Towed vehicle brake controller

• US 20030168908A1
• Filed: 04/07/2003
• Published: 09/11/2003
• Est. Priority Date: 04/14/1999
• Status: Active Grant

• Current Assignee: Hopkins Manufacturing Corporation (Hoppy Holdings Corp.)
• Original Assignee: United States Steel Corporation (U.S. Steel)
• Inventors: Robinson, Bruce, Hostetler, Jeffrey, Bailey, David F.
• Granted Patent: US 6,837,551 B2
• Time in Patent Office: Days
• US Class Current: 303/7
• CPC Class Codes: B60T 13/662 characterised by specified functions of the control system components
• CPC Class Codes: B60T 13/74 with electrical assistance or drive
• CPC Class Codes: B60T 17/223 Devices for pressurising brake systems acting on pedal
• CPC Class Codes: B60T 7/10 Disposition of hand control
• CPC Class Codes: B60T 7/107 with electrical power assistance

Abstract

A brake controller, for controlling the brakes of a towed vehicle, having a control module and a power module is provided. The control module is mounted in the cab of a vehicle used for towing, in such a manner that it can be easily seen and accessed by the driver. The control module is provided with an accelerometer, which can read acceleration forces in at least two axes, and a microprocessor which polls the accelerometer and sends braking information to the power module. The control module is also provided with a gain control, to adjust the amount of brake force information, a manual braking lever and a display panel. The power module, which may be mounted in a convenient location, preferably on the towed vehicle, receives the braking information from the control module and secures power from the towed vehicle to engage its brakes.

Claims

1. A brake controller, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

a control module for location within the cab of the towing vehicle and comprising a user interface with manual braking controls and automatic braking sensors; and

,

a power module, separate from said remote control module, comprising power drivers for supplying power to activate the brakes of the towed vehicle;

said control module being connected to said power module such that when said control module is activated the power drivers of said separate power module operate to activate the brakes of the towed vehicle.

2. The brake controller of claim 1, wherein said automatic braking sensors comprise a multi-axis accelerometer for sensing acceleration forces on the towing vehicle.

3. The brake controller of claim 1, wherein said control module is adapted to be mounted on one of the gear shift lever and dashboard of the towing vehicle.

4. The brake controller of claim 1, wherein said power module is adapted to be mounted on one of the towing vehicle and the towed vehicle.

5. The brake controller of claim 1, wherein said power module produces and sends a status signal to said control module while said control module and power module are in electrical communication.

6. The brake controller of claim 1, further comprising a visual warning system to alert the user of the separation of the towed vehicle from the towing vehicle.

7. The brake controller of claim 1, further comprising an audible warning system to alert the user of separation of the towed vehicle from the towing vehicle.

8. The brake controller of claim 1, wherein said power module comprises a breakaway switch such that upon the separation of the towed vehicle from said towing vehicle the brakes of the towed vehicle are engaged.

9. A brake controller, for use with a towing vehicle when said towing vehicle is in association with a towed vehicle, comprising;

a control module for location within the towing vehicle and comprising a user interface with manual controls including a gain control knob, a manual control lever and automatic braking sensors;

said control module producing a braking signal in the form of a pulse width modulated signal in response to a braking situation such that said pulse width modulated signal is responsive to any one or combination of the length of time of said braking situation, the position of said gain knob, the position of said manual control lever and the forces read by said automatic braking sensors in response to said braking situation.

10. The brake controller of claim 9, wherein said automatic braking sensors comprise a multi-axis accelerometer for sensing acceleration forces on the towing vehicle.

11. The brake controller of claim 9, wherein said control module is adapted to be mounted on one of the gear shift lever and dashboard of the towing vehicle.

12. A brake controller, for use with a towing vehicle when said towing vehicle is in association with the a towed vehicle, comprising:

a control module for location within the towing vehicle and comprising a user interface with manual controls including a gain control knob and automatic braking sensors comprising an accelerometer;

a power module, separate from said control module, for supplying power to activate the brakes of a towed vehicle;

wherein manipulation of said gain control knob sets, through said power module, a static braking force and the action of said accelerometer on said power module adds a dynamic braking force in response to a braking situation.

13. The brake controller of claim 12, wherein said automatic braking sensors comprise a two or more axis accelerometer for sensing acceleration forces on the towing vehicle.

14. The brake controller of claim 12, wherein said control module is adapted to be mounted on one of the gear shift lever and dashboard of the towing vehicle.

