Wireless Trailer Brake Controller Without Cab-Mounted Controls
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Solution Overview
Problem
Conventional brake controllers for towing vehicles require complex and costly installation, often obstructing the vehicle's cab and lacking intuitive interfaces, with displays and controls that are not optimally integrated for weather resistance and user convenience.
Innovation Solution
A wireless brake controller that eliminates exterior displays and controls, using a smartphone app for input and output settings, and is mounted between the towing vehicle and trailer wiring, featuring a weather-resistant housing and potted electronics for robustness and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If brake controllers are mounted in the cab of the vehicle with displays and controls, then the interface is accessible to the driver, but the installation is complex and costly, and it impinges on visual sightlines and cab simplicity
Solution Approach 1:
The patent extracts the display and control buttons from the brake controller housing, placing them on a separate user interface device that the driver holds or mounts independently. This allows the brake controller to be installed in the rear cargo area without complicating cab installation while maintaining driver accessibility through the separate interface device.
Solution Approach 2:
The system is divided into separate functional components: the brake controller unit with electronics and actuator, and a separate user interface device with display and controls. This segmentation allows independent optimization of each component's location and function, simplifying overall installation while maintaining usability.
2Ease of manufacture
If displays and control buttons are integrated on the brake controller housing, then the interface is self-contained, but the housing becomes larger and more complex, and installation is more difficult
Solution Approach 1:
The display and control buttons are extracted from the brake controller housing and placed on a separate user interface device. This reduces the housing to essential components only, simplifying manufacturing and installation while maintaining full functionality through the separate interface device.
3Reliability
If the brake controller is mounted in a protected location in the cab, then it is protected from weather, but the installation procedure is significant and costly
Solution Approach 1:
The user interface device is extracted and can be independently mounted in the cab or held by the driver, while the brake controller is simplified for easy installation in the rear cargo area. This separation allows each component to be installed in its optimal location without requiring complex integrated installation procedures.
4Adaptability or versatility
If a conventional display and controls are used on the brake controller, then the interface is traditional and familiar, but it lacks flexibility and robustness for various operating conditions
Solution Approach 1:
The user interface device is extracted as a separate component that can be protected from weather while the brake controller remains in the rear cargo area. The interface device can be held or mounted in the cab, providing flexible, weather-protected control and display functionality.
Data Source
AI summary
A brake controller is provided as an inline plug between the towing vehicle and the towed vehicle or trailer. The electronics including an accelerometer and wireless communication radio are potted within a brake controller housing package. There is no conventional display or input controls on the exterior of the brake controller package. Input settings, and possibly output messages, are communicated through a smartphone or similar software or hardware application. The brake controller can identify a hazard lighting condition and avoid braking the towed vehicle during the hazard lighting condition, and can also distinguish when braking during signaling a turn, using the turn signals of the towing vehicle.