Description:CLUTCH DISC WEAR DETECTING SYSTEM
FIELD OF THE DISCLOSURE
This invention generally relates to a field of vehicle transmission systems, and in particular, to a clutch disc wear detecting system for a vehicle.

BACKGROUND
The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
Clutch discs are essential components that engage and disengage the transmission from the engine, allowing for smooth gear shifts of a vehicle. Over time, the clutch discs wear out due to friction and usage, which can significantly impact vehicle performance, safety, and operating costs. Traditional methods of monitoring clutch wear involve manual inspections that require the disassembly of vehicle components. The primary problem lies in the inefficiency and unreliability of traditional methods for monitoring clutch wear in commercial vehicles. Clutch wear is a critical issue because it directly impacts vehicle performance, safety, and operating costs, especially in commercial vehicles subjected to heavy loads, frequent use, and varying driving conditions. Existing methods for clutch wear monitoring rely on manual inspections, which are time-consuming and require the disassembly of components, making them labor-intensive and prone to human error. These inspections often fail to provide precise or consistent results, leading to inaccurate assessments of clutch health.
Another major issue is the lack of real-time monitoring in current systems, which means clutch wear is often only identified when performance noticeably deteriorates or a complete failure occurs. This reactive approach results in unplanned vehicle downtime, disrupting operations and increasing repair costs. Furthermore, the absence of automated systems prevents fleet operators from planning maintenance schedules efficiently or addressing wear issues before they escalate.
Additionally, clutch wear is highly influenced by various dynamic factors such as driving conditions, vehicle speed, gear position, engine torque, and driver behavior. Factors like frequent clutch use in stop-and-go traffic, improper gear shifting, high engine loads during hill climbs, or towing heavy loads can significantly accelerate clutch wear. However, current systems fail to account for these parameters, making it difficult to identify or mitigate the root causes of excessive wear. This lack of contextual awareness leaves fleet managers and drivers unable to take corrective actions to prolong clutch life and maintain vehicle reliability.
According to the patent application "RU2731585C1" titled "Clutch Wear Monitoring System," the invention relates to an advanced clutch wear detection system that employs sensors and real-time data analysis to monitor clutch disc wear. This system integrates with the vehicle's onboard diagnostics (OBD) and telematics to provide continuous monitoring and instant feedback on clutch health. The sensors measure key parameters such as clutch engagement frequency, pressure, and temperature, which are analyzed by the system to accurately assess wear levels. The system can alert drivers and fleet managers of potential issues before they lead to significant damage or failure.
Another patent application, "US20150204431A1," titled "Automated Clutch Wear Detection and Monitoring," describes a system that includes a series of embedded sensors within the clutch assembly. These sensors continuously monitor wear patterns and provide real-time data to the vehicle's central processing unit. The data is then processed using advanced algorithms to predict wear trends and suggest maintenance schedules. This automated approach eliminates the need for manual inspections and significantly improves the accuracy and reliability of clutch wear assessments.
In any of the discussed prior arts, the systems involve complex sensor integrations and real-time data processing to monitor clutch disc wear. These systems offer significant improvements over traditional methods by providing accurate, reliable, and timely information on clutch health. However, there remains a need for a more efficient, cost-effective, and easily implementable solution for clutch discs wear detection in commercial vehicles.
OBJECTIVES OF THE INVENTION
An objective of the invention is to provide a clutch disc wear detecting system for a vehicle.
Furthermore, the objective of the present invention is to utilize historical data and real-time analysis to forecast wear trends, enabling proactive maintenance planning.
Furthermore, the objective of the present invention is to minimize unexpected clutch failures, ensuring higher vehicle availability and operational efficiency.
Furthermore, the objective of the present invention is to prevent costly emergency repairs and extend clutch lifespan, thereby reducing overall maintenance expenses.
Furthermore, the objective of the present invention is to provide actionable recommendations to drivers for improving driving habits and reducing clutch disc wear.
Furthermore, the objective of the present invention is to improve maintenance scheduling, reducing disruptions in fleet operations and maximizing efficiency.
Furthermore, the objective of the present invention is to eliminate the need for manual inspections or disassembly, saving time and effort.
Furthermore, the objective of the present invention is to ensure timely maintenance to prevent clutch-related failures, enhancing overall vehicle safety.
