AGV dynamic wireless charging system and control method thereof

Abstract

The application provides an AGV dynamic wireless charging system and a control method thereof, comprising a plurality of sectional transmitting coil modules laid along an AGV travel path, a vehicle-mounted controller, a receiving coil mounted at the bottom of the AGV, a central controller and a position detection module; the central controller is in communication connection with each sectional transmitting coil module and the vehicle-mounted controller, and the position detection module is used for obtaining position information of the AGV; each sectional transmitting coil module comprises a transmitting coil, a magnetic communication modulation unit, a mechanical-magnetic coupling baffle and a power switch; the mechanical-magnetic coupling baffle is rigidly mechanically coupled with a magnetic communication loop between the transmitting coil and the magnetic communication modulation unit, and the mechanical position of the mechanical-magnetic coupling baffle is the only control factor for on-off of the magnetic communication loop; when the baffle is in a closed position, the magnetic communication loop is turned on; when the baffle is in an open position, the magnetic communication loop is physically cut off; and the power switch is connected in series between a power supply loop and the transmitting coil.

Description

Technical Field

[0001] This invention belongs to the field of energy management and charging technology for automated guided vehicles (AGVs), specifically relating to a system and control method for dynamic wireless charging of AGVs. Background Technology

[0002] Currently, there are two charging methods for AGVs: wired charging and wireless charging. Wired charging requires cables and charging contacts to connect the vehicle to the power supply system for energy transfer. Wireless charging eliminates the need for cables; instead, it utilizes an alternating magnetic field to wirelessly transmit energy through magnetic coupling between the energy transmitter and receiver. Wireless charging is further divided into static charging and dynamic charging. Static charging involves the AGV moving to a fixed charging position and charging wirelessly while it is not operating. Dynamic charging allows the AGV to wirelessly charge while working, provided its battery level drops to a certain threshold.

[0003] To achieve dynamic wireless charging of AGVs, existing technologies require a wireless charger control system. The wireless charger includes a charger body and a dual-axis drive device for moving the charger body, both positioned below the ground at the AGV's work site. The AGV wireless charging method involves the following steps: acquiring charging request information sent by the AGV; the charging request information includes the AGV's current position information (first position information) and movement path information; acquiring the wireless charger body's current position information (second position information); obtaining a reference movement time based on the second position information; calculating the theoretical position information of the AGV after the reference movement time based on the first position information and movement path information; controlling the wireless charger body to move to the theoretical position; and after the AGV and the wireless charger body meet, controlling the wireless charger body to follow the AGV while wirelessly charging it. The general process is shown in the appendix of the instruction manual. Figure 1 As shown.

[0004] For example, the patent document with application number CN202210289676 can realize dynamic wireless charging of AGV, but its disadvantage is that it requires a dual-axis drive device and wireless charger body to be set up under the ground. The wireless charger body needs to move synchronously with the AGV underground, which will cause a certain amount of hollowing out underground, which poses a safety problem. Moreover, it cannot perform dynamic wireless charging on multiple AGVs at the same time, which has limitations. Summary of the Invention

[0005] To address the shortcomings and deficiencies of existing technologies, this invention provides an AGV dynamic wireless charging system and its control method. By integrating mechanical-magnetic coupling physical interlocking with near-field magnetic communication safety verification, a safety state binding is achieved during the dynamic wireless charging process. The system includes multiple segmented transmitting coil modules laid along the AGV's travel path. Each module contains an electromechanical integrated mechanical-magnetic coupling baffle structure. The mechanical position of this baffle constitutes the sole control factor for the magnetic communication loop between the transmitting coil and the magnetic communication modulation unit: when the baffle is closed, the magnetic communication loop is physically connected, and the system sends a handshake magnetic pulse signal through the transmitting coil; when the baffle is open, the magnetic communication loop is physically disconnected, and the communication function is forcibly disabled. The system is configured to only drive the baffle from the closed position to the open position and initiate power transmission after the on-board unit successfully receives and verifies the handshake magnetic pulse signal, thereby achieving an unavoidable physical binding between the safety verification state and the energy transmission state. Furthermore, the system integrates a triple-redundant fault detection and decision-making mechanism, enabling safety-oriented derating fault-tolerant operation when the baffle malfunctions and jams. Simultaneously, it employs feedforward pre-activation control based on the AGV's real-time speed and circuit stabilization time to ensure seamless energy transfer between charging sections during AGV operation. In multi-AGV scenarios, it also possesses the capability for dynamic power allocation based on the inverse proportional weight of each AGV's battery state of charge. This invention replaces traditional software electronic locks with passive mechanical interlocks, eliminating software bypass paths for security verification at the physical layer, and providing a highly reliable, highly secure, and multi-machine collaborative system-level solution for dynamic wireless charging of AGVs.

