Trailer Axle Generator Control for TRU Battery SoC Thresholds
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Solution Overview
Problem
Existing transport refrigeration units (TRUs) with axle generators are inefficient in energy use, leading to excessive fuel consumption and emissions due to unnecessary activation of generators when battery state of charge (SoC) falls below 100%, and this inefficiency increases maintenance costs.
Innovation Solution
A power supply system with a controller that activates the generator only when the battery SoC reaches a predefined threshold, optimizing power usage by predicting consumption and adjusting generator activation duration based on real-time SoC, rotational speed, and road attributes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the generator is activated whenever battery SoC falls below 100%, then the battery is kept charged, but fuel consumption and emissions increase excessively
Solution Approach 1:
The system changes the activation parameter from a fixed threshold (100% SoC) to a dynamic threshold based on predicted power consumption and trip duration. The controller calculates a dynamic SoC threshold that accounts for remaining trip time and expected power needs, activating the generator only when necessary to maintain operation above this dynamic threshold, thereby reducing unnecessary fuel consumption while ensuring adequate battery charge levels.
Solution Approach 2:
The system performs preliminary calculation of predicted power consumption and dynamic threshold before making the activation decision. By forecasting the power consumption profile for the remaining trip and pre-calculating the appropriate dynamic SoC threshold, the system avoids reactive generator activation and instead uses proactive, optimized control that minimizes fuel usage while guaranteeing sufficient battery charge.
2Reliability
If the generator is activated frequently to maintain battery charge, then battery SoC is maintained, but maintenance costs increase
Solution Approach 1:
The system dynamically adjusts the generator activation threshold based on actual trip conditions and power consumption patterns, reducing the frequency of generator activations compared to a fixed 100% threshold. This optimized activation strategy extends generator maintenance intervals by minimizing unnecessary runtime while ensuring battery SoC remains adequate for TRU operation.
3Use of energy by moving object
If the generator activation threshold is set low to save fuel, then fuel consumption decreases, but battery SoC may drop below operational levels
Solution Approach 1:
The system performs preliminary calculation of the dynamic SoC threshold based on predicted power consumption for the remaining trip. By forecasting power needs in advance and setting the activation threshold accordingly, the system ensures that the battery will maintain sufficient charge levels throughout the trip while minimizing generator runtime and fuel consumption.
Solution Approach 2:
The system continuously monitors actual power consumption and compares it with predicted consumption, adjusting the dynamic threshold and activation decisions in real-time. This feedback mechanism ensures that the battery SoC remains above operational minimums while optimizing fuel consumption by avoiding both over-activation and under-activation of the generator.
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
Reduces fuel consumption and maintenance costs by efficiently utilizing the generator and battery, maintaining optimal SoC levels without compromising TRU operation, thus enhancing energy efficiency and reducing emissions.
Implementation Method 1
the generator being configured to generate electrical power upon rotation of the axle according to a rotational speed of the axle
Implementation Method 2
a battery electrically connected to one or more components of the TRU
Data Source
AI summary
Disclosed herein is a power supply system for a transport refrigeration unit (TRU). The system comprises a battery, and a generator connected to the battery. The generator is operatively coupled to an axle of a trailer to generate electrical power upon rotation of the axle. The system further comprises a controller configured to activate the generator to generate and supply the electrical power to the battery and/or the TRU during the a trip after the TRU depletes energy stored in the battery to or below a threshold state of charge (SoC) level.