Axle Generator Power Control for Transport Refrigeration Units
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Solution Overview
Problem
Existing transport refrigeration units (TRUs) with axle generators face inefficiencies in energy use, leading to increased fuel consumption, maintenance costs, and emissions due to inefficient power management between the generator and battery.
Innovation Solution
A power supply system that includes a controller to monitor battery state of charge (SoC) and predict power consumption, activating the axle generator based on rotational speed and power needs to maintain optimal SoC levels, ensuring efficient power distribution between the battery and TRU components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the generator is continuously activated to supply power to the TRU, then the power supply reliability is improved, but the fuel consumption and maintenance costs increase
Solution Approach 1:
The system performs preliminary action by predicting the future power consumption of the TRU based on historical data and operational parameters. This allows the controller to proactively manage battery discharge levels and generator activation timing, ensuring power supply reliability while avoiding unnecessary generator operation and reducing fuel consumption.
Solution Approach 2:
The system implements feedback mechanisms by continuously monitoring the state of charge (SoC) of the battery, actual power consumption, and generator performance. This real-time feedback enables dynamic adjustment of generator activation thresholds and battery charge/discharge rates, optimizing the balance between power supply reliability and fuel efficiency.
2Loss of energy
If the generator activation threshold is lowered to reduce fuel consumption, then the fuel efficiency is improved, but the power supply reliability deteriorates
Solution Approach 1:
The system uses predictive algorithms to forecast future power consumption based on operational patterns, ambient conditions, and load requirements. This preliminary assessment allows the controller to set dynamic activation thresholds that are lower than traditional fixed thresholds, improving fuel efficiency while maintaining adequate battery charge levels to ensure power supply reliability during high-demand periods.
Solution Approach 2:
The system transitions from static, fixed generator activation thresholds to dynamic, adaptive thresholds that adjust in real-time based on predicted power consumption, current battery state of charge, and operational conditions. This dynamic approach enables the system to optimize fuel efficiency by activating the generator only when necessary while maintaining power supply reliability through condition-based decision-making.
3Duration of action of moving object
If the battery capacity is increased to extend operational duration, then the operational autonomy is improved, but the system weight and cost increase
Solution Approach 1:
The system implements self-service by using the axle generator to recharge the battery during vehicle operation, creating a regenerative energy system. This allows the battery to maintain adequate charge levels for extended operational duration without requiring a larger capacity battery, thereby avoiding increased weight. The generator serves dual purposes: powering the TRU directly and recharging the battery when excess capacity is available.
Solution Approach 2:
The system changes the operational parameters of the battery by implementing intelligent charge/discharge rate management based on real-time conditions. Instead of relying on increased battery capacity, the system optimizes the utilization of existing battery capacity through dynamic parameter adjustment, including charge acceptance rates, discharge current limits, and state of charge thresholds, thereby extending effective operational duration without adding weight.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Optimizes electrical power usage, reducing fuel consumption and maintenance costs while maintaining reliable power supply to TRU components, enhancing operational efficiency and cost-effectiveness.
Implementation Method 1
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 a rotational speed of the axle
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
Disclosed herein is a power supply system (100) for a transport refrigeration unit (TRU) (102). The system (100) comprises a battery (110), and a generator (106) connected to the battery (110). The generator (106) is operatively coupled to an axle (108) of a trailer to generate electrical power upon rotation of the axle (108). The system (100) further comprises a controller (114) operatively coupled to the battery (110), the TRU (102), and the generator (106). The controller (114) is configured to monitor a real-time SoC of the battery (110), predict electrical power consumption of the TRU (102) for a trip of a predefined duration, monitor the rotational speed of the axle (108) and correspondingly determine electrical power available at the generator (106), and activate the generator (106) to generate and supply electrical power to the battery (110) and/or the TRU (102) based on the predicted electrical power consumptions, the real-time SoC of the battery (110), and the rotational speed of the axle (108) or the electrical power available at the generator (106).