Furthermore, the objective of the present invention is to promote efficient clutch use, reducing energy loss, improving fuel economy, and minimizing emissions.
Furthermore, the objective of the present invention is to maintain a database for analyzing wear trends, supporting better decision-making and operational improvements.
 
SUMMARY
The present invention relates to a clutch disc wear detecting system for a vehicle.
According to an aspect, a clutch disc wear detecting system for a vehicle is disclosed. The clutch disc wear detecting system comprising a vehicle subsystem interface having a sensor module configured to detect one or more parameters associated with the vehicle in real-time, characterized in that at least one sensor installed inside a clutch booster of the vehicle, and configured to detect movement of a wear indicator rod of the clutch booster, a database stored with one or more historical parameters associated with the vehicle. Further, the one or more historical parameters comprises a sensor data representing a historical wear rates of the clutch disc under different driving conditions.
According to another aspect, the clutch disc wear detecting system further comprising at least one processor communicatively coupled with the sensor module and the database. Further, the at least one processor is configured to receive the one or more parameters, the one or more historical parameters, and one or more signals from the at least one sensor associated with movement of the wear indicator rod, determine at least one baseline for each of the one or more parameters, based at least on the one or more historical parameters, compare the one or more parameters with the corresponding at least one baseline, detect one or more clutch disc wear scenarios, based at least on the comparison, generate one or more alerts on an instrument cluster of the vehicle to notify the driver of the vehicle regarding the one or more clutch disc wear scenarios along with a corrective driving approach, calculate a wear ratio and a rate of wear of the wear indicator rod through the one or more signals received from the at least one sensor or the one or more historical parameters, calculate a wear percentage of the wear indicator rod through the calculated wear ratio, compare the calculated wear percentage with a first threshold value, generate a warning alert on the instrument cluster, if the calculated wear percentage is below the first threshold value, compare the calculated wear percentage with a second threshold value, is the calculated wear ratio is above the second threshold value, and generate an immediate warning alert on the instrument cluster for clutch disc replacement.
According to another aspect, a method for operating a clutch disc wear detecting system for a vehicle is disclosed. The vehicle comprising a vehicle subsystem interface having a sensor module configured to detect one or more parameters associated with the vehicle in real-time, characterized in that receiving, via at least one processor, one or more parameters from the sensor module, one or more historical parameters from a database associated with the vehicle, and one or more signals from at least one sensor installed inside a clutch booster of the vehicle, Further, the one or more historical parameters comprises a sensor data representing a historical wear rates of the clutch disc under different driving conditions and the one or more signals are associated with movement of a wear indicator rod of the clutch booster; determining, via the at least one processor, at least one baseline for each of the one or more parameters, based at least on the one or more historical parameters.
According to another aspect, the method for operating the clutch disc wear detecting system further comprising comparing, via the at least one processor, the one or more parameters with the corresponding at least one baseline; detecting, via the at least one processor, one or more clutch disc wear scenarios, based at least on the comparison; generating, via the at least one processor, one or more alerts on an instrument cluster of the vehicle to notify the driver of the vehicle regarding the one or more clutch disc wear scenarios along with a corrective driving approach; calculating, via the at least one processor, a wear ratio and a rate of wear of the wear indicator rod through the one or more signals received from the at least one sensor or the one or more historical parameters; calculating, via the at least one processor, a wear percentage of the wear indicator rod through the calculated wear ratio, comparing, via the at least one processor, the calculated wear percentage with a first threshold value; generating, via the at least one processor, a warning alert on the instrument cluster, if the calculated wear percentage is below the first threshold value; comparing, via the at least one processor, the calculated wear percentage with a second threshold value, if the calculated wear percentage is above the second threshold value; and generating, via the at least one processor, an immediate warning alert on the instrument cluster for clutch disc replacement.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate various embodiments of systems, methods, and embodiments of various other aspects of the disclosure. Any person with ordinary skills in the art will appreciate that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. It may be that in some examples one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another, and vice versa. Furthermore, elements may not be drawn to scale. Non-limiting and non-exhaustive descriptions are described with reference to the following drawings. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating principles.
