Self-Contained Trailer Drive Unit Battery Integration
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Solution Overview
Problem
The installation of caravan movers is costly and time-consuming due to the need for a bespoke power system, which requires routing cables through the caravan, compromising its integrity and increasing space usage.
Innovation Solution
A self-contained drive unit with a detachable battery and control unit, integrated into a single component that mounts directly to the trailer, eliminating the need for external cables and providing a secure, efficient power solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dedicated power system with internal battery is installed in the caravan, then the caravan mover can operate independently, but it takes up valuable space inside the caravan and requires cable penetration that compromises caravan integrity
Solution Approach 1:
The power system (battery and control unit) is extracted from the caravan interior and relocated to an external mounting position on the caravan body. The battery is mounted in a battery box that is externally secured to the caravan, eliminating the need for internal space occupation and internal cable routing, thereby preserving caravan integrity while maintaining independent operation capability
Solution Approach 2:
A cable management system with external cable guides and routing channels is introduced as an intermediary solution. This system provides protected external pathways for power cables to connect the externally mounted battery to the caravan mover, eliminating direct penetration through the caravan structure and preventing compromise of caravan integrity
2Ease of manufacture
If a bespoke power system is individually created and installed for each caravan, then the power cables can be optimally routed, but the installation time and cost significantly increase
Solution Approach 1:
The battery box, control unit mounting, and cable routing pathways are pre-configured and pre-assembled as complete external power system kits before delivery to the installation site. This preliminary preparation allows for rapid installation by simply mounting the pre-assembled units, eliminating the need for time-consuming on-site cable routing and system configuration while maintaining optimal power distribution
3Ease of operation
If the battery and control unit are mounted separately within the caravan, then each component can be optimally positioned, but the installation complexity and cost increase
Solution Approach 1:
The battery and control unit are merged into a single external mounting location on the caravan body, forming an integrated external power system. This consolidation simplifies installation by reducing the number of separate mounting operations and cable connections required, while the modular battery box design still allows for flexible positioning on the caravan exterior to optimize access and cable routing
Data Source
AI summary
The present invention relates to a drive unit in the form of a caravan mover (10) comprising a motor (12) (drive means) and a head (14) which are linked together by a gear mechanism (16). The head (14) provides a roller (15) which is rotatably mounted on a shaft. The roller (15) is arranged, in use, to be urged or pressed against the tread portion (surface) of a tyre. The drive unit is controlled by a control unit (ECU) which controls the movement of the driven roller (15) between the disengaged position and the engaged position and also controls the rotation (and direction) of the driven roller (15). The caravan mover (10) of the present invention includes an integral power supply such that the unit comprises a single integral system which is easily installed on the caravan and does not require the routing of cables from a remote power supply. The battery (30) comprises securement means in order to quickly and easily secure the battery (30) to the drive unit housing and, in particular, to the housing (20) of the motor (12). The securement of the battery (30) to the motor 6 also automatically and simultaneously aligns and connects terminals of the battery (30) to power receiving terminals of the motor (16). Such a quick and simply securement mechanism provides a battery (30) can be quickly and easily removed, for example, in order to be charged. Accordingly, the drive unit/caravan mover (10) (including the motor, roller, battery, control unit and mounting means) forms a single self-supporting component which is solely secured to the caravan/trailer at a single location by the mounting means.