A portable semi-trailer axle alignment detection system with auto-calibration and semi-automatic features and methods of detection.

Abstract

Invention discloses a portable Semi-Trailer Axle Alignment Detection System with Auto-calibration & Semi-Automatic Operation features and methods of detection. Designed to achieve precise alignment of axle concerning semi¬ trailer's chassis main beam. It comprises axle alignment detection device, optical reflectors, external device (LDR sensor, Magnetic Axle Alignment Axis Marker or Magnetically Mounted External Line Laser Module) and an OLED display module. System is equipped with auto- calibration capabilities, to adjust automatically based on real-time sensor feedback, ensuring accurate alignment without need for manual recalibration. It features user-friendly operation modes, including both manual and semi-automatic settings, accommodating varying user preferences. Arrangement of components ensures compactness, portability, easy setup for workshops & on-site scenarios, can withstand harsh conditions and supports frequent use, reliable, quick, and precise alignment solutions for semi-trailer industry.

Description

TITLE

[0001] A Portable Semi-Trailer Axle Alignment Detection System with Autocalibration and Semi-Automatic features and methods of detection.FIELD OF THE INVENTION

[0002] The present invention relates to the field of semi-trailer vehicle maintenance, particularly the axle misalignment detection. The present invention discloses novel portable semi-trailer axle alignment detection system with autocalibration and semi-automatic feature invented utilizing advanced technologies, including line laser modules and Light Dependent Resistor (LDR) sensors, to ensure the precise perpendicular alignment of the axle with respect to the semi-trailer chassis main (longitudinal) beam. This system enhances the efficiency and accuracy of the axle alignment process while reducing the reliance on cumbersome traditional manual methods.BACKGROUND

[0003] Proper axle alignment is critical for the safe and efficient operation of semitrailers. Misalignment can lead to increased tire wear, reduced fuel efficiency, and compromised handling, posing significant risks to vehicle safety and performance. Traditional axle alignment methods often involve manual measurements from the kingpin to the axle, requiring disconnection from the towing vehicle. This process is labour-intensive, time-consuming, and prone to human error, resulting in inconsistencies that can affect overall alignment precision.

[0004] Thus there is a need in the transportation industry for innovative solutions which is simplified and enhance the accuracy of axle alignment detection, faster process, cost effective, and is not labour intensive.

[0005] The present invention discloses a portable Semi-Trailer Axle Alignment Detection System with auto-calibration and semi-automatic features that addresses these challenges by providing a more efficient and reliable meansof ensuring that the axle is aligned correctly with respect to the chassis longitudinal beam or chassis main beam.

[0006] The present system utilizes advanced components such as line laser modules,Light Dependent Resistor (LDR) sensors, and a magnetic axle alignment axis marker to facilitate accurate alignment checks. By integrating autocalibration and semi-automatic operative features, the present system minimizes the need for manual adjustments and ensures real-time feedback, significantly improving the overall alignment process, compact and portable due to the easy set-up, making it convenient for use in workshop or on-site.

[0007] The present invention not only enhances operational efficiency but also contributes to safer vehicle operation, ultimately benefiting fleet operators, maintenance facilities, and the transportation industry as a whole.SUMMARY

[0008] The present invention discloses a portable Semi-Trailer Axle Alignment Detection System having Auto- calibration and Semi-Automatic features for detection of axle misalignment and help calibration. The system comprising an axle alignment detection device which have a fixed mounting assembly, a rotary assembly, optical reflector, external device (which may be LDR sensor or Alignment Axis marker or an external Line Laser) and an OLED display, all operatively connected.

[0009] The fixed mounting assembly comprise an USB Power interface, a SPST rocker switch, Wi-Fi-enabled microcontroller (ESP32), an internal power source or battery with a charging module, a sound emitting device, a servo motor with an arm, a thrust bearing assembly and magnet.

[0010] The rotary assembly with a rotary coupling shaft comprising a line laser module, a Light Dependent Resistor (LDR) sensor, a vertical projection aperture located on the RMA base, a vertical optical sensing aperture located on the RMA housing wall, a horizontal projection aperture located on the RMA base, and a horizontal optical sensing aperture located on the RMA housing wall.

[0011] The optical reflector capable of being magnetically mounted on the semi-trailer chassis main beam.

[0012] The axle alignment detection device is capable of being magnetically mounted on the chassis beneath the trailer floor.

[0013] The axle alignment detection system provides at least three different methods to detect alignment by using either LDR sensor or Alignment Axis marker or an external Line Laser along with the axle alignment detection device.BRIEF DESCRIPTION OF DRAWINGS

[0014] Fig. 1.1 further illustrates various views of the Axle Alignment Detection Device, in accordance with embodiments of the present disclosure. The views include:Fig. IF: A three-dimensional view, seen from a front bottom isometric perspective.Fig. 1G: A three-dimensional view, seen from a rear top isometric perspective. Fig. 1H: A three-dimensional view, seen from a rear bottom isometric perspective.

[0015] Fig. 1.2 illustrates various views of the magnetic mounting of the Axle Alignment Detection Device, in accordance with embodiments of the present disclosure. The views include:i. Fig. 1.2A: A three-dimensional view, seen from a front bottom isometric perspective.ii. Fig. 1.2B: An exploded view of Fig. 1.2A, seen from above, illustrating individual components.

[0016] Fig. 1.3 is an exploded view of the three-dimensional view of the Axle Alignment Detection Device, seen from a front top isometric perspective, in accordance with embodiments of the present disclosure.

[0017] Fig. 1.4 illustrates various views of the Axle Alignment Detection Device, in accordance with embodiments of the present disclosure. The views include:i. Fig. 1A: A two-dimensional front view.ii. Fig. 1A1: A section view of Fig. 1A, oriented from the center toward the left.

