FIELD OF THE INVENTION This invention relates to a vehicle brake performance testing apparatus and a method of testing a vehicle brake system. More particularly, but not exclusively, this invention relates to static testing of brake systems of trackless mobile mining equipment according to SANS 1589 and ISO 3450 standards. BACKGROUND TO THE INVENTION

It is well known for trackless mobile mining equipment to be used in mines all over the world, in both surface and underground applications. Due to the nature of the mining environment, it is required for these vehicles to move up and down declines to access work places, transport ore to processing plants, and the like. These declines can be as steep as about 15°.

An inherent risk at all of these operations is the occurrence of a runaway vehicle where, for whatever reason, a brake failure occurs and the vehicle then speeds out of control down a decline, often with devastating consequences. Runaway vehicles are known to cause severe injuries or even kill operators and bring about severe damage to the environment and equipment.

In South Africa, the brake systems of vehicles for underground applications are regulated by SANS 1589: The braking performance or trackless mobile mining vehicles, and the brake systems of vehicles for surface applications are regulated by ISO 3450: Earth-moving machinery - Wheeled or high-speed rubber-tracked machines - Performance requirements and test procedures for brake systems. Both of these standards allow for dynamic brake performance testing where the test vehicle must be declared fit depending on the brake efficiency of the vehicle, as measured. The dynamic test, however, must be performed with full load and sometimes results in severe damage to the brake system of the test vehicle. The above prevailing standards also make provision for a static brake performance pull test whereby the different braking systems of a vehicle, i.e. service, park and emergency brake systems, are tested with a known value dependant on the operational gradients plus 4 degrees and/or a maximum gradient of 20 degrees inclination. This test is currently done at most mining operations by means of a ramp test. These ramp tests are in fact principally flawed as the test is dependent on the operator correctly performing the test. Also, ramp test results are typically inaccurate and are not recorded in a legally acceptable manner as the results are manually recorded and are thus open to manipulation and fraud by the operator and/or a third party.

A further problem, especially in open cast mines, is that the standard for dump-trucks over 30 tons specifies the service brake to be tested at 20% inclination and the park/emergency brake at 15% inclination. Some of the commercials dump trucks park/emergency brakes can only do 15.5% inclination resulting in the need for two brake test ramps, which is impractical. OBJECT OF THE INVENTION

It is accordingly an object of the present invention to provide a vehicle brake performance testing apparatus and a method of testing a vehicle brake system that will, at least partially, alleviate the abovementioned problems and/or to provide a vehicle brake performance testing apparatus and a method of testing a vehicle brake system that will be a useful alternative to known apparatuses and methods of this kind.

SUMMARY OF THE INVENTION

According to a first aspect of the invention, there is provided a brake performance testing apparatus for a test vehicle, the apparatus comprising:

- a force exerting mechanism securable at a location remote from the test vehicle and connectable to the test vehicle in order to exert a force on the test vehicle in order to test a brake system thereof; and

- automatic vehicle identification means for automatically identifying the test vehicle.

There is further provided for the apparatus to include force measuring means for measuring the magnitude of the exerted force.

Preferably, the force measuring means may be in the form of a load cell.

The exerted force may be a pulling force. The force exerting mechanism may be in the form of a winch system.

The winch system may include:

- a drive shaft;

- a motor that is connected to the drive shaft for rotating the shaft; and

- an elongate flexible pulling member that is connected to the drive shaft and connectable to the test vehicle.

A gearbox may be provided in-between the drive shaft and motor in order to facilitate slow rotation of the drive shaft so to not induce shock loads on the test vehicle.

According to an example embodiment of the invention, the vehicle identification means may include a first camera that is orientated to capture a first image of the test vehicle. Alternatively, the vehicle identification means may include an electronic reader for reading identification data of the test vehicle.

The identification data may include an identification signal transmitted from the test vehicle and/or an optical representation of data carried by the test vehicle.

