Abstract:
The invention integrates a general purpose computer with a controller area network to effect an inspection regimen through the controller area network A convenient user interface, combining handheld instruments and convention displays and printers allows the driver to interact with the system. The computer provides storage for programs and processing power to implement test regimens in logical order relating to completion of the inspection.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates generally to commercial motor vehicles and more particularly to an automated vehicle inspection system providing the collection of selected data and prompting manual inspection and entry of other data to promote the generation of electronic inspection reports in an efficient and complete manner.  
           [0003]    2. Description of the Problem  
           [0004]    Commercial transport regulations provide for periodic inspection of, generation of inspection reports relating to, and documentation of maintenance on, commercial vehicles. Inspections include checking numerous operational aspects of the vehicle for conformity to normative operational standards, implementing a check off system for maintenance when indicated by inspection, as well as for scheduled maintenance, and validating the reports generated and keeping copies of the reports for a minimum time period.  
           [0005]    Vehicle interactive on board computers (OBC) have been suggested in the art for use in implementing inspection programs directed to meeting regulations. The OBC suggested in U.S. Pat. No. 5,680,328 was preferably a personal or lap top computer, which is used for receiving data inputs from a driver or maintenance personnel as part of an inspection, and for providing for the collection of data from various sensors placed on the vehicle. However, the &#39;328 patent did not describe a mechanism for actually collecting data from vehicle sensors. The OBC may electronically store inspection reports, and provide copies of the same on a display or in hard copy form.  
           [0006]    Contemporary designs for the control and management of vehicle components increasingly rely on methods derived from computer networking. Digital data is exchanged between component controllers over a common physical layer such as a twisted shielded pair of wires. Intelligible communication between two or more device controllers among a greater plurality of devices, all occurring over the common physical layer, depends upon the communicating devices being able to discriminate among messages they receive and to respond to those messages directed to them. Such methods are well known in the art and are part of the standards which the Society of Automotive Engineers (SAE) has published and continues to publish as part of the SAE J1939 protocol.  
           [0007]    The J1939 protocol provides an open protocol and a definition of the performance requirements of the medium of the physical layer, but also allows for development of proprietary protocols. The SAE J1939 protocol is a specialized application of a controlled area network (CAN) and may be readily implemented utilizing commercial integrated circuits such as the C167 Integrated Circuit from Siemens of Germany.  
           [0008]    The CAN protocol is an ISO standard (ISO 11898) for serial data communication, particularly aimed at automotive applications. The CAN standard includes a physical layer (including the data bus) and a data-link layer, which define useful message types, arbitration rules for bus access and methods for fault detection and fault confinement. The physical layer uses differential transmission on a twisted pair wire bus. A non-destructive bitwise arbitration is used to control access to the bus. Messages are small, at most eight bytes, and are protected by checksum error detection. There is no explicit address in the messages, instead, each message carries a numeric value which controls its priority on the bus, and may also serve as an identification of the contents of the message. CAN offers an error handling scheme that results in retransmitted messages when they are not properly received. CAN also provides means for removing faulty nodes from the bus. CAN further adds the capability of supporting what are termed “higher layer protocols” for standardizing startup procedures including bit rate setting, distributing addresses among participating nodes or kinds of messages, determining the layout of the messages and routines for error handling on the system level.  
           [0009]    Digital data communications over serial data paths are an effective technique for reducing the number of dedicated communication paths between the numerous switches, sensors, devices and gauges installed on the vehicles. Multiplexing the signals to and from local controllers and switches promises greater physical simplicity through displacing much of the vehicle wiring harness, reducing manufacturing costs, facilitating vehicle electrical load management, and enhancing system reliability.  
           [0010]    It would be desirable to add intelligence to a vehicle controller area network conforming to the SAE J1939 standard to implement inspection regimens.  
