Inductive Energy Transmission Coil Positioning via Stray Field Sensors
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Solution Overview
Problem
Existing contactless inductive energy transmission systems for applications like industrial robots face unforeseeable malfunctions due to variations in distance between coils, leading to abrupt transmission interruptions, as they only determine lateral offset and not axial distance, which can cause positioning inaccuracies and power transmission issues.
Innovation Solution
A system that uses stray fields generated during energy transmission to determine both lateral offset and axial distance between coils, allowing for precise positioning detection without interrupting energy transfer, using magnetic field sensors to measure the stray fields and transmit this information for adjustments, ensuring reliable power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If only lateral offset is determined using magnetic field sensors, then the positioning information is sufficient for basic alignment, but axial distance variations cause abrupt transmission interruptions and unforeseeable malfunctions
Solution Approach 1:
The patent introduces an intermediary calculation approach by using the coupling coefficient as a mediator between the magnetic field measurements and the axial distance determination. The coupling coefficient, derived from measurements by auxiliary coils, serves as an indirect indicator of axial distance, allowing the system to infer distance information without direct measurement, thus preventing transmission interruptions
Solution Approach 2:
The patent replaces direct mechanical or direct measurement systems for axial distance determination with a field-based indirect measurement system. By substituting physical direct contact or direct distance measurement with magnetic field coupling coefficient analysis, the system achieves reliable axial distance monitoring that prevents abrupt transmission interruptions
2Measurement precision
If additional auxiliary coils are added to determine axial distance, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The patent makes the auxiliary coils multi-functional by using them for both lateral offset determination and axial distance determination. The same auxiliary coils that detect lateral positioning also provide coupling coefficient measurements that indicate axial distance, eliminating the need for separate measurement systems and reducing overall device complexity
Solution Approach 2:
The patent changes the measurement parameter from direct distance measurement to coupling coefficient measurement. By measuring the coupling coefficient (a change in electrical/magnetic parameter) rather than direct physical distance, the system achieves precise axial position information while using the existing auxiliary coil structure, avoiding additional hardware complexity
3Power
If the system operates at higher power levels, then energy transmission capability is improved, but positioning inaccuracies cause unforeseeable malfunctions
Solution Approach 1:
The patent implements feedback control by continuously monitoring the coupling coefficient through auxiliary coils and using this information to detect axial distance variations. This feedback mechanism allows the system to identify positioning inaccuracies in real-time and take corrective actions, ensuring stable operation even at higher power levels where malfunctions would be more severe
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 enables continuous and reliable energy transmission by detecting and correcting any positioning inaccuracies in real-time, preventing unforeseen malfunctions and ensuring trouble-free operation even at higher power levels, without the need for additional test signals or feedback from the secondary part.
Implementation Method 1
a system for contactless energy transfer from a primary part (1) to a secondary part (1'), each of which has at least one coil (10, 10') that can be inductively coupled to one another
Implementation Method 2
The ferrite core increases the magnetic flux through its permeability to such an extent that high electrical power can be transferred even with small system sizes and small transmission areas
Implementation Method 3
a lateral offset of the secondary part (1') relative to the primary part (1) is determined based on a magnetic field generated by the coils and measured with at least one magnetic field sensor
Data Source
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AI summary
The invention relates to an apparatus for contactless inductive energy transmission from a primary part (1) to a secondary part (1') each having at least one coil (10, 10') which can be inductively coupled to one another. The apparatus is distinguished by the fact that the primary part (1) and/or the secondary part (1') has/have at least one magnetic field sensor and is/are set up to determine a relative position of the secondary part (1') with respect to the primary part (1) on the basis of a magnetic field generated by the coils (10, 10') and measured with the aid of the at least one magnetic field sensor. The invention also relates to an operating method for such an apparatus.