TIRE WITH MAGNETIC TREAD WEAR SENSOR AND TREAD WEAR MONITORING METHOD

Abstract

This invention relates to tire tread wear monitoring. A sacrificial magnet portion is arranged in a tread of the tire so that it undergoes wear along with the tread and generates a useful magnetic field signal indicative of remaining tread thickness. With a magnetic field sensor arranged on or in the tire, an overall magnetic field signal is measured, which includes the useful magnetic field signal, and a superimposed interfering magnetic field signal generated by magnetizable material contained in the tire. A non-sacrificial magnet portion is used to saturate the magnetizable material at least locally so as to make the interfering magnetic field signal sensed by the magnetic field sensor substantially independent of the useful magnetic field signal sensed by the magnetic field sensor. Further aspects of the invention relate to tires, e.g., vehicle tires, featuring a tire tread wear monitoring system.

Claims

1. A tire, comprising: a tread, the tread having arranged therein a sacrificial magnet portion exposed to tread wear, the sacrificial magnet portion generating a useful magnetic field signal varying as a function of tread wear, magnetizable material having a magnetization depending non-linearly on magnetic field strength, the magnetizable material generating an interfering magnetic field signal superimposing the useful magnetic field signal; a magnetic field sensor for measuring the useful magnetic field signal and the superimposed interfering magnetic field signal; and a permanent magnet portion arranged proximate the magnetizable material so as to decouple the interfering magnetic field signal sensed by the magnetic field sensor from the useful magnetic field signal sensed by the magnetic field sensor by substantially saturating the magnetizable material.

2. The tire as claimed in claim 1 wherein the sacrificial magnet portion and the permanent magnet portion are integrated within a stud embedded in the tread.

3. The tire as claimed in claim 2 wherein the tread comprises a recess shaped complementarily to the stud so as to secure the stud in position and relative orientation.

4. The tire as claimed in claim 1 wherein the sacrificial magnet portion comprises a plug with magnetic particles dispersed therein.

5. The tire as claimed in claim 1 wherein the sacrificial magnet portion comprises plural discrete magnetic inserts arranged radially aligned at different depths in the tread.

6. The tire as claimed in claim 1 including a breaker or a belt, the magnetizable material being part of the breaker or the belt.

7. The tire as claimed in claim 1 including a controller operatively connected to the magnetic field sensor, the controller configured to receive the useful magnetic field signal and to derive from the useful magnetic field signal an indicator of at least one of tread profile depth, tread wear and estimated remaining tread lifetime.

8. The tire as claimed in claim 1 wherein the sacrificial magnet portion, the permanent magnet portion, and the magnetic field sensor are radially aligned.

9. The tire as claimed in claim 1 wherein the sacrificial magnet portion has a magnetic moment, wherein the permanent magnet portion has a magnetic moment and wherein the magnetic moment of the sacrificial magnet portion and the magnetic moment of the permanent magnet portion are collinear.

10. The tire as claimed in claim 1 wherein the sacrificial magnet portion has a magnetic moment, wherein the permanent magnet portion has a magnetic moment and wherein the magnetic moment of the sacrificial magnet portion and the magnetic moment of the permanent magnet portion are perpendicular.

11. The tire as claimed in claim 1 wherein the magnetic field sensor includes at least one of a single-axis Hall sensor, a multi-axis Hall sensor, a magnetoresistive-effect-based magnetometer, a magnetostrictive-effect-based magnetometer and a Lorentz-force-based MEMS magnetometer.

12. The tire as claimed in claim 1 wherein the magnetic field sensor comprises a three-axis magnetometer.

13. A vehicle tire, comprising: a tread, the tread including raised areas and grooves, a sacrificial magnet portion including one or more magnetic inserts arranged in a raised area of the tread so as to undergo wear along with the tread, the one or more magnetic inserts generating a useful magnetic field signal indicative of tread thickness, a carcass defining a tire interior; a breaker or a belt arranged between the tread and the carcass, the breaker or belt including saturable magnetizable material; a magnetic field sensor arranged in the tire interior for measuring the useful magnetic field signal and a superimposed interfering magnetic field signal generated by the magnetizable material of the breaker or belt; and a non-sacrificial magnet portion including a permanent magnet magnetically saturating the magnetizable material at least locally so as to make the interfering magnetic field signal sensed by the magnetic field sensor substantially independent of the useful magnetic field signal sensed by the magnetic field sensor.

