Modular Trailer Propulsion for Retrofit Truck Electrification
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Solution Overview
Problem
Current electric vehicle systems for trucks face challenges in efficient electrification, maintenance costs, and range anxiety, particularly when towing heavy trailers, as they require significant hardware retrofits and cannot operate independently for charging, leading to increased downtime and operational inefficiencies.
Innovation Solution
A modular electric vehicle system that includes a chassis, battery pack, electric powertrain, sensor suite, and controller, allowing for after-market electrification with minimal hardware changes, providing electric arbitrage, autonomous torque augmentation, and enabling the vehicle to be selectively added or removed for charging, thus reducing downtime and extending range without idling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If electric vehicle systems are implemented for truck electrification, then propulsion efficiency is improved, but hardware complexity and retrofit requirements increase
Solution Approach 1:
The electric vehicle system is divided into modular components including a chassis, battery pack, electric powertrain, sensor suite, and controller. This segmentation allows the system to be implemented as a separate module that can be attached to existing trucks without requiring complete hardware redesign, thereby improving propulsion efficiency while limiting hardware complexity increases to specific subsystems.
Solution Approach 2:
The electric vehicle system is designed with universal coupling mechanisms (fifth wheel and landing gear) that enable it to interface with standard truck and trailer configurations. This multi-functionality allows the same electric module to be attached to various truck types and trailer combinations, improving energy efficiency across different applications without requiring application-specific hardware modifications.
2Adaptability or versatility
If the vehicle system is selectively added or removed for charging, then operational flexibility is improved, but time for attachment and detachment increases
Solution Approach 1:
The electric vehicle system incorporates pre-configured coupling mechanisms including a fifth wheel for trailer connection and retractable landing gear for ground support. These preliminary configurations allow the system to be quickly attached to and detached from trailers without requiring complex assembly or disassembly procedures, thereby enabling operational flexibility for selective charging while minimizing time loss during coupling operations.
3Power
If the electric powertrain provides torque augmentation, then propulsion capability is improved, but energy consumption increases
Solution Approach 1:
The electric powertrain is designed to provide partial torque augmentation rather than complete propulsion. The controller selectively engages the electric motor to supplement diesel engine torque during specific high-demand conditions such as acceleration or hill climbing. This partial action approach improves overall propulsion capability while limiting energy consumption to only when additional torque is genuinely needed, avoiding continuous electric motor operation.
4Ease of manufacture
If zero-hardware installations are implemented for after-market electrification, then ease of installation is improved, but structural integration challenges increase
Solution Approach 1:
The electric vehicle system serves as an intermediary module that interfaces between existing trucks and trailers. By providing standardized coupling mechanisms (fifth wheel, landing gear, vehicle couplings), the system mediates the connection without requiring direct structural modifications to the truck or trailer. This intermediary approach enables zero-hardware installations for after-market electrification while managing structural integration challenges within the self-contained module.
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 enables zero-hardware installations for truck electrification, reduces maintenance costs, extends vehicle range, and allows for autonomous torque augmentation, minimizing downtime by enabling the electric vehicle system to be used as a plug-in hybrid architecture, reducing load on diesel engines and providing efficient propulsion for towing.
Implementation Method 1
an electric powertrain including: a traction motor and a steering drive axle
Data Source
AI summary
The vehicle system can include: a set of vehicle couplings (e.g., a tractor interface, a trailer interface, etc.); a chassis, a battery pack, an electric powertrain, a sensor suite, and a controller. The modular vehicle system can optionally include landing gear, a suspension, and any other suitable set of components. The vehicle system functions to structurally support and/or tow a trailer – such as a Class 8 semi-trailer – and/or to augment/supplement a tractor propulsive capability (e.g., via a diesel/combustion engine) with a supplementary electric drive axle(s).