Centered Inductive Charging Coupler With Self-Aligning Housing
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Solution Overview
Problem
Achieving and maintaining optimal alignment of magnetic induction-based electrical energy transfer systems in flying vehicles and ground modules is complex due to the relative movement and positioning requirements for efficient energy transfer.
Innovation Solution
The electrical energy transfer device incorporates a centering system with a housing design that includes a layer of ferromagnetic elements and a centering pin, allowing for self-centering and optimal positioning of transfer elements, along with a locking system using a torus-shaped helical spring to maintain the close state, ensuring efficient energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If magnetic induction-based electrical energy transfer systems are used in flying vehicles and ground modules, then wireless energy transfer capability is achieved, but alignment complexity increases due to relative movement and positioning requirements
Solution Approach 1:
The housing structure is designed with a centering system that automatically positions the transfer elements relative to each other when the housing is in the close state, eliminating the need for complex external alignment mechanisms. The complementary shapes of the housing and transfer elements create self-centering geometry that maintains optimal alignment during operation.
Solution Approach 2:
A centering pin acts as an intermediary mechanical element between the housing and transfer elements, providing precise positioning and maintaining alignment. The centering pin physically mediates the relative position between moving parts, ensuring optimal magnetic coupling without requiring complex control systems.
2Productivity
If transfer elements are positioned to ensure optimal alignment, then energy transfer efficiency is improved, but positioning precision requirements increase
Solution Approach 1:
The transfer elements are pre-positioned within the housing structure during manufacturing, with their locations fixed relative to the housing geometry. This preliminary positioning ensures that when the housing is in the close state, the transfer elements are automatically aligned optimally without requiring high-precision dynamic adjustment during operation.
Solution Approach 2:
The housing and transfer elements have complementary asymmetric shapes that are specifically designed to guide and maintain optimal alignment. The asymmetric geometry creates a unique fit that naturally positions the transfer elements correctly, reducing the need for high-precision manufacturing tolerances while ensuring efficient energy transfer.
3Stability of the object's composition
If a centering system with housing design is implemented, then alignment stability is improved, but device complexity increases
Solution Approach 1:
The centering system is merged with the housing structure itself, rather than being a separate component. The housing simultaneously serves as the structural enclosure and the centering mechanism, with its geometry providing both protection and alignment functions. This integration reduces the number of separate parts while maintaining alignment stability.
Solution Approach 2:
The housing and transfer elements incorporate curved surfaces and rounded geometries that facilitate self-centering through mechanical guidance. The curved surfaces guide the transfer elements into optimal alignment positions through contact geometry, providing stable alignment through shape rather than through complex mechanical constraints.
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 configuration ensures reliable and efficient electrical energy transfer by maintaining precise alignment and contact between the transfer elements, enhancing the stability and effectiveness of the energy transfer process.
Implementation Method 1
configured to allow a transfer of electrical energy by magnetic induction when they are in a close state
Implementation Method 2
a layer of ferromagnetic elements 18 made of ferrite for example
Data Source
Figure 1~2
Figure 3~4
Figure 5(A)~6
AI summary
The invention relates to an electrical energy transfer device comprising first and second parts (32, 34) movable relative to each other between distant and close states, the first part (32) comprising a first housing (52), configured to house at least partially the second part (34), having at least a first lateral surface on which is positioned at least a first electrical energy transfer element, the second part (34) having a second lateral surface for each first lateral surface of the housing (52), having a general shape complementary to the shape of the first housing (52) and on which is positioned at least a second electrical energy transfer element, the first and second electrical energy transfer elements ensuring electrical energy transfer between them when the first and second parts (32, 34) are in the close state.