         SUMMARY OF THE INVENTION  
         [0011]    The invention integrates a general purpose computer with a controller area network to effect an inspection regimen through the controller area network. A convenient user interface is based on a combination of one or more devices, including handheld instruments, conventional displays, keypads, pucks and printers, and allows the driver to interact with the system. The computer provides storage for programs and processing power to implement test regimens in a logical order relating to completion of the inspection. Full integration of an OBC to an individual vehicle inspection procedure to promote efficiency and completeness, and to avoid possible damage to the vehicle, aids organization of the tasks called for by the inspection.  
           [0012]    The substantially automated inspection system of the present invention works with a vehicle having an engine and with various vehicle systems, characterized by measurable operating variables. The system includes an electrical system controller, a data communications bus connected at one node to the electrical system controller, a plurality of sensors connected to the data communications bus for transmitting data relating to the operating variables to the electrical system controller, an user input/output interface, an on board computer connected to the user input/output interface and to the data communications bus, the on board computer including memory, and a vehicle inspection regimen stored in the memory and executable on the on board computer. The program provides means for checking fluid levels against one or more limits for various vehicle systems before engine start, means for prompting an operator to start the engine if the operating fluid levels meet applicable limits, and means for completing the vehicle inspection regimen after an engine start.  
           [0013]    Additional effects, features and advantages will be apparent in the written description that follows. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]    The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:  
         [0015]    [0015]FIG. 1 is a partial cutaway view in perspective of a truck incorporating the invention;  
         [0016]    [0016]FIG. 2 is a block diagram of a computer control, network and sensor system used to implement the inspection protocols; and  
         [0017]    [0017]FIG. 3 is a flow chart illustrating the order of execution of the inspection program. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0018]    [0018]FIG. 1 is a perspective view of a truck  11  and of an electrical control system  10  installed on the vehicle. Electrical control system  10  comprises a twisted pair (either shielded or unshielded) cable operating as a serial data bus  18 . One node of bus  18  is an electrical system controller (ESC)  30 , which is the central component of a vehicle electronic control system. ESC  30  manages a number of vocational controllers connected to bus  18  as nodes and positioned on truck  11 . Collectively, bus  18  and the various nodes attached thereto form a controller area network (CAN). Truck  11  includes conventional the conventional major systems of a vehicle, including an engine, a starter system for the engine, brakes, a transmission and running lights.  
         [0019]    Active vehicle components are typically controlled by one of a group of autonomous, vocational controllers, which include a gauge cluster  14 , an engine controller  20 , a transmission controller  16 , an auxiliary instrument and switch bank  12 , and an antilock brake system (ABS) controller  22 , all of which are nodes on serial data bus  18  allowing two way communication with ESC  30 . Autonomous controllers include local data processing and programming and are typically supplied by the manufacturer of the controlled component. Bus  18  is a twisted pair cable constructed in accordance with SAE standard J1939. Although the autonomous controllers handle many functions locally and can function independently of ESC  30 , they report data to ESC  30  and can receive operational requests from ESC  30 .  
         [0020]    An on board computer (OBC)  40  is also provided on truck cab  11 . OBC  40  is based on a conventional personal or portable computer architecture and communicates with ESC  30 , either over bus  18 , or directly over a private bus. OBC  40  executes an inspection protocol leading to generation of required inspection and maintenance reports.  
         [0021]    [0021]FIG. 2 is a block diagram of the electrical control system  10 . ESC  30  can collect data from a variety of sources, both over serial data bus  18 , or from sensors and devices directly connected the ESC. One sensor is illustrated as directly connected to a port on the ESC  30  is a rear axle fluid level sensor  46 . Electrical system controller  30  also directly actuates lights  52  and can determine whether lights are working from the amount of current drawn. ESC  30  and OBC  40  may communicate over the serial data bus  18  or over a dedicated private bus  19 . OBC  40  includes conventional memory  43  (both volatile and non-volatile) and program execution capacities (CPU  41 ).  
         [0022]    A serial data bus  18  conforming to the SAE J 1939  standard provides for data communication between ESC  30  and an engine controller  20 , a transmission controller  16 , ABS controller  22 , instrument and switch bank  12 , a gauge cluster  14  and one or more sensor interface modules. These controllers and modules are in turn connected to one or more sensors which they collect data from and to which they may return data which relate to the sensors to ESC  30 . The specific connections between sensors and nodes of the system is exemplary, and other arrangements than the one illustrated are possible.  
