Electric stability control system and device for controlling sway stability of a caravan or trailer and the like

1. A system for substantially stabilizing dangerous and excessive sway of a towed vehicle, fitted with electric brakes, hitched to a towing vehicle, the system including:

an electric stability control (ESC) device adapted for mounting to a portion of the towed vehicle, the ESC device being operably connected to the electric brakes by cable, the ESC including:

a sway detector for measuring lateral acceleration of the towed, vehicle;

an actuator for activating the electric brakes of the towed vehicle, the actuator being operatively connected to the sway detector wherein the sway detector activates the actuator to apply a voltage to the brakes for a period of time when the sway detecting detects a predetermined critical condition of lateral acceleration of the towed vehicle relative to the towing vehicle;

a power source on the towing vehicle or towed vehicle interconnected to the ESC for providing power to the device;

the actuator controlling the electric brakes by providing an effective predetermined voltage input to the electric brakes dependent on the extent of swaying detected and towing load so that the towed vehicle can be substantially stabilized;

wherein the predetermined critical conditions that the sway detector detects include:

detecting a predetermined lateral acceleration of the towed vehicle relative to the towing vehicle of about 0.15 g to 0.2 g over two (2) cycles;

or detecting lateral acceleration in a cycle exceeding about 0.4 g.

2. The system of claim 1 wherein the actuator is adapted for maintaining an effective voltage input to the electric brakes of the towed vehicle for a predetermined period after the sway detector has determined rate of sway having returned to predetermined safe levels.

3. The system of claim 1 wherein the actuator is configured for maintaining the effective voltage input to the electric brakes of the towed vehicle for a predetermined period after the sway detector has determined rate of sway having returned to a predetermined safe level.

4. The system of claim 1 wherein the amount of voltage output of the actuator and the duration of braking can be varied based on a level of lateral acceleration.

5. The system of claim 1 wherein the actuator is activated to apply a predetermined input voltage to the electric brakes when the sway detector detects lateral acceleration exceeding about 0.4 g, wherein the actuator can remain in an operating mode until the lateral acceleration detected by the sway detector is reduced to about 0.15 g or less.

6. The system of claim 1 wherein the actuator is activated to apply a predetermined input voltage to the electric brakes when the sway detector detects lateral acceleration exceeding about 0.2 g for two cycles, wherein the actuator remains in an operating mode until the lateral acceleration detected by the sway detector is reduced to about 0.15 g or less.

7. The system of claim 1 wherein the input voltage for controlling electric brakes of a towed vehicle is between 4 to 12 volts and is determined by load, brake size, tire radius and weight of towed vehicle.

8. An electric stability control device for controlling electric brakes of a towed vehicle so as to substantially minimize effects of lateral acceleration during a tow condition, the device including;

a sway detector for measuring lateral acceleration of the towed vehicle;

an actuator connectable to the electric brakes for activating the electric brakes of the towed vehicle, the actuator being operatively connected to the sway detector wherein the sway detector detects a predetermined critical condition of lateral acceleration of the towed vehicle relative to a towing vehicle, wherein the predetermined critical conditions that the sway detector detects include:

detecting a predetermined lateral acceleration of the towed vehicle relative to the towing vehicle of about 0.15 g to 0.2 g over two (2) cycles;

or detecting lateral acceleration in a cycle exceeding about 0.4 g;

wherein in an operating condition, a power source is provided to power the electrical stability control, and the actuator provides an effective predetermined voltage input to the electric brakes when one of the certain critical conditions of lateral acceleration are detected based on the extent of swaying detected and towing load and for a period of time effective to substantially stabilize the towed vehicle independent of the towing vehicle.

9. The electric stability control device for controlling electric brakes of a towed vehicle of claim 8 wherein the actuator can be configured for maintaining the effective voltage input to the electric brakes of the towed vehicle for a predetermined period after the sway detector has determined rate of sway having returned to a predetermined safe level.

10. The electric stability control device for controlling electric brakes of a towed vehicle of claim 8 wherein the actuator is activated to apply a predetermined input voltage to the electric brakes when the sway detector detects lateral acceleration exceeding about 0.4 g, wherein the actuator remains in an operating mode until the lateral acceleration detected by the sway detector is reduced to about 0.15 g or less.

11. The electric stability control device for controlling electric brakes of a towed vehicle of claim 8 wherein the actuator is activated to apply a predetermined input voltage to the electric brakes when the sway detector detects lateral acceleration exceeding about 0.2 g for two cycles, wherein the actuator can remain in an operating mode until the lateral acceleration detected by the sway detector is reduced to about 0.15 g or less.

12. A sway control unit for a towed vehicle having electrically actuated brakes, the electronic sway control unit:

being mountable to the towed vehicle;

comprising an accelerometer which is adapted to sense lateral acceleration of the towed vehicle; and

operating to apply an actuating voltage to the electrically controlled brakes when the lateral acceleration of the towed vehicle meets specified criteria;

wherein said specified criteria includes:

detecting a predetermined lateral acceleration of the towed vehicle relative to the towing vehicle of about 0.15 g to 0.2 g over two (2) cycles;

or detecting lateral acceleration in a cycle exceeding about 0.4 g.

