Abstract:
An improved tractor-trailer communications and tracking system retrofitting assembly, comprising an insulated wire, a flexible wire sleeve, a sealed fuse box, a male connector and a female connector is disclosed. The insulated wire has a length sufficient to at least span the distance between the rear portion of a tractor cab or sleeper box and the power line carrier filter. A first end of the insulated wire terminates in first and second wire segments of roughly equal length. The end portion of the first wire segment has a two-way female connector electrically attached thereto and the second wire segment has a two-way male connector electrically attached thereto. A third wire segment is electrically attached to the female two-way connector at a first end and to the male two-way connector at a second end.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to a tractor-trailer communications system, and more particularly, to a wiring assembly for retrofitting tractor-trailer combinations for wireless communications devices. 
     BACKGROUND OF THE INVENTION 
     The transport industry has benefited from various technologies that were either developed in response to unique problems or adapted from other industry applications to suit the specific needs of the transport industry. Managing large fleets of transport vehicles and their cargo has been an ongoing challenge. Scheduling pick-ups and deliveries of cargo involved imprecise tasks of mapping routes, along with calculating miles and driving time. Early on, the only practical means for monitoring a driver&#39;s progress and ensuring adherence to a schedule included the use of driver logs and sporadic telephone contact between a scheduler and a driver. 
     Compounding the problem is that a single tractor may haul any number of trailers over a wide geographical area. For example, a driver may attach a trailer loaded with fresh produce in Phoenix for delivery to Austin. In Austin, the same driver may disconnect from the trailer of fresh produce and drive across town to attach a trailer loaded with furniture which needs to be delivered to Denver. In Denver, the driver detaches the trailer loaded with furniture, and attaches a trailer loaded with canned goods which needs to be delivered to Albuquerque. As demonstrated by this example, good logistical planning is critical. 
     Cellular and satellite Global Positioning System (GPS) technologies have been adapted to the transport industry in response to logistical challenges such as those outlined above. Such systems enable remote tracking of both the tractor and trailer to provide real-time or near real-time information as to the position and identification of tractor and trailer units. One such system is the OmniTRACS® Mobile Communications Solution from Qualcomm® which provides wireless communication and satellite positioning through a two-way satellite wireless link. OmniTRACS comprises an integrated keyboard and display connected to a processing unit. While on the road, a driver can use the integrated keyboard and display to send and read messages which are sent and received via satellite. 
     Another system, also provided by Qualcomm, is TrailerTRACS®, which remotely provides trailer location and operational information including a unique trailer identifier. TrailerTRACS can provide trailer location information and an identifier of whether or not the trailer is tethered to a tractor. However, when used in conjunction with the OmniTRACS system, the two systems can communicate with each other and remotely provide information and identifiers for both the tractor and the trailer. A base station, for example, would be able to determine which trailers are connected to which tractors. 
     While systems such as those provided by Qualcomm provide viable solutions to the logistical problems associated with the transport industry, installation of the systems within large fleets of tractors and trailers can be a daunting task. Because tracking and communications systems are typically integrated within the existing electrical system of a tractor and trailer, installation most often requires a technician to cut into one or more electrical and/or data wires. If the tractor and/or trailer is under warranty, such retrofitting can void all or a portion of such warranty. Also, in creating a splice, it is necessary to cut into a wire which compromises the critical insulating properties of the wire. This can lead to environmental exposure and wire corrosion, thereby disrupting critical systems. 
     One way to avoid splicing into the existing electrical system of the tractor, is to add an additional umbilical solely dedicated for the transfer of electric power and data between the tractor and trailer, or to reconfigure the existing umbilical and connectors. However, these solutions would not only be labor intensive, but would not be practical in that tractor and trailer interchangeability is critical. As such, industry standards have been defined to ensure that any tractor can safely and effectively haul any trailer. 
     The standards for power exchange between a tractor and trailer have remained constant for the past several decades. Power is generally exchanged between the two units through a seven wire cable commonly referred to as an umbilical. The umbilical provides electrical current to the trailer to power, for example, turn signals, tail lights, side marker lamps, brake lights, Automatic Braking System (ABS), and the like. In order to promote uniformity throughout the industry, the Society of Automotive Engineers (SAE) has adopted standards for both the seven wire cable (SAE J1067) and the associated seven pin connector (SAE J560). 
