Contactless Power Transfer for Linear Drive Movers
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Solution Overview
Problem
Existing motion control systems face inefficiencies in power transfer to independent movers on tracks, requiring either fixed connections that restrict motion or dedicated power stations, leading to reduced throughput and limited actuator/sensor operation.
Innovation Solution
A contactless power transmission system using inductive coupling between primary coils on the track and secondary coils on the mover, enabled by a power converter that regulates power for actuators and drive coils, allowing continuous motion without fixed connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a fixed connection (electrical conductor or hose) is provided to the mover, then power can be supplied continuously, but the motion of the mover is restricted and the system complexity increases
Solution Approach 1:
The patent replaces the mechanical connection system (fixed electrical conductors or hoses) with an electromagnetic field-based energy transfer system. The linear motor generates an electromagnetic field that can transfer energy to the mover without physical contact, eliminating the mechanical constraints imposed by fixed connections while enabling continuous power supply during unrestricted motion.
2Use of energy by moving object
If a dedicated power station location is provided where the mover stops to receive power, then power can be supplied to the mover, but the system throughput is reduced and the mover must perform additional stopping and waiting actions
Solution Approach 1:
The patent enables continuous energy transfer to the mover throughout its entire motion along the track, rather than requiring intermittent stopping at dedicated power stations. The linear motor's electromagnetic field continuously powers the mover during motion, eliminating idle stopping time and maintaining continuous productive action, thereby increasing system throughput.
Solution Approach 2:
The patent transitions from a static power supply approach (fixed power stations requiring mover stopping) to a dynamic power supply approach where energy is transferred through the electromagnetic field generated during the mover's motion itself. The linear motor dynamically generates the electromagnetic field along the track, allowing power transfer that adapts to the mover's position and motion state.
3Use of energy by moving object
If an energy source (battery or pressurized tank) is mounted on the mover, then power can be supplied to actuators and sensors, but the mover weight increases and space is occupied
Solution Approach 1:
The patent extracts the energy source from the mover itself and relocates it to the external linear motor system mounted on the track. By generating electromagnetic energy externally through the linear motor, the heavy energy storage devices (batteries or pressurized tanks) are removed from the mover, reducing its weight and available space while maintaining continuous power supply capability.
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
Enables efficient and continuous power supply to movers along the track, enhancing system throughput and flexibility by eliminating the need for fixed power connections, thus improving the operation of actuators and sensors.
Implementation Method 1
A contactless power transmission system using inductive coupling between primary coils on the track and secondary coils on the mover
Data Source
AI summary
A system and method for providing power to independent movers traveling along a track in a motion control system without requiring a fixed connection between the mover and a power source external to the mover. In one embodiment, a sliding transformer transfers power between the track and each mover. In another embodiment, an optical transmitter transfers power between the track and an optical receiver mounted on each mover. In yet another embodiment, a generator includes a drive wheel engaging the track as each mover travels along the track. A power converter on the mover receives the power generated on and/or transmitted to the mover to control an actuator or a sensor mounted on the mover or to activate drive coils mounted on the mover to interact with magnets mounted along the track and, thereby, control motion of each mover.