         [0023]    Engine controller  20  is connected to an engine coolant level sensor  25 , an engine coolant temperature sensor  26 , an engine oil level sensor  27 , an engine oil temperature sensor  28  and an engine oil pressure sensor  29 . Engine coolant level sensor  25  is typically either a pressure or capacitive type sensor, and is located at a position in the coolant system allowing level sensing while the vehicle is stationary. The sensor has either a binary output (1=level acceptable, 0=add coolant), or an analog output indicating percentage full (50% to 120% full). The sensor has a maximum sample rate of 1 measurement per second. Measurements can be broadcast on bus  18  formatted in accordance with J1939 PGN65263. The engine coolant temperature sensor  26  is preferably located at a position in the engine coolant flow system allowing taking temperature readings during engine operation. This sensor has a range of −40° C. to 125° C., with a maximum sampling rate of 1 reading per second. Measurements can be taken after the engine has been running a minimum length of time. These measurements can be broadcast on bus  18  formatted in accordance with J1939 PGN 65262.  
         [0024]    Engine oil level sensor  27  is either a capacitive or pressure type sensor, and is located at a position in the engine oil flow system allowing engine oil level sensing while the vehicle is level. Sensor  27  has either a binary output (1=level acceptable, 0=add oil), or an analog output indicating percentage full. If the output is analog, analog to digital conversion can be provided. Sensor  27  provides sampling at 2 Hz. Messages containing measurement data are transmitted over bus  18  in accordance with J1939 PGN 65263. Engine oil temperature sensor  28  is located in the oil flow system allowing measurements when the engine is running. Sensor  28  has a temperature operating range of −40° C. to 125° C., with a 1 Hz operating cycle. The message data format is J1939 PGN 65262. Engine oil pressure sensor  29  is located in the oil flow system to sample pressure during engine operation. Sensor  29  has an operating range of 0 psi to 200 psi with a sampling rate of 2 Hz. The message format is J1939 PGN 65263.  
         [0025]    Transmission controller  16  is connected to a transmission fluid level sensor  32  and, usually, to a transmission fluid temperature sensor  33 . Transmission fluid level sensor  32  is typically a capacitive or pressure type sensor, and is located in the transmission fluid flow system to obtain fluid level measurements when the vehicle is level and stationary. Sensor  32  may have an analog output (50% to 120% of full) or a logical binary output (1=level acceptable, 0=add fluid). The sampling rate is 1 Hz. The signal is routed to the transmission controller  16  and broadcast on bus  18  as a J1939 PGN 65272 signal. Transmission fluid sensor  33 , while frequently connected to transmission controller  16 , is sometimes directly connected to ESC  30 . The sensor has an operating range of 40° C. to 125° C. and a 1 Hz sampling rate. Measurements, if routed through transmission controller  16 , are formatted for data bus  18  as a J1939 PGN 65272.  
         [0026]    The anti-lock brake system (ABS) controller  22  controls the brake system and is typically connected to brake system pressure sensors  34  and brake actuation sensor  38 , analysis of measurements from which allow determination of brake system functionality. OBC  40  will direct execution of an procedure to determine if the components of the vehicle brake system are functioning correctly. Brake system pressures are broadcast on bus  18  as a J1939 PGN 65274 signal. The OBC  40  can issue instructions to ESC  30 , some for further transmission to the appropriate controller, to set and hold engine speed, to depress or pump the brakes (via brake system actuation  37 ) and for setting and releasing the parking brake  51 . Alternatively, OBC  40  may prompt the driver/operator to carry out these tasks by the user I/O interface  36 .  
         [0027]    A power steering fluid level sensor  44  is located in a power steering fluid reservoir (not shown) and may be connected either to ESC  30 , to engine controller  20 , or, as illustrated here, to a sensor interface module (SIM)  45 , which communicates with ESC  30  over bus  18 . The sensor has either a binary output (1=level acceptable, 0=add fluid), or an analog output indicating percentage full (from 50% to 120%). The sensor sampling rate is 1 Hz. Transmission of the data is broadcast on bus  18  as a J1939 PGN 65272 message.  
