BATTERY-ELECTRIC ASSISTED TOWING CONCEPT

Abstract

A system for extending the range and maneuverability of a motor vehicle during a towing operation, comprising: a battery electric vehicle (12), BEV, with a vehicle energy pack (22) that provides operating energy for the BEV (12); a powered trailer (14) which is detachably connected to the BEV (12); and a drive unit (16) with which the driven trailer (14) is equipped and communicates with the BEV (12), wherein the drive unit (16) improves the starting of the BEV (12) and driven trailer (14) and provides traction support for the driven trailer and the BEV (12), characterized in that the at least one electric motor (42, 44) is excited to provide a driving force for the driven trailer (14) and to improve the propulsion of the BEV (12), wherein the at least one electric motor (42, 44) is powered exclusively by the vehicle energy pack of the BEV (12).

Description

INTRODUCTION

[0001] The present disclosure relates to the towing of battery-electric vehicles and trailers for towing behind a battery-electric vehicle.

[0002] Towing is a significant challenge for battery electric vehicles (BEVs) due to increased energy consumption and thermal stress. For example, the towing capacity of an electric BEV pickup truck is approximately 5,000 pounds. This is lower than the towing capacity of comparable gasoline-powered pickups, which have a towing capacity of at least 7,100 pounds. Gasoline-powered pickups can also maintain a greater range than BEVs while towing.

[0003] While current battery electric vehicles fulfill their purpose when towing, there is a need for a new and improved system and procedure to increase the towing capacity and extend the towing range of a battery electric vehicle.

[0004] DE 10 2019 202 784 A1 describes a trailer for a vehicle. The trailer has an axle on which two wheels are movably mounted. It also has an electric motor for each wheel, which is connected to its wheel via a gearbox and a driveshaft, with each electric motor being configured to operate as a generator or as a motor depending on the driving situation. It has at least one energy storage device connected to the electric motors. It has at least one control unit configured to control the electric motors.

[0005] DE 10 2012 016 234 A1 relates to a new compact trailer for a passenger car or commercial vehicle 200 and to methods for controlling and using the trailer, including infrastructure and charging equipment. The trailer, in particular a push trailer with an electric drive unit and an energy storage device for operating this drive unit, can be mechanically coupled to a vehicle with an internal combustion engine or hybrid drive unit by means of a coupling system, and electrically and electronically coupled by means of a coupling system.

[0006] US 2013 / 0257144A1 comprises a towable trailer that can be mechanically coupled to a vehicle, wherein the towable trailer includes a housing unit for an auxiliary battery, a wheel is rotatably connected to the towable trailer, an auxiliary battery is arranged in the housing unit for the auxiliary battery of the towable trailer, and the vehicle includes a storage battery.

[0007] US 2008 / 0169144A1 describes a system and associated procedure for a regenerative braking system on a towed vehicle, such as a trailer or semi-trailer. The system supplies the individual wheels of the trailer with energy and braking force as needed to stabilize the trailer. Energy is recovered during braking. Batteries can be used for energy storage, as well as capacitive storage units that can quickly charge and discharge large amounts of energy. DESCRIPTION

[0008] The object of the present invention is to provide a new and improved system and method for increasing towing capacity.

[0009] The problem is solved by a system for extending the range and maneuverability of a motor vehicle during a towing operation according to claim 1. Advantageous further developments are the subject of the dependent claims.

[0010] From several perspectives, a system for extending the range and maneuverability of a motor vehicle during a towing operation comprises a battery electric vehicle (BEV) with a rechargeable energy storage system (battery pack) that provides operating energy for the BEV. A powered trailer is detachably connected to the BEV. A drive unit is attached to the powered trailer and communicates with the BEV, with the drive unit improving the BEV's starting and providing acceleration assistance.

[0011] In another aspect of the present disclosure, the drive unit includes a battery pack, wherein the battery pack provides energy to supplement energy from the vehicle's energy pack.

[0012] In another aspect of the present disclosure, the battery pack is configured as an energy pack.

