What is a brake controller and how do they work?

If you’re planning an adventure, you’ve no doubt considered all the great aspects of the journey, along with some of the things that could go wrong. You have fitted your roof racks and bike carrier, your LED lighting attached, solar blankets and wheel covers packed into the tool boxes, and your towing mirrors are set up and ready to go. 

You’ve packed your marine fuel for the boat, making sure all your battery accessories are there for your dual battery pack, and you have your power tools, air compressor and pressure washer ready for the off-roading adventure of a lifetime.

Now it’s time to attach your trailer or caravan to your vehicle, which means understanding everything you can about the towing brakes and braking accessories. Including their necessity when it comes to safe travels.

The importance of quality towing and brake controllers

Chances are, you are already aware that it takes more than just the tow vehicle’s brakes to bring the vehicle itself and its trailer to a complete stop within a suitable time frame. Considering trailer weight and speed, it becomes clear the trailer also needs to pitch in with its braking power.

This is accomplished via the trailer’s brakes, which can be one of two types: surge (mechanic or hydraulic), which relies on inertia to slow down automatically, or electric brakes, which require an electric connection to the tow vehicle to work. The principle behind surge (also known as override or overrun) brakes is simple.

The coupling contains a sliding shaft attached to the tow ball. The shaft slides when pushed due to the vehicle slowing down and exerts pressure directly on a mechanical linkage (mechanical brakes) or a link connected to a hydraulic cylinder, which in turn creates hydraulic pressure on the braking system (hydraulic brakes). These are often found on camper trailers or boat trailers.

Electric trailer brakes work by activating electromagnetic brake drums to create attrition and slow the trailer down. While surge brakes operate independently, electric trailer brakes must be connected to the tow vehicle’s power and regulated by a brake control unit or electric brake controller.

What is a brake controller?

A brake controller is an electronic device that activates and, as the word suggests, controls the electric brakes of a trailer. 

A brake controller can be roughly split into an interface positioned in the cab within the driver’s reach and the central part responsible for activating the trailer’s brakes. Electronic brake controllers can be classified into non-proportional, time-based, proportional or inertia-based types.

How do older brake controllers work? 

Older non-proportional electric brake controllers are activated when the driver presses on the car’s brakes, applying braking force over time based on the chosen setting. 

The drawback of this kind of brake controller is that even though the pressure applied on the tow vehicle’s brake pedal can vary (for instance, compare a gentle brake to an abrupt one), the response of the trailer brakes will be the same, the one configured in its settings. 

How do newer brake controllers work?

The newer proportional electric brake controllers measure the changing momentum, or inertia, of the moving car via an accelerometer; they are not directly connected to the car’s brakes and work independently of them.

 Continuously monitoring the vehicle’s dynamics, these controllers send the precise amount of voltage to the trailer brakes to ensure that the speed of the trailer matches that of the tow vehicle. This generally makes for a smoother braking experience and more efficient braking, ensuring your trailer brakes last longer.

For instance, when going downhill, you’ll want to use lower gears to slow down to decrease brake wear; inertia-based brake controllers sense that the vehicle is slowing down (rather than the vehicle’s brakes being applied) and adjust trailer braking power accordingly. 

The drawbacks of in-car installations

Conventionally, electric brake controllers have been installed “in-car”. That is, they had to be hard-wired aftermarket within the vehicle for towing. The interface would be mounted in the least obtrusive position in the cab but within reach of the driver’s seat. This would be traditionally accomplished by drilling holes into the dashboard, fixing the provided mounting brackets with screws, and attaching the interface to these brackets. 

The wiring would then be connected to the vehicle’s wiring loom and ran to the rear, terminating at the vehicle’s trailer adapters. This translated into the necessity of having a new brake controller fitted every time one used a different vehicle for towing purposes. For instance, when the trailer is lent, hired, or there is a vehicle upgrade.

How is Elecbrakes different?

Advancements in microprocessors and wireless technology have changed how electric towing systems work. Launched in 2017, the latest innovation in electric brake controllers is Australian designed, produced, and called Elecbrakes: a remote mount electric trailer brake controller installed directly on the trailer, rather than within the tow vehicle. 

