Trailer Battery Range Extender With Swappable Cells for Long-Haul Trucks
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Solution Overview
Problem
Current electric tractor trailers have limited range, typically less than 200 miles, and require lengthy recharging times, making them inefficient for long-haul cargo transportation between population centers, and they require significant infrastructure investments for battery and hydrogen technologies.
Innovation Solution
A battery range extender system for tractor trailers that includes a battery compartment with removable battery cells, a controller, and a charging port, allowing for quick exchange and recharging of battery cells, enabling extended range and compatibility with existing maintenance facilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If electric power source is used in tractor trailer, then fuel costs are reduced, but travel range is limited to less than 200 miles
Solution Approach 1:
The battery system is divided into multiple individual battery cells that can be independently removed and replaced. This segmentation allows the tractor trailer to carry multiple battery cells (e.g., 2-4 cells) that can be quickly swapped out when depleted, effectively extending the total travel range beyond what a single battery could provide while maintaining the fuel cost benefits of electric power.
Solution Approach 2:
The system changes the operational parameter from single-battery operation to multi-battery cell operation with quick exchange capability. By implementing battery cells with handles for easy removal and replacement, and providing multiple charging ports for simultaneous charging, the system transforms the range limitation into an extendable capability without sacrificing the energy efficiency of electric propulsion.
2Length of moving object
If battery recharging is performed, then travel range is extended, but time required reduces hauling efficiency
Solution Approach 1:
The battery system is segmented into multiple independently replaceable battery cells. When one battery cell is depleted, it can be quickly removed and replaced with a charged cell without waiting for recharging, significantly reducing the time loss compared to traditional recharging methods.
Solution Approach 2:
Battery cells are pre-charged at maintenance facilities, truck terminals, or other locations before being installed in the tractor trailer. This preliminary charging action ensures that replacement battery cells are ready to use, eliminating downtime during operation. The system includes multiple charging ports that allow simultaneous charging of multiple cells in advance.
3Reliability
If battery technology infrastructure is developed, then electric propulsion capability is improved, but infrastructure investment cost increases
Solution Approach 1:
The battery system is designed to be universally compatible with existing infrastructure. Multiple charging ports can accept various charging sources, and the battery cells can be charged at any location with electrical power availability, including maintenance facilities, truck terminals, and other standard locations, rather than requiring dedicated specialized infrastructure.
Solution Approach 2:
The system enables self-service battery cell replacement and charging operations. The battery cells are designed with handles for easy manual removal and installation, and the multiple charging ports allow operators to charge cells at convenient locations without requiring specialized service equipment or infrastructure investments.
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
The system extends the travel range to match a typical driver's tour of duty, reduces recharging time to less than 15 minutes, and utilizes existing infrastructure, enhancing operational efficiency and reducing infrastructure requirements.
Implementation Method 1
a battery compartment, at least one battery cell... the at least one battery cell electrically coupled with the tractor-trailer
Data Source
AI summary
A tractor trailer battery system having a battery compartment containing one or more battery units which house one or more battery cells, electrical leads from the battery units to a trailer mounted controller in electrical communication with a cab mounted controller which is in electrical communication an electric motor or hybrid engine system. The battery system allows for either the trailer mounted controller or the cab mounted controller to provide principal communication to the electric motor or hybrid engine system.