Extremely thin AGV stacker with integrated wireless charging receiving module

Abstract

The application discloses an extremely thin AGV stacker truck integrated with a wireless charging receiving module, and belongs to the technical field of AGV wireless charging. The AGV stacker truck comprises a vehicle body and a wireless charging receiving module, and the vehicle body comprises a thin chassis frame and a lifting mechanism. The wireless charging receiving module is integrated on the inner side of the bottom of the chassis frame, and a multi-coil array receiving unit, a composite heat dissipation structure and a sectional magnetic field guiding structure are arranged in layers from top to bottom inside the wireless charging receiving module. The multi-coil array receiving unit adopts a matrix type planar coil unit with an independent resonance capacitor, the output end of the matrix type planar coil unit is sequentially connected with an intelligent switching circuit and a power synthesis circuit, the optimal coil combination can be dynamically selected, and stable direct current charging power is output through vector in-phase superposition. The structure improves the parking position fault tolerance, realizes efficient heat dissipation and low-loss charging under the constraint of an extremely thin space, and is suitable for narrow operation scenes of the extremely thin AGV.

Description

Technical Field

[0001] This invention relates to the field of AGV wireless charging technology, and in particular to an ultra-thin AGV stacker truck with an integrated wireless charging receiver module. Background Technology

[0002] Existing charging solutions for AGV stackers used in confined spaces such as warehouses and workshops are mainly divided into two major routes: contact charging and inductive wireless charging. Contact charging relies on physical connection of metal plugs to achieve power transmission, while inductive wireless charging generally adopts a single-coil integrated magnetic core receiving structure, equipped with a basic power conversion circuit with fixed resonant parameters and constant output power. It relies solely on the vehicle's metal shell for natural heat dissipation and on the AGV's own navigation system to complete charging alignment. It uses segmented logic with fixed timing to achieve battery charging control, which is currently the common charging solution for industrial mobile robots.

[0003] However, existing contact charging relies on metal contact points for conductivity. Repeated plugging and unplugging over a long period can cause contact wear and increased contact resistance. In dusty or humid industrial environments, this can easily lead to leakage and short circuit safety hazards. Furthermore, the charging docking process has extremely high requirements for vehicle parking and positioning accuracy. Conventional inductive wireless charging coils have a single arrangement, and the coils are prone to mutual magnetic field interference during operation. The heat generated by the coils and magnetic cores cannot be quickly dissipated by the shell's natural heat dissipation, which can easily form localized hot spots. The integrated molded magnetic core generates a large amount of eddy current loss under the action of an alternating magnetic field, continuously reducing the power transmission efficiency. The charging circuit's resonant parameters and output power cannot be autonomously adjusted according to the vehicle's parking position or the battery's real-time operating conditions, resulting in large fluctuations in power transmission efficiency throughout the charging process. Vehicle positioning relies solely on the native navigation system, without an independent visual calibration closed-loop mechanism. Positional errors generated by navigation directly cause a significant decrease in the coupling efficiency of the transceiver. The battery charging process uses a fixed-stage, constant power output mode, which cannot combine the battery's real-time internal resistance and temperature changes to predict the risk of temperature rise and adjust the power in advance. This results in longer overall charging time and can easily cause irreversible damage to the battery cells. Summary of the Invention

[0004] The purpose of this invention is to provide an ultra-thin AGV stacker truck with an integrated wireless charging receiver module, thereby solving the above-mentioned technical problems.

[0005] To achieve the above objectives, the present invention provides an ultra-thin AGV stacker truck with an integrated wireless charging receiver module, comprising: The vehicle body includes a chassis frame and a lifting mechanism fixedly mounted on the chassis frame. The chassis frame has a thin structure, and a motion control module electrically connected to the lifting mechanism is also arranged inside the chassis frame. The drive output end of the motion control module is also connected to an AGV walking drive mechanism. The wireless charging receiver module is integrated into the bottom inner side of the chassis frame, and its interior is arranged in layers from top to bottom, including a multi-coil array receiver unit, a composite heat dissipation structure, and a segmented magnetic field guiding structure. The multi-coil array receiving unit employs multiple planar coil units arranged in a matrix. Each coil unit is equipped with a resonant capacitor to form an independent resonant circuit, which is used to couple the alternating magnetic field of the charging transmitter and generate induced alternating current. The output terminal of the multi-coil array receiving unit is electrically connected to an intelligent switching circuit and a power combining circuit in sequence. The intelligent switching circuit is used to detect the receiving power of each coil unit in real time and dynamically select the coil combination with the best receiving efficiency. The power combining circuit is used to vector-in-phase superimpose the selected multiple induced AC currents and output stable DC charging power. The upper surface of the composite heat dissipation structure is attached to the lower surface of the multi-coil array receiving unit to conduct and dissipate the heat generated by the coil operation; The upper surface of the segmented magnetic field guiding structure is attached to the lower surface of the composite heat dissipation structure to constrain the magnetic field transmission path, reduce magnetic flux leakage, and reduce eddy current loss.

[0006] Preferably, the multi-coil array receiving unit adopts 9 groups of planar coil units arranged in a 3×3 matrix. Each group of coil units is made of a flexible PCB substrate, and the overall thickness of the coil unit does not exceed 2mm. Adjacent coil units are arranged in an interleaved manner, and the center-to-center distance of the coils is 1.2-1.5 times the outer diameter of the coil, in order to reduce mutual inductance interference between coils and expand the tolerance range of parking position.

[0007] Preferably, the intelligent switching circuit includes a power detection unit, a comparison and selection unit, and a switching control unit that are connected in sequence. The input terminal of the power detection unit is connected to the output terminal of each coil unit in a one-to-one correspondence, for real-time acquisition of the induced voltage and induced current data of each coil unit; the output terminal of the power detection unit is connected to the data input terminal of the comparison and selection unit. The comparison and selection unit is used to calculate the receiving efficiency of each coil unit based on the data collected by the power detection unit, and to select the optimal working coil combination according to efficiency priority; the output of the comparison and selection unit is connected to the drive control input of the switching control unit. The switching control unit has a built-in MOSFET switch array, and its output is connected to the input of the power combining circuit. It is used to turn on the selected coil unit and connect it to the power combining circuit, and the switching response time is less than 10ms.

[0008] Preferably, the power combining circuit adopts a vector combining architecture, including a phase detection unit, an amplitude adjustment unit, and a rectification and filtering unit that are electrically connected in sequence; The input terminal of the phase detection unit is connected to the output terminal of the switching control unit to detect the phase difference of the AC input of multiple circuits; the phase difference output terminal of the phase detection unit is connected to the control input terminal of the amplitude adjustment unit to adjust the amplitude and phase of each signal through phase feedback to achieve in-phase superposition. The amplitude adjustment unit is used to adjust the amplitude of each circuit signal to ensure that each circuit signal is superimposed in phase; the signal output terminal of the amplitude adjustment unit is connected to the AC input terminal of the rectifier and filter unit. The rectifier and filter unit uses a synchronous rectifier circuit to convert the synthesized AC power into a stable DC voltage output with a ripple voltage of less than 50mV. The output terminal of the rectifier and filter unit is connected to the vehicle battery charging terminal.

[0009] Preferably, the composite heat dissipation structure includes a thermally conductive silicone layer, a graphene thermally conductive layer, a phase change heat dissipation substrate, and structured heat dissipation fins that are tightly bonded together from top to bottom. The upper surface of the thermally conductive silicone layer is attached to the lower surface of the multi-coil array receiving unit to achieve thermal conductive contact and electrical insulation. The graphene thermal conductive layer is used to diffuse the local heat generated by the lateral diffusion coil; The phase change heat dissipation substrate has a flat heat pipe structure, which is used to achieve rapid longitudinal heat conduction through internal working fluid phase change heat transfer. The structured heat dissipation fins are integrally fixedly connected to the chassis frame to increase the heat dissipation surface area.

[0010] Preferably, the segmented magnetic field guiding structure is a high-permeability manganese-zinc ferrite sheet; the manganese-zinc ferrite sheet is arranged in multiple segments, with insulating gaps between adjacent segments to block eddy current paths and improve magnetic field guiding efficiency.

[0011] Preferably, the wireless charging receiver module further includes an adaptive impedance matching unit, which is connected to the resonant branch of each coil unit; the adaptive impedance matching unit includes a coupling coefficient detection module, an adjustable capacitor array, and a control algorithm module. The input terminal of the coupling coefficient detection module is connected to the voltage and current sampling data of the power detection unit, so as to obtain the real-time coupling coefficient through the impedance calculation of the transceiver end; The adjustable capacitor array is connected in series in the resonant branch of the corresponding coil unit to adjust the branch resonant parameters. The output of the control algorithm module is connected to the control terminal of the adjustable capacitor array. Based on the fuzzy control strategy, the value of the branch resonant capacitor is dynamically adjusted to achieve adaptive impedance matching.

[0012] Preferably, it also includes a machine vision automatic alignment component, which is mounted on the outer front end of the chassis frame; The machine vision automatic alignment component includes an ultra-thin binocular camera, a QR code recognition module, an image processing algorithm module, and a path planning algorithm module. The image data output terminal of the ultra-thin binocular camera is connected to the input terminal of the image processing algorithm module, and the output terminal of the image processing algorithm module is connected to both the QR code recognition module and the path planning algorithm module. The trajectory control output terminal of the path planning algorithm module is connected to the control input terminal of the motion control module, used to identify the position markers of the charging transmitter to calculate the relative position deviation between the AGV and the transmitting coil, and to use a fuzzy PID algorithm to control the vehicle to move to the optimal charging position.

[0013] Preferably, it also includes an adaptive load detection power adjustment component, which is connected to the control terminal of the wireless charging receiver module and the detection terminal of the vehicle battery, respectively. The adaptive load detection power adjustment component includes a battery state detection module, a load feature analysis unit, a power adjustment algorithm module, and a multi-stage charging strategy module. The multi-channel sampling input of the battery state detection module is connected to the output of the vehicle battery and the rectifier filter unit, respectively. The parameter output of the battery state detection module is connected to the load feature analysis unit and the power adjustment algorithm module, respectively. The model parameter output of the load feature analysis unit is connected to the power adjustment algorithm module. The power regulation output of the power adjustment algorithm module is connected to the control terminal of the wireless charging receiver module. The stage command output of the multi-stage charging strategy module is connected to the power adjustment algorithm module, and the charging completion signal output is connected to the motion control module. This component is used to collect battery voltage, current, temperature, and SOC parameters in real time to establish a second-order RC equivalent circuit model of the battery, dynamically adjust the charging power, and sequentially execute a multi-stage charging process of pre-charging, constant current charging, constant voltage charging, and float charging.

[0014] Preferably, a wireless charging method for an ultra-thin AGV stacker truck is characterized by comprising the following steps: S1. Based on the system power-on initialization command, the set of coil units with normal working capability is obtained by performing self-checks on / off status and resonance parameters of all coil units of the multi-coil array receiving unit. S2. Based on the alternating magnetic field generated by the charging transmitter, the power detection unit of the intelligent switching circuit collects the induced voltage and induced current of each coil unit in real time to obtain the real-time received power and coupling status data of each coil unit. S3. Based on the real-time received power and coupling status data of each coil unit, the units are selected by comparison and combined according to the priority of receiving efficiency to obtain the optimal working coil combination that is suitable for the current parking position. S4. Based on the multi-channel induced AC output of the optimal working coil combination, the phase detection unit and amplitude adjustment unit of the power synthesis circuit realize the same phase alignment of each signal, and then through vector synthesis and rectification filtering, a stable DC charging output is obtained. S5. Based on the real-time detection of the coupling coefficient between the transmitting coil and the receiving coil, the resonant parameters of each branch are dynamically adjusted by the adjustable capacitor array of the adaptive impedance matching unit to obtain the maximum transmission efficiency under impedance matching conditions. S6. Based on the multi-point temperature acquisition data of the multi-coil array receiving unit, heat is diffused and exported through the stacked heat conduction path of the composite heat dissipation structure, and the charging power is dynamically adjusted through the intelligent temperature control algorithm to obtain a safe charging condition under thermal equilibrium. S7. Based on the real-time voltage, current, temperature and SOC parameters of the vehicle battery, an equivalent circuit model of the battery is constructed through an adaptive load detection power adjustment component and matched with a multi-stage charging strategy to obtain a dynamic charging power output that adapts to the current state of the battery.

[0015] Therefore, the ultra-thin AGV stacker truck with an integrated wireless charging receiver module described above has the following advantages: 1. To address the stringent vertical space constraints of ultra-thin AGV stackers, an integrated approach is adopted, layering a multi-coil array receiving unit, a composite heat dissipation structure, and a segmented magnetic field guiding structure from top to bottom. This compresses the full-function wireless charging receiving module to an ultra-thin size, adapting to the installation requirements of a thin chassis frame. This reduces the vertical space occupied by the charging module and improves the AGV's passability and flexibility in low-profile operating scenarios. Simultaneously, relying on the chassis structure, structural support and heat dissipation paths are reused, ensuring the module's mechanical strength and heat dissipation foundation within its ultra-thin form.

[0016] 2. An independent resonant plane coil array arranged in a matrix is ​​adopted, combined with an intelligent switching circuit that enables real-time power detection, efficiency priority screening, and dynamic selection of solid-state switches. This allows for adaptive dynamic adjustment of the working coil combination. By dynamically selecting the coil combination with the best coupling effect for operation, the fault tolerance range of the AGV parking position is broadened, the requirements for AGV navigation and positioning accuracy are reduced, the charging success rate is improved, and repetitive alignment operations and manual intervention are reduced.

[0017] 3. A vector power synthesis architecture combining phase detection, amplitude adjustment and synchronous rectification is adopted to perform in-phase superposition processing on the AC output of the multi-channel selection coils, eliminating the power cancellation loss caused by the phase difference of the output signals of multiple coils, improving the overall energy utilization rate of the multi-coil collaborative operation, and at the same time, it can output stable DC power, optimize the power quality of the charging output, reduce the adverse effects of ripple on the vehicle battery, and ensure the stability and reliability of the charging process.

[0018] 4. Employing a multi-layered composite heat dissipation structure, an efficient heat conduction path is constructed within the constraints of an ultra-thin space, providing excellent high-power heat dissipation capabilities. This allows for rapid dissipation of localized heat generated during coil operation, preventing hotspot accumulation and keeping the coil's operating temperature rise within a reasonable range. Combined with an intelligent power adjustment mechanism based on temperature feedback, system thermal balance control can be achieved, extending the lifespan of electronic components and coils, and improving the safety and stability of ultra-thin modules during long-term high-power operation.

[0019] 5. Using segmented high-permeability magnetic material with insulating gaps as the magnetic field guiding structure, while constraining the magnetic field transmission path, reducing magnetic flux leakage, and improving the coupling efficiency of the transmitting and receiving coils, the segmented insulation design blocks the eddy current path, which can reduce the eddy current loss inside the magnetic material. Compared with the integral magnetic structure, it has better operating efficiency and achieves the optimal balance between magnetic field guiding effect and operating loss at an ultra-thin thickness.

[0020] 6. Each coil branch is independently configured with coupling state detection, adjustable resonant elements, and intelligent control algorithms to form a branch-level adaptive impedance matching unit. This technology can respond in real time to changes in coupling state caused by AGV position offset and load fluctuations, dynamically adjust the resonant parameters of each branch, and ensure that the system always operates in the optimal impedance matching state. This reduces power reflection and efficiency loss caused by mismatch, and improves the stability of charging efficiency and system robustness under different parking positions and battery conditions.

[0021] 7. Integrating an ultra-thin vision acquisition unit, mark recognition, contour extraction, and intelligent path planning module, a visual closed-loop alignment system is constructed for the entire charging process. Before charging, the system can calculate the relative positional deviation between the AGV and the transmitting coil through multiple recognition methods, guiding the vehicle to accurately park at the optimal charging position. At the same time, it can continuously monitor the coupling efficiency and dynamically correct the parking position during the charging process, continuously ensuring a high-efficiency coupling state and reducing the impact of the AGV's own navigation error on the charging effect.

[0022] 8. By combining multi-state parameter acquisition of the battery, equivalent circuit modeling and multi-stage charging strategy, an adaptive load detection power adjustment component is constructed. It can dynamically match the optimal charging power according to the real-time operating status of the battery and execute the complete charging process in stages. At the same time, it has temperature prediction and control capabilities, which can adjust the charging power in advance. While optimizing the charging speed and shortening the charging time, it avoids the risks of overcharging and overheating, extends the service life of the vehicle battery, and improves the intelligence level and safety performance of the charging process.

[0023] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0024] Figure 1 A structural diagram of an ultra-thin AGV stacker truck with an integrated wireless charging receiver module provided by the present invention; Figure 2 A structural block diagram of an ultra-thin AGV stacker truck with an integrated wireless charging receiver module provided by the present invention; Figure 3 The flowchart illustrates a wireless charging method for an ultra-thin AGV stacker truck with an integrated wireless charging receiver module, as provided by this invention.

[0025] Figure Labels 1. Vehicle body; 11. Chassis frame; 12. Lifting mechanism; 13. Wireless charging receiver module; 14. Machine vision automatic alignment component. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages disclosed in the embodiments of the present invention clearer, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and examples. It should be understood that the specific embodiments described herein are merely illustrative of the embodiments of the present invention and are not intended to limit the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of this application. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout.

[0027] It should be noted that the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion, such as a process, method, system, product, or server that includes a series of steps or units, not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such process, method, product, or device.

[0028] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0029] Existing conventional inductive wireless charging solutions are limited by a single-coil receiving architecture. Parking position deviation will directly lead to a decrease in coupling efficiency. The overall thickness of the receiving module is too large to adapt to the space constraints of thin vehicle bodies. At the same time, the integrated magnetic core has high eddy current losses, and natural heat dissipation methods cannot quickly dissipate the heat generated by high-power operation. The resonant parameters and output power cannot be dynamically adjusted according to the coupling state and battery condition. Charging alignment relies on the vehicle's own navigation accuracy and lacks an independent calibration mechanism. Fixed-sequence charging strategies cannot adapt to the real-time state of the battery. Overall, there are significant deficiencies in charging efficiency, operational stability, and scenario adaptability.

[0030] Based on the above analysis, this invention is designed, see appendix. Figures 1-3 An ultra-thin AGV stacker truck with an integrated wireless charging receiver module includes: The vehicle body 1 includes a chassis frame 11 and a lifting mechanism 12 fixedly mounted on the chassis frame 11. The chassis frame 11 adopts a thin structure and is made of aluminum alloy. Its overall height does not exceed 50mm, which combines lightweight and high strength characteristics, and provides mechanical support and continuous heat dissipation conduction channel for the wireless charging receiver module 13.

[0031] The wireless charging receiver module 13 is integrated into the bottom inner side of the chassis frame 11, and its interior is arranged in layers from top to bottom, including a multi-coil array receiving unit, a composite heat dissipation structure, and a segmented magnetic field guiding structure; see [link to documentation]. Figure 2 As shown, the overall thickness of the module does not exceed 3.5mm. The multi-layer structure fits tightly without gaps, shortening the heat conduction and magnetic transmission path, and is suitable for narrow vertical installation space with an ultra-thin chassis.

[0032] The multi-coil array receiver unit employs multiple planar coil units arranged in a matrix. Each coil unit is equipped with a resonant capacitor to form an independent resonant circuit, used to couple the alternating magnetic field of the charging transmitter and generate induced alternating current. The resonant operating frequency is 85kHz. Matching surface-mount ceramic capacitors are independently distributed to each coil branch. See the planar layout for details. Figure 3 As shown, a single coil can resonate independently, and the branches do not interfere with each other.

[0033] The output of the multi-coil array receiving unit is electrically connected to an intelligent switching circuit and a power combining circuit in sequence. The intelligent switching circuit is used to detect the receiving power of each coil unit in real time and dynamically select the coil combination with the best receiving efficiency. The power combining circuit is used to vector-in-phase superimpose the selected multiple induced AC currents and output stable DC charging power. The upper surface of the composite heat dissipation structure is attached to the lower surface of the multi-coil array receiving unit to conduct and dissipate the heat generated by the coil operation; The upper surface of the segmented magnetic field guiding structure is attached to the lower surface of the composite heat dissipation structure to constrain the magnetic field transmission path, reduce magnetic flux leakage, and reduce eddy current loss.

[0034] Preferably, the multi-coil array receiving unit adopts 9 groups of planar coil units arranged in a 3×3 matrix. Each group of coil units is made of a flexible PCB substrate. The substrate is made of polyimide material with a substrate thickness of 0.3mm, and the overall thickness of the coil unit does not exceed 2mm. Adjacent coil units are arranged in an interleaved manner, and the center-to-center distance of the coils is 1.2-1.5 times the outer diameter of the coils, in order to reduce mutual inductance interference between coils and expand the tolerance range of parking position.

[0035] Preferably, the intelligent switching circuit includes a power detection unit, a comparison and selection unit, and a switching control unit connected in sequence. The input terminal of the power detection unit is connected to the output terminal of each coil unit in a one-to-one correspondence, which is used to collect the induced voltage and induced current data of each coil unit in real time; equipped with high-precision operational amplifiers and Hall current sensors, the voltage and current acquisition errors are extremely low.

[0036] The comparison and selection unit is used to calculate the receiving efficiency of each coil unit based on the data collected by the power detection unit, and select the optimal working coil combination according to efficiency priority. The switching control unit incorporates a MOSFET switch array, whose output is connected to the input of the power combining circuit. This allows the selected coil unit to be switched on and connected to the power combining circuit, with a switching response time of less than 10ms. It features contactless solid-state fast switching and can dynamically adjust the working coil in real time to follow the AGV's vehicle position offset.

[0037] Preferably, the power combining circuit adopts a vector combining architecture, including a phase detection unit, an amplitude adjustment unit, and a rectifier filter unit connected in sequence; The phase detection unit is used to detect the phase difference of AC inputs to multiple circuits; the phase detection accuracy can reach ±1°.

[0038] The amplitude adjustment unit is used to adjust the amplitude of each circuit signal to ensure that each circuit signal is superimposed in phase. The rectifier and filter unit employs a synchronous rectifier circuit with a conversion efficiency of 98%, used to convert the synthesized AC power into a stable DC output with a ripple voltage of less than 50mV. This low-amplitude output ripple reduces pulse impact and lowers battery wear.

[0039] Preferably, the composite heat dissipation structure includes a thermally conductive silicone layer, a graphene thermally conductive layer, a phase change heat dissipation substrate, and structured heat dissipation fins that are tightly bonded together from top to bottom. The upper surface of the thermally conductive silicone layer is attached to the lower surface of the multi-coil array receiving unit, and the single layer thickness is 0.5mm with a thermal conductivity of 3W / m·K, which is used to achieve thermal conduction contact and electrical insulation. The graphene thermal conductive layer is used to localize the heat generated by the lateral diffusion coil; The phase change heat dissipation substrate has a flat heat pipe structure and a single layer thickness of 1.2mm, with an equivalent thermal conductivity of over 10000W / m·K. It is used to achieve rapid longitudinal heat conduction through the internal working fluid phase change heat transfer. The structured heat dissipation fins are integrally fixed to the chassis frame 11 to increase the heat dissipation surface area.

[0040] Preferably, the segmented magnetic field guiding structure is a manganese-zinc ferrite sheet with high magnetic permeability; the overall thickness is 1.5mm, the relative magnetic permeability of the substrate is above 2000, the manganese-zinc ferrite sheet is arranged in multiple segments, and an insulating gap with a width of 2mm is set between adjacent segments. The gap is filled with insulating material to block the eddy current path and improve the magnetic field guiding efficiency.

[0041] Preferably, the wireless charging receiver module 13 further includes an adaptive impedance matching unit, which is connected to the resonant branch of each coil unit. The adaptive impedance matching unit includes a coupling coefficient detection module, an adjustable capacitor array, and a control algorithm module. The coupling coefficient detection module is used to acquire the coupling coefficient between the transmitting coil and the receiving coil in real time, with a coupling coefficient detection accuracy of ±0.01. The adjustable capacitor array is used to adjust the branch resonance parameters, with a capacitance adjustment range of 10~100nF, an adjustment step of 1nF, and a single adjustment response time of less than 100μs. The control algorithm module adopts a fuzzy control strategy to dynamically adjust the capacitance value to achieve adaptive impedance matching.

[0042] Preferably, it also includes a machine vision automatic alignment component 14, which is mounted on the outer front end of the chassis frame 11. The machine vision automatic alignment component 14 includes an ultra-thin binocular camera, a QR code recognition module, an image processing algorithm module, and a path planning algorithm module. It is used to identify the position markers of the charging transmitter, calculate the relative position deviation between the AGV and the transmitting coil, and use a fuzzy PID algorithm to control the vehicle to move to the optimal charging position.

[0043] Preferably, it also includes an adaptive load detection power adjustment component, which is connected to the control terminal of the wireless charging receiver module 13 and the detection terminal of the vehicle battery, respectively. The adaptive load detection power regulation component includes a battery state detection module, a load characteristic analysis unit, a power regulation algorithm module, and a multi-stage charging strategy module. It is used to collect battery voltage, current, temperature, and SOC parameters in real time to establish a second-order RC equivalent circuit model of the battery, dynamically adjust the charging power, and sequentially execute a multi-stage charging process of pre-charging, constant current charging, constant voltage charging, and float charging.

[0044] Preferably, a wireless charging method for an ultra-thin AGV stacker truck is characterized by comprising the following steps: S1. Based on the system power-on initialization command, the on / off status and resonance parameters of all coil units of the multi-coil array receiving unit are self-checked to obtain a set of coil units with normal working capability; in order to screen out faulty coil branches in advance, ensure the stable start-up of the charging system, and avoid local failures affecting the charging of the whole machine.

[0045] S2. Based on the alternating magnetic field generated by the charging transmitter, the power detection unit of the intelligent switching circuit collects the induced voltage and induced current of each coil unit in real time, and obtains the real-time received power and coupling status data of each coil unit; the entire coil is collected synchronously, and the data is refreshed in real time without delay, providing an accurate basis for coil combination selection.

[0046] S3. Based on the real-time received power and coupling status data of each coil unit, the units are selected by comparison and combined according to the priority of receiving efficiency to obtain the optimal working coil combination that is suitable for the current parking position; to achieve stable and efficient charging in the ±50mm parking space offset scenario, and reduce the AGV navigation and positioning accuracy requirements.

[0047] S4. Based on the multi-channel induced AC output of the optimal working coil combination, the phase detection unit and amplitude adjustment unit of the power synthesis circuit realize the same phase alignment of each signal, and then through vector synthesis and rectification filtering, a stable DC charging output is obtained; so as to eliminate the power loss caused by the phase difference of the multi-channel coil and improve the conversion efficiency of AC to DC.

[0048] S5. Based on the real-time detection of the coupling coefficient between the transmitting coil and the receiving coil, the resonant parameters of each branch are dynamically adjusted through the adjustable capacitor array of the adaptive impedance matching unit to obtain the maximum transmission efficiency under impedance matching conditions; to adapt to the changes in coupling coefficient caused by parking space offset and battery load fluctuation, the optimal resonance condition is maintained throughout the process.

[0049] S6. Based on multi-point temperature acquisition data from the multi-coil array receiving unit, heat is diffused and discharged through the stacked heat conduction path of the composite heat dissipation structure, and the charging power is dynamically adjusted through the intelligent temperature control algorithm to obtain a safe charging condition under thermal equilibrium; in order to suppress the continuous temperature rise of the coil, avoid the aging of electronic components caused by high temperature, and extend the service life of the wireless charging module.

[0050] S7. Based on the real-time voltage, current, temperature, and SOC parameters of the vehicle battery, an equivalent circuit model of the battery is constructed through an adaptive load detection power adjustment component, and a multi-stage charging strategy is matched to obtain a dynamic charging power output that adapts to the current state of the battery. This shortens the overall charging time while avoiding the risks of overcharging and overheating, thus protecting the vehicle battery cells.

[0051] Embodiments of the present invention: The chassis frame 11 of the vehicle body 1 is integrally milled from high-strength aluminum alloy, with an overall height of 50mm. A recessed mounting slot with suitable depth is reserved at the bottom of the chassis. The wireless charging receiver module 13 is embedded in the slot and flush with the bottom surface of the chassis. The overall thickness of the module is 3.2mm, without adding any additional vertical height to the vehicle body 1. The system's rated operating resonant frequency is 85kHz, matching a 3kW power-level wireless charging transmitter on the ground, and is compatible with a 100Ah capacity vehicle-mounted lithium iron phosphate battery.

[0052] II. Core Unit Parameters and Working Mechanism Multi-coil array receiving unit: Employs 9 independent planar coil units arranged in a 3×3 matrix. Each coil uses a 0.3mm thick polyimide flexible PCB as its substrate, with 0.1mm thick copper foil conductors. Each coil has 12 turns, an outer diameter of 45mm, and an inner diameter of 20mm. The center-to-center distance between adjacent coils is 60mm, which is 1.33 times the outer diameter of the coil, and they are arranged in an alternating pattern to suppress mutual inductance interference between coils. Each coil unit is independently connected in series with a 68nF surface-mount ceramic resonant capacitor, forming an independent series resonant circuit. Each coil can independently couple and receive alternating magnetic field energy, and the branches do not affect each other.

[0053] Intelligent Switching and Power Combining Unit: The power detection unit of the intelligent switching circuit acquires the voltage and current data of 9 coils in real time through high-precision operational amplifiers and Hall sensors. After AD conversion, the comparison and selection unit evaluates the data based on multiple dimensions such as received power, coupling coefficient, and temperature, and uses a heuristic priority algorithm to select the optimal coil combination. The switching control unit uses a MOSFET solid-state switch array with a single-channel switching response time of ≤10ms, and connects the selected coil to the back-end power combining circuit. The power combining circuit adopts a vector combining architecture with a phase detection accuracy of ±1°. It adjusts the amplitude of each channel through a digitally controlled gain amplifier to achieve in-phase superposition. The back-end is equipped with a synchronous rectification circuit and an LC filter network, with a rectification efficiency of ≥98% and an output DC voltage ripple of ≤50mV.

[0054] Composite heat dissipation and magnetic field guiding unit: The composite heat dissipation structure consists of, from top to bottom, a 0.5mm thick thermally conductive silicone layer (thermal conductivity 3W / m·K), a 0.1mm thick graphene thermally conductive layer (thermal conductivity 800W / m·K), and a 1.2mm thick flat phase change heat pipe substrate (equivalent thermal conductivity ≥10000W / m·K). The bottom layer relies on the integrated structured heat dissipation fins of the chassis frame 11, which, after anodizing, effectively increases the heat dissipation area by 40%. The coil array is equipped with 5 distributed temperature sensors, which, together with an intelligent temperature control algorithm, achieve dynamic power adjustment. The magnetic field guiding structure uses a 1.5mm thick manganese-zinc ferrite sheet with a relative permeability ≥2000, divided into 12 independent segments. Adjacent segments have a 2mm insulation gap to block eddy current paths, reducing eddy current losses by 60% compared to the integral ferrite type.

[0055] Adaptive impedance matching unit: Each coil branch is connected to an independent adjustable capacitor array with a capacitance adjustment range of 10~100nF, a step accuracy of 1nF, and an adjustment response time of ≤100μs; the coupling coefficient detection module calculates the real-time coupling coefficient through the impedance of the transmitting and receiving ends with a detection accuracy of ±0.01; the control module adopts a fuzzy control strategy to dynamically adjust the branch capacitance value to achieve adaptive impedance matching under all operating conditions.

[0056] Machine vision alignment and load power adjustment unit: A 3mm thick ultra-thin binocular camera with a resolution of 1280×720 and a field of view of 60°×45° is installed at the front of the chassis. Dual positioning is achieved through QR code recognition and Hough transform coil contour extraction. Combined with a fuzzy PID trajectory control algorithm, static alignment accuracy reaches ±2mm, system response time ≤500ms, and closed-loop position correction is enabled throughout the charging process. The battery management unit is equipped with an adaptive load detection power adjustment component with voltage detection accuracy ±5mV, current detection accuracy ±50mA, and temperature detection accuracy ±0.5℃. Based on a second-order RC equivalent circuit model, it fits battery characteristics and executes a four-stage charging strategy: pre-charging, constant current, constant voltage, and float charging. A temperature prediction control module pre-adjusts the power.

[0057] III. Performance Test Data and Effect Analysis Under standard test conditions of 25℃ ambient temperature, 3kW transmit power, and 85kHz resonant frequency, the full performance of this embodiment was verified. The test results and effect analysis are as follows: Position tolerance effect: When the AGV stops without deviation, the overall system charging efficiency reaches 92%; when the stopping position deviation is ±50mm, the charging efficiency is still maintained above 82% through intelligent switching of the optimal coil combination and impedance matching dynamic adjustment, with an average charging efficiency of 87% across the entire deviation range and a charging success rate of ≥95%. Compared with the traditional single-coil solution, the position tolerance range is improved by 60%, solving the problem of sudden drop in charging efficiency and charging failure caused by conventional AGV navigation and positioning errors.

[0058] Heat dissipation and reliability: After one hour of continuous full-power charging, the highest temperature of the coil array is 58℃, which is 33℃ higher than the ambient temperature. Compared with the traditional natural heat dissipation solution, the heat dissipation efficiency is improved by 60%, the peak operating temperature of the module is reduced by 25℃, which can avoid the accumulation of local hot spots, ensure the stability of the module during long-term high-power operation, and extend the service life of electronic components such as coils and capacitors.

[0059] Charging efficiency and battery life: For a 100Ah vehicle battery, it takes 2.5 hours to charge from 20% SOC to 100% SOC, which is 20% shorter than the traditional fixed power charging solution; the multi-stage adaptive charging strategy combined with temperature prediction control can avoid overcharging and overheating damage, and extend the battery cycle life by 30%.

[0060] Structural adaptation effect: The total thickness of the receiving module is controlled at 3.2mm, and with the ultra-thin chassis with a total height of 50mm, it can pass smoothly through height-restricted scenarios such as the bottom of low shelves and equipment gaps that conventional AGVs cannot pass through, thus improving the vehicle's operational flexibility and scenario adaptability.

[0061] In summary, this invention, relying on the synergistic optimization of multiple technologies such as intelligent switching and vector power synthesis of multi-coil arrays at the receiving end, ultra-thin stacked full-function integration, flat phase change composite heat dissipation, segmented low-loss magnetic field guidance, branch-level adaptive impedance matching, machine vision closed-loop alignment, and multi-stage load adaptive power adjustment, can compress the thickness of the full-function wireless charging receiver module 13 to 3.2mm to adapt to ultra-thin chassis of 50mm level. It still maintains a charging efficiency of over 80% within a parking deviation range of ±50mm, while achieving a comprehensive improvement in heat dissipation efficiency, overall transmission efficiency, charging speed, and battery cycle life. This systematically solves the problems of easy wear of contact charging contacts, poor environmental adaptability and high alignment accuracy requirements in existing technologies, the large module thickness of traditional wireless charging solutions making it difficult to adapt to thin vehicle bodies 1, poor positional fault tolerance of single-coil architecture, high eddy current loss of integrated magnetic core, insufficient natural heat dissipation capacity, inability to dynamically adjust resonance parameters and output power according to operating conditions, and rigid charging strategies that make it difficult to balance charging efficiency and battery life.

[0062] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. A thin AGV stacker truck with an integrated wireless charging receiver module, characterized in that, include: The vehicle body includes a chassis frame and a lifting mechanism fixedly mounted on the chassis frame. The chassis frame has a thin structure, and a motion control module electrically connected to the lifting mechanism is also arranged inside the chassis frame. The drive output end of the motion control module is also connected to an AGV walking drive mechanism. The wireless charging receiver module is integrated into the bottom inner side of the chassis frame, and its interior is arranged in layers from top to bottom, including a multi-coil array receiver unit, a composite heat dissipation structure, and a segmented magnetic field guiding structure. The multi-coil array receiving unit employs multiple planar coil units arranged in a matrix. Each coil unit is equipped with a resonant capacitor to form an independent resonant circuit, which is used to couple the alternating magnetic field of the charging transmitter and generate induced alternating current. The output terminal of the multi-coil array receiving unit is electrically connected to an intelligent switching circuit and a power combining circuit in sequence. The intelligent switching circuit is used to detect the receiving power of each coil unit in real time and dynamically select the coil combination with the best receiving efficiency. The power combining circuit is used to vector-in-phase superimpose the selected multiple induced AC currents and output stable DC charging power. The upper surface of the composite heat dissipation structure is attached to the lower surface of the multi-coil array receiving unit to conduct and dissipate the heat generated by the coil operation. The upper surface of the segmented magnetic field guiding structure is attached to the lower surface of the composite heat dissipation structure to constrain the magnetic field transmission path, reduce magnetic flux leakage, and reduce eddy current loss.

2. The ultra-thin AGV stacker truck with integrated wireless charging receiver module according to claim 1, characterized in that: The multi-coil array receiving unit uses 9 groups of planar coil units arranged in a 3×3 matrix. Each group of coil units is made of a flexible PCB substrate, and the overall thickness of the coil unit does not exceed 2mm. Adjacent coil units are arranged in an alternating manner, and the center-to-center distance between the coils is 1.2-1.5 times the outer diameter of the coil, in order to reduce mutual inductance interference between coils and expand the tolerance range of parking position.

3. The ultra-thin AGV stacker truck with integrated wireless charging receiver module according to claim 1, characterized in that: The intelligent switching circuit includes a power detection unit, a comparison and selection unit, and a switching control unit connected in sequence by signals. The input terminal of the power detection unit is connected to the output terminal of each coil unit in a one-to-one correspondence, for real-time acquisition of the induced voltage and induced current data of each coil unit; the output terminal of the power detection unit is connected to the data input terminal of the comparison and selection unit. The comparison and selection unit is used to calculate the receiving efficiency of each coil unit based on the data collected by the power detection unit, and to select the optimal working coil combination according to efficiency priority; the output of the comparison and selection unit is connected to the drive control input of the switching control unit. The switching control unit has a built-in MOSFET switch array, and its output is connected to the input of the power combining circuit. It is used to turn on the selected coil unit and connect it to the power combining circuit, and the switching response time is less than 10ms.

4. The ultra-thin AGV stacker truck with integrated wireless charging receiver module according to claim 3, characterized in that: The power combining circuit adopts a vector combining architecture, including a phase detection unit, an amplitude adjustment unit, and a rectification and filtering unit that are electrically connected in sequence. The input terminal of the phase detection unit is connected to the output terminal of the switching control unit to detect the phase difference of the AC input of multiple circuits; the phase difference output terminal of the phase detection unit is connected to the control input terminal of the amplitude adjustment unit to adjust the amplitude and phase of each signal through phase feedback to achieve in-phase superposition. The amplitude adjustment unit is used to adjust the amplitude of each circuit signal to ensure that each circuit signal is superimposed in phase; the signal output terminal of the amplitude adjustment unit is connected to the AC input terminal of the rectifier and filter unit. The rectifier and filter unit uses a synchronous rectifier circuit to convert the synthesized AC power into a stable DC voltage output with a ripple voltage of less than 50mV; the output terminal of the rectifier and filter unit is connected to the vehicle battery charging terminal.

5. The ultra-thin AGV stacker truck with integrated wireless charging receiver module according to claim 4, characterized in that: The composite heat dissipation structure includes, from top to bottom, a thermally conductive silicone layer, a graphene thermally conductive layer, a phase change heat dissipation substrate, and structured heat dissipation fins that are tightly bonded together. The upper surface of the thermally conductive silicone layer is attached to the lower surface of the multi-coil array receiving unit to achieve thermal conductive contact and electrical insulation. The graphene thermal conductive layer is used to diffuse the local heat generated by the transverse diffusion coil; The phase change heat dissipation substrate has a flat heat pipe structure, which is used to achieve rapid longitudinal heat conduction through internal working fluid phase change heat transfer. The structured heat dissipation fins are integrally fixedly connected to the chassis frame to increase the heat dissipation surface area.

6. The ultra-thin AGV stacker truck with integrated wireless charging receiver module according to claim 5, characterized in that: The segmented magnetic field guiding structure is a high-permeability manganese-zinc ferrite sheet; the manganese-zinc ferrite sheet is arranged in multiple segments, with insulating gaps between adjacent segments to block eddy current paths and improve magnetic field guiding efficiency.

7. The ultra-thin AGV stacker truck with integrated wireless charging receiver module according to claim 6, characterized in that: The wireless charging receiver module further includes an adaptive impedance matching unit, which is connected to the resonant branch of each coil unit; the adaptive impedance matching unit includes a coupling coefficient detection module, an adjustable capacitor array, and a control algorithm module. The input terminal of the coupling coefficient detection module is connected to the voltage and current sampling data of the power detection unit, so as to obtain the real-time coupling coefficient through the impedance calculation of the transceiver end; The adjustable capacitor array is connected in series in the resonant branch of the corresponding coil unit to adjust the branch resonant parameters; The output of the control algorithm module is connected to the control terminal of the adjustable capacitor array, and the branch resonant capacitor value is dynamically adjusted based on the fuzzy control strategy to achieve adaptive impedance matching.

8. The ultra-thin AGV stacker truck with integrated wireless charging receiver module according to claim 7, characterized in that: It also includes a machine vision automatic alignment component, which is mounted on the outer front end of the chassis frame; The machine vision automatic alignment component includes an ultra-thin binocular camera, a QR code recognition module, an image processing algorithm module, and a path planning algorithm module. The image data output terminal of the ultra-thin binocular camera is connected to the input terminal of the image processing algorithm module, and the output terminal of the image processing algorithm module is connected to both the QR code recognition module and the path planning algorithm module. The trajectory control output terminal of the path planning algorithm module is connected to the control input terminal of the motion control module, used to identify the position markers of the charging transmitter to calculate the relative position deviation between the AGV and the transmitting coil, and to use a fuzzy PID algorithm to control the vehicle to move to the optimal charging position.

9. The ultra-thin AGV stacker truck with integrated wireless charging receiver module according to claim 8, characterized in that: It also includes an adaptive load detection power adjustment component, which is connected to the control terminal of the wireless charging receiver module and the detection terminal of the vehicle battery, respectively. The adaptive load detection power adjustment component includes a battery state detection module, a load feature analysis unit, a power adjustment algorithm module, and a multi-stage charging strategy module. The multi-channel sampling input of the battery state detection module is connected to the output of the vehicle battery and the rectifier filter unit, respectively. The parameter output of the battery state detection module is connected to the load feature analysis unit and the power adjustment algorithm module, respectively. The model parameter output of the load feature analysis unit is connected to the power adjustment algorithm module. The power regulation output of the power adjustment algorithm module is connected to the control terminal of the wireless charging receiver module. The stage command output of the multi-stage charging strategy module is connected to the power adjustment algorithm module, and the charging completion signal output is connected to the motion control module. This component is used to collect battery voltage, current, temperature, and SOC parameters in real time to establish a second-order RC equivalent circuit model of the battery, dynamically adjust the charging power, and sequentially execute a multi-stage charging process of pre-charging, constant current charging, constant voltage charging, and float charging.

10. A thin AGV stacker truck with an integrated wireless charging receiver module according to any one of claims 1-9, characterized in that: The wireless charging method applied to the aforementioned ultra-thin AGV stacker vehicle includes the following steps: S1. Based on the system power-on initialization command, the set of coil units with normal working capability is obtained by performing self-checks on / off status and resonance parameters of all coil units of the multi-coil array receiving unit. S2. Based on the alternating magnetic field generated by the charging transmitter, the power detection unit of the intelligent switching circuit collects the induced voltage and induced current of each coil unit in real time to obtain the real-time received power and coupling status data of each coil unit. S3. Based on the real-time received power and coupling status data of each coil unit, the units are selected by comparison and combined according to the priority of receiving efficiency to obtain the optimal working coil combination that is suitable for the current parking position. S4. Based on the multi-channel induced AC output of the optimal working coil combination, the phase detection unit and amplitude adjustment unit of the power synthesis circuit realize the same phase alignment of each signal, and then through vector synthesis and rectification filtering, a stable DC charging output is obtained. S5. Based on the real-time detection of the coupling coefficient between the transmitting coil and the receiving coil, the resonant parameters of each branch are dynamically adjusted by the adjustable capacitor array of the adaptive impedance matching unit to obtain the maximum transmission efficiency under impedance matching conditions. S6. Based on the multi-point temperature acquisition data of the multi-coil array receiving unit, heat is diffused and exported through the stacked heat conduction path of the composite heat dissipation structure, and the charging power is dynamically adjusted through the intelligent temperature control algorithm to obtain a safe charging condition under thermal equilibrium. S7. Based on the real-time voltage, current, temperature and SOC parameters of the vehicle battery, an equivalent circuit model of the battery is constructed through an adaptive load detection power adjustment component and matched with a multi-stage charging strategy to obtain a dynamic charging power output that adapts to the current state of the battery.

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