DESC:FIELD OF INVENTION

The present invention relates to the brakes mechanisms in automobiles, particularly to the brake-setting mechanism in farm equipment such as tractors, more particularly to the electronic brake-setting mechanism for tractors.

BACKGROUND OF THE INVENTION

The brakes in automobiles, e.g. farm equipment like tractors are pre-set by the original equipment manufacturers (OEM) during the pre-delivery inspection (PDI) stage. Once delivery and in use, with increase in tractor running, the clearance between the friction plates increases, which in turn requires for longer pedal travel for actuating the brake. However, when the pedal travel exceeds a certain limiting threshold value, which corresponds to a desired comfort limit of the tractor driver, this higher pedal travel leads to driver’s fatigue. Therefore, the brake setting needs to be done afresh to bring the pedal travel within the driver’s comfort zone. This brake setting is done manually, either by driver or by the service personnel. At present, a purely reactive method of brake setting is in use. However, the problem with the current method of brake setting is that if not done on time, this may lead to accidental damage and thereby claims from the user.

PRIOR ART

In present day automobiles, the brake mechanism includes a brake-pedal used for decelerating or even to gradually stop the vehicles. This braking action involves driver applying the brakes by pressing the brake-pedal down, a sensor actuating the brake-lights for alerting the drivers of the following vehicles about the brake being applied to slow-down or even stop this vehicle to prevent any collision of the vehicles running behind, and if available, to deactivate the cruise control mechanism, so that engine is also slowed down, thereby saving fuel and the braking action is also quickened. As present there is no provision for measuring the worn-out brake linings/plates in the vehicles.

DISADVANTAGES WITH THE PRIOR ART

The problem with the existing brake mechanisms in the automobiles, e.g. tractors lacks in measuring the brake-pedal travel, which may indirectly indicate the wear of the brake-plates/linings, which may cause driver’s discomfort level due to increased brake-pedal travel. This sometimes also leads to accidents or unpleasant incidences, where even after applying brake-pedal by the usual movement, the vehicle does not slow-down within a desired time/distance, thereby prompting the driver panics and is forced to apply brakes suddenly to avert an imminent mishap. This situation is particularly problematic when a regular driver is not running the vehicle, because he is applying brakes based on his natural comfort zone and habit. There is no indicator or alarms provided to alert the driver to update him/her possibly about the worn-out brake-plates/linings in the brake mechanism thereof.

Therefore, there is an existing need for improving the brake mechanism of an automobile, particularly farm equipment such as a tractor, wherein the driver is warned about the current status of the increased pedal travel with respect to the normal pedal travel. This warning may be given in any form, e.g. in the form of an alert displayed on a visual display or a sound being issued, such as a buzzer. This facilitates the driver, even a non-regular driver of the tractor, to do resetting of the brake-pedal travel for bringing the pedal travel within his/her comfort zone and/or avoiding any possible collision with the following vehicles from the rear side.

OBJECTS OF THE INVENTION

Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:

An object of the present invention is to provide an accurate and quickly responsive system for alerting the vehicle driver about the deteriorated state of brake-pedal operation.

Another object of the present invention is to provide a warning system for the vehicle driver for alerting about the need for resetting the brake-pedal travel deteriorated state of brake-pedal operation.

Still another object of the present invention is to provide a system for ameliorating the operational comfort of the vehicle driver by adjusting the required brake-pedal travel in a worn-out brake-plate/disc/liner.

These and other objects and advantages of the present invention will become more apparent from the following description when read with the accompanying figures of drawing, which are, however, not intended to limit the scope of the present invention in any way.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a brake-actuating system with an electronic brake-setting mechanism, the system comprising:

• a brake assembly having at least a brake-disc and friction brake-plate mounted on a first bracket;

• a brake pedal fixed on a profiled rod by means of a sleeved bracket;

• the brake pedal provided with a footrest as upper stopper therefor;

• a position sensing means including a brake pedal position sensor mounted on a second bracket under the footrest; and

• a brake-setting adjusting element provided between the first bracket and the sleeved bracket;

wherein the brake pedal is provided with a pedal location reference plate fixed at a predetermined location on the brake pedal and the distance of the pedal location reference plate from the brake pedal is stored in the Engine Control Unit (ECU) as a predefined threshold value of gap for computing the actual pedal travel while operating brakes.

Typically, on pressing the brake-pedal, if the gap between the position sensor and the brake-pedal location reference plate is equal to the threshold reference value, no alarm is issued on the instrument cluster of the vehicle.

Typically, on pressing the brake-pedal, if the gap between the position sensor and the brake-pedal location reference plate exceeds the threshold reference value of the predefined wear-limit or setting-limit of the electronic brake-setting mechanism, an alarm is issued on the instrument cluster of the vehicle.

