Abstract:
An overload indicator is shown and described. The overload indicator may include a compression ring located between a portion of a hitch and a hitch ball, the compression ring calibrated to withstand up to a selected vertical force limit. The compression ring collapsing or flattening when applied with a force equal to or greater than the selected vertical force limit.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims benefit from U.S. Provisional Application Ser. No. 61/717,693, entitled “Overload Indicator” filed on Oct. 24, 2012, which is hereby incorporated in its entirety by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This application relates to an overload indicator and more particularly to a towing assembly overload indicator. 
       BACKGROUND 
       [0003]    Many vehicles are designed to transport freight, goods, merchandise, personal property, and other such cargo. Often, such vehicles may be arranged to tow a trailer or other towed vehicle by attaching the trailer or other towed vehicle to the towing vehicle, such as through the use of a hitch assembly. The towing industry has developed a number of different types of hitch assemblies, many of which are used for specific towing requirements. 
         [0004]    There are many different types of trailer hitches in the art that may be attached to the towing vehicle in a variety of ways, depending on the type of hitch. Some of the most common types of hitches include gooseneck, fifth wheel, front mount, and the like. Typically, trailers may be connected to the towing vehicle by way of a hitch assembly including a ball hitch or member secured to the towing vehicle and a ball socket coupling mechanism on the towed vehicle or trailer that mounts over the ball and thereby allows for the trailer to pivot behind the towing vehicle. 
         [0005]    Numerous types of hitch balls have been developed to be attached to the bumper or other rear portion of a towing vehicle. The trailer or towed vehicle may be equipped with a coupler mechanism to attach to the towing vehicle by placing the coupler mechanism over the hitch ball and securing the coupler to the hitch ball. Similar apparatuses using hitch receivers attached to the rear of the towing vehicle and drawbars may be used to secure trailers to towing vehicles. 
         [0006]    There are generally two arrangements for securing a trailer to the bed of a towing vehicle—a fifth wheel hitch and a gooseneck ball hitch. A gooseneck hitch may be utilized with a towed vehicle having a gooseneck coupler coupled to a gooseneck ball located in the bed of the towing vehicle. The gooseneck ball is either permanently or selectively secured to the frame or bed of the towing vehicle. 
         [0007]    The gooseneck coupler to gooseneck ball connection may allow for more relative movement between the towing vehicle and the towed vehicle as the towing vehicle makes turns, traverses uneven or rough terrain, and passes along inclining and declining roadways. The gooseneck ball member may be removed or lowered to a stowed position below the bed to ensure that the use of the bed is not substantially hindered by the presence of the gooseneck ball. 
         [0008]    The gooseneck coupler typically includes a manually operated clamping arrangement that retains the gooseneck ball member in the socket and thus the towed vehicle to the towing vehicle. Generally, the gooseneck coupler may be secured to the tongue of the towed vehicle, usually a forward extension of the frame. 
         [0009]    Some trailers are designed to carry heavy loads. When a trailer load is heavy as compared to the weight of the towing vehicle, applying the trailer load over or otherwise in close proximity to the rear axle of the towing vehicle may create preferable towing condition. In addition, such an arrangement may put much of the force of the trailer load onto structural members of the towing vehicle, such as the frame, whereby the hitch ball may be located in the truck bed. However, the towing vehicle may have weight limit and if that weight limit is surpassed the truck may be considered overloaded. 
         [0010]    The most common means of overloading a vehicle is from vertical force. Current vehicles used with goosenecks may overload either the truck axle or the hitch rating without any indication to the user that they have done so. Without any indication of an overload a person may continue to overload the vehicle creating damage or shorter life to the rear axle, hitch, truck frame, suspension or axle. 
         [0011]    Therefore, there is a need for a reliable gauge or indicator that identifies when a potential overloaded conditions occurs. There is also a need for this gauge or indicator to be affordable, easy to use and effective at indicating the overload condition of the towing vehicle coupled to the towing vehicle. 
