Trailer Axle Strain Gauge Mounting for Automatic Brake Proportioning
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Solution Overview
Problem
Current systems require significant user intervention to properly proportion trailer brakes based on loading conditions, leading to potential over-braking, wheel lockup, and unstable conditions due to incorrect brake settings for varying loads.
Innovation Solution
A vehicle weight sensing system with a strain gauge assembly mounted to an axle tube, which generates a signal used by the braking system to dynamically adjust brake proportion based on the trailer's weight, ensuring optimal braking performance across different loading conditions without user intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual brake proportioning is used, then device complexity is reduced, but braking performance reliability deteriorates due to user error and inability to adapt to different loading conditions
Solution Approach 1:
The system automatically senses trailer weight through strain gauges on the axle and proportionally adjusts brake gain without user intervention. The microprocessor continuously monitors weight and dynamically adjusts brake proportioning, eliminating the need for manual setup while ensuring reliable braking performance across all loading conditions.
Solution Approach 2:
The system changes the brake gain parameter dynamically based on detected weight. The microprocessor adjusts the proportional gain of the brakes as a variable parameter响应 to weight changes, transitioning from fixed manual proportioning to adaptive automatic proportioning that optimizes braking for each loading condition.
2Reliability
If automatic weight sensing and dynamic brake proportioning is implemented, then braking performance reliability is improved, but device complexity increases due to additional sensors and control systems
Solution Approach 1:
The strain gauge system serves multiple functions: it detects axle weight, determines loading conditions, and provides input for brake proportioning control. The microprocessor integrates weight sensing, signal processing, and brake control functions into a single control unit, reducing overall system complexity despite adding automatic proportioning capabilities.
Solution Approach 2:
The strain gauge acts as an intermediary that converts mechanical weight into an electrical signal that the microprocessor can process. This intermediary component enables automatic weight detection without requiring complex mechanical linkages or direct mechanical connection between the axle and brake control system.
3Volume of moving object
If strain gauge is positioned close to the mounting surface for compactness, then device compactness is improved, but measurement precision deteriorates due to reduced strain detection capability
Solution Approach 1:
The strain gauge is positioned on the vertical face of the mounting block rather than on the top surface, utilizing a different spatial dimension. This vertical positioning maintains compact horizontal footprint while achieving optimal strain detection by placing the gauge at a distance from the mounting surface that maximizes strain sensitivity.
Solution Approach 2:
The mounting block features a specifically designed geometry with a vertical face at an optimized distance from the mounting surface. This local structural feature creates an area of concentrated strain on the vertical face, allowing the strain gauge to detect maximum strain in a compact configuration. The notch in the mounting block further concentrates strain in specific regions to enhance measurement precision.
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 system ensures proper brake proportioning automatically, preventing over-braking and wheel lockup by continuously optimizing braking performance based on the trailer's instantaneous weight, enhancing safety and stability.
Implementation Method 1
A strain gauge assembly has a body including raised pads near opposite ends of the body. A thinned section is located between the raised pads. The thinned section of the body includes a strain gauge affixed thereto.
Data Source
AI summary
A vehicle weight sensing system particularly useful for trailers. An axle tube is mounted to the vehicle or trailer through its suspension members that may be leaf springs. A mounting block is affixed to the axle tube for mounting a strain gauge. The mounting block is fixed to the axle tube between the suspension members connected to the axle tube. The mounting block has a mounting surface opposite to the mating surface and a notch extends from the mating surface toward the mounting surface. The notch terminates between the mating surface and the mounting surface. The notch separates rigidified sections of the mounting block and the rigidified sections straddle the notch. The stain gauge measures strain in the axle and thereby generates a signal proportional to the weight on the trailer. The signal can be used to properly proportion a brake system on the trailer.