Brake Controller Orientation Insensitivity via Multi-Axis Inertial Sensing
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Solution Overview
Problem
Existing brake controllers for towed vehicles are sensitive to lateral acceleration and require specific mounting orientations, leading to inaccurate braking force measurement due to artefacts like noise, gravity, centripetal acceleration, and acceleration from pitch and roll, which complicates the calculation of deceleration and braking force.
Innovation Solution
A brake controller with a multi-axis inertial sensor and processor that uses feedback algorithms for calibration and validation to determine the forward direction vector, reducing the effects of lateral acceleration and artefacts, allowing for mounting in an undefined orientation and generating a braking control signal insensitive to vehicle orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If an accelerometer is used to measure vehicle braking force, then the braking force measurement is simplified, but the measurement becomes sensitive to lateral acceleration and mounting orientation due to artefacts like noise, gravity, and centripetal acceleration
Solution Approach 1:
The patent transitions from single-axis acceleration measurement to multi-axis (3D) acceleration measurement. By measuring acceleration components in three orthogonal directions and using vector mathematics to compute the magnitude of the total acceleration vector, the system eliminates sensitivity to mounting orientation and lateral acceleration artifacts, accurately capturing only the longitudinal braking deceleration.
Solution Approach 2:
The system incorporates feedback algorithms that continuously process accelerometer data to distinguish between longitudinal braking deceleration and lateral acceleration artifacts. The feedback mechanism uses the relationship between brake controller output and measured acceleration to validate and calibrate the deceleration measurement, reducing sensitivity to mounting variations and environmental artifacts.
2Adaptability or versatility
If the brake controller is designed to be insensitive to mounting orientation, then installation flexibility is improved, but the system becomes more complex requiring multi-axis sensors and feedback algorithms
Solution Approach 1:
The patent employs multi-axis accelerometers that measure acceleration in three orthogonal directions simultaneously. By computing the magnitude of the total acceleration vector and using vector projection techniques, the system achieves mounting orientation insensitivity. The mathematical processing transforms complex 3D sensor data into accurate longitudinal deceleration measurements regardless of how the sensor is mounted on the vehicle.
3Measurement precision
If existing compensation algorithms are used to eliminate components not in the horizontal plane, then gravity compensation is improved, but the system remains sensitive to lateral acceleration and horizontal components of artefacts
Solution Approach 1:
The patent moves beyond 2D horizontal plane compensation to full 3D vector analysis. By measuring and processing acceleration components in all three orthogonal directions and computing the magnitude of the total acceleration vector, the system simultaneously compensates for gravity, lateral acceleration, and other artifacts in a unified mathematical framework, achieving accurate longitudinal deceleration measurement without remaining sensitivity to lateral movements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables accurate calculation of deceleration and braking force in a forward direction, reducing sensitivity to lateral acceleration and artefacts, thus providing a more reliable and flexible braking system for towed vehicles.
Implementation Method 1
an inertial sensor including plural sensor axes adapted to be mounted in an undefined orientation relative to said longitudinal axis for generating sensor data associated with each sensor axis
Data Source
AI summary
A brake controller is disclosed for a towed vehicle braking system. The controller is adapted to be mounted in a towing or a towed vehicle having a longitudinal axis for generating a braking control signal to the towed vehicle braking system. The controller comprises an inertial sensor including plural sensor axes adapted to be mounted in an undefined orientation relative to the longitudinal axis for generating sensor data associated with each sensor axis. The controller also comprises a memory device for storing the sensor data associated with each sensor axis and a processor for processing the sensor data with the braking control signal to evaluate orientation of the inertial sensor relative to the longitudinal axis. In particular the brake controller is adapted to control activation of the towed vehicle braking system in a manner that is relatively insensitive to acceleration of the vehicle in a lateral direction and to orientation of the inertial sensor without prescribing a mounting orientation of the brake controller relative to the towing or towed vehicle. A method of operating a brake controller for a towed vehicle braking system is also disclosed.