System and method for power supply management in transport refrigeration unit

Abstract

Disclosed herein is a power supply system for a transport refrigeration unit (TRU). The system includes a battery and a generator connected to the battery. A generator is operatively coupled to an axle of the trailer to generate electrical power upon rotation of the axle. The system also includes a controller operatively coupled to the battery, the TRU, and the generator. The controller is configured to: monitor a real-time SoC of the battery; predicting an electrical power consumption of the TRU for the journey of the predefined duration; monitoring the rotational speed of the axle and correspondingly determining the electrical power available at the generator; and activating the generator to generate and supply electrical power to the battery and / or the TRU based on the predicted electrical power consumption, the real-time SoC of the battery and the rotational speed of the axle or the electrical power available at the generator.

Description

Technical Field

[0001] The present invention relates to transport refrigeration units and power supply management systems, and more particularly, to systems, methods, and controls for power supply management in a transport refrigeration unit (TRU) equipped with batteries and axle generators. Summary of the Invention

[0002] Disclosed herein is a power supply system for a transport refrigeration unit (TRU). The system includes: a battery electrically connected to one or more components of the TRU; a generator electrically connected to the battery, wherein the generator is operatively coupled to an axle of a trailer associated with the TRU and is configured to generate electrical power upon rotation of the axle and based on the rotational speed of the axle; and a controller operatively coupled to the battery, the TRU, and the generator. The controller is configured to: monitor the real-time state of charge (SoC) of the battery or the amount of energy available in the battery; predict the electric power consumption of the TRU for a trip of a predefined duration based on data related to the average electric power consumption of the TRU monitored in real time over a predefined time; monitor the rotational speed of the axle or the speed of the trailer during the trip and correspondingly determine the electric power generated by or available at the generator; and activate the generator to generate electric power during the trip and supply it to the battery and / or the TRU based on one or more of the predicted electric power consumption of the TRU, the real-time SoC of the battery or the amount of energy available in the battery, and the rotational speed of the axle or the speed of the trailer or the electric power available at the generator.

[0003] In one or more embodiments, the controller is configured to adjust the activation duration of the generator during the trip to enable the generator to generate a predefined electric power and supply it to the battery for maintaining the SoC of the battery above a predefined SoC level during the trip, or maintaining the amount of energy available in the battery above a predefined energy level for a predefined duration, wherein the predefined SoC level or the predefined energy level is selected based on a predicted electric power consumption of the TRU during the trip and a power storage capacity of the battery.

[0004] In one or more embodiments, upon detecting that the real-time SoC of the battery is greater than a predefined SoC level, the controller is configured to disable the generator based on the real-time electric power consumption of the TRU and enable supply of electric power from the battery to components of the TRU.

[0005] In one or more embodiments, upon detecting that the real-time SoC of the battery is equal to or lower than a predefined SoC level, the controller is configured to activate the generator to generate electric power and supply it to the battery based on the real-time electric power consumption of the TRU to maintain the SoC of the battery above the predefined SoC level while enabling the supply of electric power from the battery to components of the TRU.

[0006] In one or more embodiments, the generator is electrically connected to one or more components of the TRU, wherein upon detecting that a real-time SoC of the battery is equal to or below a predefined SoC level, the controller activates the generator to generate electric power and supply it from the generator to the TRU based on the real-time electric power consumption of the TRU.

[0007] In one or more embodiments, upon detecting that the electric power generated by or available at the generator is greater than the real-time electric power consumption of the TRU and the real-time SoC of the battery is monitored to be equal to or lower than a predefined SoC level, the controller enables the generator to supply electric power from the generator to the TRU based on the real-time electric power consumption of the TRU and the real-time rotational speed of the axle or the speed of the trailer, while supplying a portion of the generated electric power to the battery to charge the battery.

[0008] In one or more embodiments, the electric power generated by or available at the generator is determined based on a generator power versus speed characteristic of the generator, wherein the generator power versus speed characteristic is determined based on a speed of rotation of the axle, parameters associated with the trailer and the generator, and one or more road attributes associated with the road on which the trailer is moving during the trip.

[0009] In one or more embodiments, the system includes: a first set of sensors for monitoring in real time the electrical power consumed by one or more components or TRUs; a second set of sensors for monitoring the real-time SoC of the battery; and a third set of sensors for monitoring the rotational speed of the axle and one or more road attributes associated with the road during the trip, and correspondingly determining the electrical power generated by or available at the generator.

[0010] In one or more embodiments, the controller is configured to calculate and monitor the SoC of the battery or the remaining energy available in the battery using a battery management system (BMS) associated with the battery, where the SoC indicates the electrical power stored in or available in the battery.

[0011] In one or more embodiments, the generator is configured with a power conversion device to convert the electrical power generated by the generator into DC power for the battery and / or into AC or DC power for components of the TRU.

[0012] Also described herein is a method for power supply management in a transport refrigeration unit (TRU) equipped with an engine and a battery. The method includes: monitoring, by a controller, a real-time state of charge (SoC) of the battery or the amount of energy available in the battery; predicting, by the controller, the electrical power consumption of the TRU for a trip of a predefined duration based on data related to the average electrical power consumption of the TRU monitored in real time over a predefined time; monitoring, by the controller, the rotational speed of the axle associated with the TRU or the speed of a trailer during the trip and correspondingly determining the electrical power generated by or available at a generator; and activating, by the controller, the generator for generating and supplying electrical power to the battery and / or the TRU during the trip based on one or more of the predicted electrical power consumption of the TRU, the real-time SoC of the battery or the amount of energy available in the battery, and the rotational speed of the axle or the speed of the trailer or the electrical power available at the generator.

[0013] In one or more embodiments, the method includes the following steps: adjusting, by the controller, the activation duration of the generator during the trip so that the generator is able to generate a predefined electric power and supply it to the battery for maintaining the SoC of the battery above a predefined SoC level during the trip, wherein the predefined SoC level is selected based on the predicted electric power consumption of the TRU during the trip and the power storage capacity of the battery.

[0014] In one or more embodiments, the method includes the following steps: when the real-time SoC of the battery is greater than the predefined SoC level, the controller deactivates the generator based on the real-time electric power consumption of the TRU, and enables the electric power to be supplied from the battery to the components of the TRU.

[0015] In one or more embodiments, when the real-time SoC of the battery reaches a first predefined SoC level, the method includes the following steps: activating a generator for generating electric power and supplying it to the battery until the real-time SoC of the battery reaches a second predefined SoC level, wherein the second predefined SoC level is greater than the first predefined SoC level.

[0016] In one or more embodiments, the method includes the following steps: when the real-time SoC of the battery is equal to or lower than a predefined SoC level, the controller activates the generator based on the real-time electric power consumption of the TRU to generate electric power and supply it to the battery to maintain the SoC of the battery above the predefined SoC level while enabling the supply of electric power from the battery to components of the TRU.

[0017] In one or more embodiments, the generator is electrically connected to one or more components of the TRU, wherein when the real-time SoC of the battery is equal to or lower than a predefined SoC level, the method includes the steps of: activating the generator to generate electric power and supplying it from the generator to the TRU based on the real-time electric power consumption of the TRU.

[0018] In one or more embodiments, when the electric power generated by or available at the generator is determined to be greater than the real-time electric power consumption of the TRU and the real-time SoC of the battery is monitored to be equal to or lower than a predefined SoC level, the method includes the following steps: enabling the generator to supply electric power from the generator to the TRU based on the real-time electric power consumption of the TRU and the real-time rotation speed of the axle or the speed of the trailer, while supplying a portion of the generated electric power to the battery to charge the battery.

[0019] In one or more embodiments, the electric power generated by or available at the generator is determined based on a generator power versus speed characteristic of the generator, wherein the generator power versus speed characteristic is determined based on one or more of a speed of rotation of the axle, parameters associated with the trailer and the generator, and one or more road attributes associated with the road on which the trailer is moving during the trip.

[0020] Also described herein is a power supply control apparatus for a transport refrigeration unit (TRU) equipped with a battery and an axle generator. The apparatus includes a controller configured to be operatively connected to the TRU, a generator, and a battery management system (BMS) associated with the battery, wherein the controller includes one or more processors coupled to a memory storing instructions executable by the processors, the instructions causing the controller to monitor a real-time state of charge (SoC) of the battery, predict the TRU's electric power consumption for a trip of a predefined duration based on data related to the TRU's average electric power consumption monitored in real time over a predefined time, monitor the rotational speed of the axle or the speed of the trailer during the trip and correspondingly determine the electric power generated by or available at the generator, and activate the generator to generate and supply electric power to the battery and / or the TRU during the trip based on one or more of the predicted electric power consumption of the TRU, the real-time SoC of the battery, and the rotational speed of the axle or the speed of the trailer or the electric power available at the generator.

[0021] In one or more embodiments, the device includes: a first set of sensors for monitoring in real time the electric power consumed by one or more components or TRUs and monitoring the electric power generated by the generator; a second set of sensors for monitoring the real-time state of charge (SoC) of the battery; and a third set of sensors for monitoring the rotational speed of the wheel axle and one or more road attributes associated with the road during the trip, and correspondingly determining the electric power generated by or available at the generator.

[0022] The foregoing summary is merely illustrative and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, features, and techniques of the present disclosure will become more apparent from the following description in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The accompanying drawings are included to provide a further understanding of the subject disclosure and are incorporated in and constitute a part of this specification. The accompanying drawings illustrate exemplary embodiments of the subject disclosure and together with the description serve to explain the principles of the subject disclosure.

[0024] In the accompanying drawings, similar components and / or features may have the same reference number. In addition, various components of the same type may be distinguished by following the reference number with a second reference number that distinguishes between the similar components. If only the first reference number is used in the specification, the description applies to any of the similar components having the same first reference number, regardless of the second reference number.

[0025] Figure 1A and 1B An exemplary representation of a system for implementing power supply management in a transport refrigeration unit (TRU) equipped with an axle generator and a battery is illustrated in accordance with one or more embodiments of the subject disclosure.

[0026] Figure 2 The figure depicts an exemplary block diagram of functional modules of a power supply control device for a TRU according to one or more embodiments of the subject disclosure.

[0027] Figure 3 Illustrated are exemplary steps involved in a method for implementing power supply management in a transport refrigeration unit (TRU) equipped with an axle generator and a battery, according to one or more embodiments of the subject disclosure.

