Methods and systems for a tractor and a trailer

Methods and systems are provided for a coupling device for a tractor and a trailer. In one example, a system, comprising a tractor comprising an engine, a motor, and an electrical energy storage device, a trailer comprising a battery bank and a power distribution unit, and a coupling configured to fixedly couple the trailer to the tractor and to electrically couple the power distribution unit to the electrical energy storage device.

TECHNICAL FIELD

The present description relates generally to a hybrid tractor with a trailer comprising an electric energy supply.

BACKGROUND AND SUMMARY

Efforts are continually made to reduce automotive impacts on global warming. One example to reduce emissions may include the electrification of vehicles. Passenger vehicles travel in primarily in cities and may recharge electric energy sources frequently via available recharging stations. However, commercial vehicles, such as hybrid electric class8tractors, travel long distances between cities and may be unable to frequently recharge due to a lack of recharging stations available outside of cities.

Other examples of addressing power supply to a hybrid electric commercial vehicle include a battery pack on a trailer. One example approach is shown by Bianco in U.S. Application number 2011/0114398. Therein, a trailer battery module is configured to drive an electric motor of the tractor. The trailer is mechanically connected to the tractor via a first connection and the battery is connected to the electric motor via a second connection, separate from the first connection.

However, the inventors have identified some issues with the approach described above. For example, the trailer is connected to the tractor mechanically at a first location and the battery is electrically connected to the electric motor at a second location, wherein linkages between the electric supply and the mechanical connection are separate. This may introduce a variety of issues including adequately coupling the electric supply cable to the battery and additional time for coupling the two connections. Thus, the connection in the example of Bianco may not be robust.

In one example, the issues described above may be addressed by a system, comprising a tractor comprising an engine, a motor, and an electrical energy storage device, a trailer comprising a battery bank and a power distribution unit, and a coupling configured to fixedly couple the trailer to the tractor and to electrically couple the power distribution unit to the electrical energy storage device. In this way, the trailer is quickly coupled to the tractor via a single coupling.

As one example, the coupling comprises a pin shaft configured to couple to a fifth wheel hitch. A clamp of the coupling is configured to hold a connector on a park brake circuit or other circuit. By doing this, the connector is held securely when parked but may pivot/move during a driving mode of the tractor.

DETAILED DESCRIPTION

The following description relates to systems and methods for a coupling between a tractor and a trailer. The coupling comprises a mechanical connection and an electrical connection integrally arranged therein. The mechanical connection is configured to physically couple the tractor to the trailer to block separation thereof. The electrical connection is configured to electrically couple one or more electrical energy storage devices of the trailer to an electrical motor of the tractor. By arranging the electrical energy storage device on the trailer, more space is available to increase an electrical energy storage amount, thereby allowing the commercial vehicle to travel longer distances without demanding a recharge. Various arrangements of the tractor and trailer are illustrated inFIGS.1to3. Therein, the tractor in the examples ofFIGS.1,2, and3is a heavy-duty vehicle, such as a semi-truck or the like.

FIGS.4and5show view of a slip ring assembly of the coupling. The coupling comprises a high-voltage interlock loop (HVIL) integrated therein, as shown inFIG.6. The coupling extends from the tractor toward an interface of the trailer, as shown inFIG.7. A cable of the coupling comprises a support, such as a bridge, for supporting a weight of wires extending therethrough, as illustrated inFIG.8. A second support may be arranged outside of the cable, wherein hooks of the second support couple to openings in the trailer, as shown inFIG.9.

Turning now toFIG.1, it shows a first embodiment100of a tractor101and a trailer102. The tractor101comprises an engine110, a transmission111, and a differential112. The tractor101further comprises an electric motor113, a tractor battery114, and a drive unit115. The engine110, the transmission111, and the differential112are configured to drive a first set of wheels122and a second set of wheels124via a first drive axle123and a second drive axle125, respectively. The electric motor113, which receives power from the tractor battery114, and the drive unit115drive a third set of wheels126via a third axle127.

The tractor battery114is coupled to a power distribution unit (PDU)130of the trailer102via a cable131. As illustrated, the cable131extends through a coupling132. The coupling132is configured to mechanically couple the tractor101to the trailer102. That is to say, the engine110and the electric motor113, which drive wheels of the tractor101, may pull the trailer102via the coupling132. In this way, the coupling132may block further separation between the tractor101and the trailer102relative to a length of the coupling132.

