FIELD OF THE INVENTION
The present invention relates to a vehicle horn, and more particularly, to an electronic horn for generating a single tone sound and a method therefor, for use in vehicles.
BACKGROUND
Conventional horns for vehicles are referred to as Dia 95 Disc Type electro-mechanical horn. The disc horn operation is based on the same principle as that of an electric bell. Accordingly, such horns consist of a housing assembly, diaphragm, bobbin assembly, resonator, etc. At least, a conventional disc horn assembly for a vehicle has been depicted in Figure 1.
As depicted in Figure 1, the housing assembly includes a sheet metal housing that encases a fixed iron core rigidly held to its bottom and aligned to its center axis. Around the fixed iron core, coil assembly is mounted. One end of the coil is connected with the terminal/connector through rivet and washer and the other end is connected with a second terminal/connector through a contact breaker (CB) assembly that is held offset from the center axis of the housing. The CB assembly mainly includes two metallic strip-carrying contacts. One of the strips is of a thin steel sheet also called spring, and the other is a comparatively thicker steel sheet also called support. The ends are insulated from each other by an insulating tab except at the contacts on their ends. Normally, in idle conditions and also to an extent during the operation, these contacts of the CB assembly contact each other.
The diaphragm assembly includes a moving iron core fixed to a sheet metal diaphragm, the periphery of which is rigidly held in the housing by crimping or bolting. In operation, as the supply from a DC source is switched ON, the current flows into the coil resulting in the electromagnetic field in the fixed core. This causes the moving iron core to be pulled towards the fixed iron core. During its forward motion towards the fixed iron core, the moving iron core pushes the spring and in turn moves the contacts away from each other thus breaking the circuit. This stops the current further and causes the magnetic flux to decrease.

Due to the elasticity of the material of the diaphragm, the diaphragm pulls back the moving iron core back to its equilibrium position. As the moving iron core moves back, the spring assembly also returns to its original position, and thus contacts each other again. The circuit is again completed from a broken state and current flow resumes within the circuit. The aforesaid make and break circuit-based operation repeats again, for example at around 430 cycles per second for a high tone sound, and around 335 cycles per second for a Low tone sound. This way diaphragm with the iron core is set into periodic motion.
The diaphragm assembly additionally includes a round-sheet metal part called a resonator. During the movement of the moving core, it hits the fixed core, resulting in the vibration transferred to the resonator. The resonator comes in resonance and amplifies the sound through air columns existing between the resonator and diaphragm.
However, the conventional horn assemblies are confronted with demerits such as less lifecycle, non-durability, requiring periodic adjustments, and maybe exclusively used for horn function or in other words for loud sounds. The same at least posed challenges to the manufacturers of equipment for vehicles. For example, the Original Equipment Manufactures are likely to have space issues in their vehicle. The conventional disc horns are based on the same principle as that of an electric bell and incorporate the only feature of acting as a "Warning device" with a single tone (High / Low) with a defined life cycle of 100,000.
Furthermore, the conventional horn assemblies are confronted with demerits such as residual accumulation due to wearing of mechanical contact breaker assembly, more heat generation due to arcing in contact breaker assembly, and last but not the least, a large number of mechanical parts. This is so since that conventional disc horn includes "Contact Breaker assembly" which controls the switching of the horn.
SUMMARY
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.

In an embodiment, an electronic horn for generating a single tone sound for a vehicle, includes a housing, at least one diaphragm, at least one fixed iron core, at least one coil assembly, and at least one controlling module. The at least one diaphragm is rigidly coupled to the housing through the periphery of the diaphragm. The at least one fixed iron core is coaxial to the housing and rigidly coupled to a bottom of the housing. The at least one coil assembly is mounted around the fixed iron core and adapted to generate magnetic fields on an unregulated power supply through a pin-connector, from at least one power source. The at least one controlling module is coupled to the coil assembly and configured to generate at least one signal based on at least one input from a vehicle module connected via a relay element, and control the switching of the power supply to the coil assembly. The switching of the power supply causes a change in magnetic fields generated in the coil assembly. The change in the generated magnetic fields causes a change in the vibrating frequency of the diaphragm to generate the single tone sound.
In another embodiment, a method for generating a single tone sound from an electronic horn having a housing, at least one diaphragm, at least one fixed iron core, and at least one coil assembly, includes converting, by a voltage regulator, an unregulated power supply from a power source to a regulated power supply. The method further includes receiving, by a microcontroller, the regulated power supply from the voltage regulator connected to the power source. The method further includes receiving, by the microcontroller, at least input from a vehicle module. The method further includes sensing, by a voltage sensing element, the voltage of the power supply, on the input from the vehicle module, from the power source. The method further includes simultaneously receiving, by a MOSFET, the unregulated power supply from the power source via the coil assembly and the regulated power supply from the voltage regulator. The method further includes generating, by the microcontroller, at least one signal based on the input from the vehicle module. A duty cycle of the generated signal is based on the voltage sensed by the voltage sensing element. The method further includes controlling, by the microcontroller, the switching of the power supply to the coil assembly through the switching of the MOSFET. The method further includes changing the vibrating frequency of the diaphragm through the switching of the MOSFET to generate the single tone sound.

