Trailer safety system and methods of use thereof

Abstract

The present invention concerns systems, a kit and methods for monitoring coupling of a vehicle and a trailer or a trailer and another trailer. The system includes two sensors associated with a turntable of a towing vehicle, said sensors consisting of: a contact sensor configured to detect when a skid plate of a vehicle to be towed is in contact with the turntable; and a locking sensor configured to detect when the locking mechanism is in a locked configuration. The system further including a controller operatively connected to the two sensors and configured to receive output signals from the contact sensor and the locking sensor and to determine whether safe coupling has been achieved based on the output signals.

Claims

1. A trailer safety system for monitoring a vehicle and trailer coupling or a first trailer and second trailer coupling, said system including: two sensors associated with a turntable of the vehicle or the first trailer, said sensors consisting of: a contact sensor positioned on a front-end edge of the turntable and configured to detect when a skid plate of the trailer or the second trailer is in contact with the turntable for engagement of a kingpin of the trailer or the second trailer with a pair of jaws of the turntable; and a locking sensor configured to detect when a locking mechanism is in a locked configuration; and a controller operatively connected to the two sensors and configured to receive output signals from the contact sensor and the locking sensor and to determine whether safe coupling has been achieved based on the output signals, wherein said safe coupling is determined to have been achieved when the contact sensor detects contact between the skid plate and the turntable and the locking sensor detects that the locking mechanism is in the locked configuration after the engagement of the kingpin of the trailer or the second trailer with the pair of jaws of the turntable.

2. The system of claim 1, wherein the contact sensor is positioned to sense across an upper surface of a top plate of the turntable to detect contact between the turntable and the skid plate as the vehicle reverses towards the trailer to be towed.

3. The system of claim 1, wherein the contact sensor is centrally mounted across a front-end edge of the turntable.

4. The system of claim 1, wherein the locking sensor is positioned to detect when a locking handle associated with a locking mechanism of the turntable is at least partially retracted into the turntable and thus that the locking mechanism is in the locked configuration.

5. The system of claim 1, wherein the locking sensor is mounted at a junction between a side edge and a front-end edge of the turntable.

6. The system of claim 1, wherein the sensors are indirectly mounted to the turntable via brackets.

7. The system of claim 6, wherein the brackets are adhesively bonded to the turntable with a metal epoxy glue.

8. The system of claim 6, wherein the brackets are fitted around a rim of a top plate of the turntable and fastened in place with a threaded fastener.

9. The system of claim 1, wherein the controller includes a signal generator for generating one or more alert signals for alerting a driver.

10. The system of claim 1, wherein the controller is operatively connected to a user interface installed in or mounted to a dashboard of the vehicle, the user interface including a signal generator for generating one or more alert signals for alerting a driver.

11. The system of claim 1, further including a remotely accessible server operatively connected to the controller for receiving and remotely monitoring data corresponding to the output signals from the sensors, said server configured to generate an alert when said data received from any one of the sensors or the controller is indicative that the trailer is improperly coupled or not connected.

12. The system of claim 11, wherein the controller further includes a radio or cellular modem for wireless communication with the remotely accessible server.

13. The system of claim 11, wherein the server is in communication with a fleet database containing a plurality of coupling records for each truck/trailer coupling and/or trailer/trailer coupling.

14. The system of claim 11, wherein responsive to the remotely accessible server identifying data indicative of a trailer being improperly coupled or not coupled, the server generates and transmits an alert to a computing device of a fleet controller.

15. The system of claim 14, wherein upon identifying said data, generation and transmission of the alert is delayed to enable a driver to correct the coupling.