The cable131is configured to supply power from a battery bank140of the trailer102to the tractor battery114. In one example, the PDU130may comprise a control unit arranged therein or coupled thereto with instructions stored on non-transitory memory thereof that allow the PDU130to distribute power from the battery bank140to the tractor battery114in response to a state of charge (SOC) of the tractor battery114being less than a threshold charge (e.g., 20%). The PDU130may be further configured to receive and distribute power from a solar panel/inverter150. In one example, the PDU130may use energy from the solar panel/inverter150to recharge batteries of the battery bank140or the tractor battery114. Along with charging the battery bank, the PDU can supply supplemental electrical energy from the solar cells to extend the range of the tractor. Once the battery energy reserve falls below a threshold value e.g. 20%, the gasoline or diesel engine may become the primary vehicle power source.

In one example, the tractor battery114is a 300 kW battery and the batteries of the battery bank140are 200 to 250 kW batteries. The battery bank140comprises a first battery142, a second battery144, a third battery146, and a fourth battery148. The first battery142, the second battery144, the third battery146, and the fourth battery148may be substantially identical to one another. The PDU130may be further configured to recharge the battery bank140via a direct current fast charger (DCFC)152and an onboard charger154. The onboard charger154may be configured to convert AC input from a grid (e.g. charging station) to DC input, which charges the batteries. The onboard charger154may be further configured to modify a voltage receive from the grid to match a voltage of the batteries.

The trailer102comprises a fourth set of wheels162arranged along a fourth axle163and a fifth set of wheels164arranged along a fifth axle165. The fourth set of wheels162and the fifth set of wheels164are not directly driven by a power source. However, the engine110and the electric motor113, in combination with the coupling132may cause the fourth and fifth sets of wheels to rotate.

Turning now toFIG.2, it shows an embodiment200of a tractor201and the trailer102. Components previously introduced are similarly numbered in this figure and subsequent figures. The tractor201is similar to the tractor101ofFIG.1except that an electric motor210is arranged between the transmission111and the differential112. The tractor201is further differentiated from the tractor101ofFIG.1in that a clutch211is arranged between the transmission111and the electric motor210. In one example, the hybrid arrangement of the tractor201inFIG.2illustrates a parallel hybrid arrangement wherein the engine may be driven to drive the wheels and recharge the tractor battery114by driving the electric motor210as a generator.

Turning now toFIG.3, it shows an embodiment300of a tractor301and the trailer102. The tractor301is similar to combination of the hybrid arrangements of the tractor201ofFIG.2and the tractor101ofFIG.1. More specifically, the tractor301comprises two electric motors, including the first electric motor113and the second electric motor210.

Turning now toFIG.4, it shows an embodiment400of the coupling132coupling to a fifth wheel pin402of a tractor (e.g., tractor101or tractor201or tractor301ofFIGS.1,2, and3, respectively). As known to those of ordinary skill in the art, a fifth-wheel coupling may provide an interface between the tractor and the trailer. The coupling comprises the fifth wheel pin402protruding from the trailer and a horseshoe shaped or a U-shaped coupling, illustrated inFIG.5, on the tractor.

A pivot plate404may rotate relative to the fifth wheel pin402in conjunction with a steering wheel of the tractor. A ramp406may be fixed and allow the trailer to move in conjunction with the tractor via the pivot plate404and the coupling132.

A first set of high voltage slip rings408may be integrally arranged in the fifth wheel pin402and the pivot plate404. The first set of high voltage slip rings408may be pressed against an upper surface of the pivot plate404. A second set of high voltage slip rings410may be arranged on a shaft of the fifth wheel pin402and an inner diameter of the pivot plate404. The first and second sets of slip rings408and410may be configured to transmit signals and power from the trailer and the tractor. As such, the first and second sets of slip rings may be conductive. In one example, the first and second sets of slip rings408and410comprise graphite or a similar material with a low coefficient of friction to decrease a corona discharge potential along with having self-lubrication properties.

In the example ofFIG.4, the fifth wheel pin402is illustrated adjacent to the ramp406. However, additionally or alternatively, the fifth wheel pin402may be arranged further from to the ramp406, which may enhance a centering function of the pivot plate404in some arrangements.

Turning now toFIG.5, it shows an embodiment500of a horseshoe portion502of the coupling132. The fifth wheel pin402is omitted in the embodiment500to further illustrate the horseshoe portion502of the pivot plate404along with the first and second sets of slip rings408and410. The coupling132comprises a jaw coupling510with a pin slot512through which the fifth wheel pin402extends. The jaw coupling510may be arranged along a central portion of the horseshoe portion502(e.g., a bend of the horseshoe portion502). The pivot plate404, along with the slip rings, comprise a U-shape and extend from a first end of the ramp406to a second end of the ramp406, wherein the first end is opposite of the second end. The first end and the second end of the ramp406are separated from one another via the pivot plate404. The jaw coupling510is arranged on a first side of the pivot plate404and the first set of slip rings408are arranged on a second side of the pivot plate404, opposite the first side. In one example, the first side is an upper side and the second side is a bottom side.