[0028] Figure 4 Exemplary graphs depicting changes in battery SoC, trailer's speed, generator power, and TRU's electrical power consumption are illustrated to illustrate the working of the present invention in detail. DETAILED DESCRIPTION

[0029] The following is a detailed description of the embodiments of the present disclosure as depicted in the accompanying drawings. The embodiments are described in such detail so as to clearly convey the present disclosure. However, the amount of detail provided is not intended to limit the intended variations of the embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives that fall within the scope and spirit of the subject disclosure as defined by the appended claims.

[0030] Various terms are used herein. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term at the time of filing as reflected in printed publications and issued patents.

[0031] In the specification, when an apparatus is depicted in the accompanying drawings, reference may be made to the spatial relationships between various components and the spatial orientation of aspects of the components. However, as will be appreciated by those skilled in the art after a complete reading of this subject disclosure, the components of the invention described herein may be positioned in any desired orientation. Therefore, the use of terms such as "above," "below," "above," "below," "first," "second," or other similar terms to describe the spatial relationships between various components or to describe the spatial orientation of aspects of such components should be understood to describe the relative relationships between components or the spatial orientation of aspects of such components.

[0032] Transport Refrigeration Units (TRUs), commonly referred to as reefer units, are crucial for allowing the safe and efficient transportation of perishable goods over long distances. These units can rely on batteries or an external power source to power the TRU. A critical aspect of these systems is ensuring a consistent and reliable power source not only for the refrigeration process, but also for the auxiliary systems that support the unit's operation, including battery systems that power electronic controls, safety systems, and other critical components.

[0033] Existing refrigeration units involve axle generators for powering the TRU and batteries. The generator can be configured with an axle or hub associated with the trailer (or vehicle or container) on which the TRU is mounted. The generator can generate energy for supplying power to the TRU and charge the battery when the trailer moves or the rotation of the axle exceeds a certain speed. However, this arrangement has been considered inefficient in terms of energy use. In particular, it has been observed that trailers are driven by internal combustion engines, where fuel combustion becomes particularly challenging. Exceeding speed not only increases fuel consumption, but also leads to higher maintenance costs and increased emissions.

[0034] The present invention overcomes the aforementioned shortcomings and limitations associated with existing generator-based refrigeration units / TRUs and associated power supply management by providing an improved, cost-effective and efficient solution that optimizes electrical power usage in the refrigeration unit / TRU, thereby ensuring effective and efficient utilization of the generator and batteries without compromising the operation of the TRU.

[0035] In one or more embodiments, the transport refrigeration unit (TRU) of the present invention can be mounted on a container or trailer associated with a vehicle (also referred to herein as a trailer or prime mover). The TRU can be configured to maintain a conditioned environment in an enclosed (storage or preservation) space within the container / trailer. Various products (including but not limited to pharmaceuticals and nutritional products, as well as perishable items such as food and beverages, etc.) can be stored and transported in the container / trailer. The TRU can maintain the environment of the storage space at a specific or user-defined temperature and / or humidity based on the stored products to keep the stored products in a healthy condition and in compliance with product compliance regulations during transportation.

[0036] The TRU can be mounted on a container / trailer associated with one or more trailers, including but not limited to electric trucks, semi-electric trucks, and non-electric trucks, such that the TRU remains fluidly connected to the surroundings and further remains fluidly connected to the storage space of the container / trailer. Thus, based on the environment to be maintained in the storage space or based on the product to be transported, the TRU can be operated to adjust its cooling capacity and supply conditioned air within the storage space. Additionally, the axle, which is the central axis of the trailer, rotates to provide power to the wheels by transferring power from the engine to the wheels, thereby allowing the trailer to move. The axle can be found in both the front and rear positions on the trailer, and the axle can be powered or non-powered, depending on the configuration of the vehicle. The powered axle receives power from the engine, while the non-powered axle supports the weight of the trailer and the load associated with the trailer.

[0037] refer to Figure 1A and Figure 1B, discloses a power supply system 100 (also referred to herein as system 100) for a transport refrigeration unit (TRU) 102. The system 100 may include a generator 106 (also referred to herein as an axle generator or hub generator) that may be operatively coupled to an axle or hub 108 associated with a trailer (not shown). Furthermore, an engine 120 associated with a prime mover or vehicle may be configured to drive the trailer, which may cause the trailer's axle or hub 108 to rotate, thereby activating the generator 106 to generate electrical power based on the rotational speed of the axle / hub 108 or the speed of the trailer. Additionally, the system 100 may include a battery 110 configured with a battery monitoring system (BMS) 112. In one or more embodiments, the system 100 may include an existing battery and BMS associated with the vehicle or TRU 102. However, in other embodiments, the battery 110 and BMS 112 may also be installed separately on the TRU 102 or the vehicle associated with the TRU 102.

[0038] The battery 110 can be electrically connected to the generator 106 via the BMS 112. In addition, the battery 110 can also be configured to be electrically connected to an external electric power source 118, such as, but not limited to, an electric grid. The BMS 112 can be configured to control the charging of the battery 110 via the generator 106 or the grid 118, and also enable the supply of electric power from the battery 110 to one or more components 104-1 to 104-N (collectively designated herein as 104) of the TRU 102 or trailer. In addition, the battery 110 and the generator 106 can be electrically coupled to the components 104 of the TRU 102. In one or more embodiments, the components 104-1 to 104-N of the TRU 102 can include, but are not limited to, a compressor, a condenser fan, an evaporator fan, and an electric heater.