[0018] Fig. 2.1 illustrates various views of the Axle Alignment Detection Device, in accordance with embodiments of the present disclosure. The views include: Fig. 2A1: A three-dimensional view, seen from a rear top right isometric perspective.Fig. 2A2: A view showing internal components without the housing, as in Fig.2A1.Fig. 2A3: A view of additional components without the internal component enclosure, as in Fig. 2A2.Fig. 2A4: A further view of additional components without the internal component enclosure, as in Fig. 2 A3.Fig. 2A5: A view of further additional components without the internal component enclosure, as in Fig. 2A4.Fig. 2A6: A view illustrating further components without the internal component enclosure, as in Fig. 2A5.

[0019] Fig. 2.2 illustrates various views of the Axle Alignment Detection Device, in accordance with embodiments of the present disclosure. The views include: Fig. 2B1: A three-dimensional view, seen from a rear top left isometric perspective.Fig. 2B2: A view showing internal components without the housing, as in Fig.2B1.Fig. 2B3: A further view of the internal components, as in Fig. 2B2. Fig. 2B4: A view illustrating the internal components without the housing, as in Fig. 2B3.Fig. 2B5: A view of the internal components without the housing, as in Fig.2B4.Fig. 2B6: A view illustrating the internal components without the housing, as in Fig. 2B5.

[0020] Fig. 2.3 illustrates various views of the Axle Alignment Detection Device, in accordance with embodiments of the present disclosure. The views include: Fig. 2C1: A three-dimensional view, seen from a rear bottom right isometric perspective.Fig. 2C2: A view showing internal components without the housing, as in Fig.Fig. 2C3: A further view of the internal components, as in Fig. 2C2. Fig. 2C4: A view illustrating the internal components without the housing, as in Fig. 2C3.Fig. 2C5: A view of the internal components without the housing, as in Fig.2C4.Fig. 2C6: A view illustrating the internal components without the housing, as in Fig. 2C5.

[0021] Fig. 3 illustrates various views of the LDR sensors and line laser module mount assembly, which is part of the rotatory mounting assembly within the axle alignment detection device, a component of the semi-trailer axle alignment detection system, in accordance with embodiments of the present disclosure. The views include:Fig. 3A: A two-dimensional front view, showing the transparent mount, revealing internal elements, including the LDR sensor and Optical Projection System.Fig. 3B: A three-dimensional view of Fig. 3A, seen from a front bottom right isometric perspective.Fig. 3C: An exploded view of Fig. 3B, seen from above.

[0022] Fig. 4 illustrates various views of the magnetically mounted LDR sensor module, which is a components of the semi-trailer axle alignment detection system, in accordance with embodiments of the present disclosure. The views include:Fig. 4.1: A three-dimensional view of the LDR sensor module, seen from a front top right isometric perspective.Fig. 4.2: A view showing internal components with the transparent housing, as in Fig. 4.1.Fig. 4.3: An exploded view of Fig. 4.1, seen from above.Fig. 4.4: A two-dimensional top view.

[0023] Fig. 5 illustrates various views of the axle alignment detection device, along with the magnetically mounted optical reflector mounted on chassis main beam and the magnetically mounted LDR sensor module mounted on the axle. This configuration, as outlined in Detection Method 1, is utilized to check axle alignment. These components are part of the semi-trailer axle alignmentdetection system, in accordance with embodiments of the present disclosure. The views include:Fig. 5.1: A two-dimensional front view.Fig. 5.2: A three-dimensional view, seen from a front top right isometric perspective.

[0024] Fig. 6 illustrates various views of the magnetically mounted axle alignment axis marks, which are components of the semi-trailer axle alignment detection system, in accordance with embodiments of the present disclosure. The views include:Fig. 6.1: A two-dimensional top view.Fig. 6.2: A two-dimensional side view.Fig. 6.3: A three-dimensional view, seen from a front top right isometric perspective.Fig. 6.4: An exploded view of Fig. 6.3, seen from above.

[0025] Fig. 7 illustrates various views of the axle alignment detection device magnetically mounted underside of the semi-trailer floor, including the magnetically mounted optical reflector on chassis main beam and magnetically mounted axle alignment axis marks mounted on axle. This configuration, as outlined in Detection Method 2, is used to check axle alignment. These components are part of the semi-trailer axle alignment detection system, in accordance with embodiments of the present disclosure. The views include:Fig. 7.1: A two-dimensional front view.Fig. 7.2: A three-dimensional view, seen from a front top right isometric perspective.

[0026] Fig. 8 illustrates various views of magnetically mounted external line laser module, which are components of the semi-trailer axle alignment detection system, in accordance with embodiments of the present disclosure. The views include:Fig. 8.1: A three-dimensional view, seen from a front top left isometric perspective.Fig. 8.2: A three-dimensional view, seen from a front top right isometric perspective.Fig. 8.3: A detailed view of Fig. 8.2, showing the magnetic mounting, transparent optical projection system mount, and transparent protective housing, revealing internal elements, including the optical projection system. Fig. 8.4: An exploded view of Fig. 8.3, seen from above.Fig. 8.5: A three-dimensional view, seen from a front top left isometric perspective.Fig. 8.6: A three-dimensional view, seen from a front top right isometric perspective.Fig. 8.7: An exploded view of Fig. 8.6, seen from above.

[0027] Fig. 9 illustrates various views of the axle alignment detection device magnetically mounted underside of the semi-trailer floor, including the magnetically mounted optical reflector on chassis main beam and magnetically mounted external line laser module mounted on axle. This configuration, as outlined in Detection Method 3, is used to check axle alignment. These components are part of the trailer axle alignment detection system, in accordance with embodiments of the present disclosure. The views include:Fig. 9.1: A two-dimensional front view.Fig. 9.2: A three-dimensional view, seen from a front top right isometric perspective.

