Electric power supply system for extending range of autonomy, said system mounted on a tractor trailer during operation thereof

Abstract

The present invention relates to an electric power supply system for extending the range of autonomy of diesel, hybrid or electric tractors by incorpotating a smart axle and a battery pack in the trailer. This smart axle provides additional torque during operation, is powered by the battery pack and is controlled by other electronic components installed in the trailer. This system is able to store electric power in the battery pack located in the trailer and during a period of static charge, in other words, while the trailer is not moving. Furthermore, this electric power can be transmitted to an electric tractor during operation thereof, thus extending its range of operation and autonomy.

Description

[0001] TRAILER-MOUNTED ELECTRICAL POWER SUPPLY SYSTEM FOR RANGE EXTENSION OF TRACTORS DURING OPERATION

[0002] DESCRIPTION

[0003] OBJECT OF THE INVENTION

[0004] The present invention relates to an electrical power supply system for extending the operating range of diesel, hybrid, or electric tractors by adding a smart axle and a battery pack to the trailer. This smart axle provides additional torque during operation, is powered by the battery pack, and is controlled by other electronic components installed in the trailer. This system is capable of storing electrical energy in the battery pack located in the trailer during a period of static charging, i.e., while the trailer is not in motion. Additionally, this electrical energy can be transferred to an electric tractor during its operation, thereby extending its operating range and autonomy.

[0005] BACKGROUND OF THE INVENTION

[0006] The closest prior art consists of the inventions disclosed through the following documents:

[0007] Two Volvo patents, W02023 / 057060 and EP4323227, describe a similar invention, focusing on the control system established to manage the flow of electrical energy. A similar case is patent CN114714977A, which also emphasizes the description of the charging and discharging control method, while patent US11077765 focuses on the control of the DC-DC converter involved in that concept. Patent US11866043 establishes the communication systems that allow trailer control from the vehicle.

[0008] On the other hand, patents CN204472591 U, CN 104999921 A, and CN109263492A refer to the inclusion of an extra trailer for an unspecified type of vehicle for the purpose of extending its range. However, the objective of this work focuses on using an existing trailer, or one already necessary for cargo transport, to provide the additional functionality of range extension. That is to say, this trailer is not added solely for this purpose; rather, this advantage is in addition to the cargo transport itself. Patent US10333338 describes a system by which electrical power can be transmitted from a crane or another vehicle to another vehicle that is being towed and that, for some reason, requires extra cargo.

[0009] There are also other patents, such as US2023 / 0096878, US2024 / 0067005, MX / A / 2022 / 004866, US5963013, and GB2566490, that describe the transfer of electrical energy to a trailer or load for the purpose of powering devices located on it; whereas the purpose of this work is the transfer of power from the trailer to the electric vehicle. Similarly, patent US2023 / 0382327 refers only to the electrical distribution system for handling electrical loads on the trailer.

[0010] Additionally, several patents address how to harness electrical energy in a trailer to generate propulsion with an electric motor on one of the axles. These patents are US8700284, US11712977, and US2023 / 0373315; while commercial solutions from Trailer Dynamics and Range Energy achieve the same purpose.

[0011] Several patents similar to this work exist, such as ES1272485U, US 10737583, and CN115959224A. However, the first relates more to the energy generation system, which may use a renewable source; while the second and third do not directly address electric tractors and trailers specifically, but rather, similarly to other works, describe the inclusion of an additional trailer for the sole purpose of generating this additional energy. In turn, patent US 11351867 establishes a method for transferring electrical energy, but only to control units.

[0012] US patent 11279255 is similar to this invention; however, it describes a dolly whose primary function is to transmit electrical power from one trailer to another in multi-trailer configurations. US patent 10183563, on the other hand, describes a system that allows for the rapid switching of the power source being towed. US patent 10985511 protects the design of an optimized connector for the transfer of electrical power between trailer units and electric vehicles.

[0013] The patents mentioned above do not fully describe the functionalities established in this work. While some of them allow for the transmission of electrical charge from a trailer to an electric vehicle, this only occurs when the vehicle is stationary, whereas this invention describes a method for transmitting energy while the assembled vehicle is in motion. Furthermore, other prior patents establish an electrical connection during movement, but they use an additional trailer for this purpose; whereas this invention describes a system that can be adapted to a trailer or box without hindering its primary function, which is to transmit a charge for commercial purposes.

[0014] Therefore, there is no invention with the technical characteristics claimed here, so the differences will become evident to a person with average knowledge in the area upon description of it.

[0015] BRIEF DESCRIPTION OF THE FIGURES

[0016] Figure 1 shows a side view of the present invention with a smart axle on the trailer connected to the tractor.

[0017] Figure 2 shows a bottom view of the present invention with a smart axle on the trailer connected to the tractor.

[0018] Figure 3 shows a block diagram representing the present invention with the intelligent axle on the trailer.

[0019] Figure 4 shows a side view of the autonomy range extension system of the present invention on the trailer with the variant I configuration.

[0020] Figure 5 shows a bottom view of the present invention on the trailer with the variant I configuration. Figure 6 shows a block diagram representing the present invention in the variant I configuration.

[0021] Figure 7 shows a side view of the present invention on the trailer connected to the tractor with the configuration of vane I.

[0022] Figure 8 shows a bottom view of the present invention on the trailer connected to the tractor with the configuration of vane I.

[0023] Figure 9 shows a side view of the present invention with wheel generation of the trailer connected to the tractor with the configuration of vane II.

[0024] Figure 10 shows a bottom view of the present invention with wheel generation of the trailer connected to the tractor with the configuration of vane II.

[0025] Figure 11 shows a block diagram representing the present invention with the addition of the trailer wheel generation option with the variant II configuration.

[0026] DESCRIPTION OF THE INVENTION

[0027] The object of the present invention is to extend the operating range of tractors by supplying additional mechanical power via a smart axle located on the trailer during operation. The smart axle and its control components are powered by a battery pack located on the trailer itself. Additionally, when coupled to a tractor, the electrical energy from the battery pack located on the trailer can be adjusted and subsequently sent to the tractor during its operation, in order to increase the power available to it. In this invention, the tractor is understood to be the unit that provides the main traction to the vehicle, with or without an attached trailer. The driver is located on the tractor. The trailer is understood to be the unit that is pulled by the tractor.Traditionally, this unit does not generate its own traction and depends on the tractor for movement. This trailer can be an open platform or a box with or without refrigeration. The present invention relates to a system of connected electronic and mechanical components for extending the operating range of tractors installed on the trailer: a) Charging port: A system consisting of a connection receptacle for the battery charger, as well as the electronic components necessary to filter the electrical current from the vehicle charger (203) or, in this case, the trailer (103). This charging port is connected in series to the power distribution module in the trailer (102).b) Power Distribution Module (102a, 202a): An assembly consisting of a series of power relays, contactors, and protective fuses to ensure the correct and safe distribution of electrical power within an electrical system. The relays and contactors in this module are controlled by the control unit to connect or disconnect other components in series, such as the battery pack (104, 204) and the charging port (103, 203), or in parallel, such as the DC-DC converter (101). The control unit (102b) first checks that the operating variables are within the permitted operating ranges before connecting or disconnecting other components through this module. The power distribution module (102a) and the control unit (102b) are physically assembled in a single electronic unit (102).c) Control Unit (102b): A programmable computer capable of executing multiple algorithms to ensure the correct and safe operation of the vehicle and trailer. This device is capable of receiving signals from other components and sensors to process their information and determine the correct course of action. These actions are then executed through programmable outputs that are sent to other devices, such as the power distribution module, to activate or deactivate other signaling components. These actions result in charging the trailer's battery pack (104) or using the energy stored in it to supply additional electrical power to the electric vehicle. This control unit is also capable of performing the tasks corresponding to a battery monitoring system. This system is capable of monitoring and controlling the behavior and performance of the battery pack (104, 204).It monitors the operating conditions of the batteries, such as temperature, voltage, and current, and provides the necessary mechanisms to prevent the battery from operating outside its nominal operating range. It is also capable of estimating the battery pack's charge and communicating this status to other external components. The power distribution module (102a) and the control unit (102b) are physically assembled in a single electronic unit (102). d) Battery pack (104): An assembly of multiple battery cells electrically connected through a combination of signal and parallel connections to achieve the desired voltage and power ranges, according to the operation of the electrical system.One of these battery packs is part of the tractor's electrical system (204) and is outside the scope of this range extension system definition; whereas the battery pack located in the trailer (104) is an integral part of this system, as it provides additional power to the tractor. These battery packs (104, 204) are signaled to the corresponding power distribution modules (102a, 202a). e) DC-DC Converter (101): An electronic component capable of converting the direct current electrical supply within a certain voltage range to a direct current output within a different voltage range. The DC-DC converter (101) is connected in parallel to the output of the power distribution module (102a). f) Electronic Differential (107): A control unit capable of supplying power to the intelligent axle motors (108) mounted on one of the trailer axles.This control unit receives electrical power from the power distribution module (102a) and distributes it to the smart axle motors (108), according to the driving action required by the vehicle operator. It has connections to the fifth wheel sensor (110), which provides information on the current driving status. g) Smart axle motors (108): Electric motors mounted on one of the trailer axles. These motors provide additional mechanical propulsion to the vehicle by being powered by the electronic differential (107). They can also contribute to braking the vehicle and recover electrical energy through regenerative braking. h) Fifth wheel sensor (110): A sensor located on the fifth wheel assembly that records the force and torque applied to the kingpin.The collected information is supplied to the electronic differential (107) to determine the movement actions required by the vehicle. i) A trailer-to-tractor charging cable (109): in the case of an electric tractor, which extends from the trailer system to the tractor's charging port (203), where said tractor charging port (203) is connected to the power distribution module (202a) and the tractor's battery pack (204).

[0028] For this system to function, a battery charging device (100) is required, which is outside the scope of this invention. This device is used to recharge the battery pack by supplying an electric current through it. Typically, this component represents a complete system connected to an external power source, which includes all the components necessary to convert the supply voltage and current to the levels and parameters required by the device being charged. In this case, the devices to be charged are the battery packs in the tractor (204) and the trailer (104). The connector used to connect to the electric vehicle, if present, is generally of the CCS1 or CCS2 type, as defined by the IEC 62196 standard.

[0029] System operation description:

[0030] This system consists of a battery pack (104) located on the underside of the trailer, which is connected to a power distribution module (102a). This module is connected to a charging port (103) located on the trailer, as well as to a control unit (102b) capable of battery monitoring and electrical power flow control. The power distribution module (102a) and the control unit (102b) responsible for monitoring the battery pack are combined into a single assembly (102). The electronic differential (107), after processing the information gathered by the fifth-wheel sensor (110), supplies electrical power to the smart axle motors (108) to provide additional mechanical propulsion to the vehicle. The smart axle motors (108) can also provide electrical power back to the system through regenerative braking, as well as contribute to the vehicle's braking action.When working with a tractor, the power distribution module (102a) is connected to a DC-DC converter (101), which adjusts the electrical power to the voltage level required by the tractor's electrical system and is connected to the tractor's charging input port (203) via a charging cable (109).

[0031] The charging station (100) connects to the receptacle located on the side of the trailer (103) (Charger Input), with the general objective of recharging the trailer's battery pack (104) (Battery Pack).

[0032] The load connection receptacle (103) has an electrical connection to the power distribution module (102a), while a data connection is established to the control system containing the battery management system and control unit (102b).

[0033] The power distribution module (102a) (PDM) has an electrical connection to the charging receptacle (103), as well as a connection to the battery pack (104) and the charging DC-DC converter (101). It also has a data connection to the module containing the battery control and monitoring system (102b). Through this latter connection, the battery control and monitoring system (102b) can connect or disconnect the various electrical connections of the system, enabling the recharging of the trailer's battery pack (104) or the use of the trailer's energy to recharge the tractor's battery pack (204) after passing through the DC-DC converter (101).The battery management system / control unit (102b) has a data connection to the charging receptacle (103), the battery pack (104), and the DC-DC converter (101). This module (102b) processes voltage, temperature, and current information from the battery pack, determines the system's operating conditions, and performs the necessary connections and disconnections of the other components through the control of the power distribution module (102a).

[0034] The electronic differential (107) is connected to the power distribution module (102a), to the intelligent axle motors (108), and to the fifth wheel sensor (110). This control unit processes the information from the fifth wheel sensor (110) and supplies electrical power to the intelligent axle motors (108) from the distribution module (102a) to generate additional mechanical power.

[0035] The DC-DC converter (101) has a power connection to the power distribution module (102a) (PDM) and a data connection to the battery control and monitoring system (102b). When fitted to an electric tractor, this converter (101) includes a connection to the electric tractor's charging module (203) terminating in a CSS1 or CSS2 connector to supply additional electrical power.

[0036] For a better understanding of the present invention, a detailed description of the figures is given below.

[0037] Figure 1 shows a side view of the range extension system on the trailer connected to a tractor, covering the complete configuration. The components of this system within the trailer are shown in this figure: the DC-DC converter (101), the control unit and power distribution module (102), the trailer charging port (103), the trailer battery pack (104), the electronic differential for the trailer's smart axle (107), the smart axle electric motors (108), the fifth wheel sensor (110), and the trailer-to-tractor charging cable (109). The connecting cable runs between the trailer system and the electric tractor's charging port. On the electric tractor, the tractor's charging port (203), electronic unit (202), and battery pack (204) are shown.If connecting to a conventional diesel tractor, the connection provided by the electrical cable (109) is omitted.

[0038] Figure 2 shows a bottom view of the range extension system on the trailer connected to a tractor. The components of this system within the trailer are illustrated in this figure: the DC-DC converter (101), the control unit and power distribution module (102), the trailer charging port (103), the trailer battery pack (104), the electronic differential for the trailer's smart axle (107), the smart axle electric motors (108), the fifth wheel sensor (110), and the trailer-to-tractor charging cable (109). The connecting cable runs between the trailer system and the electric tractor's charging port. On the electric tractor, the tractor's charging port (203), electronic unit (202), and battery pack (204) are shown. If connected to a conventional diesel tractor, the connection provided by the electrical cable (109) is omitted.

[0039] Figure 3 shows a block diagram of the range extension system on the trailer. The components enclosed in the box labeled “Trailer” are part of this range extension system. There is a charging port (103) for the trailer battery pack (104), which distributes its power to a power distribution module (102a). This module, in turn, has electrical connections to the battery pack (104) and the DC-DC converter (101). The system is controlled by a control unit (102b), integrated into the power distribution module, which also functions as the Battery Monitoring System. By activating the power distribution module via the control unit (102b), the DC-DC converter (101) receives power from the trailer battery pack (104) and converts it to the voltage level required by the tractor's electrical system.The electric motors of the intelligent axle on the trailer (108) provide additional traction to the trailer, reducing the torque required by the tractor. These electric motors are controlled by the electronic differential (107) using information gathered by the fifth-wheel sensor on the tractor (110). In turn, the electric motors (108) are capable of generating electrical energy through regenerative braking. This electrical energy is sent to the electronic differential (107), then to the power distribution unit (102a), and finally to the trailer's battery pack (104) or to the DC-DC converter (101) for subsequent use by the tractor. Electrical energy from the trailer to the tractor is transmitted via the connecting cable between the trailer and the tractor (109).This energy is received by the electric tractor's charging port (203) and then distributed to the electric tractor's electronic unit (202a, 202b), which performs the functions of the electric tractor's power distribution module and battery monitoring system. This unit sends electrical energy to the electric tractor's battery pack (204). When connecting to a conventional diesel tractor, the connection provided by the electrical cable (109) is omitted.

[0040] The typical sequence of operation and use would be as follows:

[0041] 1. The battery packs of the electric tractor (204) (if applicable) and the range extension system on the trailer (104) are charged via a battery charging system (100) while both are in a stationary state. Charging stops when both battery packs reach 100% capacity, or when the electric tractor operator is ready to begin their journey.

[0042] 2. The operator disconnects the electric tractor and trailer from the charging station. The operator then connects the trailer's charging transfer cable (109) to the electric tractor's charging port (203).

[0043] 3. The diesel tractor begins to use the energy obtained from its internal combustion engine, or, in the case of an electric tractor, it uses the electrical energy stored in its battery pack (204). Simultaneously, the range extension system mounted on the trailer uses the energy from the battery pack (104) to power the smart axle motors and provide additional mechanical propulsion, reducing the load on the tractor. In the case of an electric tractor, the range extension system also provides additional electrical energy to the electric tractor's battery pack (204).

[0044] 4. The journey ends when the operator has completed their route, or, in the case of an electric tractor, when the energy in both battery packs (104, 204) is about to run out. At this point, the operator starts the sequence again from point 1.

[0045] PREFERRED ADDITIONAL MODALITIES

[0046] The trailer-mounted battery pack range extension system features additional configurations exclusive to use with electric tractors:

[0047] Vanante I - Battery pack extension:

[0048] When working with an electric tractor, the range extension system can also function as an extension of the tractor's battery pack, even without the electronic differential (107), intelligent axle motors (108), and fifth wheel sensor. Essentially, the system acts as a portable battery capable of supplying additional electrical power to an electric tractor during operation.

[0049] Figure 4 shows a side view of the range extension system on the trailer. The components of this system inside the trailer are shown in this figure: DC-DC converter (101), control unit and power distribution module (102), trailer charging port (103), and trailer battery pack (104), from left to right.

[0050] Figure 5 shows a bottom view of the range extension system on the trailer. The components of this system inside the trailer are shown in this figure: DC-DC converter (101), control unit and power distribution module (102), trailer charging port (103), and trailer battery pack (104), from left to right.

[0051] Figure 6 shows a block diagram of the range extension system. The components enclosed in the box labeled “Trailer” are part of this range extension system. There is a charging port (103) for the trailer battery pack (104), which distributes its power to a power distribution module (102). This module, in turn, has electrical connections to the battery pack (104) and the DC-DC converter (101). The system is controlled by a control unit (102), integrated into the power distribution module, which also functions as the Battery Monitoring System. By activating the power distribution module via the control unit (102), the DC-DC converter (101) receives power from the trailer battery pack (104) and converts it to the appropriate voltage level required by the tractor's electrical system.Electrical power is transmitted from the trailer to the tractor via the connecting cable between the trailer and the tractor (109). This power is received by the electric tractor's charging port (203) and then distributed to the electric tractor's electronic unit (202), which performs the functions of the power distribution module and battery monitoring system. This unit then sends electrical power to the electric tractor's battery pack (204).

[0052] Figure 7 shows a side view of the range extension system connected to the tractor. The components of this system within the trailer are shown: the DC-DC converter (101), the control unit and power distribution module (102), the trailer charging port (103), the trailer battery pack (104), and the trailer-to-tractor charging cable (109). The connecting cable runs between the trailer system and the electric tractor's charging port. The electric tractor is shown with its charging port (203), electronic unit (202), and battery pack (204).

[0053] Figure 8 shows a bottom view of the range extender system on the trailer connected to the tractor's electrical system. This figure shows the DC-DC converter (101), control unit and power distribution module (102), trailer charging port (103), trailer battery pack (104), and the trailer-to-tractor charging cable (109). The connecting cable runs between the trailer system and the electric tractor's charging port. On the electric tractor, the tractor's charging port (203), electronic control unit (202), and battery pack (204) are also shown.

[0054] Vanante II - Electric generators at the wheel terminals:

[0055] As an extension of Vanante I, the system can generate additional electrical power during travel by connecting electric generators to the wheel terminals (106) as shown in Figures 9 and 10. This power is transferred to the system's power distribution module (102) by means of an additional DC-DC converter (105) as shown in Figure 11. This power from these generators increases the total electrical power available during the electric tractor's travel.

[0056] Figure 9 shows a side view of the range extension system with the trailer wheel generator option connected to the tractor. The components of this system within the trailer are shown in this figure: the DC-DC converter (101), the control unit and power distribution module (102), the trailer charging port (103), the trailer battery pack (104), the wheel generator DC-DC converter (105), the trailer wheel generators (106), and the trailer-to-tractor charging cable (109). The connecting cable runs between the trailer system and the electric tractor's charging port. The electric tractor is shown with its charging port (203), electronic control unit (202), and battery pack (204).

[0057] Figure 10 shows a bottom view of the range extension system with the trailer wheel generator option connected to the tractor. The components of this system within the trailer are shown in this figure: the DC-DC converter (101), the control unit and power distribution module (102), the trailer charging port (103), the trailer battery pack (104), the wheel generator DC-DC converter (105), the trailer wheel generators (106), and the trailer-to-tractor charging cable (109). The connecting cable runs between the trailer system and the electric tractor's charging port. On the electric tractor, the tractor charging port (203), the tractor electronics unit (202), and the tractor battery pack (204) are shown.

[0058] Figure 11 shows a block diagram of the range extension system with the addition of the trailer wheel generator option. The components enclosed in the box labeled “Trailer” are part of this range extension system. There is a charging port (103) for the trailer battery pack (104), which distributes its power to a power distribution module (102a). This module, in turn, has electrical connections to the battery pack (104) and the DC-DC converter (101). The system is controlled by a control unit (102b), integrated into the power distribution module, which also functions as the Battery Monitoring System. By activating the power distribution module (102a) via the control unit (102b), the DC-DC converter (101) receives power from the trailer battery pack (104) and converts it to the voltage level required by the tractor's electrical system.The trailer wheel generators (106) generate electrical power during vehicle operation. This power is sent to the trailer wheel generator's DC-DC converter (105), which converts the electrical supply to the voltage level required by the trailer's range extension system. This power is then sent to the power distribution unit (102a) to be sent to the trailer's battery pack (104), or alternatively, to the DC-DC converter (101) for subsequent use by the tractor. Electrical power from the trailer to the tractor is transmitted via the trailer-tractor connection cable (109). This power is received by the electric tractor's charging port (203) and then distributed to the tractor's electronic unit (202a, 202b), which performs the functions of the tractor's power distribution module and battery monitoring system.This unit sends electrical power to the electric tractor's battery pack (204).

Claims

AMENDED CLAIMS received by the International Bureau on 27 February 2026 (27.02.2026) Having sufficiently described the invention, I consider the contents of the following claims to be novel and therefore claim them as my exclusive property:

1. An electrical power supply device mounted on a trailer (103) attachable to a tractor (202), comprising a trailer battery pack (104) connected to a power distribution module (102a) managed by a control unit (102b); a DC-DC converter (101) connected to the power distribution module (102a); a drive assembly consisting of intelligent axle motors (108) powered by an electronic differential (107); a charging cable (109) connected to the tractor's charging port (203); and a fifth wheel sensor (110) disposed on the fifth wheel assembly;characterized in that the fifth wheel sensor (110) is configured to measure the force and torque exerted on the kingpin, supplying this information to the electronic differential (107), which controls the operation of the intelligent axle motors (108) based on the measured magnitudes and the trailer electronic unit (102), comprising the power distribution module (102a) and the control unit (102b), selectively switches the energy flow from the trailer battery pack (104) to the electronic differential (107) for the power supply of the intelligent axle motors (108).;

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