To further clarify the advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Figure 1 illustrates an exploded view of a conventional disc horn for vehicles;
Figure 2 illustrates an exploded view of an electronic horn for generating a single tone
sound, in accordance with an embodiment of the present subject matter;
Figure 3 illustrates a block diagram of the electrical connection of an electronic horn of
Figure 2, in accordance with an embodiment of the present subject matter;
Figure. 4 illustrates a block diagram of a controlling module of an electronic horn of Figure
2, in accordance with an embodiment of the present subject matter;
Figure 5 illustrates a signal generated within an electronic horn of Figure 2, in accordance
with an embodiment of the present subject matter;
Figure. 6 illustrates a circuit diagram representing a controlling module schematic of an
electronic horn of Figure 2, in accordance with an embodiment of the present subject
matter;
Figure 7 illustrates a front and back view of a controlling module within an electronic horn
of Figure 2, in accordance with an embodiment of the present subject matter;
Figure 8 illustrates a front, back, and side view of an assembled electronic horn of Figure
2, in accordance with an embodiment of the present subject matter; and
Figure 9 illustrates a method for generating a single tone sound from an electronic horn of
Figure 2, in accordance with an embodiment of the present subject matter.
Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily been drawn to scale. For example, the

flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
DETAILED DESCRIPTION OF FIGURES
For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.
For example, the term "some" as used herein may be understood as "none" or "one" or "more than one" or "all." Therefore, the terms "none," "one," "more than one," "more than one, but not all" or "all" would fall under the definition of "some." It should be appreciated by a person skilled in the art that the terminology and structure employed herein is for describing, teaching and illuminating some embodiments and their specific features and elements and therefore, should not be construed to limit, restrict or reduce the spirit and scope of the claims or their equivalents in any way.
For example, any terms used herein such as, "includes," "comprises," "has," "consists," and similar grammatical variants do not specify an exact limitation or restriction, and certainly do not exclude the possible addition of one or more features or elements, unless otherwise stated. Further, such terms must not be taken to exclude the possible removal of one or more of the listed features and elements, unless otherwise stated,

for example, by using the limiting language including, but not limited to, "must comprise" or "needs to include."
Whether or not a certain feature or element was limited to being used only once, it may still be referred to as "one or more features" or "one or more elements" or "at least one feature" or "at least one element." Furthermore, the use of the terms "one or more" or "at least one" feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, "there needs to be one or more..." or "one or more element is required."
Unless otherwise defined, all terms and especially any technical and/or scientific terms, used herein may be taken to have the same meaning as commonly understood by a person ordinarily skilled in the art.
Reference is made herein to some "embodiments." It should be understood that an embodiment is an example of a possible implementation of any features and/or elements presented in the attached claims. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the attached claims fulfill the requirements of uniqueness, utility, and non-obviousness.
Use of the phrases and/or terms including, but not limited to, "a first embodiment," "a further embodiment," "an alternate embodiment," "one embodiment," "an embodiment," "multiple embodiments," "some embodiments," "other embodiments," "further embodiment", "furthermore embodiment", "additional embodiment" or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements

described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.
Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the attached claims. The attached claims and their legal equivalents can be realized in the context of embodiments other than the ones used as illustrative examples in the description below.
The present invention relates to an electronic horn for a vehicle, for generating a single tone sound, such as a low tone sound or a high tone sound. The electronic horn of the present subject matter is configured to be implemented with an internal controlling module, as described in a later part of the present disclosure.
An example of the horn of the present subject matter may be a Dia 95mm Disc E-horn with an internal controlling module that is configured to generate the single tone horn-sound through a signal generation without the need of make and break contacts. In an embodiment, the controlling module is based on a Printed Circuit Board (PCB). Similarly, in an embodiment, the generated signal is a Pulse Width Modulation (PWM) signal. The different signals' frequencies with different bands cause changes in the vibrating frequency of a diaphragm through a power MOSFET and thereby leads to the generation of the single tone i.e., a Low tone sound or a High tone sound.
The electronic horn is configurable by the presence of a specific microcontroller coding facility in the controlling module underlying the horn assembly. At least due to such unique coding and the microcontroller being configurable, a high tone and low tone variants horn sound is rendered. Coding with the microcontroller is done in a way that horn's Electronic Control Unit (ECU) can communicate with the vehicle's ECU through hardware inputs and can detect a plurality of inputs. As a part of a user interface to achieve such configuration of the microcontroller, a unique pin-connector is provided as an interface together with a potentiometer and switch-based circuit. This at least enables the user-driven tuning of the electronic horn as a part of customization to generate better sounds by the calibration. The tuning may be done externally without dismantling the horn assembly.

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

Figure 2 illustrates an exploded view of an electronic horn 100 in accordance with an embodiment of the present subject matter. In an implementation, the horn 100 may be a Dia. 95mm disc electronic horn, includes at least the following components/parts as provided below.
CJD
GD
QD
1. Resonator Washer - 01
2. Resonator - 01
3. Diaphragm washer - 01
4. Cap spring-01
5. Mobile Nucleus- 01
6. Diaphragm-01
7. Gasket-01
8. Cover-01
9. Bobbin washer- 02
10. Mosfet Rivet -01
11. PCBAssy.-Ol
12. Insulating Bush - 02
13. BobbinAssy. (Spool/Coil)-01
14. PCB Cover-01
15. Housing- 01
16. Connector Assy.-01
CJD
17. Fixed Nucleus- 01
18. BracketAssy.-Ol
19. Nut-01
Referring to Figure 2, the electronic horn 100 for generating a single tone sound for a vehicle, includes a housing 15, at least one diaphragm 6, at least one fixed iron core 17, at least one coil assembly 13, and at least one controlling module 11.
In an embodiment, the housing 15 may be made of one or more sheet metal, however, the housing 15 may be made of any other metal or plastic, without deviating from the scope of the present subject matter.

The at least one diaphragm 6 is rigidly coupled to the housing 15 through the periphery of the diaphragm 6. The at least one fixed iron core 17 or alternatively referred to as fixed nucleus 17 is coaxial to the housing 15 and rigidly coupled to a bottom of the housing 15. The at least one coil assembly 13 or a bobbin assembly 13 consisting of spool and wire is mounted around the fixed iron core 17 and adapted to generate magnetic fields on an unregulated power supply through a connector assembly having a pin-connector 16, from at least one power source 35. The connector assembly may further include one or more rivets, terminals, a signal pin, and a riveting washer.
In an embodiment, the power source may be a 24V DC battery, however, a power source of any other configuration may also be implemented, without deviating from the scope of the present subject matter.
The at least one controlling module 11 is coupled to the coil assembly 13 and configured to generate at least one signal based on at least one input from a vehicle module 35 connected via a relay element 36, and control the switching of the power supply to the coil assembly 13. The switching of the power supply causes a change in magnetic fields generated in the coil assembly 13. The change in the generated magnetic fields causes a change in the vibrating frequency of the diaphragm 6 to generate the single tone sound.
In another embodiment, the switching is generated and controlled by a controlling module assembly having the controlling module 11 and the connector assembly with a pin mechanism and epoxy coating. More particularly, as the 24V power supply is simultaneously supplied to the MOSFET via coil 24 and the voltage regulator 26. The 24V DC power supply is converted to a regulated 5 V DC power supply by the voltage regulator 26 to provide the power to the microcontroller 25. Then microcontroller 25 generates the signal i.e., Pulse Width Modulation signal, that controls the switching of the MOSFET 24. This switching energizes or de-energizes the bobbin assembly 13 at 24V.
As supply from the DC source is switched ON the current flows through a copper coil which magnetizes the fixed iron core 15. This causes the moving iron core 7 fixed on the diaphragm 6 to be pulled towards the fixed iron core 17. As the current supply is OFF through the controlled switching of the controlling module 11, causes the demagnetization

