Inductive Charging Coupler With Self-Centering Housing Alignment
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Solution Overview
Problem
Achieving optimal alignment and maintaining it between the electrical-energy emitting and receiving systems in a contactless electrical-energy transfer device is complex and challenging, especially in dynamic applications like flying vehicles and ground modules.
Innovation Solution
The device incorporates a housing with a surface of revolution that centers the electrical-energy transfer elements, ensuring optimal alignment and efficient energy transfer when the parts are in a close-up state. This design includes a layer of ferromagnetic elements and a locking system with a torus-shaped helical spring to maintain the close-up position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the electrical-energy transfer elements are positioned without a centering housing, then the device structure is simpler, but the alignment between emitting and receiving systems becomes difficult to achieve and maintain
Solution Approach 1:
The housing is designed with a surface of revolution that automatically centers the electrical-energy transfer elements through its geometric shape alone, without requiring additional active centering mechanisms. The complementary shapes of the housing and transfer element create a self-aligning system that maintains optimal alignment through its inherent geometry
Solution Approach 2:
The housing incorporates a surface of revolution with specific curvature characteristics that guide and center the transfer elements. The curved geometric profile creates natural alignment through the complementary shapes, eliminating the need for complex mechanical centering devices while ensuring precise positioning
2Adaptability or versatility
If the parts are designed to move relative to each other in dynamic applications, then the adaptability increases, but maintaining optimal alignment becomes more challenging
Solution Approach 1:
The housing design allows for dynamic relative movement between parts while maintaining alignment through its geometric constraints. The surface of revolution profile enables the transfer elements to self-center continuously during motion, adapting to position changes while preserving optimal alignment through the inherent geometric relationship between complementary shapes
3Productivity
If a housing with centering capability is implemented, then the energy transfer efficiency improves, but the device weight increases
Solution Approach 1:
The housing employs a surface of revolution with optimized curvature that provides effective centering functionality with minimal material usage. The geometric profile achieves alignment purposes through its shape alone, reducing the need for additional heavy centering components and fasteners that would increase weight
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 ensures reliable and efficient electrical energy transfer between the flying vehicle and the ground module by maintaining optimal alignment and contact, even in dynamic conditions, thereby enhancing the operational stability and efficiency of the energy transfer process.
Implementation Method 1
configured to allow a transfer of electrical energy by magnetic induction when they are in a close-up state close to one another
Implementation Method 2
a layer of ferromagnetic elements 18, for example made of ferrite
Data Source
AI summary
An electrical-energy transfer device comprising first and second parts able to move one relative to the other between distanced and close-up states, the first part comprising a first housing configured to at least partially house the second part, comprising at least a first lateral surface on which at least a first electrical-energy transfer element is positioned, the second part having a second lateral surface for each first lateral surface of the housing, having an overall shape that complements the shape of the first housing and on which surface there is positioned at least one second electrical-energy transfer element, the first and second electrical-energy transfer elements performing a transfer of electrical energy between one another when the first and second parts are in the close-up state.