Abstract:
Vehicle on-board measurement of axle load and gross combined vehicle weight is improved for an air bladder suspended vehicle by allowing for suspension hysteresis. Suspension hysteresis results in at least two distinct air pressures being possible in an air bladder for a single load. The system also reduces the disruptive effect of vehicle acceleration and deceleration on load determination. Vehicle drive train management is enhanced using the load information to effect transmission gear selection.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The invention relates to a system and method for determining drive axle loading and estimating a vehicle&#39;s sprung weight with improved accuracy.  
           [0003]    2. Description of the Problem:  
           [0004]    Axle and total vehicle load are limited by law for trucks and desirable to monitor to avoid vehicle operating conditions which would be uneconomic or contribute to poor vehicle handling. To the present time, axle loading and vehicle weight have typically been determined by placing the vehicle on, or rolling the vehicle over, a scale. Commercial scales are often located at some distance from where a load is taken on. The need to then move the vehicle to the scale can be inconvenient. Should a vehicle prove overloaded with a subsequent need to return the vehicle to the loading point, the inconvenience factor is increased. Nor is a load necessarily constant during vehicle operation. Ice storms and heavy snow can contribute to overloading a vehicle. Loads may shift due to extreme operating conditions. Thus there is a need to provide updates of axle loading during vehicle use.  
           [0005]    In response to the inconvenience and limited utility of using fixed scales to determine truck loads, and the interest in providing up to date information on axle loading, attempts have been made to provide on board vehicle weight and axle load measurement. One such technique estimates a vehicle&#39;s mass using Newton&#39;s law of acceleration. Force (torque) equals mass (the unknown) times acceleration. Full load engine torque may be obtained from a look up table and vehicle acceleration calculated from changes in vehicle speed over time. Vehicle mass is then easily calculated although several trials are often required. The accuracy of the result though depends upon engine operation meeting expected output, which can vary with age of the engine, the degree of streamlining of the vehicle, and other factors. The accuracy of the result may be further affected by external conditions such as weather and wind conditions, road slopes and the like.  
           [0006]    Also known are systems relying on strain gauges fitted to leaf and coil springs, various types of displacement transducers, and of particular interest here, pressure transducers for air bladders used on height-leveled, air spring suspended vehicles. Vehicles equipped with air spring suspensions have used air gauges to monitor overall air pressure in air suspension springs. The gauge pressure has been equated to vehicle sprung weight for display to the driver. Alternatively, the pressure of individual air springs may be equated to loads on each of the axles. Some of these systems have provided for calibration against known loads to improve accuracy of the estimated weight.  
           [0007]    One source of deviation from correct determination of vehicle weight and axle load is suspension system hysteresis. For a suspension system having air springs, the relationship of axle load to air pressure in the springs depends upon whether the load has previously increased or decreased. There are a number of sources of this hysteresis, some of which is designed into the system. Height-leveled, air spring equipped vehicles have a height control valve which will not open to allow the exhaust of air, or introduction of air, unless there is about a 900 lb. change in load. Spring bushings will exhibit some resistance to deformation. Stiction in the shock absorber allows some of the normally sprung load weight to be carried through the shock absorber.  
           [0008]    Another source of transient error when using air spring pressure sensing to estimate axle loading is a change in vehicle speed. With acceleration, or deceleration, axle loading is transferred aft or forward, respectively. The error introduced by acceleration and deceleration can be substantial and immediately updating an axle load display to reflect the measured changes can become distracting to the vehicle&#39;s operator.  
           [0009]    Many contemporary commercial vehicles optimize automatic transmission start gears, shift point and running gear selection based on a trial and error seek process carried out over 25 to 30 trials involving sustained acceleration of the vehicle. In effect, the information is a byproduct of determining the vehicles&#39; mass, as described above. Data relating to the vehicles&#39; mass may be joined with an instantaneous velocity measurement to provide inputs into a look up table which returns an optimum gear choice for either best acceleration or economy operation. However, the need for repeated trials limits the utility of the system for vehicles such as dump trucks, delivery vehicles, and tankers subject to frequent changes in load.  