FIG. 1 illustrates a block diagram of a clutch disc wear detecting system for a vehicle according to an embodiment of the present invention;
FIG. 2 illustrates a flowchart of the clutch disc wear detecting system according to an embodiment of the present invention; and
FIG. 3 illustrates a flowchart showing a method for operating the clutch disc wear detecting system according to an embodiment of the present invention.

DETAILED DESCRIPTION
Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words “comprising,” “having,” “containing,” and “including,” and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the preferred, systems and methods are now described. Embodiments of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings in which like numerals represent like elements throughout the several figures, and in which example embodiments are shown. Embodiments of the claims may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples among other possible examples.
The present invention discloses about a clutch disc wear detecting system for a vehicle. Further, the vehicle comprising a vehicle subsystem interface having a sensor module configured to detect one or more parameters associated with the vehicle in real-time. Embodiments of the present invention may comprise at least one sensor installed inside a clutch booster of the vehicle and may be configured to detect movement of a wear indicator rod of the clutch booster. Embodiments of the present invention may comprise a database stored with one or more historical parameters associated with the vehicle. The one or more historical parameters may comprise a sensor data representing a historical wear rates of the clutch disc under different driving conditions.
Embodiments of the present invention may comprise at least one processor communicatively coupled with the sensor module and the database. The at least one processor is configured to receive the one or more parameters, the one or more historical parameters, and one or more signals from the at least one sensor associated with movement of the wear indicator rod, determine at least one baseline for each of the one or more parameters, based at least on the one or more historical parameters, compare the one or more parameters with the corresponding at least one baseline, detect one or more clutch disc wear scenarios, based at least on the comparison, generate one or more alerts on an instrument cluster of the vehicle to notify the driver of the vehicle regarding the one or more clutch disc wear scenarios along with a corrective driving approach, calculate a wear ratio and a rate of wear of the wear indicator rod using the one or more signals received from the at least one sensor or the one or more historical parameters, compare the calculated wear ratio with a first threshold value and generate a warning alert on the instrument cluster, if the calculated wear ratio is below the first threshold value, and compare the calculated wear ratio with a second threshold value, is the calculated wear ratio is above the first threshold value and generate an immediate warning alert on the instrument cluster for clutch disc replacement.
FIG. 1 illustrates a block diagram of a clutch disc wear detecting system (100) for a vehicle (102), according to an embodiment of the present invention. FIG. 2 illustrates a flowchart of the clutch disc wear detecting system (100), according to an embodiment of the present invention.
In some embodiments, the clutch disc wear detecting system (100) comprise at least one sensor (104), a database (106), and at least one processor (108). In some embodiments, the clutch disc wear detecting system (100) is integrated with the vehicle (102). In some embodiments, the vehicle (102) may comprise at least one of a car, truck, van etc. Further, the vehicle (102) is assembled with an engine, wheels, cabin, a transmission assembly (not shown) and other components essential (not shown) for operation of the vehicle (102). Furthermore, the transmission assembly is configured to transmit power from the engine to the wheels. Further, the transmission assembly comprises a gearbox (not shown), a transmission shaft (not shown), and a clutch disc assembly (not shown). In some embodiments, the clutch disc assembly is configured to engage and disengage the engine from the transmission assembly, allowing a smooth transition of one gear to another gear.
Further, the clutch disc assembly comprises several components. The components comprise clutch disc, flywheel, pressure plate, release bearing. In some embodiments, the clutch disc may be configured to engage the flywheel with pressure plate to transmit torque from the engine to the transmission input shaft. In some instances, the clutch disc gets damaged due to several conditions. The conditions include at least one of an excessive wear and tear, improper driving techniques, mechanical failures, environmental factors, external damage, and overloading of the vehicle (102). In some embodiments, the clutch disc wear detecting system (100) is integrated with the vehicle (102) for detecting wears of the clutch disc and accordingly generating necessary alerts.
In some embodiments, the vehicle (102) comprises a vehicle subsystem. Further, the vehicle subsystem is communicatively coupled with the clutch disc wear detecting system (100). In some embodiments, the vehicle subsystem is operationally coupled with one or more electronic and electrical components of the vehicle (102). Further, the vehicle subsystem comprises a sensor module (110). The sensor module (110) is configured to detect one or more parameters associated with the vehicle (102) in a real-time. In some embodiments, the sensor module (110) is configured to detect the one or more parameters when the vehicle (102) is in a running state. In some embodiments, the one or more parameters comprises at least a vehicle speed, gear position, engine torque, and clutch pedal position.