[0028] Fig. 10 illustrates various views of the axle alignment condition, in accordance with embodiments of the present disclosure. The views include:Fig. 10.1: A two-dimensional top view showing the axle in a misalignment condition.Fig. 10.2: A two-dimensional top view showing the axle in a proper alignment condition.

[0029] A misalignment condition exists when there is an angular deviation between the vertical line laser beam projection (whether via laser Multi-Dot Projection as a Straight Line or Line laser beam Projection) and the axle alignment axis.

[0030] A proper alignment condition exists when there is no angular deviation between the vertical line laser beam projection (whether via laser Multi-DotProjection as a Straight Line or Line laser beam Projection) and the axle alignment axis.

[0031] Fig. 11 illustrates various views of the display module, a component of the semi-trailer axle alignment detection system, in accordance with embodiments of the present disclosure. The views include:Fig. 11.1: A three-dimensional view, seen from a front top left isometric perspective.Fig. 11.2: A detailed view of Fig. 11.1, showing the transparent enclosure, revealing internal elements, including the display screen and a Wi-Fi-enabled microcontroller (ESP32), seen from a front top left isometric perspective. Fig. 11.3: An exploded view of Fig. 11.2, seen from above.

[0032] Fig. 12 illustrates the electronic circuit block diagram of the semi-trailer axle alignment detection system’s device, including the axle's LDR sensor module, external line laser module, axle alignment axis marks, and display module for detection. It comprises the following sub-figures:Fig. 12.1: Electronic circuit block diagram of the axle alignment detection device.Fig. 12.2: Electronic circuit block diagram of the external line laser module. Fig. 12.3: Electronic circuit block diagram of the display module.Fig. 12.4: Electronic circuit block diagram of the LDR sensor module.

[0033] Fig. 13: Process flow block diagram for the axle alignment detection system for detection method 1. This diagram illustrates the sequence of steps involved in detecting axle alignment, detailing the flow of operations from initiation to the final output.

[0034] Fig. 14: Process flow block diagram for the axle alignment detection system for detection method 2. This diagram illustrates the sequence of steps involved in detecting axle alignment, detailing the flow of operations from initiation to the final output.

[0035] Fig. 15: Process flow block diagram for the axle alignment detection system for detection method 3. This diagram illustrates the sequence of steps involvedin detecting axle alignment, detailing the flow of operations from initiation to the final output.

[0036] Fig. 16: illustrates various views of the semi-trailer chassis main beam’s magnetically mounted optical reflector, which are components of the semitrailer axle alignment detection system, in accordance with embodiments of the present disclosure. The views include:Fig. 16.1: A three-dimensional view, seen from a front top left isometric perspective.Fig. 16.2: An exploded view of Fig. 16.1, seen from above.DESCRIPTION

[0037] Nothing in this specification shall be interpreted to limit the scope of the present invention.

[0038] The present invention discloses a portable Semi-Trailer Axle Alignment Detection System with Auto-calibration and Semi-Automatic features, and methods of misalignment detection using the said system. The present system is a novel system which aligns the axle perpendicular to the chassis main beam of heavy-duty vehicles, such as semi-trailers with enhanced accuracy.

[0039] In a preferred embodiment, the portable semi-trailer axle alignment detection system comprising axle alignment detection device, an optical reflector, an external device fitted on the semi-trailer axle, and an OLED all operatively connected and / or arranged.

[0040] In a preferred embodiment the axle alignment detection device comprises three section of components - a fixed mounting assembly with a magnetic mount on the top of the fixed mounting assembly; a rotary mounting assembly arranged below and fixed to the base of the fixed mounting assembly housing.

[0041] In a preferred embodiment, the fixed mounting assembly have a housing with a base; and accommodates an USB Power interface [3] with an interface mount [5], a SPST rocker switch [6], an Wi-Fi-enabled microcontroller (ESP32) [9]with a charging module mount

[0010] , an internal power source or battery

[0014] with a protective housing

[0012] along with a battery charging module

[0011] , a sound emitting device

[0015] or buzzer within a protective housing

[0012] , a servo motor

[0017] comprising an arm

[0018] operatively connected to coupling and bearing mount

[0019] , and a thrust bearing assembly with a fixed mounting assembly base

[0023] , wherein the thrust bearing assembly comprising a housing washer

[0022] , a cage

[0021] with rolling element, a shaft washer

[0020] .

[0042] In another preferred embodiment, the magnetic system mounting system [1] comprises a mounting bracket [1.1] and magnet [1.2].

[0043] In another preferred embodiment, the rotary mounting assembly (RMA) comprises a housing which is connected to the fixed mounting assembly housing through a rotary coupling shaft. The RMA housing further comprises a line laser module, a Light Dependent Resistor (LDR) sensor, a projection system mount which accommodates the LDR sensor

[0027] and the Line Laser module

[0026] , a vertical projection aperture [31A] located on the RMA

[0030] base, a horizontal projection aperture [31B] located on the RMA housing

[0029] wall, a vertical optical sensing aperture [32A] located on the RMA base

[0029] , and a horizontal optical sensing aperture [32B] located on the RMA housing

[0029] wall.

[0044] The rotary mounting assembly is responsible for accurate line laser positioning. The fixed mounting assembly accommodates various components and provides strong magnets for stable attachments. The magnetic mounting makes it easy to attach and remove the axle alignment detection device during the alignment process. The axle alignment detection device and the system can be powered by an internal battery backup, external power bank, or connected to the semi-trailer’s power line with step-down voltage converter, ensuring flexibility in various operating conditions.

[0045] In another preferred embodiment the external device may be any one of LDR sensor, or an Axle Alignment Axis marker, or an external line laser. Based on the choice of external device, the system offers at least three different detection method. Similarly, by using any similar external device to perform required function, is covered under the scope of the present invention.

