Electric Trailer Regenerative Braking With Differential Torque Control
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Solution Overview
Problem
Existing trailer systems lack a comprehensive solution that provides motive power, controlled differential power and braking for stability and maneuverability, optimized towing range, and advanced electrical power generation and storage without requiring changes to the operational configuration of existing tractors, and are not adequately responsive to safety and emergency issues.
Innovation Solution
A system with at least two electrical wheel motors and a storage bank, controlled by a trailer control system that receives sensor inputs for real-time adjustments, enabling differential torque and braking, and is adaptable to both ICE and EV tractors, allowing retrofitting to existing trailers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If regenerative braking systems are implemented in trailers, then energy recovery and towing range are improved, but system complexity and cost increase
Solution Approach 1:
The motor/generator unit performs multiple functions: it provides motive power to the trailer wheels during acceleration and climbing, acts as a generator during regenerative braking to recover energy, and can function as a standard motor during normal towing. This multi-functionality resolves the contradiction by maximizing energy recovery capabilities while avoiding the need for separate dedicated braking systems, thereby reducing overall system complexity despite the advanced functionality.
Solution Approach 2:
The regenerative braking system enables the trailer to self-charge during deceleration and downhill driving, with the motor/generator automatically converting kinetic energy back into electrical energy stored in the battery. This self-service capability improves energy recovery without requiring external charging infrastructure or complex control systems, thus enhancing energy efficiency while maintaining manageable system complexity.
2Power
If motor/generators are added to the trailer for motive power, then towing capability and range are enhanced, but weight and initial energy consumption increase
Solution Approach 1:
The system dynamically adjusts the operational parameters of the motor/generator based on real-time conditions such as terrain slope, load weight, and driving speed. During regenerative braking events, the system optimizes the conversion ratio and charging rate to maximize energy recovery, thereby offsetting the initial energy penalty of the added components. This parameter optimization resolves the contradiction by improving effective towing capability through intelligent control while minimizing the net energy cost of the additional weight.
3Productivity
If advanced sensor and control systems are implemented for real-time optimization, then operational efficiency and safety are improved, but device complexity and cost increase
Solution Approach 1:
The control system continuously monitors key parameters including motor/generator output, battery charge state, wheel speed, and braking force, then automatically adjusts operational parameters to optimize energy recovery and maintain safe operation. This feedback mechanism improves operational efficiency by maximizing regenerative braking capture while maintaining manageable complexity through rule-based control logic that responds to real-time conditions without requiring overly sophisticated algorithms.
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
Enhances safety, stability, and efficiency by providing fine-tuned trailer performance, extending towing range, and optimizing energy consumption and trajectory control without modifying the towing vehicle.
Implementation Method 1
motor/generators on the towed vehicle provide regenerative braking for the trailer
Implementation Method 2
battery source supplying power to trailer motors
Data Source
AI summary
An electric trailer with regenerative braking is adaptive to both EV and ICE tractors, extending towing range of such vehicles, coordinating with performance characteristics of a tractor for maximum tractor-trailer efficiency. Differential electrical control of wheel drives provides enhanced performance safety and driving control. Embodiments optimize performance using real-time road conditions and terrain information. The trailer provides fail-safe operation in the event of system malfunction.