     For the reasons set forth above, there is a need for a retrofitting method and assembly whereby tracking and communications systems may be quickly and safely installed within fleets of tractors and trailers. Because data relating to the tracking and communications system is exchanged between a tractor and trailer over an existing power line, it is desirable to tie into the power line, where a data signal is at its strongest and most reliable level. Moreover, there is a need for a retrofitting method and assembly that enables a technician to quickly and reliably tie into the existing tractor electrical and data transfer infrastructure, with minimal or no cutting and splicing. 
     SUMMARY OF THE INVENTION 
     To overcome the limitations in the prior art described above, and to overcome other limitations that will become apparent upon reading and understanding the present specification, hereinafter referred to as a “retrofitting assembly”, the present invention is an improved system, method, and device for conveniently retrofitting tractors and trailers with Remote Communications and Monitoring (RCM) systems. While the manner by which such a device may be configured and used to address the foregoing disadvantages will be described in greater detail herein, in general, the present invention facilitates fast and reliable installation of a communications link between a trailer RCM unit and a tractor RCM unit without cutting into an existing wire to create a splice. 
     In accordance with an exemplary embodiment of the present invention, a retrofitting assembly is provided whereby RCM systems residing respectively in a tractor and a trailer can be connected via a tractor power line. In one embodiment, the retrofitting assembly is interconnected with a dedicated ABS power and data line to provide optimal signal strength and reliable data communications. 
     The retrofitting assembly comprises, for example, an insulated primary wire, a flexible wire sleeve, a male connector and a female connector. The insulated primary wire has a length sufficient to at least span the distance between the rear portion of a tractor cab or sleeper box and the Power Line Carrier (PLC) filter. A first end of the primary wire is threaded through a small opening located near the bottom of a tractor cab, or sleeper box if so equipped. The first end is connected to a RCM processor located within the cab or sleeper box. Two short wire segments are spliced to a second end of the primary wire. The end of a first short wire segment is affixed to a first conductive prong of a male two-way connector and the end of a second short wire segment is affixed to a first conductive prong of a female two-way connector. A first end of a third short wire segment is affixed to a second conductive prong of the male two-way connector and a second end of the third short wire segment is affixed to a second conductive prong of the female two-way connector. 
     The male two-way connector is electrically attached to the dedicated Anti-lock Braking System (ABS) female two-way connector leading out of a tractor&#39;s PLC filter. The female two way connector is attached to a dedicated ABS Electronic Control Unit (ECU) power line leading to the tractor&#39;s ABS ECU. As such, the tractor RCM unit and trailer RCM unit can exchange data through an existing dedicated power line, eliminating or reducing the need to cut into a wire to create a splice. 
     More specifically, in another example, the system includes a tractor and trailer communications system configured to transmit and receive communications signals remotely. The system includes, for example, a trailer control unit suitably positioned within a trailer, wherein the trailer control unit is configured to provide a trailer identifier and send data to a remote location; a processing unit suitably positioned within a tractor, wherein the processing unit is configured to provide a tractor identifier, send data to a remote location, and receive data from a remote location; and, a retrofitting assembly configured to facilitate data exchange between the processing unit and the trailer control unit, wherein the data exchange occurs over an existing power line linking the tractor and the trailer. 
     The features and advantages of the present invention will be apparent to those of ordinary skill in the art in view of the detailed description of the exemplary embodiments, which are made with reference to the drawings, a brief description of which is provided below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above objects and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which like reference numerals represent like parts; 
         FIG. 1  is diagram showing major electrical components and wiring for PLC filter equipped tractor and a trailer with an exemplary retrofitting assembly engaged thereon according to an embodiment of the present invention; 
         FIG. 2  is a diagram illustrating an exemplary positioning of the retrofitting assembly in respect to the PLC filter in accordance with an embodiment of the present invention; 
         FIG. 3  is a drawing of an exemplary retrofitting assembly according to an embodiment of the present invention; and, 
         FIG. 4  is diagram showing major electrical components and wiring for a tractor not equipped with a PLC filter and a trailer with an exemplary retrofitting assembly engaged thereon according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     In the following description of exemplary embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized as structural and/or design changes may be made without departing from the scope of the present invention. 
     Exemplary major electrical components and wiring for a Power Line Carrier (PLC) filter equipped tractor and a trailer, with an exemplary retrofitting assembly engaged thereon, is shown in  FIG. 1  in accordance with an embodiment of the present invention. As used herein, the term “tractor” may refer to any vehicle having another vehicle in tow. Practitioners will appreciate that the electrical system configuration may vary among manufacturers and models of tractors and trailers. For example, some tractors are not equipped with a PLC filter  110 . However, the retrofitting assembly of the present invention is equally applicable in such tractors as will be discussed in greater detail herein. Although described as a “retrofitting assembly”, the invention also contemplates being incorporated in new systems, add-ons to system and/or stand alone systems. 