15. The brake controller of claim 12, wherein said power module is adapted to be mounted on one of the towing vehicle and the towed vehicle.

16. The brake controller of claim 12, wherein said power module produces and sends a status signal to said control module while said control module and power module are in electrical communication.

17. The brake controller of claim 12, further comprising a visual warning system to alert the user of the separation of the towed vehicle from the towing vehicle.

18. The brake controller of claim 12, further comprising an audible warning system to alert the user of separation of the towed vehicle from the towing vehicle.

19. The brake controller of claim 12, wherein said power module comprises a breakaway switch such that upon the separation of the towed vehicle from said towing vehicle the brakes of the towed vehicle are engaged.

20. A brake controller, for use with a towing vehicle when said towing vehicle is in association with the a towed vehicle, comprising:

control circuitry for location within the towing vehicle and comprising a user interface with manual controls including a gain control knob and automatic braking sensors comprising an accelerometer;

power circuitry for supplying power to activate the brakes of a towed vehicle;

wherein manipulation of said gain control knob sets, through said power circuitry, a static braking force and adjusts said power module'"'"'s response to said accelerometer such that the braking signal generated as result of forces read from said accelerometer is increased or decreased according to the manipulation of the gain control knob.

21. The brake controller of claim 20, wherein said automatic braking sensors comprise a multi-axis accelerometer for sensing acceleration forces on the towing vehicle.

22. The brake controller of claim 20, wherein said control circuitry is housed in a control module adapted to be mounted on one of the gear shift lever and dashboard of the towing vehicle.

23. The brake controller of claim 20, wherein said power circuitry is housed in a power module adapted to be mounted on one of the towing vehicle and the towed vehicle.

24. The brake controller of claim 20, wherein said power circuitry produces and sends a status signal to said control circuitry while said control circuitry and power circuitry are in electrical communication.

25. The brake controller of claim 20, further comprising a visual warning system to alert the user of the separation of the towed vehicle from the towing vehicle.

26. The brake controller of claim 20, further comprising an audible warning system to alert the user of separation of the towed vehicle from the towing vehicle.

27. The brake controller of claim 20, wherein said power circuitry comprises a breakaway switch such that upon the separation of the towed vehicle from said towing vehicle the brakes of the towed vehicle are engaged.

28. A towed vehicle brake controller system, for use with a towing vehicle when the towing vehicle is in association with a towed automobile having a vacuum operated braking system, comprising:

power circuitry for producing a braking signal; and

,

a supplemental vacuum pump installed within the towed vehicle and connected to said power circuitry, said vacuum pump operable in response to a braking signal received from said power circuitry to provide braking force to said braking system; and

,

an actuator attached to the brake pedal of the towed vehicle, and connected to said power circuitry, such that when said actuator receives a braking signal from said power circuitry said automobile brake pedal is depressed.

29. The brake controller system of claim 28, wherein said power circuitry causes the operation of said vacuum pump upon receipt of a brake light signal and stops the operation of said vacuum pump after a predetermined time period.

30. The brake controller system of claim 28, wherein said actuator is a solenoid.

31. A towed vehicle brake controller system, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

a control module, for location within the towing vehicle and comprising brake situation sensors and control signal generators, said control signals comprising one or more codes;

a power module comprising power drivers and a microprocessor for receiving control signals and generating braking signals, said microprocessor adapted to sense control signals to determine if a received code represents a braking situation, and said power module generating a braking signal only in response to a code representing a braking situation.

32. The brake controller of claim 31, wherein said automatic braking sensors comprise a multi-axis accelerometer for sensing acceleration forces on the towing vehicle.

33. The brake controller of claim 31, wherein said codes comprise one or more duty cycles.

34. The brake controller of claim 31, wherein said control module is adapted to be mounted on one of the gear shift lever and dashboard of the towing vehicle.

35. The brake controller of claim 31, wherein said power module is adapted to be mounted on one of the towing vehicle and the towed vehicle.

36. The brake controller of claim 31, wherein said power module produces and sends a status signal to said control module while said control module and power module are in electrical communication.

37. The brake controller of claim 31, further comprising a visual warning system to alert the user of the separation of the towed vehicle from the towing vehicle.

38. The brake controller of claim 31, further comprising an audible warning system to alert the user of separation of the towed vehicle from the towing vehicle.

