Abstract:
A vehicle load warning apparatus utilizing inductive proximity sensors to signal an alarm to an operator when a vehicle achieves a maximum weight. The vehicle load warning apparatus can also provide an intermediate warning to an operator when the vehicle approaches the maximum weight. The vehicle load warning apparatus can also utilize inductive proximity sensors at each end of both axles of a vehicle and provide imbalance warning signals if the weight on a vehicle is not equally distributed throughout the body of the vehicle.

Description:
CROSS REFERENCE TO RELATED APPLICATION(S) 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 62/128,143, filed Mar. 4, 2014. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates in general to a weight detection apparatus for a load-carrying vehicle. More particularly, the present invention relates to an electronic sensor that triggers when a vehicle&#39;s load reaches at least one predetermined weight. 
       BACKGROUND OF THE INVENTION 
       [0003]    Frequently, vehicles, including trucks designed to carry a payload, have a maximum load rating for safe operation. Typically, a vehicle can be equipped with an overload sensor that is operatively linked to the vehicle&#39;s horn so that the horn will sound if the vehicle&#39;s payload exceeds a maximum rating. In other instances, a vehicle can be loaded unevenly, thereby causing difficulties with operating the vehicle if too much weight is on one side of the vehicle relative to the opposite side. In still other instances, a vehicle may begin to reach an overloaded capacity, yet a vehicle operator may have no clear indication that an overloaded state would soon be reached as weight continues to be added onto the vehicle. It can be beneficial for an operator to know that an overloaded state is about to be met before it actually is met so that any necessary preventative steps can be taken. 
         [0004]    A need, therefore, exists in the art for one or more sensors that can indicate, in one embodiment, when a payload in a vehicle reaches the maximum safe load weight and, in another embodiment, when a load weight is unbalanced in a vehicle and, in another embodiment, when the load weight approaches the maximum load safe load weight before such load weight is met, and in yet another embodiment, the then present range of payload of the vehicle. 
       SUMMARY OF THE INVENTION 
       [0005]    According to the present invention, the foregoing and other objects and advantages are obtained by a proximity sensor mounted to the body of a vehicle having a member attached at a first end to an axle housing of the vehicle in a vertical position below the sensor. A second end of the member is disposed with respect to the sensor (i) horizontally, so as to be disposed directly under the sensor; (ii) offset in a direction from front to back of the vehicle, so as to provide a clearance distance that is less than the distance of the nominal range of the sensor between the sensor and the member in the case in which said sensor moves downward as said vehicle is loaded; and (iii) vertically, in a position such that in the case in which the vehicle approaches becoming overloaded, with the result that in the case in which the sensor deflects downward until the member has become vertically aligned with the sensor whereby the clearance distance between the sensor is within the nominal range of the sensor, thereby triggering the sensor, yet such clearance distance being great enough so as to avoid contact between the sensor and the member. 
         [0006]    According to another embodiment of the instant invention, the mounting of the sensor to the body comprises a first plate to which the sensor is mounted at its first end and a second plate having a first end to which the second end of the first plate is mounted and having a second end mounted to the vehicle body whereby the mounting of the second end of the first plate to the first end of the second plate is adjustable. 
         [0007]    According to another aspect of the invention, the vehicle load warning apparatus further comprises an electrical signal being sent from the sensor in the case in which the sensor is within the nominal range of the member wherein the signal is electrically connected via a switch to an alarm audible to the operator of the vehicle. According to another aspect of the invention, the vehicle load warning apparatus switch is in an open position, unless the vehicle is in a parked gear. 
         [0008]    According to another aspect of the invention, the vehicle load warning apparatus sensor is triggered only in the case in which the sensor remains within the nominal range of the member for at least one second. 
         [0009]    According to another aspect of the invention, the vehicle load warning apparatus proximity sensor is an inductive proximity sensor. 
         [0010]    According to another aspect of the invention the vehicle load warning apparatus member is metal. 
         [0011]    According to another aspect of the invention the vehicle load warning apparatus metal member is a bracket. 
         [0012]    According to another embodiment of the invention, there is a vehicle load warning apparatus comprising an inductive proximity sensor mounted to a first plate at a first end. The first plate has a second end mounted to a first end of a second pate. The second plate has a second end mounted to a vehicle body. A bracket is attached at a first end to the axle housing on the vehicle. A second end of the bracket is disposed in a position such that when a vehicle is loaded to a maximum weight, the inductive proximity sensor deflects with the vehicle body until the second end of the bracket is vertically aligned in front of the sensing component of the inductive proximity sensor, whereby the distance between the sensing component of the inductive proximity sensor is within a nominal range to detect the second end of the bracket, yet not so close as to permit contact between the inductive proximity sensor and the second end of the bracket. 
         [0013]    According to another aspect of the invention, the vehicle load warning apparatus&#39;s second end of the first plate and the first end of the second plate are adjustably mounted to one another. According to another aspect of the invention, the vehicle load warning apparatus further comprises a signal sent from the inductive proximity sensor when the inductive proximity sensor is within the nominal range of the second end of the bracket wherein the signal triggers an alarm. According to another aspect of the invention, the vehicle load warning apparatus&#39;s alarm is triggered only in the case in which the vehicle is in a parked gear. According to another aspect of the invention, the vehicle load warning apparatus&#39;s alarm is triggered only in the case in which the inductive proximity sensor remains within a nominal range of the second end of the bracket for at least one second. 
         [0014]    According to another embodiment of the instant invention, there exists a vehicle load warning apparatus comprising a first proximity sensor mounted to the body of the vehicle. A second proximity sensor is mounted to the body at a position above the first sensor. A member is attached at a first end to the axle housing on the vehicle in a vertical position below the first sensor. A second end of the member is disposed with respect to the first sensor (i) horizontally, so as to be disposed directly under the first sensor; (ii) offset in a direction from front to back of the vehicle, so as to provide clearance between the first sensor and the second sensor in the case in which the sensors move downward as the vehicle is loaded; and (iii) vertically, in a position such that in the case in which the vehicle is loaded to a maximum weight, the first sensor and the second sensor deflect with the body until the second end of the member has become vertically aligned, first, with the first sensor whereby the clearance distance between the first sensor and the member is within the nominal range of the first sensor thereby triggering the first sensor, while the clearance distance being great enough so as not to permit contact between the first sensor and the member, and second, with the second sensor whereby the clearance distance between the second sensor and the member is within the nominal range of the second sensor thereby triggering the second sensor, while the clearance distance being great enough so as not to permit contact between the second sensor and the member. 
         [0015]    According to another aspect of the invention, the vehicle load warning apparatus&#39;s sensors are adjustably mounted to the body. According to another aspect of the invention, the vehicle load warning apparatus of further comprises a first electrical signal being sent from the first sensor in the case in which the first sensor is within the nominal range of the member wherein the first signal is electrically connected via a switch to an alarm audible to the operator of the vehicle and a second electrical signal being sent from the second sensor in the case in which the second sensor is within the nominal range of the member wherein the second signal is electrically connected via a switch to an alarm audible to the operator of the vehicle. According to another aspect of the invention, the vehicle load warning apparatus&#39;s switch is in an open position unless the vehicle is in a parked gear. According to another aspect of the invention, the vehicle load warning apparatus&#39;s first sensor is triggered only in the case in which the sensor remains within the nominal range of the member for at least one second and wherein the second sensor is triggered only in the case in which the sensor remains within the nominal range of the member for at least one second. According to another aspect of the invention, each of the vehicle load warning apparatus&#39;s proximity sensors are an inductive proximity sensor. According to another aspect of the invention, the vehicle load warning apparatus&#39;s member is metal. According to another aspect of the invention, the vehicle load warning apparatus&#39;s metal member is a bracket. 
