Project Overview
Mass Equipment Solutions was entrusted with designing, fabricating, and installing a custom equalization system for the rear tailgate of a specialized two-level race car trailer owned by Santos Motorsports, a premier drag racing team based in Ontario, Canada. This trailer is essential for transporting their high-performance dragster to races across the country, but its existing lift system presented operational challenges that needed an innovative solution.
The Challenge
The trailer’s unique design features a tailgate that doubles as a car lift, allowing seamless movement of the race car between the ground and the upper storage level. However, the tailgate relied on two independent hydraulic motors, each driving a screw mechanism within concealed vertical columns. Without a built-in synchronization system, one side of the tailgate often moved at a slightly different speed than the other. This imbalance required constant manual adjustments by the operator—an inconvenient and time-consuming process that also posed a risk to the vehicle, particularly after long race days when precision and safety were paramount.
Engineering a Solution
Our project commenced during an ongoing trailer upgrade by Santos Motorsports, which included rebuilding the tailgate using lightweight aluminum and addressing mechanical wear issues. Partnering with Prolift Solutions Inc., we reinforced critical mechanical components such as glide blocks and bearings, increasing load capacity and longevity.
At the core of our solution was the development of a fully electronic control system equipped with a feedback loop to maintain tailgate level during operation. The goal: to transition from a manual adjustment process to a seamless, one-touch automated lift system.
Key Enhancements:
- Custom Electronics Panel: Concealed behind the trailer’s interior walls, this panel acts as the central control unit, integrating various system components.
- Laser Distance Sensors: Two high-precision sensors were installed in the confined space between the hydraulic motors and the carriage. These sensors provide real-time positional data to ensure both sides of the lift move in perfect sync.
- Remote Touch Screen Panel: This interface offers real-time lift status updates and doubles as an emergency backup control system.
- Failsafe Wired Control: While the existing system included wireless and wired remote controls, the client requested the wired remote to serve as a failsafe in case of any system malfunctions. We integrated this requirement seamlessly into the wiring architecture.
- Smart Positioning Logic: The tailgate had to function in two distinct positions:
- Fully Opened: To allow vehicle access to the upper deck without obstruction.
- Fully Closed: Ensuring a snug fit within the cowling at the top of the trailer to prevent structural damage.
- Flush Platform Alignment: To facilitate a smooth transition between the tailgate and upper deck, our system continuously monitors distance measurements, guaranteeing perfect alignment at all times.
Overcoming Space Constraints
One of the biggest challenges was the limited space available for mounting sensors. We carefully selected compact, high-precision sensors capable of delivering accurate measurements over long distances, ensuring that our system functioned flawlessly despite spatial constraints.
The Outcome
With our custom leveling system in place, Santos Motorsports now benefits from a dramatically improved tailgate lift experience. The new system:
- Eliminates manual adjustments, reducing operator workload and potential errors.
- Enhances safety, protecting the race car from lift-related damage.
- Streamlines post-race operations, allowing the team to focus on performance rather than troubleshooting lift inconsistencies.
- Increases reliability and efficiency, making vehicle loading and unloading a seamless, one-touch operation.
By combining cutting-edge electronics with precision engineering, we transformed a cumbersome, labor-intensive process into a reliable, high-tech solution tailored to the demands of professional motorsports. Santos Motorsports can now transport their race car with confidence, knowing their trailer’s tailgate lift is as fast and precise as the dragster it carries.
Here are some images of the install