An intuitive, smartphone-based solution for any trailer that gets towed by more than one vehicle, Elecbrakes eliminates the need to modify every single car used for towing purposes. Instead, the compact device goes directly on the trailer and contains a high-speed microprocessor connected to sensors, which continuously sample the operating parameters of the brakes. 

The main unit communicates wirelessly with the driver interface, a simple-to-use app compatible with both Apple and Android smartphones. 

In addition to the added flexibility, Elecbrakes also provides best-in-class configuration options (up to 5 favourite settings that you can save in the device’s memory) and continuous monitoring of brake response and key performance indicators. The data is conveyed at your fingertips directly on your smartphone via the widespread Bluetooth technology. 

Elecbrakes are compatible with 12V and 24V voltage systems and designed to operate 1 to 2 braked axles. It is also 100% dust and waterproof thanks to its tough fibre reinforced housing with the electronics fully encased in urethane. 

We believe an intelligent, trailer-based, wireless electric brake controller such as Elecbrakes makes towing so much simpler and gives you the freedom to be more flexible and spontaneous to tow with a broader range of vehicles. 

Electric brakes and their controllers are essential for managing heavier loads, as it requires significant power and control to bring the weight of the trailer (and the towing vehicle) to a complete stop. For any owner considering towing their trailer with more than one vehicle, Elecbrakes is the best solution in terms of electronic brake controllers.

Why do I need an electric brake controller?

Imagine what would happen if your trailer only had its electric trailer brakes and did not have a brake controller system. Let’s say you’re ready to start your first camping trip with your shiny new caravan secured behind your vehicle. 

You drive down your driveway towards the road, brake to turn and BOOM! Your caravan may push the vehicle into a dangerous situation. Why? Because your trailer’s electric brakes did not work. Electric trailer brakes do not activate independently; they require a brake controller to do so.

It’s easy to see why trailer brakes and brake controllers are a legal requirement worldwide, and Australia is no exception. ADR38 provides relevant legislation, specifying trailer brake requirements based on GTM (Gross Trailer Mass) and is legally binding in all states. 

The manufacturer supplies maximum GTM, and all trailers built since August 1989 must list the trailer’s ATM, GTM and tare weight on their Vehicle Identification Plate (VIP).

ADR identify three different trailer categories based on their GTM

1. GTM less than 750kg: brakes (hence brake controllers) are not regulated

While the law does not explicitly state the necessity of having brakes installed on lighter trailers, and unless the trailer is way under 750kg GTM, it is still good practice to aid your tow vehicle’s brakes. To this end, you may install surge or electric brakes. Learn more about how they work here.

2. GTM between 750kg and 2,000kg: brakes are required and must operate on both wheels of at least one axle

There are two options here.

Option one: 

The trailer can be equipped with mechanical or hydraulic override brakes, which do not require electricity to work and are therefore well-suited for boat trailers, which often end up in the water. 

The drawback of this type of trailer brake is that it is either “on” or “off,” with no in-between possible. In this case, a brake controller is not required as they activate automatically.

Option two: 

Equipping the trailer with electric brakes, which run on the electricity supplied by the vehicle. In this case, an electric brake controller is required. 

The brake controller needs to be designed in such a way as to enable the trailer’s braking force to be progressively increased and decreased, as opposed to implementing a stable braking force; this requirement entails that the brake controller must be of the proportional or inertia-based type. 

Additionally, the brake control device must be controllable from the driver’s seat. Proportional electric brake controllers enable more accurate and controlled braking and reduce wear of both towing vehicle and trailer brakes. 

At the same time, they apply the trailer brakes in proportion to the vehicle’s slowing down; they are also adjustable by the driver. 

3. GTM over 2,000kg: brakes are required and must operate on all wheels/axles

The law states that trailer brakes are mandatory and must be operational on all wheels. They must also be designed so that the braking force can be progressively increased and decreased and be adjustable from the driver’s seat.

The law also requires trailers over 2,000kg GTM have a breakaway system. A breakaway system is a device that ensures the trailer slows down on its own accord in the hazardous and unpredictable event that it becomes disconnected from your vehicle while moving. 

