measure the distance or angle between the wheel / suspension knuckle and the chassis at one or more locations. By digitally or manually computing the distance between the suspension and the chassis, any or all of the suspension angles can be measured and additional suspension geometry can be interpolated based upon this data. This type of system could be used with the vehicle at a standstill or while driving and can function independently from vehicle use.

[0013] Another potential use case of the present disclosure uses a toe plate or similar device which can be pressed against one wheel on the vehicle, with measurements taken between the measurement plane and the wheel end both in front of and behind the wheel (see FIG. 3 for example). Once the front and rear measurements are compared, the wheel toe can be adjusted by known methods to the desired position.

[0014] The present disclosure specifically covers the individual wheel measurements to reference points on the chassis through one or multiple components.These components / assemblies create a plane that can be used in conjunction with digital measurements or a plate or assembly designed to determine the angle of the wheel or suspension knuckle. Additionally, it can be utilized with various measuring tools, such as measuring tapes, laser measures, or other suitable devices, to provide accurate alignment data.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings in which like references indicate similar elements.

[0016] FIG. 1 illustrates a camber, caster, and toe used to align a vehicle’s wheels;

[0017] FIG. 2 shows a perspective view of a rear mount alignment bracket, according to a first embodiment of the present disclosure;

[0018] FIG. 3 shows a rear view of the rear mount alignment bracket, according to the first embodiment of the present disclosure;

[0019] FIG. 4 shows a side view of the rear mount alignment bracket, according to the first embodiment of the present disclosure;

[0020] FIG. 5 illustrates how an external toe plate could be used one embodiment of the present disclosure to collect the desired dimensions; and

[0021] FIG. 6 is a perspective view of a wheel alignment system that uses laser sensors.DETAILED DESCRIPTION

[0022] Various embodiments and aspects of the disclosure will be described with reference to details discussed below, and the accompanying drawings will illustrate the various embodiments. The following description and drawings are illustrative of the measurement system and method of the present disclosure and are not to be construed as limiting the disclosure. Numerous specific details are described to provide a thorough understanding of various embodiments of the present disclosure. However, in certain instances, well-known or conventional details are not described in order to provide a concise discussion of embodiments of the present disclosure.

[0023] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0024] FIG. 2 shows a rear-left underside view of a vehicle chassis 10 having an alignment plate 12 mounted under the chassis 10. The alignment plate 12 can bemounted under the chassis 10 by a mounting bracket 14. The mounting bracket 14 and the alignment plate 12 are depicted as single pieces that can be bolted together. However, either the alignment plate 12 or the mounting bracket 14 can consist of one or multiple pieces and can be attached under the chassis 10 using bolts, welds, adhesive, or by being molded directly into the chassis. Because the chassis, frame, drivetrain and suspension system of vehicles differ, the mounting bracket may differ for each vehicle type to accommodate mounting under the vehicle. The alignment plate 12 includes a front slot 16 and a rear slot 18, respectively that define measurement points along a measurement plane for measuring the alignment of a wheel 20 as will be described herein. The alignment plate 12 can be easily mounted to and removed from the mounting bracket 14 to perform quick wheel alignment adjustments.

[0025] FIG. 3 presents a rear view of a vehicle 8 with the alignment plate 12 mounted under the chassis 10 at a location inward from the wheel 20. The alignment plate 12 can be attached at any height and positioned either along the vehicle's centerline or offset towards one side and parallel to the vehicle’s centerline, as illustrated in FIG. 3.

[0026] FIG. 4 illustrates the alignment plate 12 mounted under the rear chassis 10 from a vantage point at a side of the right rear wheel 20. The mounting of the alignment plate is shown inward of the rear wheel 20. The front slot 16 and the rear slot 18 on either end of the alignment plate 12 can be used to easily latch a measuring tape in front slot 16 and the rear slot 18 to obtain easy and precise measurements. FIG. 5 illustrates how a toe plate 22 is used on an outside of the rear wheel 20 as a reference to the alignment plate 12. The toe plate 22 is aligned with the exterior surface (or alternatively an interior surface) of the wheel 20. The toe plate 22 has similar front and rear measurement slots 24, 26 to the front slot 16 and the rear slot 18 of the alignment plate 12 for easy and consistent measurements. The tape measure 30 has an end received in the front slot 16 of the alignment plate 12 and a measurement is taken from the front slot 24 of the toe plate 22. The tape measure 30 is then used with the tape measure received in the rear slot 18 of the alignment plate 12 and a measurement is taken from the rear slot 26 of the toe plate 22. These measurements can be used to check the toe angle of the tire so that the appropriate corrections can be made to the toe angle. Alternative to the tape measure, laser distance sensors, string potentiometers, rotational angle sensors or other digital sensors could be used to measure the distance between the alignment plate 12 and the toe plate 22.

[0027] The system of the present disclosure can be used under a front chassis for the alignment of the front wheels. Both the mounting bracket and the alignment plate 12 can be the same or similar to the alignment plate 12 and the mounting bracket 14 shown in FIGS. 2-5, although different hole arrangements can be used to mount the mounting bracket to the front chassis. Both the mounting bracket and the alignment plate 12 can be formed as single pieces. However, either component can consist of one or multiple pieces and can be attached to the chassis using bolts, welds, adhesive, or by being molded directly into the chassis. The referenced design can be easily mounted and removed for quick adjustments. The alignment plate 12 has a front slot 16 and a rear slot 18 on opposite ends of the alignment plate 12 that can be used to easily latch a measuring tape 30 in front and rear to obtain easy and precise measurements as discussed with respect to FIG. 5 so that appropriate toe corrections to the front wheels 20 can be made.

