Contactless Power Rail With Sliding Mover for Low-Weight Transfer
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Solution Overview
Problem
Existing contactless power transfer systems for moving carriages in industrial automation face challenges such as high weight of magnetic cores limiting acceleration, high cost, and electromagnetic interference, while flexible cables and brushes introduce vibrations and reliability issues.
Innovation Solution
A contactless power system using a stator with magnetizable walls and conductors, where a mover with a coil slides along the stator, forming magnetic circuits to induce power without contact, reducing weight and electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnetic core is used to collect power by induction, then contactless power transfer is achieved, but the weight of the magnetic core is high which reduces maximum achievable acceleration
Solution Approach 1:
The magnetic core is divided into multiple segments that can be selectively activated. Only the segments currently needed for power transfer are energized, while others remain inactive, significantly reducing the effective weight of the magnetic core during motion and improving acceleration while maintaining contactless power transfer capability.
Solution Approach 2:
The system transitions from a static, continuously active magnetic core to a dynamic configuration where magnetic core segments are activated and deactivated based on the position and power needs of the moving carriage. This dynamic operation reduces inertial weight and enables higher acceleration.
2Use of energy by moving object
If flexible cables are used to provide electrical power to the moving carriage, then power is delivered, but vibrations are induced that negatively affect movement precision
Solution Approach 1:
The mechanical flexible cable system is replaced with an electromagnetic field-based power transfer system. Power is transferred contactlessly through magnetic induction between stationary conductors and moving magnetic core segments, eliminating mechanical vibrations entirely while delivering electrical power to the moving carriage.
3Use of energy by moving object
If sliding brushes are used to transfer electrical energy, then power is transferred contactlessly, but brushes have limited lifetime and produce electrical noise
Solution Approach 1:
The mechanical sliding brush system is replaced with a non-contact magnetic induction system. Electrical energy is transferred through electromagnetic coupling between stationary conductors and moving magnetic core segments, eliminating brush wear, extending system lifetime, and eliminating electrical noise generated by brush contact.
4Use of energy by moving object
If cable chains are used to provide electrical power, then power is delivered to moving parts, but cost increases and reliability reduces
Solution Approach 1:
The mechanical cable chain system is replaced with a magnetic induction-based contactless power transfer system. This eliminates the mechanical wear, friction, and potential failure points of cable chains, significantly improving reliability while reducing maintenance costs and system complexity.
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 provides reliable, efficient, and cost-effective power transfer with reduced weight and interference, enhancing the precision and reliability of moving systems.
Implementation Method 1
A mover, moveable along the path, includes a core made of ferromagnetic material around which a coil is wound... When the mover slides along the path, the core closes two magnetic circuits, with a small air gap around the stator conductors
Implementation Method 2
Two electric conductors of significant cross sectional size are run inside the hollow profile... High intensity alternative (AC) currents are run in these two conductors... the fluxes induced in these magnetic circuits traverse the mover coil in the core, and induce electric power into the mover coil
Data Source
AI summary
Contactless electrical motion apparatus in which power is contactlessly made available to a moving part from a static part, comprises, a stator which in cross section comprising a magnetisable outer wall enclosing a conductor and a hollow space, the magnetizable outer wall having a discontinuity forming an airgap, the stator and hollow space in longitudinal section forming a rail. A moving part has a shoe or slider that fits within the hollow space to ride along the rail, the mover contactlessly filling the air gap at any given location when passing. With the airgap closed a magnetic circuit forms through the magnetizable outer wall and passes via the shoe or slider. The mover has a coil in which currents are induceable from the closed magnetic circuit.