13. The sway control unit of claim 12 wherein the towed vehicle is a single axle vehicle with brakes substantially 10 inches in diameter and having brake pads substantially 2.25 inches wide and the actuating voltage is:

in the range of 4 volts to 6 volts for a load between 500 kg and 750 kg;

in the range of 5 volts to 7 volts for a load between 750 kg and 1,000 kg;

in the range of 6 volts to 8 volts for a load between 1000 kg to 1250 kg; and

in the range of 8 to 10 volts for a load between 1250 kg and 1750 kg.

14. The sway control unit of claim 12 wherein the towed vehicle is a tandem axle vehicle with brakes substantially 10 inches in diameter and having brake pads substantially 2.25 inches wide and the actuating voltage is:

in the range of 8 volts to 10 volts for a load between 1,500 kg and 2,000 kg; and

in the range of 10 volts to 12 volts for a load between 2,000 kg and 2,500 kg.

15. The sway control unit of claim 12 wherein the towed vehicle is a single axle vehicle with brakes substantially 12 inches in diameter and having brake pads substantially 52 mm inches wide and the actuating voltage is:

in the range of 6 to 8 volts for a load between 1500 kg and 1750 kg;

in the range of 7 to 9 volts for a load between 1750 kg and 2000 kg;

in the range of 8 to 10 volts for a load between 2000 kg and 2250 kg;and

in the range of 9 to 11 volts for a load between 2250 kg and 2500 kg.

16. The sway control unit for a towed vehicle of claim 12 wherein the towed vehicle is a single axle vehicle with brakes substantially 10 inches in diameter and having brake pads substantially 2.25 inches wide and the actuating voltage is:

in the range of 4.5 to 5.5 volts for a load between 500 kg and 750 kg;

in the range of 5.5 to 6.5 volts for a load between 750 kg and 1,000 kg;

in the range of 6.5 to 7.5 volts for a load between 1000 kg to 1250 kg; and

in the range of 8.5 to 9.5 volts for a load between 1250 kg and 1750 kg.

17. The sway control unit for a towed vehicle of claim 12 wherein the towed vehicle is a tandem axle vehicle with brakes substantially 10 inches in diameter and having brake pads substantially 2.25 inches wide and the actuating voltage is:

in the range of 8.5 to 9.5 volts for a load between 1,500 kg and 2,000 kg; and

in the range of 10.5 volts to 11.5 volts for a load between 2,000 kg and 2,500 kg.

18. The sway control unit for a towed vehicle of claim 12 wherein the towed vehicle is a single axle vehicle with brakes substantially 12 inches in diameter and having brake pads substantially 52 mm inches wide:

in the range of 6.5 to 7.5 volts for a load between 1500 kg and 1750 kg;

in the range of 7.5 to 8.5 volts for a load between 1750 kg and 2000 kg;

in the range of 8.5 to 9.5 volts for a load between 2000 kg and 2250 kg; and

in the range of 9.5 to 10.5 volts for a load between 2250 kg and 2500 kg.

19. The sway control unit for a towed vehicle of claim 12 wherein the towed vehicle is a single axle vehicle with brakes substantially 10 inches in diameter and having brake pads substantially 2.25 inches wide and the actuating voltage is:

5 volts for a load between 500 kg and 750 kg;

6 volts for a load between 750 kg and 1,000 kg;

7 volts for a load between 1000 kg to 1250 kg; and

9 volts for a load between 1250 kg and 1750 kg.

20. The sway control unit for a towed vehicle of claim 12 wherein the towed vehicle is a tandem axle vehicle with brakes substantially 10 inches in diameter and having brake pads substantially 2.25 inches wide and the actuating voltage is:

9 volts for a load between 1,500 kg and 2,000 kg; and

11 volts for a load between 2,000 kg and 2,500 kg.

21. The sway control unit for a towed vehicle of claim 12 wherein the towed vehicle is a single axle vehicle with brakes substantially 12 inches in diameter and having brake pads substantially 52 mm inches wide and the actuating voltage is:

7 volts for a load between 1500 kg and 1750 kg;

8 volts for a load between 1750 kg and 2000 kg;

9 volts for a load between 2000 kg and 2250 kg; and

10 volts for a load between 2250 kg and 2500 kg.

22. An electric stability control device for controlling electric brakes of a towed vehicle so as to substantially minimize effects of lateral acceleration during as tow condition, the device including:

a sway detecting means for measuring lateral acceleration of the towed vehicle;

an actuator means for activating the electric brakes of the towed vehicle, the actuator means being operatively connected to the sway detecting means whereby the sway detecting means detects certain critical conditions of lateral acceleration including:

detecting a predetermined lateral acceleration of the towed vehicle relative to the towing vehicle over two (2) cycles; and

detecting lateral acceleration exceeding about 0.4 g

wherein when the sway detecting means detects lateral acceleration exceeding about 0.2 g for two cycles, the actuator means is activated to apply a predetermined input voltage to the electric brakes until the lateral acceleration detected by the sway detecting means is reduced to about 0.15 g or less; and

wherein when the sway detecting means detects lateral acceleration exceeding about 0.4 g, the actuator means is activated to apply a predetermined input voltage to the electric brakes until the lateral acceleration detected by the sway detecting means is reduced to about 0.15 g or less.