DESC:VEHICLE LOAD MEASUREMENT SYSTEM AND METHOD THEREOF
Field of the invention
The present invention generally relates to a vehicle load measurement and more specifically, to a vehicle load measurement system with suspension height measurement sensors.
Background of the invention
Overloading of vehicles causes problems such as increased vehicle operating cost, damage to suspension system, increased fuel intake, increase in the braking distance, liability exposure in the event of accident, etc. In order to avoid over loading, it is necessary to frequently check the loading of such vehicles. Vehicle load is generally measured by using the weigh bridge. Vehicle has to reach to the weigh bridge to measure load. In prior art patent US2010076673 (A1), height and weight based sensing system to avoid overloading a light duty truck is provided. However in US2010076673 (A1), the feature for checking flatness of the vehicle with respect to ground is absent and the claimed invention is suitable for light duty vehicles. Secondly, the suspension height changes as the vehicle moves. This causes error in the measurement. Also, there is possibility of error in the measurement due to sagging of suspension due to prolonged load carrying. These aspects are not taken into consideration in the prior art.
Hence, there exists a need to provide a system which will be suitable for all types of load carrying vehicles, trains etc, which will overcome the above mentioned drawbacks in the prior art.
Objects of the invention
An object of the present invention is to provide a vehicle load measurement system fitted in the vehicle itself, with a feature for calibration for suspension sagging.
Another object of the present invention is to provide a vehicle load measurement system which can be used for any load carrying vehicle.
Still another object of the present invention is to provide a vehicle load measurement system with a provision to immobilize the vehicle in case of overloading and a provision for communicating with the vehicle owner in such case.
Yet another object of the present invention is to provide vehicle loading data storage system which can be used for further applications.
Summary of the invention
The present invention, in one aspect, provides a vehicle load measurement system for measuring load carried by the vehicle. The system comprises of an ignition switch, a controller, a vehicle speed sensor, four suspension height sensors, a warning system, a data storage module, a calibration module and an engine management system’s electronic control unit (EMS ECU).
The ignition switch is provided on the vehicle for starting thereof. The controller is operably connected with the ignition switch for detecting status of the vehicle between anyone of ON condition and OFF condition. Further, the controller is connected to the vehicle speed sensor for determining speed of the vehicle. The four suspension height sensors include a first suspension height sensor and a second suspension height sensor configured on front axle of the vehicle whereas a third suspension height sensor and a fourth suspension height sensor configured on rear axle of the vehicle. The four suspension height sensors are operably connected with the controller for sending thereto an output signal indicative of suspension height of the vehicle. The controller processes the output of the four suspension height sensors to determine a load value indicative of load weight carried by the vehicle. The warning system includes an audio-visual display in communication with the controller for communicating to a user the load value measured by the controller. The warning system generates alert for the user informing about the overloaded condition and immobilizes the vehicle in case the measured load value is higher than an allowable load value which in turn corresponds to the load weight bearable by the vehicle without causing overloading thereof. Furthermore, the warning system generates alerts informing the user to park the vehicle on a flat surface prior to determination of the load value by the controller if the vehicle is parked on uneven surfaces, thereby eliminating errors during measurement of the load value of the vehicle. The data storage module is operably connected to the controller and is adapted for storing a database of a plurality of data sets each associated with the suspension height and respective load value for a plurality of the vehicles. The calibration module is operably connected with the controller for preventing occurrence of error caused due to sagging of suspension of the vehicle during measurement of the load value after lapse of time. The calibration module calibrates the database upon determining a mismatch between the suspension height and a factory condition base value during an unloaded condition of the vehicle measured at incremental time intervals to ensure accurate reading of the load value. The EMS ECU is connected to the controller for optimizing engine parameters including torque, power, and speed and fuel consumption, based on the load value detected by the controller for improving efficiency of the engine. The controller upon receiving output from the four suspension height sensors performs anyone of interpolation and extrapolation from the plurality of data sets to determine the load value of the vehicle associated with the measured suspension height by the four suspension height sensors.