Typically, the issued alarm is a warning sign displayed on the instrument cluster by means of a glow lamp or indicator.

Typically, the issued alarm is a buzzer or alarm sounded from the instrument cluster.

Typically, a separate position sensing mechanism is provided for LH and RH brake-pedal and a separate alarm is issued LH and RH brake operation.

Typically, an automatic brake setting means is provided by using motors and/or spring actuators to automatically reset the brakes on the electronic brake setting system issuing an alarm to reset the brake-pedal travel.

Typically, a maximum permissible brake-pedal travel is also stored in the ECU as the final warning for replacing the brake-disc and/or friction brake plates or pressure plates.

In accordance with the present invention, there is also provided a method for operating the brake-actuating system with an electronic brake-setting mechanism as claimed in anyone of the claims 1 to 8, wherein the method comprises the following steps:

• Monitoring the brake-pedal travel and signaling the captured value to the ECU and displaying the same on the instrument cluster;
• Comparing the predefined threshold value for the brake-pedal travel stored in the ECU and considered as safe and comfortable to driver for timely operation of brake-pedal;

• Issuing an alarm on/from the instrument cluster, if the actual brake pedal travel is found by the ECU as exceeding the predefined threshold value stored therein.

Typically, the alarm issued is in the form of a visible indication such as a warning bulb glowing on or an alarm/buzzer sounded from the instrument cluster for alerting the driver to immediately undertake brake-pedal resetting operation for preventing accident and thereby to enhance the driver’s operational comfort-level.

DESCRIPTION OF THE PRESENT INVENTION

In accordance with the present invention, a novel concept is proposed for taking preventive action at early stage and conducting a timely brake-setting after noticing the display of a displayed warning and/or hearing the alarm, enabling him/her to do periodic Brake setting or even changing of brakes when it reaches the maximum allowable wear-limit, thereby preventing the driver and vehicle occupants from any imminent accident probable due to increased friction plate clearances because of the wear and tear thereof.

The electronic brake actuating mechanism in accordance with the present invention consists of a brake-pedal position sensor for sensing the actual position of the brake pedal, when it is pressed by the vehicle driver, particularly when the friction plates of the brake are worn out and a gap develops between the pressure/friction plates and the brake linings, thereby increasing the distance of brake-pedal travel. Once, the brake-pedal travel exceeds a predefined limit, the electronic sensor senses the actual position of the brake-pedal and issues signals to the ECU of the instrument cluster, which in turn glow an alarm lamp provided on the instrument cluster panel for the vehicle driver to carry out the necessary brake-setting for bringing the brake-pedal travel within driver’s comfort zone and thereby within safe limits.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The present invention will be briefly described with reference to the accompanying drawings, which include:

Figure 1 shows a schematic arrangement of a brake actuating mechanism in accordance with the present invention.

Figure 2a shows a schematic arrangement of a brake actuating mechanism shown Figure 1 with the brake pedal pressed to a predefined position according to the brake setting actuating mechanism.

Figure 2b shows a portion of the instrument cluster disposed before the driver showing the alarm lamp in case of the normal brake pedal travel corresponding to Figure 2a.

Figure 3a shows a schematic arrangement of a brake actuating mechanism shown in Figure 1. However, the brake-pedal in the pressed has reached the predefined wear-limit or setting-limit as per the brake-setting actuating mechanism.

Figure 3b shows a portion of the instrument cluster disposed before the driver, in which the alarm lamp glows to indicate or warn the driver to do the resetting based on the changed gap between the position sensor and the brake-pedal location reference plate.

Figure 4 shows the schematic process of operation of the brake actuating mechanism in accordance with the present invention.

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

In the following, different embodiments of the present invention will be described in more details with reference to the accompanying drawings without limiting the scope and ambit of the present invention in any way.

Figure 1 shows a schematic arrangement of a brake actuating mechanism in accordance with the present invention. The brake actuating mechanism includes a brake assembly 100 provided with steel brake-disc and friction brake-plates 110 attached thereto. Further, a brake-pedal 120 is provided fitted with a foot-rest/plate 130. The foot-rest/plate 130 also acts a stopper for the brake pedal 120. The brake-pedal 120 is fixed on a brake-pedal rod 122 by means of a brake-pedal mounting bracket 124. The foot-rest/plate 130 carries a position sensor 140 fixed on a mounting bracket 132 fixed under the foot-rest 130. A pedal-location reference plate 150 is also fixed at a predetermined position on the brake pedal 120. The position sensor 140 senses its distance from the pedal-location reference plate 150. This normal distance is stored in the memory of the ECU (not shown). The steel brake-disc and friction brake-plate 110 carries a bracket 112. A brake-setting adjuster 160 is provided between this bracket 112 and the brake-pedal mounting bracket 124.