14. The vehicle tire as claimed in claim 13 wherein the one or more magnetic inserts, the magnetic field sensor and the permanent magnet are radially aligned, wherein the one or more magnetic inserts have a magnetic moment, wherein the permanent magnet has a magnetic moment and wherein the magnetic moment of the one or more magnetic inserts and the magnetic moment of the permanent magnet are collinear.

15. The vehicle tire as claimed in claim 13 wherein the one or more magnetic inserts, the magnetic field sensor and the permanent magnet are radially aligned, wherein the one or more magnetic inserts have a magnetic moment, wherein the permanent magnet has a magnetic moment and wherein the magnetic moment of the one or more magnetic inserts and the magnetic moment of the permanent magnet are perpendicular.

16. The vehicle tire as claimed in claim 13 including a controller operatively connected to the magnetic field sensor, the controller configured to receive the useful magnetic field signal and to communicate information derived from the useful magnetic field to an on-board diagnostics system.

17. Tire tread wear monitoring method, comprising: generating, with one or more magnetic inserts arranged in a tread of the tire so as to undergo wear along with the tread, a useful magnetic field signal indicative of remaining tread thickness, measuring, with a magnetic field sensor arranged on or in the tire, an overall magnetic field signal including the useful magnetic field signal and a superimposed interfering magnetic field signal generated by magnetizable material contained in the tire, saturating, with a permanent magnet, the magnetizable material at least locally so as to make the interfering magnetic field signal sensed by the magnetic field sensor substantially independent of the useful magnetic field signal sensed by the magnetic field sensor.

18. The method as claimed in claim 17 comprising processing the overall magnetic field signal, the processing including deriving at least one of tread profile depth, tread wear and estimated remaining tread lifetime from the overall magnetic field signal.

19. The method as claimed in claim 17 comprising issuing a warning when the at least one of tread profile depth, tread wear and estimated remaining tread lifetime reaches a threshold.

20. The method as claimed in claim 17 comprising combining the at least one of tread profile depth, tread wear and estimated remaining tread lifetime with TPMS information in a digital tire state information message or report.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] By way of example, preferred, non-limiting embodiments of the invention will now be described in detail with reference to the accompanying drawings, in which:

[0052] FIG. 1 is a cross-sectional schematic view of a vehicle tire equipped with a tire tread wear monitoring system according to an embodiment of the invention;

[0053] FIG. 2 is a simplified illustration of the evolution of a magnetic field signal at the magnetometer of a tire tread wear monitoring system according to an embodiment of the invention;

[0054] FIG. 3 is a cross-sectional schematic view of a vehicle tire equipped with a tire tread wear monitoring system according to a further embodiment of the invention;

[0055] FIG. 4 is a simplified illustration of the evolution of the useful magnetic field signal over time;

[0056] FIG. 5 is a simplified illustration of the evolution of the magnetic field signal caused by the saturating magnet and the magnetisable material, when the system operates normally (solid line) or when the saturating magnet fails (dotted line);

[0057] FIG. 6 is a partial cross-sectional schematic view of a vehicle tire equipped with a magnetic stud that comprises a sacrificial magnet portion and a non-sacrificial saturating magnet portion;

[0058] FIG. 7a is a schematic illustration of a first embodiment of a magnetic stud;

[0059] FIG. 7b is a schematic illustration of a second embodiment of a magnetic stud;

[0060] FIG. 8 is a partial cross-sectional schematic view of a vehicle tire equipped with a magnetic stud, wherein the sacrificial magnet portion comprises plural discrete magnets;

[0061] FIG. 9 is a simplified illustration of the evolution of the useful magnetic field signal over time, when the sacrificial magnet portion comprises plural discrete magnets that become eroded at distinct times; and

[0062] FIG. 10 is a simplified illustration of the installation process of a magnetic stud into a tire.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0063] The apparatuses and methods herein disclosed may use a distributed, magnetic sensing system capable of providing current tire tread depth or another indicator of tire wear. In preferred embodiments, this distributed system comprises one or more magnetic inserts installed in a raised area of the tread (e.g. in a tread block or rib) and undergoing wear along with tread rubber around and a magnetometer installed inside the tire (bonded to inner liner), radially aligned with the one or more magnetic inserts. The magnetometer measures the magnetic field. The long-term variation of the magnetic field is attributed to the erosion of the one or more magnetic inserts due to tread wear. A key challenge is to provide a stable and robust magnetic measurement, in particular in the presence of magnetizable material (e.g. one or more layers of steel breakers or belts in the tire carcass).

