Independent Cart Track Coil Layout for In-Line Wireless Power
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Solution Overview
Problem
In independent cart technology (ICT) systems, providing a portable energy source for actuators and sensors on movers is cumbersome due to weight and space constraints, and existing wireless energy transfer solutions may not be desirable for all applications.
Innovation Solution
A track assembly with drive coils for propulsion and an energy transfer coil for wireless power transmission, allowing movers to receive electrical energy through mutual inductance, enabling optional wireless energy transfer without modifying the standard ICT system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a portable energy source such as a battery is provided on the mover, then the actuator or sensor can operate independently, but the mover adds weight and takes up space
Solution Approach 1:
The energy source is extracted from the mover and placed in the stationary track. The track now contains the battery and wireless power transmission components, while the mover only carries a lightweight pick-up coil to receive power wirelessly, eliminating the need for heavy batteries on the moving component.
Solution Approach 2:
A wireless power transmission system using electromagnetic fields serves as an intermediary between the stationary energy source in the track and the moving energy consumer on the mover. This allows energy transfer without physical connection or portable energy storage on the mover.
2Duration of action of moving object
If a dedicated location along the track is provided for recharging, then the portable energy source can be recharged, but the mover must stop and wait for recharging
Solution Approach 1:
The wireless power transmission system enables continuous power transfer as the mover passes through the track section with the energy transfer coil. The mover does not need to stop or pause operation, maintaining continuous useful action while receiving power wirelessly during motion.
Solution Approach 2:
Energy is transferred to the mover in advance during its passage through the track section, storing power in the mover's energy storage device before it is needed for subsequent operation. This preliminary energy loading eliminates the need for later recharging stops.
3Device complexity
If drive coils are integrated for both propulsion and wireless energy transfer, then system complexity is reduced, but wireless transfer is not available for applications where it is not required
Solution Approach 1:
The track is segmented into distinct sections: drive coil sections for propulsion and an energy transfer section with the energy transfer coil. This segmentation allows the system to provide wireless power transfer only where needed, maintaining standard drive coil sections elsewhere, thus balancing complexity reduction with adaptability to different application requirements.
Solution Approach 2:
The system maintains universal applicability by keeping the majority of the track as standard drive coil sections that work with conventional movers, while adding an optional energy transfer section that provides wireless power capability where required. This multi-functional design allows the same track infrastructure to serve both propulsion and power transfer functions.
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
This solution provides a compact, low-cost, and flexible method for wireless energy transfer in ICT systems, reducing the need for portable energy sources and allowing for seamless integration with existing ICT systems, while minimizing track width and maintaining process efficiency.
Implementation Method 1
The second track portion includes an energy transfer circuit providing current to the energy transfer coil to transfer electrical energy through mutual inductance to pick-up coils of the movers
Implementation Method 2
The first and second track portions include respective current drive circuits providing current to respective drive coils to generate electromagnetic fields which engage mover drive members to propel each mover along the track
Data Source
AI summary
An independent cart system provides a track assembly having a first, second, and third portion with the first and second portions providing drive coils mounted along the length of the track and flanking the second portion devoid of drive coils, the second portion providing an energy transfer coil. A plurality of movers operative to travel along the track, and have a drive member and a pick-up coil mounted for electrical interaction with the energy transfer coil when a given mover is aligned with a given second track portion. The first and second track portions include current drive circuits providing current to respective drive coils to generate electromagnetic fields which engages mover drive members to propel each movers along the track and the second track portion includes an energy transfer circuit providing current to the energy transfer coil to transfer electrical energy through mutual inductance to pick-up coils of the movers.