[0013] In another aspect of the present disclosure, the battery pack is configured as a power pack.

[0014] In another aspect of the present disclosure, the drive unit comprises at least one electric motor, wherein the at least one motor is excited to provide a driving force for the driven trailer and to improve the propulsion of the BEV.

[0015] In another aspect of the present disclosure, the at least one motor is supplied with energy exclusively by the vehicle energy pack of the BEV.

[0016] In another aspect of the present disclosure, the at least one motor defines a first motor positioned in a first wheel hub of the driven trailer and a second motor positioned in a second wheel hub of the driven trailer opposite the first wheel hub.

[0017] In another aspect of the present disclosure, the drive unit comprises a battery pack and at least one motor which is driven by the energy supplied by the battery pack, wherein the at least one motor is excited to provide a driving force for the driven trailer.

[0018] In another aspect of the present disclosure, the at least one motor defines a first motor and a second motor, which is arranged opposite the first motor. A trailer module is provided with the driven trailer, the trailer module communicating between the driven trailer and the BEV and with the first motor and the second motor.

[0019] In another aspect of the present disclosure, the trailer module controls a first speed of the first motor, which differs from a second speed of the second motor, in order to improve the maneuverability of the driven trailer.

[0020] From several perspectives, a system for extending the towing range and maneuverability of a motor vehicle during a towing operation comprises a battery electric vehicle (BEV) with a vehicle energy pack that supplies the BEV with operating energy. A powered trailer is detachably connected to the BEV. A trailer module is attached to the powered trailer, establishing the connection between the powered trailer and the BEV. A drive unit is attached to the powered trailer and communicates with the trailer module and the BEV via the trailer module. The drive unit improves the BEV's starting performance and assists it during acceleration.

[0021] In another aspect of the present disclosure, the drive unit is configured as a first motor and a second motor arranged opposite the first motor around the driven trailer.

[0022] In another aspect of the present disclosure, the drive unit includes a battery pack, wherein the battery pack provides energy to supplement energy from the vehicle's energy set; and the first motor and the second motor are supplied with energy from the battery pack to provide motive power for the driven trailer.

[0023] In another aspect of the present disclosure, the drive unit is configured as at least one motor connected to and rotating at least one axle of the towed trailer, the at least one motor being supplied with energy by the battery pack to provide a driving force for the driven trailer.

[0024] In another aspect of the present disclosure, a trailer module is provided with the driven trailer, wherein the trailer module communicates between the driven trailer and the BEV as well as with the drive unit.

[0025] In another aspect of the present disclosure, a vehicle module is provided with the BEV, wherein during a towing operation of the driven trailer by the BEV the driven trailer is mechanically and electrically connected to the BEV, wherein the operation of the drive unit and the vehicle energy pack is connected to and controlled by the vehicle module.

[0026] In another aspect of the present disclosure, a communication link connects the BEV to the powered trailer to transfer energy and provide a communication path between the BEV and the powered trailer.

[0027] According to several aspects, a method for extending the towing range and maneuverability of a motor vehicle during a towing operation includes: positioning a rechargeable vehicle energy pack in a battery electric vehicle (BEV) to provide operating energy to the BEV; detachably connecting a powered trailer to the BEV; providing a trailer module to the powered trailer, with the trailer module communicating between the powered trailer and the BEV; connecting a drive unit positioned on the powered trailer in communication with the BEV via the trailer module; and exciting the drive unit by a command from the trailer module to improve the starting of the BEV and provide acceleration assistance to the BEV.

[0028] In another aspect of the present disclosure, the method further comprises: commanding the operation of a first motor of the drive unit and a second motor of the drive unit; and connecting the BEV to the driven trailer using a communication link.

[0029] In another aspect of the present disclosure, the method further includes reducing the thermal load on the BEV by distributing torque between the BEV and the driven trailer, thereby increasing the overall efficiency of the system.

[0030] Further areas of application will become apparent from the description presented here. It goes without saying that the description and specific examples serve only for illustration and are not intended to limit the scope of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The drawings described here are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. Fig. Figure 1 is a side perspective view of a battery electric vehicle and a powered trailer according to an exemplary aspect; Fig. Figure 2 is a side perspective view of a wheel with an electric motor for driving the driven trailer. Fig. 1; and Fig. Figure 3 is a diagram showing data points for motor load for a motor air gap torque compared to a motor shaft speed for the operation of the system. Fig. 1 delivers. DETAILED DESCRIPTION

[0032] The following description is merely exemplary and is not intended to limit the present disclosure, application or use.

[0033] Referring to Fig.1, a system and method for extending the range and maneuverability of a battery electric vehicle (BEV) and powered trailer 10 comprises a BEV 12 detachably connected to a powered trailer 14. According to several aspects, the BEV 12 defines a pickup truck; however, the BEV 12 is not limited to a specific vehicle type and can therefore define any motor vehicle, including but not limited to a passenger car, a sport utility vehicle (SUV), a van, a minivan, or the like. To increase the range and functionality of the BEV 12, the powered trailer 14 is equipped with a drive unit 16. According to several aspects, the drive unit 16 can be configured as a battery pack 17, which can be an energy pack or a power pack.According to several aspects, the drive unit 16 can be configured as at least one motor 34, and according to several aspects, two or more motors 34 can be configured, which are further referred to below. Fig. 2, as described, provide a driving force to propel the driven trailer 14. According to other aspects, the drive unit 16 comprises the battery pack 17 and the at least one motor 34.

[0034] If the drive unit 16 includes the battery pack 17, the battery pack 17 can contain one or more batteries in a battery pack array. The battery pack 17 can be configured as a multi-cell power pack that provides a steady power supply over an extended period. The battery pack 17 can also be configured as a power pack that delivers a higher power output than the power pack for a shorter duration. Depending on several aspects, the battery pack 17 can be located below a bed or platform 18 of the powered trailer 14, for example, in a housing 20 located below the platform 18, or the battery pack 17 can be mounted on or above the platform 18.

[0035] The battery pack 17 is rechargeable and can be charged simultaneously with a charging process of a vehicle energy pack 22, which provides operating energy for the BEV 12. The battery pack 17 can also be charged independently of the BEV 12, which allows charging at a storage location of the powered trailer 14 or with the powered trailer 14 disconnected from the BEV 12.

[0036] The driven trailer 14 is equipped with at least two wheels 24, with at least one of the at least two wheels 24 being positioned on opposite sides of the driven trailer 14 to ensure balanced support of the platform 18. The BEV 12 is similarly equipped with at least four vehicle wheels 26, as is known, with at least one of the vehicle wheels 26 defining a drive wheel. According to several aspects, the energy of the battery pack 17 can be transferred to the energy pack 22 of the vehicle and thereby transferred to one or more motors that provide the drive power for the BEV 12.

[0037] During a towing operation, the powered trailer 14 is mechanically and electrically connected to the BEV 12, with the operation of the drive unit 16 and the vehicle energy pack 22 being connected to and controlled by a vehicle module 28. The vehicle module 28 can include one or more processors, which, in exemplary aspects, are microprocessors located within the vehicle module 28. Alternatively, the processors can be located in a computer independent of the vehicle module 28 or in the cloud. The processors can execute distributed or parallel processing protocols and can include, for example, application-specific integrated circuits, a programmable gate array (including a field-programmable gate array), a digital signal processor, or a front-end processor.The processors can also contain or access information stored in a memory 30, with which the processors are individually operationally coupled. Memory is understood to be a physical device capable of storing information temporarily, as in the case of random-access memory, or permanently, as in the case of read-only memory. Representative physical devices include hard disk drives, solid-state drives, optical media, or storage that can be accessed via networks in the cloud.

[0038] The vehicle module 28 facilitates communication between the BEV 12 and the powered trailer 14. Depending on several factors, the vehicle module 28 can also communicate with a communication center located remote from the BEV 12, such as a cloud-based communication center. The vehicle module 28 enables the monitoring of energy analyses and the control of energy transfer between the first BEV 12 and the powered trailer 14. A communication link 32 connects the BEV 12 to the powered trailer 14 for energy transfer and to provide a communication path.