[0064] The magnetization of the magnetizable material, such as that of the breakers or belts, depends on the external magnetic field but not only. Changes of the magnetization and thus of the magnetic field sensed by the magnetometer may also result from chocks, material stress, temperature variations and environmental magnetic fields, which cannot be avoided on a rolling tire. Magnetic field variations (including long-term variations) sensed by the magnetometer cannot, therefore, be readily attributed to wear of the one or more magnetic inserts. In other words, the variations occasioned by magnetization changes potentially mask the variations that are due to tread wear. Consequently, tread wear cannot be determined with a sufficient level of certainty unless remedial action is taken. Carcass demagnetization did not show satisfactory results because as deformation and flexion of the tire during its lifetime made magnetization reappear quasi-randomly.

[0065] According to aspects of the invention, a permanent magnet (also referred to as “saturating magnet”) is arranged in the tire in such a way as to substantially saturate the magnetization of the magnetizable material. In the saturation region, the magnetization becomes essentially independent of variations of the external magnetic field. Furthermore, since the permanent magnet strongly biases the magnetizable material, other external parameters (e.g., chocks, material stress, temperature variations) will have only reduced influence on the magnetization. Therefore, the interfering magnetic field will be essentially constant and can be subtracted or otherwise be compensated for in the measurement.

[0066] According to an aspect of the invention, the signal-to-noise ratio of the measurement of the magnetic field generated by the one or more magnetic inserts (permanent magnet(s) in the tread of the tire—hereinafter also referred to as “tread magnet” for simplicity). The tread magnet can be used to monitor the compression and shear forces in a tread block or rib (in this case, the tread magnet works as a joystick) or to monitor the tread depth or the tire wear state as the tread magnet would be abraded as the tire tread (wear sensor).

[0067] An embodiment of the invention is illustrated in FIG. 1, which shows part of a tire 10, mounted on a wheel rim, in cross section. A tread magnet 12 is arranged in the tread 13 of the tire in such a way that it erodes together with the tread. The magnetic moment of the tread magnet 12 is oriented radially, i.e. pointing or away from to the tire axis (not shown). A magnetometer 11 is arranged in the tire interior, e.g., on an inner liner. The magnetometer 11 senses the magnetic field 14 of the tread magnet 12 (together with any superimposed magnetic fields). A strong permanent magnet 17 (“saturating magnet”) is arranged in the tire 10 so as not to be exposed to wear and very close to the breakers 16. Permanent magnet 17 is arranged on the axis of the tread magnet 12. The magnetic field strength of the saturating magnet is chosen such that it saturates the magnetization of the metallic breaker 16. The magnetometer 11 is connected to controller module 16, e.g. a TPMS (tire pressure monitoring system) module, which provides wireless communication with the vehicle's on-board diagnostic system.

[0068] FIG. 2 schematically illustrates the long-term evolution of the magnetic field strength sensed by the magnetometer 11. The permanent magnet 17 biases the magnetic field generated by the breaker 16 to a stable value h.sub.sat. The overall magnetic field signal measured by the magnetometer 11 is h.sub.sat+h.sub.tread, where h.sub.tread is the magnetic field generated by the tread magnet 12.

[0069] In the embodiment of FIG. 1, the magnetic moments of the saturating magnet and the tread magnet are collinear. The useful magnetic field signal h.sub.tread may be only a small part of the overall signal, which decreases over time as the tread magnet 12 is worn away (FIG. 2).

