WO2024239057A1

WO2024239057A1 - Automated electric trailer with unsprung wheel hub motors

Info

Publication number: WO2024239057A1
Application number: PCT/AU2024/050517
Authority: WO
Inventors: Ahmed EL SAFTY
Original assignee: Ci Corp Pty Ltd
Current assignee: Ci Corp Pty Ltd
Priority date: 2023-05-21
Filing date: 2024-05-21
Publication date: 2024-11-28
Anticipated expiration: 2025-11-21

Abstract

An Automated Electric Trailer (AET) enables improved manoeuvrability. The trailer comprises: a frame; a plurality of e-axles connected to wheels and the frame, wherein at least one e-axle is steerable and comprises a wheel hub-mounted motor and gear transmission unit that is pivotable about a central axle beam; an onboard battery system for powering the e-axles; and a retractable jockey wheel system connected to the frame.

Description

AUTOMATED ELECTRIC TRAILER WITH UNSPRUNG WHEEL HUB MOTORS

TECHNICAL FIELD

The present invention relates to the design and development of an improved Automated Electric Trailer, pulled by a towing vehicle, prime mover, or tractor for bulk goods transportation. Embodiments of the invention enable sustainable bulk goods transportation.

BACKGROUND OF THE INVENTION

For heavy bulk goods haulage, trailers have been the prime means of transport, particularly where gross vehicle combination mass exceeds 4.5 metric tonnes. Traditionally, such trailers are designed and built to serve the intended purpose, using a ladder-like chassis frame structure supported by one or more axles, wheels, and tyres and being pulled by a towing vehicle, also known as a prime mover or tractor. Several configurations of such trailers to suit the needs of bulk goods transportation exist as prior art.

At present, worldwide vehicle electrification has begun in response to the global climatechange initiative.

Currently, in the prior art, some trailer configurations do incorporate axles that are selfsteerable (axles with pivoted wheel ends, but not power-assisted to steer), to provide extra mobility to the wheels and alleviate lateral tyre friction wear and to achieve a smaller turning circle radius. Similarly, fluid power-assisted commercial vehicle steerable axles are also used in agricultural trailers to gain similar advantages in vehicle motion dynamics.

OBJECT OF THE INVENTION

It is an object of the present invention to overcome and/or alleviate one or more of the disadvantages of the prior art or provide the consumer with a useful or commercial choice.

SUMMARY OF THE INVENTION

This invention details the design of a novel Automated Electric Trailer (AET), which functions as a goods trailer capable of being towed by a towing vehicle but has onboard electric storage batteries to power multiple fluid-power-assisted, steerable, electric -motor-driven axles with regenerative braking. During slow speed manoeuvres the direction of travel of the AET is controllable by an operator/driver with a hand-held remote controller, or from the towing vehicle’s cabin. In addition, the AET’s electric power storage can function as a distance range extender and provide additional traction torque for the electric towing vehicle when used in combination.

To maximise the sustainable use of the AET, it can also function as an Autonomous Guided Vehicle (“AGV”) to manoeuvre at a very slow speed within the goods distribution or loading/unloading area independent of the towing vehicle. This feature enables the towing vehicle to perform other necessary tasks simultaneously while the AET loads/unloads the goods. The AET is supported by a unique retractable jockey wheel system when uncoupled from the towing vehicle. The current invention of the AET is intended to serve as a mobile cold-storage container fitted with refrigerated panels with over-the-roof Solar Photovoltaic (PV) and Solar Infrared (IR) panels for additional power requirements. The AET is also equipped with a built-in “Walking Floor”, typical material handling system within the cold storage container, to alleviate manual loading and unloading efforts.

Additional features that give a competitive edge to the AET in contrast to the conventional counterparts is that it is equipped with an advanced data communications system that reports the gravimetric, volumetric, battery-charge status, expected distance range etc, in addition to the driver biometric information from the towing vehicle to the ground base/depot for effective and efficient tracking of each fleet vehicle combination in its service. These features are novel and unique in this invention and are not found in conventional trailers or towing vehicles of such heavy vehicle classes in the prior art so far.

