Frame-Mounted Generator for Battery-Powered TRU
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Solution Overview
Problem
Existing power generation systems for large-vehicle transport refrigeration units face issues with reliability due to road vibrations and high costs associated with axle-differential configurations, which affect the cooling of perishable goods during unscheduled delays.
Innovation Solution
A battery-powered transport refrigeration unit with a generator mounted to the vehicle frame, utilizing a jackshaft and pulley system to isolate road shock and a regenerative system that generates power only during deceleration, combined with a solar panel for charging, minimizing battery size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the generator is mounted directly on the axle, then the generator is positioned close to the power source, but the generator reliability deteriorates due to excessive punishment from road vibration and mechanical shock
Solution Approach 1:
The power transmission system is segmented into multiple components: axle, differential, driveshaft, and frame-mounted generator. This segmentation allows each component to perform its specific function while isolating the generator from direct mechanical shocks and vibrations from the road.
Solution Approach 2:
The driveshaft acts as an intermediary component that transmits power from the differential to the generator while isolating the generator from road vibrations. The flexible coupling in the driveshaft further mediates between the rigid power source and the generator, absorbing mechanical shocks.
2Reliability
If the axle-differential and driveshaft combination is used to mount the generator on the frame, then the generator reliability is improved, but the system weight and cost increase
Solution Approach 1:
The differential serves multiple functions: it is both a necessary component for wheel drive in rear-wheel-drive vehicles and the mounting point for the generator. This multi-functionality eliminates the need for additional dedicated mounting structures, reducing overall system weight and cost.
Solution Approach 2:
The existing axle-differential-driveshaft system, which is already required for vehicle operation, is utilized to also serve as the generator mounting and power transmission system. The system serves itself by providing both propulsion and electrical power generation functions through its existing components.
3Duration of action of moving object
If a larger battery pack is used to extend operating duration during unscheduled delays, then the power availability is improved, but the battery cost and vehicle weight increase
Solution Approach 1:
The regenerative braking system enables continuous power generation during deceleration events throughout the vehicle's operation. Rather than relying solely on stored battery energy, the system continuously replenishes the battery during normal vehicle operation, effectively extending the operational duration without requiring a larger battery.
Solution Approach 2:
The system recovers kinetic energy that would otherwise be wasted during braking and deceleration events. By capturing and storing this regenerative energy in the battery, the system extends the effective operating duration of the refrigeration unit without requiring additional battery capacity.
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 solution enhances power generation reliability, reduces battery size and cost, and ensures continuous cooling of refrigerated goods by providing backup power and efficient charging, while minimizing fuel consumption and emissions.
Implementation Method 1
a jackshaft pulley driven by a pulley mounted to the wheel assembly of the vehicle
Implementation Method 2
isolating road shock from the generator
Implementation Method 3
The generator is mounted to the vehicle frame or in the case of a semi-trailer with adjustable axles, to the axle carriage. The pulley on the generator is driven by a jackshaft pulley
Implementation Method 4
A solar panel is installed on the roof of the battery powered TRU to charge the battery when the unit is stationary or in motion
Data Source
AI summary
The generation of electrical power for large-vehicle transport refrigeration units (TRU) such as semi-trailer reefers. A generator is mounted to the vehicle frame or axle carriage and driven by a wheel-pulley system. Translational motion of the heavy vehicle produces electrical power using the substantial momentum of the vehicle. The electrical power can also be supplemented by at least one solar panel mounted on the roof of the semi-trailer reefer.