Non-Contact Power Supply Mechanism for Rail-Mounted Movable Bodies
Solution Overview
Problem
Conventional power supply methods for movable bodies traveling along rails, such as in flat knitting machines, face issues with contact failure due to dust, oil, and wear, leading to inefficient power transmission.
Innovation Solution
A non-contact power supply mechanism using a primary coil along the rail, a magnetic core, and a secondary coil within a tubular member, where the magnetic core moves with the movable body, utilizing electromagnetic induction for power transfer, with reinforcing members and strategically placed magnets to enhance efficiency and prevent core contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact power supply is used between the rail and movable body, then electric power can be supplied to the movable body, but power supply is inhibited due to contact portion wear and contamination from oil and dust
Solution Approach 1:
The patent replaces the mechanical contact power supply system with an electromagnetic induction-based non-contact power supply system. The primary coil is embedded in the rail and the secondary coil is mounted on the movable body, eliminating physical contact between power supply components. This substitution resolves the wear and contamination issues inherent in contact-based systems while maintaining reliable power transfer to moving components.
2Loss of energy
If a magnetic core is provided within the primary coil to enhance power supply efficiency, then electromagnetic induction efficiency is improved, but the magnetic core may come into contact with the primary coil causing short circuits
Solution Approach 1:
The patent employs a nested structure where the magnetic core is positioned within the primary coil's magnetic field region but separated by a non-contact gap. The primary coil is embedded in the rail and the magnetic core is mounted on the movable body, creating a nested arrangement that maintains electromagnetic coupling while preventing physical contact. This nested configuration optimizes induction efficiency without compromising reliability.
3Adaptability or versatility
If the primary coil is made long to cover the entire travel range of the movable body, then power supply coverage is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent divides the power supply system into segmented components: the primary coil is embedded in the stationary rail and the secondary coil is mounted on the movable body. This segmentation allows the primary coil to be installed in fixed sections along the rail, reducing manufacturing complexity while maintaining continuous power supply coverage throughout the movable body's travel range. Each segment operates independently, simplifying installation and maintenance.
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 configuration ensures reliable, efficient power supply to movable bodies like yarn feeders in flat knitting machines, reducing contact failures and core loss, while allowing for compact design and easy maintenance.
Implementation Method 1
a secondary coil that is wound around an outer circumferential face of the tubular member and to which electric power is supplied from the primary coil due to electromagnetic induction
Implementation Method 2
the magnetic core moves within the primary coil in conjunction with the movable body, due to a magnetic force of the first magnet and the second magnetic force
Data Source
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AI summary
A device with power supply mechanism is provided that includes a power supply mechanism for contactlessly supplying electric power to a movable body. A device with power supply mechanism of the present invention includes: a movable body that travels along a rail; and a power supply mechanism that supplies electric power to the movable body, the power supply mechanism including: a primary coil that extends along the rail; a magnetic core that is provided within the primary coil and is shorter than the primary coil; a tubular member that is provided in the movable body and into which the primary coil is inserted; a secondary coil that is wound around an outer circumferential face of the tubular member and to which electric power is supplied from the primary coil due to electromagnetic induction; a first magnet provided in the magnetic core; and a second magnet provided in the tubular member, wherein the magnetic core moves within the primary coil in conjunction with the movable body, due to a magnetic force of the first magnet and the second magnetic force.