CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims the benefit of US provisional Application No. 62/980,043, filed on February 21, 2020, which is hereby incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002] The present invention relates to a nose box for a towable asset, and more particularly, to a smart nose box integrating a telematics transceiver.

BACKGROUND

[0003] The design of the tractor in a tractor-trailer varies depending upon the region but regardless of the design, it is conventional to use a J-560 interface (commonly referred to as a 7-way coupler) on the semi -trailer or other type of towable asset to ease the connection and disconnection of the trailer from the tractor. As implied by the name, a 7-way coupler includes 7 pins or terminals. One pin is for ground. The remaining six pins are conventionally used to drive the tail and running lights, marker lights, the license plate light, an auxiliary circuit such as an anti-lock brake (ABS) unit, the left turn signal, the right turn signal, and the stop lights, respectively.

[0004] The proper functioning of these various lights and circuits is vital for public safety. Various monitors have thus been developed that may wirelessly report the operating status of the lights and circuits in the trailer. But the ease of integration of such monitors is an issue. Similarly, various telematic reporting systems have been developed for the trucking industry. Customers may have thousands of rigs so the costs of retrofitting them to include monitors and telematics must be minimized.

SUMMARY

[0005] A nose box is provided that includes: a housing; a post platform within the housing, the post platform including a first plurality of posts for receiving lamp power signals from a tractor, a second plurality of posts for transmitting the lamp power signals to a towable asset, and an auxiliary post for providing power to an auxiliary circuit in the towable asset; a housing circuit board associated with post platform, the housing circuit board including a plurality of lamp monitoring circuits, a housing circuit board associated with post platform, the housing circuit board including a plurality of lamp monitoring circuits, each lamp monitoring circuit being configured to conduct a current from a respective post from the first plurality of posts to a respective post from the second plurality of posts and to measure the current to determine an operating condition of a respective lamp in the towable asset; and a lid for enclosing an interior of the housing, the lid including an inner cover configured to enclose a battery and a lid circuit board including a telematics transceiver and a power management circuit configured to power the telematics transceiver from the auxiliary post when the auxiliary post has power and to power the telematics transceiver from the battery when the auxiliary post does not have power.

[0006] In addition, a method of operating a nose box is provided that includes: receiving a plurality of lamp power signals at a first plurality of posts; conducting each lamp power signal from a respective post in the first plurality of posts through a respective monitoring circuit to a respective post in the second plurality of posts to measure a voltage and a current of each lamp power signal to determine a status of a plurality of lamps in a towable asset; receiving an auxiliary power signal at an auxiliary power post and distributing the auxiliary power signal from the auxiliary power post to an auxiliary circuit in the towable asset; performing a power line communication with the auxiliary circuit using the auxiliary power signal to obtain a status of the auxiliary circuit; and transmitting the status of the plurality of lamps and the status of the auxiliary circuit through a telematics transceiver to a user.

[0007] Finally, a nose box is provided that includes: a housing including a plurality of lamp terminals and an auxiliary power terminal; a battery; a telematics transceiver; a power management circuit; and a lid for enclosing the plurality of towable asset terminals and the plurality of tractor terminals within the housing, the lid including an inner cover configured to enclose the battery, the telematics transceiver, and the power management circuit, wherein the power management circuit is configured to charge the battery from the auxiliary power terminal while the auxiliary power terminal has power, and wherein the power management circuit is further configured to power the telematics transceiver during an activity period using the battery while the auxiliary power terminal has no power.

[0008] These and additional advantageous features of the disclosed embodiments may be better appreciated through a consideration of the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a perspective view of a smart nose box with its lid closed in accordance with an aspect of the disclosure.

[0010] FIG. 2 is a plan view of a smart nose box with its lid opened in accordance with an aspect of the disclosure.

[0011] FIG. 3A is a perspective exploded view of a post platform and the associated circuit board for a smart nose box in accordance with an aspect of the disclosure.

[0012] FIG. 3B is a perspective view exploded view, partially cut-away, of the trailer side of the post platform and circuit board of FIG. 3A.

[0013] FIG. 4 illustrates a lamp monitoring circuit for the circuit board of FIGs.

3 A and 3B in accordance with an aspect of the disclosure.

[0014] FIG. 5 is a trailer-side perspective exploded view of an inner cover for a smart nose box lid and associated circuitry in accordance with an aspect of the disclosure.

[0015] Embodiments of the present disclosure and their advantages are best understood by referring to the detailed description that follows. It should be appreciated that like reference numerals are used to identify like elements illustrated in one or more of the figures.