The present invention describes a commercial vehicle trailer designed to carry heavy goods for transportation between source and destination locations. The present embodiment of the design incorporates a lightweight ladder-style chassis frame with a group of rear axles with one or more axles that are electrically driven by unsprung wheel hub-mounted motors and gear transmissions. Each of the axles are steerable and lockable to travel in the straight path, with or without fluid-power assistance (hydraulic or pneumatic).

Each electrified steerable axle (steerable e-axle) is equipped with regenerative braking for energy-efficient driving manoeuvres during uphill and downhill travels. The e-axles are pneumatically suspended with regenerative suspension systems and equipped with wide-based wheels and tyres to conserve weight and minimise the number of components required. Each e-axle is “liftable” off the ground and suspended by the chassis pneumatically when the trailer is running empty or when carrying a lighter payload.

The wheels are equipped with pneumatic brakes and a sufficiently large, compressed air supply reservoir is mounted onboard the chassis for the suspension and brake systems. Electric motors and gear reduction transmission can be mounted as sprung or unsprung versions with their power electronics equipment mounted onboard the chassis frame. The front end of the trailer is equipped with a retractable jockey wheel system that lowers to the ground when the trailer functions as an AGV and working independently of the towing vehicle. The kingpin of the trailer is located at the front end and is equipped with automatic coupling and uncoupling mechanisms including the electrical connections of the trailer.

Electric power storage is provided by onboard battery packs nestled between the trailer’s chassis rails or mounted on the sides. An overhead fast-charging inlet is situated on top of the container at the front end of the trailer. External systems can be electrically powered by the trailer’s electric power-take-off facility - thus making it a more versatile application.

Other conventional trailer ancillaries are applicable as standard (e.g., rear taillight bar with indicators and hazard and brake lights, utility box, side under-run protection systems, lift gate, etc).

The AET's capabilities surpass those of conventional trailers, resulting in a highly efficient transport logistics system. The steerable e-axle is a significant improvement, providing enhanced agility, AGV functionality, a smaller turning circle radius, and improved stability at high speeds. Additionally, the wide-base wheels and tires offer a comfortable ride with increased road grip and fewer components per axle, contributing to weight reduction. The electric motors and transmissions mounted on the wheels are pivotable, enabling them to steer at smaller angles, a feature lacking in current and previous designs. The onboard battery storage effectively powers the electric systems on the trailer, as well as external systems that can be powered by the trailer through power- take-off facilities. The trailer is fitted with real-time data transfer capabilities such as gravimetric, volumetric, and driver biometric systems. This feature, absent in current and prior art, allows for efficient logistics monitoring by transmitting data to a ground base for real-time tracking of fleet vehicles. In case of unexpected breakdowns, quick substitution can be made.

The trailer carries a cargo container that is fitted with refrigerated panels, which are powered by Solar UV and IR panels. These panels can also provide a trickle-charge to top-up the battery packs during long-term transits. This feature enhances the food delivery systems with minimal energy deficits and maximizes the quality of delivery.

In one aspect, although it need not be the only or the broadest aspect, the invention resides in an Automated Electric Trailer (AET), comprising: a frame; a plurality of e-axles connected to wheels and the frame, wherein at least one e-axle is steerable and comprises a wheel hubmounted motor and gear transmission unit that is pivotable about a central axle beam; an onboard battery system for powering the e-axles; and a retractable jockey wheel system connected to the frame.

Preferably, the trailer will be connected mechanically, electrically, hydraulically and/or pneumatically to a towing vehicle.

Preferably, the trailer can be towed physically.

Preferably, the battery system also supplies power to lighting and other electrical ancillaries.

Preferably, the battery system can be connected to the prime mover to provide additional power to the prime mover.

