Contactless Power Module with Interlocking Coil Units
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Solution Overview
Problem
Existing contactless power supplying systems face challenges with complex and expensive power supplying modules, cumbersome assembly processes, and limited design freedom, particularly in wet environments and varied power supply modes.
Innovation Solution
A power supplying module design featuring a multi-layered printed wiring substrate with standardized coil units and a system unit, allowing for easy assembly and reconfiguration, enabling contactless power supply in various modes with enhanced manufacturing efficiency and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If each power supplying module is configured with a dedicated power supplying circuit and CPU for controlling a single power supplying coil, then the power supply control is precise and reliable, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
Multiple power supplying coils are controlled by a single shared power supplying circuit and CPU, merging control resources that were previously dedicated to each coil. This reduces device complexity and manufacturing cost while maintaining reliable power supply control through the shared control architecture.
Solution Approach 2:
The power supplying circuit and CPU are designed to universally control multiple power supplying coils rather than being dedicated to a single coil. This multi-functional approach allows one control unit to manage several coils, reducing overall system complexity while preserving control reliability.
2Reliability
If each power supplying module is configured with a dedicated power supplying circuit and CPU for controlling a single power supplying coil, then the power supply control is precise and reliable, but the manufacturing cost increases
Solution Approach 1:
Multiple power supplying coils share a common power supplying circuit and CPU, merging control resources to reduce the total number of components required. This directly lowers manufacturing cost while maintaining reliable power supply control through the shared control architecture.
Solution Approach 2:
The power supplying circuit and CPU are designed with universal functionality to control multiple coils, reducing component quantity and manufacturing cost. The multi-functional design allows a single control unit to serve several coils, improving ease of manufacture while preserving control reliability.
3Reliability
If commercial power supply is input to each power supplying module individually, then each module operates independently and reliably, but the overall system complexity and assembly difficulty increase
Solution Approach 1:
Multiple power supplying modules share a common power supply input rather than each having individual commercial power supply connections. This merging of power supply architecture reduces system structure complexity and assembly difficulty while maintaining reliable independent operation of each module through the shared power distribution network.
4Manufacturing precision
If multiple power supplying modules are laid along the transfer route with individual control circuits, then each module can be precisely controlled, but the assembly process becomes cumbersome and time-consuming
Solution Approach 1:
Multiple power supplying modules share a common power supplying circuit and control architecture, merging control resources across modules. This reduces the number of individual control circuits that need to be assembled and configured, significantly improving assembly efficiency while maintaining precise power supply control through the shared control 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 provides a high degree of design freedom, simplifies manufacturing, reduces costs, and enables efficient contactless power supply in diverse applications, including wet environments, by using standardized components and a modular layout.
Implementation Method 1
The moving body generates secondary power at the power receiving coil through electromagnetic induction resulting from excitation of the power supplying coils
Data Source
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Figure 5~6
AI summary
Coil units (CU) equipped with primary coils having the same specification are provided in a power feeding module. Coil-unit intermeshing recess sections (11) are formed on a printed circuit board (10) to match each of the coil units (CU). Pads (PD) for joining together with electrodes formed on the coil units (CU) are formed on the bottom faces (S1) of each of the coil-unit intermeshing recess sections (11). A plurality of coil units (CU) can be mounted onto the printed circuit board (10) easily, by fitting each of the coil units (CU) into each of the coil-unit intermeshing recess sections (11) and joining them together, which will enable manufacturing efficiency to be improved.