In another aspect, the present invention provides a vehicle load measurement method for measuring amount of load carried by the vehicle. The method includes the controller obtaining suspension height at front and rear position of the vehicle by taking inputs from the four suspension height sensors, upon determining the ON condition of engine and zero speed of the vehicle (parked state of the vehicle) by taking inputs from the ignition switch and the vehicle speed sensor respectively. Thereafter, the method includes the controller accessing the database stored within the data storage module, if the suspension height obtained from the first and the second suspension height sensor matches with each other, and that of the third and the fourth suspension height sensor matches with each other. Thereafter, the controller compares the obtained suspension height measured with the plurality of data sets by performing anyone of interpolation and extrapolation from the plurality of data sets to determine the load value of the vehicle associated with the obtained/measured suspension height. Thereafter, the method involves the EMS ECU optimizing the engine parameters based on the load value determined by the controller to improve efficiency of the vehicle. The load value determined by the controller is further communicated to the warning system for displaying the information to the user. However, in the event there is a mismatch between the suspension height obtained from the first suspension sensor and the second suspension sensor and that of between the third suspension sensor and the fourth suspension sensor, the warning system generates alert for the user to park the vehicle on flat surface prior to determination of the load value by the controller.
Brief description of the drawings
The objects and advantages of the present invention will become apparent when the disclosure is read in conjunction with the following figures, wherein
Figure 1 shows a block diagram of a vehicle load measurement system, in accordance with the present invention; and
Figure 2 shows a flow chart of the steps involved in the measurement of vehicle load, in accordance with the present invention.
Detailed description of the embodiments
The foregoing objects of the present invention are accomplished and the problems and shortcomings associated with the prior art, techniques and approaches are overcome by the present invention as described below in the preferred embodiments.
The present invention provides a vehicle load measurement system and method capable of being used for determination of load carried by the vehicle. The system is adapted for storage of data generated during measurement of the load for future reference. The system and the method helps in eliminating error caused due to suspension sagging thereby ensuring accuracy during measurement of the load value of the vehicle. The system and the method further help in preventing overloading of the vehicle by immobilization thereof during an overloaded condition.
The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in bracket in the following description.
Referring to figure 1, in one aspect, a vehicle load measurement system (100), hereinafter referred to as “the system (100)” for determination of load carried by a vehicle is disclosed. The system (100) comprises of an ignition switch (10), a controller (40), a vehicle speed sensor (30), four suspension height sensors, a warning system (50), a data storage module (70), a calibration module (60) and an engine management system’s electronic control unit (EMS ECU) (80). The above mentioned components are operatively connected with each other.
The ignition switch (10) is configured on the vehicle for starting thereof. The controller (40) (alternatively referred as “data logger”) is disposed in operable communication with the ignition switch (10). The ignition switch (10) informs the controller (40) regarding condition of engine of the vehicle by sending an output signal to the controller (40) indicative of status of the vehicle between anyone of ON condition and OFF condition.
The vehicle speed sensor (30) is disposed in operable communication with the controller (40). The vehicle speed sensor (30) informs the controller (40) about speed of the vehicle by sending an output signal thereto indicative of speed of the vehicle.
The four suspension height sensors disposed are disposed in operable communication with the controller (40) and are adapted for measuring suspension height of the vehicle. The four suspension height sensors are provided on front and back axles to sense the flatness of the vehicle with respect to ground. The four suspension height sensors includes a first suspension height sensor (20A) and a second suspension height sensor (20B) configured on front axle of the vehicle, whereas a third suspension height sensor (20C) and a fourth suspension height sensor (20D) configured on rear axle of the vehicle for measuring the suspension height at front and rear positions of the vehicle. In an embodiment, compression of suspension system disposed at front and rear position of the vehicle is directly proportional to the amount of load carried by the vehicle. Therefore, as the vehicle is loaded, the suspension system of the vehicle gets compressed thereby leading to change in height of the suspension of the vehicle, suggesting that the change in height of the suspension is a function of the load carried by the vehicle. Thus, measurement of the suspension height at front and rear positions of the vehicles allows in determination of the load (load weight) carried by the vehicle. In an embodiment, the four suspension height sensors are contactless suspension height sensors adapted for measuring the change in the suspension height at front and rear positions of the vehicle, and thereafter sending an output signal indicative of suspension height of the vehicle to the controller (40) connected thereto for further processing and analysis to determine a load value indicative of the load weight carried by the vehicle.
The warning system (50) is disposed in operable communication with the controller (40). The warning system (50) includes, not limiting thereto, an audio-visual display. The warning system (50) is adapted for communicating the load value of the vehicle determined by the controller (40) to a user by means of an audio or a visual display. However, if the load value determined by the controller (40) is higher than an allowable load value of the vehicle, the warning system (50) generates an alarming signal by generating audio and visual alerts informing the user about occurrence of an overloaded condition of the vehicle, and thereafter immobilizes the vehicle till release of the load carried by the vehicle to overcome the overloaded condition. In an embodiment, the allowable load value corresponds to the load weight bearable by the vehicle without causing overloading thereof. Further, the warning system (50) upon receiving corresponding signal form the controller (40) is adapted to generate alarming signal by alerting the user if the vehicle is parked on an uneven surface, thereby restricting determination of the load value of the vehicle parked on the uneven surface. Measurement of the load value when the vehicle is positioned on a flat surface thus ensures accuracy in the load value determined/ measured by the controller (40).