         SUMMARY OF THE INVENTION  
         [0010]    The invention provides an axle load sensing system for a vehicle having an air bladder support system mounted between the frame of the vehicle and its axles. Axle load determination provides direct determination of vehicle load, which in turn is used to improve start gear, running gear and shift point optimization. At least a first pressure sensor provides air pressure readings for at least one air bladder of the air bladder support system. First and second transfer functions relate the air pressure readings to the weight carried by the air bladder support system. A transfer function indicator responsive to a direction of change in air pressure readings indicates which of the first and second transfer functions is to be interrogated to determine load. A processor connected to receive the air pressure readings and responsive to the transfer function indicator executes either the first or second transfer function using the air pressure readings as an input to return an estimated load carried by the air bladder support system. The transfer function indicator is responsive to prior increases in air bladder pressure for indicating interrogation of the first transfer function and to prior decreases in air bladder pressure for indicating interrogation of the second transfer function. The processor accumulates the returned estimates to provide a running indication of the load on the air bladder support system. To compensate for transient effects of vehicle acceleration on axle loads, returned estimates and the prior accumulated returned estimates are relatively weighted before being combined. Gear selection is improved with the weight data by providing gear choice look up tables for use by a transmission controller keyed to vehicle weight and speed.  
           [0011]    Additional effects, features and advantages will be apparent in the written description that follows. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    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:  
         [0013]    [0013]FIG. 1 is a schematic view of a tractor/trailer rig with an on board weighing system according to a preferred embodiment of the invention.  
         [0014]    [0014]FIG. 2 is a schematic view of an air suspension for a vehicle adapted to provide air spring pressure information.  
         [0015]    [0015]FIG. 3 is a schematic view of a tractor with an on board weighing system.  
         [0016]    [0016]FIG. 4 is a block diagram of a vehicle electronic control system.  
         [0017]    [0017]FIG. 5 is a graphical representation of air suspension system hysteresis with axle load as functions of air bladder pressure.  
         [0018]    [0018]FIG. 6 is a graphical illustration of possible axle load correlated with acceleration against time.  
         [0019]    [0019]FIG. 7 is a schematic illustration of attachment of a trailer to be weighed.  
         [0020]    [0020]FIG. 8 is a flow chart of a load determination program executed by an electrical system controller.  
         [0021]    [0021]FIG. 9 is a graphical representation of look up tables utilized by a transmission controller. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0022]    With reference to FIG. 1, an on-board vehicle weighing system  18  according to a preferred embodiment of the invention is illustrated. On-board weighing system  18  is installed on a truck  24  comprising a tractor  26  and possibly one or two trailers  28 ,  29 . Trailers  28 ,  29  may be replaced, or removed, and may or may not be equipped with an air spring or equivalent suspension system providing vehicle height leveling with changes in load.  
         [0023]    Truck  24  includes a sprung load and an unsprung support system provided by vehicle support sections  31 ,  32 ,  33 ,  34  and  35 . All of vehicle support sections  31 - 35  comprise conventional components including wheels, one or two axles, air bladders/springs, shock absorbers, connecting links, stabilizer bars and other suspension stabilizing components, i.e. all of the vehicle&#39;s unsprung weight but a negligible portion of its sprung weight. A forward tractor  31  support system includes a steering axle. Vehicle support section  32  includes a pair of drive axles located under a fifth wheel  201  (shown in FIG. 7). Support section  32  conventionally supports a portion of the load of trailer  28 . The sprung weight of truck  24  is carried through the air springs on the axles (described below with reference to FIG. 2). Air pressure in the air springs is varied with the aim of maintaining tractor  26  and trailers  28 ,  29  at a predetermined height.  
         [0024]    On-board weighing system  18  includes instrumentalities for collecting air pressure information for the air springs/bladders. Data collection is effected using an auxiliary gauge controller  20  which communicates with a plurality of pressure sensors  22  through pressure sensor monitoring units  21 . Pressure sensors  22  may be applied one to each air spring, one to the air springs for each axle, or in the case of tractor  26 , one for the air springs for the forward vehicle support section  31 , including the steering axle, and one for the air springs used with the drive axles in vehicle support section  32 .  