       SUMMARY 
       [0012]    An overload indicator is shown and described. The overload indicator may include a compression ring located between a portion of a hitch and a hitch ball, the compression ring calibrated to withstand up to a selected vertical force limit. The compression ring collapsing or flattening when applied with a force equal to or greater than the selected vertical force limit. 
         [0013]    An overload indicator may include a load cell selectively positioned between a hitch ball and a hitch assembly, where the load cell measures a vertical force applied to at least one of the hitch ball and hitch assembly. The overload indicator may also include a microcontroller operatively coupled with the load cell, where the load cell provides an input signal to the microcontroller indicative of the vertical force measured. 
         [0014]    A hitch ball assembly may include a ball member configured to operatively engage a socket of a hitch assembly and a hitch ball flange extending from the ball member. The hitch ball assembly may also include an overload indicator positioned between the hitch assembly and the hitch ball flange, where the overload indicator is calibrated to identify when a force equal to or greater than a selected vertical force limit is applied to the overload indicator. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    Operation of the invention may be better understood by reference to the following detailed description taken in connection with the following illustrations, wherein: 
           [0016]      FIG. 1  is a cross-sectional view of a calibrated overload indicator in an uncompressed state selectively attached between a hitch ball and a gooseneck hitch receiver. 
           [0017]      FIG. 2  is a cross-sectional view of the calibrated overload indicator in a compressed state selectively attached between the hitch ball and the gooseneck hitch receiver. 
           [0018]      FIG. 3  is a perspective view of the calibrated overload indicator of  FIG. 1 . 
           [0019]      FIG. 4  is a cross-sectional view of an electrical overload indicator selectively positioned between a hitch ball and gooseneck hitch receiver. 
           [0020]      FIG. 5  is a cross-sectional view of an electrical overload indicator selectively positioned between a hitch ball and gooseneck hitch receiver. 
           [0021]      FIG. 6  is a top view of embodiments of a compression ring having a plurality of waves or undulations. 
           [0022]      FIG. 7  is a cross-sectional view of the compression ring of  FIG. 6  along line  7 - 7 . 
           [0023]      FIG. 8  is a top view of embodiments of a compression ring having a generally flat lower surface while having a top surface comprising a plurality waves or undulations. 
           [0024]      FIG. 9  is a cross-sectional view of the compression ring of  FIG. 8  along line  9 - 9 . 
           [0025]      FIG. 10  is a top view of embodiments of a compression ring having a plurality of thin radially oriented ribs. 
           [0026]      FIG. 11  is a cross-sectional view of the compression ring of  FIG. 10  along line  11 - 11 . 
           [0027]      FIG. 12  is a top view of embodiments of a compression ring having a generally annular shape having a raised portion on the upper and lower sides of the outer and inner surfaces of the compression ring. 
           [0028]      FIG. 13  is a cross-sectional view of the compression ring of  FIG. 12  along line  13 - 13 . 
           [0029]      FIG. 14  is a top view of embodiments of a compression ring having a generally annular shape having a raised portion on the upper side of the outer and inner surfaces of the compression ring. 
           [0030]      FIG. 15  is a cross-sectional view of the compression ring of  FIG. 14  along line  15 - 15 . 
           [0031]      FIG. 16  is a top view of embodiments of a compression ring having a generally annular shape having a raised portion on the upper side of the outer and inner surfaces of the compression ring. 
           [0032]      FIG. 17  is a cross-sectional view of the compression ring of  FIG. 16  along line  17 - 17 . 
           [0033]      FIG. 18  is a top view of embodiments of a compression ring having a generally annular shape having a raised portion on the lower side of the outer and inner surfaces of the compression ring. 
           [0034]      FIG. 19  is a cross-sectional view of the compression ring of  FIG. 18  along line  19 - 19 . 
           [0035]      FIG. 20  is a top view of embodiments of a compression ring having a generally annular shape having a raised portion on the upper side of the outer and inner surfaces of the compression ring. 
           [0036]      FIG. 21  is a cross-sectional view of the compression ring of  FIG. 20  along line  21 - 21 . 
