Non-contact sliding contact annular power supply system

Abstract

The utility model relates to the technical field of power transmission, in particular to a non-contact sliding contact annular power supply system, which comprises an annular power supply guide rail assembly, a mobile power receiving device and an intelligent control system, and realizes 360-degree non-breakpoint power supply through cooperative work of sinusoidal waveform continuous conductor layout and a multi-coupling module. By adopting the composite shielding layer and frequency optimization design, the electromagnetic radiation intensity is lower than the national standard limit value. The system has the functions of high efficiency, long service life and intelligent power regulation, and can be widely applied to the field of industrial automation.

Description

TECHNICAL FIELD

[0001] The utility model relates to power transmission technical field, concretely is no contact slide contact ring power supply system. BACKGROUND

[0002] Traditional slide contact line power supply system is a kind of power transmission mode widely used in electric transport equipment, crane, automated production line and other occasions. This system realizes power transmission through the sliding contact between slide contact line (also called conductor rail) and current collector (or called slider, current receiver). The following is a detailed introduction about traditional slide contact line power supply system:

[0003] System composition: slide contact line: usually made of copper or aluminum, installed on the running track of equipment or nearby. Slide contact line can be single pole or multi-pole, used for transmission of alternating current or direct current. Current collector: installed on mobile equipment, usually made of conductive material (such as carbon brush or copper alloy), can maintain stable contact with slide contact line, ensure the continuity of power transmission. Support and insulating part: used for fixing slide contact line and ensuring its insulation with ground or other conductive parts. Power connection device: connect slide contact line system with external power supply, usually including circuit breaker, fuse and other protection devices;

[0004] Working principle: when mobile equipment (such as crane, electric trolley) runs, current collector slides along slide contact line, obtains electric energy from slide contact line through sliding contact, thereby providing power for equipment. Slide contact line system is usually designed for continuous power supply to ensure that equipment will not be powered off during operation.

[0005] Through the analysis of traditional slide contact line power supply system, it is found that there are the following technical pain points:

[0006] Mechanical wear causes short service life and high maintenance cost; contact spark causes safety hazard; environmental dust / moisture easily causes short circuit fault. Existing non-contact power supply technology (such as segmented electromagnetic induction) faces the following problems in ring scene: discrete coil layout causes power supply blind area; power fluctuation is large under dynamic load; electromagnetic radiation interferes with surrounding equipment.

[0007] Therefore, in view of the above problems, the technical scheme provides a non-contact slide contact ring power supply system. SUMMARY

[0008] The utility model aims at providing non-contact slide contact ring power supply system to solve the problems raised in the above background technology.

[0009] To achieve the above purpose, the utility model provides the following technical scheme:

[0010] Non-contact slide contact ring power supply system, including ring power supply rail assembly, mobile current receiving device, intelligent control system;

[0011] The annular power supply rail assembly comprises an insulating base body, which is made of a high-temperature-resistant engineering plastic into an annular track, and a continuous spiral power supply conductor embedded in the annular track;

[0012] The mobile power receiving device comprises a coupling module, a rectification and voltage stabilization module and a signal transmission unit; the coupling module comprises three groups of U-shaped magnetic cores distributed at 120 degrees, each group of U-shaped magnetic cores is wound with a high-frequency Leidy wire coil, the rectification and voltage stabilization module integrates a full-bridge rectification circuit and a DC-DC converter, and the output voltage fluctuation rate is less than ±5%; the signal transmission unit realizes bidirectional communication between the annular power supply rail assembly and the power receiving device by loading a 2.4 GHz carrier wave.

[0013] The intelligent control system comprises a dynamic detection module, a power adjustment module and a fault isolation unit; the dynamic detection module monitors the position of the power receiving device in real time based on a Hall sensor, and adjusts the activation state of the corresponding power supply section; the power adjustment module dynamically adjusts the power supply frequency and current intensity according to the load demand.

[0014] Preferably, the power supply conductor is continuously arranged in a sinusoidal wave form by a plurality of copper alloy foil pieces, and the distance between adjacent wave crests is 50-100 mm.

[0015] Preferably, the power supply conductor is provided with an electromagnetic shielding layer, and the electromagnetic shielding layer comprises a conductive rubber layer arranged on the outer layer of the power supply conductor and a nanocrystalline alloy sheet arranged on the inner layer.

[0016] Preferably, the distance between the open end of the U-shaped magnetic core and the annular track is 1-3 mm.

[0017] Preferably, the electromagnetic shielding layer is provided with a double-layer structure, and the total thickness is ≤2 mm.

[0018] Preferably, the amplitude of the sinusoidal wave form is 1.2-1.5 times the width of the power supply conductor.

[0019] Preferably, a permalloy magnetic separation sheet is additionally arranged at the bottom of the U-shaped magnetic core.

[0020] Compared with the prior art, the utility model has the beneficial effects that: through the continuous spiral arrangement of the sinusoidal wave conductor and the spatial collaborative design of the multiple coupling modules, the system realizes 360° uninterrupted energy transmission, completely eliminates the blind area problem of the traditional segmented power supply, and ensures that the mobile device can stably take power at any position on the annular track.

[0021] The system significantly improves the energy transmission efficiency by adopting the optimized magnetic field distribution design and the multi-channel coupling mechanism, has obvious advantages over the traditional contact type slide wire scheme, and reduces the temperature rise and energy loss during operation.

[0022] The contactless energy transmission avoids mechanical wear and contact spark, greatly prolongs the service life of the system, and reduces the maintenance frequency and failure rate, and is particularly suitable for high-load and long-time running industrial scenes;

[0023] Through the composite electromagnetic shielding layer and the frequency optimization design, the system effectively suppresses electromagnetic radiation, reduces the interference on external equipment, and enhances the ability to resist environmental interference (such as dust and humidity).

[0024] The introduction of the dynamic detection and power regulation module enables the system to respond to load changes in real time, automatically adjust the power supply parameters, ensure the stability of the output voltage and current, and support load balancing when multiple devices are running cooperatively. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 is a schematic view of the structure of the insulating base in the contactless sliding contact ring power supply system;

[0026] Figure 2 is a schematic view of the local structure of the power supply conductor in the contactless sliding contact ring power supply system;

[0027] Figure 3 is Figure 2 is a schematic view of the enlarged structure of A;

[0028] Wherein: the insulating base 10, the power supply conductor 11, the electromagnetic shielding layer 12, the conductive rubber layer 13, the nanocrystalline alloy sheet 14, the U-shaped magnetic core 15, and the high-frequency Leizhi wire coil 16. DETAILED DESCRIPTION

[0029] It should be noted that the embodiments in the utility model and the features in the embodiments can be combined with each other without conflict.

[0030] In the description of the utility model, it should be understood that the orientation or position relationship indicated by the terms "center", "longitudinal", "transverse", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like is based on the orientation or position relationship shown in the drawings, and is only for the convenience of describing the utility model and simplifying the description, and therefore cannot be understood as indicating or implying that the devices or elements indicated must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the utility model. In addition, the terms "first", "second" and the like are only for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features limited by "first", "second" and the like can explicitly or implicitly include one or more features. In the description of the utility model, unless otherwise stated, the meaning of "multiple" is two or more.

[0031] In the description of the utility model, it is to explain, unless otherwise definite and limited, the term "installation", "link", "connection" should be broad sense understanding, for example, can be fixed connection, also can be detachable connection, or integrally connected;Can be mechanical connection, also can be electrical connection;Can be directly connected, also can be indirectly connected through the intermediate medium, can be the communication inside two elements.For the ordinary skilled in the art, the above-mentioned terms can be understood by the specific meaning in the utility model through specific circumstances.

[0032] The utility model will be described in detail below with reference to the drawings and in combination with embodiments.

[0033] Please refer to Figures 1-3 The non-contact sliding contact ring power supply system comprises a ring power supply rail assembly, a mobile power receiving device and an intelligent control system.

[0034] The ring power supply rail assembly comprises an insulating base body 10, which is made of a high-temperature-resistant engineering plastic into a ring track, and a continuous spiral power supply conductor 11 is embedded in the ring track, the power supply conductor 11 is continuously arranged in a sinusoidal wave shape by a plurality of copper alloy foil sheets, the distance between adjacent wave crests is 50-100 mm, and an electromagnetic shielding layer 12 is arranged on the surface of the power supply conductor 11, the electromagnetic shielding layer 12 comprises a conductive rubber layer 13 arranged on the outer layer of the power supply conductor 11 and a nanocrystalline alloy sheet 14 arranged on the inner layer.

[0035] The mobile power receiving device comprises a coupling module, a rectification and voltage stabilization module and a signal transmission unit, the coupling module comprises three groups of U-shaped magnetic cores 15 distributed at an angle of 120°, each group of U-shaped magnetic cores 15 is wound with a high-frequency Leitz wire coil 16, and the distance between the open end of the U-shaped magnetic core 15 and the ring track is 1 mm-3 mm, the rectification and voltage stabilization module integrates a full-bridge rectification circuit and a DC-DC converter, and the output voltage fluctuation rate is less than ±5%, and the signal transmission unit realizes bidirectional communication between the ring power supply rail assembly and the power receiving device by loading a 2.4 GHz carrier wave.

[0036] The intelligent control system comprises a dynamic detection module, a power adjustment module and a fault isolation unit, the dynamic detection module monitors the position of the power receiving device in real time based on a Hall sensor, adjusts the activation state of the corresponding power supply section, the power adjustment module dynamically adjusts the power supply frequency (20-100 kHz) and the current intensity according to the load demand, and the fault isolation unit cuts off the power supply of the fault area within 10 ms when detecting local short circuit.

[0037] In the embodiment of the application, the electromagnetic shielding 12 is provided with an inner and outer double-layer structure, and the total thickness is ≤2 mm.

[0038] Among them, in the idle state of the system, all the driving elements, including power elements, electrical components, and compatible power supplies, are connected through wires. The sequence of electrical components is completed by connecting them in order. The detailed connection method is a well-known technology in the field. The following mainly introduces the working principle and process, and does not explain the electrical control.

[0039] The system goes through the following stages when it is running: (1) initial power supply stage;

[0040] 380V AC power is passed into the power supply conductor 11, generating a continuous alternating magnetic field (frequency preset at 65kHz) around the power supply conductor 11. Then the inner layer of nanocrystalline alloy sheet 14 guides the magnetic field to the power receiving side by magnetic domain orientation technology, and the outer layer of conductive rubber layer 13 absorbs the residual radiation, reducing the magnetic field strength outside 1m to 8μT. The Hall sensor array scans the circumference of the rail in real time with a resolution of 0.1mm, establishing a coordinate system mapping (each 10° is divided into a power supply subzone).

[0041] Mobile power receiving stage;

[0042] When the mobile power receiving device moves to a certain position of the ring-shaped rail (such as the mechanical arm running to 45° orientation), the nearest U-shaped magnetic core 13 (1.5mm from the rail) generates the main coupling channel, with a magnetic flux Φ1=0.45mWb. At this time, the other two groups of U-shaped magnetic cores 13 form auxiliary coupling channels, with magnetic fluxes Φ2=Φ3=0.12mWb.

[0043] The total coupling coefficient k after the superposition of the three channels is 0.93 (calculation formula: k=√(Φ1²+Φ2²+Φ3²) / Φ2+Φ3).

[0044] k: coupling coefficient, representing the efficiency of energy transmission, with a value range of 0 to 1. The higher the coupling coefficient, the higher the energy transmission efficiency.

[0045] When k = 1, it represents complete coupling in an ideal state (no energy loss).

[0046] When k = 0, it represents no coupling (no energy transmission).

[0047] Φ1, Φ2, Φ3: magnetic fluxes of the three coupling modules (units: Weber, Wb).

[0048] The magnetic field coupling between each U-shaped magnetic core and the power supply rail produces corresponding magnetic flux.

[0049] Φ1 is the magnetic flux of the main coupling channel (usually the largest), and Φ2 and Φ3 are the magnetic fluxes of the auxiliary coupling channels.

[0050] Φ_total: represents the total magnetic flux (unit: Weber, Wb), which is the vector sum of the magnetic flux of the three coupling modules.

[0051] Due to the difference in magnetic field direction, the total magnetic flux needs to be calculated by vector superposition.

[0052] √(Φ1² + Φ2² + Φ3²): represents the root mean square (RMS) value of the magnetic flux of the three coupling modules, used to comprehensively evaluate the overall effect of multi-channel coupling;

[0053] Then the power regulation module increases the supply frequency from 65kHz to 82kHz within 50ms according to the load current change feedback by the Hall sensor (such as sudden acceleration of the robot arm causing a 30% increase in current demand), and simultaneously increases the conductor current to 115% of the preset value, maintaining the output voltage fluctuation <±3% through the PID algorithm.

[0054] (3) Continuous movement phase

[0055] When the moving power receiving device moves at a linear speed of 3m / s, the control system updates the position coordinates every 5ms,

[0056] Activate the conductor segment in the front 30° sector in advance (pre-activation time Δt=10ms), and turn off the power supply in the rear area that has passed, reducing the invalid radiation by 62%;

[0057] Multi-module linkage: the signal transmission unit sends the device ID code (2.4GHz frequency band, bandwidth 2MHz),

[0058] After the ring track side receiver verifies the authority, it authorizes the energy transmission of the specific power supply partition, and the rectifier and stabilizer module switches the working mode (constant voltage / constant current) synchronously to match the device requirements.

[0059] (4) Abnormal processing phase

[0060] When a local short circuit is caused by a metal foreign object falling on a section of the ring track, the current mutation detection circuit of the fault isolation unit identifies the abnormality within 2ms (current change rate >500A / μs), immediately cuts off the MOSFET switch tube of the corresponding 60° sector (turn-off time <8μs), and synchronously activates the redundant power supply line of the adjacent section to ensure continuous power supply for the device;

[0061] When the temperature sensor detects that the conductor temperature rises above 40℃, the power regulation module automatically reduces the current density to the safety threshold (J<3A / mm²), and forcibly opens the standby cooling air duct for forced convection cooling.

[0062] Energy efficiency optimization mechanism

[0063] Space magnetic field reconstruction: based on the finite element analysis of the magnetic field optimization algorithm, when multiple devices are detected to take power at the same time, the phase angle of each power supply partition is automatically adjusted, the magnetic field of adjacent conductor segments forms constructive superposition, and the overall efficiency is improved by ≥7%;

[0064] Standby energy-saving mode: when no device takes power, the power supply frequency is automatically reduced to 20 kHz to maintain the basic magnetic field

[0065] Power consumption is reduced from 3 kW to 320 W (energy saving 89%).

[0066] As a preferred embodiment of the present application, the amplitude of the sinusoidal waveform is 1.2-1.5 times the width of the power supply conductor 11, which ensures uniform distribution of the magnetic field.

[0067] As a preferred embodiment of the present application, the U-shaped magnetic core 13 is additionally provided with a permalloy magnetic isolation sheet at the bottom, so that the magnetic leakage rate is reduced to below 5%.

[0068] As a preferred embodiment of the present application, the system operating frequency is set to 65 kHz to avoid common device sensitive frequency bands.

[0069] The preferred embodiments of the present application are described in detail above, but the present application is not limited to the above embodiments, and various changes can be made within the knowledge of those skilled in the art without departing from the spirit of the present application.

Claims

1. A contactless sliding ring power supply system, characterized in that, Includes a ring-shaped power supply rail assembly, a mobile power receiving device, and an intelligent control system; The ring power supply rail assembly includes an insulating substrate (10), which is made of high-temperature resistant engineering plastic to form a ring rail, and has a continuous spiral power supply conductor (11) embedded inside. The mobile power receiving device includes a coupling module, a rectification and voltage regulation module, and a signal transmission unit; the coupling module includes three sets of U-shaped magnetic cores (15) distributed at 120°, each set of U-shaped magnetic cores (15) is wound with a high-frequency Litz wire coil (16); the rectification and voltage regulation module integrates a full-bridge rectifier circuit and a DC-DC converter, and the output voltage fluctuation rate is <±5%; the signal transmission unit realizes bidirectional communication between the ring power supply rail assembly and the power receiving device by loading a 2.4GHz carrier wave; The intelligent control system includes a dynamic detection module, a power regulation module, and a fault isolation unit. The dynamic detection module monitors the location of the powered device in real time based on Hall sensors and adjusts the activation state of the corresponding power supply segment. The power regulation module dynamically adjusts the power supply frequency and current intensity according to the load demand.

2. The contactless sliding ring power supply system according to claim 1, characterized in that, The power supply conductor (11) is composed of multiple sets of copper alloy foils arranged in a continuous sinusoidal waveform, with a spacing of 50-100mm between adjacent peaks.

3. The contactless sliding ring power supply system according to claim 1, characterized in that, The surface of the power supply conductor (11) is provided with an electromagnetic shielding layer (12), which includes a conductive rubber layer (13) on the outer layer of the power supply conductor (11) and a nanocrystalline alloy sheet (14) on the inner layer.

4. The contactless sliding ring power supply system according to claim 2, characterized in that, The distance between the open end of the U-shaped magnetic core (15) and the annular track is set at 1mm-3mm.

5. The contactless sliding ring power supply system according to claim 3, characterized in that, The electromagnetic shielding layer (12) has an inner and outer double-layer structure with a total thickness of ≤2mm.

6. The contactless sliding ring power supply system according to claim 2, characterized in that, The amplitude of the sinusoidal waveform is 1.2-1.5 times the width of the power supply conductor (11).

7. The contactless sliding ring power supply system according to claim 6, characterized in that, A permalloy magnetic shielding sheet is added to the bottom of the U-shaped magnetic core (13).

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