There is also provided for the apparatus to include operator identification means for identifying an operator of the apparatus. According to an example embodiment of the invention, the operator identification means may include a second camera that is orientated to capture a second image of the operator. Alternatively, the operator identification means may include a biometric reader for reading biometric data of the operator.

Further alternatively, the operator identification means may include an operator input for receiving data relating to the operator as entered by the operator.

The apparatus may further include control means being configured to generate test data including any one or more of:

- the identity of the test vehicle;

- the magnitude of the exerted force;

- an indication of whether the test vehicle passed or failed the test;

- the date and/or time on which the test is performed;

- the identity of an operator that is involved with the test; and

- the state of wear of the brakes. According to a second aspect of the invention, there is provided a method of testing a vehicle brake system including the steps of:

- connecting a brake performance testing apparatus to a test vehicle;

- exerting a force on the test vehicle in order to test a brake system thereof; and

- automatically identifying the test vehicle. The method may also include the step of measuring the magnitude of the exerted force.

The exerted force may be a pulling force.

Preferably, the test vehicle may be identified at any one or more of immediately before, during and immediately after the force is exerted.

According to an example embodiment of the invention, the test vehicle may be identified by capturing a first image thereof.

Alternatively, the test vehicle may be identified by reading identification data of the test vehicle. The identification data may include an identification signal transmitted from the test vehicle and/or an optical representation of data carried by the test vehicle.

There is also provided for an operator involved with the test to be identified. The operator may be identified by any one or more of:

- capturing a second image of the operator;

- reading data relating to the operator; and

- reading biometric data of the operator. The method may further include the step of generating test data including any one or more of:

- the identity of the test vehicle;

- the magnitude of the exerted force;

- an indication of whether the test vehicle passed or failed the test;

- the date and/or time on which the test is performed;

- the identity of an operator that is involved with the test; and

- the state of wear of the brakes. According to some example embodiments of the invention, the test data may be transmitted to at least one preselected address. The address may be any one or more of an email address, memory address and telephone number.

These and other features of the invention are described in more detail below.

BRIEF DESCRIPTION OF THE ACCOMPANYING DIAGRAMS

One embodiment of the invention is described below, by way of a non-limiting example only and with reference to the accompanying diagrams in which:

Figure 1 is a first front perspective view of a vehicle brake performance testing apparatus in accordance with the invention;

Figure 2 is a second front perspective view of the apparatus of figure 1 ; Figure 3 is a top view of the apparatus of figure 1 ;

Figure 4 is a side view of the apparatus of figure 1 ; Figure 5 is a high-level block diagram illustrating the apparatus of figure 1 in communication with a backend; and

Figure 6 is a flow diagram illustrating a method of testing a vehicle brake system in accordance with the invention.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the figures, a brake performance testing apparatus for a test vehicle (not shown) in accordance with the invention is generally indicated by reference numeral 10 in figures 1 to 5, and a method of testing a vehicle brake system is generally indicated by reference numeral 100 in figure 6.

The apparatus 10 includes a force exerting mechanism 12 securable at a location remote from the test vehicle and connectable to the test vehicle in order to exert a force A on the test vehicle in order to test a brake system thereof, such as its service, park and/or emergency brake systems. Automatic vehicle identification means 14 is also provided for automatically identifying the test vehicle.

In an example embodiment of the apparatus 10, a base 15 is provided and the force exerting mechanism 12 is in the form of a winch system 12 which is preferably electrically operated and mounted on the base 15. The winch system 12 is arranged to exert a pulling force A (shown in figures 3 and 4) on the test vehicle to test its brake system. As is best shown in figures 2 and 3, force measuring means 16, in the form of a load cell 16, is provided for measuring the magnitude of the exerted force A.

The winch system 12 includes a drive shaft 18, an electrically-operated motor 20 that is connected to the drive shaft 18 for rotating it, and an elongate flexible pulling member, in the form of a pulling chain 22, that is connected to the drive shaft 18 and connectable to the test vehicle. The chain 22 is preferably an ultra-high tensile chain.

