Inductive Wireless Sensor Power with Super Capacitor Buffer

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Battery-powered wireless sensors on construction and agricultural equipment face issues with contamination from dirt, debris, and oxidization due to physical contacts, leading to unreliable connections and frequent replacements.

Innovation Solution

A wireless sensor assembly utilizing inductive battery power transfer with a primary resonant coil battery pack and a secondary resonant coil receiver, combined with super capacitors, allowing for contactless power delivery and temporary power storage to maintain functionality during battery replacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a battery with physical contacts is used to power the wireless sensor, then the sensor can be powered continuously, but the physical contacts are susceptible to contamination from dirt, debris, and oxidization leading to unreliable connections

Engineering Contradiction:

Improveconnection reliabilityVSAvoidcontamination from dirt, debris, and oxidization

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical contact-based battery connection system with an inductive power transfer system using electromagnetic fields. The battery pack contains a primary coil that wirelessly transmits power to a secondary coil in the sensor, eliminating physical contacts and their susceptibility to contamination from dirt, debris, and oxidization.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an electromagnetic field as an intermediary between the battery and sensor for power transfer. The primary coil generates an oscillating magnetic field that couples with the secondary coil, allowing power transmission without direct physical contact, thus preventing contamination issues.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Duration of action of moving object

If the battery is replaced in the field to maintain operation, then the sensor can continue functioning, but the replacement process causes power interruption and loss of function

Engineering Contradiction:

Improvecontinuous operation timeVSAvoidpower interruption during battery replacement

Core Design Contradiction:

Duration of action of moving objectVSLoss of time

Solution Approach 1:

The patent incorporates a super capacitor into the sensor that is pre-charged during normal operation. When the battery is removed for replacement, the super capacitor provides preliminary stored energy that maintains power to the sensor, allowing the battery to be swapped without interrupting sensor function or causing data loss.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The super capacitor acts as an energy buffer or cushion that is charged in advance during normal operation. This stored energy cushions against the power interruption that would normally occur during battery replacement, ensuring continuous operation and preventing loss of sensor function.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Use of energy by moving object

If a battery with physical contacts is used, then the sensor can be powered, but the contacts require frequent maintenance and replacement due to wear and tear

Engineering Contradiction:

Improvepower deliveryVSAvoidmaintenance and replacement frequency

Core Design Contradiction:

Use of energy by moving objectVSEase of repair

Solution Approach 1:

The patent eliminates the mechanical contact system entirely by using inductive power transfer through electromagnetic fields. The primary coil in the battery pack wirelessly couples with the secondary coil in the sensor, providing power delivery without physical contacts that would otherwise wear and require maintenance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides a reliable, dust-resistant, and easy-to-handle wireless sensor system that maintains operation without interruptions during battery swaps, as the super capacitors ensure continuous power and the inductive charging prevents contamination-related issues.

Implementation Method 1

A wireless sensor assembly that utilizes an inductive battery power transfer with a primary resonant coil battery pack and a secondary resonant coil receiver

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

The wireless sensor additionally has a super capacitor therein such that the wireless sensor is able to stay powered for a given amount of time after the battery pack has been removed

Methodology Applied

Scientific EffectCapacitance: Capacitance

Data Source

PatentUS9780604B1Inductive battery power transfer for powering wireless sensors for construction and agricultural equipment

Publication Date: 2017.10.03 DANFOSS POWER SOLUTIONS INC

AI summary

A wireless sensor assembly that includes a battery pack and a wireless sensor. The battery pack is placed in spaced relation to the wireless sensor and inductively powers the wireless sensor utilizing primary and secondary resonant coils presented within the battery pack and wireless sensor. The wireless sensor additionally has super capacitors therein to continue to operate the wireless sensor during the changing of the battery pack.