Modular Inductive Charging Coil for Forklift Trucks
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Solution Overview
Problem
Existing battery charging systems for industrial trucks face challenges in flexible adaptation of the primary coil's size and shape, leading to inefficiencies in power transmission and positioning, especially when using high-performance batteries like lithium-ion batteries which require efficient charging during short breaks or while in motion.
Innovation Solution
A battery charging device with a primary coil embedded in the floor, composed of modules that can operate as composite or route modules, allowing for flexible geometric shaping and intelligent activation based on the industrial truck's position and direction, enabling efficient power transfer and adaptive charging during movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the primary coil is divided into multiple modules to enable flexible geometric shaping and adaptive activation, then the adaptability and positioning flexibility are improved, but the device complexity increases due to multiple cable connections and control settings required for each module
Solution Approach 1:
The primary coil is divided into multiple independent modules that can be individually activated or deactivated. Each module contains its own coil and can be controlled separately through cable connections, allowing the system to adapt to different charging scenarios by activating only the necessary modules.
Solution Approach 2:
Each module is designed to perform multiple functions: it can operate as a standalone unit, connect to adjacent modules to form larger charging areas, and be configured in different geometric arrangements. The modules serve both as power transmission elements and as positioning references for the industrial truck.
2Power
If the primary coil cross-sectional area is increased to cover the entire secondary coil area, then the power transmission efficiency is improved, but the positioning flexibility and maneuverability of the industrial truck are reduced
Solution Approach 1:
The system dynamically adjusts the active primary coil area based on the industrial truck's position and charging requirements. Modules can be selectively activated to match the size and shape of the secondary coil, optimizing power transmission while allowing the truck positioning flexibility.
Solution Approach 2:
Different modules can be activated with different power levels or configurations based on local requirements. The system applies power transmission only where needed, matching the secondary coil's position and orientation, rather than requiring a uniformly large primary coil area.
3Productivity
If modules are activated in sequence along a route for charging during motion, then the productivity is improved by enabling charging during travel, but the latency in power delivery increases due to sequential activation
Solution Approach 1:
The system activates modules in advance before the industrial truck reaches them during motion. By detecting the truck's approach and pre-activating the next module in the route, the system minimizes latency and ensures continuous power transmission without interruption.
Solution Approach 2:
The sequential module activation is designed to ensure continuous power transmission to the moving industrial truck. By overlapping the activation of adjacent modules and maintaining power delivery without interruption, the system enables uninterrupted charging during motion.
4Volume of stationary object
If high-performance batteries with high energy density are used to increase range and service life, then the volume efficiency is improved, but the charging power requirements and alignment precision needs increase
Solution Approach 1:
The segmented module design allows for finer-grained alignment adjustments. Instead of requiring precise alignment with a large monolithic primary coil, the system can activate individual modules or small groups of modules, reducing the alignment tolerance requirements while maintaining effective power transfer.
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 allows for flexible and efficient charging by synchronizing module coils to cover a larger area, minimizing alignment requirements and latency in power delivery, enabling high-power transmission and cost-effective charging options for industrial trucks.
Implementation Method 1
a battery charging device for inductively charging a traction battery of an industrial truck with a primary coil (3) which is embedded in a floor surface that can be driven over by an industrial truck, the primary coil being made up of one or more modules arranged next to one another with respective module coils, and the primary coil being capable of transmitting electrical power to a secondary coil (4) of the industrial truck
Data Source
Figure 1
Figure 2a~2d
Figure 3~4
AI summary
In a battery charging device for the inductive charging of a traction battery of a forklift truck, the primary coil (1) is embedded in a floor surface (7) that can be driven over by a forklift truck (2), the primary coil (1) being constructed from one or more adjacent modules (8) with respective module coils (9), and the primary coil (1) being able to transfer electrical power to a secondary coil (4) of the forklift truck (2), each module (8) can be set to operate as a compound module or as a travel module with respect to a defined adjacent module (8), wherein in operation as a compound module the module coil (9) is operated synchronously with the adjacent module (8) and in operation as a travel module is activated by the adjacent module (8) when the latter detects a forklift truck (2), or conversely, the adjacent module (8) is activated when the module (8) itself detects a forklift truck (2).