         [0025]    The pressure sensor monitoring units  21  communicate with auxiliary gauge controller  20  over a communications/power supply link  38  located in the trailers  28 ,  29 , which are connected to each other and to the tractor over disconnect plugs  40 . The disconnect plug  40  for the forward trailer  28  is connected to a communications/power link  18  in tractor  26 . Communications/power link  18  is connected to auxiliary gauge controller  20 , which is a node of a controller area network (CAN) including an electronic system controller  30  and a CAN data link  16  interconnecting a plurality of controllers for various vehicle functions.  
         [0026]    [0026]FIG. 2 is illustrative generally of the functional components of any of vehicle support sections  31 - 35 . A pair of air springs  44  is mounted between axle  46  and side frame rails  48  of a vehicle frame. The inflation pressure of air springs  44  is regulated with a height-leveling valve  52  mounted to one of the frame side rails  48  and operated by a valve-actuator arm  54  and push rod  52  connected to axle  46 . The pressurization in air springs  44  is illustrated as being individually controlled by providing each with its own height leveling valve, one being mounted to each frame rail  48 . More typically, each support section will have one valve, but by providing individual air bladder control, side to side height is more readily maintained. Height leveling valve  52  allows the introduction of compressed air to or exhausts air from air springs  44  through an air line  60  connecting the leveling valve  52  and the air springs  44 . The air springs  44  are directed to supporting the vehicle at a target height above axle  46 . Compressed air is supplied to the leveling valve  52  by a delivery air line  62  from an air tank. Excess air is vented from an exhaust port  63 .  
         [0027]    Motion of the frame side rails  48  on the air springs  44  is damped by shock absorbers  64  mounted in parallel to the air springs  44  between axle  46  and frame side rails  48 . While shock absorbers  64  are illustrated as positioned inboard from air springs  44 , they are typically located forward from or aft of the air springs. An air pressure sensor  22  is connected into air line  60  to obtain an average pressure reading for the two or four air springs provided in a vehicle support section.  
         [0028]    Air spring inflation pressure established by height leveling valve  52  with the pressure usually being related to one of two possible loads on the spring. This stems from valve  52  being designed with a dead band to prevent seeking. Stiction in shock absorbers  64  can result in the shock absorbers carrying a portion of the spring weight. Air spring bushings (not shown) may resist deformation at different rates depending on load. All of these factors contribute to suspension hysteresis.  
         [0029]    Referring particularly to FIG. 3, a tractor  26  illustrates individual height leveling valves  52  and pressure sensors  21  being provided for each air spring  44  for complete axle load determination. Additional suspension stabilizing linkages  66  are associated with each air spring  44  depending from frame side rails  48 . Air lines  62  connect to a compressed air tank  68  installed on tractor  26  between side frame rails  48 . An engine  70  provides motive power for tractor  26 , driving a propeller shaft  76  by a semi-automatic transmission  72 . Propeller shaft  76  is connected between the transmission  72  and a pair of differentials  74 . A tachometer  75  is coupled to propeller shaft  76  to determine the average rotational velocity of the drive wheels and thereby allow vehicle speed to be estimated.  
         [0030]    With reference to FIG. 4, a vehicle electronic control system or CAN  100  for tractor  26  is schematically illustrated. Vehicle electronic control system  100  is a generalization of applications of contemporary digital networks to motor vehicles, based on the Society of Automotive Engineers SAE J1939 standard for controller area networks. Other CAN prototypes exist and the invention will work with those as well. An SAE J1939 compliant bus  16  interconnects a plurality of controllers related to primary vehicle functions. Among these controllers are an engine controller  140 , an anti-lock brake system controller  160 , a gauge controller  120 , a transmission controller  130  (for automatic and semi-automatic equipped vehicles), an auxiliary gauge controller  20  and an electronic system controller (ESC)  30 . Vehicles may in the future include a stability and height controller  150  although at present vehicle height control is handled mechanically. Nonetheless, vehicle weight and axle load information are of direct use to the engine controller  140 , ESC  30  and transmission controller  130 .  
