MODULAR TRAILER SYSTEM

Abstract

A trailer brake and monitoring system with a trailer control module, which has a processor, a signal input, a first wheel speed input, a second wheel speed input, a valve output, and a data port. The processor receives a signal from the signal input, and the processor sends the signal to the data port. The processor receives a first wheel speed signal from the first wheel speed input and a second wheel speed signal from the second wheel speed input. The processor is configured to send a first brake signal to the valve output based on at least one of the first wheel speed signal and the second wheel speed signal. The trailer control module may include third and fourth wheel speed inputs and a second valve output. The data port may be a power input configured for connection with a PLC cable and/or a CAN port.

Claims

1. A trailer brake and monitoring system comprising: a trailer control module comprising a processor, a brake control pressure input, a brake supply pressure input, a first wheel speed input, a second wheel speed input, a third wheel speed input, a fourth wheel speed input, a first valve output, a second valve output, and a data port, wherein the processor receives a brake control pressure signal from the brake control pressure input and a brake supply pressure signal from the brake supply pressure input, wherein the processor generates and sends a first warning signal to the data port when the brake control pressure signal is not within a predefined brake control pressure range, and wherein the processor generates and sends a second warning signal to the data port when the brake supply pressure signal is not within a predefined brake supply pressure range, wherein the processor receives a first wheel speed signal from the first wheel speed input and a second wheel speed signal from the second wheel speed input, wherein the processor is configured to send a first brake signal to the first valve output based on at least one of the first wheel speed signal and the second wheel speed signal, wherein the processor receives a third wheel speed signal from the third wheel speed input and a fourth wheel speed signal from the fourth wheel speed input, and wherein the processor is configured to send a second brake signal to the second valve output based on at least one of the third wheel speed signal and the fourth wheel speed signal.

2. The system of claim 1, wherein the trailer control module further comprises a third valve output, and wherein the processor is configured to send a third brake signal to the third valve output based on at least one of the third wheel speed signal and the fourth wheel speed signal.

3. The system of claim 1, wherein the trailer control module further comprises a power input.

4. The system of claim 1, wherein the data port comprises a power input.

5. The system of claim 1, wherein the data port comprises a controller area network port.

6. The system of claim 1, further comprising a communications device coupled to the data port, wherein the communications device receives the first warning signal and the second warning signal, and wherein the communications device wirelessly sends the first warning signal and the second warning signal to a central server.

7. The system of claim 1, further comprising a mounting bracket to which the trailer control module is mounted.

8. The system of claim 7, further comprising a brake valve that is mounted to the mounting bracket, wherein the brake valve is coupled to the first valve output, and wherein the brake valve comprises a supply pressure inlet, an emergency brake pressure outlet, a control pressure inlet, and a service brake pressure outlet.

9. The system of claim 8, further comprising a reservoir purge valve that is mounted to the mounting bracket, wherein the reservoir purge valve comprises a reservoir inlet port, an exhaust port, and a control port that is coupled to the supply pressure inlet of the brake valve.

10. The system of claim 9, further comprising a booster valve that is mounted to the mounting bracket, wherein the booster valve comprises a service brake control inlet, a service brake control outlet that is coupled to the control pressure inlet of the brake valve, and a supply inlet.

11. A trailer brake and monitoring system comprising: a trailer control module comprising a processor, a signal input, a first wheel speed input, a second wheel speed input, a valve output, and a controller area network port, wherein the processor receives a signal from the signal input, wherein the processor sends the signal to the controller area network port, wherein the processor receives a first wheel speed signal from the first wheel speed input and a second wheel speed signal from the second wheel speed input, and wherein the processor is configured to send a first brake signal to the valve output based on at least one of the first wheel speed signal and the second wheel speed signal.

12. The system of claim 11, further comprising a communications device that is coupled to the controller area network port, wherein the communications device receives the signal, and wherein the communications device wirelessly sends the signal to a central server.

13. The system of claim 11, wherein the trailer control module further comprises a power input comprising a data port.

14. The system of claim 11, wherein the signal input comprises at least one of a brake control pressure input and a brake supply pressure input, wherein the signal comprises a brake pressure signal, and wherein the processor generates and sends a warning signal to the controller area network port when the brake pressure signal is not within a predefined brake pressure range.

15. The system of claim 11, wherein the trailer control module further comprises a third wheel speed input, a fourth wheel speed input, and a second valve output, wherein the processor receives a third wheel speed signal from the third wheel speed input and a fourth wheel speed signal from the fourth wheel speed input, and wherein the processor is configured to send a second brake signal to the second valve output based on at least one of the third wheel speed signal and the fourth wheel speed signal.

16. The system of claim 11, further comprising a mounting bracket to which the trailer control module is mounted.

17. The system of claim 16, further comprising a brake valve that is mounted to the mounting bracket, wherein the brake valve is coupled to the valve output, and wherein the brake valve comprises a supply pressure inlet, an emergency brake pressure outlet, a control pressure inlet, and a service brake pressure outlet.

18. The system of claim 17, further comprising a reservoir purge valve that is mounted to the mounting bracket, wherein the reservoir purge valve comprises a reservoir inlet port, an exhaust port, and a control port that is coupled to the supply pressure inlet of the brake valve.

