Kingpin Force Sensing for Dynamic Trailer Tow Control
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Solution Overview
Problem
Existing trailer tow systems lack dynamic control mechanisms to efficiently manage forces and movements, leading to inefficiencies such as jackknife events, increased emissions, and fuel consumption, while also being vulnerable to unauthorized access and theft.
Innovation Solution
A system and method that utilizes a kingpin with integrated sensors to detect and calculate forces, coupled with a controller to manage torque output and wheel speeds, enabling dynamic tow control, including modes for hibernation, manual, and tow, and incorporating security features to prevent unauthorized access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dynamic torque control is implemented on the trailer, then jackknife events are prevented and trailer control is improved, but device complexity increases due to integrated sensors and controllers
Solution Approach 1:
The patent combines multiple functions into integrated components: force sensors are embedded within the kingpin structure, the controller is integrated with the drive system, and the torque control mechanism is merged with the wheel drive assembly. This consolidation improves reliability through coordinated control while managing complexity through functional integration rather than separate discrete components.
Solution Approach 2:
The controller acts as an intermediary between the force sensors detecting kingpin forces and the drive system applying torque. It processes sensor signals, calculates required torque based on force magnitude and direction, and commands the drive system accordingly. This intermediary function enables sophisticated trailer control without requiring direct mechanical linkages, managing system complexity through intelligent mediation.
2Loss of energy
If motorized drive system with torque control is added to the trailer, then fuel consumption and emissions are reduced through efficient movement management, but device complexity and initial energy requirements increase
Solution Approach 1:
The system continuously monitors forces applied to the kingpin through integrated sensors and uses this feedback to dynamically adjust torque output. The controller receives real-time force data, calculates optimal torque requirements based on force magnitude and direction, and commands the drive system accordingly. This closed-loop feedback enables energy-efficient operation by applying torque only when and where needed, reducing overall fuel consumption despite the added complexity of the motorized system.
Solution Approach 2:
The drive system transitions from a static, always-engaged configuration to a dynamic system that adjusts torque output based on real-time operating conditions. The controller modulates motor torque according to the magnitude and direction of forces detected at the kingpin, enabling the trailer to adapt its power consumption to actual movement requirements. This dynamic operation reduces energy loss compared to conventional always-on trailer systems.
3Reliability
If integrated sensors and controllers are implemented in the kingpin, then unauthorized access is detected and security is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The force sensors are integrated directly into the kingpin structure rather than being mounted as separate external components. This merging of sensing functionality into the structural element itself enables unauthorized access detection through normal force monitoring while avoiding the complexity of adding separate security hardware. The same sensor infrastructure serves both operational control and security functions, improving security without proportionally increasing manufacturing complexity.
4Productivity
If real-time force detection and torque adjustment are implemented, then trailer operation efficiency is improved and jackknife events are prevented, but use of energy and system complexity increase
Solution Approach 1:
The system uses real-time feedback from force sensors monitoring kingpin forces to dynamically adjust torque output. The controller continuously processes force data, determines optimal torque requirements based on force magnitude and direction, and commands the drive system accordingly. This feedback mechanism improves operational efficiency by preventing jackknife events through proactive torque adjustment while consuming energy only when force corrections are needed, rather than continuous energy expenditure.
Solution Approach 2:
The torque adjustment operates in periodic cycles: the sensors detect forces, the controller calculates required corrections, and the drive system applies torque adjustments at discrete intervals based on detected force changes. This periodic action rather than continuous operation improves productivity by maintaining trailer control while reducing overall energy consumption compared to constant torque application.
Data Source
AI summary
One variation of a method includes, during a first time period: detecting a direction of motion of a trailer; detecting a first force applied to a kingpin; detecting an incline angle of the trailer; calculating a first target preload force opposite the direction of motion and inversely proportional to the incline angle; and in response to the first force falling below the first target preload force, triggering a motor to increase torque output opposite the direction of motion. The method further includes, during a second time period: detecting a second force applied to the kingpin; detecting a decline angle of the trailer; calculating a second target preload force opposite the direction of motion and inversely proportional to the decline angle; and in response to the second force falling below the second target preload force, triggering the motor to increase torque output opposite the direction of motion.