         [0016]    According to another embodiment of the invention, there exists a vehicle load warning apparatus comprising a first proximity sensor mounted to the rear driver side of the body of the vehicle. A driver side member is attached at a first end to the driver side rear axle housing of the vehicle. A second proximity sensor is mounted to the rear passenger side of the body of the vehicle. A passenger side member is attached at a first end to the passenger side rear axle housing of the vehicle. A second end of the driver side member and a second end of the passenger side member is disposed horizontally equidistant from the ground on which the vehicle rests, such that, first, in the case in which the vehicle becomes overloaded in an unbalanced manner such that the center of gravity of the load deflects toward the driver side of the vehicle, the first sensor moves downward so as to be no longer horizontally equidistant from the ground with the second sensor with the result that the driver side member becomes vertically aligned with and within the nominal range of the first sensor without contact between the first sensor and the driver side member, thereby triggering the first sensor, and, second, in the case in which the vehicle becomes overloaded in an unbalanced manner such that the center of gravity of the load deflects toward the passenger side of the vehicle, the second sensor moves downward so as to be no longer horizontally equidistant from the ground with the first sensor with the result that the passenger side member becomes vertically aligned with and within the nominal range of the second sensor without contact between the second sensor and the passenger side member, thereby triggering the second sensor. 
         [0017]    According to another aspect of the invention, the vehicle load warning apparatus further comprises an electrical signal being sent from the first sensor in the case in which the sensor is within the nominal range of the driver side member wherein the signal is electrically connected via a first switch to a first alarm audible to the operator of the vehicle indicating overload unbalanced toward driver side of the vehicle and an electrical signal being sent from the second sensor in the case in which the sensor is within the nominal range of the passenger side member wherein the signal is electrically connected via a second switch to a second alarm audible to the operator of the vehicle indicating overload unbalanced toward passenger side of the vehicle. 
         [0018]    According to another aspect of the invention, the vehicle load warning apparatus&#39;s first switch and the second switch are in an open position, unless the vehicle is in a parked gear. According to another aspect of the invention, the vehicle load warning apparatus&#39;s first sensor is triggered only in the case in which the sensor remains within the nominal range of the driver side member for at least one second and the second sensor is triggered only in the case in which the sensor remains within the nominal range of the passenger side member for at least one second. According to another aspect of the invention, each of the sensors is an inductive proximity sensor. According to another aspect of the invention, each of the driver side member and the passenger side member is metal. According to another aspect of the invention, each of the metal members are a bracket. 
         [0019]    According to another embodiment of the invention, the vehicle overload warning apparatus uses a proximity sensor mounted to the body of the said vehicle in a horizontal position relative to the axle housing of said vehicle and a member attached to said axle housing in a horizontal position relative to and directly below said sensor so that, in the case in which said vehicle approaches becoming overloaded said sensor deflects downward with the result that the distance between said sensor and said member is within the nominal range of said sensor, thereby triggering said sensor and uses additionally a bump stop attached to said body of said vehicle having a width great enough so as to contact said axle housing in the case in which said body and said sensor deflect downward to avoid contact between said sensor and said member. According to another embodiment of the invention, there is disclosed a vehicle load warning apparatus and range of payload indicator system based on the combination of a first proximity sensor mounted to the body of said vehicle and a second proximity sensor mounted to said body at a position above said first sensor, and a member attached at a first end to the axle housing on the said vehicle in a vertical position below said first sensor with the second end of said member being disposed with respect to said first sensor (i) horizontally, so as to be disposed directly under said first sensor; (ii) offset in a direction from front to back of said vehicle, so as to provide clearance between said first sensor and said second sensor in the case in which said sensors move downward as the vehicle is loaded; and (iii) vertically, in a position such that in the case in which said vehicle is loaded to a maximum weight, said first sensor and said second sensor deflect with said body until said second end of said member has become vertically aligned, first, with said first sensor whereby said clearance distance between said first sensor and said member is within the nominal range of said first sensor thereby triggering said first sensor, said clearance distance being great enough so as not to permit contact between said first sensor and said member, and second, with said second sensor whereby said clearance distance between said second sensor and said member is within the nominal range of said second sensor thereby triggering said second sensor, said clearance distance being great enough so as not to permit contact between said second sensor and said member whereby a predetermined first payload range is indicated to the operator of said vehicle in the case in which said first sensor has been triggered but said second sensor has not been triggered, and whereby a predetermined second payload range that is greater than said first payload range is indicated to the operator of said vehicle in the case in which said second sensor has been triggered. It will be apparent that such a vehicle load warning apparatus and range of payload indicator system can be constructed with more than two sensor, to wit, using a multiplicity of proximity sensors mounted directly one above the other to the body of said vehicle, and a member attached at a first end to the axle housing on the said vehicle in a vertical position below the lowest mounted of said multiplicity of sensors with the second end of said member being disposed with respect to said multiplicity of sensors (i) horizontally, so as to be disposed directly under said lowest mounted sensor; (ii) offset in a direction from front to back of said vehicle, so as to provide clearance between each of said sensors in the case in which said sensors move downward as the vehicle is loaded; and (iii) vertically, in a position such that in the case in which said vehicle is loaded said sensors deflect with said body until said second end of said member has become vertically aligned, first, with said lowest mounted sensor whereby said clearance distance between said first sensor and said member is within the nominal range of said first sensor thereby triggering said first sensor, said clearance distance being great enough so as not to permit contact between said first sensor and said member, and thereafter with each of said sensors in turn, whereby said clearance distance between each of said sensors and said member is within the nominal range of said sensor thereby triggering said sensor, said clearance distance being great enough so as not to permit contact between any of said sensors and said member whereby a predetermined first payload range is indicated to the operator of said vehicle in the case in which said lowest mounted sensor has been triggered but said second sensor has not been triggered, and in turn whereby predetermined payload ranges that are greater than said first payload range are in turn indicated to the operator of said vehicle in the case in which each of said sensors in turn has been triggered. 
         [0020]    As one skilled in the art can readily appreciate, there are many and varied ways in which the operator of the vehicle can be apprised of the different loading situations described in the various embodiments disclosed herein. For example, in addition to employing an alarm that is electrically sounded by the triggering of a sensor in an overload situation, one can use in addition to or in place of such an audible signal a signal light, which might remain lit until such overload situation has been ameliorated. Additionally, different sounds for alarms, or number of signal lights lit, can be used to signify coming close to overload as opposed to overloaded, or for each payload range entered in the embodiment having that availability. Finally, the electronic signals emanating in the case in which a proximity sensor is triggered can be used to drive digital or analog meters or gauges visible to the operator, for example, mounted on or included in the dashboard of said vehicle. 
         [0021]    Other features and advantages of the instant invention will be apparent to those skilled in the art from their application of ordinary skill to the description and drawings contained herein. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]    The invention will become more readily apparent from the following description of preferred embodiments thereof shown, by way of example only, in the accompanying drawings wherein: 
           [0023]      FIG. 1  is a rear side elevational view according to a first embodiment of the invention without a load on a vehicle. 
           [0024]      FIG. 2  is a rear side elevational view according to said first embodiment of the invention without a load on a vehicle. 
           [0025]      FIG. 3  is a rear side elevational view according to said first embodiment of the invention with a load on a vehicle. 
           [0026]      FIG. 4  is a zoomed in rear side elevational view according to said first embodiment of the invention with a load on a vehicle. 
           [0027]      FIG. 5  is a perspective view according to one embodiment of the invention without a load on a vehicle. 
           [0028]      FIG. 6  is a rear side elevational view according to a second embodiment of the invention without a load on a vehicle. 
           [0029]      FIG. 7  is a zoomed in rear side elevational view according to said second embodiment of the invention without a load on a vehicle. 
           [0030]      FIG. 8  is a rear side elevational view according to said second embodiment of the invention with a load on a vehicle. 
           [0031]      FIG. 9  is a zoomed in rear side elevational view according to said second embodiment of the invention with a load on a vehicle. 
           [0032]      FIG. 10  is a rear side elevational view according to a third embodiment of the invention with a load on a vehicle. 
           [0033]      FIG. 11  is a perspective view according to a fourth embodiment of the invention without a load on a vehicle. 
           [0034]      FIG. 12  is a rear side elevational view according to a fifth embodiment of the invention with a load on a vehicle. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0035]      FIG. 1  depicts a vehicle overload sensor according to a first embodiment of the instant invention, generally identified as numeral 10. A zoomed in image of the vehicle overload sensor is depicted in  FIG. 2 . The vehicle overload sensor  10  comprises a pair of proximity sensors  14  attached to a vehicle body  16  at opposing ends of an axle on vehicle body  16 . The vehicle overload sensor  10  further comprises a pair of brackets  18  attached to opposing sides of axle housing  12 . In a preferred embodiment, the overload sensor  10  is located on the rear axle on a vehicle. In other embodiments, the overload sensor  10  is used on multiple axles. 
         [0036]    Proximity sensors  14  utilize inductive proximity to indicate when a vehicle&#39;s suspension has moved the distance known to correlate to the maximum weight for a particular vehicle. As weight is added to a vehicle, the suspension deflects and proximity sensors  14  move closer to brackets  18 . The distance between proximity sensors  14  and brackets  18  can be calibrated when a known maximum cargo weight is loaded on the vehicle. Turning to  FIG. 5 , one proximity sensor  14  is depicted. Proximity sensor  14  is adjustably affixed to the vehicle body  16  by means known to those having ordinary skill in the art. As shown in  FIG. 5 , proximity sensor  14  has a plate  22  mated to a second plate  24 . Second plate  24  is secured to vehicle body  12 . Slots  20  are found in both plate  22  and second plate  24 . Bolts (not depicted) can be slid in slot  20  to affix plate  22  to second plate  24 . In this manner, the vertical position of plate  22  relative to second plate  24  can be adjusted. A second slot  26  is depicted on second plate  24 . In this manner, plate  22  can be adjusted horizontally relative to second plate  24 . 
         [0037]    Turning to  FIG. 3 , overload sensor  10  is depicted in a load bearing operational state. A zoomed in view of  FIG. 3  is shown in  FIG. 4 . In  FIG. 4 , the vehicle&#39;s suspension has deflected as the maximum cargo weight has been added to the vehicle. In this operational state, proximity sensors  14  have moved with the vehicle&#39;s suspension and each of the proximity sensors  14  are now covered by each of the brackets  18 . The distance between proximity sensors  14  and brackets  18  is close enough to activate each of the proximity sensors  14 , yet still far enough away from brackets  18  to avoid physical contact between proximity sensors  14  and brackets  18 . This distance is sometimes referred to as an operative range or a nominal range. 
         [0038]    A second embodiment of the instant invention is depicted on  FIG. 6 .  FIG. 6  depicts a vehicle without a cargo load.  FIG. 7  is a zoomed in image of  FIG. 6 . In  FIG. 7 , the vehicle overload sensor now comprises a first set of proximity sensors  14  and a second set of proximity sensors  26 . In other embodiments (not depicted) a plurality of additional pairs of proximity sensors can be added in a horizontal relationship to the existing proximity sensors. In this second embodiment of the instant invention, as the cargo weight increases toward an overloaded operational state, the first set of proximity sensors  14  are activated as the suspension deflects and the first set of proximity sensors  14  come into alignment with brackets  18  in the manner previously described herein. At this intermediate state, a proximity sensor warning alerts the operator that the vehicle load is approximating the overload state. If additional cargo weight is added to the vehicle, the second set of proximity sensors  26  come into alignment with brackets  18  in the manner previously described herein as the suspension continues to deflect and the cargo weight achieves an overloaded operational state. Such an overloaded functional state is depicted in  FIG. 8  and  FIG. 9 . 
