Abstract:
A sensor support is provided for tire inspection or testing that can be used over a range of tire profiles and widths to place one or more sensors at a surface of the tire. The shape or profile of the sensor support is adjustable to accommodate tire surfaces of different shapes or profiles. A locking feature can be provided to maintain the shape of the sensor support during use.

Description:
FIELD OF THE INVENTION 
     The subject matter of the present disclosure relates generally to a flexible sensor support that can be used to position one or more sensors at a tire surface and has a flexible, adjustable shape for use with tires varying over a range of widths and profiles. 
     BACKGROUND OF THE INVENTION 
     A known tire construction uses reinforcement cords or support elements that extend from bead to bead through the sidewall, shoulder, and tread sections of the tire. Sometimes referred to collectively as the tire carcass, these cords are typically anchored in the beads and maintain the overall shape of the tire as the tire is inflated and used. Such cords are usually oriented substantially along the radial direction (a direction perpendicular to the axis of rotation) and can include e.g., a ferrous metal. 
     During use of the tire, these cords may be damaged e.g., from impact with objects in the roadway, travel over curbs, and other damaging events. In some situations, the cords may be completely broken during such an event. Unfortunately, this damage may not be readily discoverable from a visual inspection of the exterior of the tire because the cords are contained within the rubber materials used to construct the tire. 
     Commercial tires are commonly reused after a process referred to as retreading. With retreading, worn tread is removed from the tire and a new tread belt or tread section is installed onto the tire. Replacement of the tread is less expensive than replacing the whole tire and allows additional mileage to be obtained using the same tire carcass. 
     Before replacing the tread, however, it is advantageous to inspect the tire, including the cords of the carcass for damage or wear. In certain situations, inspection may reveal that replacement or other repair of the tire is required rather than retreading. However, as stated above, not all damage to interior elements such as e.g., the cords of the carcass are readily apparent from a visual inspection alone. 
     As the cords for commercial tires such as heavy truck tires are frequently constructed from a ferrous material, one or more sensors can be used to detect cord breaks not otherwise ascertainable from a visual inspection of the tire. It is desirable to automate such an inspection process so that multiple tires may be inspected economically and expediently. However, tires come in a variety of shapes and sizes. More specifically, the profile and width (along the axial direction) can vary substantially from tire to tire. Some sensors require placement at the surface of the tire either in contact with the tire or in close proximity thereto. Accordingly, challenges exist with accurately and consistently positioning one or more sensors over a range of tire profiles and widths so as to detect e.g., damage to the cords of the carcass. 
     Therefore, a device that can be properly positioned at the surface of the tire to facilitate inspection of the tire would be useful. More particularly, a device that can properly position one or more sensors along the surface of a tire over a range of tire profiles and widths would be beneficial. Such a device that can be used with a variety of different sensor types would also be useful. 
     SUMMARY OF THE INVENTION 
     The present invention provides a sensor support for tire inspection or testing that can be used over a range of tire profiles and widths to place one or more sensors at a surface of the tire. The shape or profile of the sensor support is adjustable to accommodate tire surfaces of different shapes or profiles. A locking feature can be provided to maintain the shape of the sensor support during use. Additional objects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention. 
     In one exemplary embodiment of the present invention, a sensor support is provided that is removably positionable near a surface of a tire. The sensor support includes a flexible substrate defining a longitudinal direction. The flexible substrate is bendable along the longitudinal direction between a first position and a second position. A biasing member is attached to the substrate and is configured for urging the substrate towards the first position. A locking member is positioned proximate to the flexible substrate and is configured for holding the flexible substrate in a second position wherein the flexible substrate conforms to a profile of the surface of the tire. At least one flexibly supported sensor is attached to the flexible substrate. The sensor is configured for detecting damage at or below the surface of the tire. 
     In still another exemplary embodiment, the present invention provides an adjustable sensor support for use in tire inspection. The sensor support defines longitudinal and lateral directions. The sensor support includes a flexible substrate configured for bending along the longitudinal direction to adjust to a shape of a surface of the tire. The flexible substrate includes a plurality of interlocking elements attached to each other and rotatable relative to each other along the longitudinal direction. A biasing member is attached to the substrate and is configured for urging the substrate against bending along the longitudinal direction. A plurality of sensors are arranged along a longitudinal direction and are supported by the flexible substrate. The sensors are configured for detecting damage to the tire. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which: 
         FIG. 1  illustrates a cross-sectional view of an exemplary tire with a side view of an exemplary embodiment of a sensor support of the present invention positioned at an interior surface of the tire. 