19. The system of claim 18, further comprising a booster valve that is mounted to the mounting bracket, wherein the booster valve comprises a service brake control inlet, a service brake control outlet that is coupled to the control pressure inlet of the brake valve, and a supply inlet.

20. A trailer brake and monitoring system comprising: a trailer control module comprising a processor, a brake control pressure input, a brake supply pressure input, a first wheel speed input, a second wheel speed input, a third wheel speed input, a fourth wheel speed input, a first valve output, a second valve output, a controller area network port, and a power input with a data port, wherein the processor receives a brake control pressure signal from the brake control pressure input and a brake supply pressure signal from the brake supply pressure input, wherein the processor generates and sends a first warning signal to the controller area network port and the data port when the brake control pressure signal is not within a predefined brake control pressure range, and wherein the processor generates and sends a second warning signal to the controller area network port and the data port when the brake supply pressure signal is not within a predefined brake supply pressure range, wherein the processor receives a first wheel speed signal from the first wheel speed input and a second wheel speed signal from the second wheel speed input, wherein the processor is configured to send a first brake signal to the first valve output based on at least one of the first wheel speed signal and the second wheel speed signal, wherein the processor receives a third wheel speed signal from the third wheel speed input and a fourth wheel speed signal from the fourth wheel speed input, and wherein the processor is configured to send a second brake signal to the second valve output based on at least one of the third wheel speed signal and the fourth wheel speed signal; and a communications device coupled to the controller area network port, wherein the communications device receives the first warning signal and the second warning signal, and wherein the communications device wirelessly sends the first warning signal and the second warning signal to a central server.

21. The system of claim 20, further comprising a mounting bracket to which the trailer control module is mounted.

22. The system of claim 21, further comprising a brake valve that is mounted to the mounting bracket, wherein the brake valve is coupled to the first valve output, and wherein the brake valve comprises a supply pressure inlet, an emergency brake pressure outlet, a control pressure inlet, and a service brake pressure outlet.

23. The system of claim 22, further comprising a reservoir purge valve that is mounted to the mounting bracket, wherein the reservoir purge valve comprises a reservoir inlet port, an exhaust port, and a control port that is coupled to the supply pressure inlet of the brake valve.

24. The system of claim 23, further comprising a booster valve that is mounted to the mounting bracket, wherein the booster valve comprises a service brake control inlet, a service brake control outlet that is coupled to the control pressure inlet of the brake valve, and a supply inlet.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG. 1 is a front elevational view showing a trailer brake and monitoring system in accordance with one embodiment of the invention described herein;

[0027] FIG. 2 is a rear elevational view of the trailer brake and monitoring system of FIG. 1;

[0028] FIG. 3 is a front elevational view of a trailer control module of the trailer brake and monitoring system of FIG. 1;

[0029] FIG. 4 is a schematic view showing components coupled to certain data ports of the trailer brake and monitoring system of FIG. 1;

[0030] FIG. 5 is a perspective view showing the trailer control module of FIG. 3 mounted to an air reservoir tank;

[0031] FIG. 6 is a schematic view of the trailer brake and monitoring system of FIG. 1;

[0032] FIGS. 7A-7E show 2S/1M configurations of the trailer brake and monitoring system of FIG. 1 for different types of single or multi-axle trailer configurations;

[0033] FIGS. 8A-8D show 2S/2M configurations of the trailer brake and monitoring system of FIG. 1 for different types of multi-axle trailer configurations;

[0034] FIGS. 9A-9D show 4S/2M configurations of the trailer brake and monitoring system of FIG. 1 for different types of multi-axle trailer configurations;

[0035] FIGS. 10A-10C show 4S/2M configurations of the trailer brake and monitoring system of FIG. 1 for different types of multi-axle trailer with lift axle(s) configurations;

[0036] FIGS. 11A-11E show 4S/2M configurations of the trailer brake and monitoring system of FIG. 1 for different types of multi-axle trailer configurations, as recommended for spread axle applications;

[0037] FIGS. 12A-12C show 4S/2M configurations of the trailer brake and monitoring system of FIG. 1 for different types of multi-axle trailer with lift axle(s) configurations, as recommended for spread axle applications;

[0038] FIGS. 13A-13D show 4S/3M configurations of the trailer brake and monitoring system of FIG. 1 for different types of full and semi-trailer configurations;

[0039] FIGS. 14A-14B show a preferred mounting location of the trailer brake and monitoring system of FIG. 1 for a drop deck trailer; and

[0040] FIGS. 15A-15B show a preferred mounting location of the trailer brake and monitoring system of FIG. 1 for a straight rail trailer.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

[0041] A trailer brake and monitoring system in accordance with one embodiment of the invention described herein is identified generally with the reference numeral 10 in FIG. 1. The trailer brake and monitoring system includes a trailer control module 12, a brake valve 14, a reservoir purge valve 16, a booster valve 18 (FIG. 2), a communications device 20 (FIG. 4), and a mounting bracket 22 to which the trailer control module 12, brake valve 14, reservoir purge valve 16, and booster valve 18 are mounted.

