Electric Air Brake Modulation for Pickup-Towed Trailers
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Solution Overview
Problem
Medium and heavy-duty trailers with air brakes require air pressure from the towing vehicle, which is not typically provided by standard pickup trucks, making it difficult for these vehicles to tow trailers with air brakes effectively.
Innovation Solution
A system that uses a proportional electrical braking signal from the towing vehicle to control the air brakes on the trailer through an electrically actuated valve, which releases air at a controlled rate, allowing the trailer to mimic the braking force of the towing vehicle, even without pneumatic connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If standard pickup trucks are used to tow trailers with air brakes, then the towing vehicle can transport the trailer, but the vehicle cannot provide the required air pressure to control the air brakes
Solution Approach 1:
The patent introduces an intermediary device - an electrically actuated valve - that converts electrical signals from the pickup truck's existing brake controller into controlled air pressure releases. This mediator bridges the gap between the electrical braking system of the pickup truck and the pneumatic braking system of the trailer, enabling compatibility without requiring the truck to have native air brake capabilities.
Solution Approach 2:
The invention replaces the missing pneumatic supply system in the pickup truck with an electrically controlled pneumatic release system. Instead of providing continuous air pressure through a pneumatic line from the truck, the system uses electrical signals to trigger controlled air releases from the trailer's own supply tank, substituting the mechanical/pneumatic supply function with an electrical control mechanism.
2Reliability
If pickup trucks are equipped with complex pneumatic components to supply air to trailers, then air brake control becomes possible, but the device complexity and cost increase significantly
Solution Approach 1:
The patent extracts the air supply function from the towing vehicle and places it on the trailer itself. The trailer is equipped with its own air compressor and supply tank, eliminating the need for the pickup truck to have complex pneumatic supply components. Only simple electrically actuated release valves are needed on the trailer to dispense air when required.
Solution Approach 2:
The trailer becomes self-sufficient by carrying its own air compressor and supply tank, generating and storing its own air supply without relying on the towing vehicle's pneumatic system. The trailer's braking system serves itself by using its own stored air pressure, controlled by electrically actuated valves that respond to signals from the pickup truck's brake controller.
3Force
If air is released from the supply tank at high pressure, then braking force is sufficient, but the risk of uncontrolled braking and safety hazards increases
Solution Approach 1:
The patent employs dynamically controllable electrically actuated valves that can modulate the rate of air pressure release in real-time. These valves respond to the proportional braking signals from the pickup truck's brake controller, adjusting the air flow rate to match the required braking force while preventing uncontrolled or excessive pressure releases. The system transitions from static high-pressure storage to dynamic controlled delivery.
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
Enables pickup trucks to safely tow trailers with air brakes by converting standard electrical braking signals into controlled air pressure, eliminating the need for complex pneumatic components and ensuring reliable braking performance.
Implementation Method 1
An electrically actuated valve is in fluid communication with the supply tank and the air brake. The electrically actuated valve is for releasing air from the supply tank at a controlled rate.
Implementation Method 2
The spring brake is in a released state when compressed air is applied to it.
Implementation Method 3
A release valve is in fluid communication with the supply tank and has an energized state corresponding to the release valve receiving electrical current and a non-energized state in the absence of electrical current.
Data Source
AI summary
A system for electrically controlling air brakes on a trailer having an electrically actuated valve for releasing pressurized air at a controlled rate. The trailer is connectable to a standard electrical connector on a towing vehicle that provides a proportional braking signal. The proportional signal is sent to a controller that actuates the electrically actuated valve. When the controller receives the proportional braking signal from the towing vehicle representing no braking force, the controller actuates the electrically actuated valve to produce no air pressure to the air brake. When the controller receives the proportional braking signal from the towing vehicle representing full braking force, the controller actuates the electrically actuated valve to provide air to the air brake corresponding to full braking force of the air brakes.