Trailer Connector Coupling With Pneumatic Fail-Safe Actuation

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Solution Overview

Problem

Existing methods for establishing electrical and pneumatic connections between towing and trailer vehicles require manual intervention, which is undesirable in the context of autonomous driving systems.

Innovation Solution

A device comprising a pneumatic cylinder with a valve arrangement and a control unit that automates the establishment of electrical and pneumatic connections, utilizing a bistable cylinder activation valve to maintain the coupling state even in the event of control unit failure, and includes manual switching valves for backup control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If manual intervention is used to establish connections, then operational simplicity is maintained, but automation level deteriorates

Engineering Contradiction:

Improveautomation of connection establishmentVSAvoidmanual intervention requirement

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

The system performs connection establishment autonomously using the pneumatic cylinder to move the plug connector unit into engagement with the trailer vehicle's connectors, eliminating the need for manual intervention while maintaining operational simplicity through automated self-service

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical connection establishment with an automated pneumatic system. The pneumatic cylinder uses compressed air to actuate the plug connector unit, substituting human physical action with a controlled mechanical-pneumatic system that achieves the same connection function

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If controller activation is used to control the pneumatic cylinder, then precision control is improved, but system reliability deteriorates due to potential controller failure

Engineering Contradiction:

Improvecontrol precisionVSAvoidsystem reliability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The valve arrangement is designed with fail-safe characteristics that provide beforehand cushioning against controller failure. The system incorporates redundant safety mechanisms in the valve arrangement that ensure the pneumatic cylinder maintains its position or returns to a safe state even when the controller fails, protecting against potential control errors

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The system incorporates feedback mechanisms where the controller receives status information about the connection state and pneumatic cylinder position. This feedback loop allows the controller to monitor system state and make adjustments, while the valve arrangement's fail-safe design ensures that feedback failures do not lead to unsafe states

Inventive Principle:

Principle #23Feedback

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

Enables secure, automated establishment and maintenance of electrical and pneumatic connections between towing and trailer vehicles, ensuring operational safety and efficiency, particularly suitable for autonomous systems.

Implementation Method 1

The device comprises a pneumatic cylinder (18) having a vehicle end (20) configured for connecting to a part (24) of the towing vehicle (16), and having a plug connector end (22) configured for connecting to a plug connector unit (26). The pneumatic cylinder has a coupling state and a release state and a piston (28) of the pneumatic cylinder is extended further out of a cylinder (30) of the pneumatic cylinder in the coupling state than in the release state.

Methodology Applied

Scientific EffectPneumatics: Pressure Gradient

Implementation Method 2

The valve arrangement (44) is configured for connecting a first chamber (40) of the pneumatic cylinder to a compressed air supply (46) to shift from the release state to the coupling state, and configured for connecting a second chamber (42) of the pneumatic cylinder to the compressed air supply to shift the pneumatic cylinder from the coupling state to the release state.

Methodology Applied

Scientific EffectCompressed air supply: Pressure Increase

Data Source

PatentUS20250367994A1Device for automatically establishing connections between a tractor vehicle and a trailer vehicle, and a system and method therefor

Publication Date: 2025.12.04 ZF CV SYST GLOBAL GMBH

AI summary

A device for automatically establishing electrical and pneumatic connections between a towing and a trailer vehicle, including a pneumatic cylinder having a vehicle end configured for connecting to a part of the towing vehicle, and having a plug connector end configured for connecting to a plug connector unit. The pneumatic cylinder has a coupling and a release state and a piston of the pneumatic cylinder is extended further out of a cylinder of the pneumatic cylinder in the coupling state than in the release state. The device includes a valve arrangement configured for connecting a first chamber of the pneumatic cylinder to a compressed air supply to shift from the release state to the coupling state, and configured for connecting a second chamber of the pneumatic cylinder to the compressed air supply to shift the pneumatic cylinder from the coupling state to the release state.