Trailer Brake Current Control Under Low Battery Conditions
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Solution Overview
Problem
Trailers equipped with automatic brake systems often face issues where the trailer battery is at a low state of charge, leading to excessive current draw from the towing vehicle's 12V power supply, which can result in blown fuses due to the electromechanical braking system's high current demand exceeding available capacity.
Innovation Solution
A braking current management system comprising a battery health module that determines the available current from both the trailer and towing vehicle batteries, generating a signal to control the trailer brake control module, which adjusts the brake pressure build rate and current application to maintain current draw within safe limits, preventing fuse overload.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electromechanical braking system draws current from the towing vehicle's 12V power supply when the trailer battery is low, then the braking system can operate, but the current draw exceeds the power supply capacity causing blown fuses
Solution Approach 1:
The braking system dynamically adjusts its current draw based on the available power from the towing vehicle's battery. The control module monitors battery state of charge and modulates the electromechanical brake actuator operation to match available power capacity, preventing fuse overload while maintaining braking functionality.
Solution Approach 2:
The system changes operational parameters of the braking system based on power availability. When the towing vehicle's battery state of charge is low, the system reduces current draw by adjusting brake actuator duty cycle and pressure build rate, thereby preventing electrical system overload while maintaining adequate braking performance.
2Productivity
If the trailer brake control system operates at full power demand, then optimal braking performance is achieved, but the current draw exceeds available current from the 12V supply circuit
Solution Approach 1:
The system applies partial action by operating the electromechanical brake actuator at reduced power levels when the towing vehicle's battery cannot support full power demand. The control module adjusts the duty cycle and pressure build rate to provide adequate braking performance within available electrical constraints, rather than attempting full power operation that would exceed circuit capacity.
Solution Approach 2:
The braking control system continuously monitors the state of charge of the towing vehicle's battery and adjusts its power consumption accordingly. This feedback mechanism allows the system to optimize the balance between braking performance and electrical power consumption, ensuring current draw remains within available supply capacity.
Data Source
AI summary
A braking current management system for use in a towed trailer. The braking current management system comprises a battery health module configured to determine an amount of available battery current associated with the towed trailer and to generate therefrom an available current signal. The system further includes a trailer brake control module configured to receive the available current signal and, in response to the available current signal, to control an amount of current applied to a trailer brake associated with the towed trailer.