The data storage module (70) is disposed in operable communication with the controller (40) for storing and processing the loading data of the vehicle. The data storage module (70) is adapted for storing a database of a plurality of data sets having each set associated with the suspension height and correlated load value (weight) for a plurality of the vehicles. Further, the data storage module (70) stores the load value for the vehicle as determined by the controller (40) based on the suspension height measured by the four suspension height sensors for future reference. The system is capable of matching the measured value with the prefilled values of suspension height and displaying the corresponding load conditions accordingly.
The calibration module (60) is disposed in operable communication with the controller (40) for preventing occurrence of error caused due to sagging of the suspension of the vehicle during measurement of the load value during intermittent time intervals. The calibration module (60), helps in auto and manual calibration for the suspension sagging. The calibration module (60), both intermittently or before determination of the load value by the controller (40), obtains the suspension height from the four suspension height sensors (20A, 20B, 20C, 20D) during an unloaded condition of the vehicle, and thereafter compares the suspension height with a factory condition base value for that vehicle. In the event, the calibration module (60) determines a mismatch between the suspension height in unloaded condition and the factory condition base value, the calibration module (60) calibrates the database accordingly, thus ensuring accuracy in measurement of the load value by the controller (40) during the loaded condition of the vehicle. The factory base value is the suspension height measured by sensors after the assembly of complete vehicle, which is taken as a base value for calibration purpose.
The EMS ECU (80) is disposed in operable communication with the controller (40). Based on the load value determined by the controller (40), the EMS ECU (80) performs optimization of engine parameters of the vehicle to improve on the efficiency and performance of the vehicle. In an embodiment, the engine parameters include, not limiting thereto, torque, power, speed and fuel consumption of the vehicle.
Output from the four suspension height sensors (20A, 20B, 20C and 20D), the speed sensor (30) and the calibration module (60) is fed to the controller (40) which in turn is operably connected to the auto visual display (50), data storage and processor (70) and EMS ECU (80).
The controller (40), upon receiving the suspension height at the front and the rear position of the vehicle, further processes the information to determine the load value upon satisfying the below conditions: suspension height measured by the first suspension height sensor (20A) matches exactly with that measured by the second suspension height sensor (20B); and the suspension height measured by the third suspension height sensor (20C) matches exactly with that measured by the fourth suspension height sensor (20D). In the event, the aforementioned conditions are not met, the controller (40) communicates the warning system (50) to inform the user that the vehicle is parked on the uneven surface and asking the user to park the vehicle on the flat surface for accuracy in the load value. In an embodiment, the controller (40) determines the load value only in the parked state of the vehicle (when the output of the vehicle speed sensor is ‘zero’) and when the ignition is ON. Further, for determining the load value, the controller (40) performs anyone of interpolation and extrapolation from the plurality of data sets and compares the suspension height with the database to arrive at the load value corresponding to the suspension height measured by the four suspension height sensors.
Referring to figure 2, in other aspect, a vehicle load measurement method (200), hereinafter referred to as “the method (200)” for determination of load carried by the vehicle is disclosed. The method (200) is explained in conjunction with the system (100). The first step involves the controller (40) checking for status of the engine of the vehicle by taking inputs from the ignition switch (10).
Upon determining the ON condition of the vehicle, the method (200) at step (110), includes the controller (40) taking inputs from the vehicle speed sensor (30) to determine state of the vehicle between anyone of a parked state and a running state. The vehicle speed sensor having output as ‘zero’ suggests that the vehicle is in the parked state (static condition) (Step 120).
Thereafter, upon determining ON condition of the engine and the parked state of the vehicle (Step 120), the method (200) at step (130) involves the controller (40) communicating with the four suspension height sensors (20A, 20B, 20C, 20D) to obtain the measured suspension height therefrom. Thereafter, the controller (40) upon receiving the suspension height at the front and the rear position of the vehicle, checks whether following conditions are satisfied before determining the load value of the vehicle:
• the suspension height measured by the first suspension height sensor (20 A) matches exactly with that measured by the second suspension height sensor (20B) i. e. if 20A= 20B; and
• the suspension height measured by the third suspension height sensor (20C) matches exactly with that measured by the fourth suspension height sensor (20D) i. e. if 20C= 20D.