           [0037]      FIG. 22  is a top view of other embodiments of a compression ring having a plurality of raised tabs. 
           [0038]      FIG. 23  is a cross-sectional view of the compression ring of  FIG. 22  along line  23 - 23 . 
           [0039]      FIG. 24  is a top view of embodiments of a compression ring having a generally annular shape having generally hour-glass shaped portions on the outer and inner surfaces of the compression ring. 
           [0040]      FIG. 25  is a cross-sectional view of the compression ring of  FIG. 24  along line  25 - 25 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0041]    Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the invention. Moreover, features of the various embodiments may be combined or altered without departing from the scope of the invention. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments and still be within the spirit and scope of the invention. 
         [0042]    A calibrated overload indicator  100  is shown in  FIGS. 1-3 . The overload indicator  100  may be selectively positioned in any appropriate location on a towing assembly, such as for example selectively and operatively coupled with an assembled gooseneck hitch assembly  105  and hitch ball  107 . The gooseneck hitch assembly  105  may be of any appropriate construction, such as by way of a non-limiting example, the gooseneck hitch assembly  105  may be constructed as described in U.S. Patent Application Publication Number 20100109285, which is hereby incorporated by reference. Further, the hitch ball  107  may be of any appropriate construction. By way of a non-limiting example, the hitch ball  107  may be constructed as shown and described in U.S. Pat. Nos. 8,011,685 and 6,616,168, both of which are hereby incorporated by reference. 
         [0043]    In some embodiments, the overload indicator  100  may be selectively positioned between a top surface  109  of a gooseneck collar  111  of the gooseneck hitch assembly and underneath a hitch ball flange  117  of the hitch ball  107 . The overload indicator  100  may notify or otherwise indicate to a user that a structural limitation event has occurred, such as by way of a non-limiting example, the towing vehicle being overloaded. By way of a non-limiting example, each axle of a towing vehicle has a vertical force limit, sometimes called the “dynamic limit,” and the overload indicator  100  may be tuned or calibrated to the corresponding limits of a vehicle axle of a particular towing vehicle. When the selected vertical force limit is reached, or surpassed, the overload indicator  100  may indicate this condition, such as by becoming compressed or flattened. In some embodiments, the overload indicator  100  may permanently compress or flatten once the selected vertical force limit is reached or surpassed. 
         [0044]    Once compressed or flattened, the flattening of the overload indicator  100  may introduce a vertical gap (or freeplay/slop) in the connection between the hitch ball  107  and the gooseneck hitch assembly  105 . Once this vertical gap is present, every vertical variation in a road or driving surface may create a noise as the hitch ball  107  moves within the gooseneck hitch assembly  105 . The noise may be generated when the hitch ball  107  moves vertically within a sleeve (not shown) of the gooseneck hitch (not shown) of the towed vehicle, such as by way of a non-limiting example moving ⅜″ to ½″. This noise may act as an indicator that the towing vehicle was or is overloaded and has reached or surpassed its vertical force limit. The noise created due to the flattened overload indicator  100  may be even more pronounced when the towing vehicle travels over rough terrain. By way of a non-limiting example, the flattened overload indicator  100  is shown in  FIG. 2 . 
         [0045]    In some embodiments, the overload indicator  100  may be fit snuggly or have an interference fit with the hitch ball  107 . More specifically, the overload indicator  100  may be press fit onto a shank  121  of the hitch ball  107 . This may allow the overload indicator  100  to be inspected every time the hitch ball  107  is removed. The overload indicator  100  may be replaced to reset the system either due to the overload indicator  100  being flattened or because of a changing vertical force limit, such as being used a towing vehicle having a load limit on its axle that is different. 
