Movable Power Coupling for Industrial Robots
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Solution Overview
Problem
Industrial equipment with moving automation or payloads faces reliability concerns due to flexing wires and contamination from relative movement, which existing power transmission methods fail to adequately address.
Innovation Solution
A contactless induction coupling system using a first induction section with rail extensions and a second induction section with shoe portions, allowing relative movement to induce current and provide power transmission without physical contact, utilizing alternating magnetic flux across a gap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional service loops with conductors and e-chains are used to provide power to moving components, then power transmission is achieved, but wire flexing causes reliability concerns and particle contamination is generated
Solution Approach 1:
The patent replaces the mechanical contact-based power transmission system (conductors and e-chains that physically connect stationary and moving components) with an electromagnetic induction-based contactless power transmission system. The primary coil generates a magnetic field that induces current in the secondary coil, eliminating the need for physical wire connections and thereby preventing wire flexing and particle contamination while maintaining reliable power transmission to moving components.
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary medium to transfer power between the stationary primary coil and the moving secondary coil. This magnetic field acts as a mediator that enables energy transmission without direct physical contact, solving the reliability issues associated with traditional mechanical connections while preventing contamination from wire flexing.
2Object-affected harmful factors
If contactless induction coupling is used to provide power to moving components, then particle contamination is eliminated, but the system requires precise alignment and gap maintenance
Solution Approach 1:
The patent incorporates movable guide rails and adjustable mounting mechanisms that allow the primary and secondary coils to dynamically adjust their relative positions. This dynamic adjustment capability enables the system to maintain optimal alignment and gap distance even when the moving component undergoes position changes, thereby reducing the complexity of precise alignment requirements while eliminating particle contamination through contactless power transmission.
Solution Approach 2:
The patent employs adjustable parameters including gap distance, coil orientation, and magnetic field strength to optimize the induction coupling efficiency. By allowing these parameters to be adjusted based on the relative position between stationary and moving components, the system can maintain effective power transmission without requiring extremely precise fixed alignment, thus reducing device complexity while preventing contamination.
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 ensures reliable and contamination-free power transmission to moving components, enhancing the reliability and efficiency of power delivery in industrial settings.
Implementation Method 1
The first induction section is configured to induce current in the second induction section, including when the second core moves relative to the first core along the extensions, to provide a contactless induction coupling between the first induction section and the second induction section
Data Source
AI summary
An apparatus comprises a first induction section comprising a first core and a first coil on the first core. A second induction section comprises a second core and a second coil on the second core. The first core comprises rail extensions, where at least two of the rail extensions extend from opposite ends of the first core. The second core comprises shoe portions located at respective ones of the rail extensions, where a gap is provided between each of the rail extensions and respective ones of the shoe portion. The second induction section is configured to move relative to the first induction section in a path along the extensions. The first induction section is configured to induce current in the second induction section, including when the second core moves relative to the first core along the extensions, to provide a contactless induction coupling between the first induction section and the second induction section.