Brake Disc Generator Layout for Self-Powered Trailer Braking
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Solution Overview
Problem
Trailers face challenges in self-generating electricity due to space constraints and the need for external power sources like tractor batteries or diesel generators, which are noisy, polluting, and require frequent maintenance.
Innovation Solution
A regenerative braking power generation system is installed in the brake disc space of a trailer, featuring a permanent magnet synchronous generator with a ring-shaped rotor and stator coil, converting AC power to DC and vice versa using rectification and inverter units, eliminating the need for external power sources and diesel generators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a diesel generator is separately installed in the trailer to produce electrical energy, then power supply capability is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The generator is merged with the brake disc assembly, combining the braking system and power generation system into a single integrated unit. The generator is installed in the space portion of the brake disc, sharing the same mounting structure and rotational axis, which simplifies installation and reduces maintenance complexity while maintaining electrical energy production capability
Solution Approach 2:
The brake disc assembly serves dual functions: providing braking capability and generating electrical energy. The generator integrated into the brake disc space portion allows the same rotational mechanism to perform both braking and power generation, eliminating the need for a separate diesel generator and reducing overall system complexity
2Use of energy by moving object
If a diesel generator is installed in the trailer, then electrical energy is produced, but noise and noxious gas are generated
Solution Approach 1:
The mechanical combustion-based diesel generator is replaced with an electromagnetic generator that converts mechanical energy directly to electrical energy without combustion. This substitution eliminates the sources of noise and noxious gas while maintaining the ability to produce electrical energy, as the generator operates silently through electromagnetic induction rather than combustion
3Use of energy by moving object
If battery power is received from the tractor, then electrical energy is supplied to the trailer, but modification of the tractor is required
Solution Approach 1:
The trailer becomes self-sufficient in electrical energy production through the integrated generator-brake disc system. The generator produces electrical energy independently without requiring modifications to the tractor's battery system or wiring, allowing the trailer to serve its own power needs and eliminating installation complexity associated with external power connections
4Area of stationary object
If the generator is installed in the brake disc space portion, then space utilization is improved, but the brake disc structure becomes more complex
Solution Approach 1:
The generator is nested within the space portion of the brake disc, utilizing the existing brake disc geometry and mounting structure. The generator fits into the concave space of the brake disc, maximizing space utilization without requiring additional external mounting structures, thereby minimizing structural complexity while achieving efficient space use
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
This system effectively utilizes residual space for self-electricity generation, reducing maintenance costs and environmental impact by eliminating the need for external power sources and diesel generators, while providing reliable power to both DC and AC loads.
Implementation Method 1
a generator installed in a space portion concavely formed in one side surface of the brake disc, wherein the generator includes a ring-shaped rotor fixed to an inner circumferential surface of the space portion of the brake disc in tight contact therewith, the rotor having a plurality of permanent magnets disposed (arranged) thereon at equal intervals and a stator fixed to an outer circumferential surface of the axle corresponding to the rotor, the stator being constituted by a stator coil
Data Source
AI summary
Disclosed is a regenerative braking power generation system for trailers configured such that a generator is installed in a brake disc space portion of a trailer to self-generate electricity necessary for the trailer, wherein the regenerative braking power generation system includes at least one axle (3) fixed to a chassis (2) of a trailer, a wheel hub (5) and/or a brake disc (6) axially installed at an outer surface of the axle (3) via a plurality of bearings (4) so as to be passively rotated, a space portion (7) concavely formed in one side surface of the brake disc (6), a permanent magnet (8) fixed to an inner circumferential surface of the space portion (7) in tight contact therewith, the permanent magnet being configured to be rotated along with the brake disc (6), and a generator stator (9) fixed to an outer circumferential surface of the axle (3) corresponding to the permanent magnet (8). AC power produced by the generator (10) is converted into DC power by a rectification unit (20) constituted by a plurality of full-wave diodes (D1, D2, D3, D4, D5, and D6) and a smoothing capacitor (C), a rechargeable battery (secondary battery) or a battery (40) is charged with the DC power by a charge controller (30), the DC power is supplied to a DC (direct current) load (50), and the power in the battery (40) is converted into AC power of 50 to 60 Hz by an inverter (60) and is supplied to an AC (alternating current) load (70).