Modular Inductive Charging Track for Low-Clearance Industrial Trucks
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Solution Overview
Problem
Existing inductive charging systems for industrial trucks with low ground clearance face challenges in flexible primary coil adjustment and require structural changes to the floor for dynamic charging, which is costly and impractical for industrial settings.
Innovation Solution
A modular battery charging device with start and end modules featuring ramps for vehicle access, embedded primary coils and power electronics within concrete or plastic charging modules, and track guides for safe vehicle travel, allowing for dynamic inductive charging without altering the floor structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If primary coils are embedded in the floor for dynamic charging, then inductive charging can be provided during vehicle movement, but structural changes to the floor are required which are costly and impractical
Solution Approach 1:
The charging system is divided into modular charging units that can be placed on the floor without structural modifications. Each unit contains its own primary coil and power electronics, allowing flexible deployment and removal without affecting the floor structure.
Solution Approach 2:
A modular charging unit acts as an intermediary between the power source and the vehicle's secondary coil. This unit can be positioned on the floor surface and moved to different locations, providing inductive charging without requiring embedded installation in the floor structure.
2Power
If the primary coil cross-sectional area is increased for high power transmission, then power transmission capability is improved, but positioning flexibility is reduced
Solution Approach 1:
The charging system uses multiple smaller primary coils arranged in arrays within modular units. These can be selectively activated and positioned to match the vehicle's secondary coil size, providing flexible power transmission without requiring a single large fixed coil.
Solution Approach 2:
The system dynamically adjusts the active primary coil configuration based on the vehicle's position and the required power level. Multiple coils can be activated simultaneously or sequentially to optimize power transmission while maintaining positioning flexibility.
3Productivity
If industrial trucks with low ground clearance are used, then operational efficiency is improved, but access to embedded floor charging systems is difficult
Solution Approach 1:
The charging system is divided into removable modular units that can be positioned at different locations. This allows industrial trucks with low ground clearance to access charging by positioning the modular unit where there is sufficient clearance, without requiring floor modifications.
Solution Approach 2:
Instead of embedding coils in the floor plane, the system uses modular units that can be positioned above the floor surface. This vertical positioning provides adequate clearance for low-ground-clearance vehicles while maintaining inductive charging functionality.
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
Enables flexible and safe inductive charging of industrial trucks with low ground clearance without altering the floor, reducing costs and enhancing operational efficiency by embedding primary coils and power electronics within the charging modules, which can be easily laid and relocated.
Implementation Method 1
a charging unit is inductively coupled to a secondary coil of the vehicle via a primary coil and transfers electrical power
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a battery charging device for inductively charging a traction battery of a vehicle (11) that travels on a floor (12), in particular a ground-based industrial truck, with charging modules (10) arranged side by side and driven over by the vehicle (11), each containing at least one primary coil (8) that can transfer electrical power to a secondary coil (13) of the vehicle (11), so that the traction battery can be charged while the vehicle (11) drives over it. It is proposed that the charging modules (10) can be placed on the floor (12) and comprise at least one initial module (1) and at least one end module (2), each having a ramp (3, 4) over which the vehicle (11) can drive up and down from the floor (12) onto the charging modules (10).