of the fixed iron core 15. Due to the elasticity of the material of the diaphragm 6, the diaphragm 6 pulls back the moving iron core 5 back to its equilibrium position. As the moving iron core 5 moves back, the controlling module 11 controls the switching again and the current supply is ON. The current starts following again and magnetizes the fixed iron core 17.
This process repeats again at around 430 cycles per second for a high tone sound approximately and around 335 cycles per second for a low tone sound approximately. This way, the diaphragm 6 with the moving iron core 5 is set into a periodic motion.
The moving iron core 5 may collide with the fixed iron core 17 during its movement. Due to the movement of the diaphragm 6, the air between the diaphragm and the resonator 2 is compressed and decompressed. Thus, the resonator 2 amplifies the tone sound.
In an embodiment, the controlling module 11 may further include one or more other components, for example, an RC Snubber 27 for surge voltage protection, a Schottky diode 29 for reverse polarity protection, and a Zener Diode 28 for over-voltage protection.
Figure 3 illustrates a block diagram of an electrical connection of an electronic horn 100 of Fig. 2, in accordance with an embodiment of the present subject matter. The vehicle module 35 is connected to the power source 32 through a plurality of electrical safety elements linked in series. Examples of the plurality of electrical safety elements include fuses 33, 34. For example, the electrical connection of the horn 100 may include a fuse-1 33, a fuse-2 34, a vehicle module 35, and the relay 36, between the connection of the power source 32, and the 24V DC horn 100. As depicted in Figure. 3, the 24V DC power from the battery is connected to the horn 100.
Figure 4 illustrates a block diagram of a controlling module 11 schematic of an electronic horn 100 of Fig. 2, in accordance with an embodiment of the present subject matter. The controlling module 11 includes a voltage regulator 26, a microcontroller 25, and a MOSFET 24. The voltage regulator 26 is connected to the power source 32 and adapted to convert the unregulated power supply of the power source 32 to a regulated power supply. The microcontroller 25 is connected to the voltage regulator 26 at one end,

for receiving the regulated power supply, and a voltage sensing element 34 at another end, for sensing the voltage of the power supply, on the input from the vehicle module 35, from the power source 32. The MOSFET 24 is connected to the power source 32 at one end via the coil assembly 13 and the microcontroller 25 at another end, and adapted to simultaneously receive the unregulated power supply from the power source 32 via the coil assembly 13 and the regulated power supply from the voltage regulator 26.
The microcontroller 25 is adapted to generate the at least one signal based on the input from the vehicle module 35, for controlling the switching of MOSFET 24 which in turn controls the switching of the power supply to the coil assembly 13. A duty cycle of the generated signal is based on the voltage sensed by the voltage sensing element 34. The at least one signal causes a change in the vibrating frequency of the diaphragm through the MOSFET 24 to generate the single tone sound.
In an embodiment, the regulated power supply is 5 V DC, however, any other power configuration may be supplied, without deviating from the scope of the present subject matter. Similarly, in an embodiment, the vehicle module 35 is a horn switch.
It will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the scope of the invention. For example, the present invention or at least one technical feature of the present invention may be implemented using any combination of computer programming software, firmware, or hardware.
In an embodiment, the controlling module 11 is designed on a printed circuit board, however, in another embodiment, the controlling module 11 may be designed in a different way, without deviating from the scope of the present subject matter.
The memory may include any non-transitory computer-readable medium known in the art including, for example, volatile memory, such as static random access memory (SRAM) and dynamic random access memory (DRAM), and/or non-volatile memory, such as read-only memory (ROM), erasable programmable (ROM), flash memories, hard disks, optical disks, and magnetic tapes.