16. A method of assisting in safe coupling of a trailer to a vehicle, said method including: determining when a skid plate of the trailer is aligned and resting on top of a turntable of the vehicle based on an output signal of a contact sensor positioned on a front-end edge of the turntable and configured to detect when the skid plate is in contact with the turntable; determining when a kingpin of the trailer engages with a pair of jaws of the turntable based on an output signal of a locking sensor configured to detect when a locking mechanism is in a locked configuration, wherein said locking mechanism transitions to the locked configuration upon engagement of the kingpin and the pair of jaws; and alerting a driver in a cab of the vehicle when safe coupling has been achieved, said alerting including an alert signal generated by a controller operatively connected to the contact sensor and the locking sensor and configured to receive output signals from the contact sensor and the locking sensor, wherein said safe coupling is determined to have been achieved when the contact sensor detects contact between the skid plate and the turntable and the locking sensor detects that the locking mechanism is in the locked configuration.

17. The method of claim 16, wherein when the vehicle is correctly positioned for engagement between the turntable and the skid plate of the trailer, the drive reverses the vehicle until contact is determined by the contact sensor.

18. The method of claim 16, wherein upon detecting contact, the contact sensor transmits an output signal to the controller and the controller generates a continuous first alert signal alerting the driver of contact.

19. The method of claim 18, wherein upon generation of the first alert signal, the driver continues to reverse the vehicle towards the trailer until the kingpin of the trailer engages with the pair of jaws of the turntable causing the locking mechanism of the turntable to transition to the locked configuration and a locking handle to at least partially retract into the turntable.

20. The method of claim 19, wherein upon detecting the locking handle in an at least partially retracted state, the locking sensor transmits an output signal to the controller indicating that the locking mechanism is in the locked configuration and the controller kills the continuous first alert signal.

21. The method of claim 20, wherein the controller generates a second alert signal alerting the driver that safe coupling has been achieved.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

(2) FIG. 1 is a diagram showing a trailer aligned for coupling with a turntable of a vehicle;

(3) FIG. 2 is an upper perspective view of a turntable of a vehicle;

(4) FIG. 3 is an upper perspective view of part of a turntable of a vehicle fitted with a trailer safety system according to an embodiment of the present invention;

(5) FIG. 4 is a top view of the turntable as shown in FIG. 3 with the trailer safety system fitted;

(6) FIG. 5 is a perspective view showing an unfitted version of the trailer safety system as shown in FIG. 4;

(7) FIGS. 6A and 6B are respective views of a contact sensor and locking sensor of the system as shown in FIGS. 4 and 5 with associated brackets for fitting to a turntable of a vehicle;

(8) FIGS. 7A and 7B respective show an upper perspective view and internal view of a controller of the trailer system as shown in FIGS. 4 and 5;

(9) FIG. 8 is an upper perspective view of part of a dashboard of a prime mover showing an in-built user interface of the trailer system according to another embodiment of the present invention;

(10) FIGS. 9A and 9B respectively show perspective views of different plug-types for connecting components of the trailer safety system together;

(11) FIG. 10 is a side view of a vehicle coupled to a trailer including two trailer units (also known as a “B-double combination”);

(12) FIG. 11 is a side view of a vehicle coupled to two trailers (also known as a “road train”). The two trailers are coupled together with a dolly;

(13) FIG. 12 is a side view of the dolly as shown in FIG. 12;

(14) FIG. 13 is a front view of a trailer as shown in FIG. 10 or 11;

(15) FIG. 14 is a front view of the dolly as shown in FIG. 11 or 12;

(16) FIGS. 15A to 15C respectively show an upper perspective view and side view of a ringfeder bolt coupling fitted with a trailer safety system according to an embodiment of the present invention and a towing eye;

(17) FIG. 16 is a top view of a turntable from a trailer or dolly fitted with a trailer safety system according to another embodiment of the present invention; and

(18) FIG. 17 is a schematic showing parts of a trailer safety system according to another embodiment of the present invention.

DETAILED DESCRIPTION

(19) FIGS. 3 to 9B show a trailer safety system (100) or parts thereof according to an embodiment of the present invention for use with a turntable (700) of a prime mover (i.e., a vehicle).