         [0031]    ESC  30 , unlike most of the other modules, is not concerned strictly with the function of a particular system or subset of devices, but monitors all of the other controllers and can be used to implement algorithms directed to optimizing vehicle operation. ESC  30  may also be assigned direct control of a subset of vehicle functions, here including monitoring operation of brake pedal system  118 , monitoring a switch package  131  and acting as a gateway between the public J1939 bus  16  and a proprietary J1939 bus  116 . ESC  30  also manages a wireless telemetry unit  905  which may be provided to relay vehicle load information to an operational base.  
         [0032]    Engine controller  140  manages operation of an internal combustion engine  70 . Engine controller generates an estimate of instantaneous engine torque from fuel flow, engine rpms and appropriate preprogrammed look up tables. Engine torque is then made available on the bus  16 . Anti-lock brake system controller  160  controls application of brakes  161  and is limited by indication of wheel lock up from wheel speed sensors  162 . In some vehicles ABS  160  may provide a vehicle speed signal determined from the outputs of the wheel speed sensors  162  although this function is conventionally handled by engine controller  140 , which is connected to a transmission tachometer  75 . Transmission tachometer  75  generates a vehicle speed estimate based on the average rotational speeds of the drive wheels of tractor  26  from a transmission output shaft. Gauge controller  120  typically handles a standard instrument package. Auxiliary gauge controller  20  handles additional instruments and dash board inputs as well as the readings of pressure sensors  22  taken from air lines  62 . A transmission controller  130  controls transmission  72  and is operated to dynamically select start gears, to modify shift points and to select a running gear of transmission  72  based on vehicle weight, speed and engine torque.  
         [0033]    Vehicles may in the future be equipped with a height and stability controller  150  which will adjust vehicle height and individual air spring pressurization to counter the effects of persistent cross winds, cornering, indication of excessive vehicle roll, etc. as indicated by axle load determination. Such a controller would require displacement input from the push-rods  56  positioned about a vehicle. The stability and height controller  150  could then operate on these inputs and perhaps on differential wheel speed information supplied by ABS  160  to control air pressure valves  52  for air springs located along the sides of the vehicle. Actual pressure data from auxiliary gauge controller  20  can provide feedback pressurization limit.  
         [0034]    Vehicle load measurements are formatted as signals by scaling the measurement to be proportioned to the load range which is of interest to the operator. The information is then formatted for transmittal over the SEA J 1939 bus  16  as provided by the protocol. The signal is picked up by gauge controller  120  for display to the operator, by transmission controller  130  to be used as an argument in interrogating a gear choice look up table, and for transmission over a wireless link. Gauge controller  120  translates the signal into a useful output for a stepper motor  901 , which drives a load gauge  903 .  
         [0035]    The several controllers are data processing units implemented using conventional microprocessor and memory technology. They are programmable and have access to stored look up tables which may be loaded with empirically collected data.  
         [0036]    Referring now to FIG. 5, indicated vehicle axle load is a function of air pressure in the air bags or springs and whether the load is increasing or decreasing. The pressure data illustrated was developed from a preproduction prototype International 8600 series tractor with tandem drive axles and is referred to here for illustrative purposes only. As described above, suspension hysteresis results primarily from suspension component striction and a built in dead band in the inflation control valve. Axle load is also a function of whether the vehicle is accelerating or decelerating, which shifts weight temporarily from or onto an axle.  
         [0037]    [0037]FIG. 6 shows acceleration and axle load as functions of time, illustrating the correlation of measured axle weight to time, shows the effects of acceleration and deceleration on a drive axle, illustrating the transfer of weight off of the axle during periods of positive acceleration and the transfer of weight on to the axle during periods of negative acceleration. Other axles may show an opposite correlation. Where individual sensors are allocated, one to an axle or one per air spring, a simple pressure transducer will accurately reflect the transfer of load on to or off of an axle. If such readings are directly applied to on board instrumentation, the readout can appear unstable to the driver/operator. The algorithm utilized by the present invention applies a heavy filter (lightly weighting the current sample) when vehicle speed is changing and a light filter (heavily weighting the current sample) when vehicle speed is constant. This stabilizes the readout during vehicle operation but allows quick update of readings during vehicle loading and unloading.  
