Trailer Drive System Weighing via Motor Current
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Solution Overview
Problem
Current methods for determining the weight of trailers are limited, requiring access to fixed scales, are location-dependent, and often result in inaccurate measurements due to the need for solid and level ground, slow driving speeds, and additional storage space, with existing systems failing to maintain the required 3% measurement tolerance.
Innovation Solution
A drive system with a weighing function that indirectly determines trailer weight by measuring the power consumption of the driving motors on level and sloping sections, using existing maneuvering system components like DC motors, temperature, and speed sensors, and a module to calculate the trailer mass with minimal required measurement data, ensuring accurate and location-independent weighing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If permanently installed scales are used to weigh trailers, then measurement accuracy can be maintained, but users must make considerable detours and return to the place of residence for overweight cases
Solution Approach 1:
The patent replaces the mechanical weighing system (permanently installed scales with sensors) with an electrical measurement system that uses the existing maneuvering drive motors. By measuring the electrical current consumption of the motors during controlled acceleration and deceleration phases, the system calculates trailer weight without requiring mechanical contact with the ground or specialized weighing infrastructure.
Solution Approach 2:
The patent makes the maneuvering drive system serve dual functions: both maneuvering the trailer and determining its weight. The existing motors, controllers, and sensors are utilized for weighing purposes, eliminating the need for separate weighing equipment and making the system available at any location where the trailer can be maneuvered.
2Measurement precision
If scales are placed on the ground for weighing, then weight measurement is possible, but solid and level ground is required and additional storage space is needed
Solution Approach 1:
The patent eliminates the requirement for ground-based mechanical scales by substituting the weighing function with electrical measurements of motor current consumption. This allows weighing to be performed anywhere the trailer can be maneuvered, without requiring solid and level ground or additional storage space for scale equipment.
3Measurement precision
If slow driving over scales is used for measurement, then weight data can be captured, but the clutch must slip clearly leading to incorrect measurements above 3% tolerance
Solution Approach 1:
The patent replaces the mechanical measurement process (slow driving over scales with clutch slipping) with an electrical measurement approach. By monitoring motor current consumption during controlled acceleration and deceleration, the system determines weight without mechanical slip, achieving both accuracy within 3% tolerance and reduced measurement time.
Solution Approach 2:
The patent implements a feedback control system where the controller monitors motor current consumption in real-time during maneuvering phases. Based on this feedback, the system calculates the trailer weight and can adjust the maneuvering process if needed, ensuring accurate measurements within the 3% tolerance limit while maintaining efficient operation.
4Device complexity
If maneuvering drive motors are used for weighing, then existing components can be utilized without additional weight, but indirect measurement requires complex calculation processes
Solution Approach 1:
The patent uses feedback from motor current sensors to provide real-time data on power consumption during controlled maneuvering phases. The controller processes this feedback information along with known motor characteristics and measured acceleration/deceleration rates to calculate trailer weight, achieving accurate indirect measurement through systematic data processing.
Solution Approach 2:
The patent determines trailer weight by measuring changes in motor operating parameters (current consumption, acceleration rate, deceleration rate) during controlled maneuvering phases. By analyzing these parameter changes and relating them to the known motor characteristics and trailer inertia, the system calculates the trailer weight indirectly with good accuracy.
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 solution provides a reliable, accurate, and location-independent method for determining trailer weight with an accuracy of ±3%, utilizing existing components in the maneuvering system, ensuring compliance with weight tolerance limits and enabling weighing anywhere without additional weight or storage space.
Implementation Method 1
for each side of the trailer at least one drive device with a DC motor (13) that can drive the wheels (21) of the trailer
Implementation Method 2
the drive roller (25) is brought into engagement with the running surface so that rotation of the drive motor causes the corresponding wheel of the trailer to also rotate
Data Source
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AI summary
The invention relates to a drive system (10) for a trailer (20), comprising a control unit (11) and at least one drive device (12) for each side of the trailer, with a DC motor (13) capable of driving the wheels (21) of the trailer (20), characterized in that the system includes devices (14, 15, 16) for determining the current consumption of the motors (13) and a module (17) for calculating the mass of the trailer (20) based on the determined current consumption of the motors (10), taking into account the rotational speed and temperature. The invention further relates to a measuring section (30) for use with such a system (10), wherein the measuring section (30) comprises a first flat section (31) and a second wedge-shaped section (32) with a known gradient.