(20) Referring to FIG. 3, the system (100) includes two sensors associated with the turntable (700), namely a contact sensor (110) configured to detect when a skid plate of a trailer is in contact with the turntable (700) and a locking sensor (120) configured to detect when the locking mechanism of the turntable is in the locked configuration by a position of the locking handle (770) relative to the turntable (700).

(21) Each of the sensors (110, 120) is a proximity sensor configured to detect the presence of a nearby object.

(22) The contact sensor (110) is positioned on a front end edge (715) of the turntable (700) to detect the presence of a skid plate of a trailer and thus contact between the skid plate and the turntable (700). The contact sensor (110) is positioned to sense across the upper surface (712) of the top plate (710) of the turntable (700) to detect contact between the turntable (700) and a skid plate as the prime mover reverses towards a trailer to be towed.

(23) Advantageously, by configuring the contact sensor (110) to detect contact, the contact sensor (110) ensures that a kingpin does not overshoot the turntable (700) but rather that the turntable (700) and the trailer are correctly positioned relative to each other for the kingpin to be correctly received in an entry channel for engagement in the kingpin locking aperture (740).

(24) The contact sensor (110) has a nominal range (i.e., maximum distance that the sensor can detect) configured to detect contact between the turntable (700) and the skid plate of the trailer of between about 0 mm and 30 mm. The nominal range is adjustable to enable the sensor (110) to be precisely calibrated to detect as soon as the skid plate of the trailer is in contact with the turntable (700).

(25) As shown, the contact sensor (110) is centrally positioned across the front-end edge (715).

(26) The sensor (110) is mounted to the front-end edge (715) with bracket (112). The bracket (112) is fastened to the front-end edge (715) of the turntable (700) with a metal epoxy glue.

(27) Referring briefly to FIG. 6A, in another embodiment, the sensor (110) is mounted to the front-end edge (715; not shown) with bracket (112), which fits about a rim (714; not shown) of the turntable (700; not shown) and is secured in place with a threaded fastener (113).

(28) Referring back to FIG. 3, the locking sensor (120) is configured to detect the presence of the locking handle (770) for thus detecting that the locking mechanism is in the locked configuration after engagement of the kingpin of the trailer with the jaws of the locking mechanism of the turntable (700).

(29) The locking sensor (120) also has a nominal range configured to detect the proximity of the locking handle (770) to the locking sensor (120) when in the locked configuration and to differentiate when the locking handle (770) is in an unlocked configuration. In this regard, the locking sensor has a nominal range of between about 0 mm and about 15 mm. Again, the nominal range of the locking sensor (120) is adjustable to enable the sensor (120) to be precisely calibrated to detect as soon as the locking handle (770) of the locking mechanism is in a locking position indicative that the locking mechanism is in the locking configuration and thus that the kingpin is engaged by the turntable (700).

(30) The locking sensor (120) is associated with a side of the turntable (700) adjacent the locking handle (770) at a junction between the front-end edge (715) and side edge (718).

(31) The sensor (120) is mounted with bracket (122). The bracket (122) is fastened to the side edge (718) with a metal epoxy glue.

(32) Referring briefly to FIG. 6B, in another embodiment, the sensor (120) is mounted to the junction between the front-end edge (715; not shown) and side edge (718; not shown) front-end edge (715; not shown) with bracket (122), which fits about the rim (714; not shown) of the turntable (700; not shown) and is secured in place with a threaded fastener (123).

(33) Referring back to FIG. 3, the locking sensor (120) is positioned to sense outwards for detecting the presence of the locking handle (770) at is nears the sensor (120) indicative that the locking handle (770) has retracted into the turntable and thus that the locking mechanism is in the locked configuration.

(34) Referring to FIGS. 4 and 5, each of the sensors (110, 120) responsive to detecting the skid plate or the locking handle (770) transmits an electrical output signal to a controller (200).

(35) The controller (200) is operatively connected to the two sensors (110, 120) and configured to receive the electrical output signals and determine whether safe coupling has been achieved based on the output signals received. In turn, the controller (200) is operatively connected to a user interface (220) located in a cab of the prime mover.

(36) The controller (200) is operatively connected to the sensors (110, 120) and the user interface (220) by electrical wiring. In some embodiments, the controller (200) is further connected to a GPS unit (280) and a power source (power from the vehicle; 290).

(37) The wiring from each respective sensor (110, 120) and the wiring from the controller (200) are connectable by weatherproof plugs and sockets (510). Best shown in FIGS. 9A and 9B.

(38) Referring to FIGS. 7A and 7B, the controller (200) is remotely located relative to the sensors, typically within the cab of the prime mover, although in some embodiments it may be located along the body of the trailer.

(39) As shown, the controller (200) includes a housing (210). The housing (210) typically has the shape of a rectangular prism.

(40) Referring to FIG. 7A, the controller (200) includes a signal generator for generating one or more alert signals. As shown, the signal generator of the controller (200) includes three visual signalling devices each in the form of a light-emitting diode (“LED”; 212, 214, 216) for respectively indicating when the controller (200) is powered, when an alarm is being generated and when there is a safe coupling.

(41) Referring to FIG. 8 and as previously indicated, the controller (200; not shown) is in turn operatively connected to a user interface (220) installed behind the dashboard in the cab of the prime mover. The controller (200; not shown) is operatively connected by electrical wiring.

(42) The user interface (220) also includes a signal generator for generating one or more alert signals for alerting a driver.

(43) For example, the signal generator generates at least one first alert signal when an output signal is received from the contact sensor indicative that the skid plate is in contact with the turntable, and the at least one first alert signal is maintained until an output signal is received from the locking sensor indicative that the locking mechanism is in the locked configuration, thus confirming that the trailer has been safely coupled. At this stage, the signal generator generates at least one second alert signal.

(44) The signal generator includes at least one audio signalling device in the form of a pulsating beeper. The beeper is integrated in the dashboard of the prime mover.

(45) The signal generator also includes two visual signalling devices in the form of two light-emitting diodes (“LEDs”; 240, 250) forming part of the user interface (220).

(46) A first LED (240) emits a red light when the contact sensor detects contact between the turntable and a skid plate of a trailer. As shown, an outer cover (242) of the first LED (240) includes an unlock padlock symbol to indicate that the trailer is not yet safely coupled to the prime mover.

(47) A second LED (250) emits a green light when the locking sensor detects the presence of the locking handle in a retracted state indicative that the locking mechanism of the turntable is in the locked configuration. As also shown, an outer cover (252) of the second LED (250) includes a locked padlock symbol to indicate that the trailer is now safely coupled to the prime mover.

(48) Referring again to FIGS. 7A and 7B, the controller (200) further include a communications module for connecting the controller (200) and the system (200) to an external device, such as, e.g., a remotely accessible server, an external processing device (e.g., computer, tablet, smart phone, smart watch or PDA), an external display, an external printer or a storage device (e.g., a hard drive).

(49) The communication module is in the form of a wireless communication module, such as, e.g., a wireless network interface controller, such that the controller may wirelessly connect to an external device through a wireless network (e.g., Wi-Fi (WLAN) communication, Satellite communication, RF communication, infrared communication, or Bluetooth™).

(50) The controller (200) also includes a microcomputer, including one or more processors and a memory. The one or more processors are low power processors. The processors include multiple inputs and outputs coupled to other electronic components of the controller (200).

(51) Lastly, the controller (200) draws power from the vehicle for powering the electrical components of the system (100).

(52) FIGS. 10 to 14, 16 and 17 show a trailer safety system (100) or parts thereof according to another embodiment of the present invention for use with a turntable (700) of a trailer (800).

(53) Referring to FIG. 10, the system (100) can be used to monitor safe coupling between a first trailer (800A) having a rear turntable (700) and a second trailer (800B).

(54) Alternatively and referring to FIG. 11, the system (100) can be used to monitor safe coupling between dolly (600) having a turntable (700) and a second trailer (800).

(55) FIG. 12 shows a side view of the dolly (600) shown in the FIG. 11. As shown, the controller (200) of the system (100) in such embodiments is mounted to a front portion of the dolly (600).

(56) FIG. 13 shows a front view of the second trailer (800) as shown in FIGS. 10 and 11. The kingpin (820) and skid plate (810) are plainly visible extending downward from a front portion of the trailer (800) for engagement with a turntable of a first trailer or a dolly.

(57) FIG. 14 shows a front view of the dolly (600) as shown in FIGS. 11 and 12. The dolly (600) includes a draw bar (610) for coupling to a hitch of a first trailer and a turntable (700) for coupling to a second trailer.

(58) Referring to FIG. 16, the system (100) includes two sensors associated with the turntable (700), namely a contact sensor (110) configured to detect when a skid plate of a trailer is in contact with the turntable (700) and a locking sensor (120) configured to detect when the locking mechanism of the turntable is in the locked configuration by a position of the locking handle (770) relative to the turntable (700).

(59) The contact sensor (110) is positioned on a front end edge (715) of the turntable (700) to detect the presence of a skid plate of a trailer and thus contact between the skid plate and the turntable (700). The contact sensor (110) is positioned to sense across the upper surface (712) of the top plate (710) of the turntable (700) to detect contact between the turntable (700) and a skid plate as the prime mover reverses towards a trailer to be towed.

(60) The locking sensor (120) is configured to detect the presence of the locking handle (770) for thus detecting that the locking mechanism is in the locked configuration after engagement of the kingpin of the trailer with the jaws of the locking mechanism of the turntable (700).

(61) Each of the sensors (110, 120) responsive to detecting the skid plate or the locking handle (770) transmits an electrical output signal to the controller (200).

(62) As shown, the controller (200) is operatively connected to the two sensors (110, 120) and configured to receive the electrical output signals and determine whether safe coupling has been achieved based on the output signals received.

(63) The controller (200) is operatively connected to the sensors (110, 120) by electrical wiring. In particular, electrical wiring extends from the controller (200), which is mounted on a front end of the trailer, to the turntable (700).

(64) Again, the wiring from each respective sensor (110, 120) and the wiring from the controller (200) are connectable by a pair of weatherproof plug and sockets (510).

(65) The controller (200) includes a housing (210). The housing (210) typically has the shape of a rectangular prism.

(66) The controller (200) includes a user interface (220). As previously mentioned, the housing (210) is configured to be mounted to a front portion of each trailer having a turntable (700; shown only in FIG. 16) such that a driver coupling a multiple trailer combination can confirm safe coupling has been achieved between adjacent trailers with a quick visual inspection of the controller (200) when connecting airlines and electrical cables between the trailers.

(67) As before, the controller (200) includes a signal generator for generating one or more alert signals for alerting a driver.

(68) For example, the signal generator generates at least one first alert signal when an output signal is received from the contact sensor indicative that the skid plate is in contact with the turntable, and the at least one first alert signal is maintained until an output signal is received from the locking sensor indicative that the locking mechanism is in the locked configuration, thus confirming that the trailer has been safely coupled. At this stage, the signal generator generates at least one second alert signal.

(69) The signal generator includes two visual signalling devices in the form of two light-emitting diodes (“LEDs”; 240, 250) forming part of the user interface (220).

(70) A first LED (240) emits a red light when the contact sensor (110; shown only in FIG. 16) detects contact between the turntable (700; shown only in FIG. 16) and a skid plate to indicate that the first trailer is not yet safely coupled to the second trailer.

(71) A second LED (250) emits a green light when the locking sensor (120; shown only in FIG. 16) detects the presence of the locking handle (770; shown only in FIG. 16) in a retracted state indicative that the locking mechanism of the turntable (700; shown only in FIG. 16) is in the locked configuration to indicate that the first trailer is now safely coupled to the second trailer.

(72) As previously described, the controller (200) a communications module; and a microcomputer, including one or more processors and a memory.

