Load-Dependent Trailer Brake System With Electronic Control
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Solution Overview
Problem
Existing trailer brake systems face reliability issues and high costs due to the need for mechanical or pneumatic connections between load sensing valves and suspension systems, which can lead to inadequate adjustment of braking force based on trailer load.
Innovation Solution
A trailer brake system utilizing an electronic controller and electrically-controlled proportional valve to generate load-dependent control signals, eliminating the need for mechanical or pneumatic connections and ensuring a failsafe operation by regulating braking signals independently, while maintaining a pressure-controlled load sensing valve for self-contained operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical or pneumatic connection is used between the load sensing valve and the suspension system, then the braking force can be adjusted based on trailer load, but the system becomes cumbersome, expensive and vulnerable to reliability issues
Solution Approach 1:
The patent replaces the mechanical or pneumatic connection between the load sensing valve and suspension system with an electrical connection. The electronic controller receives electrical signals from load sensors (such as drawbar load sensors or axle load cells) and processes this information to control the proportional valve, thereby eliminating the need for complex mechanical linkages and improving system reliability.
Solution Approach 2:
The patent introduces an electronic controller as an intermediary between the load sensing elements and the brake actuation system. This controller processes electrical signals from load sensors and generates appropriate control signals for the proportional valve, serving as a mediating device that eliminates the need for direct mechanical or pneumatic connections while maintaining load-dependent brake control.
2Device complexity
If an electrical proportional valve is used to control the load sensing valve, then the need for mechanical or pneumatic connections is eliminated, but the system may be vulnerable to electrical failures
Solution Approach 1:
The patent incorporates a failsafe mechanism where the load sensing valve is designed to default to a fully open position in the event of electrical system failure or loss of control pressure. This ensures that if the proportional valve fails or electrical power is lost, the brake command signal automatically defaults to a safe state that prevents wheel locking, thereby cushioning against the potential harm of electrical failures.
Solution Approach 2:
The system includes monitoring capabilities where the electronic controller can detect the operational status of the proportional valve and electrical system. This feedback mechanism allows the system to identify failures and activate appropriate safety protocols, ensuring that electrical failures do not compromise braking safety.
3Ease of manufacture
If a pressure-controlled load sensing valve is maintained, then existing off-the-shelf valves can be used making modification cheap and simple, but the system requires a pressure source to control the load sensing valve
Solution Approach 1:
The patent maintains the pressure-controlled load sensing valve design, which allows the use of existing off-the-shelf valves that are already optimized for pneumatic or hydraulic brake systems. The same valve can be controlled either through traditional pneumatic connections or through the new electrical proportional valve system, providing universality and reducing modification costs while leveraging proven technology.
Solution Approach 2:
The system is designed to be self-contained by using the existing brake system pressure supply to operate the load sensing valve. The pressure-controlled valve automatically responds to pressure changes in the brake command line, eliminating the need for separate pressure sources or additional actuators, thereby simplifying the overall system architecture.
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 solution provides a cost-effective, reliable load-dependent braking system that maintains minimum legislative braking pressure even in failure scenarios, preventing wheel locking and simplifying installation and retrofitting, applicable to both pneumatic and hydraulic systems.
Implementation Method 1
a pressure-controlled relay valve having a first control port which is connected to a command line
Implementation Method 2
the load sensing valve being operable to modify a brake command signal dependent upon the trailer load
Implementation Method 3
an electrical proportional valve, and an electronic controller in communication with the proportional valve and configured to generate a load-dependent control signal
Data Source
AI summary
A trailer brake system that generates load-dependent braking forces. Variable trailer load information is used to generate load-dependent control signals which serve to control an electrically-controlled proportional valve. A load sensing valve serves to modify brake command signals in dependence on a control pressure that is regulated by the proportional valve.