         [0046]    In some embodiments, the overload indicator  100  may include an annular body  150  an example of which is shown in  FIG. 3  as an annular ring. The annular ring  150  may be a generally flattened shaped ring that may include a top or first surface  153  and a bottom or second surface  155 . The top surface  153  may include a plurality of frangible or crushable indicators  161  such as for example generally hemi-spherically shaped members  161  attached to the top surface  153  of the ring  150 . The hemi-spherically shaped members  161  may be attached using fasteners, adhesives, welding, or the like or may be monolithically formed with the ring  150 . The bottom surface  155  may include a plurality of crushable or frangible indicators  163  such as for example generally hemi-spherically shaped members  163  attached to the bottom surface  155  of the ring  150 . The hemi-spherically shaped members  163  may be attached using fasteners, adhesives, welding, or the like or may be monolithically formed with the ring  150 . It should be understood, however, that the shape of the generally hemi-spherically shaped members  161 ,  163  are exemplary and that any appropriately shaped frangible or crushable member may be used. The overload indicator  100  may be made of any appropriate material, including, without limitation, steel, metal, plastic, polymeric material, a combination of two or more thereof, or any other known material in the art. 
         [0047]    In some embodiments, the overload indicator  100  may be about 5 mm to about 30 mm in height. In other embodiments the overload indicator  100  may be about 10 mm to about 20 mm in height. The overload indicator  100  may have a selected compression structure specifically designed or calibrated to flatten or crush when a pre-determined vertical force is applied to the overload indicator  100 . 
         [0048]    While the overload indicator  100  is shown and described with the gooseneck hitch  105  and hitch ball  107 , the overload indicator  100  may be used with other types of towing assemblies. By way of a non-limiting example, the overload indicator  100  may be used with a fifth wheel hitch assembly, a rear mounted hitch assembly (such as a hitch receiver and hitch ball), or the like. Moreover, while the load indicator  100  is shown and described with indicating a generally vertical overload occurrence, the load indicator  100  may also be capable of indicating generally horizontal or combination of vertical and horizontal overload situations, including, without limitation predetermined angular overload situations. 
         [0049]    Additional embodiments of an overload indicator according the present teachings are described below. In the descriptions, all of the details and components may not be fully described or shown. Rather, the features or components are described and, in some instances, differences with the above-described embodiments may be pointed out. Moreover, it should be appreciated that these other embodiments may include elements or components utilized in the above-described embodiments although not shown or described. Thus, the descriptions of these other embodiments are merely exemplary and not all-inclusive nor exclusive. Moreover, it should be appreciated that the features, components, elements and functionalities of the various embodiments may be combined or altered to achieve a desired overload indicator without departing from the spirit and scope of the present invention. 
         [0050]    Other embodiments of an overload indicator  200  are shown in  FIGS. 4-5 . In these embodiments, the overload indicator  200  may include an electronic load cell  271 . Any appropriate number of load cells  271  may be used, such as by way of a non-limiting example, one, two, three, etc. The load cells  271  may be selectively positioned in any appropriate position on the gooseneck hitch  105  and/or the hitch ball  107  such that the load cells  271  may measure an amount of vertical load being applied to the gooseneck hitch  105  and/or the axle of the towing vehicle. By way of a non-limiting example, the overload indicator  200  may utilize a pair of load cells  271  that may be positioned opposite one another, i.e., generally about 180 degrees apart. 
         [0051]    In these embodiments, the load cells  271  may be operatively coupled with a microcontroller  275  that may be positioned in an appropriate position on the towing vehicle. A wire  277  may be used to operatively couple the load cells  271  with the microcontroller  275 . In other embodiments, the load cells  271  may be wirelessly operatively coupled with the microcontroller  275 . Further, while each load cell  271  is shown as being operatively coupled to a separate microcontroller  275 , a single microcontroller  275  may be used and each of the load cells  271  may be operatively coupled with such microcontroller  275 . In other embodiments, the load cells  271  may be operatively coupled with an appropriate electronic system of the towing vehicle, such as by way of a non-limiting example, being operatively coupled to a microcontroller of the towing vehicle. 
         [0052]    As shown in  FIG. 4 , the load cells  271  may be positioned between the top surface  109  of the gooseneck collar  111  of the gooseneck hitch assembly and underneath the hitch ball flange  117  of the hitch ball  107 . Still further, while two load cells  271  are shown any number of load cells may be used, including, without limitation, one, two three, etc. 