In the event, the aforementioned conditions are not satisfied, (i.e. 20A ? 20B and 20C ? 20D) (Step 132), then the method (200), at step (135), involves the controller (40) communicating the warning system (100) to inform the user that the vehicle is not parked on the flat surface, and not determining the load value until the user parks the vehicle on the flat surface.
When the outputs of the suspension height sensors on front and rear axle exactly matches with each other ((i.e. 20A = 20B, 20C = 20D) (Step 140), or the flatness of the vehicle is confirmed, then the method (200), at step (150), involves the controller (40) accessing the database stored within the data storage module (70) and comparing the measured suspension height with the plurality of data sets stored within the database to determine the load value for the vehicle by performing anyone of interpolation and extrapolation from the plurality of data sets. Particularly, the controller (40) compares the measured suspension height with the prefilled data in the database regarding suspension height and corresponding load weight in the vehicle, for example a cargo, to identify the load value in cargo.
Thereafter, the method (200), at step (160), involves the controller (40) communicating the load value to the warning system (50) to inform the same to the driver / user. In an embodiment, the load value is communicated to the user/ driver or the vehicle owner through an SMS/e-mail. In the event, the load value is higher than the allowable load value for the vehicle; the warning system (50) generates an alarming signal informing the user about an overloaded condition by immobilizing the vehicle such that the engine cannot be cranked. (Step 170).
Upon determination of the load value by the controller (40), the EMS ECU (80) receives the load value therefrom to optimize the engine parameters including torque, power, speed & the fueling based on the load value to make the vehicle fuel efficient.
Thus, the present invention provides the system (100) and the method (200) for measuring the load value of the vehicle during ON condition of the engine and in the parked state of the vehicle. The system (100) and the method (200) is further adapted for immobilizing the vehicle in the event of an overloaded condition of the vehicle.
Advantages of the invention
1. The system (100) and the method (200) of the present invention facilitates on the spot vehicle load measurement
2. The vehicle load is measured only when the vehicle is not moving and is standing on flat / even surface. This increases the accuracy in load measurement.
3. The system (100) and the method (200) provide calibration for suspension sagging, which adds to the accuracy in load measurement.
4. The data in the data storage system can be used further for knowing the usage patterns and design the vehicle accordingly in future and for settlement of warranty and insurance claims.
5. The system (100) provides information about the actual loading conditions to the vehicle owner.
6. If the vehicle is overloaded then the system (100) is capable of immobilizing the vehicle and engine cannot be cranked.
7. The load input can be given to the EMS ECU (80) to control Torque, Power, speed & the fueling as per the load condition to optimize the fuel consumption and make the vehicle fuel efficient.
8. The system (100) can communicate the load condition to vehicle owner by SMS/E-Mail.
9. The measured values can be used for displaying the tyre pressure requirement as per detected load.
10. The measured values can be used for head lamp leveling auto correction (vehicle stance will get changed due to loading condition) to provide better road visibility.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention

,CLAIMS:We Claim:
1. A vehicle load measurement system (100), configured on a vehicle and capable of being used for measuring load carried by the vehicle, the vehicle load measurement system (100) comprising of:
an ignition switch (10) configured on a vehicle for starting thereof;
a controller (40) disposed in operable communication with the ignition switch (10) to receive a signal therefrom indicative of status of the vehicle between anyone of ON condition and OFF condition;
a vehicle speed sensor (30) disposed in operable communication with the controller (40) for sending an output signal indicative of speed of the vehicle to the controller (40);
four suspension height sensors disposed in operable communication with the controller (40) for sending thereto an output signal indicative of suspension height of the vehicle, the four suspension height sensors including a first suspension height sensor (20A) and a second suspension height sensor (20B) configured on front axle of the vehicle whereas a third suspension height sensor (20C) and a fourth suspension height sensor (20D) configured on rear axle of the vehicle for measuring the suspension height at front and rear position of the vehicle, wherein the controller (40) processes the output signal obtained from the four suspension height sensors to determine a load value indicative of load weight carried by the vehicle;
a warning system (50) having an audio-visual display disposed in operable communication with the controller (40) for receiving and communicating the measured load value of the vehicle to a user, wherein if the measured load value is higher than an allowable load value, the warning system (50) generates an alarming signal informing the user about an overloaded condition of the vehicle by immobilizing the vehicle and restricting any further loading of the vehicle, wherein the allowable load value corresponds to the load weight bearable by the vehicle without causing overloading thereof, wherein in the event the vehicle is parked on an uneven surface, the warning system (50) generates alerts informing the user to park the vehicle on a flat surface prior to determination of the load value by the controller (40);
a data storage module (70) disposed in operable communication with the controller (40) for storing a database of a plurality of data sets each associated with the suspension height and respective load value for a plurality of the vehicles;
a calibration module (60) disposed in operable communication with the controller (40) for preventing occurrence of error caused due to sagging of suspension of the vehicle during measurement of the load value after lapse of time, the calibration module (60) adapted for calibrating the database upon determining a mismatch between the suspension height and a factory condition base value during an unloaded condition of the vehicle measured at incremental time intervals thereby ensuring accurate measurement of the load value by the controller (40), wherein the factory condition base value is the suspension height measured after vehicle assembly, without any load; and
an engine management system’s electronic control unit (EMS ECU) (80) disposed in operable communication with the controller (40) for optimizing engine parameters based on the load value detected by the controller (40) to improve efficiency of the vehicle, the engine parameters including torque, power, speed and fuel consumption of the vehicle,
wherein, the processing of the output signal obtained from the four suspension height sensors (20A, 20B, 20C, 20D) by the controller (40) includes performing anyone of interpolation and extrapolation from the plurality of data sets to determine the load value of the vehicle which corresponds to the suspension height measured by the four suspension height sensors (20A, 20B, 20C, 20D).