[0046] In another embodiment, in a LDR sensor module, the LDR sensor

[0027] placed on a sensor housing [35A] with a base [35C] together fitted on a mounting bracket [35D] and the module is enabled to be magnetically mounted on the semi-trailer axle. The LDR module housing [35B] is fitted with a USB Power Interface [4], a power input interface mount [5], a Wi-Fi enabled microcontroller [9].

[0047] In another embodiment, the Magnetically Mounted Optical Reflectors (34) mounted on the semi-trailer chassis main beam (37) is a crucial components of the Semi-Trailer Axle Alignment Detection System. It reflects the horizontal line laser beams (36B) back to the horizontal LDR sensors (27) of the alignment device (33). This reflection is essential for determining the perpendicular alignment status of the axle (39) with semi-trailer chassis main beam (37), enabling the system to assess whether the axle is properly aligned or requires further adjustment. Reflective Surfaces

[0041] of these reflectors are constructed from high-quality mirrors or flexible mirror sheets, ensuring accurate line laser beam reflection with minimal distortion.

[0048] In an embodiment, the reflectors (34) are equipped with a magnetic mounting mechanism, comprising a durable mounting bracket (42) and strong magnets (1.2). This design facilitates secure installation on the semi-trailer’s chassis main beam (37), allowing for quick attachment and detachment without the need for drilling or permanent modifications. This ensures a firm hold during operation, enhancing the overall reliability of the alignment process.

[0049] In another embodiment, the LDR sensor housing (35A) comprises a total of 13 rows, each equipped with a pair of LDR sensors—one positioned on the left and one on the right side. This configuration results in a total of 26 LDR sensors (13 pairs), allowing for comprehensive detection of the vertical line laser beam across multiple points along the axle.

[0050] In another embodiment, the Axle Alignment Axis marker module [35.1] comprise a raised marks panel [35.1 A] with raised marks [35.1C] on a mounting bracket [35.1B] enabled to be magnetically mounted.

[0051] In another embodiment, Line Laser Module [35.2] comprise a line laser

[0026] in a module housing

[0046] with a removable panel

[0047] fitted with a USB power interface [4], a power input interface mount [5], arranged on a mount bracket [44, 48] enabled to be magnetically mounted.

[0052] In a preferred embodiment, the alignment system works by positioning the semi-trailer axle (39) perpendicular to the chassis main beam (37). For portability, the system features magnetic mounting options, allowing the device (33) to be securely attached to the semi-trailer’s underside floor

[0038] and the optical reflectors (34) to be securely attached to the semi-trailer chassis main beam (37). The LDR sensor module (35) or Magnetic Axle Alignment Axis Marker (35.1) or Magnetically Mounted External Line Laser Module (35.2), to be securely attached to the axle (39). This provides a seamless and accurate alignment procedure through advanced projection, sensing, and feedback mechanisms, effectively overcoming the limitations of traditional methods.

[0053] In a preferred embodiment, the system adjusts itself automatically using feedback from sensors, ensuring accurate alignment without requiring manual adjustments which is the auto-calibration feature of the system.

[0054] In the present invention the perpendicular alignment detection method uses a magnetically mounted optical reflector (34) and LDR sensor module (35) or magnetic axle alignment axis marker (35.1) or magnetically mounted external line laser module (35.2) along with the device’s line laser module (26) and LDR sensors (27) to detect and confirm axle alignment.

[0055] The LDR Sensors and Line Laser Modules provides highly accurate detection and feedback for alignment, using the horizontal and vertical line laser module (26) and LDR sensors (27). The Line Laser Module / optical Projection system includes horizontal and vertical line laser modules positioned perpendicularly to each other. The optical projection system (26) employs line lasers to ensure precise alignment detection. This technology enables the system to provide accurate measurements and assessments of axle alignment. These line lasermodules are responsible for projecting line laser beams used to detect the alignment of the axle with respect to the chassis main beam and the axle. The LDR Sensor or the Optical Sensor (27) include horizontal and vertical LDR sensors, also positioned perpendicularly to each other, and are tasked with detecting the reflected or projected line laser beams for alignment feedback. Both the line laser modules (26) and LDR sensors (27) are mounted on an LDR sensor and Projection System Mount (28). This mount is housed within the Rotary Mounting Assembly Housing (29) of the device’s rotating mounting assembly (33).

[0056] The horizontal line laser module projects the line laser beam (36B) toward the optical reflector (34), which is mounted on the chassis main beam (37).

[0057] The vertical line laser module projects the line laser beam (36A) toward the LDR sensor module (35) or Magnetic Axle Alignment Axis Marker (35.1), which is mounted on the axle (39).

[0058] The projected line laser beams pass through the Optical Sensing Apertures (32A, 32B) and Projection System Apertures (31A, 31B), allowing for vertical and horizontal alignment detection. This ensures that the axle is properly aligned in relation to the trailer's chassis main beam, providing real-time feedback for precise axle alignment.

[0059] In a preferred embodiment, the alignment process is controlled by a servo motor (17), which rotates the optical projection system mounted on an LDR sensor and projection system mount (28) within a rotary mounting assembly housing (29) until alignment is achieved. The servo motor (17) is securely mounted on a servo motor mount (16), with the servo motor arm (18) facilitating precise adjustments. The servo motor’s rotation is supported by a thrust bearing shaft washer (20), thrust bearing rolling element with cage (21), thrust bearing housing washer (22), and a bearing housing (23) to ensure smooth movement. The rotary coupling shaft (24) transmits rotational force to the rotary mounting assembly top (25) for precise angular adjustments.

[0060] In a preferred embodiment, as the servo motor (17) rotates the rotary mounting assembly, it aligns the horizontal line laser module (26) perpendicular with the magnetically mounted optical reflector (34) mounted on the semi-trailer chassis main beam (37). Once the horizontal line laser beam projection (36B) is aligned and detected by the LDR sensors (27), theservo motor (17) stops. The system then checks the vertical line laser beam projection (36A) alignment with the magnetically mounted LDR sensor module (35) on the semi-trailer axle (39). If the alignment is perfect, the buzzer (15) in a protective housing (13) emits a sound to notify the use. ESP32 (9) forms the core of the control system. It processes signals from the LDR sensors (27) and controls the servo motor (17). This ESP32 (9) is mounted on a dedicated microcontroller and charging module mount (10) within the device (33).