         [0053]    As shown in  FIG. 5 , the load cells  271  may be positioned between an end portion  127  of the hitch ball  107  and a bottom surface  191  of the gooseneck hitch  105 . While the load cells  271  are shown in these positions, the load cells  271  may be in any appropriate position. By way of a non-limiting example, one load cell  271  may be positioned as shown in  FIG. 4  and another load cell may be positioned as shown in  FIG. 5 . 
         [0054]    In operation, when an overload condition occurs, the load cells  271  may send a signal to and through the microcontroller  275 . A warning system (not shown) may be included in the towing vehicle to alert the operator of such condition. The warning system may be of any appropriate configuration. By way of a non-limiting example, the warning system may include a light, an audible noise, a display or a combination of such. In other embodiments, the towing vehicle may include a display that may receive a signal from the microcontroller  275 , which receives a signal from the load cells  271  that may identify the loaded weight. In such embodiments, the operator may use this information to determine if the towing vehicle has reached an overloaded condition. In these embodiments, the microcontroller  275  may be operatively coupled with the towing vehicle controller or the load cells  271  may be operatively coupled directly to the towing vehicle controller, or both. In some embodiments, this may be accomplished through hard-wiring or may be accomplished wirelessly through any appropriate method. 
         [0055]    Additional embodiments of an overload indicator are shown in  FIGS. 6-15 . These overload indicators may generally operate similar to that overload indicator  100  shown and described above. The embodiments described below of the overload indicator may be generally flattened when a predetermine load is exceeded. 
         [0056]    In some embodiments, as shown in  FIGS. 6 and 7 , an overload indicator  300  is shown. The overload indicator  300  may include a compression ring  310  that may include a plurality of waves or undulations  320  that generally extend an entire perimeter or may extend only a portion of the perimeter. As can be seen in the cross-sectional view of  FIG. 7 , the compression ring  310  may include a plurality of waves or undulations  320  that may compress or flatten at the selected vertical force limit. 
         [0057]    In other embodiments, as shown in  FIGS. 8 and 9 , an overload indicator  400  is shown. The overload indicator  400  may include a compression ring  410  that may comprise a generally flat lower surface  417  while having an upper surface  419  that may include a plurality of waves or undulations  420 . As can be seen in the cross-sectional view of  FIG. 9 , the compression ring  410  may include a generally flat lower surface  417  while having a plurality of waves or undulations  420  at the upper surface  419 . In some embodiments, the waves or undulations  420  may generally extend the length of the perimeter or may extend a portion of the length of the perimeter. Upon reaching the selected vertical force limit, the waves or undulations  420  of the compression ring  410  may compress or flatten. 
         [0058]    In other embodiments, as shown in  FIGS. 10 and 11 , an overload indicator  500  is shown. The overload indicator  500  may include a compression ring  510  that may include a plurality of thin radially oriented ribs  522 . As can be seen in the cross-sectional view of  FIG. 11 , the compression ring  510  may include a plurality of thin radially oriented ribs  522 . Upon reaching the selected vertical force limit, the plurality of thin radially oriented ribs  522  of the compression ring  510  may compress or flatten. In some embodiments, the ribs  552  may be annular or circumscribe portions of the compression ring  510 . 
         [0059]    In other embodiments, as shown in  FIGS. 12 and 13 , an overload indicator  600  is shown. The overload indicator  600  may include a compression ring  610  compression ring that may include a generally annular shape having a raised portion  612  on an upper surface  613  and raised portion  614  on a lower surface  615 , see  FIG. 13 . Upon reaching the selected vertical force limit, the raised upper and lower portions  612 ,  614  of the upper and lower surfaces  613 ,  615  of the compression ring  610  may compress or flatten or one of the upper and lower portions  612 ,  614  may flatten. 