Preferably, the battery system can be trickle charged using a solar panel mounted on a container of the trailer.

Preferably, the trailer further comprises regenerative braking and a regenerative suspension system to charge the onboard battery system. Preferably, the trailer further comprises fluid power systems to energise a fluid power- assisted steering mechanism to enable the wheels to steer.

Preferably, the trailer further comprises fluid power systems to energise pneumatic systems, wherein the pneumatic systems include air suspensions, brakes, or other onboard pneumatic systems.

Preferably, the trailer functions as an AGV when uncoupled from a towing vehicle.

Preferably, the trailer comprises three e-axles in a group.

Preferably, the trailer further comprises an automatic coupling and uncoupling mechanism to connect electrically and mechanically with a towing vehicle.

Preferably, the trailer further comprises a fast overhead charging facility on the top front end of a trailer container attached to the frame.

Preferably, the trailer further comprises a first axle that is self-steered and not power assisted and is liftable for light payloads to avoid excessive tyre wear.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a schematic representation of an embodiment of the present invention showing an axonometric view of the AET with a transparent container box to show the chassis frame and centrally mounted battery packs and steerable e-axles in the steered position, and a fastcharging inlet on top of the container box at the front end.

Figure 2 is the schematic representation of the steerable e-axle for the AET, which comprises an axle beam “6”, with pivoted ends “7”, powered by a fluid power cylinder “8”, to enable steering of the wheel-mounted motor and transmissions “9”, as well as the wheels and tyres “10”.

Figure 3 is a diagrammatic representation of a flow chart of AET functionalities. Figure 4 is a top view schematic embodiment of an unsprung wheel-hub-mounted drive train configuration on the rear triaxle group of the AET showing a top view and a sectional elevation of the same, in which three axles in the rear axle group of the trailer are shown. Each axle “11”, mounted underneath the Chassis rail of the AET’s frame “12” shown in Figure 5, has at each of its ends - a pivot “13”, onto which a wheel hub-mounted motor and gear transmission unit “14”, which are steered by a steering mechanism “15”, which is powered by a fluid power cylinder “16”, are connected to the wheels and tyres - marked “10”.

Figure 5 is a sectional side view of the embodiment shown in Figure 4.

Figure 6 is a top view schematic representation of another embodiment of the present invention showing the axle layout with a self-steer liftable front axle, with usual notations and a pneumatic axle lift mechanism “17”.

Figure 7 is a sectional side view of the embodiment shown in Figure 6.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the present invention define a novel Automated Electric Trailer (“AET”), which functions as a goods trailer capable of being towed by a vehicle. The AET features onboard electric storage batteries that power multiple fluid-power-assisted, steerable, electric- motor-driven axles with regenerative braking, whose speeds and direction of travel are controllable by an operator/driver from the towing vehicle’s cabin. In addition, the AET’s electric power storage can act as a distance range extender and provide additional traction torque for the electric towing vehicle when used in combination. In addition of functioning as a conventional trailer, the AET can also function as an Autonomous-Guided-Vehicle (“AGV”). The innovative retractable jockey wheel system and automatic coupling/uncoupling system enables the AET to travel at very slow speeds within the goods distribution or loading/unloading yard. Solar PV and/or IR panels are installed on top of the AET’s goods container for additional power take-off.

Figure 1 illustrates the main components of an AET including a multitude of electrified power- assisted steerable axles - marked “1”. These are termed “steerable e-axles” henceforth. The main components of the AET constitute a multitude of electrified power-assisted steerable axles “1” (“steerable e-axles”), mounted underneath a lightweight chassis ladder frame “2”, as shown in Figure 1. Each e-axle is “liftable” off the ground and can be suspended by the chassis pneumatically when the trailer is running empty or when carrying a lighter payload. At the front end of the AET, is the retractable jockey wheel system, “3”, which supports the AET when decoupled from the towing vehicle.

