Wireless power supply on production line

Abstract

A wireless power supply system for a test system includes a transmitter associated with an assembly rail and a receiver associated with a component. The transmitter transmits wireless power to the receiver.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 544,380, filed September 1, 2023, the disclosure of which is incorporated herein by reference in its entirety. Background Technology

[0003] During manufacturing, workers on the assembly line manually perform certain tasks. For example, some components on the assembly line may need to be tested during production. This requires workers to manually connect and disconnect power to the components for testing. Summary of the Invention

[0004] A wireless power supply system for a test system includes a transmitter associated with an assembly rail and a receiver associated with a component. The transmitter transmits wireless power to the receiver.

[0005] In an example wireless power supply system of the test system, a tray is connected to the component, and the tray moves relative to the assembly rail.

[0006] In an example wireless power supply system for the test system, the system includes a power source that supplies power to the transmitter, and the transmitter transmits wireless power signals to the receiver to wirelessly power the components during testing.

[0007] In an example wireless power supply system of the test system, one of electromagnetic resonance or induction is used to wirelessly transmit power from the transmitter to the receiver.

[0008] In an example wireless power supply system of the test system, the receiver is connected to the tray via a first attachment mechanism, and the transmitter is connected to the mounting rail via a second attachment mechanism.

[0009] In an example wireless power supply system of the test system, the first attachment mechanism and the second attachment mechanism are each threaded fasteners or screws.

[0010] In an example wireless power supply system for the test system, a connector connects the component to the receiver, and power travels from the receiver to the component through the connector for testing.

[0011] In an example wireless power supply system for testing, the system includes a controller, a display associated with the controller, and a communication module. Data acquired during testing is wirelessly transmitted between the communication module and the controller via bidirectional wireless signals and displayed on the display.

[0012] In an example wireless power supply system of the test system, the communication module is associated with the tray, and a wireless data communication transceiver located between the controller and the communication module wirelessly transmits the data between the controller and the communication module.

[0013] In an example wireless power supply system for the test system, the controller sends signals to the transmitter via a wired line to control the one-way transmission of wireless power from the transmitter to the receiver during testing.

[0014] In an example wireless power supply system for testing the system, the system includes a motor, a conveyor belt moved by the motor, a connection station, a test station, and a disconnection station. A tray and the components attached to the tray move along the conveyor belt from the connection station to the test station and to the disconnection station along the production line.

[0015] In an example wireless power supply system for testing, the system includes a host computer, and the test station comprises multiple test stations, each including a controller, sensors, and a display. When each of the sensors detects the tray at one of the multiple test stations, a signal is sent to the host computer to signal the motor to stop the conveyor belt, allowing the test to be performed. The controller sends a signal to the transmitter to initiate wireless power transmission from the transmitter to the receiver to power the test.

[0016] In an example wireless power supply system of the test system, data obtained from the test at the test station is transmitted to the host computer and the controller and displayed on the display, and when the test is completed, the host computer sends a signal to the transmitter to stop transmitting wireless power to the receiver.

[0017] In an example wireless power supply system for testing, if the component passes the test, the host computer sends a signal to the motor to move the conveyor belt, causing the tray to leave the test station.

[0018] In an example wireless power supply system for the test system, once the test is completed at the test station, the host computer sends a signal to the motor to move the conveyor belt, causing the tray to leave the test station and move to the disconnection station, where the component is disconnected from the tray. Attached Figure Description

[0019] Figure 1 The components are shown at the testing station on the production line; and

[0020] Figure 2 The stations along the production line are shown. Detailed Implementation

[0021] Figure 1 Test station 10 is shown at the end of production line 12. Component 14 is attached to tray 16. In one example, component 14 is a vehicle seat. Although a vehicle seat is illustrated and described below, other types of components 14 can be tested on production line 12.

[0022] Tray 16 moves relative to assembly rail 18. Wireless power supply system 20 includes a transmitter 22 and a receiver 24. Transmitter 22 is associated with assembly rail 18, and receiver 24 is associated with tray 16. Power supply 26 supplies power to transmitter 22, and transmitter 22 transmits wireless power signals 28 to receiver 24 to wirelessly power component 14 during testing. In one example, power supply 26 is an AC-DC charger.

[0023] In one example, electromagnetic resonance is used to transfer power from transmitter 22 to receiver 24. In another example, induction is used to transfer power from transmitter 22 to receiver 24.

[0024] Receiver 24 is connected to tray 16 via attachment mechanism 30, and transmitter 22 is connected to mounting rail 18 via attachment mechanism 32. In one example, attachment mechanisms 30 and 32 are each threaded fasteners or screws. Connector 34 connects component 14 to receiver 24 and collects and stores data collected from tests performed on component 14. Wired line 36 connects component 14 to connector 34, and wired line 38 connects connector 34 to receiver 24. Power travels from receiver 34 through connector 34 and to component 14 via wired lines 36 and 38 respectively for testing.

[0025] Test station 10 also includes a controller 40 and a display 42 associated with the controller 40. In one example, the controller 40 is a programmable logic controller (PLC). In one example, the display 42 is on the controller. The display 42 shows data acquired during testing.

[0026] Communication module 44 is associated with tray 16. Communication exists in both directions between connector 34 and communication module 44 via signal 84. In one example, a signal is sent to provide data collected from a test from connector 34 to communication module 44.

[0027] Wireless data communication transceiver 46 is used to wirelessly transmit any data or test data between controller 40 and communication module 44, and is located between controller 40 and communication module 44. Wireless data communication transceiver 46 wirelessly transmits data between controller 40 and communication module 44 via bidirectional wireless signal 48. Wireless data communication transceiver 46 can be Bluetooth, WiFi, wireless power antenna, or any type of wireless technology. Data can be transmitted via CAN or LIN network. Data obtained from the test is displayed on display 42.

[0028] During testing, communication module 44 sends the test results and information collected by connector 34 to controller 40. This information may include data related to seat memory function checks, occupant classification function checks (to ensure accurate occupant weight reflection), electrical functionality of cooling fans in components, seatbelt functionality, and seat heaters. Controller 40 knows the type of seat and therefore knows which tests to run or not to run. Tests related to seat memory function checks and occupant classification function checks (to ensure accurate occupant weight reflection) utilize high-speed bidirectional communication via CAN and LIN.

[0029] The controller 40 also sends signals to the transmitter 22 of the wireless power supply system 20 via wired line 50 to control the one-way transmission of wireless power signals 28 from the transmitter 22 to the receiver 24. The communication module 44 is also powered by the receiver 24 via wired line 52.

[0030] Figure 2 Production line 12 is shown, comprising connection station 54, test station 10, and disconnection station 56. In one example, there are six test stations 10 located between connection station 54 and disconnection station 56. Any test, including the tests described above, can be performed at each of the test stations 10. At each test station 10, the test results are displayed on display 42 of controller 40 and transmitted to host computer 58. Trays 16 with attached components 14 move from station to station along production line 12 along conveyor belt 60 moved by motor 57.

[0031] After component 14 is manufactured during production, it arrives at connection station 54. At connection station 54, component 14 is attached to tray 16. Controller 72 at connection station 54 communicates with host computer 58 via signal 74. Host computer 58 sends signal 64 to motor 57 to move conveyor belt 60 and tray 16 with attached component 14 from connection station 54 to test station 10.

[0032] Each test station in test station 10 includes a controller 40 and a sensor 70, and the sensor 70 detects the presence of the tray 16 at each test station 10. When the sensor 70 detects the tray 16 at test station 10, it sends a signal 68 to the host computer 58, and the host computer 58 communicates with the motor 57 and sends a signal 64 to the motor 57 to stop the conveyor belt 60, so that the tray 16 with component 14 is positioned at test station 10 so that testing can be performed.

[0033] Then, the host computer 58 sends a signal to the controller 40 to send a signal to the transmitter 22 to initiate the wireless power transmission to the receiver 24 as described above for testing. At the test station 10, wireless power is transmitted from the transmitter 22 associated with the mounting rail 18 to the receiver 24 associated with the tray 16 to power the assembly 14 for testing. When wireless power is transmitted to the assembly 14, the light 76 on the transmitter 22 and the light 78 on the receiver 24 are illuminated. Figure 1 (as shown in the image).

[0034] Data obtained from the tests performed on component 14 at test station 10 is transmitted from connector 34 to communication module 44 via signal 84, and from communication module 44 to controller 40 via wireless data transceiver 46 via wireless signal 48 for display on display 42. Once the test is complete, host computer 58 sends a signal to transmitter 22 to stop wireless power transmission. Thus, power is only transmitted wirelessly when tray 16 is located at test station 10. Test results are sent by controller 40 to host computer 58 for manufacturer registration. Once the test is complete, controller 40 sends signal 66 containing test data to host computer 58 as described above.

[0035] If component 14 passes the test at test station 10, the host computer 58 sends a signal to the motor 57 to move the conveyor belt 60, causing the tray 16 to leave test station 10 and move to another test station 10, where the process is repeated. The tray 16 continues to move to additional test stations 10, repeating the above process until all tests are completed at all test stations 10. Only when component 14 passes the test at a previous test station 10 does the tray 16 leave test station 10 to continue to the next test station 10. If component 14 fails the test at test station 10, the controller 40 sends a signal 66 to the host computer 58 to alert the manufacturer.

[0036] Once all tests have been performed at all test stations 10, tray 16 is moved to disconnect station 56. Controller 80 at connection station 54 communicates with host computer 58 via signal 82. At disconnect station 56, component 14 is disconnected from tray 16.

[0037] Any characteristic of component 14 can be tested. For example, the quality of component 14 can be tested or its functionality can be tested or checked. The following characteristics or qualities can be tested: continuity, sound, memory, thermistor, thermal current, fan current, occupant classification system, and fan noise level.

[0038] The foregoing description is merely an example of the principles of the invention. Many modifications and variations of the invention are possible in light of the above teachings. Preferred embodiments of the invention have been disclosed, but those skilled in the art will recognize that certain modifications will fall within the scope of the invention. Therefore, it is to be understood that the invention can be practiced in ways other than those specifically described within the scope of the appended claims. For this reason, the following claims should be studied to determine the true scope and content of the invention.

Claims

1. A wireless power supply system for a testing system, the wireless power supply system comprising: The transmitter associated with the assembly rail; as well as A receiver associated with a component, wherein the transmitter transmits wireless power to the receiver.

2. The wireless power supply system of claim 1, comprising a tray connected to the component, and the tray being movable relative to the mounting rail.

3. The wireless power supply system of claim 1, comprising a power source for supplying power to the transmitter, and the transmitter transmitting wireless power signals to the receiver to wirelessly power the component during testing.

4. The wireless power supply system of claim 3, wherein one of electromagnetic resonance or induction is used to wirelessly transmit power from the transmitter to the receiver.

5. The wireless power supply system of claim 1, wherein the receiver is connected to the tray via a first attachment mechanism, and the transmitter is connected to the mounting rail via a second attachment mechanism.

6. The wireless power supply system according to claim 5, wherein the first attachment mechanism and the second attachment mechanism are each threaded fasteners or screws.

7. The wireless power supply system of claim 1, comprising a connector that connects the component to the receiver, wherein power travels from the receiver to the component via the connector for testing.

8. The wireless power supply system of claim 1, comprising a controller, a display associated with the controller, and a communication module, wherein data acquired during testing is wirelessly transmitted between the communication module and the controller via a bidirectional wireless signal and displayed on the display.

9. The wireless power supply system of claim 8, wherein the communication module is associated with the tray, and a wireless data communication transceiver located between the controller and the communication module wirelessly transmits the data between the controller and the communication module.

10. The wireless power supply system of claim 8, wherein the controller sends signals to the transmitter via a wired line to control the unidirectional transmission of wireless power from the transmitter to the receiver during testing.

11. The wireless power supply system of claim 1, comprising a motor, a conveyor belt moved by the motor, a connection station, a test station, and a disconnection station, wherein a tray and the components attached to the tray move along the conveyor belt from the connection station to the test station and to the disconnection station along the production line.

12. The wireless power supply system of claim 11, comprising a host computer, wherein the test station comprises a plurality of test stations, each test station including a controller, sensors, and a display, wherein when each of the sensors detects the tray at one of the plurality of test stations, a signal is sent to the host computer to send a signal to the motor to stop the conveyor belt, so that a test can be performed, and the controller sends a signal to the transmitter to initiate the transmission of wireless power from the transmitter to the receiver to power the test.

13. The wireless power supply system of claim 12, wherein data obtained from the test at the test station is transmitted to the host computer and the controller and displayed on the display, and upon completion of the test, the host computer sends a signal to the transmitter to stop transmitting wireless power to the receiver.

14. The wireless power supply system of claim 11, wherein if the component passes the test, the host computer sends a signal to the motor to move the conveyor belt, causing the tray to leave the test station.

15. The wireless power supply system of claim 11, wherein once the test is completed at the test station, the host computer sends a signal to the motor to move the conveyor belt, causing the tray to leave the test station and move to the disconnection station, at which the component is disconnected from the tray.

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