[0042] Referring to FIG. 6, the trailer control module 12 includes a processor 24 that is electrically coupled with, configured to receive data or instructions from, and configured to transmit data or instructions to: a brake supply pressure input 26, a brake control pressure input 28, a first wheel speed input 30, a second wheel speed input 32, a third wheel speed input 34, a fourth wheel speed input 36, a first valve output 38, a second valve output 40, a third valve output 42, a controller area network (CAN) port 44, a power input 46, a first auxiliary port 48, and a second auxiliary port 50. Processor 24 may be electrically coupled with memory 25 such as flash upgradable memory storing instructions for processing by processor 24. As shown in FIG. 3, trailer control module 12 includes a housing 52 that contains processor 24. Brake supply pressure input 26, brake control pressure input 28, first wheel speed input 30, second wheel speed input 32, third wheel speed input 34, fourth wheel speed input 36, first valve output 38, second valve output 40, third valve output 42, CAN port 44, power input 46, first auxiliary port 48, and second auxiliary port 50 include external ports configured for releasable coupling with wire connectors to place the ports in electrical communication with external components as described below.

[0043] Brake control pressure input 28 is electrically coupled via a wire with a pressure sensor 53 (FIG. 1) that is threadably received by a port in brake valve 14. The pressure sensor 53 is operable to measure a brake control pressure within brake valve 14 and convert the measured brake control pressure into an electrical brake control pressure signal that is transmitted to brake control pressure input 28. The brake control pressure within brake valve 14 corresponds to the pressure supplied by brake valve 14 to service brake chambers 54 and 56 of brake actuators 58 and 60.

[0044] Brake supply pressure input 26 is electrically coupled via a wire with a pressure sensor 62 (FIG. 1) that is threadably received by a port in brake valve 14. The pressure sensor 62 is operable to measure a brake supply pressure within brake valve 14 and convert the measured brake supply pressure into an electrical brake supply pressure signal that is transmitted to brake supply pressure input 26. The brake supply pressure within brake valve 14 corresponds to the pressure supplied by brake valve 14 via an air reservoir (preferably located on a tractor and not shown) to emergency brake chambers 96 and 98 of brake actuators 58 and 60.

[0045] First wheel speed input 30, second wheel speed input 32, third wheel speed input 34, and fourth wheel speed input 36 are electrically coupled respectively with a first wheel speed sensor 64, a second wheel speed sensor 66, a third wheel speed sensor 68, and a fourth wheel speed sensor 70, shown in FIG. 4. The first, second, third, and fourth wheel speed sensors 64, 66, 68, and 70 are each operable to detect the frequency of rotation and/or speed of a vehicle wheel and send a corresponding electrical wheel speed signal to the applicable first, second, third, or fourth wheel speed inputs 30, 32, 34, and 36.

[0046] First valve output 38 is electrically coupled via a wire with an anti-lock braking system (ABS) 72 (FIG. 1) of brake valve 14. First valve output 38 is configured to send a brake signal to ABS 72 to control the operation of ABS 72. Second valve output 40 is configured to be electrically coupled with an ABS of a second brake valve 132 (FIGS. 8A-13D), and third valve output 42 is configured to be electrically coupled with an ABS of a third brake valve 134 (FIGS. 13A-13D). Second brake valve 132 and third brake valve 134 preferably have the same or similar configuration as brake valve 14 described herein.

[0047] Referring to FIG. 4, controller area network (CAN) port 44 is electrically coupled to a communications device 20, a tire pressure and temperature monitoring system 74, and a stability module 76 via cables 78a-e. CAN port 44 is preferably SAE J1939 and ISO 11898 compatible and meets the CAN 2.0b extended frame standard. CAN port 44 operates as a data port that can send data from trailer control module 12 to external devices and receive data from the external devices. Communications device 20 is preferably a telematics unit that is in wireless communication with a central server 79 (FIG. 6). Tire pressure and temperature monitoring system 74 includes a communications module 80 that is in wireless communication with a plurality of tire sensors 82a-h. Stability module 76 preferably provides trailer roll over control and automatic braking. CAN port 44 may be electrically coupled to other devices such as a trailer lift axle control device that controls the position of lift axles during operation of a trailer (e.g., Haldex's ILAS E trailer lift axle control system). CAN port 44 is preferably configured to include at least four separate electrical connections. Two of the electrical connections operate to receive and transmit data using differential signaling. Two of the electrical connections include a 12V power source and ground such that CAN port 44 can be used to power auxiliary components that are connected to the CAN port 44, such as the communications device 20, tire pressure and temperature monitoring system 74, and stability module 76. Processor 24 can preferably shut off power through the 12V power source of the CAN port 44 so that there is sufficient power for trailer control module 12 at critical moments, such as during a potential rollover or jackknife condition. CAN port 44 is preferably operable with diagnostic tools such as Haldex's Infocenter2, Haldex Diagnostics+, and Haldex Fleet+.

[0048] Power input 46 is electrically coupled to a cable 84 that provides power to trailer control module 12. Power input 46 is preferably configured for connection with a power line carrier (PLC) protocol 7-way cable. Power input 46 preferably has the capability to both receive power from an external source for powering trailer control module 12 and act as a data port that sends data from trailer control module 12 to external devices and receives data from the external devices. For example, power input 46 may receive stoplight power (voltage) through PLC cable 84. Power input 46 and PLC cable 84 preferably receive signals and data from, and transmit signals and data to, a tractor to which a trailer having trailer brake and monitoring system 10 is coupled. Power input 46 and PLC cable 84 are preferably operable with diagnostic tools such as Haldex's PLC Infocenter, PLC PC Diagnostics, third party PLC diagnostic tools, and ABS fault lamp blink codes.