The modules, amongst other things, include routines, programs, objects, components, data structures, etc., which perform particular tasks or implement data types. The modules may also be implemented as, signal processors, state machines, logic circuitries, and/or any other device or component that manipulate signals based on operational instructions.
Further, the modules can be implemented in hardware, instructions executed by a processing unit, or by a combination thereof. The processing unit can comprise a computer, a processor, a state machine, a logic array, or any other suitable devices capable of processing instructions. The processing unit can be a general-purpose processor which executes instructions to cause the general-purpose processor to perform the required tasks or, the processing unit can be dedicated to performing the required functions. In another embodiment of the present disclosure, the modules may be machine-readable instructions software that, when executed by a processor/processing unit, perform any of the described functionalities.
Figure 5 illustrates a signal generated within an electronic horn 100 of Fig. 2, in accordance with an embodiment of the present subject matter. As illustrated, an ON or active cycle represents the current flow or power supply ON state, and similarly, an OFF or inactive cycle represents no current flow or power supply OFF state. In an embodiment, a duty cycle of the generated signal is based on the voltage sensed by the voltage sensing element 34. The fixed iron core 17 is magnetized when the power supply from the power source 32 is ON by virtue of an ON state of the generated signal, causing a moving iron core 5 fixed on the diaphragm 6 to be pulled towards the fixed iron core 17 and demagnetized when the power supply is OFF through the controlled switching by the virtue of OFF state of the generated signal.
The moving iron core 5 is pulled back, by the diaphragm 6, to its equilibrium position, due to the elasticity of the material of the diaphragm 6, when the power supply is OFF through the controlled switching by the virtue of OFF state of the output signal.
The controlling module 11 controls the switching again, and due to the ON state of the output signal, the power supply is resumed ON, the power supply starts again and

magnetizes the fixed iron core, and, accordingly, the diaphragm 6 with the moving iron core 5 is set into a periodic motion.
Figure 6 illustrates a circuit diagram representing a controlling module 11 schematic of an electronic horn of Fig. 2, in accordance with an embodiment of the present subject matter. More specifically, the circuit diagram represents the circuit diagram representation of components as identified in the preceding figures.
An example, an input vs. output specification along with status may be depicted as follows in Table 3, however, any other circuit configuration may also be implemented, without deviating from the scope of the present subject matter.
Table 3

Input rated voltage : 24V on terminal connector
Voltage operating range: 16-32V

Frequency for normal horn application: 335±25Hzto440±25Hz
Sound pressure level: 85 dB A minimum @ 7m from Vehicle mounting position at 26V and 105-115 dB A @ 2m for normal horn function at 26V.
Current consumption: 2A maximum at 24V DC
PWM As per Figure 5 rough sketch.
Insulation Resistance IR More than 3MQ @500V DC
Figure 7 illustrates a front and back view of a controlling module 11 within an electronic horn of Fig. 2, in accordance with an embodiment of the present subject matter. Overall, the different signals cause changes in the vibrating frequency of the diaphragm 6 through the MOSFET 24 to generate a single tone i.e., a Low tone sound or a High tone sound.
In an embodiment, the controlling module 11 may also include a Transient-voltage-suppression (TVS) for load dump, a reverse polarity protection diode, and a Voltage sensing element for over and under-voltage protection through a microcontroller 25 and

automatic duty cycle calibration of the generated signal of microcontroller 25. An example of the reverse polarity protection diode is Avalanche diode/ Schottky diode.
Figure 8 illustrates the front, back, and side view of an assembled electronic horn 100 of Fig. 2, in accordance with an embodiment of the present subject matter. In accordance with the present subject matter, the disc E-horn with high tone and low tone sounds in Dia. 95mm is provided for a vehicle use. Overall, the electronic horn 100 is provided with a life cycle of 1,000,000. The electronic horn 100 of the present subject matter is only a single tone sound (i.e., a Low tone sound or a High tone sound), and calibrated externally through a Potentiometer.
Figure 9 illustrates a method 900 for generating a single tone sound from an electronic horn 100 of Fig. 2, in accordance with an embodiment of the present subject matter. At block 902, the method 900 for generating a single tone sound from an electronic horn 100 having a housing 15, at least one diaphragm 6, at least one fixed iron core 17, and at least one coil assembly 13, includes converting, by a voltage regulator 26, an unregulated power supply from a power source 32 to a regulated power supply. At block 904, the method 900 further includes receiving, by a microcontroller 25, the regulated power supply from the voltage regulator 26 connected to the power source 32.
At block 906, the method further includes receiving, by the microcontroller, at least input from a vehicle module 35. At block 908, the method further includes sensing, by a voltage sensing element 34, the voltage of the power supply, on the input from the vehicle module 35, from the power source 32. At block 910, the method further includes simultaneously receiving, by a MOSFET 23, the unregulated power supply from the power source 32 via the coil assembly 13 and the regulated power supply from the voltage regulator 26. At block 912, the method further includes generating, by the microcontroller, at least one signal based on the input from the vehicle module. A duty cycle of the generated signal is based on the voltage sensed by the voltage sensing element 34. At block 914, the method further includes controlling, by the microcontroller, the switching of the power supply to the coil assembly through the switching of the MOSFET. At block 914, the method further includes changing the vibrating frequency of the diaphragm through the switching of the MOSFET to generate the single tone sound.