     DC power originating with a tractor ignition system is distributed to various components and subsystems of tractor  100  and trailer  102  through a Power Distribution Module (PDM)  104 . As used herein, PDM  104  comprises any hardware and/or software suitably configured to facilitate the provisioning of electric power to any number of DC-powered components located on both the tractor and on the trailer. It will be appreciated that the positioning and configuration of PDM  104  may vary among makes and models of tractors and that some configurations may include more than one PDM  104 . 
     If a tractor  100  is so equipped, power first passes through a PLC filter  110  by way of a PDM power line  106  before being distributed to other components and subsystems. As used herein, a PLC filter  110  comprises any hardware and/or software suitably configured to condition electronic signals by isolating varying signal frequencies and removing signal noise from data communications traveling over a power line. 
     To distribute power to various components and subsystems of trailer  102 , DC power is routed from PLC filter  110  to a tractor power point  128  by way of an auxiliary power line  116 . As used herein, tractor power point  128  and trailer power point  132  comprises any hardware suitably configured to receive an umbilical  130  connector. Trailer power point  128  may be of various configurations; however the present industry standard is a SAE J560 seven-way connector. 
     From tractor power point  128 , auxiliary power and Anti-lock Braking System (ABS) data is passed to and from the trailer power point  132  by way of umbilical  130 . As used herein, umbilical  130  comprises any hardware suitably configured to carry electric current and/or data between tractor power point  128  and a corresponding trailer power point  132 . As is conventional in the art, and in one embodiment, an umbilical is a seven wire jacketed cable with a SAE J560 seven-way connector attached to each end. 
     Auxiliary power is dispersed to various trailer  102  components and subsystems through one or more trailer auxiliary power lines  144 , while ABS power and data is dispersed to the trailer ABS through one or more dedicated trailer ABS power lines  146 . Auxiliary powered components and subsystems may include, for example, turn signals, brake lamps, tail lamps, side marking lamps, and clearance lamps. Dedicated trailer ABS power line  146  may provide data exchange between the tractor  100  and trailer  102  for various trailer subsystems including, for example, ABS, suspension control, tire pressure sensors, RCM systems, and the like. Data originating from, or intended for, a trailer control unit  136  also utilizes dedicated trailer ABS power line  146  by way of a trailer control unit power and data line  134 . In accordance with another embodiment, trailer auxiliary power line  144  and dedicated trailer ABS power line  146  may be one in the same. 
     As described above, various tractor and trailer subsystems not only consume power, but also produce and/or consume data. One such subsystem is the ABS. Most tractor-trailers on the road today are equipped with sophisticated braking systems that require serial data communications with an ABS ECU  114 , which monitors and controls the trailer&#39;s ABS. Data is shared between the trailer&#39;s ABS system and ABS ECU  114  through umbilical  130 , the tractor auxiliary power line  124 , PLC filter  110 , and ECU power/data line  112 . The data passes through the PLC filter  110  to remove any electrical noise that may interfere with processing at the ABS ECU  114 . 
     During braking, the wheel speed sensors on trailer  102  measure the rotational speed of the wheels and forward this information to ABS ECU  114 . If ABS ECU  114  determines that one wheel is decelerating faster than another (indicating that the brake is about to lock), ABS ECU  114  directs solenoid valves to open, releasing hydraulic pressure to the brake until the rotational speed of the errant wheel matches the others. If ABS ECU  114  receives a signal indicating a problem within the trailer ABS, then it sends a signal to a trailer ABS indicator lamp, which is, in an exemplary embodiment, positioned within the operator&#39;s field of vision. 
     Other subsystems utilizing serial data communications between tractor  100  and trailer  102  are systems that provide RCM capabilities. Such systems are often standard equipment or upgrades on many late model tractors and trailers, however earlier models are routinely retrofitted with these systems. Such RCM systems include, for example, OmniTRACS and TrailerTRACS, both by Qualcomm. OmniTRACS provides wireless communications and satellite positioning capabilities through a two-way satellite wireless link. A tractor equipped with the OmniTRACS system can be tracked from a remote location and the driver can send and receive email communications with schedulers. TrailerTRACS is installed within a trailer and may be configured to provide position reports, including the identity of the trailer, when connected with OmniTRACS. 