         [0028]    Fuel level sensors  48  are located in the vehicle&#39;s fuel tanks (not shown) and may be connected either to ESC  30 , or, as illustrated here, to a SIM  53 , which communicates with ESC  30  over bus  18 . The sensor has an analog output indicating percentage full (from 0% to 100%). The sensor sampling rate is 1 Hz. SIM  53  provides analog to digital conversion of the sensor output and broadcast of a data message on bus  18  as a J1939 PGN 65276 message.  
         [0029]    A windshield washer fluid level sensor  48  is located in a windshield washer fluid reservoir (not shown) and is typically connected to a SIM  49 , which communicates with ESC  30  over bus  18 . The sensor has a binary output (1=level acceptable, 0=add fluid). The sensor sampling rate is 1 Hz. Transmission of the data is broadcast on bus  18  as a J1939 PGN 65276 message.  
         [0030]    Electrical system controller (ESC)  30  is represented as communicating directly with a number of devices. Such connections may be provided via ports which may be configured as power supply ports or serial data ports. Vehicle lights  52  are powered directly from ports on ESC  30 . The operational integrity of vehicle lights  52  may be determined by current drawn. Other devices or sensors may similarly be directly connected to ESC  30 , or they may be connected to bus  18  by a sensor or device interface module allowing data to be broadcast to ESC  30 , or devices and sensors may be handled by one of the other autonomous controllers, such as engine controller  20 . Rear axle oil level sensor  46  is connected either directly to ESC  30 , or by a sensor interface module to bus  18 . Sensor  46  may have either an analog output (50% to 120% of full), converted to digital data, or a binary output (1=level acceptable, 0=add oil). The maximum sampling rate is 1 Hz. The J1939 specification does not assign a message format for rear axle differential oil level, requiring a proprietary message format if transmission of data is handled by a SIM.  
         [0031]    ESC  30  is connected to a battery condition sensor  24 . Battery condition sensor  24  preferably represents a system comprising ammeters coupled to battery leads, battery voltage sensing and temperature sensors. The determination of battery capacity and charge entails execution of an algorithm and reference to battery performance and history tables. The complexity of the system may vary from application to application and the system may, in some circumstances, be different. This algorithm may be executed by OBC  30 , which also provides for storage of a condition evaluation algorithm and the needed tables on memory  43 . OBC provides a CPU  41  to execute the algorithm. Data relating to battery  23  is passed through ESC  30  from battery condition sensor  24 .  
         [0032]    ESC  30  is also connected to a tire pressure sensor  42 . Tire pressure sensing may be provided for in a number of ways, including inferential pressure measurement based on relative tire rotational velocities (in which case measurements may be handled by the ABS controller  22 ), or by direct methods, such as battery powered sensors mounted in the tires, in which case the pressure measurements may be directly communicated by a connection between the sensors  42  and ESC  30 . A gauge cluster  14  and an instrument and switch bank  12  communicate with ESC  30  over data bus  18 . Additional components may be attached to bus  18  and accommodated by the inspection routine if deemed important, such a pump controller on a fuel tanker.  
         [0033]    Driver inputs and prompts are handled by user I/O interface  36 , which may be implemented in a touch screen display, conventional displays, and keyboards or pads. I/O interface  36  is under the direct control of OBC  40 , accepts driver indication of task completions, including in cab and walk around inspection items, and further directs aspects of the brake inspection routine which cannot be economically automated. Driver acknowledgment of critical errors requiring immediate attention is provided. Prompts or buttons in interface  36  allow for this. OBC  40  can provide for storage of reports in memory  43 , which includes volatile and nonvolatile sections. Alternatively, the interface  36  may include a printer allowing hard copies of the reports to be printed. As described above, some aspects of the inspection procedure can require driver actions, such as pumping or depressing the brakes, which are prompted on I/O interface  36 . For walk around portions of the inspection a wireless handheld unit  136  may by be used by the driver to receive prompts from OBC  40  via a wireless communication card  135 .  