[0070] FIG. 3 illustrates an embodiment of the invention, wherein the saturation magnet 17 is arranged such that its magnetic moment is perpendicular to the magnetic moment of the tread magnet. In FIG. 3, the axis of the magnetic moment of the tread magnet 12 is shown at reference number 18 and the axis of the magnetic moment of the saturating magnet 17 is shown at reference number 19. In the illustrated configuration, the useful magnetic field h.sub.tread at the location of the magnetometer 11 is oriented essentially radially, whereas the interfering magnetic field h.sub.sat at the location of the magnetometer 11 is essentially perpendicular to the useful magnetic field. Consequently, the magnetometer 11 could be a single-axis device and oriented parallel to axis 11 of the tread magnet 12. A first advantage of this configuration is that the magnetic sensor only measures the useful magnetic signal (FIG. 4 reference number 13) without scarifying a significant part of its range for the magnetic field of the saturating magnet 17 and the breaker 16. A second advantage is that the saturating magnet 17 generates a magnetization in great part parallel to the breakers 16. This may potentially saturate the breakers 16 over a larger area, further increasing the stability of the measurement of h.sub.tread. In this configuration, the use of a 3-axis magnetometer would allow a self-diagnostic function of the system: in addition to the useful magnetic signal h.sub.tread (measured on the sensor axis parallel to the polarity of the tread magnet), a signal h.sub.sat computed as the norm of the magnetic field strengths h.sub.1 and h.sub.2 along the two perpendicular axes could be used to detect the presence of the saturating magnet. In case of ejection of the saturating magnet 17 during the lifetime of the tire 10, the signal h.sub.sat would suddenly drop (FIG. 5, dashed line). The magnetometer or any controller connected thereto may be configured to detect such a drop and generate an alarm upon detection. A 2-axis magnetometer could also be used to allow the self-diagnostic function but, in this case, the axis of the sensor that monitors the presence of the saturating magnet should always be parallel to the polarity of this magnet and must remain in its original orientation over the lifetime of the tire. The use of a 3-axis sensor would alleviate the requirement of precise alignment of the saturating magnet with the sensor. Accordingly, the use of a 3-axis magnetometer may be preferred because it may allow easier installation in the tire.

[0071] The magnetometer 11 is preferably multi-axis and based on Hall effect for better accuracy and wider range measurement. However, the sensor could also be based on the magneto-resistive effect, the magneto-strictive effect or be a Lorentz-force-based MEMS sensor.

[0072] It may be worthwhile noting that a single saturating magnet could be used. Alternatively, plural saturating magnets separated by rubber compound could be arranged in the tire. The saturating magnets could be of same size and/or have substantially the same magnetic moment. Alternatively, saturating magnets of different size and/or magnetic moments could be used. The saturating magnets may be arranged so as to precisely shape the form of the magnetic field generated to saturate the magnetizable material in the tire, in particular any steel breakers or belts.

[0073] According to embodiments of the invention, illustrated in FIGS. 6 and 7, the tread magnet 12 and the saturating magnet 17 may be installed in a post-cured tire in order not to expose the magnets to the high temperatures that the tire undergoes during the curing process, which could affect their magnetic properties. The magnets 12, 17 are placed in a stud 20 (hereinafter also named: “magnetic stud”), which is arranged in a form-fitting recess or cavity provided in the tread 13.

[0074] The saturating magnet 17 is located at the radially inner end of the stud 20, the tread magnet 12 at the radially outer end. The stud 20 is roughly mushroom-shaped, its base being larger in diameter than its stem. The shape secures the stud 20 in a preformed, complementarily shaped cavity in the tire tread 13. The stud 20 guarantees a fix and stable position of the saturation magnet 17 close to the breakers 16 over the lifetime of the tire. Apart from the magnets 12, 17 themselves, the stud 20 is made of non-magnetic material in order to be magnetically transparent: for instance, aluminum or a polymer that supports high temperatures (like PEEK) could be used. The radially outer side of the saturation magnet 17 must be located radially inward from the level of the tire tread indicator 22 in order to not be affected by the wear of the tire tread.

[0075] The saturating magnet 17 is preferably made of rare earth material in order to strongly saturate the breakers 16. Since a rare earth magnet (e.g. neodymium magnet) could be brittle, the non-magnetic stud material that houses the saturating magnet should be large enough to protect it against mechanical stress. Additionally, or alternatively, the saturating magnet 17 could be of plastic- or elastomer-bonded type (magnetic powder mixed with polymer or rubber-like material) in order to be protected against corrosion and to provide robustness against mechanical shocks.

[0076] If the magnetic moment of the saturation magnet 17 is parallel to the breakers (for auto-diagnostic function), the use of a 2-axis magnetometer requires a precise and fix orientation of the saturation magnet parallel to the diagnostic axis of the magnetometer over the lifetime of the tire. This requires a rotationally non-invariant form of the stud 20 that prevents rotation of the stud relative to the tire. For instance, a locking pin 24 (FIG. 7a) or a polygonal shape 26 (FIG. 7b) of (part of) the stud 20 may be considered in order to guarantee a fix orientation of the stud 20 in the tire tread.