Moreover, the sensor module (110) comprises a vehicle speed sensor (not shown), a gear position sensor (not shown), an engine torque sensor (not shown), and a clutch pedal position sensor (not shown). Further, the vehicle speed sensor is configured to detect the vehicle speed during the running state of the vehicle (102). In an example embodiment, the vehicle speed sensor is mounted on the transmission assembly or wheel hub of the vehicle (102). Further, the gear position sensor is configured to detect the gear position of a gear box (not shown) of the transmission assembly of the vehicle (102). In some embodiments, the gear position corresponds to a current gear engaged. In an example embodiment, the gear position sensor is installed on a gear shift linkage (not shown) or within the gearbox of the vehicle (102).
Further, the engine torque sensor is configured to detect the engine torque of the vehicle (102). In an example embodiment, the engine torque sensor is mounted on a crankshaft (not shown) or flywheel (not shown) of the vehicle (102). Further, the clutch pedal position sensor is configured to detect the clutch pedal position. The clutch pedal position comprises an engaged position and a disengaged position. Further, the engaged position of the clutch pedal represents pressing of the clutch pedal. Further, the disengaged position of the clutch pedal represents releasing of the clutch pedal. In an example embodiment, the clutch pedal position sensor is mounted on a clutch pedal assembly (not shown) or in close proximity to the clutch pedal.
In some embodiments, the clutch disc wear detecting system (100) further comprises the at least one sensor (104). In some embodiments, the at least one sensor (104) is installed inside a clutch booster (not shown) of the vehicle (102). Further, the at least one sensor (104) is configured to detect movement of a wear indicator rod (not shown) of the clutch booster. The clutch booster is installed between the clutch pedal and a clutch master cylinder (not shown) of the clutch disc assembly. Further, the clutch booster is configured to reduce efforts required to engage and disengage the clutch disc. Further, the clutch booster is configured to amplify force applied by the driver on the clutch pedal.
In some embodiments, the clutch booster comprises a diaphragm (not shown) or piston mechanism (not shown). Further, the clutch booster utilized vacuum or hydraulic pressure to assist the driver while applying force on the clutch pedal. In some embodiments, the clutch booster further comprises the wear indicator rod. Further, the wear indicator rod is configured to move in response to wear and tear of the clutch disc. The wear indicator rod is configured to provide a measurable indication of the clutch disc’s physical condition.
In some embodiments, the at least one sensor (104) is mounted inside the clutch booster. Further, the at least one sensor (104) is configured to detect movement of the wear indicator rod of the clutch booster. In some embodiments, the at least one sensor (104) may correspond to at least one of an infrared (IR) sensor, hall effect sensor, or a linear position sensor. In some embodiments, the at least one sensor (104) is configured to generate one or more voltage signals associated with the detected wear of the clutch disc through the wear indicator rod.
In some embodiments, the clutch disc wear detecting system (100) further comprises the database (106). Further, the database (106) is communicatively coupled with the clutch disc wear detecting system (100). The database (106) is configured to store one or more historical parameters associated with the vehicle (102). In some embodiments, the one or more historical parameters comprises a sensor data representing historical wear rates of the clutch disc under different driving conditions.
In some embodiments, the database (106) is configured to serve as a central repository for storing the one or more parameters and the one or more historical parameters. Further, the database (106) is configured to handle data of different volume. The data includes the one or more parameters and the one or more historical parameters. In some embodiments, the database (106) comprises at least one of general purpose databases (e.g., MySQL, PostgreSQL) or special purpose databases (e.g., MongoDB, Cassandra). In one example embodiment, the database (106) comprises multiple tables or collections to store different type of data such as the one or more parameters and the one or more historical parameters.
In some embodiments, the clutch disc wear detecting system (100) comprises the at least one processor (108). Further, the processor is communicatively coupled with the sensor module (110), the at least one sensor (104), and the database (106). Moreover, the at least one processor (108) may include suitable logic, input/ output circuitry, and communication circuitry that are operable to execute one or more instructions stored in a memory (not shown) to perform predetermined operations. In one embodiment, the at least one processor (108) may be configured to decode and execute any instructions received from the sensor module (110), the at least one sensor (104), and the database (106). The at least one processor (108) may be configured to execute one or more computer-readable program instructions, such as program instructions to carry out any of the functions described in this description. Examples of the at least one processor (108) include one or more general purpose processors and/or one or more special purpose processors.