The jockey wheels are fitted with rubber tyres that free-wheel around their pins and aid in the slow-speed manoeuvres of the AET, which is very useful for within-the-yard movement without the need for a towing vehicle. That allows the towing vehicle to attend to other important tasks, improving overall efficiency. The AET is equipped with an automatic coupling/decoupling mechanism “ACD”, which enables the electrical and mechanical connections to be connected or disconnected. The Container “4”, is mounted on top of the chassis rails “2”, with the Overhead Charging facility “OHC”, for fast charging the Sodium Solid State, long-life, recyclable battery packs “5”, located between the two longitudinal chassis rails.

The AET is equipped with pneumatic suspension (also known as air suspension), which includes regenerative suspension units that transform the suspension oscillations caused by road undulations into electrical energy. This energy is then stored in the battery pack labelled "5," ensuring maximum conservation of electrical energy.

Figure 2 depicts a schematic of a steerable e-axle, which comprises of the central axle beam “6”, with pivots “7”, on each end, to enable the wheel ends to turn. The actuation is performed by the steering mechanism powered by a fluid-powered steer cylinder “8”, to turn the wheelmounted motor and gear transmission system “9”, to move the wide-based wheels and wide tyres “10”. Brake systems and other ancillaries (not shown for clarity) also become standard features of this e-axle. All electrical wiring to and from electric motors leads to the power electronics module mounted on the chassis frame (not shown for clarity).

The steering mechanism of the steerable e-axle can be mechanically locked, with the wheels in the driving straight position. This is particularly necessary when the truck-trailer combination is moved in the reverse direction to avoid erratic trailer moments, which could lead to ‘jack-knifing’ of the trailer relative to its towing vehicle. The mechanical lock can be electrically driven using solenoid-controlled pins to bolt the pivots to immobilise them.

Once uncoupled from the towing vehicle, the AET performs as an AGV to manoeuvre at very slow speeds within the loading/unloading area, using electric proximity sensors to avoid/move around obstacles where required. This is achieved via the aid of onboard sensors, remote controllers, LIDAR, RADAR, ultrasonic sensors, cameras, and other electronic functions to transfer the AET’s position data to be processed.

Real-time customisable/programmable data metrics and data transfer such as the AET’s gravimetric, volumetric, telemetric, and biometric (vehicle driver’s status), are electronically transferred to the control base AET monitoring station via the internet by the Master Controller Unit (MCU), of the AET.

Figure 3 is a flow diagram that provides the MCU and support system’s electronic architecture to achieve the listed functionalities of the AET. As seen in Figure 3, the MCU interfaces with the Battery and the AGV/Manual Controller to perform the primary tasks. The AGV manual controller is located not only within the driver’s cabin of the towing vehicle but also in the form of a handheld remote-control unit. The manual controller controls the various operations of the AET such as loading/unloading using the “Walking-floor” material handling system to load/retrieve the cargo from the container. The steering of e-axles and the rise/lowering of the jockey wheel system can be controlled using this controller unit. Sensor data is fed into this system as well for safety switch-off and to warn the user of any collision-related hazards.

The MCU interfaces with the display unit for a clear view of the controls and operations for the user of the AET. The MCU also has a remote data transfer facility via the Internet to the control base. The MCU controls the power take-off from the battery storage to the towing vehicle, range extension as well as the control of the recouped brake energy into the battery packs. The MCU is enabled to receive command signals from the towing vehicle dashboard as well. The power take-off feature is very useful for not only the towing vehicle, but also other electrical appliances required to be used with the AET and its services. The towing vehicle signals the MCU to provide battery power when range extension is required. Onboard load cells determine the payload in the trailer container, using sensors and such data is also handled by the MCU to transfer to the control base via the Internet. All performance instructions of the MCU are programmed into it and are customisable to amend or disable chosen features.

AGV manual controller serves as a manual override feature for control by the driver or the user of the AET. When the AET is near the ground-based fast charging facility, the overhead fast charger can also be connected to quickly recharge the battery packs.