DETAIFED DESCRIPTION

[0016] To provide improved monitoring and telematics, a smart nose box is provided that integrates the circuit monitoring, telematics, and a power line communication receiver. The following description will be directed to nose boxes compatible with the Phillips i-Box™ form factor or the Phillips S7™ form factor. However, it will be appreciated that any suitable nose box form factor may benefit from the principles and techniques disclosed herein.

[0017] An example smart nose box 100 that is compatible with the Phillips i- Box™ form factor is shown in FIG. 1. A housing 105 includes J-560 coupler such as a Phillips Quick-Change socket QCS2® 125 that when opened may receive a 7-way coupler from the tractor. As implied by the term “nose,” smart nose box 100 is placed at the front of a trailer. As used herein, the term “trailer” is used generically to refer to a semi-trailer, a chassis, a flat bed, or any other suitable towable asset that may be towed by the tractor and receive the tractor’s 7-way coupler. In that regard, the terms “trailer” and “towable asset” are used interchangeably herein. Housing 105 includes a lid 110 that may be rotated away from housing 105 on an axis 130 to expose an inner surface of lid 110 and an interior of housing 105. Lid 110 may also include a solar panel 120 on its outer surface for recharging of a battery in smart nose box 100 as will be discussed further herein. Housing 105 includes a removable grommet 135 so that a 7-way harness and other leads may exit housing 105 and extend to their trailer destinations.

[0018] Smart nose box 100 is configured to monitor various components 101 in the towable asset such as the ABS module, a tire pressure monitoring system (TPMS) receiver, a tire inflation system, a cargo sensor, a door sensor, and so on. Information regarding the status or signals from these components may be transmitted to a user by a telematics transceiver in smart nose box 100 as will be explained further herein. The status for a monitored component may include whether the component is operative, inoperative, open circuited, short circuited and so on. [0019] Nose box 100 is shown in FIG. 2 with the lid 110 opened away from housing 105 to expose a platform 205 in the interior of housing 105. A 7-way wiring harness 215 is shown that connects between corresponding pins or terminals in the J- 560 coupler 125 and corresponding posts 210 on platform 205. In some embodiments, there are three rows of posts 210. A top row of posts 210 receives the red, black, brown, green, and yellow wires from 7-way wiring harness 215. Each wire connects to a corresponding post 210. As known in the 7-way wiring arts, red is for the brake/stop lights, black is the for the license plate lighting, brown is for the marker lights, green is for the left turn signal light, and yellow is for the right turn signal light. The corresponding lights in the trailer may also be denoted as lamps.

[0020] The top row of posts 210 receives the red, black, brown, green, and yellow wires from 7-way wiring harness 215. The red, black, brown, green, and yellow wires from a trailer 7-way wiring harness (not illustrated) connect to the bottom row of posts 210. The top row of posts 210 may thus be denoted as the upstream (tractor-side) posts whereas the bottom row of posts 210 may be denoted as the downstream (trailer- side) posts. This separation between upstream and downstream posts on the circuit board 205 is quite advantageous with regard to the monitoring of the corresponding lamps as will be further discussed herein.

[0021] 7-way wiring harness 215 also includes aground wire (which is typically colored white) that connects to a ground post 220. Platform 205 may include two ground posts 220 that are shorted to each other through a ground strap or plate 225. In addition, 7-way wiring harness 215 includes a blue wire that couples to an auxiliary post

230 on platform 205 for powering an auxiliary circuit within the trailer. Each of posts

210, 220, and 230 may be threaded so that a wire fitting may be connected to the post by a nut or fastener that is screwed down on the threads. The blue wire in the 7-way wiring harness 215 as well as the corresponding blue wire in the trailer’s 7-way wiring harness both share auxiliary post 230. This is advantageous with regard to an accurate monitoring of the brake lights as will be explained further herein.

[0022] A housing circuit board 305 is affixed to a back side of platform 205 as shown in the exploded view of FIG. 3A. Housing circuit board 305 includes a circular aperture 310 for each of posts 230, 210, and 220. Each circuit aperture 310 is surrounded by a conductive ring 315 on housing circuit board 305. Platform 205 and housing circuit board 305 are shown in FIG. 3 A from the perspective of the tractor. This side of the housing circuit board 305 may be denoted as the front side whereas a back side faces the trailer. A partially cut-away exploded view of the back side of housing circuit board 305 and platform 205 from the perspective of the trailer is shown in FIG. 3B. It may thus be seen that the posts extend through platform 205 to project from the backside of platform 205 and include threaded bores 325. A screw 320 for each post extends from the backside of housing circuit board 305 through an aperture 310 to be received in the post’s threaded bore 325. As also seen in FIG. 3B, the backside of housing circuit board 305 may also include a conductive ring 315 surrounding each aperture 310. The resulting fastening of circuit board 305 to posts 210, 230, and 220 (FIG. 3A) is quite advantageous in that no soldering is necessary. Despite the lack of soldering, circuitry on both the front and back sides of housing circuit board 315 can electrically couple to each post through a circuit board contact to the corresponding conductive ring 315. Note that conductive rings 315 may be placed on just one circuit board surface around an aperture 310 in alternate embodiments as vias may be used that conduct from one side of the housing circuit board surface to another to allow circuitry on both sides of the housing circuit board to electrically couple to the conductive ring 315 and thus to the corresponding post. Note that the post platform 205 is configured to seal housing circuit board 205 within housing 105 to protect housing circuit board 205 from the elements.