Further, the at least one processor (108) is configured to receive the one or more parameters, the one or more historical parameters, and one or more signals from the at least one sensor (104). The one or more signals are associated with the movement of the wear indicator rod. In one example embodiment, the one or more signals correspond to the one or more voltage signals generated by the at least one sensor (104). Further, the at least one processor (108) receives the one or more parameters, the one or more historical parameters, and the one or more signals when the clutch pedal position is in the engaged position.
Moreover, the at least one processor (108) is configured to determine at least one baseline for each of the one or more parameters, based at least on the one or more historical parameters. Further, the at least one processor (108) is configured to determine the at least one baseline for the vehicle speed. Further, the at least one processor (108) is configured to determine the at least one baseline for the gear position. Further, the at least one processor (108) is configured to determine the at least one baseline for the engine torque. Further, the at least one processor (108) is configured to determine the at least one baseline for the clutch pedal position. Thereafter, the at least one processor (108) is configured to determine the at least one baseline for the rate of wear of the wear indicator rod. In some embodiments, the at least one processor (108) is configured to compare the one or more parameters with the corresponding at least one baseline. Further, the at least one processor (108) is configured to detect one or more clutch disc wear scenarios, based at least on the comparison. Further, the one or more clutch disc wear scenarios comprise at least one of low-speed driving conditions, engine torque below a corresponding baseline, high-speed driving conditions, and climbing conditions.
In some embodiments, the at least one processor (108) is configured to generate one or more alerts on an instrument cluster (112) of the vehicle (102) to notify the driver of the vehicle (102) regarding the one or more clutch disc wear scenarios along with a corrective driving approach. Further, the one or more alerts comprise at least one of visual alerts or auditory alerts. Further, the visual alerts are displayed over the instrument cluster (112). In one example embodiment, the visual alerts comprise pop-up notifications, color-coded warnings, or animated icons. In some embodiments, the auditory alerts are generated by an audio system (not shown) of the vehicle (102). In one example embodiment, the auditory alerts comprise beep sounds, siren sounds, or voice alerts.
In some embodiments, the instrument cluster (112) is configured to display the corrective driving approach through different animations that guides the driver through corrective actions. For example, an animation might show the optimal way to shift gears or manage engine torque to reduce clutch disc wear.
In some embodiments, the at least one processor (108) is configured to calculate a wear ratio and a rate of wear of the wear indicator rod using the one or more signals received from the at least one sensor (104) or the one or more historical parameters. In some embodiments, the at least one processor (108) is configured to detect the wear ratio through the one or more signals (i.e., the one or more voltage signals) received from the at least one sensor (104). Further, the at least one processor (108) is configured to determine the wear indicator rod distance using the one or more signals. Further, the at least one processor (108) is configured to utilize an equation 1 to determine the wear indicator rod distance, d=K*〖〖(V〗_ref-Sensor Voltage)〗^(1⁄n) ------ 1.
In some embodiments, the at least one processor (108) is configured to determine whether the clutch disc is engaged through the one or more parameters received from the sensor module (110). Further, the at least one processor (108) is configured to determine a rod displacement value of the wear indicator rod using the determined wear indicator rod distance, when the clutch disc is engaged. In some embodiments, the at least one processor (108) is configured to determine the rod displacement value of the clutch disc wear using the one or more historical parameters, when the clutch disc is disengaged. In some embodiments, the rod displacement value is a difference between a current rod position value and a baseline position value. Further, the rod displacement value is determined by an equation 2, Rod Displacement=Current Rod Position-Baseline Position ------ 2.
Furthermore, the at least one processor (108) is configured to calculate the wear ratio using the rod displacement value, a first variable and a second variable. Further, the first variable correspond to a max allowable displacement value and the second variable correspond to an assembly factor. In some embodiments, the wear ratio is calculated by diving the rod displacement value from the first variable and multiplying with the second variable. Further, the wear ratio is calculated by an equation 3, Wear Ratio=(Rod Displacement)/(Max. Allowable Displacement)*Assembly Factor ------ 3.