At a first end 24 thereof, the chain 22 is secured to the base 15, and intermediate the first end 24 and opposite second end (not shown) thereof, the chain 22 connects to a sprocket 26 that is mounted on the shaft 18 so to be rotatable with the shaft 18. The shaft 18 is retained in position by means of a pair of bearings 28 secured in opposing sides of a sprocket housing 30. The chain 22 is reeled over the sprocket 26 in such a manner that, when opening the housing 30, the length of chain 22 between its first end 24 and the sprocket 26 can be adjusted with ease.

The chain 22 is routed through a snatch block 32 which is connectable to the test vehicle in a conventional manner. As shown, the snatch block 32 includes a hook 33.

A gearbox 34 is provided in-between the drive shaft 18 and motor 20 in order to facilitate slow rotation of the drive shaft 18 so to not induce shock loads on the test vehicle when a test of its brake system is initiated. The gearbox 34 is, like the motor 20, secured to the base 15 and forms part of the winch system 12. A torque arm 36 is attached to the drive shaft 18 and arranged such to, in use, and as a result of rotation of the drive shaft 18, push against the load cell 16 that is positioned on the base 15, whereby the pulling force A is measured as a reaction force on the load cell 16.

The vehicle identification means 14 is preferably in the form of a first camera 14 that is orientated to capture a first image of the test vehicle, to thereby automatically identify the test vehicle. The test vehicle is thus identified in a legally acceptable manner that does not depend on an operator identifying the vehicle. The identification means is hence arranged to gather identification data directly from the vehicle. It is envisaged that in other embodiments of the invention, the vehicle identification means could comprise an electronic reader for reading identification data of the test vehicle. The identification data may comprise an identification signal transmitted from the test vehicle - for example by means of an RFID tag that is fitted to the vehicle - and/or an optical representation of data carried by the test vehicle such as, for example, an image including a code.

The apparatus 10 further includes operator identification means 38 (shown in figure 5 and discussed below) for identifying a user or operator of the apparatus 10. The operator identification means 38 may comprise automatic operator identification means that does not require the operator to enter his or her details, including a second camera (not shown), or a biometric reader (not shown) for reading biometric data of the operator. Further alternatively, the operator identification means 38 may comprise data relating to the operator as entered by the operator via an industrial keyboard 50, screen (display) 52 and/or other input device 53, as is best shown in figure 1 . For example, the data relating to the operator, may comprise a username, employee number or code, name, surname, and/or password. The apparatus 10 also includes anchoring means 40 for anchoring the base 15 firmly in position at the location being remote from the vehicle. According to this example embodiment of the invention, the anchoring means 40 includes a plurality of bolts 40 which are anchored into the ground, for example into a concrete slab floor (not shown) provided for this purpose. Alternatively, or in addition, one or more elongate anchoring members (not shown) may be provided, in the form of, for example an anchoring chain, that is securable to the base 15 in order to retain the apparatus 10 in position.

A storage compartment 46 also is provided on the base 15 for storing, amongst others, the chain 22, snatch block 32 and/or anchoring chain (if applicable) during transportation of the apparatus 10.

As is best shown in figure 2, the first camera 14 is located in an operator stand 48 and orientated to capture a first image of the test vehicle to thereby identify the test vehicle. Referring to figure 5, the apparatus 10 further includes control means 64 for controlling operation of the apparatus 10. Preferably, the control means 64 is in the form of a local controller 64 that is located inside the operator stand 48. Amongst others, the local controller 64 is configured to perform any one or more of the following:

- receive input instructions from the operator of the apparatus 10 via the keyboard 50, screen 52 and/or input device 53; - receive, evaluate and/or store identification data from the first camera 14;

- receive, evaluate and/or store operator identification data;

- control the operation of the winch system 12;

- control the operation of the first camera 14;

- receive, evaluate and/or store data from the winch system 14;

- receive, evaluate and/or store data from the load cell 16;

- provide feedback to the operator via screen 52, light (not shown) and/or speaker (not shown);

- generate a notification including test data including any one or more of:

o the identity of the test vehicle;

o the identity of the operator involved with the test;

o the location where the test is performed;

o the date and/or time on which the test is performed;

o the magnitude of the exerted force A;

o the state of wear of the vehicle's brakes; and

o an indication of whether the test vehicle passed or failed the test; and

- cause the test data to be stored locally and/or transmitted to a remote location.

