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Multi-Axis Hitch Force Sensing for Powered Trailers

Smart Kingpin Force Measurement for Electric Trailer Propulsion

Battery-powered and hybrid-electric trailers use onboard motors to provide propulsion assistance during acceleration and climbing, while regenerative braking can recover energy during deceleration. To coordinate these functions with the tow vehicle, the trailer control system requires continuous information about the forces being transferred through the tractor-trailer connection.

For heavy duty or semi truck applications, ANYLOAD transformed the trailer kingpin itself into a multi-axis force sensor. Measuring force directly at the coupling provides real-time feedback for propulsion assist, regenerative braking, traction control, load monitoring, and vehicle dynamics without adding a separate sensor assembly.

Défi

  1. Safety-Critical Structural Component: The kingpin remains responsible for mechanically securing the trailer to the tractor. Adding sensing features, strain gauges, wiring, and electronics cannot compromise its strength, fatigue life, or coupling geometry.
  2. Multi-Axis Force Measurement: The towing force must be distinguished from vertical and lateral forces generated by trailer weight, cornering, articulation, and crosswinds. Sensor geometry must provide useful sensitivity while minimizing cross-talk between channels.
  3. Continuous Dynamic Loading: The kingpin experiences vibration, shock, changing load direction, acceleration, braking, and repeated road cycles. Both structural integrity and signal performance must remain stable throughout the expected service life.
  4. Vehicle Controls Integration: Force data must be delivered reliably to the trailer’s control system with the correct communication protocol, update rate, scaling, diagnostics, and fault behavior.

Solution

  1. Instrumented Multi-Axis Kingpin: Strain gauges and optimized sensing features were integrated directly into the kingpin, allowing the structural component to measure multiple force axes while retaining its normal mechanical function.
  2. FEA and Fatigue Validation: Finite element analysis (FEA) was used to optimize strain locations, improve sensitivity, reduce cross-talk, and identify stress concentrations. Design iterations addressed structural durability and measurement performance, with validation focused on maintaining mechanical integrity and reliable force measurement under repeated dynamic loading.
  3. CAN Bus Digital Integration: ANYLOAD developed a digital CAN bus output to interface directly with the trailer’s command and vehicle-control systems. Integration required hardware development, communications configuration, software troubleshooting, signal verification, and coordination between the sensor electronics and customer control architecture.
  4. Real-Time Propulsion Feedback: Calibrated force data provides the control system with a direct measurement of the interaction between tractor and trailer. This can support propulsion assistance, regenerative braking, drive torque control, traction and stability strategies, and intelligent energy management.

Conclusion

A force-sensing kingpin turns an existing safety-critical trailer component into a real-time vehicle dynamics sensor. Multi-axis measurement, FEA-driven structural development, fatigue validation, CAN bus integration, and coordinated hardware and software engineering provide powered trailer manufacturers with the force feedback required for responsive and efficient electric propulsion systems.

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Mots-clés :
Force Sensing Kingpin, Smart Kingpin Sensor, Powered Trailer Force Sensor, Electric Trailer Sensor, Truck Trailer Sensor, Multi-Axis Hitch Sensor, Trailer Propulsion Assist, Regenerative Braking Sensor, Drive Torque Control, CAN Bus Load Cell, CAN Bus Force Sensor, Hybrid Electric Trailer

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Multi-Axis Force Sensor
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Fully custom force sensor’s for unique applications.

  • Miniaturisation
  • Multi-Axis Sensing
  • Testing & Validation
  • High Precision
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