Brake Adjustment Monitor Device for Automotive Vehicles

1. Field of the Invention

This invention relates to devices used to monitor the brake wear and adjustment on vehicles employing air brake systems, such as, trucks, tractor trailers, buses and the like. The new device provides a simple means to install a monitoring system for monitoring each of the brakes of a vehicle.

2. Description of Related Art

There are currently published and known systems in the art which typically use a permanent magnet as a basis for measuring brake wear wherein the magnet is mounted to a rod which moves when the air brakes are activated. For example, the push rod of a brake system travels a certain distance when air pressure is applied to an air chamber assembly which distance is a function of brake wear and adjustment of the brake assembly. A magnetically activated switch is used in cooperation with the magnet such that if the push rod moves a certain distance the switch is activated to signal that the brake must be attended to for repair. Examples of such systems are disclosed in U.S. Pat. No. 4,757,300 and 4,855,712.

Other attempts to use measured motion of the push rod, other brake rods and rotation of the connection between the push rod and shock adjuster arm have also been proposed. In U.S. Pat. No. 5,689,231, a transducer engaged with a clevis pin monitors rotation relative to the push rod and shock adjuster arm to provide indication when brake repair may be necessary.

The present invention provides a simple mechanism for monitoring brake wear and adjustment by using a cable attached to a pull or breakaway switch to signal when the air brake system push rod has traveled beyond a predetermined distance relative to the air chamber. This device is relatively easy to install on existing brakes using for attachment points existing threaded bolts, screws and the like. The pull or breakaway switch may be a rugged self contained unit with two electrical leads and have a simple cable attachment. No devices need to be mounted to the push rod obviating the concern for proper location of such units.

One object of the present invention is simple, straight forward attachment of the brake monitor device to existing or new air brake systems to signal the event of an air brake rod movement beyond a predetermined distance. Another object is to allow such brake monitoring device to operate using an existing vehicle power source or using a power source independent of the vehicle. A further object is to provide indication of monitoring device activation on separate trailers as well as on motorized vehicles.

In accordance with the description presented herein, other objectives of this invention will become apparent when the description and drawings are reviewed.

FIG. 1 illustrates a perspective view of a pull or breakaway switch.

FIG. 2 illustrates a schematic view of the switch attached to a bulb warning system using an independent power source.

FIG. 3 illustrates a schematic representation of the monitoring device having a plurality of bulb warning indication locations.

FIG. 4 illustrates a pull type switch and cable in the monitor position.

FIG. 5 illustrates a pull type switch and cable in the activated position.

FIG. 6 illustrates a breakaway type switch and cable in the monitoring position.

FIG. 7 illustrates a breakaway switch and cable in the activated position.

FIG. 8 illustrates the brake adjustment monitor device installed with an air brake system.

FIG. 9 illustrates the brake adjustment monitor device installed with a spring brake automatic air break out system as currently required on at least one axle of a vehicle.

The brake adjustment monitor device comprises a pull or breakaway switch attached to the vehicle air brake chamber structure and having a cable attached to the rods or slack adjustment arm of a vehicle air brake system. The cable length when installed is adjusted to activate the switch when the air brake rod has traveled a predetermined distance. The predetermined distance is an indication that in air brake systems the brake pads and drum (25) have reached a condition in which the brakes will soon no longer engage or function. The switch is electrically connected to one or more bulb indicators and if desired a sound signaling device.

Referring to FIGS. 1 through 3, the monitoring device has a switch (1) with electrical leads (2) and cable (3). The electrical leads (2) are in communication with one or more bulbs (4) for indicating the switch (1) open or closed status. The bulb (4) warning indicators may be on the rear (5) of a trailer (6) or motorized vehicle (7), on the front (8) so as to be viewed in the drivers rear view mirrors (9) and/or mounted with the vehicle dash board indicators (10). Obviously these bulbs (4) may be augmented with a warning sound device such as a buzzer (not shown).

For any vehicle, but in particular for a trailer as illustrated in FIG. 3, the monitoring device may use a power supply (11) independent of the vehicle standard electrical power system such as brake light system or ignition switch power system. This provides added safety margin as the monitoring device does not depend on proper vehicle electrical connection to provide warning of brake wear. Of course the monitoring device may be connected to the vehicle electrical power system as is commonly understood. By placing bulb (4) warning indicators on the front (8) of a trailer, an operator may be warned of brake wear even if the vehicle to trailer electrical system has not been properly connected.

Referring to FIGS. 4 through 9, the switch (1) and cable (3) are illustrated in both monitoring and activated conditions and are shown attached to vehicle brake assemblies (12). In the preferred embodiment the switch (1) has bracket (13) with aperture (14). An angle bracket (15) is attached to an existing threaded bolt (16) on the air brake air chamber assembly (17). The bracket (13) is then attached, either fixedly or rotatably, to the angle bracket (15).

The cable (3) on one end is attached to an activation pin (18) of the switch (1) and on the opposite end to an existing bolt, screw, pin or the like of the slack adjuster arm (19) of the brake assembly (12). When the cable (3) is installed, its length is adjusted to cause it to pull the activation pin (18) should the brake push rod (20) travel more than a predetermined distance when the vehicle operator depresses the brake peddle. This distance of travel is based on brake type to indicate wear on the brake has reached a predetermined point such that brake failure is imminent.

In operation with the brakes not engaged the cable (3) may have a slack as illustrated in FIGS. 4, 6, 8 and 9. When the brakes are operated by the vehicle operator, the diaphragm in the air chamber assembly (17) urges the attached push rod (20) outwards which in turn moves the slack adjuster arm (19). This brake assembly operation causes the cable (3) to pull against the force of activation pin (18) which with sufficient movement will cause the cable (3) to become taut. If the travel of the push rod (20) reaches the predetermined distance of travel, the switch (1) is activated by the distance of movement of the activation pin (18) as illustrated in FIG. 5 or the release of the activation pin (18) as illustrated in FIG. 7. In the case of FIG. 7 a visual indication of wear is provided with the dangling cable (3) and activation pin (18). In either configuration the activation pin (18) movement causes the switch (3) to signal push rod (20) movement the predetermined distance to warn of needed brake service.

While in the preferred embodiment the cable (3) has been described as attached to an existing location on the slack adjustment arm (19) as the simplest installation, obviously the cable (3) may have means for attachment such as to the push rod (20) itself. So long as the cable (3) is drawn tout by the movement of the push rod (20) relative to the air chamber assembly (17) the brake monitoring switch (1) and cable (3) may be attached in the most convenient manner depending on the particular brake system.

While the invention has been particularly shown and described with respect to the illustrated and preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention.