Vehicle anti-lock brake systems assembly verification system

A process for testing an antilock brake system for a mobile vehicle, the vehicle having at least two axles with at least two wheels per axle, each wheel on an opposite end of the axle, each wheel having an actuating fluid brake cylinder which when actuating fluid is applied will apply braking force to the associated wheel, each brake cylinder having a supply of actuating fluid through a hold valve and a decay valve, each hold valve being inline with the supply of actuating fluid such that when the hold valve is closed actuating fluid is denied to the associated brake cylinder thereby preventing braking force on the associated wheel, each decay valve being engaged to the brake cylinder such that actuation of the decay valve will cause actuating fluid to be bled off of the associated brake cylinder thereby removing braking force on the associated wheel, an antilock brake electronic control module for controlling operation of the hold valves and decay valves, each wheel having a radial speed sensor for detecting radial speed of the wheels, each radial speed sensor providing a wheel speed signal to the antilock brake electronic control module, the antilock brake electronic control module capable of detecting wheel lock up from the radial speed sensors and capable of adjusting braking force on the associated wheel to remove a detected wheel lockup condition, and the vehicle having an internal electronic network to which the antilock brake electronic control module is engaged, comprising the steps of:

• engaging a testing unit to the internal electronic network of the vehicle;
• verifying that the internal electronic network is electrically active and communication between the testing unit and the antilock brake electronic control module;
• comparing a system configuration from the antilock brake electronic control module with an expected antilock brake configuration for the vehicle for a match, passing the antilock brake configuration test if the actual matches the expected, and failing the configuration test if the actual does not match the expected;
• querying the antilock brake electronic control module for any electronic control module firmware self identified faults;
• alternatively activating a pair of independent rollers to which each wheel of an axle to be tested rest upon, measuring wheel speed for each rotated wheel through the radial speed sensor for the wheel and communicated to the testing unit through the antilock brake electronic control module, passing each wheel speed test if wheel speed is within a preset wheel speed range, and failing each wheel speed test if each wheel is not within the preset wheel speed range;
• alternatively activating the rollers, measuring rolling resistance of each rolled wheel through the roller for that wheel, passing each wheel for the rolling resistance test if measured resistance is under a preset rolling resistance range, and failing each wheel for the rolling resistance test if rolling resistance is at or above the preset rolling resistance range;
• alternatively cycling the hold and decay valves for each wheel with the brakes applied, measuring antilock brake actuating fluid pressure to verify operation of each hold and decay valve;
• storing results of tests;
• and
• disengaging the testing unit from the internal electronic network of the vehicle.

A process for testing an antilock brake system for a mobile vehicle, comprising the steps of:

• using a testing unit engaged to an internal electronic network of a vehicle, verifying the network active and communication between the testing unit and an antilock brake electronic control module of the vehicle, passing if network active and communications open;
• comparing an antilock brake configuration detected from the electronic control module with an expected configuration from a data management system to which the testing unit is in communication with, passing if configuration comparison is a match;
• querying the electronic control module for any electronic control module manufacturer program detecting self identified faults, passing if no self identified faults;
• alternatively activating rollers to which each wheel for each axle to be tested are engaged to rotate the wheels, measuring wheel speed from on-vehicle sensors engaged to the electronic control module, passing if the detected speed for each wheel is within a preset range;
• continuing wheel rotation, measuring each wheels resistance against turning, passing if the resistance for each wheel is under a preset resistance limit;
• alternatively cycling antilock brake modulating valves for each wheel with brakes applied, measuring brake actuating fluid pressure to verify operation of each valve, passing if measured pressures for each valve operation are within expected pressure ranges for the specific combination of valve position and brake applied condition;
• and
• measuring brake force for each wheel as a function of resistance against the rollers turning the wheels being tested, comparing the individual brake force to a preset minimum value and comparing brake force between wheels on same axle, passing if brake force each wheel tested above minimum and if differential force between wheels of the same axle are below a maximum preset differential value.

A testing system for testing an antilock brake system for a mobile vehicle, the vehicle having at least two axles with at least two wheels per axle, each wheel on an opposite end of the axle, each wheel having an actuating fluid brake cylinder which when actuating fluid is applied will apply braking force to the associated wheel, each brake cylinder having a supply of actuating fluid, an antilock brake electronic control module for controlling operation of modulating valves to control the pressure of the actuating fluid at the individual brake cylinders, each wheel having a radial speed sensor for detecting radial speed of the wheels, each radial speed sensor providing a wheel speed signal to the antilock brake electronic control module, the antilock brake electronic control module capable of detecting wheel lock up from the radial speed sensors and capable of adjusting braking force on the associated wheel to remove a detected wheel lockup condition, and the vehicle having an internal electronic network to which the antilock brake electronic control module is engaged, comprising:

• a testing unit for electrical engagement to the internal electronic network of the vehicle;
• said testing unit in communication with a data management system;
• a pair rollers for rotating opposite wheels on an axle of the vehicle to be tested, said rollers being controlled by said testing unit through said data management system;
• said testing unit capable of detecting whether the electronic network of the vehicle is active and whether communication is possible with the antilock brake electronic control module;
• said testing unit capable of detecting the specific vehicle identification number and of querying said data management system with the vehicle identification number to determine an expect antilock brake system configuration;
• said testing unit capable of querying the antilock brake electronic control module for an antilock brake system configuration and comparing the expected configuration with the configuration from the electronic control module;
• said testing unit capable of querying the antilock brake electronic control module for any electronic control module firmware self identified faults;
• a driver prompt sign controlled by said testing unit through said data management system for querying the driver of vehicle status and giving direction to the driver as to when to apply and when to release a brake pedal of the vehicle;
• said testing unit capable of receiving vehicle wheel speed unit through the antilock brake electronic control module and said testing unit capable of comparing the wheel speed with an expected speed from the data management system and determining if wheel speed is as expected during a test;
• said rollers capable of measuring wheel resistance against turning to provide an indication of either free movement of a vehicle wheel and braking force on a wheel, and said roller capable of providing wheel resistance information to the testing unit;
• and
• said testing unit capable of directing operation of the antilock brake modulating valves through the antilock brake electronic control module along with directions to a driver of the vehicle through driver prompt sign as far as when to apply the brakes of the vehicle, said testing unit capable of receiving actuating fluid pressure indications from the antilock brake electronic control module and comparing the pressure indication with expected parameters for the particular modulator valve operations.

A testing system for testing an antilock brake system for a mobile vehicle, the vehicle having at least two axles with at least two wheels per axle, each wheel on an opposite end of the axle, each wheel having an actuating fluid brake cylinder which when actuating fluid is applied will apply braking force to the associated wheel, each brake cylinder having a supply of actuating fluid, an antilock brake electronic control module for controlling operation of modulating valves to control the pressure of the actuating fluid at the individual brake cylinders, each wheel having a radial speed sensor for detecting radial speed of the wheels, each radial speed sensor providing a wheel speed signal to the antilock brake electronic control module, the antilock brake electronic control module capable of detecting wheel lock up from the radial speed sensors and capable of adjusting braking force on the associated wheel to remove a detected wheel lockup condition, and the vehicle having an internal electronic network to which the antilock brake electronic control module is engaged, comprising:

• a testing unit for electrical engagement to the internal electronic network of the vehicle;
• said testing unit in communication with a data management system;
• a pair rollers for rotating opposite wheels on an axle of the vehicle to be tested, said rollers being controlled by said data management system;
• said data management system capable through said testing unit of detecting whether the electronic network of the vehicle is active and whether communication is possible with the antilock brake electronic control module;
• said data management system capable through said testing unit of detecting the specific vehicle identification number and of querying said data management system with the vehicle identification number to determine an expect antilock brake system configuration;
• said data management system capable through said testing unit of querying the antilock brake electronic control module for an antilock brake system configuration and comparing the expected configuration with the configuration from the electronic control module;
• said data management system capable through said testing unit of querying the antilock brake electronic control module for any electronic control module firmware self identified faults;
• a driver prompt sign controlled by said testing unit through said data management system for querying the driver of vehicle status and giving direction to the driver as to when to apply and when to release a brake pedal of the vehicle;
• said data management system capable through said testing unit of receiving vehicle wheel speed unit through the antilock brake electronic control module and said testing unit capable of comparing the wheel speed with an expected speed from the data management system and determining if wheel speed is as expected during a test;
• said rollers capable of measuring wheel resistance against turning to provide an indication of either free movement of a vehicle wheel and braking force on a wheel, and said roller capable of providing wheel resistance information to said data management system capable through said testing unit;
• and
• said data management system capable through said testing unit of directing operation of the antilock brake modulating valves through the antilock brake electronic control module along with directions to a driver of the vehicle through driver prompt sign as far as when to apply the brakes of the vehicle, said testing unit capable of receiving actuating fluid pressure indications from the antilock brake electronic control module and comparing the pressure indication with expected parameters for the particular modulator valve operations.

A portable testing unit for monitoring and testing components on a mobile vehicle, comprising:

• a portable computer with a communication connector for plugging in to a vehicle internal electronic network through plug-in outlet on the vehicle;
• an interface unit in-series with said portable computer to vehicle communication connector;
• a vehicle power supply line through said plug-in connector running in parallel to said communication connector, said power supply line having an in-series power converter which converts vehicle electrical system voltage power to a voltage acceptable to energize and operate said portable computer;
• a battery for said portable computer capable of being charged through said vehicle power supply line, said battery capable of energizing and operating said portable computer when said computer is operated in a stand-alone mode;
• a scanner electrically engaged to said portable computer through a scanner communication connector, said scanner capable of reading a bar code on a vehicle corresponding to the vehicle identification number of the vehicle, and said scanner capable of providing the vehicle identification number to the portable computer;
• said computer capable of correlating the vehicle identification number with stored data relating to vehicle component configuration;
• and
• a scanner power connector connected in between said portable computer and said scanner in parallel with said scanner communication connector, said scanner power connector providing electrical energy needs of said scanner directly from said portable computer.

A computer program product for use with a computer which may communicate with an internal electronic network of a mobile vehicle and with a data management system and components for verifying assembly of an antilock braking system of the vehicle, said computer program product comprising:

• a computer useable medium having computer readable program code means embodied in said medium for causing the computer in communication with an internal electronic network of a vehicle to verify the network is active and that there is communication between the computer and an antilock brake electronic control module of the vehicle, and causing the computer to record a passing result if the network is active and there is communication with the antilock brake electronic control module, otherwise causing the computer to record a failing result;
• computer readable program means for causing the computer to compare an antilock brake configuration detected from the antilock brake electronic control module with an expected configuration from a data management system to which the computer is in communication, and causing the computer record a passing result if the configuration comparison is a match, otherwise causing the computer to record a failing result;
• computer readable program means for causing the computer to query the antilock brake electronic control module for any electronic control module manufacturer program detecting self identified faults, and causing the computer to record a passing result if there are no self identified faults, otherwise causing the computer to record a failing result;
• computer readable program means for causing the computer to alternatively activate rollers to which each wheel for each axle to be tested are engaged to rotate the wheels, causing the computer to query and receive measured wheel speed from on-vehicle sensors engaged to the electronic control module, and causing the computer to record a passing result if the detected speed for each wheel is within a preset speed range, otherwise causing the computer to record a failing result;
• computer readable program means for causing the computer to direct the roller to continue wheel rotation, causing the computer to query and receive measured each wheels resistance against turning from the rollers, and causing the computer to record a passing result if the resistance for each wheel is under a preset resistance limit, otherwise causing the computer to record a failing result;
• computer readable program means for causing the computer to direct the antilock brake electronic control module to alternatively cycle antilock brake modulating valves for each wheel with brakes applied, measuring brake actuating fluid pressure to verify operation of each valve, and causing the computer to record a passing result if measured pressures for each valve operation are within expected pressure ranges for the specific combination of valve position and brake applied condition, otherwise causing the computer to record a failing result;
• and
• computer readable program means for causing the computer to query and receive measured brake force for each wheel as a function of resistance against the rollers turning the wheels being tested, causing the computer to compare the individual brake force to a preset minimum value and causing the computer to compare brake force between wheels on same axle, and causing the computer to record a passing result if brake force on each wheel tested is above minimum, otherwise to record a failing result and causing the computer to record a passing result if differential force between wheels of the same axle is below a maximum preset differential value, otherwise to record a failing result.