         [0039]    With respect to each embodiment of the instant invention, when either proximity sensors  14  or, if applicable, second set of proximity sensors  26  come into alignment with brackets  18 , a signal may, according to a preferred embodiment, trigger the vehicle&#39;s horn to sound as to warn a user that the weight of the cargo equals or exceeds a predetermined value. In another embodiment of the instant invention, a separate horn or other alarm may be used in place of the vehicle&#39;s horn. As an advantage of systems using contact switches to achieve the same ends, sensor  10  is inexpensive, durable and readily available. 
         [0040]    Additionally, according to another embodiment of the instant invention depicted on  FIG. 10 , if the cargo in a vehicle is disproportionately loaded on either the right or the left side of the vehicle, it is possible that the weight of the cargo would be in excess of a pre-established weight maximum relative to the other side of the vehicle. In such a circumstance, a separate signal is sent by sensor  10  in order to alert a user to the differential balance. In another embodiment of the instant invention, the disproportionate load alarm will be identical to the alarm sounded when the maximum cargo load is achieved. In another embodiment, sensor  10  sends a signal to a cabin-mounted display that alerts a drive to configurations indicating disproportionately loaded cargo and, separately, a maximum cargo load weight and, optionally, an intermediate cargo weight. 
         [0041]    As well, according to another embodiment of the instant invention depicted in  FIG. 11 , in one side of a vehicle overload sensor apparatus  10  a proximity sensor  14  mounted on body  16  of the vehicle is disposed in a position that is horizontal with respect to axle housing  12 . As the payload of the vehicle increases, horizontally disposed sensor  14  deflects downward toward similarly horizontally disposed member  18 . At the time that member  18  is within the nominal range of sensor  18 , sensor  18  is triggered indicating an overload situation to the operator; however, to insure that sensor  14  cannot come into contact with member  18  so as to be damaged, a bump stop  28  is shown mounted to the bottommost member of vehicle body  16 , having a width that in contacting axle housing  12  prevents contact between sensor  14  and member  18 . One skilled in the art can easily implement this apparatus on each side of the vehicle, preventing damage to sensors  14  mounted on each side of that body  16  of such a vehicle. 
         [0042]    Another embodiment of the invention is shown in FIG. 12  in which a vehicle load warning apparatus and range of payload indicator system  10  is depicted that is based on the combination of a multiplicity of proximity sensors  14 . In this preferred embodiment, a first set of proximity sensors  14 , a second set of proximity sensors  26 , and a third set of proximity sensors  30 , are mounted in a vertical alignment on each side of body  16  of the vehicle. As the cargo weight increases, the first set of proximity sensors  14  are activated as the suspension deflects and the first set of proximity sensors  14  come into alignment with brackets  18  in the manner previously described herein. At this intermediate state, a proximity sensor warning alerts the operator that the vehicle load has moved into a new payload stage as previously determined by the characteristics of the vehicle. If additional cargo weight is added to the vehicle, the second set of proximity sensors  26  come into alignment with bracket members  18  in the manner previously described herein as the suspension continues to deflect and the cargo weight achieves a second range of payload state, and similarly, as one skilled in the art can appreciate, as payload increases further the third set of proximity sensors  30  come within the nominal range of members  18 , thereby warning the operator that vehicle has reached its greatest payload stage. According to another embodiment, it can be appreciated that one having ordinary skill in the art can adapt a fourth or more proximity sensors of the type herein described in successive vertical alignment with one another according to the method herein described in order to create additional intermediary alarms. 
         [0043]    In a preferred embodiment, sensor  10  permits proximity sensors  14  to come into a detectable distance from brackets  18  for a period of time before triggering a signal. The signal is transmitted if and only if the detectable distance is maintained for at least as long as the predetermined time. In so doing, certain false positives due to, for example, a bumpy road, would not trigger the signals referred to herein. 
         [0044]    In one embodiment of the instant invention, vehicle overload sensor  10  operates in the manner herein described regardless of whether the vehicle is in park, neutral, drive or reverse. In another embodiment of the instant invention, vehicle overload sensor  10  would only operate in the manner herein described when the vehicle is stationary (i.e. in park or neutral).