39. The brake controller of claim 31, wherein said power module comprises a breakaway switch such that upon the separation of the towed vehicle from said towing vehicle the brakes of the towed vehicle are engaged.

40. A brake controller, for use with a towing vehicle when said towing vehicle is in association with the a towed vehicle, comprising:

a multi-axis accelerometer adapted to sensing braking forces on said towing vehicle and causing the activation of the brakes of the towed vehicle.

41. The brake controller of claim 40, wherein said multi-axis accelerometer reads forces on two axes.

42. The brake controller of claim 40, wherein said multi-axis accelerometer reads forces on three axes.

43. The brake controller of claim 40, further comprising a visual warning system to alert the user of the separation of the towed vehicle from the towing vehicle.

44. The brake controller of claim 40, further comprising an audible warning system to alert the user of separation of the towed vehicle from the towing vehicle.

45. The brake controller of claim 40, further comprising a breakaway switch such that upon the separation of the towed vehicle from said towing vehicle the brakes of the towed vehicle are engaged.

46. A brake controller, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

a control module for location within the towing vehicle and comprising a user interface with manual braking controls, automatic braking sensors, and a status signal display light;

a power module, separate from said remote control module, comprising power drivers for supplying power to activate the brakes of the towed vehicle, said power module comprising a breakaway switch and a status signal generator electrically connected to said signal display light;

said control module being connected to said power module such that when said control module is activated power drivers of the separate power module operate to activate the brakes of the towed vehicle; and

said breakaway switch being operable to activate the brakes of the towed vehicle when the towed vehicle is separated from the towing vehicle.

47. The brake controller of claim 46, wherein said control module is adapted to be mounted on one of the gear shift lever and dashboard of the towing vehicle.

48. The brake controller of claim 46, wherein said automatic braking sensors comprise a multi-axis accelerometer for sensing acceleration forces on the towing vehicle;

49. The brake controller of claim 46, further comprising a visual warning system to alert the user of the separation of the towed vehicle from the towing vehicle.

50. The brake controller of claim 46, further comprising an audible warning system to alert the user of separation of the towed vehicle from the towing vehicle.

51. A towed vehicle brake controller, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

a control module, for location within the towing vehicle and comprising a user interface comprising manual braking controls, an accelerometer comprising acceleration force sensors, and a microprocessor programmed to receive acceleration force data from said accelerometer and produce a braking signal in response thereto;

a power module comprising power drivers, braking signal receptors and a power amplifier in electrical communication with said microprocessor such that when said microprocessor produces a braking signal, said power module receives said signal, and provides power to a towed vehicle brake system.

52. The towed vehicle brake controller of claim 51, wherein said brake system of the towed vehicle comprises electronic trailer brakes.

53. The towed vehicle brake controller of claim 51, wherein said brake system of the towed vehicle comprises an automobile braking system supplemented with a vacuum pump, to supply brake power, and an actuator to depress the automobile brake pedal.

54. The towed vehicle brake controller of claim 51 wherein said braking signal is a pulse width modulated signal.

55. The towed vehicle brake controller of claim 51, wherein said control module is separate from said power module.

56. The towed vehicle brake controller of claim 51, wherein said power module is mounted on a towed vehicle.

57. The towed vehicle brake controller of claim 51, wherein said power module is connected to said control module by control wire.

58. The towed vehicle brake controller of claim 51, wherein said manual controls include a gain adjustment knob for increasing or decreasing braking power in the towed vehicle.

59. The brake controller of claim 51, wherein manipulation of said gain control knob sets, through said power module, a static braking force and the action of said accelerometer on said power module adds a dynamic braking force in response to a braking situation.

60. The brake controller of claim 51, wherein manipulation of said gain control knob sets, through said power module, a static braking force and adjusts said power module'"'"'s response to said accelerometer such that the braking signal generated as result of forces read from said accelerometer is increased or decreased according to the manipulation of the gain control knob.

61. The towed vehicle brake controller of claim 51, wherein said power module produces and sends a status signal to said control module while said control module and power module are in electrical communication.

62. The towed vehicle brake controller of claim 51, further comprising a visual warning system to alert the user of the separation of the towed vehicle from the towing vehicle.

63. The towed vehicle brake controller of claim 51, further comprising an audible warning system to alert the user of separation of the towed vehicle from the towing vehicle.

64. The brake controller of claim 51, wherein said power module comprises a breakaway switch such that upon the separation of the towed vehicle from said towing vehicle the brakes of the towed vehicle are engaged.