[0006] The specific technical solution adopted by this invention to solve its technical problem is as follows:

[0007] This invention first provides a dynamic wireless charging system for AGVs, including multiple segmented transmitting coil modules laid along the AGV's travel path, an on-board controller, a receiving coil installed at the bottom of the AGV, a central controller, and a position detection module. The central controller is communicatively connected to each segmented transmitting coil module and the on-board controller, and the position detection module is used to acquire the AGV's position information. Each segmented transmitting coil module includes a transmitting coil, a magnetic communication modulation unit, a mechanical-magnetic coupling baffle, and a power switch; the mechanical-magnetic coupling baffle is rigidly mechanically coupled to the magnetic communication circuit between the transmitting coil and the magnetic communication modulation unit, and its mechanical position is the sole control factor for the on / off state of the magnetic communication circuit; when the baffle is in the closed position, the magnetic communication circuit is conductive; when the baffle is in the open position, the magnetic communication circuit is physically disconnected; the power switch is connected in series between the power supply circuit and the transmitting coil. The on-board controller integrates a magnetic resonance detection unit, and the receiving coil is also electrically connected to the magnetic resonance detection unit as a magnetic signal detector. The magnetic communication modulation unit is configured to send a handshake magnetic pulse signal through the transmitting coil only when the magnetic communication circuit is conductive. The magnetic resonance detection unit is configured to listen to the handshake magnetic pulse signal through the receiving coil and determine the safe state based on whether the handshake magnetic pulse signal can be successfully demodulated and verified. The central controller is configured to: after the magnetic resonance detection unit determines that the safe state has passed, control the power switch of the corresponding segmented transmitting coil module to close and drive the mechanical-magnetic coupling baffle to switch to the open position, so that the transmitting coil transmits electrical energy to the receiving coil through magnetic resonance.

[0008] The core improvement of this invention lies in integrating the physical protection structure with the safety interlock function. It controls the communication circuit's on / off state through purely mechanical means, eliminating any software intervention path and fundamentally preventing the security risks of electronic interlocks being easily cracked or falsely triggered. Simultaneously, the segmented transmitting coil architecture eliminates the need for any underground moving parts, completely resolving the safety issues associated with ground-level perforations in existing technologies.

[0009] Furthermore, the mechanical-magnetic coupling baffle includes a permanent magnet fixed to its side and a magnetically controlled switch connected in series in the magnetic communication circuit; the movement of the baffle causes the permanent magnet to approach or move away from the magnetically controlled switch, thereby controlling the on / off state of the magnetic communication circuit. This structure achieves wear-free magnetic circuit switching through the non-contact cooperation between the permanent magnet and the magnetically controlled switch, has a long service life, high reliability, and requires no complex electrical connections.

[0010] Furthermore, the magnetically controlled switch is a reed switch, including a closed-position reed switch and an open-position reed switch; the closed-position reed switch is connected in series between the transmitting coil and the magnetic communication modulation unit; the open-position reed switch is connected to the state detection input terminal of the segment controller for feedback of the baffle position status. This dual-reed switch design not only realizes the on / off control of the communication loop but also provides real-time feedback of the actual physical position of the baffle, forming a closed-loop detection, further improving the system's safety and controllability.

[0011] Furthermore, the transmitting coil also serves as the communication antenna of the magnetic communication modulation unit, integrating energy transmission and magnetic communication signal transmission. This design reuses the physical structure of the transmitting coil, eliminating the need for an additional communication antenna, simplifying the system hardware composition, reducing costs, and avoiding the problem of independent communication antennas being susceptible to interference from metallic environments, thus improving communication reliability.

[0012] Furthermore, the magnetic resonance detection unit is also configured to detect the amplitude of the induced voltage across the receiving coil; the central controller is further configured to: when the magnetic resonance detection unit cannot demodulate a valid handshake magnetic pulse signal, if the detected amplitude of the induced voltage is greater than a first preset threshold and the position detection module confirms that the AGV is within the corresponding transmission segment range, then it is determined to be a baffle jamming open fault, derating charging is performed and the fault is reported; if the detected amplitude of the induced voltage is less than a second preset threshold, then it is determined that the effective charging segment has not been reached, and charging is prohibited. This triple-redundant fault detection mechanism can accurately distinguish between two different fault modes: "baffle jamming open" and "communication circuit disconnection," maximizing system operation while ensuring safety, and avoiding charging interruptions caused by a single fault.

[0013] Furthermore, the central controller is also configured to perform feedforward pre-activation control: based on the AGV position and speed information obtained by the position detection module, and combined with the system stabilization time and magnetic communication handshake interaction time, a pre-activation advance is calculated. Before the AGV reaches the boundary of the corresponding launch segment by the pre-activation advance, a pre-activation command is sent to that launch segment. Feedforward pre-activation control ensures that when the AGV arrives at the charging segment, the magnetic communication handshake has been completed, and the system is ready for power transmission, achieving seamless charging switching and eliminating charging blind spots and power fluctuations.