         [0034]    [0034]FIG. 3 is a high level flow chart illustrating one possible procedure executed on OBC  30  to implement a preferred embodiment of the invention. The exemplary procedure begins with movement of the vehicle key to the on position from OFF (step  54 ). At step  56  it is determined if the pre-trip inspection mode has been triggered. These can occur at: (1) the request of the driver; (2) each time the key is moved from off to on; (3) each key on instance after a minimum time interval since the last key on instance; (4) each key on instance when the engine coolant temperature is below a minimum threshold; (5) each occasion of a change of driver; (6) a specific time of day; or (7) a minimum time interval since the last inspection. Particular triggering condition(s) are selected at the time when an OBC  30  is configured for a particular vehicle. The selections remain in effect until changed by the user/operator. Interrogation of the inspection triggering conditions is indicated by step  55 . If none of the conditions is matched the routine is exited.  
         [0035]    The routine has a pre-engine start segment (steps through step  76 ) and a post engine start segment (steps  78  to  97 ). If at step  56  an inspection is indicated, step  58  is executed to determine if the last inspection report, stored in memory  43 , has been signed off. By “signed off” is usually taken as indication by a driver, possibly using a password or code, that an inspection was performed. Step  58  can also be used to force branching to step  60 , for example in the case that it is simply desired to review the report. If not, the branch to step  60  is taken and the driver is prompted to review the last inspection report and to make notes and sign off on the report at step  62 . Following verification of signing off on the previous report (the YES branch from step  58  or following step  62 ), inquiry is made by the I/O interface  36  to the driver as whether to begin the inspection (step  64 ). In not, for example in the situation where review of a prior report had been required, the program may be exited by step  65 .  
         [0036]    Following the YES branch from step  64  an inspection of the vehicle is begun. At step  66  all fluid level sensors are interrogated. Next, at step  68 , the fluid level measurements are compared to minima criteria for acceptability. For each fluid level not meeting recommended levels step  69  is executed along the NO branch from step  68  to set a fluid level error flag. Upon analysis of all fluid levels processing is represented as progressing to a step  70  dealing with a default error flag for automatic transmission fluid level. Low transmission fluid level can result in catastrophic transmission damage and an engine start is not permitted unless transmission fluid level is confirmed to be above a minimum. If transmission fluid level is below the flag minimum another fluid level error flag algorithm is run (step  74 ) followed by determination as to whether the fluid level, even though below recommended minimums, is sufficient to allow a safe start (step  76 ). These steps occur only if the message relating to transmission fluid level is expressed in terms of percentage of full. If it is not, the routine is exited (step  77 ), otherwise, or following the YES branch from step  72 , processing continues to step  78  and a prompt to the driver to start the engine.  
         [0037]    Once the engine has been started battery condition may be updated. If battery condition is determined as unacceptable at step  80  a flag indicating the need for maintenance is set. Next the several pressure and temperature readings are compared to norms, and if any are out of norm, processing is temporarily interrupted (step  82 ) to set the appropriate flag (step  83 ). Then step  84  is executed to compare tire pressure measurements against minimum required levels. If a tire has inadequate pressure a flag is set (step  85 ). Following step  84  the driver is prompted to turn on the vehicle&#39;s lights (step  86 ). At step  88  the current drawn by the lights is compared with the minimum figure indicating that the lights are all working. If current draw is low a flag is set at step  89 . Next the driver is prompted to perform in cab and walk around checks. A handheld display device may be used at this point. Step  92  represents execution of brake system checks, which may be automated or manual. Brake system is operation is compared with acceptable operating variables at step  94 . If a variable is out of norm a brake system error flag is set using a sub process (represented by step  95 ). Finally, at step  96  a new inspection report is generated and the program is exited (step  97 ).  
         [0038]    The present invention automates many applicable portions of a pre-trip inspection and provides immediate return information to the driver in the form of a electronic inspection report. This in turn saves both time and helps insure completeness of the reports.  
         [0039]    While the invention is shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit and scope of the invention.