[0077] On the opposite, radially outer, side of the stud, the tread magnet 12 extends across the entire tread depth, from the surface of the tire tread (at least) down to the level of the tread wear indicator 22 of the tire. Preferably, the stud stem is thin around the tread magnet 12, in order not to locally alter the wear of the tread. The tread magnet preferably comprises or consists of a plastic- or elastomer-bonded magnet having mechanical properties close to those of the tread rubber compound in which the stud is embedded. This guarantees that the tread magnet 12 wears down in the same way as the tread 13.

[0078] According to an embodiment, illustrated in FIG. 8, the tread magnet 12 comprises a stack of multiple thin individual magnets 28. The gaps between the individual magnets 28 may be filled with non-magnetic tread compound material. With this tread magnet configuration, the magnetic field strength of the tread magnet 12 decreases stepwise (FIG. 9) when an individual magnet wears away. The advantage of such configuration is to identify multiple discrete wear states. In the magnetic field signal sensed by the magnetometer, clear transitions 30 or steps appear, the counting of which allows identifying precisely to which depth the tread has been eroded. The configuration with multiple individual magnetic inserts 28 may thus simplify both signal processing and calibration of the system.

[0079] The tread wear measurement system is preferably installed in the tire after curing. Calibration of the system can be effected on a per tire-type basis if production tolerances affecting the system's response curve of the system (e.g. the magnetometer's response curve, magnetic dipole moments, positioning of the magnets and the magnetometer, etc.) can be kept satisfactorily low. When necessary, calibration can also be carried out tire per tire. The following installation and calibration sequence can be easily automatized for installing the system in a tire. The tire is supposed to be already equipped with a cavity 32 wherein the magnetic stud will be installed. The magnetometer 11 is placed in the tire interior, on the inner liner, aligned with the cavity 32.

[0080] If the polarity direction of the saturation magnet is perpendicular to the stud axis (for auto-diagnostic), before installation of the stud 20, the perpendicular component h.sub.sat0 is measured. When a 3-axis magnetometer is used, the value h.sub.sat0 is computed as:

h.sub.sat0=√{square root over (h.sub.1.sup.2+h.sub.2.sup.2)},

where h.sub.1 and h.sub.2 are the components of the magnetic field at the magnetometer in the directions tangential to the breaker 16. When a 2-axis magnetometer is used, one sensing direction of the magnetometer has to be oriented on the axis of the stud, the other sensing direction must be parallel to the magnetic moment of the saturating magnet and h.sub.sat0 is simply measured in this direction.

[0081] In a second step, the stud 20 only equipped with the saturating magnet 17 is then inserted into the cavity 32. In this situation, the magnetic field sensed by the magnetometer 11 is the same as if the tread magnet had been entirely worn down and the corresponding magnetic field signal measured by the magnetometer 11 can be taken as a reference value, hereinafter denoted as h.sub.tread0.

[0082] Again, if the saturating magnet has a dipole moment perpendicular to the tread magnet, an initial value of the perpendicular magnetic field (denoted h.sub.sat1) can be obtained in the same way as h.sub.sat0, at the same stage as h.sub.tread0.

[0083] In a third step, the tread magnet is fixed (e.g. glued) into the stud 16 and an initial value, hereinafter denoted as h.sub.tread1, is then recorded with the magnetometer.

[0084] The tread depth can be obtained by measuring the magnetic field signal on the axis of the tread magnet (h.sub.tread), computing the relative normalized variation

[00001]$\frac{h_{\mathrm{tread}}-h_{\mathrm{tread}}0}{h_{\mathrm{tread}}1-h_{\mathrm{tread}}0}$

and deriving therefrom the remaining tread depth, the worn-away tread height, the remaining mileage, etc. The step of deriving remaining tread depth, etc., could include calculation, rule-based processing and or using one or more look-up tables.

[0085] If the auto-diagnostic function is used, a threshold value may be set somewhere between h.sub.sat0 and h.sub.sat1, e.g., to (h.sub.sat0+h.sub.sat1)/2. If the currently measured h.sub.sat (obtained in the same way as h.sub.sat0 and h.sub.sat1) is below this threshold, the stud may be presumed to have been ejected from the tire, which will trigger an alarm. The monitoring of h.sub.sat can further be used for temperature compensation. It should be noted that a different threshold could be used as well.

[0086] While specific embodiments have been described herein in detail, those skilled in the art will appreciate that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof.