US-12617452-B2 - Electrically powered trailer system with regenerative braking

US12617452B2US 12617452 B2US12617452 B2US 12617452B2US-12617452-B2

Abstract

An electric trailer with regenerative braking is adaptive to both EV and ICE tractors, extending towing range of such vehicles, coordinating with performance characteristics of a tractor for maximum tractor-trailer efficiency. Differential electrical control of wheel drives provides enhanced performance safety and driving control. Embodiments optimize performance using real-time road conditions and terrain information. The trailer provides fail-safe operation in the event of system malfunction.

Inventors

Mark Rinker
Stewart Rinker

Assignees

Mark Rinker
Stewart Rinker

Dates

Publication Date: 20260505
Application Date: 20230501

Claims (19)

1 . An electrically powered trailer, comprising: a hitch configured to connect the electrically powered trailer to a tractor; a plurality of motor/generators comprising an at least one right side motor/generator and an at least one left side motor/generator, each such motor/generator providing torque while consuming a motive electrical power when configured as motor and further providing braking while generating a braking electrical power when configured as generator; at least two drive wheels comprising a right drive wheel and a left drive wheel, the right drive wheel configured to be driven by the at least one right side motor/generator and the left drive wheel configured to be driven by the at least one left side motor/generator; an electrical power storage bank electrically connected to the plurality of motor/generators, the electrical power storage bank configured controllably to release charge to provide the motive electrical power consumed by the plurality of motor/generators, the electrical power storage bank further configured to receive and store the charge from the braking electrical power generated by the plurality of motor/generators; a plurality of sensors, comprising: a left wheel velocity sensor and a right wheel velocity sensor; at least one right load sensor configured with the right wheel and configured to measure a right forward drag and/or a right rear drag on the right wheel and at least one left load sensor configured with the left wheel and configured to measure a left forward drag and/or a left rear drag on the left wheel; a towing load sensor configured to provide data measuring towing tension between the tractor and the electrically powered trailer at the hitch; a hitch angle sensor configured to provide data measuring angular displacement between the electrically powered trailer and the tractor; and a trailer control system, comprising: a controller configured to receive input from the plurality of sensors; a plurality of effectors under control of the controller, comprising: a torque/braking selector effector configured differentially to select each of the plurality of motor/generators as either motor or generator; a power control effector configured differentially to control the motive electrical power from the electrical power storage bank consumed by the motor/generator when the motor/generator is selected as motor; a braking control effector configured differentially to apply braking to the motor/generator when the motor/generator is selected as generator; the controller further configured to apply the torque or braking differentially to the plurality of motor/generators by way of the plurality of effectors in response to the input from the plurality of sensors.
2 . The electrically powered trailer according to claim 1 , wherein the at least two drive wheels are capable of a passive rotation and are configured to revert to the passive rotation in an event of system failure.
3 . The electrically powered trailer according to claim 1 , wherein the controller is configured to apply a total torque or braking to the plurality of motor/generators in response to the data measuring towing tension from the towing load sensor, and the controller is further configured to apply a differential torque or braking to the plurality of motor/generators in response to the data measuring angular displacement from the hitch angle sensor.
4 . The electrically powered trailer according to claim 3 , further comprising: a GPS receiver providing location data to the trailer control system; a route source of travel data to the trailer control system; wherein the trailer control system is configured to maximize efficiency of the electrically powered trailer in operation of the plurality of motor/generators in response to the location data from the GPS receiver and the route source of travel data.
5 . The electrically powered trailer according to claim 4 , in which the route source of travel data is at least one of a map data source, a terrain data source and a road conditions data source.
