Trailer Brake Controller Diagnostics With Independent High-Side Drivers

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Existing brake control units lack integral diagnostic capabilities to identify faults or shorts within their electrical systems and often fail to communicate errors to the towing vehicle's instrument panel, leading to unsafe towing conditions due to sway and potential loss of control.

Innovation Solution

A brake control unit with a processor and drivers that generate independent braking signals and diagnose faults by processing feedback signals, integrated with the towing vehicle's systems to provide diagnostic information and fault location, allowing seamless integration and communication with existing vehicle systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If brake control units are designed as aftermarket non-integral systems, then installation flexibility is improved, but communication capability with the towing vehicle's instrument panel deteriorates

Engineering Contradiction:
Improveinstallation flexibilityVSAvoiderror communication capability
Core Design Contradiction:
Adaptability or versatilityVSLoss of information

Solution Approach 1:

The brake control unit is designed with multi-functionality to serve both as a standalone aftermarket unit and as an integrated system component. It incorporates universal communication protocols that enable it to interface with the towing vehicle's existing instrument panel and diagnostic systems, while maintaining its independent operation capabilities. This allows the unit to communicate errors and status information through the vehicle's existing display systems.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Reliability

If diagnostic capabilities are added to identify fault locations, then system reliability is improved, but device complexity increases

Engineering Contradiction:
Improvefault identification capabilityVSAvoiddiagnostic system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The diagnostic system implements feedback mechanisms where the brake control unit continuously monitors its own operational parameters and communicates status information back to the processor and instrument panel. When faults are detected in the electrical system or brake controller, the system provides real-time feedback about the nature and location of the fault, enabling operators to take corrective action without requiring complex external diagnostic equipment.

Inventive Principle:
Principle #23Feedback

3Reliability

If mechanical sway control equipment is used, then sway control effectiveness is improved, but system maintenance requirements increase

Engineering Contradiction:
Improvesway control effectivenessVSAvoidmaintenance requirements
Core Design Contradiction:
ReliabilityVSEase of repair

Solution Approach 1:

The system replaces mechanical sway control equipment with an electronic control approach. The brake control unit uses electronic signals and processor-based algorithms to detect and counteract sway conditions, eliminating the need for mechanical components such as spring arms, friction pads, and linkages. This electronic substitution maintains sway control effectiveness while significantly reducing maintenance requirements, as electronic systems have no wear parts requiring regular inspection and replacement.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12384336B2Driver and diagnostic system for a brake controller
Publication Date: 2025.08.12 HORIZON GLOBAL AMERICAS INC
  • US12384336B2 patent drawing
  • US12384336B2 patent drawing
  • US12384336B2 patent drawing

AI summary

A brake control unit includes a processor, a first high side driver and a second high side driver. The processor sends signals to the first high side driver and the second high side driver. The first and second high side drivers process the signals independent of each other. The processor diagnoses faults and locations of faults based on feedback from the high side drivers. The first high side driver controls the braking of a first trailer brake. The second high side driver controls the braking of a second trailer brake.