[0049] First auxiliary port 48 and second auxiliary port 50 are configured to be electrically coupled with auxiliary components such as those to measure tire pressure, tire inflation, tire temperature, brake temperature, brake stroke, the door switch, suspension pressure, tail fin deployment, power spring connection, steer axle lock, reverse detection, low reservoir, anti dock walk, lift axle, suspension dump, trailer roll stability, and hub odometer. First auxiliary port 48 and second auxiliary port 50 are preferably configured so that one of the first and second auxiliary ports 48, 50 is a switched input and the other of first and second auxiliary ports 48, 50 is a 12 Vdc output that is activated in response to a signal received at the switched input. For example, the first and second auxiliary ports 48 and 50 may act as an on/off switch to provide an action determined by pressures, temperature, power voltage and other inputs. First auxiliary port 48 and/or second auxiliary port 50 may control operation of a trailer lift axle control device that controls the position of lift axles during operation of a trailer (e.g., Haldex's ILAS E trailer lift axle control system).

[0050] Brake valve 14 is preferably a full function ABS (FFABS) valve, such as the Haldex FFABS valve or the valve disclosed in U.S. Pat. No. 5,722,740, which is hereby incorporated by reference herein. Brake valve 14 controls the flow of air to and from the brake actuators 58 and 60. Referring to FIG. 6, brake valve 14 includes a supply pressure inlet 86, a control pressure inlet 88, a service brake pressure outlet 90, and an emergency brake pressure outlet 92. Supply pressure inlet 86 is coupled via a gladhand 94 (FIG. 1) to a source of pressurized air, such as an air reservoir on a tractor to which is connected a trailer containing the trailer brake and monitoring system 10. Control pressure inlet 88 is coupled to booster valve 18, as described in more detail below. Service brake pressure outlet 90 is coupled with the service brake chambers 54 and 56 of brake actuators 58 and 60. Emergency brake pressure outlet 92 is coupled with the emergency brake chambers 96 and 98 of brake actuators 58 and 60. Air entering brake valve 14 through supply pressure inlet 86 is preferably routed in a conventional manner through the brake valve 14 to an air reservoir 100 (FIG. 2) mounted on a trailer and to emergency brake chambers 96 and 98, such as described in U.S. Pat. No. 5,722,740. Brake valve 14 preferably routs air from air reservoir 100 through service brake pressure outlet 90 when pressurized air is supplied to control pressure inlet 88 depending on the condition of ABS 72, as described in U.S. Pat. No. 5,722,740.

[0051] Reservoir purge valve 16 is preferably a purge valve, such as the Haldex Reservoir Purge Valve or the valve disclosed in U.S. Patent Application Publication No. 2017/0146137, which is hereby incorporated by reference herein. Reservoir purge valve 16 exhausts air and contaminants from air reservoir 100 when there is a loss of supply pressure at supply pressure inlet 86 (i.e., when the emergency brakes of brake actuators 58 and 60 are actuated). Reservoir purge valve 16 includes a control port 102 that is in fluid communication with the supply pressure inlet 86 of brake valve 14, a reservoir inlet port 104 that is in fluid communication with a port of air reservoir 100, and an exhaust port 106.

[0052] Booster valve 18 (FIG. 2) is preferably a booster or relay valve, such as a Haldex Relay Valve. Booster valve 18 has a service brake control inlet 108 that is in fluid communication with a service brake control line of a tractor via a gladhand 109, a supply inlet 110 that is in fluid communication with air reservoir 100, a service brake control outlet 112 that is in fluid communication with the control pressure inlet 88 of brake valve 14, and another service brake control outlet 114 that may be placed in fluid communication with a rear trailer via a gladhand 116. Preferably, when a driver of a tractor depresses a brake pedal, pressurized air from the tractor enters the service brake control inlet 108, which causes air from supply inlet 110 to exit booster valve 18 through service brake control outlet 112 and enter brake valve 14 through control pressure inlet 88.

[0053] Communications device 20 (FIG. 4) is preferably a telematics unit. Communications device 20 receives data from CAN port 44 and transmits the data to a central server 79 for storage or processing. Communications device 20 preferably wirelessly transmits the data to central server 79 where it can be stored, processed, and/or transmitted to other locations or devices. Communications device 20 may wirelessly transmit the data over a cellular data connection or a wireless internet connection. Communications device 20 may include a processor with the capability to process data received from CAN port 44.

[0054] Mounting bracket 22 provides a mounting surface for mounting trailer control module 12, brake valve 14, reservoir purge valve 16, booster valve 18, and alarm 130. Trailer control module 12, brake valve 14, reservoir purge valve 16, booster valve 18, and alarm 130 may be removably or permanently mounted to mounting bracket 22. Referring to FIG. 2, mounting bracket 22 includes a mounting plate 118 to which the trailer control module 12, brake valve 14, reservoir purge valve 16, booster valve 18, and alarm 130 are mounted. Mounting plate 118 includes slots, one of which is identified as 120, that receive fasteners to adjustably mount clamp assemblies 122 and 124 to mounting plate 118. As shown in FIGS. 14A-14B, clamp assemblies 122 and 124 are configured to removably clamp to I-beams 202a and 202b of a trailer 200 for removably coupling mounting bracket 22 to the trailer 200. Mounting bracket 22 may be configured and function as described in U.S. Pat. No. 8,511,929 and/or U.S. Patent Application Publication No. 2011/0236128, each of which are hereby incorporated by reference herein. In the event of a failure of trailer brake and monitoring system 10, it may be replaced with a new trailer brake and monitoring system 10 by removably coupling the mounting bracket 22 of the old trailer brake and monitoring system 10 from engagement with the vehicle to which it is mounted and coupling the mounting bracket 22 of the new trailer brake and monitoring system 10 with the vehicle.

