Towed Vehicle Brake Handoff Using Dummy Load Feedback
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Solution Overview
Problem
Primary brake controllers in towed vehicle braking systems often enter failsafe or shutdown modes when secondary brake controllers activate, unnecessarily disabling features due to lack of feedback on brake actuator connection.
Innovation Solution
A secondary brake control system that includes a dummy load and signal processor to emulate brake actuator connection to the primary brake controller, allowing seamless switching between control configurations and modifying primary brake control signals to prevent failsafe triggers, enabling simultaneous use of features from both controllers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a secondary brake controller is activated to improve braking control features, then braking control capability is improved, but the primary brake controller enters failsafe mode due to lack of feedback signals
Solution Approach 1:
The patent introduces a dummy load as an intermediary component that mediates between the secondary brake controller and the primary brake controller. The dummy load receives brake control signals from the primary controller and provides feedback signals back to it, allowing the secondary controller to activate and improve braking control while preventing the primary controller from entering failsafe mode due to missing feedback.
Solution Approach 2:
The dummy load creates a copy or simulation of the expected electrical feedback signal that would normally be provided by the brake actuators to the primary brake controller. This copied signal maintains the primary controller's operational state even when the secondary controller is actively controlling the brakes, resolving the contradiction between improved control capability and system reliability.
2Reliability
If the primary brake controller requires feedback from brake actuators to maintain operation, then system reliability is improved, but activation of secondary brake controller causes unnecessary shutdown due to feedback interruption
Solution Approach 1:
The dummy load serves as an intermediary that bridges the feedback gap created by secondary controller activation. It intercepts the brake control signals, provides the necessary feedback to the primary controller to maintain its operational state, while allowing the secondary controller to freely activate and control the brake actuators without causing unnecessary shutdowns.
3Reliability
If a dummy load is connected to emulate brake actuator connection, then primary brake controller reliability is improved, but system complexity increases due to additional components and switching mechanisms
Solution Approach 1:
The dummy load is designed with multi-functionality to reduce overall system complexity. It simultaneously provides feedback signals to the primary brake controller, receives brake control signals from it, and can be switched into or out of the circuit as needed. This universal component performs multiple functions that would otherwise require separate components, thereby managing system complexity while maintaining reliability.
4Ease of operation
If seamless switching between primary and secondary brake control is implemented, then ease of operation is improved, but device complexity increases due to switching mechanisms
Solution Approach 1:
The dummy load acts as an intermediary that facilitates seamless switching between primary and secondary brake controllers. By providing a continuous feedback path to the primary controller regardless of which controller is actively driving the brake actuators, it enables smooth handoffs without requiring complex interlocking switching mechanisms or state management logic.
Data Source
AI summary
A system and method for configuring and controlling towed vehicle brakes via a secondary brake control system controlled by a towing vehicle primary brake controller by responding to events or errors through adoption of different structural configurations and modes of operation so that it may adapt to use different blends of input from the primary brake controller and/or a secondary brake controller of the secondary braking control system, while preventing the use of the secondary braking controller from causing errors or failsafe mode activation of the primary brake controller. Signals from the primary brake controller may be modified before they reach braking actuators of the towed vehicle, and/or the primary braking controller may be completely disconnected from the braking actuators while a dummy load simulate feedback that the primary controller needs to receive from the brake actuators.