In some embodiments, the at least one processor (108) is configured to calculate a rate of wear of the wear indicator rod. Further, the rate of wear of the wear indicator rod is a derivative of the calculated wear ratio of the wear indicator rod. Further, the rate of wear is calculated by an equation 4, Rate of Wear=(d(Wear))/dt ----- 4. Furthermore, the at least one processor (108) is configured to compare the calculated rate of wear of the wear indicator rod with the at least one baseline for the rate of wear of the clutch disc. In some embodiments, the at least one processor (108) is configured to generate an alarm, if the calculated rate of wear exceeds the at least one baseline for the rate of wear. Further, the instrument cluster (112) of the vehicle (102) is configured to display the generated alarm as a high rate of clutch disc wear to notify the driver of the vehicle (102).
In some embodiments, the at least one processor (108) is configured to calculate a wear percentage of the wear indicator rod. Further, the wear percentage is calculated by an equation 5, Wear %=Wear Ratio*100 ------ 5. In some embodiments, the at least one processor (108) is configured display the wear percentage on the instrument cluster (112) of the vehicle (102). Further, the at least one processor (108) is configured to compare the wear percentage with a first threshold value. The first threshold value corresponds to a warning threshold. In some embodiments, the at least one processor (108) is configured to generate a warning alert on the instrument cluster (112), if the calculated wear percentage is below the first threshold value.
Further, the at least one processor (108) is configured to compare the wear percentage with a second threshold value. The second threshold value corresponds to a critical threshold. In some embodiments, the at least one processor (108) is configured to generate an immediate warning alert on the instrument cluster (112) for clutch disc replacement, if the calculated wear percentage is above the second threshold value. In some embodiments, the at least one processor (108) is configured to generate another warning alert along with a clutch disc replacement schedule on the instrument cluster (112) if the calculated wear percentage is between the first threshold value and the second threshold value.
FIG. 3 illustrates a flow chart showing a method (300) for operating a clutch disc wear detecting system (100) for a vehicle (102), according to an embodiment of the present invention.
At operation 302, the at least one processor (108) is configured to receive the one or more parameters from the sensor module (110), the one or more historical parameters from the database (106) associated with the vehicle (102), and the one or more signals from the at least one sensor (104) installed inside the clutch booster of the vehicle (102). Further, the one or more historical parameters comprises the sensor data representing the historical wear rates of the clutch disc under different driving conditions and the one or more signals are associated with movement of the wear indicator rod of the clutch booster. The one or more signals are associated with the movement of the wear indicator rod. Further, the at least one processor (108) receives the one or more parameters, the one or more historical parameters, and the one or more signals when the clutch pedal position is in the engaged position.
At operation 304, the at least one processor (108) is configured to determine the at least one baseline for each of the one or more parameters, based at least on the one or more historical parameters. Further, the at least one processor (108) is configured to determine the at least one baseline for the vehicle speed. Further, the at least one processor (108) is configured to determine the at least one baseline for the gear position. Further, the at least one processor (108) is configured to determine the at least one baseline for the engine torque. Further, the at least one processor (108) is configured to determine the at least one baseline for the clutch pedal position. Thereafter, the at least one processor (108) is configured to determine the at least one baseline for the rate of wear of the wear indicator rod.
At operation 306, the at least one processor (108) is configured to compare the one or more parameters with the corresponding at least one baseline. At operation 308, the at least one processor (108) is configured to detect the one or more clutch disc wear scenarios, based at least on the comparison. Further, the one or more clutch disc wear scenarios comprise at least one of low-speed driving conditions, engine torque below a corresponding baseline, high-speed driving conditions, and climbing conditions.
At operation 310, the at least one processor (108) is configured to generate the one or more alerts on the instrument cluster (112) of the vehicle (102) to notify the driver of the vehicle (102) regarding the one or more clutch disc wear scenarios along with a corrective driving approach. Further, the one or more alerts comprise at least one of visual alerts or auditory alerts. Further, the visual alerts are displayed over the instrument cluster (112). In one example embodiment, the visual alerts comprise pop-up notifications, color-coded warnings, or animated icons. In some embodiments, the auditory alerts are generated by an audio system of the vehicle (102).