         [0038]    Estimation of gross combination vehicle weight (GCVW) is usually obtained by adding the axle loads. However, where a trailer  28  does not have an array of load pressure sensors  22 , an estimation routine is programmed with certain assumptions about the load. By way of example, it may be assumed that tractor  26  weight is a known quantity, and the weight distribution between the forward vehicle support section  31  and the drive support section  32  are also known. The weight and distribution information can be programmed into the ESC  30  at the assembly plant, by the dealer or by the operator. When a trailer  28  and a tractor  26  are attached, the weight of the load in the trailer may, for example, be assumed to be evenly divided between the trailer&#39;s axles (vehicle support structure)  33  and the tractor&#39;s  26  drive axles (vehicle support structure)  32 . Referring to FIG. 7, GCVW is then simply twice the measured weight on the drive axles, plus the empty weight on the steer axle, with half the trailer load (M 1 ) being carried by the aft vehicle support structure  33  and the other half (M 2 ) by the fifth wheel  201 . The accuracy of this estimate can be improved by taking into account fifth wheel  201  position and allowing for different weight distributions between the vehicle support structures. This form of estimation does not work for double or triple trailer combinations.  
         [0039]    The algorithm of the present invention is implemented on ESC  30  on data received from the auxiliary gauge controller  20  relating to air spring pressure levels and vehicle speed information which is provided by the transmission (or power train) controller  130 . The algorithm generates GCVW and axle load data which are returned to the auxiliary gauge controller  20  for display on an axle load display  121 . Consistent with the SAE J1939 protocol, the data, once placed on the J1939 bus  16 , are available to any other controller programmed to recognize and use them.  
         [0040]    In implementing the algorithm, air pressure in the air springs  44  is periodically sampled, and a transfer function is used to convert the pressure measurement to a load figure on an axle. Typically the transfer function is substantially linear, with a slope and an offset. Other functions are however possible. Accuracy of the calculation is improved by taking into account the prevailing direction of suspension travel. If air suspension pressure last increased, a slope and offset are used reflecting a transfer function similar to the function  400  in FIG. 5 is used. If the pressure last decreased, a slope and offset are used which is similar to function  402 . The difference between the curves equated to axle load can be as large as 3000 lbs. Once a new axle load calculation is made, it does not immediately replace the prior value. Instead, a filtered valve is used as the estimate. The filter constant applied to the newest measurement varies depending on whether the vehicle is at a steady state speed or changing speed. If vehicle speed is changing, a heavy filter is used to diminish the effect of the update, i.e. the new measurement is lightly weighted. If vehicle speed is constant a light filter increases the weight given of the new measurement, i.e. the new measurement is heavily weighted. This algorithm allows the displayed load to be updated rapidly if the vehicle is stationary and being loaded, but steadies the display during periods of vehicle operation.  
         [0041]    For the algorithm, GCVW is determined for a vehicle comprising trailers lacking air pressure sensors. GCVW is determined by incorporating the measured weight on the drive axle and adding to that the empty weight of the tractor on the steering axle. For vehicles with a tandem drive axle the input weight is the combined weight on the two axles. The portion of the weight to include may be varied depending upon distribution of the load in the trailer and portions of the tractor&#39;s fifth wheel relative to the drive axles. GCVW estimate is prone to various sources of error, fifth wheel position, trailer axle position, unevenly distributed loads, and the presence of double and triple trailers.  
         [0042]    Referring to FIG. 8, an algorithm  299  begins at step  300  moving first to a determination of whether the ignition key position is in the run or accessory positions (step  302 ). The algorithm executes only upon a YES determination, and consequently the NO branch decision step  302  exits the program (step  304 ). The measurement of the axle weight for only one axle is described although the process is repeated for other axles, with appropriate substitution of the transfer functions.  