[0014] Furthermore, the central controller is configured to execute a dynamic power allocation strategy for multiple AGVs: when multiple AGVs simultaneously enter the same launch segment, the allocation weight is calculated based on the battery state of charge of each AGV, and charging power is allocated according to the weight ratio, wherein the allocation weight is inversely proportional to the battery state of charge. This strategy can prioritize the charging needs of AGVs with low battery levels, improving the overall charging efficiency of the system and the operational stability of the AGV cluster.

[0015] Furthermore, the power weight W assigned to the nth AGV n satisfy:

[0016]

[0017] Among them, SOC n Let C be the state of charge (SBC) value of the battery of the nth AGV, where C is a preset constant greater than zero.

[0018] By introducing a preset constant C, the problem of infinite weights when the battery state of charge approaches zero can be avoided, thus ensuring the rationality and stability of power allocation.

[0019] Furthermore, the mechanical-magnetic coupling baffle also includes a reset elastic element, used to push the baffle to the closed position when there is no external driving force. The reset elastic element can automatically reset the baffle to the closed position when charging ends or the system is powered off, restoring the magnetic communication circuit and preparing for the next charging, while ensuring the safety of the system in the power-off state.

[0020] This invention also provides a dynamic wireless charging control method for AGVs, applied to the aforementioned dynamic wireless charging system for AGVs, comprising the following steps:

[0021] S1. Standby monitoring phase: The mechanical-magnetic coupling baffle of the segmented transmitting coil module is in the closed position, the magnetic communication circuit is turned on, and the magnetic communication modulation unit sends a handshake magnetic pulse signal through the transmitting coil; the magnetic resonance detection unit of the vehicle controller periodically monitors the handshake magnetic pulse signal through the receiving coil.

[0022] S2, Security Verification Phase: The magnetic resonance detection unit demodulates the received handshake magnetic pulse signal and performs verification.

[0023] S3, Power Transmission Stage: If the verification is successful, the central controller controls the power switch of the corresponding transmitting segment to close and drives the mechanical-magnetic coupling baffle to switch to the open position, physically cutting off the magnetic communication circuit, and the transmitting coil transmits electrical energy to the receiving coil through magnetic resonance.

[0024] S4. Charging Termination Stage: When the AGV leaves the launch section or the battery charge state reaches the preset threshold, the central controller controls the power switch to open, the mechanical-magnetic coupling baffle to reset to the closed position, the magnetic communication circuit is restored, and the system returns to the standby listening stage.

[0025] This control method follows the safety logic of "verify first, then charge," ensuring that power transmission will only be initiated when the baffle is confirmed to be in the closed position and communication is normal. At the same time, the communication circuit is physically cut off during the power transmission phase, completely avoiding interference from the high-power magnetic field to the communication and ensuring the safety and stability of the charging process.

[0026] Compared to existing technologies, this invention and its preferred solution eliminate the need for underground mobile charging devices, eradicating the safety hazards caused by ground-level perforations, while significantly reducing the system's mechanical failure rate and maintenance costs. It achieves parallel charging and dynamic power allocation for multiple AGVs, overcoming the resource bottleneck of traditional one-to-one charging and supporting large-scale AGV cluster applications. Employing a purely mechanical safety interlocking mechanism, it ensures the safety of the charging process from a physical perspective, avoiding the risks of interference or tampering with electronic interlocks. Through feedforward pre-activation control, it achieves seamless connection of the charging process, eliminating charging blind spots and power fluctuations, and improving the continuous working capability of AGVs. The integrated energy-information design simplifies the system structure, reduces hardware costs, and improves the system's anti-interference capability and operational stability. Attached Figure Description

[0027] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments:

[0028] Figure 1 A flowchart of an existing dynamic wireless charging method for AGVs;

[0029] Figure 2 This is a schematic diagram of the overall layout of the AGV dynamic wireless charging system according to an embodiment of the present invention;

[0030] Figure 3 This is a longitudinal sectional view of the mechanical-magnetic coupling baffle according to an embodiment of the present invention;

[0031] Figure 4 This is a schematic diagram of the magnetic communication modulation and demodulation circuit according to an embodiment of the present invention;

[0032] Figure 5 This is a flowchart of the triple redundancy fault detection and safety decision-making process according to an embodiment of the present invention;

[0033] Figure 6 This is a block diagram of the overall architecture of the AGV dynamic wireless charging system according to an embodiment of the present invention;

[0034] Figure 7 This is a flowchart illustrating the overall workflow of the AGV dynamic wireless charging system according to an embodiment of the present invention. Detailed Implementation

[0035] To make the features and advantages of the present invention more apparent and understandable, specific embodiments are described below in detail:

[0036] It should be noted that the following detailed descriptions are exemplary and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0037] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0038] Currently, AGV charging methods are mainly divided into two types: wired charging and wireless charging. Wired charging connects the vehicle to the power supply system via cables and charging contacts to achieve power transmission. Wireless charging eliminates the need for physical cables, utilizing alternating magnetic fields to achieve wireless power transmission. Energy transfer is completed through magnetic coupling between the power transmitter and the AGV's power receiver.

[0039] Wireless charging is further divided into static charging and dynamic charging: static charging requires the AGV to move to a fixed charging position and stop working before charging; dynamic charging allows the AGV to wirelessly charge while moving along its working path when the battery level is lower than a preset threshold.

[0040] To achieve dynamic wireless charging for AGVs, a mobile wireless charging scheme (application number: CN202210289676) has been proposed. This scheme requires a wireless charger and a dual-axis drive device to be installed below the ground at the AGV's work site. The charging method includes: acquiring charging request information from the AGV, containing its current position and movement path; acquiring the current position information of the wireless charger; calculating the reference movement time of the wireless charger and the theoretical arrival position of the AGV; controlling the wireless charger to move to the theoretical position; and after the AGV and the wireless charger meet, controlling the wireless charger to move synchronously with the AGV and perform wireless charging. The charging process is as follows: Figure 1 As shown.

[0041] While the aforementioned existing technologies can achieve dynamic wireless charging for AGVs, they have the following inherent drawbacks:

[0042] 1. Significant safety hazards: It requires large-scale excavation and installation of dual-axis drive tracks below ground, forming a large-area hollow structure, which poses safety risks such as ground collapse and personnel falling.

[0043] 2. Poor system scalability: It can only achieve a one-to-one charging mode and cannot provide dynamic charging services for multiple AGVs at the same time, which seriously restricts the large-scale application of AGV clusters.

[0044] The AGV dynamic wireless charging system disclosed in this invention adopts a distributed control architecture, consisting of a ground-side subsystem and a vehicle-side subsystem. The overall system layout is as follows: Figure 2 As shown, a total of 14 independent segmented transmitting coil modules are arranged along the AGV's circular travel path, and the central controller is located at the center of the site to achieve unified global scheduling.

[0045] The overall control architecture of the system in this embodiment is as follows: Figure 6 As shown, the central controller serves as the global core, connecting downwards to each segment controller and receiving feedback information from the AGV's onboard system. The ground power supply provides power to all ground-side equipment. The ground-side subsystem includes the ground power supply, the central controller, the position detection module, and multiple segmented transmitting coil modules laid along the AGV's preset travel path. The onboard subsystem includes the onboard controller installed inside the AGV and the receiving coil installed at the bottom of the AGV. The ground power supply, as the system's electrical infrastructure, provides stable DC power to all segmented transmitting coil modules. The central controller, as the global scheduling core, establishes real-time communication connections via the CAN bus with the segment controllers of each segmented transmitting coil module and the onboard controllers of all AGVs, responsible for global status monitoring, charging task scheduling, safety interlock control, and fault handling. The position detection module uses UWB ultra-wideband positioning or lidar positioning to acquire the AGV's precise position coordinates and travel speed information in real time, and uploads the data to the central controller, providing support for pre-activation scheduling and position verification.

[0046] In this embodiment, each segmented transmitting coil module is the basic execution unit for realizing energy transmission and safe interaction on a fixed road section. It mainly consists of a pre-embedded frame, a transmitting coil, a magnetic communication modulation unit, a mechanical-magnetic coupling baffle, a power switch, and a segmented controller. The pre-embedded frame is a rectangular metal structure with an internal cavity size of 400mm × 300mm × 80mm. A mounting position for the transmitting coil is reserved at the bottom, and it is fixed to the ground using expansion bolts. The upper surface is flush with the ground. The transmitting coil adopts a planar spiral structure and is laid at the bottom of the pre-embedded frame cavity. It serves as both a power coil for high-power electrical energy transmission and a transmitting antenna for magnetic communication signals, achieving integrated transmission of energy and information. The magnetic communication modulation unit and the segmented controller are integrated and installed in a protective box on the side of the pre-embedded frame. The power switch is connected in series in the power transmission circuit between the ground power supply and the transmitting coil, and its on / off state is controlled by the segmented controller according to the instructions of the central controller.

[0047] As a preferred option, a passive magnetic resonant relay array can be laid between adjacent segmented transmitting coil modules, using a high Q-value design to achieve energy relay transmission between adjacent segments, further eliminating charging blind spots and improving the continuity of energy transmission during AGV operation.

[0048] The longitudinal cross-sectional structure of the mechanical-magnetic coupling baffle in this embodiment is as follows: Figure 3As shown. The mechanical-magnetic coupling baffle is the core structure of this invention for achieving physical layer security interlocking. It rigidly couples the physical protection function with the magnetic communication circuit topology switching function, without any software intervention or bypass path. The baffle body is made of high-permeability silicon steel sheet laminate and stainless steel support plate composite. The silicon steel sheet thickness is 5mm, the stainless steel support plate thickness is 3mm, and the total dimensions are 380mm×280mm×15mm. The baffle body is slidably installed in the pre-embedded frame via T-shaped guide rails on both sides, and can slide back and forth along the AGV travel direction, with two defined working positions: closed and open. A reset spring is connected between the rear end of the baffle body and the pre-embedded frame. The spring wire diameter is 2mm, the free length is 100mm, and the compression stroke is 60mm. When no external force is applied, the reset spring will push the baffle body to the closed position, completely covering the area where the transmitting coil is located.

[0049] In this embodiment, the drive mechanism of the baffle adopts a relay-fork linkage structure. The relay model is HF115F / 012-1ZS3, with a coil voltage of 12VDC and a contact capacity of 16A. It is fixed to the side of the pre-embedded frame by a bracket. The insulated fork is made of nylon with a thickness of 8mm, and its front end is embedded in a groove on the side of the baffle body. When the relay is energized, the armature is attracted, causing the fork to push the baffle body to slide 60mm, compressing the return spring and moving the baffle body to the open position, exposing the transmitting coil underneath. When the relay is de-energized, the armature is released, and the return spring pushes the baffle body back to the closed position.

[0050] In this embodiment, the magnetic circuit switching contact assembly consists of a permanent magnet pressure block and two reed switches. The permanent magnet pressure block is made of neodymium iron boron (N52) material and measures 20mm × 10mm × 5mm, fixed to the side of the baffle body. Both reed switches are MKA14103 normally open type, with an operating distance of 10-15mm, and are fixed to the closed and open positions on the side of the embedded frame, respectively. The installation distance between the two reed switches is 60mm, perfectly matching the sliding stroke of the baffle body. The closed reed switch is connected in series in the communication circuit between the transmitting coil and the magnetic communication modulation unit. When the baffle body is in the closed position, the permanent magnet pressure block aligns with the closed reed switch, the reed switch contacts close, and the magnetic communication circuit is established. When the baffle body slides to the open position, the permanent magnet pressure block moves away from the closed reed switch, the contacts open, and the magnetic communication circuit is physically cut off. The open position reed switch is connected to the status detection input terminal of the segment controller. When the baffle body is in the open position, the permanent magnet pressure block is aligned with the open position reed switch, the contact is attracted, and a status signal that the baffle is in place is fed back to the segment controller.

[0051] The principle of the magnetic communication modulation and demodulation circuit in this embodiment is as follows: Figure 4As shown. The magnetic communication circuit is divided into two parts: the transmitting side and the receiving side. The transmitting side is integrated into the segment controller of the segmented transmitting coil module, and the receiving side is integrated into the AGV's on-board controller. The transmitting side circuit uses an STM32F103C8T6 MCU as its core, with a main frequency of 72MHz. It communicates with the segment controller through a UART interface to generate the data frame to be transmitted and control the FSK modulation timing. The FSK modulator uses an AD9850 DDS module to convert the digital signal into a frequency offset keying signal. Logic "1" corresponds to 112kHz, logic "0" corresponds to 108kHz, the center frequency is 110kHz, and the frequency offset is ±2kHz. The modulated signal is amplified by an H-bridge circuit composed of an IR2104 half-bridge driver chip and an IRF540N MOSFET, with a drive voltage of 12V, an output current capability of 5A, and a switching frequency higher than 200kHz. The amplified signal output terminal is connected to the transmitting coil via a closed reed switch. The transmitting coil has an outer diameter of 250mm, a wire diameter of 1.5mm, 15 turns, an inductance of 120μH, and is matched with a resonant capacitor to a resonant frequency of 110kHz. The Q value is greater than 50.

[0052] In this embodiment, the receiving coil in the receiver circuit is a planar rectangular coil, measuring 300mm × 200mm, with a wire diameter of 2.0mm, 10 turns, and an inductance of 80μH. It also serves as a magnetic signal detection antenna. The receiving coil and a 26nF precision capacitor are connected in parallel to form a resonant network, resonating at 110kHz with a resonant impedance of 5kΩ and a bandwidth of 2kHz, used to enhance signal selectivity. The signal picked up by the receiving coil first passes through an envelope detector composed of 1N4148 diodes to extract the modulation envelope, and then passes through an RC low-pass filter composed of a 10kΩ resistor and a 10nF capacitor to filter out carrier remnants, with a cutoff frequency of approximately 1.6kHz. The filtered analog signal is then fed into an LM393 voltage comparator, converted to digital logic levels, and finally demodulated using an STM32F103C8T6 MCU for FSK demodulation and data frame verification. The entire demodulation link has a detection sensitivity of less than 100mV, a response time of less than 0.5ms, and a demodulation bit error rate of less than 10%. -4 .