[0061] In a preferred embodiment in Alignment Feedback and display mechanism, the buzzer (15) in device (33) provides audible feedback when the axle is aligned. Additionally, a display screen (50), mounted in a display module housing (51), offers visual feedback to the user, showing the alignment status in real-time. The screen is protected by a display module top enclosure (49) and integrates with the ESP32 (9) via the display module base enclosure (52).

[0062] The alignment status feedback is transmitted wirelessly from the device’s ESP32 (9) to the ESP32 (9) in the display module using Wi-Fi signals, ensuring that the user receives real-time updates regarding the axle alignment. This wireless communication allows for more flexible monitoring of the alignment process without requiring direct physical connections between the device and the display.

[0063] The ESP32 (9) in the LDR Sensor Module (35) plays a crucial role in processing signals from the LDR sensors (27) when they detect the vertical laser beam (36A).

[0064] Upon simultaneous detection of the beam by both the left and right LDR sensors, the ESP32 wirelessly communicates this alignment data to the main ESP32 (9) in the alignment detection device (33) via Wi-Fi.

[0065] Once the main ESP32 receives confirmation of proper axle alignment, it triggers the buzzer, providing real-time audio feedback to the operator. This feedback mechanism ensures that the operator is promptly informed of the axle's alignment status, facilitating quick adjustments if necessary and enhancing the overall efficiency of the axle alignment process.

[0066] The axle alignment detection system provides real time feedback showing alignment status on a display, allowing for quick adjustments on the spot. Its small setup makes it compact and portable, making it convenient for use in workshops or on-site.

[0067] In a preferred embodiment the axle alignment detection system detects misalignment using axle alignment detection device and LDR sensor module.

[0068] In another preferred embodiment the axle alignment detection system detects misalignment using axle alignment detection device and Axle Alignment Axis marker module.

[0069] In another preferred embodiment the axle alignment detection system detects misalignment using axle alignment detection device and an external line laser module.

[0070] The axle alignment detection system Axle Alignment Method comprising first a parallel alignment (front -to- back) followed by a second perpendicular alignment (side-to-side).

[0071] In the Parallel Alignment (Front-to-Back Alignment), the axle

[0039] is aligned to be parallel to the semi-trailer’s longitudinal centerline or chassis main beam (37). This ensures that the axle (39) runs in line with the semi-trailer’s length. The alignment is done by measuring the distance from the kingpin (the point that connects the semi-trailer to the tractor) or a reference point on the trailer to the axle ends on both sides. If the distances are equal, the axle is considered to be properly aligned.

[0072] In the Perpendicular Alignment (Side-to-Side Alignment), the axle (39) is aligned to be perpendicular to the semi- trailer's chassis main beam (37) or chassis, ensuring the axle is straight across the width of the trailer. This method involves aligning the axle at a 90-degree angle to the semi-trailer's main beam. Systems such as line laser alignment tools (like the one in this invention) help achieve this by using perpendicular line laser projections and sensors to check whether the axle is misaligned or correctly positioned.

[0073] Proper alignment in both methods ensures balanced tire wear and improves fuel efficiency by reducing drag.

[0074] Alignment detection - The vertical line laser beam (36A) is projected toward the axle from the alignment detection device. Upon striking a pair of LDR sensors within the LDR sensor module (35), the sensors detect the beam (36A), confirming that the axle is vertically aligned, meaning it is perpendicular to the chassis main beam (37). This detection process is verified when both the left and right LDR sensors of a respective pair simultaneously detect the beam (36A). This simultaneous detection signifies that the axle is properly aligned. However, if any angular deviation is detected, the system indicates misalignment of the axle, prompting manual adjustments. These adjustments must continue until the laser beam (36A) is parallel to the raised rows of LDR sensors, ensuring proper vertical alignment of the axle with the chassis main beam.

[0075] In a preferred embodiment, the axle alignment detection system uses the magnetically mounted LDR sensor module

[0035] as the external device fitted on the axle of the semi-trailer, corresponding Figure 5. In this method involves first the horizontal line laser module (26) projects line laser beams (36B) towards the optical reflector (34) mounted on the chassis main beam (37). Then the reflected laser beams (36B) from the optical reflector returns to the horizontal LDR sensor (27) inside the device (33), confirming horizontal alignment. The vertical line laser module (26) projects line laser beams (36A) toward the LDR sensors (27) of the magnetically mounted LDR sensor module (35) on the axle (39). The detection of these vertical laser beams (36A) by the LDR sensors (27) confirms that the axle (39) is vertically aligned, ensuring it is perpendicular to the chassis main beam (37). Proper alignment is achieved when the axle (39) is perpendicular to the semi-trailer chassis main beam (37). This is confirmed by ensuring the device (33) is aligned perpendicularly to the chassis main beam with no angular deviation between the vertical line laser beams (36A) and the axle alignment axis (40).

[0076] In a preferred embodiment, the axle alignment detection system uses magnetic Axle Alignment Axis Marker, corresponding Figure 7. In this method the horizontal line laser module (26) projects line laser beams (36B) toward the optical reflector (34) mounted on the chassis main beam (37). Then the optical reflector reflects laser beams (36B) which are detected by the horizontal LDR sensor (27) of the device

[0033] , confirming horizontal alignment. Then the vertical line laser module (26) projects vertical laser beams (36A) towards the Magnetic Axle Alignment Axis Marker (35.1) mounted on the axle (39). Whenthe vertical laser beams (36A) strike the raised mark on the marker, it indicates proper vertical alignment of the axle, confirming it is perpendicular to the chassis main beam.