         FIG. 2  illustrates a perspective view of an exemplary embodiment of a sensor support of the present invention. A flexible circuit board carrying multiple sensors is also shown before attachment to the sensor support as will be further described. 
         FIG. 3  provides a side view of the exemplary sensor support of  FIG. 2 . 
         FIG. 4  provides an end view of the exemplary sensor support of  FIG. 2 . 
         FIG. 5  is a cross-sectional view of the exemplary sensor support of  FIG. 2  with dashed lines indicating a first position for the exemplary sensor support. 
         FIGS. 6 and 7  are top views of the exemplary sensor support of  FIG. 2 .  FIG. 6  shows a locking feature in an engaged position with the sensor support whereas  FIG. 7  shows a locking feature in a disengaged position. 
         FIGS. 8, 9, and 10  are side, end, and perspective views, respectively, of an exemplary base of the sensor support shown in  FIG. 2 . 
         FIGS. 11, 12, and 13  are end, top, and side views, respectively, of an exemplary embodiment of an interlocking member of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     For purposes of describing the invention, reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
       FIG. 1  illustrates a cross-sectional view of an exemplary tire  50  with a side view of an exemplary embodiment of a sensor support  100  of the present invention positioned at an inner surface  56  of tire  50  for purposes of inspection. The construction of tire  50  includes cords (not shown) that extend along radial direction R from bead section  60 , through sidewall  52 , along the axial direction A through tread section  64 , and along radial direction R through sidewall  54  to bead section  62 . Cords  50  are constructed from a ferrous material, are embedded in the materials used to construct tire  50 , and can be damaged during use of tire  50  as previously described. 
     For this exemplary embodiment, sensor support  100  includes at least one flexibly supported sensor  108  that is positioned at the inner surface  56  of tire  50  along sidewall  54 . Sensor support  100  can be positioned so that sensor  108  is in contact with inner surface  56  or in close proximity thereto. As shown in  FIG. 1 , the profile or shape of sensor support  100 —particularly along sensor  108 —matches the profile of inner surface  56  of tire  50  along sidewall  54 . 
     By way of example, during inspection, tire  50  is rotated past sensor support  100  with sensor  108 . As will be further described, sensor  108  is configured to detect damage, e.g., breaks, in the cords of tire  50 . The positioning of sensor support  100  shown in  FIG. 1  is provided by way of example only. Sensor support  100  can also be positioned along inner surface  56  at sidewall  52 . In still other embodiments, sensor support  100  can be configured for positioning along the external surface  58  at sidewall  52  or  54 . Sensor support  100  can be hand-held or can be placed into position by a mechanical device. 
     A representative tire width and profile is shown in  FIG. 1  with tire  50 . However, one of skill in the art will understand that tires are manufactured with a range of profiles and widths which e.g., affects the curvature or shape of sidewalls  52  and  54  and, therefore, the profile or shape of inner surface  56  and outer surface  58 . Depending upon the type of sensor  108  employed, accuracy and/or consistency of the inspection process over a range of tire widths and profiles can be affected by whether sensor support  100  can be repeatedly located at a fixed position along an inner or outer surface of each tire. Furthermore, some sensors require placement in contact with, or in close proximity to, a surface of the tire. The sensor support of the present invention has a profile that can be adjusted to match the profile or shape of a tire surface—particularly along the curved sidewall—so that one or more sensors can be accurately and consistently positioned at or near the tire surface. 
     Referring now to  FIGS. 2, 3, 4, and 5 , sensor support  100  includes a flexible substrate  102  that extends along a longitudinal direction LN. As illustrated in  FIG. 5 , flexible substrate  102  is constructed for bending (i.e. to be selectively bendable) along the longitudinal direction between a first position FP (shown in dashed lines) and a second position SP. This flexibility allows sensor support  100  to be shaped to match the profile of a tire surface during inspection. It should be understood that first position FP and second position SP are shown by way of example—i.e. the flexibility of sensor support  100  allows it to assume profiles have more or less curvature than what is shown in  FIG. 5 . More particularly, second position SP can be at the position shown in  FIG. 5  or at positions with more or less curvature as well. Although shown as linear in  FIG. 5 , flexible substrate  102  could also have a first position FP that includes curvature along the longitudinal direction LN. 