[0053] This embodiment uses a dedicated handshake magnetic pulse data frame structure for magnetic communication. Each frame is 7 bytes long, with a transmission rate of 19.2 kbps and a transmission time of approximately 2.9 ms. The first two bytes of the data frame are a preamble, fixed at 0xAA 0x55, used for bit synchronization and frame start identification at the receiving end. The third byte is the segment address ID, ranging from 0x01 to 0xFF, used to distinguish different transmitting coil modules and prevent signal crosstalk between adjacent segments. The fourth byte is the status code: 0x00 indicates a fault in the transmitting segment or that it has been disabled; 0x01 indicates the baffle is closed and the circuit is functioning normally. Bytes 5 and 6 are the data payload, currently filled with 0x0000, reserved for future expansion of power levels, protocol versions, etc. The seventh byte is a CRC checksum, using the CRC-8 algorithm with a polynomial of 0x31, covering the first six bytes of data, used to verify the correctness of data transmission.

[0054] In this embodiment, the magnetic resonance detection unit of the vehicle controller needs to perform a security verification after demodulating the received handshake magnetic pulse signal. A successful security handshake is determined only if four conditions are met simultaneously: 1) the preamble matches a preset value; 2) the segment address ID matches the target transmitting segment address the AGV is about to enter; 3) the status code is 0x01, indicating that the transmitting segment is functioning normally; and 4) the CRC check passes. If any condition is not met, a communication anomaly is determined, and the charging process is prohibited.

[0055] The logical flow of triple redundancy fault detection and safety decision-making in this embodiment is as follows: Figure 5 As shown. To address potential mechanical jamming faults in the baffle, this invention employs a triple-redundant fault detection mechanism. The first detection is magnetic communication demodulation detection, which preliminarily determines the on / off state of the magnetic communication circuit by successfully demodulating and verifying the handshake magnetic pulse signal. The second detection is magnetic field strength detection, where a magnetic resonant detection unit detects the amplitude of the induced voltage through the receiving coil, indirectly reflecting the alternating magnetic field strength around the transmitting coil. The third detection is physical position confirmation, which uses a position detection module to obtain the real-time position of the AGV and confirm whether the AGV has entered the range of the corresponding transmitting segment.

[0056] In this embodiment, when the magnetic resonance detection unit cannot demodulate the effective handshake magnetic pulse signal, the system will initiate the second and third detections. If the induced voltage amplitude across the receiving coil is greater than the first preset threshold of 200mV, and the position detection module confirms that the AGV has entered the corresponding transmission segment range, it is determined to be fault mode A, where the baffle is stuck in the open position. At this time, the system allows charging to continue, but will limit the charging power to 50% of the single-segment rated power (30kW), and immediately report to the central controller via the CAN bus, marking the transmission segment as fault-derating operation status, and the on-board human-machine interface displays the corresponding fault prompt information. When the AGV leaves the transmission segment, the central controller will permanently mark the segment as fault-prohibited entry status and push a maintenance work order to the operation and maintenance system. The segment will remain locked until manual reset and detection are completed. If the detected induced voltage amplitude is less than the second preset threshold of 20mV, it is determined to be fault mode B, where the communication circuit is disconnected or the transmission segment is not activated. At this time, the system prohibits charging, and the AGV will continue to move to the next transmission segment or report an error requesting manual intervention.

[0057] In this embodiment, the central controller executes a feedforward pre-activation control algorithm based on the AGV's real-time position and speed to pre-activate the transmitter segment the AGV is about to arrive at, ensuring a seamless connection in the charging process. The pre-activation advance is calculated using the formula Tpre = Doffset / Vagv + Tsettle + Thandshake, where Doffset is the pre-activation trigger distance, Vagv is the AGV's current speed, Tsettle is the stabilization time required for the transmitter circuit to go from standby to stable output (typically 50ms), and Thandshake is the time required to complete one round of magnetic communication handshake interaction (typically 20ms). The pre-activation trigger distance is dynamically adjusted according to the AGV's speed; the higher the speed, the larger the trigger distance to ensure sufficient safety margin. For example, when the AGV travels at 0.5m / s, the pre-activation trigger distance is set to 1.5m, initiating pre-activation approximately 3 seconds in advance; when the AGV travels at 3.0m / s, the pre-activation trigger distance is set to 14.5m, initiating pre-activation approximately 5 seconds in advance.

[0058] When multiple AGVs simultaneously enter the charging range of the same transmitting segment, the central controller executes a dynamic power allocation strategy for the multiple AGVs, dynamically distributing the total charging power based on the battery state of charge of each AGV. The maximum output power of a single transmitting coil module is 30kW, and the maximum output current is 60A. The system calculates an allocation weight for each AGV, using the formula W. n = 1 / (SOC n + 0.01), where W n Assigning weights to the nth AGV, SOC nThe value of the battery state of charge (SBC) for the nth AGV is introduced with a value of 0.01 to avoid the problem of infinite weights when the SBC approaches zero. The central controller allocates corresponding charging current and power based on the weight ratio of each AGV. The system recalculates the weights every 100ms and dynamically adjusts the power allocation according to the changes in the AGV battery SBC to achieve optimal utilization of charging resources. For example, when the battery SBCs of three AGVs are 15%, 35%, and 60%, the calculated weights are 6.25, 2.78, and 1.64, respectively, with a total weight of 10.67, corresponding to power allocation ratios of 58.5%, 26.0%, and 15.4%.

[0059] The complete workflow of the system in this embodiment is as follows: Figure 7 As shown. The overall system workflow is as follows: During the standby listening phase, the mechanical-magnetic coupling baffles of all segmented transmitting coil modules are in the closed position, the closed-position reed switch is turned on, and the magnetic communication circuit is established. The magnetic communication modulation unit broadcasts a handshake magnetic pulse signal with the segment address ID at a period of 10ms through the transmitting coil. The magnetic resonance detection unit of the vehicle controller listens for the magnetic communication signal in the 110kHz frequency band at a period of 100ms. At this time, the overall system power consumption is less than 5W.

[0060] When the central controller detects that the AGV is about to arrive at a certain transmission segment through the position detection module, it calculates the pre-activation advance amount in advance and sends a pre-activation command to the segment controller of that transmission segment. After receiving the command, the segment controller confirms that the baffle is in the closed position, and the magnetic communication modulation unit begins to broadcast the handshake magnetic pulse signal cyclically at a higher frequency. After the AGV enters the communication range of the transmission segment, the magnetic resonance detection unit demodulates the received handshake magnetic pulse signal and performs safety verification.

[0061] If the safety verification passes, the central controller sends a power transmission command to the segment controller of the corresponding transmitting segment. Upon receiving the command, the segment controller first closes the power switch, then energizes the relay, causing the fork to push the baffle body to the open position. At this point, the permanent magnet pressure block moves away from the closed-position reed switch, physically cutting off the magnetic communication circuit. Simultaneously, it aligns with the open-position reed switch, sending a baffle positioning signal back to the segment controller. The transmitting coil begins transmitting high-power electrical energy to the AGV's receiving coil via magnetic resonance, and the AGV's battery management system begins charging. Throughout the power transmission phase, the magnetic communication circuit remains physically disconnected, completely preventing interference from the high-power magnetic field on the communication signal.

[0062] When the position detection module detects that the AGV's tail has completely left the launch section boundary and the distance exceeds the preset safety distance (typically 0.5m), or when the AGV's battery charge level reaches the preset threshold of 90%, the central controller sends a charging termination command to the section controller. Upon receiving the command, the section controller first disconnects the power switch and then cuts off the power supply to the relay. The reset spring pushes the baffle body back to the closed position, the permanent magnet pressure block realigns with the closed reed switch, the magnetic communication circuit is restored, and the system returns to standby listening mode, waiting for the arrival of the next AGV. If the launch section is in a fault-derating operation state, after the AGV leaves, the central controller will mark it as fault-prohibited entry, awaiting manual maintenance.

[0063] In addition to the specific embodiments described above, there are several alternative solutions to the technical solution of this invention. For example, the driving mechanism of the mechanical-magnetic coupling baffle can use a micro linear motor with a lead screw drive, or a rotary cam mechanism to convert the rotational motion into the reciprocating motion of the baffle, which is suitable for high-frequency start-stop applications and can reduce the mechanical wear of relay contacts. The modulation method of magnetic communication can use ASK amplitude shift keying instead of FSK frequency shift keying, and use load modulation technology to change the reflection impedance of the coil on the receiving side to achieve reverse data transmission, simplifying circuit design and reducing the complexity of modulation and demodulation. The position detection module can use RFID radio frequency identification or a magnetic navigation sensor with an encoder odometer, which is suitable for applications with relatively low positioning accuracy requirements.

[0064] It should be noted that, unless otherwise defined, the technical or scientific terms used in this invention should have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0065] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the protection scope of the present invention.

[0066] This invention is not limited to the preferred embodiment described above. Anyone inspired by this invention can derive other forms of AGV dynamic wireless charging systems and their control methods. All equivalent variations and modifications made within the scope of the claims of this invention should be included within the scope of this invention.

Claims

1. A system for dynamic wireless charging of AGVs, characterized in that, It includes multiple segmented transmitting coil modules laid along the AGV's travel path, an on-board controller, a receiving coil installed at the bottom of the AGV, a central controller, and a position detection module; The central controller is communicatively connected to each segmented transmitting coil module and the vehicle controller, and the position detection module is used to obtain the position information of the AGV; Each segmented transmitting coil module includes a transmitting coil, a magnetic communication modulation unit, a mechanical-magnetic coupling baffle, and a power switch. The mechanical-magnetic coupling baffle is rigidly mechanically coupled to the magnetic communication circuit between the transmitting coil and the magnetic communication modulation unit, and its mechanical position is the sole control factor for the on / off state of the magnetic communication circuit. When the baffle is in the closed position, the magnetic communication circuit is conducting; when the baffle is in the open position, the magnetic communication circuit is physically disconnected. The power switch is connected in series between the power supply circuit and the transmitting coil. The vehicle controller integrates a magnetic resonance detection unit, and the receiving coil is also electrically connected to the magnetic resonance detection unit as a magnetic signal detector. The magnetic communication modulation unit is configured to send a handshake magnetic pulse signal through the transmitting coil only when the magnetic communication circuit is turned on; The magnetic resonance detection unit is configured to listen to the handshake magnetic pulse signal through the receiving coil, and determine the safety status based on whether the handshake magnetic pulse signal can be successfully demodulated and verified. The central controller is configured to: after the magnetic resonance detection unit determines that the safety status has passed, control the power switch of the corresponding segmented transmitting coil module to close, and drive the mechanical-magnetic coupling baffle to switch to the open position, so that the transmitting coil transmits electrical energy to the receiving coil through magnetic resonance.

2. The AGV dynamic wireless charging system according to claim 1, characterized in that: The mechanical-magnetic coupling baffle includes a permanent magnet fixed to its side and a magnetically controlled switch connected in series in the magnetic communication circuit; the movement of the baffle causes the permanent magnet to approach or move away from the magnetically controlled switch, thereby controlling the opening and closing of the magnetic communication circuit.

3. The AGV dynamic wireless charging system according to claim 2, characterized in that: The magnetic switch is a reed switch, including a closed reed switch and an open reed switch; the closed reed switch is connected in series between the transmitting coil and the magnetic communication modulation unit; the open reed switch is connected to the state detection input terminal of the segment controller for feedback of the baffle position status.

4. The AGV dynamic wireless charging system according to claim 1, characterized in that: The transmitting coil also serves as the communication antenna of the magnetic communication modulation unit, realizing the integration of energy transmission and magnetic communication signal transmission.

5. The AGV dynamic wireless charging system according to claim 1, characterized in that: The magnetic resonance detection unit is also configured to detect the amplitude of the induced voltage across the receiving coil; the central controller is also configured to: when the magnetic resonance detection unit cannot demodulate the effective handshake magnetic pulse signal, if the detected amplitude of the induced voltage is greater than a first preset threshold and the position detection module confirms that the AGV is within the corresponding transmission segment range, then it is determined to be a baffle jamming open fault, derating charging is performed and the fault is reported; if the detected amplitude of the induced voltage is less than a second preset threshold, then it is determined to be that the effective charging segment has not been reached, and charging is prohibited.

6. The AGV dynamic wireless charging system according to claim 1, characterized in that: The central controller is also configured to perform feedforward pre-activation control: based on the AGV position and speed information obtained by the position detection module, combined with the system stabilization time and magnetic communication handshake interaction time, calculate the pre-activation advance, and send a pre-activation command to the corresponding launch segment before the AGV reaches the boundary of the corresponding launch segment by the time of the pre-activation advance.

7. The AGV dynamic wireless charging system according to claim 1, characterized in that: The central controller is also configured to execute a multi-AGV power dynamic allocation strategy: when multiple AGVs enter the same launch segment at the same time, the allocation weight is calculated based on the battery state of charge of each AGV, and the charging power is allocated according to the weight ratio. The allocation weight is inversely proportional to the battery state of charge.

8. The AGV dynamic wireless charging system according to claim 7, characterized in that: The power weight W assigned to the nth AGV n satisfy: Among them, SOC n Let C be the state of charge (SBC) value of the battery of the nth AGV, where C is a preset constant greater than zero.

9. The AGV dynamic wireless charging system according to claim 1, characterized in that: The mechanical-magnetic coupling baffle also includes a reset elastic element for pushing the baffle to the closed position when there is no external force driving it.

10. A dynamic wireless charging control method for AGVs, characterized in that, The AGV dynamic wireless charging system according to any one of claims 1-9 includes the following steps: S1. Standby monitoring phase: The mechanical-magnetic coupling baffle of the segmented transmitting coil module is in the closed position, the magnetic communication circuit is turned on, and the magnetic communication modulation unit sends a handshake magnetic pulse signal through the transmitting coil; the magnetic resonance detection unit of the vehicle controller periodically monitors the handshake magnetic pulse signal through the receiving coil. S2, Security Verification Phase: The magnetic resonance detection unit demodulates the received handshake magnetic pulse signal and performs verification; S3, Power Transmission Stage: If the verification is successful, the central controller controls the power switch of the corresponding transmitting segment to close and drives the mechanical-magnetic coupling baffle to switch to the open position, physically cutting off the magnetic communication circuit, and the transmitting coil transmits electrical energy to the receiving coil through magnetic resonance. S4. Charging Termination Stage: When the AGV leaves the launch section or the battery charge state reaches the preset threshold, the central controller controls the power switch to open, the mechanical-magnetic coupling baffle to reset to the closed position, the magnetic communication circuit is restored, and the system returns to the standby listening stage.

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