[0077] In a preferred embodiment, the Magnetic Axle Alignment Axis Marker (35.1)(reference to FIG. 6 and 7) serves as a manual alignment tool and a reference for the axle alignment axis, providing an alternative to the LDR Sensor Module (35) within the axle alignment detection system. The marker is specifically designed to identify any angular deviation between the vertical line laser beams (36A) and the axle alignment axis (40). The raised mark panel (35.1A) features multiple raised marks (35.1C) arranged in a row, parallel to the axle alignment axis. These raised marks work in conjunction with the axle alignment axis marks mounting bracket (35.1B), which ensures accurate positioning of the marker along the axle.

[0078] The alignment is confirmed when there is no angular deviation, indicating that the vertical line laser beams (36A) are parallel to the raised marks (35.1C) on the raised mark panel (35.1A). This visual representation enables operators to easily assess whether the axle is correctly aligned, facilitating precise adjustments as necessary. The marker’s magnetic mount ensures easy and secure attachment to the axle without causing any permanent modifications.

[0079] In a preferred embodiment, the axle alignment detection system uses magnetically Mounted External Line Laser Module [35.2], corresponding Figure 8 and 9. In this method the horizontal line laser module (26) projects line laser beams (36B) toward the optical reflector (34) mounted on the chassis main beam (37). The optical reflector reflects laser beams (36B) which are detected by the horizontal LDR sensor (27) of the device (33), confirming horizontal alignment. The magnetically mounted external line laser module (35.2) on the axle (39) projects vertical line laser beams (36AA) toward the vertical LDR sensor (27) of the device (33). The detection of the vertical laser beams (36AA) by the LDR sensor (27) in the device (33) confirms that the axle is vertically aligned, ensuring it is perpendicular to the chassis main beam. This functionality, combined with the module's magnetic mounting and realtime signal processing, ensures accurate and efficient axle alignment detection, minimizing setup time and reducing the margin of error in axle positioning. The integration of wireless feedback via the device's ESP32microcontroller ensures that the operator receives real-time information about the alignment status.

[0080] Magnetic Mounting: Equipped with strong magnets and a mounting bracket, the module can be securely attached to the axle without requiring permanent modifications. This magnetic setup allows for quick positioning and removal, making the module highly adaptable to different operational environments. The module is powered via a USB connection to the main device (33), ensuring uninterrupted operation during the alignment process.

[0081] The Magnetic Mounting Mechanism allows for easy installation across various trailer models, without the need of drilling. This feature ensures a secure attachment during operation, providing stability and reliability.

[0082] Non-magnetic fixation is achieved using Allen bolts, washer, screws.

[0083] In another embodiment, the system operates on a versatile power supply system, utilizing either a rechargeable battery or an external source. This flexibility allows the device to function effectively under different conditions, accommodating diverse operational environments. The power supply and control system is a crucial component of the Semi-Trailer Axle Alignment Detection System. It can be powered through various means an internal battery backup, an external power bank, or by connecting to the semi-trailer’s power line via a step -down voltage converter. This system provides power to the Device (33), LDR sensor module (35), and Display module.

[0084] In another embodiment, the internal power source consists of a rechargeable battery (14) housed within an internal power source protective housing (12). The battery is charged via a USB power interface (4) connected to a charging module (11), which is securely mounted on the power input interface mount (5). The power system is controlled by an SPST rocker switch (6), allowing the user to manage the power supply to the device.

[0085] The ESP32 microcontroller serves as the brain of the device, managing all functions and processing sensor data. It facilitates seamless communication between components, ensuring efficient operation and data handling.

[0086] The device features a buzzer and display screen that provide immediate feedback on alignment status. This feature keeps operators informed about the axle's position, enhancing decision-making during the alignment process.

[0087] In a preferred embodiment, the auto-calibration process (reference Figure 1.3,3, 5, 7, 9, 10, 13, 14, 15 and 16) involves, firstly, Initial Setup and Self-Testingwherein upon powering the device (3) using the USB power interface (4) and activating the SPST rocker switch (6), the ESP32 (9) conducts a self- test. This self- test ensures all components, such as the servo motor (17) and LDR sensors (27), are functioning correctly before alignment begins. Secondly, Detection of Laser Beams wherein the servo motor (17) rotates the laser module (26) from 0 to 180 degrees. As the rotary mounting assembly of the device (33) rotates, the LDR sensors (27) detect the reflected laser beams from the optical reflectors (34). The microcontroller (9) continuously monitors the sensor readings to determine when the laser beams are reflected back accurately. Thirdly, User Feedback and Confirmation, wherein once the autocalibration process is complete, the servo motor (17) get stop and may display a message on the OLED display screen (50) indicating that it has successfully calibrated. If misalignment persists, the system can provide troubleshooting instructions or alert the user to manually check the optical reflector positions.

