Arc-Shaped Coil Module for AGV Wireless Charging

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Solution Overview

Problem

Current induction type power supply systems for automatic guided vehicles (AGVs) face inefficiencies in wireless charging due to positional deviations, leading to reduced charging efficiency and potential collisions with charging stations, especially in rail-less systems where precise alignment is challenging, and existing solutions are not suitable for clean room or hazardous environments.

Innovation Solution

A coil module design featuring a metal frame with a shock absorption structure, a magnetic conductor for heat dissipation, and an arc-shaped non-metallic upper lid to mitigate collisions and ensure efficient energy transfer, combined with multiple coil modules for enhanced power output capabilities, allowing for flexible and safe wireless charging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the AGV moves along adhesive tapes in a rail-less system, then the disposition cost is reduced and flexibility is improved, but the positioning accuracy deteriorates with a deviation of approximately 3 cm

Engineering Contradiction:

Improvedisposition costVSAvoidpositioning accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent changes the geometric parameters of the coil module, specifically designing an arc-shaped upper lid with a radius of curvature of 5-10 cm. This parameter change allows the coil module to accommodate positional deviations of 3 cm while maintaining effective charging distance, resolving the contradiction between rail-less flexibility and positioning accuracy.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the charging station and AGV are designed to make the two coils as close as possible when the AGV stops, then the charging efficiency is enhanced, but the collision risk increases when the AGV deviates

Engineering Contradiction:

Improvecharging efficiencyVSAvoidcollision risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies beforehand cushioning by designing the upper lid with an arc shape that protrudes toward the AGV. This arc-shaped structure acts as a cushion that absorbs collision forces when the AGV deviates from its intended position, preventing damage to the charging device while allowing the coils to remain close for efficient charging.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent employs spheroidality by designing the upper lid with an arc structure having a radius of curvature of 5-10 cm. This curved geometry allows the charging station to tolerate AGV positional deviations of approximately 3 cm without causing collision, while maintaining optimal charging distance for efficiency.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Device complexity

If an electric brush is used for charging the AGV, then the charging method is simple, but the electric brush wears rapidly and generates dust and spark

Engineering Contradiction:

Improvecharging method simplicityVSAvoiddust and spark generation

Core Design Contradiction:

Device complexityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the mechanical electric brush charging system with an induction type wireless charging system using electromagnetic induction between two coils. This substitution eliminates the harmful effects of dust and spark generation associated with mechanical contact, while maintaining charging functionality through non-contact energy transfer.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enhances charging efficiency and safety by absorbing collision forces and maintaining efficient energy transfer, even with positional deviations, while enabling flexible deployment and cost-effective power supply systems suitable for various environments.

Implementation Method 1

a preferable charging method is wireless charging using electromagnetic induction. The wireless charging method is performed with electromagnetic induction between two coils

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a magnetic conductor for heat dissipation

Methodology Applied

Scientific EffectHeat dissipation: Conduction (thermal)

Data Source

PatentUS10600547B2Induction type power supply system and coil module thereof

Publication Date: 2020.03.24 FU TONG TECH

AI summary

A coil module for an induction type power supply system includes a metal frame, a coil, a circuit board and an upper lid. The coil is disposed on a first surface of the metal frame. The circuit board, disposed on a second surface of the metal frame, includes a control circuit for controlling operations of the coil. The upper lid, for covering the coil, is composed of a non-metal material and has an arc structure.