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A vehicle brake monitor assembly for an air disk brake includes a brake actuator having a pushrod projecting from inside a chamber of said brake actuator. The pushrod releasably actuates a lever arm of a caliper thereby moving the disk brake into a braking position when the pushrod is in an extended position and releasing the disk brake from the braking position when the pushrod is in a retracted position. The pushrod includes a pushrod shaft and a contact member biased in a telescoping relationship relative to the pushrod shaft and the lever arm of the caliper abuts the contact member counteracting the bias of the contact member. A sensor is integrated with the assembly proximate the contact member and detects movement of the pushrod relative to the lever arm and to the pushrod shaft.

Titel:	ELECTRONIC STROKE SENSOR FOR AIR DISC BRAKE
Autor/in / Beteiligte Person:	Wallace, Thomas Edward ; Rink, Richard J. ; Chandler, Mark David ; Singletary, Glenn ; Oster, Wayne ; Lepard, Steve ; Prager, Christopher
Link:	View record in USPTO Patent Applications (Volltext)
Veröffentlichung:	2011
Medientyp:	Patent
Sonstiges:	Nachgewiesen in: USPTO Patent Applications Sprachen: English Document Number: 20110308897 Publication Date: December 22, 2011 Appl. No: 13/162691 Application Filed: June 17, 2011 Assignees: MGM Brakes, Inc. (Charlotte, NC, US) Claim: 1. A vehicle brake monitor assembly for an air disk brake, comprising: a brake actuator including a pushrod projecting from inside a chamber of said brake actuator, said pushrod releasably actuating a lever arm of a caliper thereby moving the disk brake into a braking position when said pushrod is in an extended position and releasing the disk brake from the braking position when the pushrod is in a retracted position; said pushrod including a pushrod shaft and a contact member biased in a telescoping relationship relative to said pushrod shaft and said lever arm of the caliper abutting said contact member thereby counteracting the bias of said contact member; a sensor integrated with said assembly proximate said contact member, said sensor detecting movement of said contact member relative to said lever arm and to said pushrod shaft. Claim: 2. The assembly set forth in claim 1, wherein said sensor comprises at least one of an optical sensor, a magnetic sensor, a mechanical sensor or a radio frequency enhanced sensor. Claim: 3. The assembly set forth in claim 1, wherein said contact member of said pushrod includes a signal medium detectable by said sensor. Claim: 4. The assembly set forth in claim 1, wherein said sensor is disposed inside a sensor pack located between said brake actuator and said caliper. Claim: 5. The assembly set forth in claim 1, wherein said sensor detects movement of said contact member by sensing variations in said signal medium. Claim: 6. The assembly set forth in claim 5, wherein said variations in said signal medium include separable signal features or a transitioning signal feature varying a degree of signal generated by said signal medium. Claim: 7. The assembly set forth in claim 5, wherein said separable signal features include a detectable surface, a semi-detectable surface, and a non-detectable surface. Claim: 8. The assembly set forth in claim 1, wherein said contact member comprises a sleeve circumscribing said pushrod shaft, and being biased relative to said pushrod shaft in a telescoping direction by a biasing member. Claim: 9. The assembly set forth in claim 1, wherein said sensor senses separation between said pushrod shaft and said contact member thereby identifying a hanging brake. Claim: 10. The assembly set forth in claim 1, wherein said pushrod includes a shim disposed between said contact member and said pushrod shaft for adjusting a length of said pushrod. Claim: 11. A method of monitoring the stroke of a brake actuator of an air disk braking system having a pneumatic chamber actuating a pushrod for exerting force on a lever arm of the air disk brake, said pushrod including a pushrod shaft and a contact member disposed in a telescoping relationship with said pushrod shaft, said method comprising the steps of: detecting a length of extension of said pushrod by sensing transition of a sensible medium disposed upon said pushrod thereby distinguishing between a normal and an overstroke condition of said pushrod; and detecting contact between said pushrod and said lever arm of said air disk brake by determining the length of telescopic extension of said contact member relative to said pushrod shaft thereby identifying a hanging brake condition. Claim: 12. The method set forth in claim 11, wherein said steps of detecting length