At operation 312, the at least one processor (108) is configured to calculate the wear ratio and the rate of wear of the wear indicator rod through the one or more signals received from the at least one sensor (104) or the one or more historical parameters. In some embodiments, the at least one processor (108) is configured to detect the wear ratio through the one or more signals (i.e., the one or more voltage signals) received from the at least one sensor (104). Further, the at least one processor (108) is configured to determine the wear indicator rod distance using the one or more signals. In some embodiments, the at least one processor (108) is configured to determine whether the clutch disc is engaged through the one or more parameters received from the sensor module (110). Further, the at least one processor (108) is configured to determine a rod displacement value of the wear indicator rod using the determined wear indicator rod distance, when the clutch disc is engaged. In some embodiments, the rod displacement value is a difference between a current rod position value and a baseline position value. Furthermore, the at least one processor (108) is configured to calculate the wear ratio using the rod displacement value, a first variable and a second variable.
At operation 314, the at least one processor (108) is configured to calculate the wear percentage of the wear indicator rod through the calculated wear ratio. In some embodiments, the at least one processor (108) is configured display the wear percentage on the instrument cluster (112) of the vehicle (102). At operation 316, the at least one processor (108) is configured to compare the calculated wear ratio with the first threshold value. The first threshold value corresponds to a warning threshold.
At operation 318, the at least one processor (108) is configured to generate the warning alert on the instrument cluster (112), if the calculated wear ratio is below the first threshold value. At operation 320, the at least one processor (108) is configured to compare the calculated wear ratio with the second threshold value, is the calculated wear ratio is above the first threshold value. The second threshold value corresponds to a critical threshold.
At operation 322, the at least one processor (108) is configured to generate the immediate warning alert on the instrument cluster (112) for clutch disc replacement. In some embodiments, the at least one processor (108) is configured to generate another warning alert along with a clutch disc replacement schedule on the instrument cluster (112) if the calculated wear percentage is between the first threshold value and the second threshold value.
It has thus been seen the clutch disc wear detecting system (100) for a vehicle (102), as described. The clutch disc wear detecting system (100) in any case could undergo numerous modifications and variants, all of which are covered by the same innovative concept; moreover, all of the details can be replaced by technically equivalent elements. In practice, the components used, as well as the numbers, shapes, and sizes of the components can be whatever according to the technical requirements. The scope of protection of the invention is therefore defined by the attached claims.

Dated this 21st Day of February, 2025
Ishita Rustagi (IN-PA/4097)
Agent for Applicant
, Claims:CLAIMS
We Claim:
1. A clutch disc wear detecting system (100) for a vehicle (102), comprising a vehicle subsystem interface having a sensor module (110) configured to detect one or more parameters associated with the vehicle (102) in real-time, characterized in that:
at least one sensor (104) installed inside a clutch booster of the vehicle (102) and configured to detect movement of a wear indicator rod of the clutch booster;
a database (106) stored with one or more historical parameters associated with the vehicle (102), wherein the one or more historical parameters comprises a sensor data representing a historical wear rates of the clutch disc under different driving conditions; and
at least one processor (108) communicatively coupled with the sensor module (110) and the database (106), wherein the at least one processor (108) is configured to:
receive the one or more parameters, the one or more historical parameters, and one or more signals from the at least one sensor (104) associated with movement of the wear indicator rod;
determine at least one baseline for each of the one or more parameters, based at least on the one or more historical parameters,
compare the one or more parameters with the corresponding at least one baseline;
detect one or more clutch disc wear scenarios, based at least on the comparison;
generate one or more alerts on an instrument cluster (112) of the vehicle (102) to notify the driver of the vehicle (102) regarding the one or more clutch disc wear scenarios along with a corrective driving approach;
calculate a wear ratio and a rate of wear of the wear indicator rod using the one or more signals or the one or more historical parameters,
calculate a wear percentage of the wear indicator rod through the calculated wear ratio;
compare the calculated wear percentage with a first threshold value and generate a warning alert on the instrument cluster (112), if the calculated wear percentage is below the first threshold value; and
compare the calculated wear percentage with a second threshold value, is the calculated wear percentage is above the second threshold value and generate an immediate warning alert on the instrument cluster (112) for clutch disc replacement.

2. The clutch disc wear detecting system (100) as claimed in claim 1, wherein the one or more parameters comprises a vehicle speed, gear position, engine torque, and clutch pedal position.