[0039] Referring to Fig. 2 and back again Fig.1, according to several aspects, at least one of the at least two wheels 24 of the driven trailer 14 comprises the at least one motor 34, which may be installed in a wheel hub 36. According to other aspects, individual wheels of the at least two wheels 24 of the driven trailer 14 comprise the at least one motor 34, such that a single wheel of the at least two wheels 24 defines driven wheels. According to several aspects, the at least one motor 34 is supplied with electrical energy from the battery pack 17. According to several aspects, the energy for the electrical operation of the at least one motor 34 of the driven trailer 14 can also be supplemented with energy from the vehicle energy pack 22 of the BEV 12, or the energy can be provided by the battery pack 17 and the vehicle energy pack 22.

[0040] The direct drive of one of the at least two wheels 24 of the driven trailer 14 by one or more of the at least one motors 34 enables the driven trailer 14 to provide acceleration capability for the driven trailer 14 and for the BEV 12. The operation of the at least one motor 34, either individually or in tandem, also increases the maneuverability of the driven trailer 14 and the BEV 12 both in the forward or driving direction and in the reverse or back direction.

[0041] With continued reference to the Fig. 1 and Fig.2. According to several aspects, the at least one motor 34 of the driven trailer 14 can also be operated when the driven trailer 14 is disconnected from the BEV 12, using energy from the battery pack 17. This facilitates easy positioning of the driven trailer 14 for storage and maneuvering for connection to the BEV 12. The driven trailer 14 can also be equipped with a fastening device that enables automatic connection of the driven trailer 14 to the BEV 12. According to several aspects, a trailer module 38 can be provided on the driven trailer 14, which functions similarly to the vehicle module 28 and can communicate with it. The trailer module 38 can also operate independently of the vehicle module 28.The trailer module 38 supports the operation of the at least one motor 34 of the driven trailer 14, including independent operation of the at least one motor 34, and can assist with energy transfer and recharging of the battery pack 17. Similar to the vehicle module 28, the trailer module 38 facilitates communication between the BEV 12 and the driven trailer 14. In several respects, the trailer module 38 can also communicate with a communication center located remotely from the driven trailer 14, such as a cloud-based communication center. Furthermore, the vehicle module 28 monitors energy analyses and controls the energy transfer between the first BEV 12 and the driven trailer 14.

[0042] According to several aspects and with continued reference to the Fig. 1 and Fig.Section 2 defines the at least one motor 34 as a first electric motor 40, which is arranged in a first wheel hub 42 of the driven trailer 14, and a second electric motor 44, which is arranged in a second wheel hub 46 of the driven trailer 14. The first electric motor 40 and the first wheel hub 42 are arranged opposite the second electric motor 44 and the second wheel hub 46 in order to balance the drive power delivered to the driven trailer 14. According to further aspects, the at least one motor 34 described above is not limited to being connected to the wheel hub 36 and can instead be connected to at least one axle 48 of the towed trailer 14 and cause it to rotate, for example, using a known differential.When driving forward and especially when driving backward with the driven trailer 14, selective operation of the at least one motor 34, in particular by operating the first electric motor 40 at a different speed than the second electric motor 44, improves the maneuverability of the driven trailer.

[0043] Referring to Table 1 below and again to Fig. 1. The powered trailer 14 can be configured in four ways to offer individual subsets of benefits. Table 1: Configuration A Configuration B Configuration C configuration Motors, No power source Engines, Power Package Motors, energy package Area 0 + ++ Towing capacity + + 0 handling + + + Cost - -- ----

[0044] A first configuration, defined as Configuration A, increases the towing capacity of the powered trailer 14 while relying on the energy storage capacity of the energy pack 22 of the BEV 12. Configuration A provides one or more of the at least one motors 34 to drive at least one of the at least one wheels 24, with the at least one motor 34 drawing operating energy from the energy pack 22 of the BEV 12. Providing the at least one motor 34 improves the trailer's handling and reduces its cost, as the battery pack 17 is no longer needed in the powered trailer 14.

[0045] A second configuration, defined as Configuration B, provides all the advantages of the present disclosure. Configuration B includes the at least one motor 34, which provides drive power for the driven trailer 14 and provides energy for the operation of the at least one motor 34 and for supplementing the energy of the vehicle energy pack 22 of the BEV 12 by using a power pack as a battery pack 17. The operating range of the BEV 12 and the driven trailer 14 is improved with Configuration B, along with improved towing capability and trailer handling. The cost of Configuration B is reduced because the cost of the power pack is lower than that of an energy pack, offsetting the cost of the at least one motor 34.

[0046] A third configuration, defined as Configuration C, offers the advantages of Configuration B and, in addition, greater range, albeit at an extra cost. Configuration C includes an energy pack in the form of battery pack 17, which provides a maximum range advantage. The towing capacity of Configuration C is considered a neutral advantage, as the weight of the at least one motor 34 and the energy pack (battery pack 17) increases the mass of the powered trailer 14. The handling of Configuration C is an improvement over trailers without their own propulsion. The cost of Configuration C is considered the highest of the three configurations.

[0047] With reference to Fig. 3 and again on Fig. 1 and Fig.Figure 2 provides a diagram with 50 data points on the motor load for a motor air gap torque 52, measured in Nm, compared to a motor shaft speed 54 in rpm. A first zone 56 contains data points that illustrate how the transfer of drive torque to the driven trailer 14 reduces the motor load of the BEV 12, with points above a reference line 58 being eliminated. The reduction in motor load improves efficiency and reduces the thermal load on the vehicle energy pack 22 of the BEV 12. A second zone 60 provides data points that identify the effects of regenerative braking by the driven trailer 14.Regenerative braking, used with the powered trailer 14 in configuration B or configuration C identified above with reference to Table 1, improves the range in urban traffic when the charging capacity of the BEV 12 is reduced or lost due to regenerative braking. The regenerative braking provided by the BEV 12 decreases below approximately 10 km / h vehicle speed, whereas the regenerative braking charging capacity of the powered trailer 14 is continuously available below 10 km / h trailer speed down to zero.

[0048] The combination of the powered trailer 14 with the towing vehicle, BEV 12, offers a reduction in the thermal load of the BEV 12 by: 1) reducing or eliminating inefficient operating points of the drive system in the BEV 12 vehicle by providing torque support; 2) reducing heat output for the combined units of the BEV 12 and the powered trailer 14; 3) increasing overall system efficiency by reducing power consumption per mile, thereby increasing range; 4) the powered trailer 14 supplements the towing capacity, as the towing vehicle, the BEV 12, and the BEV 12 operate within their thermal limits, while simultaneously achieving a higher towing capacity than would be possible with a non-powered trailer;and 5) Using regenerative braking, the driven trailer 14 recovers some of the kinetic energy absorbed by the driven trailer 14, thereby reducing the energy output for towing the driven trailer 14.;

[0049] The system and method of the present disclosure also improves the following aspects of driving behavior during a towing operation. The acceleration capability of the BEV 12 when towing the driven trailer 14 is increased by the torque provided by the at least one motor 34. The maneuverability of the trailer is also improved, particularly when individually driven wheels are provided.

[0050] The present system comprises at least one motor 34 to drive the wheels 24 of the driven trailer 14 or one or more axle(s) 48 of the towed driven trailer 14, and optionally includes a battery pack or energy pack, which can be modular in size. The system operates in conjunction with a primary towing vehicle such as the BEV 12.

[0051] An operating method of the system distributes the drive torque proportionally between the towed powered trailer 14 and the towing vehicle, the BEV 12, thus optimizing the operating efficiency of the overall combination of towing and towed elements. The operating method of the system can improve the maneuverability of the towed powered trailer 14 by utilizing the torque of the wheels when a motor is present at individual wheels of the powered trailer 14. The method for distributing torque between the towing vehicle, the BEV 12, and the powered trailer 14 can predict an axle or engine torque demand using an advanced driver assistance system (ADAS).

[0052] The system disclosed in this document comprises a modular rechargeable energy storage system (RESS) that can contain modular packs in a compartment that can be integrated into the chassis of the powered trailer 14.

[0053] A system and method described in this disclosure distributes energy and torque between the towing battery electric vehicle (BEV) and a motorized trailer. A motorized intelligent trailer with (wheel) motors or motors connected to an axle, and a modular rechargeable energy storage system are provided. Communication with a main powertrain in the towing vehicle, the BEV 12, enables torque and energy management as well as control of the trailer maneuver. A starting aid and an acceleration aid provided by the powered trailer 14 make the mass of the powered trailer 14 less noticeable to the operator of the BEV 12.

[0054] A system and method for extending the range and maneuverability of a battery electric vehicle (BEV) and a powered trailer 10, as described in this disclosure, offers several advantages. These include the distribution of energy and torque between the towing vehicle BEV 12 and the powered trailer 14. The powered trailer 14 can be a motorized intelligent trailer with at least one motor 34 and a modular rechargeable energy storage system, which defines the battery pack 17. The powered trailer 14 communicates with a vehicle module 28 in the towing vehicle BEV 12, which provides torque and energy management as well as maneuverability control. The powered trailer 14 provides a starting boost for the BEV 12 and an acceleration boost, so that the mass of the powered trailer 14 is less noticeable to the BEV 12.The powered trailer 14 also provides the drive unit 16 for starting and acceleration assistance and, if the battery pack 17 is present, ensures the regenerative charging of the battery pack 17 and the vehicle energy pack 22 of the BEV 12.

[0055] The description of the present revelation is merely exemplary, and variations that do not deviate from the core of the present revelation are to be considered within the scope of the present revelation. Such variations are not to be considered a deviation from the spirit and scope of the present revelation.

Claims

[1] A system for extending the range and maneuverability of a motor vehicle during a towing operation, comprising: a battery electric vehicle (12), BEV, with a vehicle energy pack (22) that provides operating energy for the BEV (12); a powered trailer (14) which is detachably connected to the BEV (12); and a drive unit (16) with which the driven trailer (14) is equipped and communicates with the BEV (12), wherein the drive unit (16) improves the starting of the BEV (12) and driven trailer (14) and provides traction support for the driven trailer and the BEV (12), characterized by , that the at least one electric motor (42, 44) is excited to provide a driving force for the driven trailer (14) and to improve the propulsion of the BEV (12), wherein the at least one electric motor (42, 44) is powered exclusively by the vehicle energy pack of the BEV (12). [2] The system according to claim 1, characterized by , that the drive unit (16) includes a battery pack (17), wherein the battery pack (17) provides energy to supplement the operating energy of the vehicle energy pack (22). [3] The system according to claim 2, characterized by , that the battery pack (17) is configured as an energy pack. [4] The system according to claim 2, characterized by , that the drive unit (16) is designed as at least one electric motor (42, 44). [5] The system according to claim 4, characterized by , that the drive unit (16) comprises a first motor positioned in a first wheel hub (42) of the driven trailer (14) and a second motor positioned in a second wheel hub (46) of the driven trailer (14) opposite the first wheel hub (42). [6] The system according to claim 1, characterized by , that the drive unit (16) comprises a battery pack (17) and at least one motor which is driven by the energy supplied by the battery pack (17), wherein the at least one motor is excited to provide a driving force for the driven trailer (14). [7] The system according to claim 1, characterized by , that the drive unit (16) comprises a first motor and a second motor arranged opposite the first motor, and further comprises a trailer module (38) equipped with the driven trailer, wherein the trailer module (38) communicates between the driven trailer (14) and the BEV (12) and with the first motor and the second motor. [8] The system according to claim 7, characterized by, that the trailer module (38) controls a first speed of the first motor which differs from a second speed of the second motor in order to improve the maneuverability of the driven trailer (14).

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