The coupling132may integrate an electrical connection514into the bottom side of the ramp406. As illustrated inFIG.5, the electrical connection514extends from the bottom side of the first end of the ramp406. In one example, the electrical connection514is a high-voltage socket.

A mating connector, such as the jaw coupling510, may be fixedly held in place via a pneumatic clamp on a circuit of the park brake. By doing this, the mating connector may be securely held when parked but allowed to pivot during driving conditions. Thus, the jaw coupling portion is fixed when the park break circuit is active and pivotable when the park break circuit is inactive. In one example, the mating connector comprises a curly hose style (e.g., a spring coil wrap) for allowing the coupling132and/or portions thereof to bounce and/or rebound. While the electrical connection514is illustrated on the bottom side of the ramp406, it will be appreciated that it can be arranged on the sides or back of the ramp406and/or the pivot plate404without departing from the scope of the present disclosure.

The pneumatic clamp may be actuated to vertically raise and lower to engage and disengage the coupling132from the tractor101. The electrical connection514may be automatically connected once the pneumatic clamp is fully actuated in a first direction and automatically disconnected once the pneumatic clamp is fully actuated in a second direction. The cable, which passes through the electrical connection514, is configured to twist and/or flex from side to side by at least 120 degrees to accommodate vehicle movements, coupling elements movements, and the like.

Turning now toFIG.6, it shows an embodiment600of a high-voltage interlock loop (HVIL) circuit comprising HVIL pins602and an HVIL socket604. In one example, the HVIL pins602are male pins and the HVIL socket604is female pins. In one example, a HV contact ring606, which may be a slip ring in one example, electrically completes the HVIL pins602to the HVIL socket604. In one example, the cable of the trailer, which extends from the PDU, may electrically couple to the HVIL socket604and a cable from the tractor battery may electrically couple to the HVIL pins602. By utilizing the HVIL circuit, the electrical connection between the trailer and the tractor may be more secure, which may mitigate arcing and other issues associated with high-voltage connections partially separating. To enhance the connection between the HVIL pins602and HVIL socket604, a center tolerance of +/−2 mm in pin position may be desired. In one example, the contact ring606is one of a plurality of rings, wherein the plurality of rings is not electrified until HVIL pins602and the HVIL socket604are fully coupled to respective cables of the tractor and trailer. In one example, two or more of the wires and cables leading to the HVIL circuit may be twisted and/or locked together with the HVIL pins602and the HVIL socket604.

In one example, the HVIL pins602are arranged on a first half of the connection and the HVIL socket604is arranged on a second half of the connection. The first half and the second half are substantially identical in shape and size apart from the first half comprising the HVIL pins602and the second half comprising the HVIL socket604. In one example, the slip ring is arranged in a central opening of each of the first half and the second half of the connection. The slip ring may be a flexible elastomeric material configured to allow a high-voltage electrical connection to pass therethrough. Each half of the connection may comprise the slip ring, wherein the slip rings may be pressed against one another and form a sealed engagement with one another when the connection is fully engaged.

Turning now toFIG.7, it shows an embodiment700of the trailer102physically and electrically coupling to the tractor via the coupling132. In one example, the coupling132is pressed against a portion of the HVIL circuit corresponding to the trailer by extending a cable702from the tractor to the trailer102. Once contact is made, the coupling132is rotated and pressed down into a locked position, thereby fixedly and electrically coupling the trailer102and the tractor.

Turning now toFIG.8, it shows an embodiment800of a support802through which a plurality of wires812of the cable702extend. In one example, the support802is a bridge. The support802comprises curved ends804separated by long sides806. In one example, the support802comprises a rectangular shape with curved edges. The support802may support a weight of the plurality of wires812of the cable702, which may limit inadvertent electrical disconnection of the trailer from the tractor. The support802comprises a plurality of openings808, wherein each opening is configured to allow a wire of the plurality of wires812to pass therethrough. The plurality of wires812comprises a first wire814, a second wire816, and a third wire818, each passing through corresponding openings of the plurality of openings808. In one example, the first wire is a hot wire, the second wire816is a carrier wire, and the third wire818is a ground wire.

Turning now toFIG.9, it shows an embodiment900of the coupling132. As illustrated, a connector latch902of the coupling132secures onto the trailer. In one example, the connector latch902may bear a majority of a weight of the cable702. A handle910is physically coupled to the cable702, wherein the handle910comprises a first hook912and a second hook914arranged at opposite ends of the handle910. The first hook912and the second hook914couple to a corresponding latch pin of the trailer.