of extension of said pushrod is further defined by detecting excessive length of extension during a high pressure phase thereby identifying free brake condition exceeding a normal free brake condition. Claim: 13. The method set forth in claim 11, wherein said step of detecting a length of extension of said pushrod is further defined by sensing transition between a plurality distinguishable, sensible mediums disposed upon said contact member. Claim: 14. The method set forth in claim 11, wherein said step of detecting a length of extension of said pushrod is further defined by sensing a linear transition of said sensible medium. Claim: 15. The method set forth in claim 11, wherein said steps of detecting a length of extension of said pushrod and detecting contact between said pushrod and said lever arm are further defined by providing an optical sensor, a magnetic sensor, a mechanical sensor or a radio frequency enhanced sensor. Claim: 16. The method set forth in claim 11, wherein said steps of detecting a length of extension of said pushrod and detecting contact between said pushrod and said lever arm are further defined by detecting varying degrees of reflectivity of said contact member. Claim: 17. The method set forth in claim 11, wherein said steps of detecting a length of extension of said pushrod and detecting contact between said pushrod and said lever arm are further defined by transmitting an optical signal toward said sensible medium and receiving a reflective signal at an optical sensor. Claim: 18. The method set forth in claim 17, wherein said steps of transmitting an optical signal toward said sensible medium and receiving a reflective signal at an optical sensor is further defined by transmitting an infrared signal. Claim: 19. The method set forth in claim 11, further including the step of providing a sensor pack having a sensor capable of detecting a length of extension of said pushrod and detecting contact between said pushrod and said lever arm. Claim: 20. The method set forth in claim 11, wherein said step of identifying a hanging brake condition is further defined by detecting contact between said pushrod and said lever arm of said air disk brake by determining the length of telescopic extension of said contact member relative to said pushrod shaft during a low pressure phase. Claim: 21. A vehicle brake monitor assembly for an air brake, comprising: a brake actuator having a pushrod slidably extending from a chamber of said brake actuator, said pushrod actuating a lever arm of the air brake thereby moving the vehicle brake into an actuated position when said pushrod is disposed in an extended position and allowing the brake to move into a retracted position when said pushrod is disposed in a retracted position; said pushrod comprising a pushrod shaft and a contact member having a telescoping bias from said pushrod shaft; an optical sensor transmitting a light signal toward said contact member and detecting an amount of reflectivity from said contact member thereby signaling a controller a location of said contact member for identifying a plurality of conditions of said brake actuator. Claim: 22. The assembly set forth in claim 21, wherein said sensor comprises an infrared sensor thereby transmitting an infrared signal toward said contact member and detecting an amount of reflectivity of said infrared signal from said contact member. Claim: 23. The assembly set forth in claim 21, wherein said contact member includes a reflective coating having varying degrees of reflectivity thereby enabling said sensor to detect the location of said contact member. Claim: 24. The assembly set forth in claim 21, wherein said contact member includes a reflective surface, a non-reflective surface, and a semi-reflective surface thereby providing a varying degree of reflectivity to said sensor. Claim: 25. The assembly set forth in claim 21, wherein said sensor is disposed in a sensor pack disposed between said brake actuator and the air brake housing. Claim: 26. The assembly set forth in claim 21, wherein said sensor is electronically connected to a controller and said controller is programmed to determine a normal brake condition, an overstroke brake condition, and a hanging brake condition based upon air pressure and a level of reflectivity signaled to said controller from said sensor. Claim: 27. The assembly set forth in claim 21, said contact member releasably interfaces with the lever arm of said brake. Claim: 28. The assembly set forth in claim 21, wherein the air brake comprises an air disk brake. Current U.S. Class: 188/111R Current International Class: 16

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ELECTRONIC STROKE SENSOR FOR AIR DISC BRAKE