7-Pin Trailer Brake Controller With External Inertial Sensing
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Solution Overview
Problem
Existing brake controllers for towed vehicles face challenges when mounted externally, requiring precise accelerometer positioning, accessible power supply, and weather protection, while also needing to allow driver control and compatibility with various wiring standards.
Innovation Solution
A brake controller with an inertial sensor and processor housed in a weather-protected housing, integrated into a towing vehicle's 7-pin trailer connection socket, generating braking control signals based on deceleration and brake light signals, and featuring adaptable connectors and power management to ensure reliable operation and reduced installation costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the brake controller is mounted externally on the towing vehicle, then the interior trim is protected from damage and the controller is more versatile, but the accelerometer positioning becomes more difficult and weather protection is required
Solution Approach 1:
The brake controller is divided into separate functional modules: the housing with mounting bracket, the accelerometer assembly, the electrical connector, and the protection cover. This segmentation allows each component to be optimized independently and simplifies installation by allowing flexible positioning of the housing on various exterior surfaces of the towing vehicle.
Solution Approach 2:
The mounting bracket is designed to accommodate multiple orientations and positions on exterior surfaces. The bracket includes adjustable mounting holes and flexible positioning features that allow the controller to be mounted on vertical, horizontal, or angled surfaces, providing three-dimensional mounting flexibility while maintaining proper accelerometer orientation relative to gravity.
2Ease of manufacture
If the brake controller is mounted externally, then installation in cabin or engine bay is avoided, but the connector and housing need weather protection and gravel protection
Solution Approach 1:
The housing is designed with integrated mounting brackets that can be secured to exterior surfaces using simple fastening methods. The electrical connector includes sealed contacts and protective boots that prevent water and debris ingress while maintaining electrical connectivity. These flexible protection features shield the internal components from weather and gravel damage.
3Device complexity
If the brake controller uses combined brake and turn lights, then wiring complexity is reduced, but the processor must accurately determine brake light signals from combined signals
Solution Approach 1:
The processor continuously monitors the combined light signals from the towing vehicle and uses feedback algorithms to distinguish between brake light activation and turn signal activation. By analyzing the timing, duration, and intensity patterns of the combined signals, the processor can accurately determine when brakes are applied even though the wiring remains simple.
Solution Approach 2:
The processor acts as an intermediary that receives the combined light signals through the simple wiring connection and processes them to extract separate brake and turn signal information. This intermediary processing layer enables accurate signal differentiation without requiring separate physical wiring for brake and turn signals.
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
The solution provides a versatile, cost-effective, and reliable brake controller that can be mounted externally, ensuring accurate braking control and lighting synchronization, while minimizing installation complexity and enhancing connector reliability through intelligent power management and redundancy.
Implementation Method 1
an inertial sensor including plural sensor axes for generating sensor data associated with each sensor axis; a processor for processing said sensor data to estimate a deceleration of the towing vehicle
Data Source
AI summary
The present invention relates to a brake controller for a towed vehicle braking system, including a housing or a loom, including an input connector for electrical connection to a towing vehicle and an output connector for electrical connection to a towed vehicle.