65. A towed vehicle brake controller, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

a control module, for location within the towing vehicle and comprising manual braking controls including a gain control knob and a manual brake lever, an accelerometer comprising acceleration force sensors, and a microprocessor programmed to receive acceleration force data from said accelerometer and produce a braking signal in response thereto;

a power module comprising power drivers, braking signal receptors and a power amplifier in electrical communication with said microprocessor such that when said microprocessor produces a braking signal, said power module receives said signal, and provides power to a towed vehicle brake system; and

wherein manipulation of said gain control knob sets, through said power module, a static braking force and adjusts said power module'"'"'s response to said accelerometer such that the braking signal generated as result of forces read from said accelerometer is increased or decreased according to the manipulation of the gain control knob.

66. The brake controller of claim 65, wherein said power module comprises a breakaway switch such that upon the separation of the towed vehicle from said towing vehicle the brakes of the towed vehicle are engaged.

67. The towed vehicle brake controller of claim 65, wherein said brake system of the towed vehicle comprises electronic trailer brakes.

68. The towed vehicle brake controller of claim 65, wherein said brake system of the towed vehicle comprises an automobile braking system supplemented with a vacuum pump, to supply brake power, and an actuator to depress the automobile brake pedal.

69. The towed vehicle brake controller of claim 65, wherein said braking signal is a pulse width modulated signal.

70. The towed vehicle brake controller of claim 65, wherein said control module is separate from said power module.

71. The towed vehicle brake controller of claim 65, wherein said power module is connected to said control module by control wire.

72. The towed vehicle brake controller of claim 65, wherein said power module is mounted on a towed vehicle.

73. A towed vehicle brake controller system, for use with a towing vehicle when the towing vehicle is in association with a towed automobile having a vacuum operated braking system:

control circuitry, for location within the towing vehicle and comprising manual braking controls, an accelerometer comprising acceleration force sensors, and a microprocessor programmed to receive acceleration force data from said accelerometer and produce a braking signal in response thereto;

power circuitry comprising power drivers, braking signal receptors and a power amplifier in electrical communication with said microprocessor such that when said microprocessor produces a braking signal, said power module receives said signal, and produces a representative signal;

a supplemental vacuum pump installed within the towed vehicle and connected to said power circuitry, said vacuum pump operable in response to a braking signal received from said power circuitry to provide braking force to said braking system; and

, an actuator attached to the brake pedal of the towed vehicle, and connected to said power circuitry, such that when said actuator receives a braking signal from said power circuitry said automobile brake pedal is depressed.

74. The brake controller system of claim 73, wherein said power circuitry is housed in a power module and said control circuitry is housed in a control module.

75. The brake controller system of claim 73, wherein said power circuitry causes the operation of said vacuum pump upon receipt of a brake light signal and stops the operation of said vacuum pump at after predetermined time period.

76. The brake controller system of claim 73, wherein said microprocessor produces a pulse width modulated braking signal and said representative signal from said power circuitry is a pulse width modulated signal.

77. The brake controller system of claim 73, comprising a brake light cut off switch wherein the brake lights of the towed automobile are responsive to the braking of the towing vehicle and not the activation of the brakes of the towed vehicle.

78. The brake controller system of claim 73, wherein said power circuitry produces and sends a status signal to said control circuitry while said control circuitry and power circuitry are in electrical communication.

79. The brake controller system of claim 78, comprising a breakaway control system wherein upon the said supplemental vacuum pump operates continually upon the cessation of said status signal and said power circuitry causes a specific duty cycle in said actuator such that the towed vehicle is stopped.

80. The brake controller system of claim 73, wherein said actuator is a solenoid.

81. A brake controller, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

a control module for location within the towing vehicle, connected to the ignition switch of the towing vehicle, and comprising manual braking controls and automatic braking sensors for producing braking signals; and

a power module, separate from said remote control module, comprising power drivers for supplying power to activate the brakes of the towed vehicle, connected to the brakes of the towed vehicle and a battery in the towed vehicle;

said control module being connected to said power module such that only when said ignition of the towing vehicle is on, said control module may produce and send braking signals to said power module which may then engage the brakes of the towed vehicle.

82. The brake controller of claim 81, wherein said power module is connected to said battery with heavy gauge wire and to said control module with lighter gauge wire.

83. The brake controller of claim 81, wherein said control module to power module connection is a low power connection.

84. The trailer brake controller of claim 81, further comprising a visual warning system to alert the user of the separation of the towed vehicle from the towing vehicle.