Figure 2a shows a schematic arrangement of a brake actuating mechanism shown Figure 1. Here, the brake pedal 120 is pressed to a position predefined of the brake setting actuating mechanism. Here, the gap between the position sensor 140 and the brake-pedal location reference plate 150 is X1. This position is read by the ECU as normal position.

Figure 2b shows a portion of the instrument cluster 170 disposed before the driver showing the alarm lamp 175 in non-glowing position for the normal brake pedal travel corresponding to Figure 2a.

Figure 3a shows another schematic arrangement of a brake actuating mechanism shown in Figure 1. Here, the brake-pedal 120 is pressed. So, the gap between the position sensor 140 and the brake-pedal location reference plate 150 has become X2. In this position is read by the ECU as brake-pedal 120 having reached the predefined wear-limit or setting-limit of the brake-setting actuating mechanism.

Figure 3b shows a portion of the instrument cluster 170 provided before the driver, in which the alarm lamp 175 is glowing to indicate or warn the driver to carry out the brake-pedal resetting depending on the changed gap (X1-X2) between the position sensor and the brake-pedal location reference plate 150.

Figure 4 shows the schematic process of operation of the brake actuating mechanism in accordance with the present invention. In step 10, the brake pedal 120 travels and which is sensed by the position sensor 140 in the next step 20. This sensed value is forwarded to the Engine Control Unit (ECU), which activates or keeps the indicator 175 depending on whether the gap between the position sensor 140 and the brake-pedal location reference plate 150 is equal to the predetermined gap value stored in the ECU. If ECU determines this gap to be more than the predetermined value fed into the ECU, it actuates the indicator 175 provided on the instrument cluster 170 and it glows in RED to warn the driver to do resetting of the brake plates/liners and the brake-pedal to bring it to normal gap, so that any untoward incidents are avoided. Alternatively, the ECU can be configured to sound a warning buzzer to alert the driver to carry out this resetting for the same purpose.

WORKING OF THE INVENTION

Normally, the brake-pedal setting / adjustment is done by adjusting the brake-pedal travel with respect to the dead weight for ensuring to maintain a proper gap between the vehicle brake’s pressure plates and friction plates. This ensures a proper brake application for getting an optimal life of the friction plates / liners of the vehicle brake by achieving optimized brake efficiency.

Usually, the brake lining’s friction material wears off due to repetitive application of brakes. This brake lining wear increases the gap between the pressure plate and friction plates and thereby increases the required brake-pedal travel to achieve optimum braking operation. Therefore, the brake-pedal setting is very critical for efficient braking operation in any vehicle, therefore it needs to be reset / readjusted after reaching a certain level of increased brake-pedal travel.

This level of brake-pedal travel can be predefined according to the driver’s comfort level as well as for a safe operation of the vehicle brakes. The brake-pedal setting can be done as and when the tractor / vehicle undergoes any service inspection according to predefined preventive maintenance schedule.

However, at present, there is no provision on the tractor / vehicle braking mechanism / actuation system for indicating to the driver and/or maintenance personnel to carry out the brake-setting, which can enable the driver or the service personnel to perform the brake-setting, even if the preventive maintenance schedule is not due.

It is very important for the driver/service personnel to get timely intimation as to when the friction plates of the brake have reached to the maximum permissible wear-limit thereof in order to be replaced immediately to avoid any imminent accident of the tractor / vehicle.

The electronic brake-setting mechanism in accordance with the invention can be operated as under:

• A brake-pedal position sensor disposed under the brake-pedal foot plate/rest continuously senses the brake-pedal travel and signals this value to ECU on the instrument cluster.

• ECU on the instrument cluster is already fed with a pre-set threshold value predefined for the brake-pedal travel considered safe and comfortable to driver for timely operation of brake-pedal.

• If the ECU finds this sensed brake-pedal travel to be exceeding the predefined value fed therein, a visible indication, a warning bulb or an alarm/buzzer sounded for the driver to do brake-setting at early stage for preventing any possible accident and/or to enhance the driver’s operational comfort-level.

• This brake operation is done by pressing brake pedal by Tractor/vehicle operator, which actuates pressure plate through linkages of brake, pressure plates expands & building internal pressure on friction/brake lining plates which are inserted on brake shaft, due to pressure friction increases on brake plate & tends to stop due to resistance, which eventually tries to stops brake shaft to reduce the tractor/vehicle speed.