It has a battery mounted on the trailer and a cable connecting the trailer to the vehicle and is activated if the trailer breaks free, pulling the cable out of its plug.

A switch will then trigger the battery and apply the trailer brakes to slow the trailer down. The brakes will remain locked for 15 minutes. 

You should always check that the battery is charged (it should be able to operate for at least 15 minutes) and that the breakaway system is functioning properly. Take a battery charger with you on your adventures to ensure it’s always in top working condition.

To test, pull the cable: the trailer brakes should lock automatically. Then, replace the cable in the switch to disengage. 

In addition to the above requirement, NSW Roads and Maritime Services also state (VIB 6, 2007) that the towing vehicle must continuously charge the breakaway system. 

It also requires a warning device, fitted within the driver’s eyesight or earshot, that warns the driver should the deep-cycle batteries’ charge fall below the required level, rendering the trailer brakes incapable of meeting the requirement.

If you plan to tow any trailer with GTM above 750kg, electric brakes and an electric brake controller are your best bet to be safe and compliant with legal requirements.

We at Elecbrakes have developed the electric brake controller that fits the bill. Elecbrakes is a proportional brake controller mounted onto the trailer rather than the car, eliminating the need for hardwiring the tow vehicle. 

Once installed on the trailer, Elecbrakes will open up a world of opportunities. Any vehicle big enough to tow your trailer can now do so, with no additional set-up procedures or costs apart from a tow bar. In addition, there is no drilling of the dashboard or hardwiring of the vehicle necessary. 

Elecbrakes works via wireless Bluetooth technology: the trailer-installed device utilises Bluetooth 4.0 to communicate wirelessly with your smartphone via the intuitive Elecbrakes app, continuously monitoring brakes’ conditions and performance, helping you keep an eye on the trailer’s service needs. 

Our app is also fully customisable: The driver can easily control the brake response with precise settings (you can choose up to 5 favourite programs) through the smartphone app, available both for Apple and Android. 

Any adjustments made to the programs are stored in the device’s memory, meaning the owner can fine-tune the programs for any other user wishing to use the trailer in the future. A driver borrowing or renting a trailer equipped with Elecbrakes will only need to download the free app on their phone. It is the only set-up required once the trailer is attached to the towing vehicle. 

Elecbrakes are compatible with 12V and 24V voltage systems and designed to operate 1 to 2 braked axles. It is 100% dust and waterproof thanks to its tough fibre reinforced housing with the electronics fully encased in urethane.

The trailer-mounted, compact device employs a high-speed microprocessor connected to sensors, which continuously sample the various operating parameters a thousand times per second. Its long-range capabilities guarantee a consistent, trustworthy wireless connection without dropouts under typical operating conditions.

Being both proportional and controllable right from the driver’s seat, Elecbrakes fully complies with ADR38 and is the new alternative to traditional “in-car” brake controllers. As a result, no matter how many vehicles will tow your trailer, you will only need to install Elecbrakes once. And you’ll have the peace of mind of a high-precision, safe, and compliant solution to your towing needs.

Unless your trailer weighs less than 750kg when loaded, you will be required to install brakes. We recommend installing a proportional electric brake controller, such as Elecbrakes, to ensure compliance, safety and protection of what’s valuable to you, all the while giving you the freedom of using a range of vehicles to tow your trailer.

How do I install an electric brake controller?

Vehicle-based brake controller installation

Vehicle-based electric brake controllers require modifications to the tow vehicle (or vehicles), usually to the dash area. Each towing vehicle requires a brake controller set, although some newer models have a “removable” interface (you will still need to install the bracket and the wires). 

Most electric brake controllers consist of the main unit, often hidden under the dash, and a user interface unit installed on the dash within the driver’s reach. Both units should be mounted inside the vehicle with screws or other secure fitting methods to avoid any movement. 

Whether the brake controller is of motion-sensing or time-delay type, you may need to position the main unit at a certain angle for the direction of motion. 

You will then fix the provided mounting brackets with screws by drilling a few holes into the dashboard and attaching the interface to these brackets. 

Then, you will connect the brake controller’s wiring to the vehicle’s wiring loom and run it to the rear of the vehicle and the trailer plug, whether it’s a pin flat plug or round plug.