Few of the major advantages, or distinguishing technical features, in addition to the discussed preceding passages, of the present invention over the conventional solutions are:
• The dimension of the controlling module (i.e., PCB) is adapted for a horn having a diameter of 95 mm as per vehicle packaging area in Heavy Commercial Vehicle (HCV).
• The controlling module (i.e., PCB) is disposed in the housing.
• The controlling module assembly generates and controls the switching through a Pulse Width Modulation (PWM).
• The controlling module having a feature of fundamental PWM frequency of the microcontroller can be calibrated through an external connector.
• The duty cycle of the PWM is automatically controlled with respect to voltage through voltage sensing.
• Unique microcontroller coding in the controlling module (i.e., PCB): Unique coding/programing of the microcontroller which is capable to add the feature of frequency and duty cycle calibration.
• Unique pin/connector, and design/application: This gives the uniqueness of the horn, to programmable from outside, to obtain sound by the coding.
• All the internal components of horn Assembly including Electronic components can sustain a minimum lOg vibrational load at all the three-axis.
• The horn provides a disc E-horn in Dia. 95mm for vehicles, with a warning sound.
• The horn encompasses an extended life cycle of 10,00,000, and doesn't require any adjustment during its life cycle.
• Reduction in mechanical components thus enabling higher assembly efficiency as per DFMA and eliminated wear and tear.
While specific language has been used to describe the present disclosure, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the forgoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment.

We Claim:

1. An electronic horn (100) for generating a single tone sound for a vehicle , comprising:
a housing (15);
at least one diaphragm (6) rigidly coupled to the housing (15) through the periphery of the diaphragm (6);
at least one fixed iron core (17) coaxial to the housing (15) and rigidly coupled to a bottom of the housing (15);
at least one coil assembly (13) mounted around the fixed iron core (17) and adapted to generate magnetic fields on an unregulated power supply through a pin-connector (16), from at least one power source (32); and
at least one controlling module (11) coupled to the coil assembly (13) and configured to generate at least one signal based on at least one input from a vehicle module (35) connected via a relay element (36), and control the switching of the power supply to the coil assembly (13),
wherein the switching of the power supply causes a change in magnetic fields generated in the coil assembly (13), and wherein the change in the generated magnetic fields causes a change in the vibrating frequency of the diaphragm (6) to generate the single tone sound.
2. The horn (100) as claimed in claim 1, wherein the controlling module (11) comprises:
a voltage regulator (26) connected to the power source (32) and adapted to convert the unregulated power supply of the power source (32) to a regulated power supply;
a microcontroller (25) connected to the voltage regulator (26) at one end, for receiving the regulated power supply, and a voltage sensing element (34) at another end, for sensing the voltage of the power supply, on the input from the vehicle module (35), from the power source (32); and
a MOSFET (24) connected to the power source at one end via the coil assembly (13) and the microcontroller (25) at another end, and adapted to simultaneously receive the unregulated power supply from the power source (32) via the coil assembly (13) and the regulated power supply from the voltage regulator (26),

wherein the microcontroller (25) is adapted to generate the at least one signal based on the input from the vehicle module (35), for controlling the switching of MOSFET (24) which in turn controls the switching of the power supply to the coil assembly (13), wherein a duty cycle of the generated signal is based on the voltage sensed by the voltage sensing element (34), and wherein the at least one signal causes a change in the vibrating frequency of the diaphragm through the MOSFET (24) to generate the single tone sound.
3. The horn (100) as claimed in claim 1 or 2, wherein the vehicle module (35) is connected to the power source (32) through a plurality of electrical safety elements linked in series.
4. The horn (100) as claimed in claim 3, wherein the plurality of electrical safety elements are fuses (33, 34).
5. The horn (100) as claimed in claim 1, wherein the pin-connector (16) acts as an interface for reconfiguring the microcontroller (25) to enable a user-driven tuning of the single tone sound by calibration.
6. The horn (100) as claimed in claim 1, wherein a dimension of the controlling module (11) is adapted for a horn having a diameter of 95 mm as per vehicle packaging area in Heavy Commercial Vehicle (HCV).