[0023] The electrical coupling to each post is advantageous with regard to monitoring the lamps using circuitry on housing circuit board 305. For example, consider a monitoring circuit 400 as shown in FIG. 4 that couples between a tractor- side conductive ring 315 (corresponding to one of the posts 210 in the top row of the posts in FIG. 2) to a trailer-side conductive ring 315 (corresponding to one of the posts 210 in the bottom row of the posts). Each monitoring circuit 400 would be integrated onto either the front side or the back side of housing circuit board 305. In monitoring circuit 400, each of the corresponding posts 210 would correspond to the same lamp. There would thus be a monitoring circuit 400 between the red wire posts 210 for the brake lights, another for the marker lights between the brown wire posts 210, and so on for the remaining lamps. Each monitoring circuit 400 includes a switch such as an NMOS transistor Ml that is upstream of a current sense circuit 405 and a voltage monitor 415. Current sense circuit 405 may be a Hall sensor or may be a sense resistor. In addition, monitoring circuit 400 includes a fuse such as an e-fuse 410 to protect the trailer lamp from excessive currents.

[0024] A controller such as a microcontroller (MCU) 420 on housing circuit board 305 determines the health of the lamp being driven by monitoring circuit 400 by monitoring the sensed voltage and the sensed current. Should the MCU 420 detect that the voltage is too low, a problem is detected with regard to the power signal coming from the trailer. On the other hand, if the voltage is normal (typically 12 V) but the current is too low, either the corresponding lamp is malfunctioning or broken. MCU 420 may then report the health of the corresponding lamp to a user using a telematics transceiver in lid 105 as will be explained further herein.

[0025] Referring again to FIG. 2, note that the auxiliary post 230 is used to power an auxiliary circuit in the trailer such as an anti -lock-brake (ABS) module. The current draw of such a module is variable depending upon the mode of the ABS module. Housing circuit board 305 thus does not need a monitoring circuit 400 for auxiliary post 230 such that there is no need for a trailer-side auxiliary post 230 and a tractor-side auxiliary post 230. But hosing circuit board 305 may include a voltage monitor to verify whether the auxiliary post 230 is receiving the proper voltage from the tractor (e.g., 12 V).

[0026] To provide extra robustness for powering an ABS module, it is known to power the ABS module through both the trailer’s blue wire and its red wire. In this fashion, if the auxiliary power from the tractor is absent such as due to a blown fuse, the ABS module will still be powered every time the brakes are applied from the resulting powering of the trailer’s red wire. To accommodate this practice, the trailer-side red post in the top row of posts as shown in FIG. 2 also couples to a wire 250 that ends in a coupler 260. A tractor-side wire (not illustrated) couples to coupler 260 and extends through grommet 135 to provide back-up power to the ABS module. Note that wire 250 does not couple to the trailer-side red post 210 because such a coupling would corrupt the current measurement by the monitoring circuit 400 for the brake lights should the ABS module draw power from the trailer’s red wire instead of from the trailer’s blue wire. [0027] The voltage of auxiliary post 230 and the voltage/current health of the lamps as monitored by monitoring circuits 400 may be reported by MCU 420 may drive a data cable 140 that couples to a corresponding data cable 140 that is received by a telematics unit in lid 110. Various other data signals may also be propagated through data cables 140 and 145. A power and ground cable 150 couples from housing circuit board 305 to a coupler to drive a corresponding power and ground cable for the telematics unit in lid 110.

[0028] A trailer-side exploded view of an inner cover 505 for lid 110 is shown in FIG. 5. To allow the reporting of telematics while the trailer is disconnected from a tractor, inner cover 510 supports a rechargeable battery 510 (e.g., a lithium-ion battery). A lid circuit board 520 is attached to inner cover 510 and includes a telematics transceiver 525. Any suitable wireless technology may be used for telematics transceiver 525 including cellular or WiFi. A cellular telematics transceiver 525 is particularly convenient due to the omnipresence of cellular coverage at virtually all warehouse locations and also due to the range of a cellular connection. The following discussion will thus assume that telematics transceiver 525 is a cellular transceiver.