In use, the operator identifies the test vehicle and records the particulars of the test vehicle onto the apparatus 10, including the location where the test is performed, the make and/or model of the test vehicle and details of the operator of the apparatus 10. Once the information is entered, the control means 64, from pre-stored data, accordingly determines the pulling force A that is to be exerted on the test vehicle. The test vehicle is then connected to the apparatus 10 by means of the snatch block 32 and a first image is captured of the test vehicle by the first camera 14. The vehicle's service brake is applied and held (with the test vehicle's engine running) where after the required pulling force A is exerted by the winch system 12, upon being instructed by the operator. The local controller 64 receives its input instructions from the operator through the industrial keyboard 50, screen 52 and/or other input device 53 and accordingly controls the operation of the motor 20 and first camera 14 by activating the motor 20, through a variable speed drive, in order to exert the pulling force A, and by activating the first camera 14.

The force A applied to the motor 20 is measured against the pre-set data. When the two values equate, the force A applied by the motor 20 is released from the winch system 12 and the data received from the load cell 16 is recorded and stored into a memory arrangement 68 (test data is accordingly stored into a memory address of the memory arrangement 68 for every test as will be discussed in further detail below). If the pre-set load is not reached the test vehicle failed the test, a visual indication is provided to the operator, the test is halted and a communication is transmitted to a third party, preferably a supervisor.

If the vehicle successfully passed the first test, the neutral brake is applied (with the engine running) whilst the required pulling force A is exerted by the winch system 12. If test vehicle failed the test, a visual indication is provided to the operator, the test is halted and a communication is transmitted to a third party, preferably a supervisor. If the test vehicle passed the second test, the park brake is applied (with the test vehicle's engine off and the driver of the vehicle not being in the test vehicle) whilst the required pulling force A is exerted by the winch system 12. The load A is released from the winch system 12 and the data received from the load cell 16 is recorded. If the test vehicle failed the test, a visual indication is provided to the operator, the test is halted and a communication is transmitted to a third party, preferably a supervisor.

After completion of each of the aforementioned tests a 10% overload test is done and the actual force exerted A reached is recorded. This value is used for trending purposes to determine the degradation of the brakes.

The first camera 14 could capture images of the test vehicle at the different stages during the testing process, i.e. immediately before, during and/or immediately after the pulling forces A are exerted.

If the test vehicle passed the third test, the brake test is successfully completed, all data is downloaded and a report is generated by the control means 64. User identification means 38 (shown in figure 5) such as, but not limited to biometric identification means may be provided for identifying the operator of the apparatus 10. The report includes, amongst others, the following test data and identification information:

- make and/or model of the test vehicle;

- weight of the test vehicle;

- identification number of the vehicle;

- magnitude of the pulling force A of the test; - result of the test(s);

- date the test was performed;

- location where the test was performed;

- details of the operator that performed the test such as data relating to the identity of the operator; and

- at least one image of the test vehicle.

After completion of the test, the test report can be downloaded via a port 55 such as a USB interface for printing at a later stage. Alternatively, a report of the test may be transmitted to a backend 62 (shown in figure 5) as will be described in more detail below.