E-axle configurations can be numerous, however, two such embodiments of the rear axle group layout are described here as innovative and fulfil several identified shortcomings of the conventional prior art.

Figures 4 and 5 illustrate a schematic representation of one embodiment of the axle group layouts of the AET, shown respectively in top and sectional elevation views. All components are schematically represented to describe the functions and the intent of the invention. This embodiment depicts an unsprung wheel-hub-mounted drive train configuration on the rear triaxle group of the AET showing a top view and a sectional elevation of the same, in which three axles in the rear axle group of the trailer are shown. Each axle “ 11”, mounted underneath the Chassis rail of the AET’s frame “12”, has at each of its ends - a pivot “13”, onto which a wheel hub-mounted motor and gear transmission unit “14”, which are steered by a steering mechanism “15”, which is powered by a fluid power cylinder “16”, is connected to the wheels and tyres - marked “10”.

Figures 6 and 7 illustrate a schematic representation of another embodiment of the present invention showing the axle layout with a self-steer liftable front axle, with usual notations and a pneumatic axle lift mechanism “17”.

In this patent specification, adjectives such as first and second, left and right, above and below, top and bottom, upper and lower, front and back, etc., are used solely to define one element or method step from another element or method step without necessarily requiring a specific relative position or sequence that is described by the adjectives. Words such as “comprises” or “includes” are not used to define an exclusive set of elements or method steps. Rather, such words merely define a minimum set of elements or method steps included in a particular embodiment of the present invention.

The above description of various embodiments of the present invention is provided for purposes of description to one of ordinary skill in the related art. It is not intended to be exhaustive or to limit the invention to a single disclosed embodiment. Numerous alternatives and variations to the present invention will be apparent to those skilled in the art of the above teaching. Accordingly, while some alternative embodiments have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art. Accordingly, this patent specification is intended to embrace all alternatives, modifications and variations of the present invention that have been discussed herein, and other embodiments that fall within the spirit and scope of the above-described invention.

Claims

1. An Automated Electric Trailer (AET), comprising: a frame; a plurality of e-axles connected to wheels and the frame, wherein at least one e-axle is steerable and comprises a wheel hub-mounted motor and gear transmission unit that is pivotable about a central axle beam; an onboard battery system for powering the e-axles; and a retractable jockey wheel system connected to the frame.

2. The trailer of claim 1, wherein the trailer will be connected mechanically, electrically, hydraulically and/or pneumatically to a towing vehicle.

3. The trailer of claim 1, wherein the trailer can be towed physically.

4. The trailer of claim 1, wherein the battery system also supplies power to lighting and other electrical ancillaries.

5. The trailer of claim 1, wherein the battery system can be connected to the prime mover to provide additional power to the prime mover.

6. The trailer of claim 1, wherein the battery system can be trickle charged using a solar panel mounted on a container of the trailer.

7. The trailer of claim 1, further comprising regenerative braking and a regenerative suspension system to charge the onboard battery system.

8. The trailer of claim 1, further comprising fluid power systems to energise a fluid power-assisted steering mechanism to enable the wheels to steer.

9. The trailer of claim 1, further comprising fluid power systems to energise pneumatic systems, wherein the pneumatic systems include air suspensions, brakes, or other onboard pneumatic systems.

10. The trailer of claim 1, wherein the trailer functions as an AGV when uncoupled from a towing vehicle.

11. The trailer of claim 1, comprising up to three e-axles in a group.

12. The trailer of claim 1, further comprising an automatic coupling and uncoupling mechanism to connect electrically and mechanically and hydraulically or pneumatically with a towing vehicle.

13. The trailer of claim 1, further comprising a fast overhead charging facility on the top front end of a trailer container attached to the frame.

14. The trailer of claim 1, further comprising a first axle that is self- steered and not power assisted and is liftable for light payloads to avoid excessive tyre wear.