[0055] FIGS. 14A-14B show trailer brake and monitoring system 10 mounted to a drop deck trailer 200. In this configuration, trailer brake and monitoring system 10 is preferably positioned behind air reservoir 100, which is positioned behind a protective shield 204 mounted underneath the trailer 200 and extending downward toward the ground. FIGS. 15A-15B show trailer brake and monitoring system 10 mounted to a straight rail trailer 300. Clamp assemblies 122 and 124 removably clamp to I-beams 302a and 302b of trailer 300 for removably coupling mounting bracket 22 to the trailer 300. Trailer brake and monitoring system 10 is positioned behind air reservoir 100.

[0056] An optional mounting of trailer control module 12 and brake valve 14 is shown in FIG. 5. Trailer control module 12 is mounted to brake valve 14 with a bracket 125. A threaded air reservoir port 127 of brake valve 14 engages a threaded opening of air reservoir 100 to mount trailer control module 12 and brake valve 14 to air reservoir 100. Air reservoir 100 is mounted to a vehicle in a conventional manner. With this mounting arrangement, reservoir purge valve 16, booster valve 18 and other components of trailer brake and monitoring system 10 may be mounted to the vehicle using mounting bracket 22 or as otherwise known in the art.

[0057] A height control valve 126 (FIG. 2) is placed in fluid communication with air reservoir 100 through a pressure protection valve 128. As is generally known in the art, height control valve 126 is mounted to a frame of a vehicle, such as a trailer, and includes a lever that is mounted to a movable suspension component of the vehicle, such as a trailing arm. As the trailing arm moves up, the height control valve 126 introduces air from the air reservoir into an air spring suspension of the vehicle to level the vehicle, and as the trailing arm moves down, the height control valve 126 exhausts air from the air spring suspension. The pressure protection valve 128 blocks the flow of air to height control valve 126 when the air pressure in air reservoir 100 drops below a predetermined level.

[0058] Trailer brake and monitoring system 10 also includes an alarm 130 that is electrically coupled via a wire with trailer control module 12. Alarm 130 preferably sounds an audible alarm to warn an operator of a particular condition sensed by trailer control module 12, as described in more detail below.

[0059] In operation, processor 24 (FIG. 6) receives a brake control pressure signal from brake control pressure input 28 and a brake supply pressure signal from brake supply pressure input 26. The brake control pressure signal corresponds to the pressure supplied by brake valve 14 to the service brake chambers 54 and 56 (FIG. 1) of brake actuators 58 and 60, and the brake supply pressure signal corresponds to the pressure supplied by brake valve 14 to the emergency brake chambers 96 and 98 of brake actuators 58 and 60.

[0060] Processor 24 compares the brake control pressure signal to a predefined brake control pressure range, which may be stored in memory 25 coupled with processor 24. If the brake control pressure signal is not within the predefined brake control pressure range (e.g., the brake control pressure signal indicates that the brake control pressure is too high or too low for the present condition of trailer brake and monitoring system 10), processor 24 generates and sends a first warning signal to CAN port 44 and power input 46. The first warning signal is sent from CAN port 44 to communications device 20, which wirelessly sends the first warning signal to central server 79. Power input 46 may send the first warning signal to a display panel or alarm in the cab of the tractor to notify the driver of a potentially unsafe operating condition. The first warning signal may also be sent to alarm 130 for sounding an audible alarm.

[0061] Processor 24 compares the brake supply pressure signal to a predefined brake supply pressure range, which may be stored in memory 25 coupled with processor 24. If the brake supply pressure signal is not within the predefined brake supply pressure range (e.g., the brake supply pressure signal indicates that the brake supply pressure is too high or too low for the present condition of trailer brake and monitoring system 10), processor 24 generates and sends a second warning signal to CAN port 44 and power input 46. The second warning signal is sent from CAN port 44 to communications device 20, which wirelessly sends the second warning signal to central server 79. Power input 46 may send the second warning signal to a display panel or alarm in the cab of the tractor to notify the driver of a potentially unsafe operating condition. The second warning signal may also be sent to alarm 130 for sounding an audible alarm.

[0062] Central server 79 preferably stores the occurrence of any first and second warning signals and any corresponding data relating to the brake control pressure signal and/or brake supply pressure signal causing the warning signal. Central server 79 preferably also receives and stores a history over time of the brake control pressure signal and brake supply pressure signal from CAN port 44 and may perform the steps of comparing the brake control pressure signal with a brake control pressure range, comparing the brake supply pressure signal with a brake supply pressure range, generating a first warning signal if the brake control pressure signal is not within the brake control pressure range, and generating a second warning signal if the brake supply pressure signal is not within the brake supply pressure range. Central server 79 preferably sends a notification, such as an e-mail or a text message, to a fleet service operator to notify them of a potential error condition with the vehicle on which trailer brake and monitoring system 10 is installed. The fleet service operator may also have access to the data stored in central server 79 via a web portal or other software that notifies the fleet service operator when a first or second warning signal is generated or received by central server 79.