6 . The electrically powered trailer according to claim 3 , further comprising: a power level sensor configured to indicate to the controller when the electrical power storage bank is full; a means of dispersing an excess charge from the electrical power storage bank as heat; a charge regulation effector configured selectively to direct the braking electrical power to the electrical power storage bank or to the means of dispersing the excess charge; and wherein the controller is further configured to employ the charge regulation effector to direct the charge from the braking electrical power generated by the plurality of motor/generators to the electrical power storage bank when the power level sensor does not indicate that the electrical power storage bank is full and to the means of dispersing the excess charge when the power level sensor indicates that the electrical power storage bank is full.
7 . The electrically powered trailer according to claim 6 , wherein the means of dispersing the excess charge is selected from at least one of a thermal resistive radiator, a heater for a passenger compartment in the tractor, and a heat sink for storage of thermal energy.
8 . The electrically powered trailer according to claim 3 , further comprising: an odometer configured to provide data on distance traveled; a power meter providing data measuring power consumed by the plurality of motor/generators; wherein the controller is further configured to apply the total torque or braking to the plurality of motor/generators in response to the data on distance traveled provided by the odometer and the data measuring power consumed provided by the power meter so as to maximize trailer efficiency.
9 . The electrically powered trailer of claim 1 wherein the at least one right load sensor includes a right forward load sensor and a right rear load sensor, and the at least one left load sensor includes a left forward load sensor and a left rear load sensor.
10 . The electrically powered trailer of claim 9 wherein the right forward load sensor is configured to measure a forward drag on the right wheel and the right rear load sensor is configured to measure a rear drag on the right wheel, and the left forward load sensor is configured to measure a forward drag on the left wheel and the left rear load sensor is configured to measure a rear drag on the left wheel.
11 . A combination of a tractor and a trailer, the tractor towing the trailer, the trailer controllably and differentially powered by a plurality of electrical motor/generators, the combination comprising: a trailer electrical power storage bank supplying power to and storing charge from the plurality of electrical motor/generators; a trailer control system; sensor data supplied to the trailer control system from at least one sensor, the at least one sensor including at least one right load sensor configured with a right wheel of the trailer and configured to measure a right forward drag and/or a right rear drag on the right wheel and at least one left load sensor configured with a left wheel of the trailer and configured to measure a left forward drag and/or a left rear drag on the left wheel; wherein the trailer control system is configured to operate the plurality of electrical motor/generators differentially in response to the tractor data.
12 . A combination according to claim 11 , wherein the tractor data comprises braking commands from an operator of the tractor.
13 . A combination according to claim 11 , wherein an on-board engine and transmission control system of the tractor generates the tractor data.
14 . A combination according to claim 11 , wherein an online diagnostics port of the tractor generates the tractor data.
15 . A combination according to claim 11 , wherein the tractor is driven by an engine, the tractor data supplied to the trailer control system is a characteristic performance curve of the engine, wherein the trailer control system is further configured to operate the plurality of electrical motor/generators in tandem with the characteristic performance curve of the engine so as to optimize efficiency of the combination.
16 . A combination according to claim 15 , wherein the tractor is driven by an internal combustion engine.
17 . A combination according to claim 15 , wherein the tractor is an electric vehicle.
18 . A combination according to claim 15 , wherein the tractor is a hybrid electric-internal combustion vehicle.
19 . An electrically powered trailer, comprising: a plurality of motor/generators operating to provide torque or braking differentially to a plurality of drive wheels; an electrical power storage bank supplying power to and receiving charge from the plurality of motor/generators; a trailer control system; sensor data supplied to the trailer control system from at least one sensor, the at least one sensor including at least one right load sensor configured with a right wheel of the trailer and configured to measure a right forward drag and/or a right rear drag on the right wheel and at least one left load sensor configured with a left wheel of the trailer and configured to measure a left forward drag and/or a left rear drag on the left wheel; a GPS receiver providing location data to the trailer control system; an information source of route data to the trailer control system; wherein the trailer control system is configured to maximize efficiency of the electrically powered trailer in operation of the plurality of motor/generators in response to the location data from the GPS receiver and route data from the information source of route data.

Description

CROSS-REFERENCE TO RELATED APPLICATION This application claims the benefit of U.S. provisional patent application No. 63/337,331, filed May 2, 2022, incorporated herein by reference. BACKGROUND OF THE INVENTION Field of the Invention This specification relates to trailers that are transported behind towing vehicles. This specification further relates to such trailers that can supply their own motive power. Yet further, this specification relates to powered trailers employing regenerative braking and related technology to increase towing range. Further still, this specification relates to systems for such powered trailers to gather and process data to provide real-time optimization of tractor-trailer operation in transit with user interface. Description of the Related Art A towed vehicle arrangement comprises a towing vehicle (which may be a tractor, a truck, an SUV, a passenger car, a van or any other motorized vehicle) and a trailer. For simplicity's sake, the towing vehicle will be referred to herein simply as a tractor. In the towed vehicle arrangement, the tractor has traditionally supplied all the motive power and the trailer or semi-trailer has been a passive towed vehicle. Further, braking of the towed vehicle has generally been exclusively in response to control by the tractor operator. For safety and maneuverability, larger modern trailers employ braking systems. Earlier systems employed separate driver controls dedicated to trailer brake operation. For example, U.S. Pat. No. 3,985,395 to Watanabe is a remote control brake system for trailers, in which a system signal controlled by the movement of an actuator on the tractor cab proportionally controls brake pressure applied to trailer brakes. Later systems couple trailer brake control with the standard braking applied by the driver of the tractor vehicle. For example, U.S. Pat. No. 6,666,527 to Gill et al. describes an electro-hydraulic brake actuating device for a trailer, whereby a control sensor indicates the degree of braking in the towing vehicle and a controller responsively provides appropriate differential hydraulic braking to the trailer. Some more recent systems replace hydraulic trailer braking with regenerative electronic braking. For example, U.S. Pat. No. 6,516,925 to Napier et al. describes a system and method for braking a towed conveyance, in which motor/generators on the towed vehicle provide regenerative braking for the trailer. Similarly, U.S. Pat. No. 8,215,436 to DeGrave et al. describes a system and method for a regenerative braking system on a towed vehicle. Since the resistive generators employed in regenerative braking also can serve as motors, systems have been developed in which electrical motive power is supplied to the trailer along with braking functionality. Such systems enable additional control and towing range in tractor-trailer operation. U.S. Pat. No. 8,365,849 to Bartel discloses a control system for trailers to maintain a constant towing load on the towing vehicle. Bartel's system comprises a closed loop controller, a towing arm assembly, a load measuring device, an electric hub motor, brakes, a motor controller and a brake controller disposed on the trailer. The controller generates a command signal to either modulate the brakes or motor up or down depending on the sign of the command signal, providing braking or acceleration as needed. Because motorizing the trailer adds power, the tractor-trailer combination's capability is enhanced. U.S. Pat. No. 8,820,443 to Ferri provides an all in one towing system, in which a trailer has its own mechanical differential drive train system communicatively coupled to an electronic control unit of the lead vehicle to ensure that the power output of the trailer matches the power output of the lead vehicle. Thereby, vehicles can tow Ferri's trailers with heavier loads than possible with passive, unpowered trailers, enabling increased capability and range for the tractor-trailer combination. However, Ferri's trailer, whose motive power relies entirely on a mechanical differential drive train, affords only gross control of trailer trajectory and is not adequately responsive to safety and emergency issues such as jackknifing. Regenerative braking systems, providing the multiple utilities of energy storage, motive power and braking for the vehicle, can be advantageously employed in the trailer of a tractor-trailer combination. For example, U.S. patent application number 20080023234 to Wang describes a self-controlled, electric powered trailer employing regenerative braking to charge the battery source supplying power to trailer motors. Utilization of regenerative braking technology in the trailer can extend the range of the tractor-trailer combination. For example, U.S. Pat. No. 10,752,102 to Lampsa et al. describes a trailer mounted battery range extender for electric truck tractor, the purpose of which is to provide a trailer battery system capable of powering or providing sup