Inductive Charging Coil for Industrial Truck
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing industrial truck charging methods, particularly for high-performance batteries, are inefficient and prone to wear and tear due to the need for frequent plug connections and manual alignment, which can lead to damage and increased maintenance costs.
Innovation Solution
An industrial truck equipped with a flat secondary coil on one of its outer surfaces for inductive charging, featuring a control unit that guides the truck to a charging station for optimal alignment and power transfer, eliminating the need for mechanical connections and enabling autonomous or semi-autonomous positioning for efficient and quick charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug connection is used for charging the traction battery, then the battery can be charged, but the connector and cable are subject to wear and tear and increased risk of damage
Solution Approach 1:
The patent replaces the mechanical plug connection system with an inductive charging system using electromagnetic fields. A primary coil in the charging station wirelessly transmits power to a secondary coil in the industrial truck, eliminating physical contact between connector and cable, thus preventing wear and tear while maintaining charging functionality
Solution Approach 2:
The patent introduces electromagnetic fields as an intermediary medium for power transmission. Instead of direct electrical contact through plugs and cables, energy is transferred through the air via electromagnetic coupling between primary and secondary coils, serving as a non-contact mediator that eliminates mechanical stress on connection components
2Reliability
If manual alignment and plug connection is required for charging, then the battery can be charged, but the charging process is complex and time-consuming
Solution Approach 1:
The patent implements automatic alignment and positioning systems that enable the industrial truck to charge itself without manual intervention. Sensors and control systems automatically guide the truck into correct positioning with the charging station, and the inductive charging activates automatically when in range, eliminating complex manual alignment procedures
Solution Approach 2:
The patent replaces manual mechanical alignment operations with automated electronic control systems. The charging process is simplified from a complex manual procedure involving positioning and plugging to an automated wireless process that begins automatically when the truck approaches the charging station
3Productivity
If frequent intermediate charging is performed, then the battery can maintain optimal charge levels, but the wear and tear on charging components increases disproportionately
Solution Approach 1:
The patent replaces mechanical plug-and-play charging with wireless inductive charging, allowing the industrial truck to perform frequent quick charges during work breaks without incurring disproportionate wear. The contactless nature of the charging system enables rapid top-up operations that would be costly in terms of component fatigue if performed frequently with traditional connectors
Solution Approach 2:
The patent enables continuous or near-continuous charging operations by allowing frequent intermediate charging without interruption to the work process. The industrial truck can quickly recharge at charging stations between tasks, maintaining optimal battery levels throughout the workday without the need for lengthy charging periods or battery changes
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 solution simplifies and shortens the charging process, reducing wear and tear on charging components and allowing for frequent, efficient intermediate charging without mechanical stress, thereby extending the service life of charging equipment and cables.
Implementation Method 1
a secondary coil (4) for inductively picking up electrical power in order to charge a battery (20)
Data Source
AI summary
In a forklift truck with a secondary coil (4) for inductively absorbing electrical power to charge a battery, the absorbed electrical power is used to charge a traction battery of the battery-electrically operated forklift truck (2) and the secondary coil (4) is arranged over a surface on one of the six outer surfaces of the forklift truck (2), in particular a side surface or a bottom surface.