3. The clutch disc wear detecting system (100) as claimed in claim 2, wherein the sensor module (110) comprises:
a vehicle speed sensor configured to detect the vehicle speed,
a gear position sensor configured to detect the gear position,
an engine torque sensor configured to detect the engine torque, and
a clutch pedal position sensor configured to detect the clutch pedal position, wherein the clutch pedal position comprises an engaged position and a disengaged position, wherein the at least one processor (108) is configured to receive the one or more parameters, the one or more historical parameters, and the one or more signals when the clutch is at the engaged position.

4. The clutch disc wear detecting system (100) as claimed in claim 1, wherein the wear ratio is calculated by diving a rod displacement value from a first variable and multiplying with a second variable, wherein the first variable correspond to a max allowable displacement value and the second variable correspond to an assembly factor, wherein the rod displacement value is a difference between a current rod position value and a baseline position value.

5. The clutch disc wear detecting system (100) as claimed in claim 1, wherein the rate of wear of the wear indicator rod is a derivative of the calculated wear ratio of the wear indicator rod, wherein the at least one processor (108) is configured to compare the rate of wear with a corresponding baseline and generate an alert on the instrument cluster (112) of the vehicle (102) if the rate of wear exceeds the corresponding baseline.

6. The clutch disc wear detecting system (100) as claimed in claim 1, wherein the at least one processor (108) is configured to generate another warning alert along with a clutch disc replacement schedule on the instrument cluster (112) if the calculated wear percentage is between the first threshold value and the second threshold value.

7. The clutch disc wear detecting system (100) as claimed in claim 1, wherein the one or more clutch disc wear scenarios comprises low-speed driving conditions, engine torque below a corresponding baseline, high-speed driving conditions, and climbing conditions.

8. The clutch disc wear detecting system (100) as claimed in claim 1, wherein the first threshold value corresponds to a warning threshold and the second threshold value corresponds to a critical threshold.

9. The clutch disc wear detecting system (100) as claimed in claim 1, wherein the one or more alerts, the warning alert, and the another warning alert comprises at least one of a notification alert on the instrument cluster (112) and/or an alert sound through an audio system of the vehicle (102).

10. A method (300) for operating a clutch disc wear detecting system (100) for a vehicle (102), comprising a vehicle subsystem interface having a sensor module (110) configured to detect one or more parameters associated with the vehicle (102) in real-time, characterized in that:
receiving, via at least one processor (108), one or more parameters from the sensor module (110), one or more historical parameters from a database (106) associated with the vehicle (102), and one or more signals from at least one sensor (104) installed inside a clutch booster of the vehicle (102),
wherein the one or more historical parameters comprises a sensor data representing a historical wear rates of the clutch disc under different driving conditions and the one or more signals are associated with movement of a wear indicator rod of the clutch booster, at operation (302);
determining, via the at least one processor (108), at least one baseline for each of the one or more parameters, based at least on the one or more historical parameters, at operation (304);
comparing, via the at least one processor (108), the one or more parameters with the corresponding at least one baseline, at operation (306);
detecting, via the at least one processor (108), one or more clutch disc wear scenarios, based at least on the comparison, at operation (308);
generating, via the at least one processor (108), one or more alerts on an instrument cluster (112) of the vehicle (102) to notify the driver of the vehicle (102) regarding the one or more clutch disc wear scenarios along with a corrective driving approach, at operation (310);
calculating, via the at least one processor (108), a wear ratio and a rate of wear of the wear indicator rod through the one or more signals received from the at least one sensor (104) or the one or more historical parameters, at operation (312);
calculating, via the at least one processor (108), a wear percentage of the wear indicator rod through the calculated wear ratio, at operation (314);
comparing, via the at least one processor (108), the calculated wear ratio with a first threshold value, at operation (316);
generating, via the at least one processor (108), a warning alert on the instrument cluster (112), if the calculated wear ratio is below the first threshold value, at operation (318);
comparing, via the at least one processor (108), the calculated wear ratio with a second threshold value, is the calculated wear ratio is above the first threshold value, at operation (320); and
generating, via the at least one processor (108), an immediate warning alert on the instrument cluster (112) for clutch disc replacement, at operation (322).

Dated this 21st Day of February, 2025
Ishita Rustagi (IN-PA/4097)
Agent for Applicant