[0039] In one or more embodiments, the system 100 may include a power supply control device 200 (also referred to herein as the device 200 ) configured to connect to the generator 106 , the battery 110 , the BMS 112 , and the components 104 of the TRU 102 . The device 200 may be retrofitted into an existing TRU equipped with the axle generator 108 and the battery 110 . Figure 1A and Figure 2, the device 200 may include a first set of sensors 116-1, which are electrically configured, in conjunction with the components 104 and the generator 106 of the TRU 102, to monitor in real time the electrical power consumed by the components 104 or the TRU 102, and also to monitor the electrical power generated by the generator 106. Furthermore, the device 200 may include a second set of sensors 116-2, which are operatively configured, in conjunction with the BMS 112 associated with the battery 110, to monitor the real-time state of charge (SoC) of the battery 110. Furthermore, the device 200 may include a third set of sensors 116-3, which are operatively configured, in conjunction with the axle 108 of the trailer, to monitor the rotational speed of the axle 108 and road attributes associated with the road during the trip. The rotational speed of the axle 108 and the road attributes associated with the road may allow the device 200 to determine the electrical power generated by or available at the generator 106. Road attributes may include, but are not limited to, incline, grade, downhill conditions, etc.

[0040] In one or more embodiments, the first group of sensors 116-1 and the second group of sensors 116-2 may include, but are not limited to, current sensors, voltage sensors, wattmeters, energy meters, and frequency and phase meters. Furthermore, the third group of sensors 116-3 may include, but are not limited to, inclinometers (tilt sensors), accelerometers, gyroscopes, GPS sensors, speed sensors (wheel or axle speed sensors), and slope sensors.

[0041] The system 100 or device 200 may also include a controller 114 that communicates with the first set of sensors 116-1, the second set of sensors 116-2, and the third set of sensors 116-3 and is also operatively connected to the generator 106, the BMS 112, and the components 104 of the TRU 102. The controller 114 may include one or more processors 202 coupled to a memory 204 storing instructions, the instructions being executable by the processors 202, that cause the controller 114 to perform one or more specified operations.

[0042] In one or more embodiments, the controller 114 can be configured to monitor the electrical power consumption of the TRU 102 using the first set of sensors 116-1 over the duration of one or more trips (previous trips and / or ongoing trips). This can allow the controller 114 to determine the average electrical power consumption of the TRU 102 for an ongoing or upcoming trip. The controller 114 can correspondingly predict the electrical power consumption of the TRU 102 for a trip of a predefined duration (the ongoing trip) based on the determined average electrical power consumption of the TRU 102. The predefined duration of a trip herein corresponds to the effective operating duration of the TRU during the trip, which includes the duration that the TRU is on, but does not include the duration that the TRU is off during the trip. For example, if the total trip duration is 4 hours, but the TRU can be off for 30 minutes during that trip, the effective duration of the trip is 3.5 hours. Therefore, the electrical power consumption of the TRU is calculated based on 3.5 hours instead of the full 4 hours.

[0043] In addition, the controller 114 can use the second set of sensors 116-2 to monitor the real-time SoC of the battery or the amount of energy available in the battery. The controller 114 can also use the third set of sensors 116-3 to monitor the rotational speed of the axle or the speed of the trailer during the ongoing trip and correspondingly determine the electric power available at or generated by the generator 106. Thus, the controller 114 can actuate the generator 106 based on one or more of the predicted electric power consumption of the TRU 102, the real-time SoC of the battery 110 or the amount of energy available in the battery 110, and the rotational speed of the axle 108 or the speed of the trailer, or the electric power available at the generator 106 to generate electric power available at the generator 106 during the ongoing trip and supply it to the battery 110 and / or the TRU 102. In one or more embodiments, the controller 114 can activate the generator 106 by operably engaging the drive shaft of the generator 106 with the axle 108 of the trailer using one or more actuators, which can cause the drive shaft to rotate with the axle 108, thereby generating electric power.

[0044] In one or more embodiments, the controller 114 can be configured to adjust the activation duration of the generator 106 during the trip so that the generator 106 can generate a predefined amount of electrical power and supply it to the battery 110 to maintain the SoC of the battery 110 above a predefined SoC level or the amount of energy available in the battery above a predefined energy level for a predefined duration during the trip. The predefined SoC level or predefined energy level can be selected based on the predicted electrical power consumption of the TRU 102 during the trip and the power storage capacity (rating) of the battery 110.

[0045] In a non-limiting example, for a battery with a capacity of 4 kilowatt-hours (kWh), if the TRU is predicted to consume 1 kilowatt (kW) per hour, the TRU can operate for 4 hours before the battery is depleted (4kWh / 1kW=4 hours). Therefore, for a 1-hour trip, the predefined SoC level of the battery can be selected to be 25% of the battery capacity. This can allow the battery to power the TRU for at least 1 hour without relying on the generator or grid power. In another non-limiting example, if the consumption rate of the TRU is doubled to 2kW per hour, the operating time of the TRU is halved, resulting in only 2 hours of operation before the battery is depleted (4kWh / 2kW=2 hours). In such a scenario, for a 1-hour trip, the predefined SoC level of the battery can be selected to be 50% of the battery capacity, thereby allowing the battery to power the TRU for at least 2 hours without relying on the generator.

[0046] refer to Figure 4 , illustrates an exemplary graph depicting changes in battery SoC, trailer speed, generator power, and electrical power consumption of the TRU 102 during a trip. As depicted, if the battery SoC remains above a predefined threshold, the generator 106 remains off and does not generate power. However, once the battery SoC drops to this predefined level, the generator 106 activates to generate power and supplies it to the battery 110, thereby maintaining the battery SoC above the set threshold. The generator's power output can correspond to the rotational speed of the wheel axle or the speed of the vehicle (trailer).

[0047] In one or more embodiments, when the real-time SoC of the battery 110 is detected to be greater than a predefined SoC level during a trip, the controller 114 can disable or disengage the generator 106 from the axle to limit the power generated by the generator 106. Furthermore, the controller 114 can activate the BMS 112 based on the real-time power consumption of the TRU 102 to enable the supply of power from the battery 110 to the components of the TRU 102. In a non-limiting example, if the predefined SoC level is determined and set to 25%, and the real-time SoC of the battery remains above 25% while powering the TRU 102, the controller 114 can keep the generator 106 disabled. This can help reduce the amount of fuel burned by the trailer's engine 120 to power the generator 106 during a trip, making the overall system efficient and cost-effective without compromising the operation of the TRU 102.

[0048] Furthermore, in one or more embodiments, upon detecting that the real-time SoC of the battery 110 is equal to or lower than a predefined SoC level, the controller 114 may be configured to activate the generator 106 to generate and supply electric power to the battery 110. In a non-limiting example, if the predefined SoC level is determined and set to 25%, but the real-time SoC of the battery 110 reaches or falls below 25% when powering the TRU 102, the controller 114 may activate the generator 106 to supply electric power to the battery 110.

[0049] In one or more embodiments, the generator 106 may also be directly electrically connected to the TRU 102. In such embodiments, upon detecting that the real-time SoC of the battery 110 is equal to or below a predefined SoC level, the controller 114 may be configured to activate the generator 106 to generate and supply electrical power directly to the TRU 102 and / or the battery 110. This may allow the system to maintain the SoC of the battery 110 above a predefined SoC level based on the real-time electrical power consumption of the TRU 102 while powering the components of the TRU 102.

[0050] Furthermore, in one or more embodiments, upon detecting that the electrical power generated by or available at the generator 106 is greater than the real-time electrical power consumption of the TRU 102 and the real-time SoC of the battery 110 is determined to be equal to or below a predefined SoC level, the controller 114 may enable the generator 106 to generate electrical power based on the real-time electrical power consumption of the TRU 102 and the real-time rotational speed of the axle 108 or the speed of the trailer, and supply it from the generator 106 to the TRU 102. In a non-limiting example, if the predefined SoC level of the battery 110 is set to 25%, and the real-time SoC of the battery 110 drops below this threshold while powering the TRU 102, but it is detected that the available power from the generator 106 exceeds the real-time power consumption of the TRU 102, in such a scenario, the controller 114 may activate the generator 106 to supply electrical power directly to the battery 110 while also powering the TRU. This arrangement can help maintain the battery SoC above the predefined level and ensure that the power supply to the TRU 102 is not compromised.

[0051] Furthermore, while a portion of the generated electric power is supplied to battery 110 to charge battery 110, the electric power generated by or available at generator 106 is determined based on the generator power of generator 112 and one or more speed characteristics. The generator power and one or more speed characteristics are determined based on one or more of the speed of rotation of the axle, parameters associated with the trailer and generator 106, and road attributes associated with the road on which the trailer is moving during the trip. For example, in a non-limiting example, when the trailer is moving at 30 km / hr, the generator may generate 0 to 3 kW of power. Similarly, when the trailer is moving at 90 km / hr, the generator may generate 0 to 15 kW of power.

[0052] Furthermore, in one or more embodiments, the BMS 112 may further connect the battery 110 to an external power source 118, such as a power grid, which may supply electric power to the battery 110 when the trailer is stationary and detects that the real-time SoC level of the battery 110 is less than a predefined SoC level. Furthermore, in one or more embodiments, the controller 114 may generate an alarm signal to notify the driver or user to stop the trailer and charge the battery 110 to maintain TRU operation.

[0053] In one or more embodiments, the system 100 or the device 200 may include one or more human machine interfaces (HMIs) (208, such as Figure 2 ). The controller 114 can allow one or more registered users to monitor one or more of the real-time electrical power consumption of the TRU 102, the electrical power generated by the generator 106, the state of charge (SOC) or electrical power stored or available in the battery 110, and the electrical power supplied by the generator 106 to the battery 110. In one or more embodiments, the HMI 208 can be installed in the cab of the trailer or vehicle and / or within the container / trailer in which the TRU is installed. In addition, in some embodiments, the HMI 208 can also be a mobile phone or other portable computing device 200s associated with the user, but is not limited thereto.

[0054] In one or more embodiments, the device 200 may include a communication module 206 operatively coupled to the controller 114, which may enable the device 200 to establish secure communications with sensors, the BMS 112, the HMI 208, and various other components 104 associated with the TRU 102 and the vehicle. The communication module 206 may be a wired medium and / or a wireless medium. For example, the communication module may be a transceiver, but is not limited to this, and may include but is not limited to an antenna, an Ethernet port, a USB port, or any other port that can be configured to receive and transmit location and attribute data. In addition, in one or more embodiments, the communication module 206 may include an Ethernet module, a Wi-Fi module, a Bluetooth module, a Zigbee module, a GSM / GPRS module, a LoRa module, a 5G module, an RS-232 / RS-485 serial communication module, a CAN (Controller Area Network) module, but is not limited to this.

[0055] refer to Figure 1A and Figure 1B In one or more embodiments, the battery 110 and the BMS 112 may be packaged as a battery pack 110-A. The battery pack 110-A may include one or more battery cell modules (also referred to herein as battery cells 110) and a power conversion unit (PCU) 122 that is used to convert the electric power received and / or supplied by the battery 110 within a predetermined range suitable for the battery cells 110, the TRU 102, and the grid (external power source) 118. The battery pack 110-A may also include one or more interfaces that facilitate connection of the battery pack 110 with the TRU 102, the generator 106, the controller 114, and the grid 118.

[0056] In one or more embodiments, the PCU 122 within the battery pack 110-A or BMS 112 can facilitate management and conversion of electrical power to ensure optimal performance, efficiency, and compatibility with the connected load (TRU) or charging source (generator 106 or external power source 118). The PCU 122 may include one or more rectifiers 122-1, one or more inverters 122-2, and / or one or more DC-DC converters (not shown). The rectifier(s) 122-1 can be configured to convert AC power supplied by the generator 106 or external power source 118 into DC power for the battery cells 110. Additionally, the inverter 122-2 can be configured to convert the DC power level output by the battery cells 110 into AC power for the AC-powered components 104 of the TRU 102 during a charging mode of operation or a power supply mode and / or to AC power to the grid 118 during a power export mode. Furthermore, the DC-DC converter can be configured to adjust the DC power level output by the battery unit 110 during the power supply mode to match the input DC level of the DC power-based components 104 of the TRU 102. Furthermore, in one or more embodiments, the PCU 122 can include a bidirectional AC-DC converter (operating as a rectifier 122-1 and an inverter 122-2) configured to facilitate the exchange of electrical power between the battery unit 110 and the grid 118 (external power source). Thus, the PCU 122 can facilitate maximizing energy utilization and protecting the battery unit 110 from overvoltage or undervoltage conditions.

[0057] refer to Figure 3 , discloses a method 300 for implementing power supply management in a transport refrigeration unit (TRU). The method 300 may involve a battery 110, a BMS 112, a generator 106, an apparatus 200, and a Figure 1A and Figure 1BThe method 300 may include a step 302 of monitoring the real-time state of charge (SoC) of the battery, followed by a step 304 of predicting the electric power consumption of the TRU for a trip of a predefined duration. The electric power consumption of the TRU may be predicted based on data regarding the average electric power consumption of the TRU for one or more monitored trips (previous and / or ongoing trips) over the duration. At steps 302 and 304, devices or sensors may facilitate monitoring the electric power consumption of the TRU and the SoC maintained by the battery. Furthermore, the method 300 may include a step 306 of monitoring the rotational speed of the axle or the speed of the trailer associated with the TRU during the ongoing trip and correspondingly determining the electric power generated by or available at the generator. Accordingly, the method 300 may include a step 308 of activating the generator for generating electric power during the trip and supplying it to the battery and / or the TRU based on one or more of the predicted electric power consumption of the TRU, the real-time SoC of the battery, and the speed of the trailer or the electric power available at the generator.

[0058] In one or more embodiments, method 300 may include adjusting the activation duration of the generator during the trip to enable the generator to generate a predefined amount of electric power and supply it to the battery to maintain the battery's SoC above a predefined SoC level during the trip. The predefined SoC level may be selected based on the TRU's predicted electric power consumption during the trip and the battery's power storage capacity.

[0059] In one or more embodiments, when the real-time SoC of the battery during a trip is greater than a predefined SoC level, method 300 may include deactivating or disengaging the generator from the axle to limit the generator's power generation. Furthermore, method 300 may include activating the BMS based on the TRU's real-time power consumption to enable the supply of power from the battery to the TRU's components. This can help reduce the amount of fuel burned by the trailer's engine to power the generator during a trip, making the overall system efficient and cost-effective without compromising the TRU's operation.

[0060] In one or more embodiments, when the real-time SoC of the battery reaches a first predefined SoC level, method 300 may include the following steps: activating the generator to generate and supply electric power to the battery until the real-time SoC of the battery reaches a second predefined SoC level. The second predefined SoC level may be greater than the first predefined SoC level. For example, in a non-limiting example, once the SoC reaches the first predefined SoC level (e.g., 30%), the generator may remain activated to charge the battery until the SoC of the battery reaches the first predefined SoC level (e.g., 40%). This may help prevent frequent activation or deactivation of the generator.

[0061] Furthermore, in one or more embodiments, when the real-time SoC of the battery is equal to or lower than a predefined SoC level, the method 300 may include the step of activating the generator to generate and supply electric power to the battery.

[0062] In one or more embodiments, the generator may also be directly electrically connected to the TRU. In such embodiments, when the real-time SoC of the battery is equal to or below a predefined SoC level, method 300 may include the step of activating the generator to generate and supply electrical power directly to the TRU and / or the battery. This may allow the system to maintain the battery's SoC above a predefined SoC level based on the TRU's real-time electrical power consumption while simultaneously powering the TRU's components.

[0063] Furthermore, in one or more embodiments, when the electric power generated by or available at the generator is greater than the real-time electric power consumption of the TRU and the real-time SoC of the battery is equal to or lower than a predefined SoC level, method 300 may include the following steps: enabling the generator to generate electric power and supply it to the TRU based on the real-time electric power consumption of the TRU and the real-time rotational speed of the axle or the speed of the trailer. This can help maintain the SoC of the battery above the predefined level and ensure that the power supply to the TRU is not compromised.

[0064] Thus, the present invention (system, apparatus and method) overcomes the shortcomings and limitations associated with existing generator-based refrigeration units / TRUs and associated power supply management by providing an improved, cost-effective and efficient solution that optimizes electrical power usage in the refrigeration unit / TRU, ensuring that the generator and batteries are effectively and efficiently utilized without compromising the operation of the TRU.

[0065] Although the subject disclosure has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the subject disclosure as defined by the appended claims. Modifications may be made to adapt a particular situation or material to the teachings of the subject disclosure without departing from the scope of the subject disclosure. Therefore, it is intended that the subject disclosure not be limited to the particular embodiments disclosed, but that the subject disclosure include all embodiments falling within the scope of the subject disclosure as defined by the appended claims.

[0066] In interpreting the specification, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms "comprises" and "comprising" should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps can be combined or utilized or exist together with other elements, components, or steps not explicitly referenced. In the event that the specification claims refer to at least one of something selected from the group consisting of A, B, C..., and N, the text should be interpreted as requiring only one element from the group, rather than A plus N, or B plus N, etc.

Claims

1. A power supply system for a transport refrigeration unit (TRU), wherein the system comprises: a battery electrically connected to one or more components of the TRU; a generator electrically connected to the battery, wherein the generator is operatively coupled to an axle of a trailer associated with the TRU, the generator configured to generate electrical power upon rotation of the axle and based on a rotational speed of the axle; as well as a controller operatively coupled to the battery, the TRU, and the generator, wherein the controller is configured to: monitoring the real-time state of charge (SoC) of the battery or the amount of energy available in the battery; predicting the electric power consumption of the TRU for a trip of a predefined duration based on data relating to the average electric power consumption of the TRU monitored over a predefined time and in real time; monitoring the rotational speed of the axle or the speed of the trailer during the trip and correspondingly determining the electrical power generated by or available at the generator; as well as The generator is activated to generate electric power during the trip and supply it to the battery and / or the TRU based on the predicted electric power consumption of the TRU, the real-time SoC of the battery or the amount of energy available in the battery, and one or more of the rotational speed of the axle or the speed of the trailer or the electric power available at the generator.

2. The system according to claim 1, wherein: The controller is configured to adjust the activation duration of the generator during the trip so that the generator can generate a predefined electric power and supply it to the battery for maintaining the SoC of the battery above a predefined SoC level during the trip, or maintaining the amount of energy available in the battery above a predefined energy level for the predefined duration, wherein the predefined SoC level is selected based on the predicted electric power consumption of the TRU during the trip and the power storage capacity of the battery.

3. The system according to claim 2, wherein: Upon detecting that the real-time SoC of the battery is greater than the predefined SoC level, the controller is configured to deactivate the generator based on the real-time electric power consumption of the TRU and enable supply of electric power from the battery to the components of the TRU.

4. The system according to claim 2, wherein: Upon detecting that the real-time SoC of the battery is equal to or lower than the predefined SoC level, the controller is configured to activate the generator to generate the electric power and supply it to the battery based on the real-time electric power consumption of the TRU, so as to maintain the SoC of the battery above the predefined SoC level while enabling the supply of electric power from the battery to the components of the TRU.

5. The system according to claim 2, wherein: The generator is electrically connected to the one or more components of the TRU, wherein upon detecting that the real-time SoC of the battery is equal to or lower than the predefined SoC level, the controller activates the generator to generate electric power and supply it from the generator to the TRU based on the real-time electric power consumption of the TRU.

6. The system according to claim 5, wherein: Upon detecting that the electric power generated by or available at the generator is greater than the real-time electric power consumption of the TRU and the real-time SoC of the battery is monitored to be equal to or lower than the predefined SoC level, the controller enables the generator to supply electric power from the generator to the TRU based on the real-time electric power consumption of the TRU and the real-time speed of the trailer or the rotational speed of the wheel axle, while supplying a portion of the generated electric power to the battery to charge the battery.

7. The system according to any one of claims 1 to 6, wherein: The electric power generated by or available at the generator is determined based on a generator power versus speed characteristic of the generator, wherein the generator power versus speed characteristic is determined based on one or more of a speed of rotation of the wheel axle, parameters associated with the trailer and the generator, and one or more road attributes associated with a road on which the trailer is moving during the trip.

8. The system according to any one of claims 1 to 7, wherein: The system comprises: a first set of sensors for monitoring, in real time, the electrical power consumed by the one or more components or the TRU; a second set of sensors for monitoring the real-time SoC of the battery or the amount of energy available in the battery; and A third set of sensors is used to monitor the rotational speed of the wheel axle and the one or more road attributes associated with the road during the trip and correspondingly determine the electrical power generated by or available at the generator.

9. The system according to any one of claims 1 to 8, wherein: The controller is configured to: The SoC of the battery or the remaining energy available in the battery is calculated and monitored using a battery management system (BMS) associated with the battery, wherein the SoC indicates the electrical power stored in or available in the battery.

10. The system according to any one of claims 1 to 9, wherein: The generator is configured with a power conversion unit to convert the electric power generated by the generator into DC power for the battery and / or into AC or DC power for components of the TRU.

11. A method for power supply management in a transport refrigeration unit (TRU) equipped with an engine and a battery, wherein the method comprises: monitoring, by a controller, the real-time state of charge (SoC) of the battery or the amount of energy available in the battery; predicting, by the controller, the electric power consumption of the TRU for a trip of a predefined duration based on data relating to average electric power consumption of the TRU monitored over a predefined time and in real time; monitoring, by the controller, a rotational speed of the axle associated with the TRU or a speed of the trailer during the trip and correspondingly determining the electrical power generated by or available at a generator; as well as The generator is activated by the controller to generate electric power during the trip and supply it to the battery and / or the TRU based on the predicted electric power consumption of the TRU, the real-time SoC of the battery or the amount of energy available in the battery, and one or more of the rotational speed of the generator or the speed of the trailer or the electric power available at the generator.

12. The method according to claim 11, wherein The method comprises the steps of adjusting, by the controller, an activation duration of the generator during the trip so that the generator is able to generate a predefined electric power and supply it to the battery for maintaining the SoC of the battery above a predefined SoC level during the trip, wherein the predefined SoC level is selected based on the predicted electric power consumption of the TRU during the trip and a power storage capacity of the battery.

13. The method according to claim 12, wherein: The method includes the following steps: when the real-time SoC of the battery is greater than the predefined SoC level, deactivating, by the controller, the generator based on the real-time electric power consumption of the TRU, and enabling the electric power to be supplied from the battery to the components of the TRU.

14. The method according to claim 12, wherein: When the real-time SoC of the battery reaches a first predefined SoC level, the method includes the following steps: activating the generator to generate the electric power and supply it to the battery until the real-time SoC of the battery reaches a second predefined SoC level, wherein the second predefined SoC level is greater than the first predefined SoC level.

15. The method according to claim 12, wherein: The method includes the following steps: when the real-time SoC of the battery is equal to or lower than the predefined SoC level, the controller activates the generator based on the real-time electric power consumption of the TRU to generate the electric power and supply it to the battery to maintain the SoC of the battery above the predefined SoC level while enabling the electric power to be supplied from the battery to the components of the TRU.

16. The method according to claim 11, wherein The generator is electrically connected to the one or more components of the TRU, wherein, when the real-time SoC of the battery is equal to or lower than the predefined SoC level, the method comprises the steps of: activating the generator to generate electric power and supplying it from the generator to the TRU based on the real-time electric power consumption of the TRU.

17. The method according to claim 16, wherein When the electric power generated by or available at the generator is determined to be greater than the real-time electric power consumption of the TRU and the real-time SoC of the battery is monitored to be equal to or lower than the predefined SoC level, the method includes the following steps: enabling the generator to supply electric power from the generator to the TRU based on the real-time electric power consumption of the TRU and the real-time rotational speed of the wheel axle or the speed of the trailer, while supplying a portion of the generated electric power to the battery to charge the battery.

18. The method according to any one of claims 11 to 17, wherein The electric power generated by or available at the generator is determined based on a generator power and speed characteristic of the generator, wherein the generator power and one or more speed characteristics are determined based on a speed of rotation of the wheel axle, parameters associated with the trailer and the generator, and one or more road attributes associated with the road on which the trailer is moving during the trip.

19. A power supply control device for a transport refrigeration unit (TRU) equipped with a battery and an axle generator, the device comprising: a controller configured to be operatively connected to the TRU, the generator, and a battery management system (BMS) associated with the battery, wherein the controller includes one or more processors coupled to a memory storing instructions, the instructions executable by the processors, that cause the controller to: Monitoring the real-time state of charge (SoC) of the battery; predicting the electric power consumption of the TRU for a trip of a predefined duration based on data relating to the average electric power consumption of the TRU monitored over a predefined time and in real time; monitoring the rotational speed of the wheel axle or the speed of the trailer during the trip and correspondingly determining the electrical power generated by or available at the generator; as well as Based on the predicted electric power consumption of the TRU, the real-time SoC of the battery, and one or more of the rotational speed of the wheel axle or the speed of the trailer or the electric power available at the generator, the generator is activated to generate electric power during the trip and supply it to the battery and / or the TRU.

20. The device according to claim 19, wherein The device comprises: a first set of sensors for monitoring, in real time, the electrical power consumed by the one or more components or the TRU, and the electrical power generated by the generator; a second set of sensors for monitoring the real-time state of charge (SoC) of the battery; and A third set of sensors is used to monitor the rotational speed of the wheel axle and the one or more road attributes associated with the road during the trip and correspondingly determine the electrical power generated by or available at the generator.

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