Contactless Power and Data Transfer for High-Speed Rotors
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Solution Overview
Problem
Existing contactless power and data transfer systems for rotor-stator systems are not suitable for high rotational speeds due to instability under centrifugal forces, mechanical stress, and noise susceptibility, lacking compactness and ease of installation.
Innovation Solution
A contactless power and data transfer system comprising a stator flange and rotor flange with L-shaped magnetic core parts and annular support surfaces, using ferrite materials and flexible silicone elastomers to maintain stability and magnetic coupling, along with striplines and microstrips for data transfer, ensuring robustness and efficient data transmission at high speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional contactless power and data transfer systems are used in rotor-stator systems, then power and data can be transferred without physical contact, but the systems become unstable under high centrifugal forces and mechanical stress at very high rotational speeds
Solution Approach 1:
The system is divided into separate stator and rotor flange assemblies that can be independently designed and optimized. The rotor flange assembly contains the rotating components while the stator flange assembly contains the stationary components, allowing each to be engineered for its specific mechanical and electromagnetic requirements
Solution Approach 2:
The patent changes the physical parameters of the system by using flexible silicone elastomer materials that can accommodate centrifugal expansion at high speeds, and by designing L-shaped magnetic core parts with specific geometric parameters that maintain magnetic coupling stability under rotational stress
2Ease of manufacture
If rotor elements are mounted on cantilevered structures, then installation is simplified, but the elements become susceptible to mechanical failure under high centrifugal forces
Solution Approach 1:
The patent uses composite construction by mounting magnetic core parts and electrical elements on flexible silicone elastomer material that provides both mechanical support and flexibility. This composite approach allows the rotor elements to withstand high centrifugal forces while maintaining ease of installation and replacement
3Ease of manufacture
If rotor elements are mounted on cantilevered structures, then installation is simplified, but the elements become susceptible to noise and external influences
Solution Approach 1:
The patent merges the mounting function and shielding function into a single integrated rotor flange assembly design. The flexible silicone elastomer material serves both as a mounting substrate and as a shielding barrier against noise and external electromagnetic influences, while maintaining ease of installation
4Productivity
If more sensor electronics are installed on the rotor to increase data processing capability, then data rate increases, but space and installation time increase
Solution Approach 1:
The rotor flange assembly is designed as a universal platform that can accommodate multiple sensor electronics and data acquisition components in a compact configuration. The flexible silicone elastomer mounting system allows for easy installation and reconfiguration of electronics to meet varying data processing requirements without increasing overall space requirements
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 system effectively transfers power and data at high rotational speeds up to 10,000 RPM, withstanding centrifugal forces and providing stable electromagnetic coupling, while being compact and modular for easy integration and installation.
Implementation Method 1
contactless electromagnetic coupling between said stator flange and said rotor flange is achieved
Implementation Method 2
L-shaped magnetic core parts and annular support surfaces, using ferrite materials and flexible silicone elastomers to maintain stability and magnetic coupling
Data Source
AI summary
Assemblies and systems for contactless power and/or data transfer. The power transfer system includes at least a pair of opposing magnetic cores, each core having an L-shaped cross section. The data transfer system includes at least a pair of opposing stripline and/or microstrip conductors. Components for the power and/or data transfer system are preferably supported by a supporting surface in the rotor and/or stator. In some embodiments, the power and/or data transfer system is provided in a rotor flange and/or a stator flange for modularity.