[0063] Processor 24 receives a first wheel speed signal from the first wheel speed input 30, a second wheel speed signal from the second wheel speed input 32, a third wheel speed signal from the third wheel speed input 34, and a fourth wheel speed signal from the fourth wheel speed input 36. Processor 24 is configured to send a first brake signal to the first valve output 38 and to ABS 72 of brake valve 14 based on at least one of the first wheel speed signal and the second wheel speed signal. The first brake signal activates or deactivates ABS 72 based on the first wheel speed signal and/or second wheel speed signal. The brake valve 14 controls braking of at least one of the wheels whose speed is sensed by the first wheel speed sensor 64 and the second wheel speed sensor 66. For example, if the wheel corresponding with first wheel speed input 30 and/or second wheel speed input 32 begins to skid, the first brake signal may activate ABS 72 to stop the wheel(s) from skidding.

[0064] Processor 24 is configured to send a second brake signal to second valve output 40 and an ABS of second brake valve 132 (FIGS. 8A-13D) based on at least one of the first wheel speed signal, second wheel speed signal, third wheel speed signal and the fourth wheel speed signal. The second brake signal activates or deactivates the ABS of the second brake valve 132 based on the first wheel speed signal, second wheel speed signal, third wheel speed signal and/or the fourth wheel speed signal. The second brake valve 132 controls braking of at least one of the wheels whose speed is sensed by the third wheel speed sensor 68 and the fourth wheel speed sensor 70.

[0065] Processor 24 is configured to send a third brake signal to the third valve output 42 and an ABS of a third brake valve 134 (FIGS. 13A-13D) based on at least one of the third wheel speed signal and the fourth wheel speed signal. The third brake signal activates or deactivates the ABS of the third brake valve 134 based on the third wheel speed signal and/or the fourth wheel speed signal. The third brake valve 134 controls braking of at least one of the wheels whose speed is sensed by the third wheel speed sensor 68 and the fourth wheel speed sensor 70.

[0066] FIGS. 7A-13D show exemplary embodiments of configurations of first, second, third, and fourth wheel speed sensors 64, 66, 68, and 70 and of brake valve 14, second brake valve 132, and third brake valve 134 for different types of vehicles and setups.

[0067] FIGS. 7A-7E show 2S (sensor)/1M (modulator or brake valve) configurations of trailer brake and monitoring system 10 for five different types of single or multi-axle trailer configurations: a single axle (dolly) (FIG. 7A), a single axle (air or spring suspension) (FIG. 7B), a tandem axle (air suspension) (FIG. 7C), a tandem axle (spring suspension) (FIG. 7D), and a tri-axle (air or spring suspension) (FIG. 7E). Positions of first and second wheel speed sensors 64 and 66 and of brake valve 14 are indicated in FIGS. 7A-7E for the different configurations. In these configurations, third and fourth wheel speed sensors 68 and 70 and second and third valve outputs 40 and 42 are not used. In each configuration shown in FIGS. 7A-7E, the brake valve 14 controls the operation of the braking assemblies on both sides of the vehicle.

[0068] FIGS. 8A-8D show 2S/2M configurations of trailer brake and monitoring system 10 for four different types of multi-axle trailer configurations: a single axle (air or spring suspension) (FIG. 8A), a tandem axle (spring suspension) (FIG. 8B), a tandem axle (air suspension) (FIG. 8C), and a tri-axle (air or spring suspension) (FIG. 8D). Positions of first and second wheel speed sensors 64 and 66, of brake valve 14, and of second brake valve 132 are indicated in FIGS. 8A-8D for the different configurations. In these configurations, third and fourth wheel speed sensors 68 and 70 and third valve output 42 are not used. In each configuration shown in FIGS. 8A-8D, the brake valve 14 controls the operation of the braking assemblies on one side of the vehicle, and the second brake valve 132 controls the operation of the braking assemblies on the other side of the vehicle.

[0069] FIGS. 9A-9D show 4S/2M configurations of trailer brake and monitoring system 10 for four different types of multi-axle trailer configurations: a tandem axle (air or spring suspension) (FIG. 9A), a tri-axle (air or spring suspension) (FIG. 9B), a quad-axle (air suspension) (FIG. 9C), and a quad-axle (spring suspension) (FIG. 9D). Positions of first, second, third, and fourth wheel speed sensors 64, 66, 68, and 70, of brake valve 14, and of second brake valve 132 are indicated in FIGS. 9A-9D for the different configurations. In these configurations, third valve output 42 is not used. In each configuration shown in FIGS. 9A-9D, the brake valve 14 controls the operation of the braking assemblies on one side of the vehicle, and the second brake valve 132 controls the operation of the braking assemblies on the other side of the vehicle.

[0070] FIGS. 10A-10C show 4S/2M configurations of trailer brake and monitoring system 10 for three different types of multi-axle trailer with lift axle(s) configurations: a tandem axle (FIG. 10A), a tri-axle (FIG. 10B), and a quad-axle (FIG. 10C). Positions of first, second, third, and fourth wheel speed sensors 64, 66, 68, and 70, of brake valve 14, and of second brake valve 132 are indicated in FIGS. 10A-10C for the different configurations. In these configurations, third valve output 42 is not used. In each configuration shown in FIGS. 10A-10C, the brake valve 14 controls the operation of the braking assemblies on one side of the vehicle, and the second brake valve 132 controls the operation of the braking assemblies on the other side of the vehicle.