A computer program product for use with a computer which may communicate with an internal electronic network of a mobile vehicle and with a data management system and components for verifying assembly of an antilock braking system of the vehicle, the vehicle having at least two axles with at least two wheels per axle, each wheel on an opposite end of the axle, each wheel having an actuating fluid brake cylinder which when actuating fluid is applied will apply braking force to the associated wheel, each brake cylinder having a supply of actuating fluid through a hold valve and a decay valve, each hold valve being inline with the supply of actuating fluid such that when the hold valve is closed actuating fluid is denied to the associated brake cylinder thereby preventing braking force on the associated wheel, each decay valve being engaged to the brake cylinder such that actuation of the decay valve will cause actuating fluid to be bled off of the associated brake cylinder thereby removing braking force on the associated wheel, an antilock brake electronic control module for controlling operation of the hold valves and decay valves, each wheel having a radial speed sensor for detecting radial speed of the wheels, each radial speed sensor providing a wheel speed signal to the antilock brake electronic control module, the antilock brake electronic control module capable of detecting wheel lock up from the radial speed sensors and capable of adjusting braking force on the associated wheel to remove a detected wheel lockup condition, and the vehicle having an internal electronic network to which the antilock brake electronic control module is engaged, said computer program product comprising:

• a computer useable medium having computer readable program code means embodied in said medium for causing the computer in communication with the internal electronic network of a vehicle to verify that the internal electronic network is electrically active, and causing the computer to record a passing result for the network active test if active, and causing the computer to record a failing result for the network active test if not active;
• computer readable program means for causing the computer to verify communication through between the computer and the antilock brake electronic module, passing the communication test if open communication is found, and failing the communication test if no communication between the computer and the antilock brake electronic module;
• computer readable program means for causing the computer to identify the vehicle by vehicle identification number using a bar code reader engaged to the computer;
• computer readable program means for causing the computer to query a data management system in communication with the computer as to an expected antilock brake configuration for the vehicle;
• computer readable program means for causing the computer to query the antilock brake electronic control module for system configuration;
• computer readable program means for causing the computer to compare the system configuration from the antilock brake electronic control module with the expected antilock brake configuration for a match, causing the computer to record a passing result for the antilock brake configuration test if the actual matches the expected, and causing the computer to record a failing result for the configuration test if the actual does not match the expected;
• computer readable program means for causing the computer to query the antilock brake electronic control module for existence of any electronic control module firmware self identified faults, causing the computer to record a passing result if no firmware self identified faults, and causing the computer to record a failing result if there are firmware self identified faults;
• computer readable program means for causing the computer to query and receive from a driver of the vehicle which axle of the vehicle is aligned to a pair of independent rollers with one wheel on each roller to identify the axle to be tested;
• computer readable program means for causing the computer to activate one of the rollers to roll a first rotated wheel of the axle to be tested;
• computer readable program means for causing the computer to query and receive measured wheel speed for the rotated wheel through the radial speed sensor for the first rotated wheel and communicated to the computer through the antilock brake electronic control module, causing the computer to record a passing result for the first wheel speed test if wheel speed within a preset wheel speed range, and causing the computer to record a failing result for the first wheel speed test if not within the preset wheel speed range;
• computer readable program means for causing the computer to query and receive measured rolling resistance of the first rolled wheel through the roller for that wheel, causing the computer to record a passing result for the first wheel rolling resistance test if under a preset rolling resistance range, and causing the computer to record a failing result for the first wheel rolling resistance test if rolling resistance is at or above the preset rolling resistance range;
• computer readable program means for causing the computer to activate a second roller of the rollers to roll a second wheel of the axle to be tested;
• computer readable program means for causing the computer to query and receive measured wheel speed for the rotated wheel through the radial speed sensor for the second rotated wheel and communicated to the computer through the antilock brake electronic control module, causing the computer to record a passing result for the second wheel speed test if wheel speed within the preset wheel speed range, and causing the computer to record a failing result for the second wheel speed test if not within the preset wheel speed range;
