Inductive Charging Floor Assembly With Load-Distributing Coil Support
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Solution Overview
Problem
Existing stationary underbody assemblies for inductive vehicle charging lack sufficient load-bearing capacity, which can lead to damage when vehicles drive over them.
Innovation Solution
The solution involves a stationary underbody assembly with special pressure platforms on a strand carrier, which supports a spirally wound conductor of a flat coil. This design enhances the mechanical load-bearing capacity by distributing loads uniaxially through pressure platforms, preventing direct loading on the flat coil and core arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the underbody assembly is designed with a simple structure, then the manufacturing cost is reduced, but the load-bearing capacity is insufficient when vehicles drive over it
Solution Approach 1:
The underbody assembly is segmented into distinct functional components: a housing structure, a core arrangement with ferrite plates for magnetic flux guidance, and a strand carrier with pressure platforms for mechanical load bearing. This segmentation allows each component to be optimized for its specific function while working together to solve the overall technical contradiction.
Solution Approach 2:
The strand carrier is designed with pressure platforms that extend in the spacing direction (vertical dimension) between the base plate and housing cover. This dimensional extension creates a load distribution structure that transfers vehicle loads uniaxially to the base plate, preventing direct loading of the flat coil and core arrangement while maintaining a compact horizontal footprint.
2Reliability
If the flat coil and core arrangement are directly supported on the base plate, then the structure is simplified, but the risk of damage when vehicles drive over the assembly increases
Solution Approach 1:
The strand carrier with its pressure platforms acts as an intermediary load distribution structure between the vehicle wheels and the flat coil/core arrangement. This intermediary component prevents direct contact and load transfer to the sensitive electromagnetic components, thereby protecting them from damage while vehicles drive over the assembly.
Solution Approach 2:
The pressure platforms are designed to distribute loads uniaxially before they reach the flat coil and core arrangement. This beforehand load distribution cushions the sensitive components from direct mechanical impacts and concentrated stresses that would occur if vehicles drove directly over them, preventing damage before it can occur.
3Strength
If the pressure platforms are large in area, then the load distribution is improved and deflection is reduced, but the space for magnetic flux guidance is reduced
Solution Approach 1:
The pressure platforms are strategically positioned and sized to provide adequate load distribution only in the regions where mechanical support is needed, while leaving the central and adjacent areas open for magnetic flux guidance. This local optimization allows each region of the underbody assembly to serve its primary function without compromising the other.
Solution Approach 2:
The pressure platforms extend in the spacing direction (vertical dimension) rather than occupying excessive horizontal area. By utilizing the vertical space between the base plate and housing cover, the design achieves adequate load distribution capability without encroaching on the horizontal space required for magnetic flux guidance between the core plates and flat coil.
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 enhanced load-bearing capacity significantly reduces the risk of failure in the underbody assembly components, allowing vehicles to drive over without causing damage, while maintaining efficient inductive charging.
Implementation Method 1
In a stationary underbody assembly outside the vehicle, there is a primary coil that interacts inductively with a secondary coil ('vehicle assembly’) in the vehicle in order to charge the energy storage unit.
Implementation Method 2
Also provided is a core arrangement with at least one core body, for example a ferrite plate, for magnetic flux guidance
Data Source
AI summary
A stationary underbody assembly for an inductive charging device for inductive charging of a motor vehicle is disclosed. The stationary underbody assembly includes a housing with a base plate and a housing cover covering the base plate. A flat coil held by a strand carrier, which has a spirally wound conductor and is spaced from the base plate along a spacing direction. A core arrangement with at least one core body for magnetic flux guidance. A cavity formed between the at least one core body and the base plate. A support provided between the flat coil and the base plate. The strand carrier has a pressure platform. A load distribution structure is arranged between the housing cover and the strand carrier.