[0088] The present system and methods have the following advantages over the traditional setup:i. Quick Setup: Magnetic mounting allows for fast, tool-free installation of components, enabling rapid deployment.ii. Auto- Calibration: The system automatically calibrates itself by verifying the alignment of the horizontal laser beam, ensuring accuracy without manual adjustments. Auto-calibration enhances accuracy, reduces manual effort, and ensures reliable performance for axle alignment in heavy-duty vehicles. The auto- calibration process provides several key benefits such as - Increased Accuracy through continuous calibration; Reduced Manual Intervention for quicker setup; Enhanced Reliability adapting to conditions; User Confidence with feedback via the screen (50) and buzzer (15).iii. Semi-Automatic Alignment: The servo motor rotates the laser modules for alignment, providing real-time feedback through audio and visual signals, requiring minimal operator intervention.iv. Enhanced Precision: The use of laser beams and LDR sensors reduces human error, ensuring accurate axle alignment for better vehicle performance.v. Real-Time Feedback: Immediate audio and visual indicators inform operators when alignment is confirmed.vi. Wireless Communication: ESP32 microcontrollers facilitate seamless data exchange without the need for physical wiring.vii. User-Friendly Operation: Simple controls and magnetic mounts make the system easy to operate and transport.viii. Cost-Effective: Reduces manual measurement needs and alignment errors, lowering operational costs.ix. Improved Safety and Efficiency: Proper alignment enhances fuel efficiency, tire longevity, and overall vehicle safely.x. Reduced Downtime: The efficient alignment process minimizes the time spent on maintenance and adjustments.xi. Versatility: Compatible with various semi-trailer types, making it adaptable for different vehicles.xii. Durable Design: Built with robust materials, the system is designed to withstand harsh operating conditions, ensuring longevity and reliability. xiii. Aerodynamic enhancements such as curved surfaces, angled edges, or recesses to reduce wind resistance and optimize performance during operation, while maintaining structural integrity and durability for prolonged use.xiv. Constructed from materials including, but not limited to, high-strength polymers, metals, or composite materials, selected for their durability, resistance to environmental conditions, and ability to maintain precision alignment, with customizable options based on specific operating environments or future technological developments.xv. Integrated mounting features such as mounting points, brackets, slots, or other attachment mechanisms that allow for easy installation and secure attachment using methods including, but not limited to, mechanical fasteners, magnetic attachments, or adhesives, ensuring versatility across different trailer configurations.xvi. Designed to accommodate various shapes and sizes, including but not limited to rectangular, circular, or custom shapes, ensuring compatibility with different vehicle types and alignment detection needs, allowing for seamless integration into various system configurations.xvii. Engineered with adjustable mounting features, allowing for repositioning or rotation of the components as necessary to achieve optimal alignment, and incorporating various attachment methods, including mechanical fasteners, magnetic mounts, welding, or adhesives, for flexibility in diverse applications.xviii. Incorporating additional integrated features such as customizable housings, reinforced structures for enhanced durability, design elements aimed at minimizing environmental impact, improving heat dissipation, and facilitating easy maintenance and repair for long-term operational efficiency.

