Fault-Tolerant Trailer Brake Actuator Controller
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Solution Overview
Problem
Existing trailer braking systems lack fault tolerance, diagnostic capabilities, and integration with tow vehicle systems, leading to issues such as tire flat spots, trailer sway, and inadequate braking performance during heavy braking or degraded connections.
Innovation Solution
A trailer brake actuator controller that supports fault-tolerant operations, provides diagnostic functionality, and integrates with tow vehicle systems through serial communications, enabling individual wheel speed control and varying braking levels to maintain directional control and deceleration rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If existing trailer braking systems use standardized 7 pin connectors with limited diagnostics, then ease of operation is improved, but reliability deteriorates due to inability to detect degraded connections or brake faults
Solution Approach 1:
The patent implements feedback mechanisms where the brake controller continuously monitors electrical parameters (voltage, current, resistance) through the brake wire connection and provides real-time diagnostic information about connection quality and brake system status, enabling detection of degraded connections while maintaining standardized connector compatibility
Solution Approach 2:
The patent uses the existing brake wire as an intermediary communication channel, transmitting both braking control signals and diagnostic data through the standardized 7 pin connector, thereby adding reliability monitoring capabilities without requiring separate communication hardware
2Ease of operation
If existing systems apply braking pulses to all brakes uniformly, then ease of operation is improved, but reliability deteriorates during sway events or when individual brakes fail
Solution Approach 1:
The patent segments the braking control by enabling independent monitoring and control of individual brakes or brake groups, allowing the system to isolate and disable only faulted brakes while maintaining operation of healthy brakes, thereby improving reliability without complicating the overall braking operation
Solution Approach 2:
The patent implements dynamic braking control where the system adapts braking pulse distribution in real-time based on detected conditions such as sway events or individual brake faults, transitioning from uniform braking to differentiated braking strategies as needed
3Object-affected harmful factors
If existing ABS controllers release brakes when wheel speed drops below threshold, then tire flat spots are reduced, but directional control deteriorates during heavy braking
Solution Approach 1:
The patent applies local quality by allowing different wheels to have different brake release characteristics based on their individual speed measurements and load conditions, enabling precise control of each brake to prevent flat spots while maintaining overall directional stability through coordinated braking
4Device complexity
If existing systems perform limited braking diagnostics, then device complexity is reduced, but reliability deteriorates due to inability to detect brake wire degradation or mechanical brake faults
Solution Approach 1:
The patent implements self-service diagnostics where the brake controller automatically monitors its own operational parameters including electrical connections, brake actuator responses, and wheel speed sensor functionality, providing reliability monitoring without requiring external diagnostic equipment or increasing system complexity
Data Source
AI summary
A system and method of controlling individual trailer brakes on a towed trailer supporting numerous fault tolerant behaviors including activating each operational brake when a brake is shorted. System operates in multiple modes where it operates with traditional brake controllers, operates in a degraded braking mode without a brake controller and in the preferred mode it retrieves vehicle information from tow vehicle and then communicates with a brake actuator controller over the trailer brake wire. When braking system includes wheel sensors traditional antilock releases are provided and unlike other braking systems this brake actuator controller can maintain wheel speeds below the trailer speed reducing or eliminating periodic wheel releases. System also diagnoses the mechanical operation of the trailer brakes including; identifying when brake adjustment is required, when brake friction surfaces are degrading, as well as diagnosing sensors, braking signals and brake actuator interfaces.