In figure 5 is shown a high-level block diagram, illustrating the apparatus 10 in communications via a communications path 60 with a backend 62, for example by means of the Internet, local network, or the like. The communications path 60 could be wireless, wired and a combination of the aforegoing. The local controller 64 comprises a processor 66 connected to the memory arrangement 68. The screen 52 is connected to the controller 64 in known manner. The user identification means 38 and vehicle identification means 14 are also in communication with the local controller 64. To provide communications between the apparatus 10 and the backend 62, a transmitter 72 (such as a modem) is provided. In some embodiments, the transmitter 72 could be a transceiver. Backend 62 comprises a server 74, including a database 76 and a backend processor 78. It will be appreciated that, instead of providing the transmitter 72 and communications path 60, the test report may be stored by the local controller 64 into the memory arrangement 68 and later retrieved, for example by means of a physical USB flash drive or the like from port 55 for further analysis.

In figure 6 is shown a flow diagram, illustrating a method 100 of testing a vehicle brake system. At 1 10, the process is started. At 1 12, the vehicle is moved onto a test slab and the brake testing apparatus 10 is connected to the vehicle. At 1 14, data relating to the vehicle is entered into the apparatus 10. At 1 16, a thickness of the vehicle's relevant brake pad is measured, for example with callipers. At 1 18, the brake wear data is evaluated and compared to the Original Equipment Manufacturer (OEM) specification. If the brake wear does not comply to the OEM specification, the test is discontinued at 120 and the responsible person is notified. If the brake wear complies, at 122 the vehicle is put into the relevant gear and a service-brake thereof is tested. This step 122 is performed while the engine is running 124.

At 126, the vehicle brake is tested to the SANS 1589, or other prevailing standard, which test either fails 128, or passes. If this test passes, at 130, a first 10% overload test is performed and data relating to the first overload test is captured by local controller 64. At 132, the vehicle is put into neutral and the vehicle's brake(s) are tested while the engine is running 134.

At 136, the vehicle brake is again tested to the SANS 1589, or other prevailing standard, which test either fails 138, or passes. If this test passes, at 140, a second 10% overload test is performed and data relating to the second overload test is captured by local controller 64. Next, the vehicle is put into park and/or service brake at 142. The engine is switched off at 146 and the operator exits the vehicle.

At 148, the vehicle brake is again tested to the SANS 1589, or other prevailing standard, which test either fails 150, or passes. If this test passes, at 152, a third 10% overload test is performed and data relating to the third overload test is captured. At 154, the test report is generated and automatically stored, which completes the test at 156. At 158, data relating to at least the report is sent to a relevant party (such as a service provider of backend 62) for further processing at 160 (by backend processor 78). An entire fleet of the relevant mine (or other facility) may be analysed and monitored by the apparatus 10 and method 100 as shown at 162. At 164, the relevant party reports back to the responsible person at the mine. It will be appreciated that data relating to the test may be captured by local controller 64 and stored into memory arrangement 68 during every step of the method 100 described above. The data relating to the test may accordingly also be stored by backend processor 78 into the database 76 at backend 62 (or may be sent to an email address). It will further be appreciated that the test vehicle may be a mining vehicle or any other vehicle of which the brake(s) require testing.

It is envisaged that the invention provides a self-contained apparatus 10 and method 100 that with the minimum amount of effort can test and evaluate the brake systems, especially those of trackless mining equipment while recording all data, date stamping the process with photographic evidence of the test and to generate a legally acceptable report.

It will be appreciated by those skilled in the art that the invention is not limited to the precise details as described herein and that many variations are possible without departing from the scope and spirit of the invention. For example, the vehicle identification means may comprise electronic identification means such as Radio- frequency identification. Also, in order for the apparatus 10 to automatically identify the test vehicle, a passive tag may be fitted to the test vehicle and the apparatus 10 could include a receiver for identifying the tag and thus the vehicle when the vehicle is in the proximity of the receiver. The force exerting mechanism 12 may alternatively be in the form of a piston or a rod which is connectable to the electric motor 10, for example via gears. It will further be appreciated that other driving means such as, but not limited to, pneumatic, hydraulic and combustion driving means may be provided instead of the electric motor 20.

The description is presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention.