Bearing-Integrated Wireless Power Transfer With Alignment Tolerance

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Solution Overview

Problem

Existing wireless power transfer systems face limitations in range and alignment requirements, particularly in magnetic and electric induction systems, with inefficiencies in power transfer due to tight coupling and alignment issues.

Innovation Solution

A bearing is designed with a wireless power transfer system enclosed between inner and outer races, featuring a transmitter and receiver coils positioned radially adjacent to the races, with shields to focus magnetic fields and improve efficiency, and a ferrite-less coil design to enhance robustness and alignment tolerance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If magnetic induction systems use tightly coupled coils with coupling factor above 0.5, then power transfer efficiency is improved, but alignment requirements become stringent and range is limited

Engineering Contradiction:

Improvepower transfer efficiencyVSAvoidalignment tolerance

Core Design Contradiction:

Loss of energyVSAdaptability or versatility

Solution Approach 1:

The patent changes the fundamental parameter of power transfer from magnetic field coupling to electric field coupling. By using capacitive electrodes instead of magnetic coils and operating in the electric domain, the system achieves loose coupling with coupling factor below 0.5 while maintaining high efficiency and extended range, thereby resolving the contradiction between efficiency and alignment tolerance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent substitutes the magnetic induction mechanism with electric induction mechanism. By replacing magnetic coils and magnetic field coupling with capacitive electrodes and electric field coupling, the system eliminates the stringent alignment requirements inherent in magnetic systems while achieving efficient power transfer over extended ranges

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If resonant magnetic systems use loosely coupled inductors with coupling factor below 0.5, then alignment issues are rectified and range is increased, but system complexity increases due to capacitor requirements

Engineering Contradiction:

Improvealignment toleranceVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the capacitor components from the resonant power transfer system. By operating in the electric domain with capacitive electrodes, the system achieves resonant coupling without requiring additional capacitor elements, thereby simplifying the overall system architecture while maintaining loose coupling benefits

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent substitutes the resonant magnetic system requiring capacitors with a resonant electric system using capacitive electrodes. This substitution eliminates the need for separate capacitor components and their associated complexity while achieving the desired loose coupling and extended range

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Volume of stationary object

If wireless power transfer system is enclosed between bearing races, then power transfer occurs within limited volume, but alignment maintenance during rotation becomes challenging

Engineering Contradiction:

Improvepower transfer volumeVSAvoidalignment stability

Core Design Contradiction:

Volume of stationary objectVSReliability

Solution Approach 1:

The patent substitutes magnetic field-based power transfer with electric field-based power transfer using capacitive electrodes. The electric field configuration between the capacitive transmitter and receiver electrodes maintains stable coupling during rotation, eliminating the alignment instability problems encountered in magnetic systems while operating within the confined bearing volume

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 enables efficient wireless power transfer within the bearing, even during rotation, with improved alignment tolerance and reduced heat loss, enhancing reliability and efficiency compared to conventional systems.

Implementation Method 1

the transmitter has a transmitter coil with a certain inductance that transfers electrical energy from the power source to the receiver, which has a receiver coil with a certain inductance. Power transfer occurs due to coupling of magnetic fields between the coils or inductors of the transmitter and receiver

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

Power transfer occurs due to coupling of magnetic fields between the coils or inductors of the transmitter and receiver

Methodology Applied

Scientific EffectMagnetic field coupling: Magnetic Field

Data Source

PatentUS20250286407A1Wireless power transfer in a bearing

Publication Date: 2025.09.11 SOLACE POWER INC

AI summary

There is provided a bearing comprising an inner race, an outer race and one or more roller elements positioned radially between the inner and outer races. The bearing further comprises a wireless power transfer system affixed to or integrally formed with the at least one of the races.