Electric Brake Controller Power Secrets

In the world of manufacturing, cost cutting is a top priority. Too often, the results are poor products and sub-standard materials. At Hensley Mfg., we take a different approach: safety and performance come first. We pride ourselves on designing the best product for our customers and following up with outstanding customer service. For more on Power like Water click here.

1. Remove Heat - Get rid of heat problems by using superior 100 Amp switching (FET) circuits. 90% of the brake controllers use heat sinks due to cheaper component technology. Make the jump and spend the money on more powerful switching circuits. This is the major reason that even the expensive brake controllers in the industry burn up. This will increase your power output approximately by 20%. Secret: Hensley Mfg uses solid state superior quality switches (FETs) in parallel to eliminate any heat even during 32 Amp continuous output situations.

2. Separation of Current Sense and Switching - In the circuitry separate the current sensors and the switching circuitry. Although this is much more expensive it is desired and if the correct current sensor is employed increases the power output by up to 7%. Secret:  Hensley Mfg has selected a current sensor that supports up to 50 AMPS with 0.001% power loss through the sensor.

3. Use more copper - Use heavy weight copper on the circuit board. Also use more layers instead of a 2 layer board use at least a 4 layer printed circuit board. Secret: Hensley Mfg uses a 6 layer very heavy copper manufactured printed circuit board.

4. Short circuit protection - Use nanosecond (one billionth of a second) sensitive solid state logic to remove power during short circuit detection. Use the same circuit to enable the power once the short has been repaired on the trailer or vehicle. Secret: Hensley Mfg uses a solid state logic circuit that is smart enough to turn power off and on in nanoseconds.

5. Pig Tails - The use of pig tails (wires) soldered directly into the circuit board and not having connectors increases power output by 2% on the low end and up to 7% on the high end. Secret: Hensley Mfg uses heavy gauge wire for the power transfer soldered directly into the circuit board.

6. Reverse Polarity - This is a tough problem in high amperage applications. The answer: Use a 100+ AMP rated switch to control the reverse polarity, stay away from diodes due to the heat and voltage drops. Secret: Hensley Mfg uses high quality solid state switches to solve this problem.

7. Butt Splices - The use of butt splices or crimp connectors also increases the power since the amount of metal actually resembles the amount of copper in the wire. Also the crimp connection reduces contact resistance. This helps by 1% on the low end and up to 4% on the high end. Secret:  Hensley Mfg includes the correct gauge splices with the TruControl™ brake controller kits.

For Your Information (FYI) - Please know this we put superior quality circuits with superior quality components together at an expense to us that is worth the safely and power output of our product line. We also supervise the manufacturing of our products personally here in the United States. Once you try our TruControl™ Brake Controllers you'll never go back. Keep in mind along with all this power is very smooth stopping, note our patented algorithms. Check out our testimonials and see what our customers say about it. Prior to designing our own brake controller we did research and found out that even the most expensive brake controllers do not work as well as we needed them to, and we also found out that they manufacture overseas and have very high margins, they only employ about $17 worth of parts and sell for well over $100.

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