TECHNICAL & ECONOMIC ADVANTAGES OF THE INVENTION

The electronic brake-setting mechanism configured in accordance with the present invention has the following advantages:

? Alert can be given by an indication, e.g. visual display/lamp and an audio alarm or buzzer.

? Separate sensing mechanism can be provided for LH and RH brake-pedals and separate indication is given for LH and RH brakes.

? Very importantly, it can also be extended to “Automatic adjustment/setting” by using motors, spring actuators etc., which will automatically reset the brakes when E-Brake system gives indication to carry out the re-setting of the brake-pedal travel as discussed above in details.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.

The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. The description provided herein is purely by way of example and illustration. The various features and advantageous details are explained with reference to this non-limiting embodiment in the above description in accordance with the present invention.
The descriptions of well-known components and manufacturing and processing techniques are consciously omitted in this specification, so as not to unnecessarily obscure the specification. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, the skilled person will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments described herein.

The skilled person can easily make innumerable changes, variations, modifications, alterations and/or integrations in terms of materials and method used to configure, manufacture and assemble various constituents, components, subassemblies, assemblies and in terms of the size, shapes, orientations and interrelationships without departing from the scope and spirit of the present invention. It is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.

The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the disclosure unless there is a statement in the specification to the contrary.

Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, shall be understood to implies including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps.

The use of the expression “a”, “at least” or “at least one” shall imply using one or more elements or ingredients or quantities, as used in the embodiment of the disclosure in order to achieve one or more of the intended objects or results of the present invention. ,CLAIMS:We claim:

1. A brake-actuating system with an electronic brake-setting mechanism, the system comprising:

• a brake assembly having at least a brake-disc and friction brake-plate mounted on a first bracket;

• a brake pedal fixed on a profiled rod by means of a sleeved bracket; the brake pedal provided with a footrest as upper stopper therefor;

• a position sensing means including a brake pedal position sensor mounted on a second bracket under the footrest; and

• a brake-setting adjusting element provided between the first bracket and the sleeved bracket;

wherein the brake pedal is provided with a pedal location reference plate fixed at a predetermined location on the brake pedal and the distance of the pedal location reference plate from the brake pedal is stored in the Engine Control Unit (ECU) as a predefined threshold value of gap for computing the actual pedal travel while operating brakes.

2. Brake-actuating system as claimed in claim 1, wherein on pressing the brake-pedal, if the gap between the position sensor and the brake-pedal location reference plate is equal to the threshold reference value, no alarm is issued on the instrument cluster of the vehicle.

3. Brake-actuating system as claimed in claim 1, wherein on pressing the brake-pedal, if the gap between the position sensor and the brake-pedal location reference plate exceeds the threshold reference value of the predefined wear-limit or setting-limit of the electronic brake-setting mechanism, an alarm is issued on the instrument cluster of the vehicle.

4. Brake-actuating system as claimed in claim 3, wherein the issued alarm is a warning sign displayed on the instrument cluster by means of a glow lamp or indicator.

5. Brake-actuating system as claimed in claim 3, wherein the issued alarm is a buzzer or alarm sounded from the instrument cluster.

6. Brake-actuating system as claimed in claim 1, wherein a separate position sensing mechanism is provided for LH and RH brake-pedal and a separate alarm is issued LH and RH brake operation.

7. Brake-actuating system as claimed in anyone of the claims 1 to 6, wherein an automatic brake setting means is provided by using motors and/or spring actuators to automatically reset the brakes on the electronic brake setting system issuing an alarm to reset the brake-pedal travel.

8. Brake-actuating system as claimed in anyone of the claims 1 to 7, wherein and a maximum permissible brake-pedal travel is also stored in the ECU as the final warning for replacing the brake-disc and/or friction brake plates or pressure plates.

9. A method for operating the brake-actuating system with an electronic brake-setting mechanism as claimed in anyone of the claims 1 to 8, wherein the method comprises the following steps:

• Monitoring the brake-pedal travel and signaling the captured value to the ECU and displaying the same on the instrument cluster;

• Comparing the predefined threshold value for the brake-pedal travel stored in the ECU and considered as safe and comfortable to driver for timely operation of brake-pedal;

• Issuing an alarm on/from the instrument cluster, if the actual brake pedal travel is found by the ECU as exceeding the predefined threshold value stored therein.

10. Method as claimed in claim 9, wherein the alarm issued is in the form of a visible indication such as a warning bulb glowing on or an alarm/buzzer sounded from the instrument cluster for alerting the driver to immediately undertake brake-pedal resetting operation for preventing accident and thereby to enhance the driver’s operational comfort-level.

Dated: this day of 03rd September, 2015. SANJAY KESHARWANI
APPLICANT’S PATENT AGENT