Many vehicles suitable for towing, such as SUVs and vans, produced in the mid-1990s and onwards, include a factory-installed “quick plug”, located under the dash, which allows to plug in a standard brake controller’s wiring set, which saves installation time.

Elecbrakes installation

Ease of use and ease of installation is a priority here at Elecbrakes. This is why Elecbrakes can be installed and set up in 5 easy steps that require only a few tools from your tool kit and minimal mechanical knowledge, all easily accomplished in under 2 hours.

What are the benefits of having the Elecbrakes installed on the trailer and not on the car?

Traditionally, although devised to control the braking system of a trailer, electric brake controllers have been built to be mounted on the tow vehicle, then wired and connected to the trailer through the vehicle’s wiring via the tow bar. 

This is often a lengthy process that requires a degree of mechanical know-how to implement modifications to one’s car.

Elecbrakes is innovative and different because this electric brake controller is a trailer-mounted solution rather than an in-car one.

The distinction may be a bit fuzzy until you think about the practicalities of towing. You must remember:

• The vehicle needs to be powerful enough to take on the trailer’s weight.
• It needs to have a tow bar where you can hook the trailer.
• It needs an appropriate electric brake controller to tell the trailer brakes when to activate. 

We at Elecbrakes believe that towing does not need to be that complicated. It’s not all about dash cameras and fancy steering wheels. Towing should be about the freedom and flexibility to match different vehicles to different trailers. 

We have developed a unique solution: An electric brake controller mounted on the trailer rather than the tow vehicle. It makes sense if you think about it: not all cars tow, but all trailers get towed.

1. Trailer mounting

Elecbrakes is the electric brake controller mounted onto the trailer rather than the car, eliminating the need for modifying or in any way adapting the tow vehicle, apart from fitting it with a tow bar (if you don’t already have one). 

No drilling the dashboard or hardwiring the vehicle of any sort. 

2. Bluetooth technology

This is possible because Elecbrakes works via wireless Bluetooth technology. 

The trailer-installed component communicates wirelessly with the intuitive Elecbrakes app directly on your smartphone, which you will need to keep secured on its dashboard holder and within reach while you drive.

3. App 

Anybody can download and quickly set up the Elecbrakes app, which is available for both Apple and Android, entirely for free, so your only investment in a brake controller is the Elecbrakes device to be mounted on your trailer.

4. Customisable options

The Elecbrakes app allows you to save up to 5 different settings (road conditions, trailer load, etc.) so that set-up is relatively straightforward. 

These settings will then be stored on the trailer’s Elecbrakes device, so new drivers will have easy access to them when driving it. Any vehicle big enough to tow your caravan is free to do so, with minimum time and effort. 

5. Monitors usage and performance

And that’s not all. In addition to granting you the flexibility of using a variety of vehicles to tow your trailer, Elecbrakes also continuously monitors brakes’ usage and performance. 

This helps you keep an eye on the trailer’s service needs and reminds you when it’s time to change your trailer brakes. 

6. Motion sensors

Elecbrakes are also motion-sensing. The trailer-mounted, compact device employs a high-speed microprocessor connected to sensors, which continuously sample vehicle dynamics and other operating parameters a thousand times per second. 

Its long-range capabilities guarantee a consistent, trustworthy wireless connection without dropouts under typical operating conditions.

7. Compliance

Being both proportional and controllable right from the driver’s seat, Elecbrakes fully complies with ADR38 and is the new alternative to traditional “in-car” brake controllers. 

No matter how many vehicles will tow your trailer, you will only need to install Elecbrakes once — and have the peace of mind of a high-precision, safe, and compliant solution to your towing needs.

Why Elecbrakes?

Elecbrakes is the best solution for a high-quality, practical, time and cost-effective electric brake controller. We like to make towing simple, with a brake controller directly on the trailer and connecting with the driver’s smartphone.

So, what are you waiting for? First, grab your engine oil, solar panels, wiring kit and any other extras (you might want to include some extra fuel filters, switch inserts, driving light replacements, cable ties, and anything you need for tyre care or other repair tools). 

Then check out the electronic brake controllers available with Elecbrakes (our regular price is highly affordable) and get ready for the adventure of a lifetime.