The support802is arranged in the handle910and assists the connector latch902in bearing the weight of the cable702. The support802spans the width of the handle910and is positioned distally to the hooks to form a triangular shape.

In one example, the support802is configured to support the electrical wires while being positioned in the handle910. The handle910may comprise a width equal to a width of the connector latch902. Additionally, the support802may span an entire length of the handle910form the first912to the second hook914. When the first and second hooks engage with latch pins of the trailer and the handle is fully seated and locked in position via the hooks. The support802may be positioned in a same plane as the wires exiting the cable702and thereby able to provide support (e.g., strain relief) to the cable702and/or connector latch902. As illustrated inFIG.8, the wires exiting the cable702may pass through openings of the support802between the connector and the connector latch902.

In this way, a coupling between a tractor and a trailer may be simplified such that a physically coupling and an electrical coupling may be completed via a single coupling. The technical effect of integrating the electrical coupling with the mechanical coupling is to simplify a connection between the tractor and the trailer. By doing this, a user may more quickly and accurately couple the tractor and the trailer.

An embodiment of a system comprises a vehicle comprising an engine, a motor, and an electrical energy storage device, a trailer comprising a battery bank and a power distribution unit, and a coupling configured to fixedly couple the trailer to the vehicle and to electrically couple the power distribution unit to the electrical energy storage device. A first example of the system further includes where the coupling comprises a high-voltage interlock loop feature. A second example of the system, optionally including the first example, further includes where the coupling comprises a jaw coupling feature fixedly coupling a pivot plate and a fifth wheel pin of the coupling. A third example of the system, optionally including one or more of the previous examples, further includes where the pivot plate and the fifth wheel pin comprise slip rings. A fourth example of the system, optionally including one or more of the previous examples, further includes where opposite ends of a ramp extend from ends of the pivot plate, and wherein an electrical connection extends along a bottom side of the ramp. A fifth example of the system, optionally including one or more of the previous examples, further includes where a cable comprises one or more electrical wires of an electrical coupling portion of the coupling, wherein a handle extends below the cable and supports a weight of the cable. A sixth example of the system, optionally including one or more of the previous examples, further includes where the trailer comprises a solar panel configured to supply energy to the battery bank. A seventh example of the system, optionally including one or more of the previous examples, further includes where the power distribution unit is configured to supply electrical energy to the electrical energy storage device via the coupling. An eighth example of the system, optionally including one or more of the previous examples, further includes where the coupling is the only coupling between the vehicle and the trailer.

An embodiment of a system, comprises a heavy-duty vehicle comprising an engine and an electric motor, wherein the electric motor is configured to receive power from a battery, a trailer comprising a battery bank, a power distribution unit, and a solar panel, wherein the power distribution unit is configured to supply energy from the battery bank to the battery via an electrical connection, and a coupling device coupling the heavy-duty vehicle to the trailer, wherein the coupling device blocks separation of the heavy-duty vehicle and the trailer, wherein the electrical connection is integrally arranged in the coupling device. A first example of the system further includes where a handle comprising hooks is configured to support a cable of the coupling device. A second example of the system, optionally including the first example, further includes where a support extends along an entire length of the handle between the hooks. A third example of the system, optionally including one or more of the previous examples, further includes where electrical wires pass through openings of the support. A fourth example of the system, optionally including one or more of the previous examples, further includes where the coupling device comprises a clamp configured to couple a jaw coupling portion to a park break circuit. A fifth example of the system, optionally including one or more of the previous examples, further includes where the jaw coupling portion is fixed when the park break circuit is active and pivotable when the park break circuit is inactive.

An embodiment of a hybrid or electric tractor trailer, comprises a tractor comprising an electric motor and a tractor battery, a trailer comprising a plurality of batteries, and a coupling configured to couple the trailer to the tractor at a hitch, the coupling further comprising an electrical connection extending through the hitch and configured to couple the plurality of batteries to the tractor battery. A first example of the tractor trailer further includes where the coupling comprises a pin shaft configured to couple to the hitch, wherein the hitch is a fifth wheel hitch. A second example of the tractor trailer, optionally including the first example, further includes where the coupling comprises a jaw coupling feature fixedly coupling a pivot plate and a fifth wheel pin of the coupling, and wherein the pivot plate and the fifth wheel pin comprise slip rings. A third example of the tractor trailer, optionally including one or more of the previous examples, further includes where the pivot plate is configured to rotate about the fifth wheel pin. A fourth example of the tractor trailer, optionally including one or more of the previous examples, further includes where the coupling comprises a high-voltage interlock loop (HVIL) circuit comprising HVIL pins and an HVIL socket, wherein a cable from a power distribution unit of the tractor trailer couples to the HVIL socket.

The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, and other features, functions, and/or properties disclosed herein.