[0028] It should be further understood that an alignment plate 12 can be mounted to a differential or other structure under the chassis by a mounting bracket 14.

[0029] FIG. 6 shows a system for determining a wheel’s camber or toe using either visual or sound wave measurement sensors 50. The sensors 50 can be mounted to the wheel hub / knuckle 52 and a reference surface 54 is mounted to the vehicle sub frame 56. The reference surface 54 can be a plate 57. The visual or sound wave measurement sensors 50 are commonly referred to as a time of flight measurement system in which a visual or audio signal is emitted from the sensor against a reference surface. The sensor 50 detects the time from audio or visual emission to the time of bounce back detected and can determine the distance from the sensor 50 to the reference surface 54 with an accuracy of up to 0.1 mm. Examples sensors include laser measurement sensors, ultrasonic measurement sensors, Bluetooth proximity sensors, although other distance sensors can be used. In the system of FIG. 6, the sensors 50 can be mounted to the knuckle 52 (wheel supporting structure that rotatably supports the wheel and connects to the vehicle suspension system- in the case of the front wheels, the knuckle is a steering knuckle).. It should be understood that the sensors 50 can be alternatively mounted to the vehicle sub frame 56 and the reference surface 54 can be mounted to the knuckle 52. Each of the sensors 50 can be mounted to a plate 58 that can be mounted to either the knuckle 52 or the vehicle sub frame 56. The sensors 50 can include one or more top mounted sensors 50a, 50b (two are shown laterally spaced) and one or more bottom mounted sensor 50c (one of which is shown vertically spaced below the top mountedsensors 50a, 50b). The top mounted sensors 50a, 50b are laterally spaced and can be used to determine the toe of the wheel 20. In particular, the sensors 50a, 50b, 50c can be connected, via wired connection or wireless connection to a processor 60. The processor 60 can be a vehicle onboard processor that can give feedback in real time to a driver of the vehicle that a wheel or wheels are out of alignment through a display screen or audible indicator 62. The processor 60 can be calibrated with the distance that each of the reference surfaces 54 are spaced from a known zero toe and / or zero camber position and if the distance changes as sensed by the sensors 50a-50c, the processor 60 can notify the user of the misaligned condition.

[0030] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well- known processes, well-known device structures, and well-known technologies are not described in detail.

[0031] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0032] When an element or layer is referred to as being "on," “engaged to,” "connected to," or "coupled to" another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," “directlyengaged to,” "directly connected to," or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0033] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0034] Spatially relative terms, such as “inner,” “outer,” "beneath," "below," "lower," "above," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0035] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

CLAIMSWhat is claimed is:

1. A method of measuring and adjusting the toe of a wheel of a vehicle, comprising; mounting an alignment plate below the vehicle in parallel with a vehicle centerline; measuring a first distance from a first reference location of the alignment plate to a first portion of a toe plate disposed against the wheel; measuring a second distance from a second reference location of the alignment plate to a second portion of the toe plate; comparing the first distance to the second distance; and adjusting a toe of the wheel based upon a difference between the first distance and the second distance.

2. The method according to claim 1 , wherein the alignment plate is bolted to a mounting bracket mounted to the vehicle.

3. The method according to claim 2, wherein the mounting bracket is welded to the vehicle.

4. The method according to claim 2, wherein the mounting bracket is bolted to the vehicle.

5. The method according to claim 1 , wherein the first reference location and the second reference location of the alignment plate include a front slot and a rear slot formed in the alignment plate, respectively.

6. The method according to claim 5, wherein the first portion of the toe plate includes a first slot and the second portion of the toe plate includes a second slot.

7. The method according to claim 6, wherein the measuring a first distance from a first reference location of the alignment plate to a first portion of a toe plate includes inserting a tape measure in the front slot of the alignment plate and the first slot of the toe plate and measuring the distance therebetween and the measuring a second distancefrom the second reference location of the alignment plate to a second portion of the toe plate includes inserting the tape measure in the rear slot of the alignment plate and the second slot of the toe plate and measuring the distance therebetween.

8. A method of measuring a wheel alignment of a wheel of a vehicle, comprising; mounting multiple distance sensors to one of a knuckle and a vehicle structure; measuring a first distance from a first distance sensor to a first reference location on the other of the knuckle and the vehicle structure; measuring a second distance from a second distance sensor to a second reference location on the other of the knuckle and the vehicle structure; comparing the first distance to the second distance; and providing an indication of a wheel alignment condition.

9. The method according to claim 8, wherein the wheel alignment condition is a toe angle.

10. The method according to claim 8, wherein the wheel alignment condition is a camber angle.1 1. The method according to claim 8, wherein the multiple distance sensors are laser sensors.

12. The method according to claim 8, wherein the multiple distance sensors are mounted to the knuckle and the reference location is on the vehicle sub frame.

13. The method according to claim 8, wherein the reference location is on a plate mounted to the vehicle sub frame.

14. The method according to claim 8, wherein the multiple distance sensors are mounted to a plate.

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