Wheel-End Power Conversion With Inboard Step-Up Drive for Trailers
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Solution Overview
Problem
The increasing demand for electric power on semi-trailers has outpaced the existing power generation and transmission capacity, necessitating the conversion of kinetic energy from truck/trailer motion into storable/usable electrical energy.
Innovation Solution
The integration of a power conversion unit at the wheel end of trucks or trailers, which converts mechanical energy from the rotation of the axle shaft into electrical energy through a step-up drive ratio unit, allowing for the storage of electrical energy in batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a power conversion unit is integrated at the wheel end, then electrical energy generation capability is improved, but device complexity increases
Solution Approach 1:
The patent combines the power conversion unit with the wheel end structure, merging multiple functions (power generation, suspension, wheel rotation) into a single integrated assembly. This reduces overall system complexity by eliminating separate mounting structures and shared space requirements.
Solution Approach 2:
The wheel end structure serves multiple functions: it supports the wheel, provides suspension mounting points, and houses the power conversion unit. This multi-functionality eliminates the need for dedicated space for power generation components, reducing overall device complexity.
2Productivity
If a step-up drive ratio unit is added inboard of the stub-axle spindle, then power conversion efficiency is improved, but device complexity increases
Solution Approach 1:
The step-up drive ratio unit is nested within the wheel end structure, specifically positioned inboard of the stub-axle spindle. This nesting approach allows the drive ratio unit to occupy space that would otherwise be unused, adding power conversion functionality without increasing overall device footprint or complexity.
3Adaptability or versatility
If suspension systems are designed to accommodate power conversion elements, then adaptability is improved, but manufacturing difficulty increases
Solution Approach 1:
The suspension system is designed with flexible mounting arrangements that can accommodate the power conversion unit in various configurations. The mounting structure allows for adjustment and adaptation to different power conversion element sizes and shapes, enhancing versatility while maintaining manufacturability through standardized components.
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 solution enables the efficient conversion and storage of kinetic energy, providing a reliable source of electric power for truck/trailer applications, such as powering refrigeration units and lights.
Implementation Method 1
a power conversion unit operatively connected to the step-up drive ratio unit, such that mechanical energy from rotation of the axle shaft is converted, through the step-up drive ratio unit and the power conversion unit, into electrical energy
Data Source
AI summary
A truck or trailer includes a wheel, a stub axle spindle extending through the wheel and having a through bore, a step-up drive ratio unit inboard of said stub-axle spindle, an axle shaft extending through the through bore of the stub-axle spindle, and a power conversion unit operatively connected to the step-up drive ratio unit. The axle shaft is operatively connected to the step-up drive ratio unit, such that, as the axle shaft rotates with the wheel, mechanical energy from rotation of the axle shaft is converted into electrical energy. A special suspension system allows for installation of the stub axle spindle, and such suspension systems are a separate focus herein as well as being usable in combination with the power conversion elements.