Regenerative Drive Axle Energy Storage for Stopover HVAC
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Solution Overview
Problem
Current hybrid vehicle systems for tractor-trailers are limited in fuel efficiency improvement as the trailer remains a passive load, leading to significant fuel costs for the trucking industry, with average fuel economy of 6.5 miles per gallon for tractor-trailers and annual fuel expenditures exceeding $100 billion.
Innovation Solution
A hybrid suspension system is integrated into the tractor-trailer configuration, featuring an electrically-powered drive axle that supplements primary motive forces, enables regenerative braking, and powers auxiliary systems like HVAC during engine idling, utilizing a battery management system and heat exchanger to optimize energy storage and usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the fuel-fed engine is shut off during stopover to reduce fuel consumption, then fuel efficiency is improved, but the HVAC system cannot operate without power
Solution Approach 1:
The patent converts the previously wasted kinetic energy during braking into useful electrical energy through regenerative braking. The electric motor-generator acts as a generator during deceleration, converting mechanical energy to electrical energy that charges the battery, thereby providing power for HVAC operation during stopovers without requiring the fuel-fed engine to remain running.
Solution Approach 2:
The system enables the vehicle to power its own auxiliary systems during stopovers through self-generated electricity from regenerative braking. The battery stores energy recovered during braking and supplies it during idle periods, making the system self-sufficient without external fuel consumption or grid connection.
2Loss of energy
If regenerative braking is implemented to capture energy during deceleration, then energy recovery is improved, but the system complexity increases with additional components
Solution Approach 1:
The electric motor-generator serves multiple functions: it acts as a motor during acceleration, as a generator during regenerative braking, and as a power source for auxiliary systems. This multi-functionality reduces the need for separate dedicated components for each function, thereby limiting the increase in system complexity while maximizing energy recovery potential.
Solution Approach 2:
The system dynamically changes the operating parameters of the electric motor-generator based on vehicle conditions. During deceleration, the motor-generator's rotational speed and electrical load are adjusted to optimize energy recovery, while during acceleration, parameters are changed to provide motive power. This parameter flexibility allows a single component to handle multiple operational modes.
3Loss of energy
If the electric motor-generator is used for regenerative braking, then braking energy is recovered, but the mechanical braking system effectiveness may be reduced
Solution Approach 1:
The patent merges the regenerative braking system with the traditional mechanical friction braking system into a unified braking architecture. The electronic control unit coordinates both systems, using regenerative braking for energy recovery during moderate deceleration and mechanical braking for high-force stopping or when regenerative capacity is insufficient. This combination ensures that neither system compromises the other's effectiveness.
Solution Approach 2:
The system incorporates feedback control through the electronic control unit, which continuously monitors vehicle speed, deceleration rate, battery state of charge, and braking force requirements. Based on this feedback, the controller dynamically adjusts the distribution of braking force between the regenerative and mechanical systems, ensuring optimal energy recovery while maintaining safe and effective braking performance under all conditions.
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 reduces fuel consumption by approximately 30%, enhances trailer dynamics, and provides a built-in auxiliary power unit, improving fuel efficiency and reducing emissions.
Implementation Method 1
receive energy recovered using the drive axle in a regenerative braking mode of operation
Implementation Method 2
a heat exchanger for at least moderating temperature of the battery during the over-the-roadway travel
Data Source
AI summary
A through the road (TTR) hybridization strategy is proposed to facilitate introduction of hybrid electric vehicle technology in a significant portion of current and expected trucking fleets. In some cases, the technologies can be retrofitted onto an existing vehicle (e.g., a trailer, a tractor-trailer configuration, etc.). In some cases, the technologies can be built into new vehicles. In some cases, one vehicle may be built or retrofitted to operate in tandem with another and provide the hybridization benefits contemplated herein. By supplementing motive forces delivered through a primary drivetrain and fuel-fed engine with supplemental torque delivered at one or more electrically-powered drive axles, improvements in overall fuel efficiency and performance may be delivered, typically without significant redesign of existing components and systems that have been proven in the trucking industry.