• computer readable program means for causing the computer to query and receive measured rolling resistance of the second rolled wheel through the roller for that wheel, causing the computer to record a passing result for the second wheel rolling resistance test if under a preset rolling resistance range, and causing the computer to record a failing result for the second wheel rolling resistance test if rolling resistance is at or above the preset rolling resistance range;
• computer readable program means for causing the computer to direct the closure of the hold valve for the second wheel of the axle to be tested;
• computer readable program means for causing the computer to direct the driver of the vehicle to apply the brakes of the vehicle and causing the computer to query and receive measured actuating pressure downstream of the first wheel hold solenoid, causing the computer to record a passing result for the second wheel hold valve test if actuating fluid pressure is within a preset pressure range around the last value, and causing the computer to record a failing result for the second wheel hold valve test if actuating fluid pressure is out of the preset pressure range;
• computer readable program means for causing the computer to direct the driver to release the brakes of the vehicle;
• computer readable program means for causing the computer to direct the opening of the second wheel hold valve;
• computer readable program means for causing the computer to direct the closure of the first wheel hold valve for the first wheel of the axle to be tested;
• computer readable program means for causing the computer to direct the driver to apply the brakes of the vehicle and causing the computer to query and receive measured actuating fluid pressure downstream of the first wheel hold solenoid, causing the computer to record a passing result for the first wheel hold valve test if actuating fluid pressure is within a preset pressure range around the last value, and causing the computer to record a failing result for the first wheel hold valve test if actuating fluid pressure is out of the preset pressure range;
• computer readable program means for causing the computer to direct the opening of the first wheel hold valve;
• computer readable program means for causing the computer to query and receive measured individual wheel brake force applied using the rollers for each wheel to measure resistance force;
• computer readable program means for causing the computer to compare the measured first wheel brake force to a preset minimum brake force limit, causing the computer to record a passing result for the first wheel brake force test if the measured first wheel brake force is greater than the preset minimum brake force limit, and causing the computer to record a failing result for the first wheel brake force test if the measured first wheel brake force is less than or equal to the preset minimum brake force limit;
• computer readable program means for causing the computer to compare the measured second wheel brake force to a preset minimum brake force limit, causing the computer to record a passing result for the second wheel brake force test if the measured second wheel brake force is greater than the preset minimum brake force limit, and causing the computer to record a failing result for the second wheel brake force test if the measured second wheel brake force is less than or equal to the preset minimum brake force limit;
• computer readable program means for causing the computer to compare the measured first wheel brake force with the measure second wheel brake force to determine a differential brake force from the first wheel to the second wheel, causing the computer to record a passing result for the brake force wheel differential test if the differential is under a preset brake force differential limit, and causing the computer to record a failing result for the brake force wheel differential test if the differential is at or above the preset brake force differential limit;
• computer readable program means for causing the computer to direct the opening of the second wheel decay valve for the second wheel of the axle to be tested and causing the computer to query and receive measured actuating fluid pressure for the actuating fluid cylinder for the second wheel, causing the computer to record a passing result for the second wheel decay valve test if actuating fluid pressure is below a preset decay valve pressure limit, and causing the computer to record a failing result for the second wheel decay valve test if actuating fluid pressure is at or above the preset decay valve pressure limit;
• computer readable program means for causing the computer to direct closure of the second wheel decay valve;
• computer readable program means for causing the computer to direct the opening of the first wheel decay valve for the first wheel of the axle to be tested and causing the computer to query and receive measured actuating fluid pressure for the actuating fluid cylinder for the first wheel, causing the computer to record a passing result for the first wheel decay valve test if actuating fluid pressure is below a preset decay valve pressure limit, and causing the computer to record a failing result for the first wheel decay valve test if actuating fluid pressure is at or above the preset decay valve pressure limit;
• computer readable program means for causing the computer to direct closure of the first wheel decay valve;
• computer readable program means for causing the computer to direct the driver to release the brakes of the vehicle;
• and
• computer readable program means for causing the computer to store results of tests.