[0071] FIGS. 11A-11E show 4S/2M configurations of trailer brake and monitoring system 10 for five different types of multi-axle trailer configurations, as recommended for spread axle applications: a tandem axle (air or spring suspension) (FIG. 11A), a tri-axle (air or spring suspension) (FIG. 11B), a quad-axle (air suspension) (FIG. 11C), a quad-axle (spring suspension) (FIG. 11D), and a full trailer (air or spring suspension) (FIG. 11E). Positions of first, second, third, and fourth wheel speed sensors 64, 66, 68, and 70, of brake valve 14, and of second brake valve 132 are indicated in FIGS. 11A-11E for the different configurations. In these configurations, third valve output 42 is not used. In each configuration shown in FIGS. 11A-11E, the brake valve 14 controls the operation of the braking assemblies for one or more axles on both sides of the vehicle, and the second brake valve 132 controls the operation of the braking assemblies for one or more axles on both sides of the vehicle.

[0072] FIGS. 12A-12C show 4S/2M configurations of trailer brake and monitoring system 10 for three different types of multi-axle trailer with lift axle(s) configurations, as recommended for spread axle applications: a tandem axle (FIG. 12A), a tri-axle (FIG. 12B), and a quad-axle (FIG. 12C). Positions of first, second, third, and fourth wheel speed sensors 64, 66, 68, and 70, of brake valve 14, and of second brake valve 132 are indicated in FIGS. 12A-12C for the different configurations. In these configurations, third valve output 42 is not used. In each configuration shown in FIGS. 12A-12C, the brake valve 14 controls the operation of the braking assemblies for one or more axles on both sides of the vehicle, and the second brake valve 132 controls the operation of the braking assemblies for one or more axles on both sides of the vehicle.

[0073] FIGS. 13A-13D shows 4S/3M configurations of trailer brake and monitoring system 10 for four different types of full and semi-trailer configurations: a full trailer (air suspension) (FIG. 13A), a full trailer (air or spring suspension) (FIG. 13B), a semi-trailer tandem axle (air or spring suspension) (FIG. 13C), and a semi-trailer tri-axle (air suspension) (FIG. 13D). Positions of first, second, third, and fourth wheel speed sensors 64, 66, 68, and 70, of brake valve 14, of second brake valve 132, and of third brake valve 134 are indicated in FIGS. 13A-13D for the different configurations. In each configuration shown in FIGS. 13A-13D, the brake valve 14 controls the operation of certain braking assemblies on one side of the vehicle, the second brake valve 132 controls the operation of certain braking assemblies on the other side of the vehicle, and the third brake valve 134 controls the operation of braking assemblies for an axle on both sides of the vehicle.

[0074] Referring to FIG. 6, processor 24 may monitor stoplight power (voltage) provided to power input 46 through PLC cable 84 and compare that measured value to the brake control pressure signal from brake control pressure input 28. If the actual measured value differs from or exceeds a maximum allowable deviation (for example, if the brake control pressure signal indicates that the service brakes of the vehicle are being applied but the stoplight power voltage indicates that power is not being supplied to the brake lights), processor 24 may generate and send a warning signal to CAN port 44, power input 46, and alarm 130 in a similar manner as described above with respect to the first and second warning signals.

[0075] Processor 24 may receive data through CAN port 44, power input 46, and/or first and second auxiliary ports 48 and 50 corresponding to: tire pressure, tire inflation, tire temperature, brake temperature, brake stroke, the door switch, suspension pressure, tail fin deployment, power spring connection, steer axle lock, reverse detection, low reservoir, anti dock walk, lift axle, suspension dump, trailer roll stability, and hub odometer. Processor 24 may compare the data to a predefined set-point or ranges for such data and/or to other data received by processor 24 to determine if an error condition exists. If an error condition exists, processor 24 may generate and send a warning signal to CAN port 44, power input 46, and alarm 130 in a similar manner as described above with respect to the first and second warning signals. Further, the warning signal may be transmitted to communications device 20 and central server 79, as described above. Exemplary types of warning signals that may be generated by processor 24 are described below.

[0076] Processor 24 may generate a brake drag warning signal in the event that a low-pressure situation is detected (e.g., a known pressure range may allow a brake system to still function but will be known to cause brake drag) within a range of pressures. It is contemplated that a brake drag warning signal may be transmitted to a user/driver in the cab of the tractor-trailer through power input 46 and PLC cable 84 or may also be transmitted to central server 79 through CAN port 44.

[0077] Additional warning signals that may be generated by processor 24 include an incorrect connection warning signal, a closed service/control valve warning signal, a closed emergency/supply warning signal, no stoplight power warning signal, and an ABS warning signal. As the brake system is serviced and/or repaired, it is possible to reconnect the various pressure lines incorrectly. By measuring the brake control pressure and brake supply pressure, processor 24 is able to determine if a pressure line(s) is incorrectly connected to the brake valve 14. It is further contemplated that the position of the brake valve 14 may be measured and this data and/or information may be transmitted to processor 24 through first valve output 38 such that a warning or alarm may be generated in the event the brake valve 14 fails to actuate as designed. All of these indications may be generated/transmitted as described above.