         [0043]    Algorithm  299  operates on air pressure measurements, the sampling of which is indicated at step  306 . These measurements are subject to filtering (step  308 ) described in the following steps. With each new measurement the status of a pressure direction flag (step  310 ) is determined. If the direction flag is not positive (the NO branch) the new measurement is compared to the prior period value plus a deadband offset. If the new value does not exceed the old value plus the offset the NO branch is taken from step  312  to step  314  where the value New_Axle_Weight is determined by multiplying the pressure reading by a value from a decreasing slope look up table. This valve reflects a multiplication of the reading by a conversion factor and adding a decreasing load offset. If the new pressure value is greater than the old value, plus the deadband, the flag direction flag is reset to indicate the positive change (step  316 ) and New_Axle_Weight is determined at step  318  using the values from a look up table for the increasing load situation.  
         [0044]    Where the pressure change direction flag is negative, a different route through the algorithm is taken following step  310 . The YES branch from step  310  leads to a comparison step  320  which evaluates the newly measured value against the old value less the deadband. So long as the new pressure reading does not fall below this barrier processing will continue along the NO branch to step  318  for determination of a value of New_Axle_Weight. When the new pressure reading falls below the old value less the deadband value, processing follows the YES branch from step  320  to step  322  which provides for reset of the pressure direction flags to negative and then calculation of the value for New_Axle_Weight using the look up table  314  realization of the transfer function for increasing pressure situations  
         [0045]    Once New_Axle_Weight has been determined, the weight the sample is to be given in calculating axle weight is determined based on vehicle acceleration. At step  324  it is determined if the vehicle acceleration is equal to zero. If acceleration is zero New_Axle_Weight is given a large weight C_filt (i.e. a value close to but less than one) at step  328 . If acceleration is not zero, C_filt is set to a small value (i.e., a positive value much nearer to zero than to one) at step  326 . After either step  326  or  328  Axle_Weight may be determined at step  330 . There Axle-Weight equals C_filt times New_Axle_Weight added to  1 -C_filt times the prior value for Axle-Weight. C_filt may, in a more sophisticated implementation of the invention be itself an increasing function in vehicle acceleration. Once Axle-Weight is determined the value is placed on the primary J1939 bus  16  for the use of the several controllers at step  332 . Then gross combined vehicle weight is determined from the axle weight calculation at step  334  by combining the several Axle_Weight measurements. Step  334  reflects implementation for a tractor and trailer where the trailer has no air pressure sensors. Finally, at step  336 , GCVW is placed on the J1939 bus for the use of other controllers. Processing then concludes at step  305 .  
         [0046]    The present invention may be implemented in one of several embodiments. It may be implemented on a tractor  26  only. In its simplest form one pressure sensor would be used for the drive axle. Trailers with air suspension allow the use of sensors with the trailer. If a trailer does not have sensors, weight for single trailer may be estimated by changes in load on the tractors drive axles.  
         [0047]    Referring to FIG. 9, a transmission controller  130  selects a gear for automatic transmission  72  based upon vehicle load, vehicle speed and engine torque, all of which information is provided to controller  130  over bus  16 . Transmission  72  operation may be optimized for power using a power look up table  501  or economy using economy look up table  503 . Torque output may be limited by engine controller  140  as a function of weight. Particularly, torque may be limited for a heavily loaded vehicle. Accordingly some portions of tables  501  and  503  may not include entries for all combinations of torque, speed and vehicle weight.  
         [0048]    The measurement of vehicle weight allows improvement in vehicle performance. If vehicle weight is known, better control of a semi-automatic transmission becomes possible. Unnecessary gear shifts under light loads may be avoided while effective torque limiting may be implemented under heavy loads to avoid drive line component damage or the need to derate engines. Effective drive line control with torque limiting algorithms affords effective drive line component protection through transitory derating of an engine. When axle load at each wheel is determined, basic dynamic control of the suspension becomes possible. Vehicle usage based service intervals may be more fully optimized in view of the knowledge about operating conditions by the invention.  
         [0049]    While the invention is taught with application to a trailer loaded evenly, allowance may be made for an uneven load and variation of the proportion of the weight falling on the tractor drive axles based on where in the trailer the load is placed. A non-centered fifth wheel may be accounted for similarly.  
         [0050]    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.