Trailer Brake Gain Control Using Hitch Load Resistance Estimation
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Solution Overview
Problem
Current methods for setting trailer brake gain require manual adjustments and testing, which can be time-consuming and challenging, especially when operating conditions change, leading to suboptimal braking performance.
Innovation Solution
A system that automatically sets trailer brake gain using sensor data from the vehicle, including hitch load, longitudinal and vertical forces, speed, acceleration, and steering angle, to compute the trailer resistance force and adjust the gain accordingly without driver input or testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual gain setting and testing is used, then the driver can control braking intensity, but the process is time-consuming and requires repeated adjustments
Solution Approach 1:
The system automatically determines optimal brake gain settings by monitoring hitch forces and trailer resistance during normal operation, eliminating the need for manual driver intervention. The processor continuously analyzes sensor data and self-adjusts gain parameters without requiring driver testing or repeated adjustments.
Solution Approach 2:
The system uses real-time feedback from hitch load sensors to monitor actual trailer resistance forces and automatically adjusts brake gain accordingly. The processor compares measured hitch forces with expected values and dynamically modifies gain settings to optimize braking performance under varying conditions.
2Force
If gain is set too high, then braking force is increased, but trailer wheels may lock up during braking
Solution Approach 1:
The system continuously monitors hitch forces during braking events and uses this feedback to dynamically adjust gain settings. By comparing actual hitch force measurements with predicted resistance forces, the system automatically reduces gain when trailer wheels approach lock-up conditions, preventing instability while maintaining effective braking.
Solution Approach 2:
The brake gain setting is transformed from a static manual configuration to a dynamic parameter that automatically adjusts based on real-time operating conditions. The processor modifies gain levels continuously during operation, adapting to changing trailer resistance, speed, and braking intensity to maintain optimal control.
3Reliability
If gain is set too low, then trailer braking effectiveness is reduced, but the towing vehicle's brakes must do more work
Solution Approach 1:
The system uses hitch force feedback to determine when increased braking force is needed. When the processor detects that the trailer requires more braking contribution to achieve optimal stopping distance, it automatically increases gain settings, allowing the trailer brakes to share the workload effectively without compromising stability.
Solution Approach 2:
The system dynamically changes the brake gain parameter based on measured trailer resistance and operating conditions. By adjusting this key parameter in real-time, the system optimizes the division of braking effort between the towing vehicle and trailer, improving stopping distance performance while maintaining control stability.
4Adaptability or versatility
If automatic gain scaling is implemented, then continuous optimal control is achieved, but the system complexity increases
Solution Approach 1:
The processor leverages existing vehicle sensors (hitch load sensors, speed sensors, acceleration sensors) already present in modern vehicles, making them serve dual purposes: monitoring vehicle dynamics and determining trailer braking requirements. This approach achieves automatic gain scaling without adding dedicated specialized hardware.
Solution Approach 2:
The system uses hitch forces as an intermediary measurement to indirectly determine trailer resistance and optimal brake gain. Rather than directly measuring trailer braking requirements, the system monitors the forces transmitted through the hitch connection, providing a reliable proxy that simplifies the control algorithm.
Data Source
AI summary
Methods and systems automatically scale and set trailer brake gain without a need for vehicle driver input and without testing. Scaling a trailer brake gain of a trailer towed by a vehicle includes obtaining sensor data via one or more sensors of the vehicle, including from a hitch load sensor. A processor computes a trailer resistance force of the trailer based on the sensor data. The processor automatically updates the trailer brake gain based on both the sensor data and the trailer resistance force.