     Flexible substrate  102  is constructed from a plurality of interlocking members  110  that are connected together along longitudinal direction LN and are rotatable relative to each other. Referring now to  FIGS. 11, 12, and 13 , one or more of the interlocking members  110  include an axle  126  having ends  132  and  134  and extending along lateral direction LA between opposing sides  114  and  116  of member  100 . A pair of jaws  128  and  130  are positioned on opposing sides  114  and  116 . Each jaw  128  and  130  is shaped to receive the axle  126  of an adjacent interlocking member  110  along the longitudinal direction LN. More particularly, for this exemplary embodiment, axle  126  is received in a snap-fit or complementary manner into jaws  128  and  130  but is still rotatable therein so that adjacent interlocking members  100  are rotatable relative to one another whereby flexible substrate  102  can bend along longitudinal direction LN. 
     The overall range of movement of interlocking members  110  relative to each other can be limited using stops positioned on opposing sides  114  and  116  at each jaw  128  and  130 . Referring specifically to  FIG. 13 , for example, during rotation of adjacent interlocking members  10 , the forward stop  136  of one interlocking member  110  will eventually contact a rear stop  174  of an adjacent interlocking member  110 . The dimensions and shape of stops  136  and  174  can be modified to control the range of rotation of adjacent interlocking members  110  and thus the overall flexibility or bendability of sensor support  100  along longitudinal direction LN. 
     One or more of interlocking members  110  also includes a seat  112  extending along lateral direction LA between opposing sides  114  and  116  of a member  110 . A pair of fingers  118  and  120  are positioned in an opposing manner at sides  114  and  116  and extend towards each other along lateral direction LA and over seat  112 . As such, fingers  118  and  120  each define a slot  122  and  124 , respectively. 
     Referring now to  FIGS. 3, 4, 5, 6, and 7 , flexible supported sensor  108  is positioned within slots  122  and  124  and between seat  112  and pair of fingers  118  and  120  of adjacent interlocking members  110  of flexible substrate  102 . During assembly, tabs  176  and  178  at the ends of flexible supported sensor  108  are inserted into slots  180  and  182  in base  142 . Before insertion, flexibly supported sensor  108  may have a linear profile as shown in  FIG. 2 . After assembly, the operation of fingers  118  and  120  along with the insertion of tabs  178  and  178  will bend or shape flexibly supported sensor  108  to the profile taken by the rotation of interlocking members  110  of flexible substrate  102 . 
     For this exemplary embodiment, sensor support  100  includes a biasing member  104  that is attached to, or that otherwise acts upon, flexible substrate  102 . Axles  126  of one or more of the interlocking members  110  each include an aperture  140  as shown in  FIGS. 5, 11, and 13 . Referring now to  FIGS. 2 and 5 , biasing member  104  is received through multiple apertures  140  that are aligned along longitudinal direction LN. With this exemplary embodiment of sensor support  100 , biasing member  104  is equipped as a leaf spring that urges or biases flexible substrate  102  towards first position FP shown in  FIG. 5  and against bending of the flexible substrate from the first position FP. Thus, when flexible substrate  102  is bent away from first position FP towards second position SP, biasing member  104  will return flexible substrate  102  to first position FP unless flexible substrate  102  is locked into a particular shape or profile such as e.g., second position SP. 
     Accordingly, sensor  100  includes a locking member  106  as shown in  FIGS. 4, 6 , and  7 . Locking member  106  can be used to fix or lock flexible substrate  102  into a particular profile or shape, which in turn fixes the shape or profile of flexibly supported sensor  108 . For this exemplary embodiment, locking member  106  is supported by base  142  and includes a clamping member  152  having a pair of arms  156  and  160  that extend along lateral direction LA towards the plurality of interlocking members  110 . Clamping member is connected to, and positioned by, a shaft  156  that is controlled by pneumatic cylinder  154 . 
     During, for example, an inspection, pneumatic cylinder  154  can be activated to move clamping member  152  (arrows E in  FIG. 6 ) from the unlocked position shown in  FIG. 7  to the locked position shown in  FIG. 6  where arms  156  and  160  will engage and immobilize interlocking members  110  of flexible substrate  102 —thereby fixing the shape or profile thereof. Conversely, pneumatic cylinder can be activated to move clamping member  142  (arrows D in  FIG. 7 ) from the locked position shown in  FIG. 6  to the unlocked position shown in  FIG. 7  where arms  156  and  160  are disengaged so that interlocking members  110  of flexible substrate  102  are free to rotate relative to each other. As such, biasing member  104  will urge flexible substrate  102  to return to the first position FP shown in  FIG. 5 . 