85. The trailer brake controller of claim 81, further comprising an audible warning system to alert the user of separation of the towed vehicle from the towing vehicle.

86. The brake controller of claim 81, wherein said power module produces an electrical signal which illuminates a status light on said control module, such that the electrical separation of said control module from said power module extinguishes said status light.

87. The brake controller of claim 81, wherein said automatic braking sensors comprise a multi-axis accelerometer for sensing braking forces in two axes of movement of the towing vehicle.

88. The brake controller of claim 81, wherein said manual braking controls include a manual brake lever to allow the manual application of brake force proportional to the position of said brake lever.

89. A brake controller, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

a control module for location within the towing vehicle and comprising a user interface with manual braking controls comprising a manual operated brake lever; and

a power module, separate from said control module, comprising power drivers for supplying power to activate the brakes of the towed vehicle;

said control module being electrically connected to said power module such that when said braking lever is depressed the brakes of a towed vehicle are engaged proportionally to the degree that the lever is depressed.

90. The trailer brake controller of claim 89, wherein said power module produces and sends a status signal to said control module while said control module and power module are in electrical communication.

91. The trailer brake controller of claim 89, further comprising a visual warning system to alert the user of the separation of the towed vehicle from the towing vehicle.

92. The trailer brake controller of claim 89, further comprising an audible warning system to alert the user of separation of the towed vehicle from the towing vehicle

93. A method of applying the brakes of a towed vehicle when it is in association with a towing vehicle including the steps of:

providing a brake controller comprising a control module and a separate power module, said control module being housed within the cab of the towed vehicle, said power module being housed in the towing vehicle;

providing an accelerometer, a microprocessor and a user interface with manual controls in said control module, such that said control module can generate braking signals in response to braking situations in the towing vehicle; and

providing power drivers, a power amplifier and a microprocessor in said power module;

connecting said control module and said power module, such that braking signals from said control module cause said power module to engage the brakes of the towed vehicle.

94. The method of applying the brakes of a towed vehicle of claim 93, including the step of providing a manual brake lever and a gain knob on said control module.

95. The method of applying the brakes of a towed vehicle of claim 93, including the step of connecting said control module and said power module with control wire.

96. The method of applying the brakes of a towed vehicle of claim 93, including the step of connecting said control module to the ignition switch of the towed vehicle and providing power to said brake controller when said ignition switch is turned on.

97. A brake controller, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

control circuitry for sensing a braking situation and generating a control signal, said control signal comprising a multisequenced signal comprising two or more braking level signals lasting the duration of the braking situation;

power drive circuitry, in communication with said control circuitry, for receiving control signals and generating braking signals to operate the brakes of said towed vehicle.

98. The brake controller of claim 97, wherein said braking level signals are of different brake power levels

99. The brake controller of claim 97, wherein said braking level signals are of different lengths of time.

100. The brake controller of claim 97, wherein said braking level signals are of different brake power levels and different lengths of time.

101. The brake controller of claim 97, wherein said discrete braking level signals include a terminal braking signal lasting the duration of the braking situation.

102. The brake controller of claim 97, wherein said multisequenced signal comprises a series of predetermined braking periods.

103. A brake controller, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

control circuitry for sensing a braking situation and generating a control signal, said control signal comprising a multisequenced signal comprising two or more braking level signals lasting the duration of the braking situation;

a gain controller adapted to change said control signal proportionally to the position of said gain controller;

power drive circuitry, in communication with said control circuitry, for receiving control signals and generating a braking signal to operate the brakes of said towed vehicle.

104. The brake controller of claim 103, wherein increasing gain causes a proportional increase in brake power and decreasing gain causes a proportional decrease in brake power.

105. The brake controller of claim 103, wherein increasing gain causes a proportional increase in time of braking of the first of said braking level signals and decreasing gain causes a proportional decrease in time of braking of the first of said braking level signals.

106. A towed vehicle brake controller, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

control circuitry, for location within the towing vehicle and comprising manual braking controls including a gain control knob and a manual brake lever, an accelerometer comprising acceleration force sensors, and a microprocessor programmed to receive acceleration force data from said accelerometer and produce a control signal in response thereto;

said control signal comprising a multisequenced signal comprising two or more braking level signals lasting the duration of the braking situation;

power circuitry comprising power drivers, braking signal receptors and a power amplifier in electrical communication with said microprocessor such that when said microprocessor produces a control signal, said power module receives said signal, and provides power to a towed vehicle brake system; and

wherein manipulation of said gain control knob sets, through said power module, a static braking force and adjusts said power module'"'"'s response to said accelerometer such that the braking signal generated as result of forces read from said accelerometer is increased or decreased according to the manipulation of the gain control knob.