(73) Referring to FIG. 17, in this variation of the embodiment shown in FIG. 16, the weatherproof plug and sockets are contained in a junction box (500) mounted to a portion of the trailer together with the controller (200), and the user interface (220) is operatively connected to the controller (200) by electrical wiring. The user interface (220) includes a signal generator including two visual signalling devices in the form of two light-emitting diodes (“LEDs”; 240, 250) as described above. The user interface (220) is again configured to be mounted to a front portion of each trailer having a turntable (700; shown only in FIG. 16) such that a driver coupling a multiple trailer combination can confirm safe coupling has been achieved between adjacent trailers with a quick visual inspection of the user interface (220) when connecting airlines and electrical cables between the trailers.

(74) As shown in both FIGS. 16 and 17, the system (100) includes a photovoltaic solar panel (400), an inverter and one or more batteries for storing generated electricity and from which the controller (200) and system (100) components can draw power.

(75) The solar panel (400) can be mounted to a sun-exposed portion of a trailer.

(76) In the embodiment shown in FIG. 16, the solar panel (400) is operatively connected to the controller (200), which also houses the inverter and the one or more batteries.

(77) In the embodiment shown in FIG. 17, the solar panel (400) is instead operatively connected to the junction box (500), which in this embodiment houses the inverter and the one or more batteries.

(78) FIGS. 15A to 15C show a trailer safety system (1100) or parts thereof according to another embodiment of the present invention for use monitoring a ringfeder bolt coupling (1500) between a leading vehicle or trailer and a trailing trailer.

(79) The ringfeder bolt coupling (1500) enables the trailing trailer to be coupled to a leading vehicle by a draw bar connection. The draw bar having a towing eye (1510) as shown in FIG. 15C at a front or forward end of the draw bar. The towing eye (1510) is configured to be received within and coupled to coupling body (1520), shown in FIGS. 15A and 15B, mounted to a rear end of the leading vehicle or trailer.

(80) The coupling body (1520) includes a rear-faced opening (1522) for at least partially receiving the towing eye (1510; shown in FIG. 15C) and a sliding coupling pin (1524; shown only in FIG. 15A) configured to be received through a central opening (1512) or “eye” of the towing eye (1510; shown in FIG. 15C) to couple the trailing trailer to the leading vehicle or trailer.

(81) The coupling further includes an internal locking mechanism for automatically sliding the coupling pin (1524; shown only in FIG. 15A) to a downwardly extending locked configuration in which the pin (1524; shown only in FIG. 15A) may extend through the central opening (1512) or “eye” of the towing eye (1510; shown in FIG. 15C) when present, and an unlocked configuration in which the pin (1524; shown only in FIG. 15A) is held clear of the central opening (1512) or “eye”. Sliding of the pin (1524; shown only in FIG. 15A) to the unlocked configuration is manually actuated by locking handle (1526) extending from the coupling body (1520).

(82) Referring to FIG. 15B, the coupling body (1520) further includes indicator pin (1528) configured to provide an external indicator when the locking mechanism is in the locked configuration. The indicator pin (1528) protrudes proudly from the surface of the coupling body (1520) when the locking mechanism is in the locked configuration.

(83) Referring to FIG. 15B, the system (1100) includes two sensors associated with the coupling body (1520), namely a proximity sensor (1110) configured to detect when the presence of the towing eye (1510; shown in FIG. 15C) of the trailing trailer as it enters the rear-facing opening (1522) of the coupling body (1520) and a locking sensor (1120) configured to detect the protruding indicator pin (1528) indicative that the locking mechanism is in the locked configuration.

(84) Each of the sensors (1110, 1120) is a proximity sensor configured to detect the presence of a nearby object.

(85) The sensors (1110, 1120) are mounted with brackets (1112, 1122) to an external surface of the coupling body (1520). The brackets (1112, 1122) are fastened to the coupling body (1520) with a metal epoxy glue.

(86) Both sensors (1110, 1120) are operatively connected to the controller (200; not shown) as previously described by electrical wiring.

(87) In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.

(88) Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

(89) In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.