     Locking member  106  as shown in the figures is provided by way of example only. Other configurations or mechanisms for fixing the profile or shape of flexible substrate  102  may be used as well. Also, it should be understood that in other embodiments of the present invention, locking member  106  is not present. For example, in certain exemplary embodiments, the sensor support  100  is positioned against the surface of the tire and held in such position during inspection and/or testing. While held in position against the tire surface, the shape or profile of flexible substrate  102  and, therefore, flexibly supported sensor  108 , will assume the profile of the tire surface. Still other techniques may be used as well. 
     Flexible substrate  102  is rotatably supported by base  142  having a curved surface  162 . As shown in  FIGS. 8, 9, and 10 , base  142  includes a pair of pivot arms  164  and  166  defining slots  168  and  170 , respectively. Slots  168  and  170  receive an axle  126  of one of the interlocking members  110  and allow such axle  126  to rotate therein. As such, flexible substrate  102  can rotate or pivot about arms  164  and  166 . For this exemplary embodiment, a bracket  172  is attached to base  142  and can be used to connect sensor support  100  with an arm or other device for positioning within a tire. Base  142  and bracket  172  as shown in the figures are provided by way of example only—other configurations may be used as well. 
     A variety of configurations and types may be used for flexibly supported sensor  108  depending upon, for example, the nature of the inspection or testing desired. A specific embodiment will now be described. However, using the teachings disclosed herein, one of skill in the art will understand that one or more sensors of other types and operation may be used as well. 
     As shown in  FIGS. 2, 3, 6, and 7 , for this exemplary embodiment of sensor support  100 , flexibly supported sensor  108  includes a plurality of Hall Effect sensors  144  that are positioned in an arrangement that extends linearly along the longitudinal direction LN of the flexible substrate  102 . Sensor  108  includes a flexible, printed circuit board  150  onto which the Hall Effect sensors  144  are mounted. 
     A magnet  146  is positioned into a channel  148  defined in base  142 . Magnet  142  extends along the longitudinal direction LN in a manner that is adjacent to the arrangement of Hall Effect sensors  144 . For this exemplary embodiment, magnet  146  has a length along the longitudinal direction LN that is slightly longer than the corresponding length of the arrangement of Hall Effect sensors  144  as shown in  FIGS. 2 and 3 . Hall Effect sensors  144  can be used to detect changes in the magnetic field provided by magnet  146 . Such changes will be caused by e.g., one or more breaks in a ferrous reinforcement cord in the carcass of a tire. 
     Using  FIG. 1  for example, sensor support  100  is positioned against inner surface  56  of sidewall  54  of tire  50 . The shape of surface  56  causes flexible substrate  102  to bend against the force of biasing member  104  into a profile that matches the shape of the inner surface  56 . This shape can be maintained by a force that maintains sensor support  100  against inner surface  56  and/or flexible substrate  102  can be locked into position using locking member  106  as previously described. 
     Tire  50  is then rotated past flexibly supported sensor  108  with the plurality of Hall Effect sensors  144  positioned against or in close proximity to inner surface  56 . As shown, the plurality of Hall Effect sensors  144  are oriented along radial direction R or within a range of +/−6 degrees of the radial direction. As tire  50  rotates, changes in the magnetic field caused by a break in the radially-oriented, reinforcement cords will be detected by the Hall Effect sensors  144 , which in turn will provide a signal that can be received by, for example, a processing device. The rotation of the tire can be synchronized with this signal so that the inspection reveals where on tire  50  a break in the cords has occurred. 
     This above described method for using sensor support  100  is provided by way of example. Other methods may be used as well as will be appreciated by one of skill in the art using the teachings disclosed herein. In addition, the present invention is not limited to the use of a sensor support for detecting cord damage and may be used to position one or more sensors near the surface of a tire for other types of inspection and/or testing as well. 
     Thus, while the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. For example, the biasing member  104  need not be an element separated from flexible supported sensor  108  as shown. Instead, flexible supported sensor  108  could be constructed to include a biasing member therein. Other variations of the invention may be configured as well. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art using the teachings disclosed herein.