[0029] To conserve power, the default mode of telematics transceiver 525 is a sleep mode in which telematics transceiver 525 is powered down. Telematics transceiver 525 may be scheduled to periodically wake-up and check for commands from a user such as delivered over the internet (the “cloud”) and then through a cellular connection to telematics transceiver 525. In addition, telematics transceiver 525 may be scheduled to periodically wake up to transmit data through the cellular link and through the cloud to a user. One form of data to report may be the position of the trailer such as determined through a GPS receiver 535 that is also integrated onto lid circuit board 520. In addition, lid circuit board 520 may include a local networking transceiver such as a Bluetooth transceiver 530 to receive data from Bluetooth-enabled sensors on the trailer. The trailer may include additional sensors and circuits that communicate with a controller (e.g., a MCU) 540 on lid circuit board 520.

[0030] With regard to this communication, platform 205 includes a center row of posts 270. A pair of posts 270 connect through housing circuit board 305 and data cables 150 and 155 to MCU 540. MCU 540 is configured to support a Control Area Network (CAN) bus transceiver for this pair of posts 270. A CAN bus routed from the trailer through grommet 135 may then be wired to this pair of posts 270 to couple to CAN-bus-enabled sensors in the trailer. Another pair of posts 270 may correspond to a RS 485 bus that is also routed to appropriate sensors in the trailer. The CAN bus and the 485 bus is also routed through data cables 150 and 155 to MCU 540. In this fashion, a wide variety of sensors in the trailer may be networked to MCU 540. For example, the TPMS receiver, a cargo sensor, a door sensor, a weight sensor, and so on may be networked to MCU 540. Other sensors may be networked to MCU 540 through a Bluetooth connection with Bluetooth transceiver 530.

[0031] In addition to the coupling through the CAN and proprietary buses for receiving data and sensor status, the trailer’s auxiliary lead may be used to transmit data and commands using a power line communications (PUC) module 515. For example, the ABS module may report error conditions over the auxiliary lead to auxiliary post

230. Circuit board 305 receives auxiliary post 230 in a corresponding conductive ring

315 so that the auxiliary post PUC signaling may be coupled over data cables 150 and

155 to PUC module 515. PUC module 515 decodes the PUC signaling to provide the data to MCU 540 so that it may then be transmitted by the telematics transceiver 525 to a user in the cloud. Conversely, MCU 540 may transmit a query to PLC module 515 that is then translated to the PLC protocol and transmitted through data cables 150 and 155, circuit board 305, auxiliary post 230 and its corresponding ring 315 to the auxiliary lead in the trailer. The query may be a command to the ABS module to provide a status.

[0032] Regardless of the type of buses and whether PLC module 515 is included, note the advantages of the battery 510. Even with the trailer disconnected from the tractor’s 7-way coupler or connected but with the auxiliary lead (the blue wire) in the tractor’s 7-way coupler without power, telematics transceiver 525 may periodically wake up for an activity period to either listen for commands from a user such as downloaded from the cloud over a cellular link to the telematics transceiver 525 or to periodically wake up and provide a GPS location.

[0033] Lid circuit board 520 also contains a power management circuit 545. When auxiliary post 230 has power, power management circuit 545 is configured to use auxiliary post power from auxiliary post 230 as routed through the corresponding conductive ring 315, housing circuit board 305, and power cables 140 and 145 to power management circuit 545 to power the remaining electronics on. Since the auxiliary post voltage is 12 V, power management circuit 545 may include a DC-DC switching power converter such as a buck converter to convert the 12 V into a lower, more suitable DC power supply voltage for the lid electronics.

[0034] Since the telematics is integrated into lid 110, a user may retrofit a conventional nose box with lid 110 should the user not desire the monitoring of the lamps as discussed with regard to circuit board 305 in housing 105. A conventional nose box housing may merely have the posts for a 7-way cabling to the trailer lamps and auxiliary circuit. Since there would be no circuit board 305 in such a conventional nose box house, data cable 155 may couple to an adapter to the blue (auxiliary) and ground posts within the housing.

[0035] As those of some skill in this art will by now appreciate and depending on the particular application at hand, many modifications, substitutions and variations can be made in and to the materials, apparatus, configurations and methods of use of the devices of the present disclosure without departing from the scope thereof. In light of this, the scope of the present disclosure should not be limited to that of the particular embodiments illustrated and described herein, as they are merely by way of some examples thereof, but rather, should be fully commensurate with that of the claims appended hereafter and their functional equivalents.