Brake Controller Requirements and Desires

Manufactures always try to cut cost without thinking about the end product "Safety"! For us here at Hensley Mfg. Safety and Power is worth the development time and resources required. We pride ourselves on designing the best product for our customers without considering the sales cost in the design stage. Then later we set the best price based on the product bill of material costs.

These next list of points will describe the desires and contrast the our solution.

So In a perfect world what exactly do we want?

• Automatically protect the brake controller if I connect it backwards. Reverse polarity protection.
• Automatically detect a stop light or brake wire short or problem and shut off the power. Let the user know there is a short. Short circuit detection in nanoseconds.
• Automatically modify the gain to handle different driving situations, such as heat and frequency of use. This is the creation of Current Compensation in Brake Controllers.
• Automatically detect the speed and brake accordingly, keeping a Smooth but powerful brake. Uses a patented software algorithm.
• Automatically detect the trailer brakes and determine if your pulling an Electric Brake Trailer or a Hydraulic Brake Trailer. Uses solid state sensors to determine the brake type hydraulic or electric automatically.
• Automatically detect if I'm driving down hill or up hill and brake accordingly (based on the decline angle). Use a solid state gyro.
• Automatically detect if I'm backing up in reverse and stop accordingly. Measures both directions of deceleration.
• Automatically measure the proportional stopping of the vehicle and emulate it exactly. Uses a patented software algorithm.
• Don't Heat up the circuitry and cause more power loss when pulling high amps. Use switches for very high amperage applications (excess of 100 AMPS).
• Don't requiring the use of heat sinks or metal bottoms! Use plenty of high amperage switches in to overcome this problem.
• Don't have any power loss at the plug-in connections. Use soldered in heavy gauge pigtails.
• Don't tap into the brake line and void the vehicle warranty or disturb the ABS brake system. Only uses electrical connections.
• Make Installation easy (15 Minutes or less). Uses 4 wires and two screws, with a quick (10 second) calibration procedure.
• Make the menu's very user friendly and not necessary after installation.

Okay I guess this list of desires is long enough! Now for the good news...Were' done!

This was on the drawing board since August of 2004, by September of 2006 every item on the list was designed and completed! We would like to extend a special thanks to all the Hensley Partners in Michigan, Texas, Tennessee and Florida that helped us through the alpha and beta testing phases. We really appreciate the use of your tow vehicles and trailers. The varied configurations really helped us during the design phases.

Using today's proven electrical circuit and software technologies we have melded our hardware and software teams research and development group to the same goal. Come up with the best solution using software and hardware together in tandem. Our software design team has written patent pending algorithms while our hardware design team designed patent pending circuits to support this mission.

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