2. The vehicle load measurement system (100) as claimed in claim 1, wherein the four suspension height sensors (20A, 20B, 20C, 20D) are contactless suspension height sensors.
3. A vehicle load measurement method (200), the vehicle load measurement method (200) capable of being used for measuring load carried by the vehicle, the vehicle load measurement method (200) comprising the steps of:
receiving inputs from an ignition switch (10) of the vehicle by a controller (40) connected thereto indicative of status of engine of the vehicle between anyone of ON condition and OFF condition;
receiving inputs from a vehicle speed sensor (30) by the controller (40) connected thereto regarding speed of the vehicle to determine state of the vehicle between anyone of a parked state and a running state upon determining the ON condition of the engine of the vehicle;
communicating with four suspension height sensors by the controller (40) connected thereto for obtaining a suspension height measured at front and rear position of the vehicle upon determining the parked state of the vehicle, the four suspension height sensors including a first suspension height sensor (20A) and a second suspension height sensor (20B) configured on front axle of the vehicle whereas a third suspension height sensor (20C) and a fourth suspension height sensor (20D) configured on rear axle of the vehicle for measuring the suspension height at front and rear position of the vehicle respectively, wherein, in the parked state the output of the vehicle speed sensor is equal to zero;
accessing a database stored within a data storage module (70) by the controller (40) connected thereto in the event the suspension height measured by the first suspension height sensor (20A) and the second suspension height sensor (20B) exactly matches with each other, whereas the suspension height measured by the third suspension height sensor (20C) and the fourth suspension height sensor (20D) exactly matches with each other, the database having a plurality of data sets each associated with the suspension height correlated with a respective load value for a plurality of the vehicles, the load value indicative of load weight carried by the vehicle;
determining load value for the vehicle by the controller (40) using the measured suspension height at front and rear position of the vehicle for comparison thereof with the plurality of data sets, wherein the controller (40) performs anyone of interpolation and extrapolation from the plurality of data sets to determine the load value of the vehicle associated with the measured suspension height;
optimizing engine parameters based on the determined load value by an engine management system’s electronic control unit (EMS ECU) (80) connected to the controller (40) to improve efficiency of the vehicle, the engine parameters including torque, power, speed and fuel consumption of the vehicle; and
communicating the determined load value by the controller (40) to a warning system (50) connected thereto for displaying the determined load value to a user, wherein, if the determined load value is higher than an allowable load value, the warning system (50) generates an alarming signal informing the user about an overloaded condition by immobilizing the vehicle and restricting any further loading of the vehicle, wherein the allowable load value corresponds to the load weight bearable by the vehicle without causing overloading thereof,
wherein, the database is calibrated automatically using a calibration module (60) connected thereto upon determining a mismatch between suspension height measured at an unloaded condition of the vehicle and a factory condition base value at incremental time intervals to ensure accurate measurement of the load value by the controller (40), and
wherein, in the event there is a mismatch between the suspension height measured by the first suspension height sensor (20A) and the second suspension height sensor (20B) and that of between the third suspension height sensor (20C) and the fourth suspension height sensor (20D), the vehicle load measurement method (200) comprises communicating the warning system (50) about the occurrence of such a event by the controller (40) for generating alerts notifying the user to park the vehicle on a flat surface prior to determination of the load value by the controller (40).
Dated this 27th day of October 2017

Prafulla Wange
(Agent for applicant),
(IN/PA-2058)