[0078] Additional parameters that may be monitored by processor 24 and that may form the basis for a warning signal or indication include: tire pressure, tire inflation, tire temperature, brake temperature, brake stroke, door (ajar), suspension pressure, tail fin deployment, power spring condition, steer axle lock, reverse detection, low reservoir, anti dock walk, lift axle and suspension dump. The indication may be provided as an alarm, a warning lamp, a wireless message, a signal, or any combination thereof.

[0079] Failure of one or more tires on a tractor-trailer can be very dangerous. This is complicated by the fact that a tire may catastrophically fail with little or no warning or a tire may fail (e.g. on the trailer) and the operator does not become aware of the failure until much later. The tire pressure, tire inflation and tire temperature are all indications to the operator providing data relating to the status of the tires on the tractor-trailer allowing the operator to take quick action in the event of a failure. The information can also allow the operator to address any problems with the tires relatively early so as to avoid catastrophic failure on the road. The devices used to measure the above parameters may comprise any of the standard measurement devices.

[0080] The brake temperature and brake stroke are indications that provide warnings if the temperature of the brakes rises above a threshold level or if the measured stroke of the brake indicates excessive wear. The safe operation of the braking system in a tractor-trailer is critical. In the event that the braking system gets too hot, an indication may be generated so that the braking system can be inspected and/or serviced as necessary to ensure proper functionality. The brake stroke indication can be generated by a linear location measurement that can provide a service needed alert.

[0081] The door (ajar) indication may comprise, for example, a switch that indicates whether the door on the trailer is fully closed or not. It is understood that the switch may be programmable as either a normally closed or normally open switch.

[0082] The suspension pressure indication relates to a pressure measurement to ensure that the air pressure in the suspension system does not exceed a defined threshold. This threshold can be either a high limit or a low limit or both. The measurement device could comprise any of a transducer, a pressure switch or a sensor.

[0083] Tail fin deployment may comprise an indication generated by a switch as described in connection with the door (ajar) indication. This would alert the operator that the tail fin was in a deployed position so that it could be retracted properly prior to operating the vehicle.

[0084] With respect to the power spring condition indication, fractures or catastrophic failure of the power spring due to, for example, corrosion or wearing of the device can be very dangerous. To avoid this, a measurement that indicates that the power spring may be damaged or wearing can be obtained by a linear location measurement or measuring a home location for the power spring. If the power spring begins to wear, the power spring will not return to the original or home location that it originally started from when installed. Alternatively, the measurement could comprise a continuity measurement.

[0085] The steer axle lock is a function that locks the steering axle once the vehicle reaches a certain speed. At relatively low speed, the steer axle functionality provides the operator of the vehicle with greater maneuverability; however, such functionality is not safe at higher speeds. Accordingly, the steering axle may automatically lock at a desired vehicle speed, which may be fully programmable. The indication provides the monitoring device with information that the lock has engaged.

[0086] The reverse detection indication can be used to actuate various devices on the trailer such as a back-up alarm (audible sound) or reverse lights, etc. The measurement device providing the indication may in one embodiment comprise a Hall Effect switch.

[0087] It is important to receive information relating to the pressure in the primary air reservoir that provides pressurized air to the suspension system and the air brake system. A low reservoir indication may be generated by pressure measurement that may comprise any known type of pressure sensor or switch.

[0088] An anti dock walk indication provides a warning to the operator that the anti dock walk system is engaged and must be disengaged prior to operation of the vehicle.

[0089] The lift axle provides the operator with an indication that the lift axle should be in the down position. The axle in a tractor-trailer may set in either an up or down position, however, when the trailer is loaded the axle should be set in the down position. This indication will alert the operator to lower the axle if the weight of the trailer exceeds a threshold value. This threshold may be completely programmable.

[0090] The suspension dump provides an indication that the air in the suspension system has been rapidly exhausted from the air bags. Due to the fact that the axles of the tractor-trailer are relatively far apart (variable based on the length of the vehicle), when the vehicle makes a sharp turn the tires on the trailer axles have a tendency to be dragged sideways rather than rolling forward. This dragging severely wears the tires leading to premature failure. However, if the air in the suspension system is dumped in one of the axles (e.g., the forward axle of the two rear axles on the trailer), this allows for less wearing of the tires.

[0091] All or some of the data may be transmitted as data to central server 79 where historical data may be accumulated for each vehicle. In this manner, trends may be followed and maintenance could be anticipated/scheduled according to the vehicle's historical data prior to failure of device(s) and/or system(s). It is also contemplated that control for a backup alarm may be provided such that a backup indicated is generated and transmitted. In one embodiment, different transmission paths for the indication and backup indication may be used to ensure delivery of the indication. The system could utilize two wired transmission paths, or wireless transmission, or power line connection as desired to ensure reliable transmission. It is understood that the transmission method can be selected based on the application.

[0092] From the foregoing it will be seen that this invention is one well adapted to attain all ends and objectives herein-above set forth, together with the other advantages which are obvious and which are inherent to the invention.

[0093] Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative, and not in a limiting sense.

[0094] While specific embodiments have been shown and discussed, various modifications may of course be made, and the invention is not limited to the specific forms or arrangement of parts and steps described herein, except insofar as such limitations are included in the following claims. Further, it will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.