7. The horn (100) as claimed in claim 1 or 2, wherein the generated signal is pulse-width modulations (PWM) signal.
8. The horn (100) as claimed in claim 1 or 2, wherein the controlling module (11) is disposed in the housing.
9. The horn (100) as claimed in claim 1 or 2, wherein an Electronic Contol Unit (ECU) of the horn (100) is configured to communicate with an ECU of the vehicle module (35) through hardware input and detect a plurality of inputs.
10. The horn (100) as claimed in claim 1 or 2, wherein the microcontroller (25) is
configured to provide the frequency and duty cycle calibration.

11. The horn (100) as claimed in claim 1 or 2, wherein the controlling module (11) having
the microcontroller (25) to generate the signal is configured to be calibrated through an
external connector.
12. The horn (100) as claimed in claim 11, wherein the external connector is a potentiometer.
13. The horn (100) as claimed in claim 1 or 2, wherein the controlling module (11) comprises a Transient-voltage-suppression (TVS) for load dump, a reverse polarity protection diode, and a Voltage sensing element for over and under-voltage protection through a microcontroller (25).
14. The horn (100) as claimed in claim 1 or 2, wherein the controlling module (11) comprises at least one Resistor-Capacitor (RC) Snubber (27) for surge voltage protection, at least one Schottky diode (29) for reverse polarity protection, and at least one Zener Diode (28) for over-voltage protection.
15. The horn (100) as claimed in claim 1 or 2, wherein the fixed iron core (17) is magnetized when the power supply from the power source (32) is ON by virtue of an ON state of the generated signal, causing a moving iron core (5) fixed on the diaphragm (6) to be pulled towards the fixed iron core (17) and demagnetized when the power supply is OFF through the controlled switching by the virtue of OFF state of the generated signal.
16. The horn (100) as claimed in claim 15, wherein the moving iron core (5) is pulled back, by the diaphragm (6), to its equilibrium position, due to the elasticity of the material of the diaphragm (6), when the power supply is OFF through the controlled switching by the virtue of OFF state of the output signal.
17. The horn (100) as claimed in claim 16, wherein the controlling module (11) controls the switching again, and due to the ON state of the output signal, the power supply is resumed ON, the power supply starts again and magnetizes the fixed iron core, and, accordingly, the diaphragm (6) with the moving iron core (5) is set into a periodic motion.

18. The horn (100) as claimed in claim 1, wherein the single tone is one of a high tone sound and a low tone sound.
19. The horn (100) as claimed in claim 14, wherein the switching of the power supply at 430 cycles per second produces a high tone sound.
20. The horn (100) as claimed in claim 14, wherein the switching of the power supply at 335 cycles per second produces a low tone sound.
21. A method (900) for generating a single tone sound from an electronic horn (100) comprising a housing (15), at least one diaphragm (6), at least one fixed iron core (17), and at least one coil assembly (13), the method comprising:
converting, by a voltage regulator (26), an unregulated power supply from a power source (32) to a regulated power supply;
receiving, by a microcontroller (25), the regulated power supply from the voltage regulator (26) connected to the power source (32);
receiving, by the microcontroller (24), at least input from a vehicle module (35);
sensing, by a voltage sensing element (34), the voltage of the power supply, on the input from the vehicle module (35), from the power source (32);
simultaneously receiving, by a MOSFET (23), the unregulated power supply from the power source (32) via the coil assembly (13) and the regulated power supply from the voltage regulator (26);
generating, by the microcontroller (24), at least one signal based on the input from the vehicle module (35), wherein a duty cycle of the generated signal is based on the voltage sensed by the voltage sensing element (34);
controlling, by the microcontroller (24), the switching of the power supply to the coil assembly (13) through the switching of the MOSFET (23); and
changing the vibrating frequency of the diaphragm (6) through the switching of the MOSFET (23) to generate the single tone sound.