     In accordance with an exemplary embodiment, the tractor installed RCM processor  108  is OmniTRACS and the trailer installed RCM control unit  136  is TrailerTRACS. However, it will be appreciated that the present invention may be equally applicable to other makes, models, and configurations of RCM systems. As such, the specific reference to the Qualcomm RCM products (OmniTRACS and TrailerTRACS) is for the purpose of explanation and does not serve to limit the scope of the invention. 
     TrailerTRACS can provide positioning reports, identification, and other information to a remote location whether or not the trailer  102  is attached to a tractor  100 . A TrailerTRACS control unit  136 , which is positioned either within the cargo area of a trailer  102  or within the trailer nosebox, sends and receives radio signals by way of a satellite antenna  140 , which is connected with the TrailerTRACS control unit  136  via a trailer antenna line  138 . However, in order for a remote station to have access to information pairing a tractor identifier with a trailer identifier, the TrailerTRACS control unit  136  should be in serial data communications with the OmniTRACS processing unit  108 . 
     To optimize the strength and integrity of serial data communications between OmniTRACS processor  108  and TrailerTRACS control unit  136 , retrofitting assembly  118  is optimally integrated within an existing dedicated line that is configured to transport data signals. The National Highway Transportation and Safety Administration (NHTSA) has mandated that all tractor and trailer units manufactured after 1998 must be ABS equipped and provide a dedicated power line and ground to an ABS ECU  114 . Because a dedicated ECU power line  114  also transports data, it is well-suited to supply power and serial data communications to the OmniTRACS processor  108  and TrailerTRACS control unit  136 . Moreover, the physical positioning of the retrofitting assembly  118  along the ECU data line  112  provides for optimal signal strength and reliability. The retrofitting assembly  118  completes a circuit between PLC filter  110  and ABS ECU  114  and communicates serial data signals to OmniTRACS processor  108 . Retrofitting a tractor  100  and trailer  102  with the Qualcomm RCM in accordance with an exemplary embodiment of the present invention will be disclosed herein. 
     With reference to  FIG. 2 , PLC filter  200  includes an auxiliary power connector  220  attached thereto to provide power to any number of trailer components and subsystems. A dedicated ABS ECU power connector  210  and dedicated ground  215  provide power and data communications to the ABS ECU  114 . Auxiliary power connector  220  provides power to the tractor power point  128  via an auxiliary power line  124 . Therefore, when umbilical  130  connecting the trailer  102  and tractor  100  is properly engaged, data signals originating from the TrailerTRACS control unit  136  are transported to the trailer&#39;s power point  132  by way of a dedicated data line  134  that merges with a trailer dedicated ABS power line  146 . The data is transported across the umbilical  130 , over auxiliary power line  124 , through PLC filter  110  and over the retrofitting assembly  118  to be received by the OmniTRACS processing unit  108 . The OmniTRACS processing unit  108  then routes a “trailer present” signal to the tractor&#39;s antenna  122  by way of an antenna line  120 , wherein the signal is transmitted along with other identifying information to a remote monitoring location. A tractor operator may interact with OmniTRACS processing unit  108  to send and receive email through an integrated keyboard and display unit  150 , which is suitably connected to OmniTRACS processing unit  108  by way of an interface data line  148 . 
     With reference again to  FIG. 2 , a diagram is provided illustrating an exemplary positioning of the retrofitting assembly in respect to the PLC filter in accordance with an embodiment of the present invention. Reference will also be made to various components presented in  FIG. 1  to demonstrate how the retrofitting assembly of the present invention is integrated within the electrical system of a tractor. DC power that is supplied by PDM  104  is received by an auxiliary connector  220  of PLC filter  200 . Auxiliary connector  220  is electrically coupled to PDM power line  106 . A typical PLC filter  200  configuration includes a power supply line  205 , which is electrically coupled to auxiliary power line  124  to transport power to any number of trailer components and subsystems. ABS connector  210  facilitates the exchange of data signals between the trailer ABS and the tractor ABS ECU  114 . An ABS ground  215  is also provided in accordance with some PLC filter  200  configurations. The ABS connector  210  is fitted with a male two-way connector  225  of retrofitting assembly and a female two-way connector  230  of retrofitting assembly is fitted with the ABS ECU power line connector  255 . ABS ECU power line connector  255  has a first power line  260  electrically affixed thereto which originates at PDM  104 , which provides ABS ECU  114  with dedicated power. A second power line  265  provides power and data exchange between ABS ECU  114  and the trailer ABS. Male two-way connector  225  and female two-way connector  230  of retrofitting assembly are interconnected by a ground wire segment  235  and a male connector signal carrying segment  240  and female connector signal carrying segment  245 . The two signal carrying wire segments merge into a single signal carrying wire  250 , which provides a data conduit to OmniTRACS processing unit  108 . 