Claims

Claims[0089] We Claim:[0090]1. A portable Semi-Trailer Axle Alignment Detection System [100] with Autocalibration and Semi-Automatic features for detection of axle misalignment and calibration, the system comprising:A. an axle alignment detection device [33] to be fitted magnetically on the semi-trailer floor [38], the device comprising:i. a fixed mounting assembly housing [3] with a base [23];wherein the fixed mounting assembly housing [3] comprising:a. an USB Power interface [3] with an interface mount [5];b. a SPST rocker switch [6];c. Wi-Fi-enabled microcontroller (ESP32) [9] with a charging module mount [10];d. an internal power source or battery [14] with a protective housing [12] along with a battery charging module [11];e. a sound emitting device [15] within a protective housing [12]; f. a servo motor [17] comprising an arm [18] operatively connected to coupling and bearing mount [19]; andg. a thrust bearing assembly with a fixed mounting assembly base [23], wherein the thrust bearing assembly comprising a housing washer [22], a cage [21] with rolling element, a shaft washer [20];ii. a mounting system [1] comprising a mounting bracket [1.1] and magnet [1.2], with the mounting system [1] fitted on the top of the fixed mounting assembly housing [3]; andiii. a rotary mounting assembly (RMA) housing [29] along with a base [30] and a top [25], with the rotary mounting assembly top [25] is connectedwith the fixed mounting assembly base [23] through a rotary coupling shaft [24],wherein the rotary mounting assembly housing [29] comprising a. a line laser module [26] or optical projection system;b. a Light Dependent Resistor (LDR) sensor [27] or an optical sensor [27];c. a projection system mount [28] which accommodates the LDR sensor [27] and the Line Laser module [26];d. a vertical projection aperture[31A] located on the RMA base [29]; e. a vertical optical sensing aperture [31B] located on the RMA housing [29] wall;f. a horizontal projection aperture [32A] located on the RMA base [29];andg. a horizontal optical sensing aperture [32B] located on the RMA housing [29] wall.B. an optical reflector [34] capable of being magnetically mounted on the semitrailer chassis main beam [37];C. an external device [35] to be fitted on the semi-trailer axle [39] to detect perpendicular alignment of axle to the chassis main beam [37], wherein the external device may be a LDR sensor module [35] or an optical sensor; or Axle Alignment Axis marker module [35.1], or an external Line Laser Module [35.2] or an optical projection system; andD. an Organic Light emitting diode (OLED) display module [51] for real time alignment status feedback and / or a smartphone application interface configured to receive alignment data wirelessly via Wi-Fi or cellular connectivity for enabling remote monitoring by operators or fleet managers,all operatively arranged,wherein the axle alignment detection device [33] is powered using the power interface is selected from a USB power interface, a wireless electrical power interface, or a connection to the trailer’s onboard electrical system, andESP32 conducts self- test ensuring proper functioning of internal component and post self- test, the servo motor [17] inside the device [33] rotates the line laser modules [26] from 0 to 180 degree, wherein the horizontal line laser module [26] projects a horizontal line laser beam [36B] towards the optical reflector [34] mounted on the chassis main beam [37], and where the internal components fails self-test, the ESP32 sends notification for manual calibration through rotation of rotary mounting assembly back and forth within a range of 0-180 degree, until the horizontal LDR sensor detects the reflected laser beam from the optical reflector on the main beam confirming correct alignment of the device aligned to continue;wherein detection and confirmation of perpendicular alignment of rotary assembly to the chassis main beam [37] through detection of horizontal line laser beam [36B] is reflected by the optical reflector [34] to the horizontal LDR sensor [27] within the device [33], and microcontroller continuously monitors the sensor reading;wherein post establishment of perpendicular alignment of the device [33] with the chassis main beam is confirmed using anyone of the external device [35] which may be a LDR sensor module [35], or Axle Alignment Axis marker module [35.1], or an external Line Laser Module [35.2].[0091]2. The portable Semi-Trailer Axle Alignment Detection System [100] with Autocalibration and Semi-Automatic feature for detection of axle misalignment and calibration, as claimed in claim 1, wherein the LDR sensor module [35] comprising:LDR sensor [27] placed on a sensor housing [35A] which is placed in a sensor module housing [35B] and a base [35C] together fitted on a mounting bracket [35D] enabled to be magnetically mounted,wherein module housing [35B] is fitted with a USB Power Interface [4], a power input interface mount [5], a wifi enabled microcontroller [9].[0092]3. The portable Semi-Trailer Axle Alignment Detection System [100] with Autocalibration and Semi-Automatic feature for detection of axle misalignment andcalibration, as claimed in claim 1, wherein the Axle Alignment Axis marker module [35.1] comprising:a raised marks panel [35.1A] with raised marks [35.1C] on a mounting bracket [35.1B] enabled to be magnetically mounted.[0093]4. The portable Semi-Trailer Axle Alignment Detection System [100] with Autocalibration and Semi-Automatic feature for detection of axle misalignment and calibration, as claimed in claim 1, wherein the External Line Laser Module [35.2] comprising:a line laser [26] in a module housing [46] with a removable panel [47] fitted with a USB power interface [4], a power input interface mount [5], arranged on a mount bracket enabled to be magnetically mounted.[0094]5. A method of detecting axle misalignment using portable Semi-Trailer Axle Alignment Detection System [100] with Auto -calibration and Semi-Automatic feature, as claimed in claim 1, the method comprising:a. mounting the Axle alignment detection device (33) to the underside of the semi-trailer floor (38) using the mounting system [1];b. mounting the optical reflector (34) on the chassis main beam (37);c. mounting the LDR sensor module (35) on the axle (39) using magnetic mounts for easy positioning;d. powering the axle alignment detection system [100] using the USB power interface (4), activated using rocker switches (6) located on the detection device (33);e. post powering the system [100], ESP32 conducts self- test ensuring proper functioning of internal component and post self- test, the servo motor [17] inside the device (33) rotates the line laser modules (26) from 0 to 180 degree, wherein the horizontal line laser module (26) projects a horizontal line laser beam (36B) towards the optical reflector (34) mounted on the chassis main beam [37], and where the internal components fails self- test, the ESP32 sends notification for manual calibration through rotation of rotary mounting assembly back and forth within a range of 0-180 degree, until the horizontal LDR sensor detects the reflected laser beam from the opticalreflector on the main beam confirming correct alignment of the device aligned to continue;f. detecting and confirming perpendicular alignment of rotary assembly to the chassis main beam [37] through detection of horizontal line laser beam [36B] which is reflected by the optical reflector [34] to the horizontal LDR sensor (27) within the device (33), and microcontroller continuously monitor the sensor reading;g. post establishment perpendicular alignment of device [33] with the chassis main beam [37], confirming the alignment of the axle to the chassis main beam [37] using anyone of the external device [35]A. wherein the external device is a LDR sensor module,i. the vertical line laser module (26) projects a vertical line laser beam (36A) towards the LDR sensor module (35) mounted on the axle (39), ii. confirming the vertical or perpendicular alignment of axle to the chassis main beam [37] through detection of vertical line laser beam (36A) by the both side LDR sensors (27) presents in a row of LDR sensor housing (35A) of the LDR sensor module (35), and the servo motor stops;iii. detecting vertical laser beam and Communicating signals from the LDR sensors [27] using the ESP32 microcontroller (9) in the LDR sensor module (35);iv. transmitting the processed data wirelessly using Wi-Fi to the main ESP32 (9) in the alignment detection device (33) to ensuring real-time communication and data processing;v. triggering of the buzzer (15) by ESP32 (9) upon confirming correct axle alignment providing an audible alert to confirm that the alignment is complete, and simultaneously displaying the alignment status on the display screen (50) of the display module for visual confirmation; and transmitting real-time alignment feedback is wirelessly from the device’s ESP32 (9) to the display module ESP32 (9), ensuring that the operator receives up-to-date information about the axle’s alignment status via Wi-Fi signals.B. wherein the external device is an Axle Alignment Axis Marker Module[35.1]i. the vertical line laser module (26) projects a vertical line laser beam (36A) towards the magnetic-mounted axle alignment axis marker (35.1) mounted on the axle (39); andii. visually analyzing for angular deviation, wherein no angular deviation indicates that the vertical line laser beam (36A) is parallel to the raised marks (35.1C) on the raised mark panel (35.1A), confirming the axle to be vertically aligned, or perpendicular to the chassis main beam (37).C. wherein the external device is an external line laser module (35.2),i. the external line laser module (35.2), mounted on the axle, projects a vertical line laser beam (36AA) towards the vertical LDR sensor (27) of the axle alignment detection device (33);ii. when the vertical line laser beam (36AA) is detected by the vertical LDR sensors (27) of the device (33), it confirms that the axle is vertically aligned, or is perpendicular to the chassis main beam (37); andiii. detection of vertical laser beams by the LDR sensors and processing of those laser beam through ESP32 microcontroller in the device [33], and detection of alignment when buzzer sounds. The ESP32 then transmits real-time alignment feedback wirelessly to the ESP32 in the display module, which shows the alignment status on a display screen, keeping the operator updated either wireless manner or in wired manner.

6. The method of detecting axle misalignment using portable Semi-Trailer Axle Alignment Detection System [100] with Auto-calibration and Semi-Automatic feature, as claimed in claim 5, wherein if misalignment persists, the system provides troubleshooting instructions or alert the user to manually check the optical reflector positionsSwarupa Ghosh IN / PA – 3169 Patent Attorney / Agent

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