107. The brake controller of claim 106, wherein said braking level signals are of different lengths of time.

108. The brake controller of claim 106, wherein said braking level signals are of different brake power levels and different lengths of time.

109. The brake controller of claim 106, wherein said discrete braking level signals include a terminal braking signal lasting the duration of the braking situation.

110. The brake controller of claim 106, wherein said multisequenced signal comprises a series of predetermined braking periods.

111. A brake controller, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

control circuitry for sensing a braking situation and generating a control signal;

power drive circuitry, in communication with said control circuitry, for receiving a control signal and generating a braking signal to operate the brakes of said towed vehicle;

wherein a break in communication between said control circuitry and said power drive circuitry causes said power drive circuitry to produce a braking signal comprising a multisequenced signal comprising two or more braking level signals lasting the duration of the braking situation and engage the brakes of said towing vehicle accordingly.

112. The brake controller of claim 111, wherein loss of communication is caused by a break-away condition.

113. The brake controller of claim 111, wherein said braking level signals are of different brake power levels

114. The brake controller of claim 111, wherein said braking level signals are of different lengths of time.

115. The brake controller of claim 111, wherein said braking level signals are of different brake power levels and different lengths of time.

116. The brake controller of claim 111, wherein said discrete braking level signals include a terminal braking signal lasting the duration of the braking situation.

117. The brake controller of claim 111, wherein said multisequenced signal comprises a series of predetermined braking periods.

118. A towed vehicle brake controller system, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

a control module, for location within the towing vehicle and comprising a status display;

a power module, separate from said control module, comprising a status signal generator;

said status signal display being responsive to a signal generated by said status signal generator such that when said power module is operative, said status signal generator produces and sends a status signal which engages said status display.

119. The brake controller of claim 118, wherein said status display is a light emitting diode and said power module causes said light emitting diode to be lit while said power module and control module are in electrical communication.

120. The brake controller of claim 118, wherein said control module comprises an audible alert generator which emits an alarm when no status signal is received from said power module.

121. The brake controller of claim 118, wherein said control module comprises an audible alert generator which emits an alarm, for a predetermined time period, when no status signal is received from said power module.

122. A towed vehicle brake controller system, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

a control module, for location within the towing vehicle and comprising an audible alert generator;

a power module, separate from said control module, comprising a status signal generator;

said audible alert generator being responsive to a signal generated by said status signal generator such that when said power module is operative, said status signal generator produces and sends a status signal and when said status signal is terminated said audible alert generator emits an alarm.

123. The brake controller of claim 122, wherein said alarm terminates after a predetermined period of time.

124. The brake controller of claim 122, wherein said control module comprises a status signal light which is lit when a status signal is received from said power module.

125. A brake controller, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

control circuitry for sensing a braking situation and generating a control signal;

power drive circuitry, including logic circuitry, in communication with said control circuitry, for receiving control signals and generating braking signals to operate the brakes of said towed vehicle, said power drive circuitry comprising heat sensors such that when components of said power drive circuitry reach threshold temperatures said heat sensors cause said logic circuitry to interrupt said braking signals.

126. The brake controller of claim 125, wherein said control circuitry is housed in a control module and said power circuitry is housed in a separate power module.

127. A brake controller, for use with a towing vehicle when the towing vehicle is in association with a towed vehicle, comprising:

control circuitry for sensing a braking situation and generating a control signal;

power drive circuitry, including logic circuitry, in communication with said control circuitry, for receiving control signals and generating braking signals to operate the brakes of said towed vehicle, said power drive circuitry comprising heat sensors such that when components of said power drive circuitry reach threshold temperatures said heat sensors cause said logic circuitry to modulate said braking signals in proportion to said control signal and the temperature of the heat sensors.

128. The brake controller of claim 127, wherein components of said power drive circuitry are matched to characteristics of said brakes of said towed vehicle such that threshold temperatures in said power circuitry and said brakes occur at about the same time in a braking situation.

129. The brake controller of claim 128, wherein said control circuitry is housed in a control module and said power circuitry is housed in a separate power module.