       FIG. 3  is a drawing of an exemplary retrofitting assembly in accordance with an exemplary embodiment of the present invention. While specific exemplary wire gages, insulating materials, connectors, and the like will be described herein, practitioners will appreciate that various other materials and configurations may be used in the manufacture of the retrofitting assembly without departing from the scope of the invention. 
     In an exemplary embodiment, female connector  300  and male connector  305  are Delphi® GT Series sealed connectors. Specifically, male connector  305  may be a GT Series male 2-way sealed connector, while female connector  300  may be a GT  150  female unshrouded sealed 2-way connector. However, regardless of configuration, the connectors are insulated and sealed in order to protect the terminals from environmental exposure. 
     In another embodiment, and with reference to  FIG. 4 , the retrofitting assembly may be installed in a tractor that is not equipped with a PLC filter. In this embodiment, the power line connecting to male connector  305  may conduct greater amperage due to being in direct connection with PDM power line  406 . PDM power line  406  typically conducts up to thirty amps, whereas current passing through a PLC filter is reduced to approximately 10 amps. As such, wire segments  310 ,  315 , and  320  are, in an exemplary embodiment, a 10-gauge insulated copper wire. When the retrofitting assembly is configured for installation within a tractor equipped with a PLC filter, wire segments  310 ,  315 , and  320  are 12-gauge insulated copper wire. Wire segment  325  is a 14-gauge insulated copper wire. However, practitioners will appreciate that the specific wire gages may vary according to specific amperage requirements. 
     Wire segment  315  and segment  320  are electrically connected to wire segment  325  where the connection is sealed and insulated, in an exemplary embodiment, with a heat shrinkable wraparound. A waterproof fuse holder  330 , such as a Cooper Bussmann® BUSS-HFB is, in an exemplary embodiment, is positioned along the length of wire segment  325 . Waterproof fuse holder  330  houses a fuse to protect the circuitry of the OmniTRACS processing unit  108  from possible power surges. 
     A flexible wire sleeving  335  protects wire segment  325  when installed within a tractor. The retrofitting assembly may be secured to the tractor structure or existing wire bundles by way of straps or any other means known in the art. With frequent motion, an unprotected wire may be subject to chaffing of the wires&#39; insulation. Over time, this could lead to exposure of the wire which may cause damage to the OmniTRACS processing unit or other electrical system components. Therefore, a durable and flexible wire sleeving helps to shield wire segment  325  from excess wear due to friction, debris, and environmental factors. Wire sleeving  335  covers the length of wire segment  325  from just below the waterproof fuse holder  430  to where wire segment  325  enters the cab or sleeper box of the tractor  142 . A stripped end  345  of wire segment  340  is received by the OmniTRACS processing unit  108 . 
       FIG. 4  is a diagram showing major electrical components and wiring for a tractor, not equipped with a PLC filter and a trailer with an exemplary retrofitting assembly engaged thereon, according to an embodiment of the present invention. As described above, the retrofitting assembly  412  of the present invention may also be incorporated within various other tractor electrical system configurations, including those that are not equipped with a PLC filter. 
     DC power originating from tractor PDM  404  is distributed to tractor power point  418  by way of PDM power line  406 . Prior to reaching tractor power point  418 , primary power line  406  splits to form an auxiliary power line  416  and a dedicated ABS power line  414 . To distribute power to various components and subsystems of trailer  402 , electric power is transported from PDM  404  to tractor power point  418  by way of auxiliary power line  416  and/or dedicated ABS power line  414 . 
     From tractor power point  418 , auxiliary power, ABS power, and ABS data is passed to and from a trailer power point  422  by way of umbilical  420 . Auxiliary power is dispersed to various trailer  402  components and subsystems through one or more trailer auxiliary trailer power lines  428 , while ABS power and data is distributed to the trailer ABS through one or more dedicated trailer ABS power lines  430 . Dedicated trailer ABS power line  428  may provide data exchange between tractor  100  and trailer  102  for various trailer subsystems in addition to the trailer ABS. Data originating from, or intended for, TrailerTRACS control unit  426  also utilizes dedicated trailer ABS power line  428  by way of a TrailerTRACS control unit power and data line  424 . According to another embodiment, auxiliary trailer power lines  428  and dedicated trailer ABS power line  428  may be one in the same. 
     The foregoing descriptions of the exemplary embodiments of the invention have been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not with this detailed description, but rather by the claims appended hereto.