Trailer Front Mounting Box for Self-Aligning Connector Coupling

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Solution Overview

Problem

Existing systems struggle to automate the establishment of electrical and pneumatic connections between towing and trailer vehicles, particularly in autonomous driving scenarios, and face challenges with alignment sensitivity and mechanical impacts.

Innovation Solution

A mounting box mounted on the trailer front with a device comprising an outrigger, alignment device, and gripper arm that automatically aligns and connects truck connectors with box connectors, using rollers and gripper arms to pivot and slide into position, ensuring robust and easy alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If automated connection systems are implemented between towing and trailer vehicles, then the extent of automation is improved, but the device complexity increases due to the need for alignment devices, rollers, and coordination mechanisms

Engineering Contradiction:

Improveautomation of connection establishmentVSAvoidcomplexity of alignment and connection system

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The mounting box is designed to perform alignment automatically through its geometric features (alignment area, side walls, convex shape) without requiring external alignment devices. The system self-aligns by utilizing the physical interaction between the mounting box and the trailer front, eliminating the need for complex automated alignment mechanisms

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The alignment function is extracted from the connection device and integrated into the mounting box structure itself. The mounting box independently handles alignment through its geometric design, allowing the connection device to focus solely on the connection task, thereby simplifying the overall system

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of operation

If alignment devices with rollers are used to align connectors, then the ease of operation is improved, but the reliability decreases due to sensitivity to impurities and mechanical impacts

Engineering Contradiction:

Improveease of alignmentVSAvoidrobustness to impurities and impacts

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The mounting box uses a robust, simple geometric structure (alignment area with side walls) instead of delicate alignment devices. This sacrificial, simple structure can withstand impurities and mechanical impacts without being damaged, maintaining reliability while providing ease of alignment

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The alignment area acts as an intermediary element between the mounting box and the connection device. It provides a physical guide that facilitates alignment through contact, replacing the need for sensitive rollers while maintaining ease of operation

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If connectors are exposed for easy connection, then the ease of operation is improved, but the reliability decreases due to vulnerability to mechanical impacts and damage

Engineering Contradiction:

Improveaccessibility of connectorsVSAvoidprotection from damage

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The connectors are nested within the mounting box structure, specifically in connection sections that are positioned within the box's interior or protected areas. This nesting provides protection from external mechanical impacts while maintaining accessibility for connection operations through designated openings or access points

Inventive Principle:

Principle #7Nested doll (Nesting)

4Adaptability or versatility

If the mounting box is designed for universal compatibility across various trailers, then the adaptability is improved, but the manufacturing precision requirements increase to ensure proper alignment

Engineering Contradiction:

Improvecompatibility with various trailersVSAvoidprecision of alignment features

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The mounting box is designed with universal geometric features (standardized alignment area dimensions, convex shape, side wall configurations) that can accommodate different trailer types. The alignment functionality is achieved through robust geometric relationships rather than precision-critical features, allowing manufacturing within standard tolerances while maintaining compatibility

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP4663436A1Mounting box for being mounted on a trailer front for establishing a connection between a towing vehicle and a trailer vehicle

Publication Date: 2025.12.17 ZF CV SYST GLOBAL GMBH

Figure 1~4
Figure 5~8

AI summary

The invention relates to a mounting box (40) for being mounted on a trailer front (36). The mounting box (40) extends along a width, a height and a length (48) and is limited by a front surface (42) comprising a flat or curved alignment area (46). The alignment area (46) extends in the length (48) of the mounting box (40) and measures at least 1 m, at least 1,5 m or at least 2 m in a length direction (50) defined by the length (48) of the mounting box (40). The mounting box (40) comprises a connection section (57), wherein the connection section (57) comprises a plurality of box connectors (56) fixedly mounted on the mounting box (40) for providing an electrical, pneumatic or hydraulic connection with corresponding truck connectors (23). The connection section (57) is arranged above or below the alignment area (46) in a height direction (66) defined by the height of the mounting box, so that the alignment area (46) provides a continuous surface which is uninterrupted by the box connectors (56).