Trailer Brake Cooling via Transmission-Driven Pumps
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Solution Overview
Problem
Existing brake cooling systems for heavy-duty trailers, especially those using gooseneck hitches, face inefficiencies due to increased braking demands, complex control systems, and reliance on the hauling vehicle's power unit, leading to suboptimal cooling performance and maintenance challenges.
Innovation Solution
A self-reliant brake cooling system utilizing a transmission-driven power circuit to operate cooling pumps and fans, with a separate fluid circuit for brake cooling, featuring variable speed motors controlled by temperature and pressure sensors to optimize cooling flow and air exchange, eliminating the need for a separate engine and simplifying the design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a separate engine is installed on the trailer for brake cooling, then cooling capacity is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The system uses the trailer's own wheel rotation to drive the transmission pump, which in turn drives the cooling pump and fan. This self-powered approach eliminates the need for a separate engine while maintaining adequate cooling capacity for the brakes.
Solution Approach 2:
The transmission pump serves multiple functions: it powers the cooling pump for brake cooling, drives the fan for heat exchanger operation, and can potentially serve other trailer functions. This multi-functionality replaces the need for a dedicated engine while reducing overall system complexity.
2Device complexity
If the hauling vehicle's power unit is used for trailer brake cooling, then device complexity is reduced, but reliability deteriorates due to dependency on external vehicle
Solution Approach 1:
The trailer brake cooling system is made self-reliant by using the trailer's own wheel rotation to power the cooling system through the transmission pump, eliminating dependency on the hauling vehicle's power unit and improving reliability.
3Power
If multiple pumps are used to provide cooling flow to each wheel brake chamber, then cooling performance is improved, but device complexity and difficulty of repair increase
Solution Approach 1:
Multiple pump functions are merged into a single transmission pump that powers both the cooling pump and fan through hydraulic motors. This consolidation maintains cooling performance while reducing the number of separate pump components and simplifying the overall system.
4Loss of energy
If sequential flow diversion through valves is used at high speeds, then energy loss is reduced, but cooling effectiveness deteriorates
Solution Approach 1:
The system dynamically adjusts cooling flow based on operating conditions. At high speeds, the increased wheel rotation automatically increases transmission pump output, providing sufficient cooling flow without needing to divert flow through valves, thus maintaining both energy efficiency and cooling effectiveness.
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 system provides improved cooling efficiency, reduced complexity, and enhanced reliability, allowing for higher vehicle speeds and easier maintenance, while eliminating the need for a separate engine and reducing the risk of brake failure.
Implementation Method 1
an air-to-oil (or other fluid-to-oil) heat exchanger (cooler) to remove heat from the cooling oil
Implementation Method 2
a pump assembly that can receive ground driven power from the wheels, via a transmission, to move fluid through the wet brake housings to cool them
Data Source
AI summary
A brake cooling system uses a pair of subsystems to efficiently provide brake cooling and operation of the system. A first subsystem uses an axle assembly to drive one or more pumps to drive a variable speed cooling flow pump motor and a variable speed fan motor. A second subsystem includes one or more cooling flow pumps that are driven by variable speed cooling flow pump motor to supply a cooling fluid to an air-fluid heat exchanger for cooling and then supply the cooled fluid from the heat exchanger to brakes of the axle assembly. The variable speed fan motor drives a fan for the air-fluid heat exchanger for cooling of fluid passing therethrough. The system also includes a means for controlling the speed of the motors to regulate the heat exchanger operation and cooling flow through the heat exchanger and brakes of the axle assembly.