Trailer Brake Control Unit with Wheel Speed Sensors
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Solution Overview
Problem
Current trailer brake systems require manual adjustment by the driver based on trailer weight, road conditions, and weather, leading to potential overworking of tow vehicle brakes or risk of over-braking when adjustments are not made correctly.
Innovation Solution
A trailer brake system incorporating a sensor system with wheel speed sensors and a brake control unit that communicates with the tow vehicle to automatically determine hydraulic pressure for each wheel, enabling anti-lock braking, electronic stability control, and hill-start/hill-hold assist functions, eliminating the need for driver adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual brake controller adjustment is used, then the system is simple and easy to operate, but the reliability deteriorates due to potential overworking of tow vehicle brakes or over-braking when adjustments are not made correctly
Solution Approach 1:
The brake control system automatically adjusts brake controller gain based on real-time sensor data about trailer weight and braking conditions, eliminating the need for manual driver adjustment. The system self-regulates by monitoring wheel speed, G-force, and other parameters to maintain optimal brake pressure without human intervention.
Solution Approach 2:
The system continuously monitors braking conditions using sensors that detect wheel speed, trailer weight, and G-force during braking events. This feedback is processed by a microcontroller that automatically adjusts the brake controller gain to optimize braking performance and prevent both over-braking and under-braking conditions.
2Reliability
If automatic sensor-based brake pressure adjustment is implemented, then the reliability and safety are improved, but the device complexity increases due to additional sensors and control units
Solution Approach 1:
The brake control system integrates multiple functions into a single control unit that processes data from various sensors (wheel speed, G-force, weight) and automatically adjusts brake pressure. This multi-functional approach consolidates what could be separate complex systems into one integrated unit, reducing overall system complexity while maintaining high reliability.
Solution Approach 2:
The system replaces manual mechanical adjustment mechanisms with electronic sensing and control. Instead of requiring physical adjustment of brake controller gain, the system uses electronic sensors and a microcontroller to automatically regulate brake pressure, substituting complex mechanical adjustment systems with simpler electronic control.
3Ease of operation
If driver manually adjusts brake gain based on trailer weight, then the system remains simple, but the ease of operation deteriorates due to the need for continuous adjustment based on varying conditions
Solution Approach 1:
The brake control system automatically adjusts brake controller gain based on real-time sensor data about trailer weight and braking conditions, eliminating the need for manual driver adjustment. The system self-regulates by monitoring wheel speed, G-force, and other parameters to maintain optimal brake pressure without human intervention.
4Loss of energy
If the tow vehicle brakes are used to stop both the tow vehicle and trailer, then the system remains simple, but the loss of energy increases due to overworking the tow vehicle brakes
Solution Approach 1:
The brake control system segments the braking function between the tow vehicle and trailer by automatically adjusting the trailer brake activation and pressure. Instead of relying solely on the tow vehicle brakes to stop both vehicles, the system independently controls trailer brake application based on real-time conditions, distributing the braking workload and reducing energy loss in the tow vehicle brakes.
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
This system ensures safer towing by automatically adjusting brake pressure based on real-time sensor data, preventing wheel lockup and trailer instability, and reducing strain on tow vehicle brakes.
Implementation Method 1
The sensor system includes at least one wheel speed sensor associated with each wheel of the trailer
Implementation Method 2
a hydraulic pump supported by the trailer and configured to apply pressure by way of a brake line to a brake associated with each one of the wheels when receiving a brake signal
Data Source
AI summary
The disclosure provides a trailer brake system that includes a sensor system and a brake control unit. The sensor system is supported by a trailer and includes at least one wheel speed sensor associated with each wheel of the trailer. The brake control unit is supported by the trailer and is in communication with a tow vehicle configured to tow the trailer. The brake control unit is configured to: receive sensor data from the sensor system, and receive a brake signal from the tow vehicle indicative of a driver pressing a brake pedal of the tow vehicle. The brake control unit is also configured to: determine, for each brake, a hydraulic pressure based on the sensor data and the brake signal; and apply pressure by way of brake lines to the brake associated with each wheel, based on the hydraulic pressure.