         [0060]    In other embodiments, as shown in  FIGS. 14 and 15 , an overload indicator  700  is shown. The overload indicator  700  may include a compression ring  710  that may include a generally annular shape having a raised portion  722  extending upward from a lower surface  725 . As can be seen in the cross-sectional view of  FIG. 15 , the raised portion  722  of the compression ring  710  may extend annularly outward. Upon reaching the selected vertical force limit, the raised portion  722  of the compression ring  710  may compress or flatten. 
         [0061]    In other embodiments, as shown in  FIGS. 16 and 17 , an overload indicator  800  is shown. The overload indicator  800  may include a compression ring  810  having a generally annular shape and including a raised portion  822  extending from a lower surface  824  of the compression ring  810 . In these embodiments, the raised portion  822  of the compression ring  810  may have a generally pyramidal shaped with a generally hollow core  831 . This is shown in more detail in the cross-sectional view of  FIG. 17  of the compression ring  810 . Upon reaching the selected vertical force limit, the raised portion  822  of the compression ring  810  may compress or flatten, which generally collapses the hollow core  831 . 
         [0062]    In other embodiments, as shown in  FIGS. 18 and 19 , an overload indicator  900  is shown. The overload indicator  900  may include a compression ring  910  having a generally annular shape with a raised portion  922  on a lower side  925  of outer and inner surfaces of the compression ring  910 . As can be seen in the cross-sectional view of  FIG. 19 , the compression ring  910  may include the raised portion  922 . Upon reaching the selected vertical force limit, the raised portion  922  of the outer and inner surfaces of the compression ring  910  may compress or flatten. 
         [0063]    In other embodiments, as shown in  FIGS. 20 and 21 , an overload indicator  1000  is shown. The overload indicator  1000  may include a compression ring  1010  that may include a generally annular shape having a raised portion  1022  on the upper side of an outer surface of the compression ring  1010 . The raised portion  1022  may have a generally polygonal shaped hollow center  1031 . This can be seen in more detail in the cross-sectional view of  FIG. 21 . Upon reaching the selected vertical force limit, the raised portion  1022  of the compression ring  1010  may compress or flatten, which may collapse in the hollow center  1031 . 
         [0064]    In other embodiments, as shown in  FIGS. 22 and 23 , an overload indicator  1100  is shown. The overload indicator  1100  may include a compression ring  1110  having a plurality of tabs  1127  that may extend from top and bottom surfaces  1129 ,  1131  of the compression ring  1110 . As can be seen in the cross-sectional view of  FIG. 23  tabs  1127  may be of any appropriate shape and size and may be positioned at any appropriate portion of the top and bottom surfaces  1129 ,  1131 . Upon reaching the selected vertical force limit, the tabs  1127  of the compression ring  1110  may compress or flatten. 
         [0065]    In other embodiments, as shown in  FIGS. 24 and 25 , an overload indicator  1200  is shown. The overload indicator  1200  may include a compression ring  1210  having a generally annular shape that may include a generally hour-glass shaped portion  1231  on outer and inner surfaces of the compression ring  1210 . As can be seen in the cross-sectional view of  FIG. 25 , the generally hour-glass shaped portions  1231  may include a cavity  1235 . Upon reaching the selected vertical force limit, the generally hour-glass shaped portion  1231  of the compression ring may compress or flatten; or more specifically, may generally collapse the cavity  1235 . 
         [0066]    The features and elements of the embodiments shown and described above may be combined or separately utilized in any appropriate manner. These embodiments may be positioned at any appropriate position on the hitch ball  107  and the gooseneck hitch  105 , such as for example as described above. Upon a predetermined load, such as a vertical load, which may be applied to the calibrated overload indicators, such calibrated overload indicators may compress or otherwise flatten. This may then create a predetermined gap between the hitch ball  107  and the gooseneck coupler (not shown) such that an identifiable banging noise may occur, which may indicate an overload situation. 
         [0067]    Although the embodiments of the present invention have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the present invention is not to be limited to just the embodiments disclosed, but that the invention described herein is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the claims hereafter. The claims as follows are intended to include all modifications and alterations insofar as they come within the scope of the claims or the equivalent thereof.