Rotating Contactless Power Transfer with U-Shaped Coil Core
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Solution Overview
Problem
Existing contactless energy transmission systems are complex and costly, lacking simplicity and effectiveness.
Innovation Solution
A system with rotatable primary and secondary windings featuring a U- or C-shaped coil core for enhanced inductive coupling, allowing for constant magnetic flux density and cost-effective production, along with a parallel resonant circuit and medium-frequency voltage supply for efficient energy transfer and data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two inductively coupled windings are rotated in relation to one another with different radii, then contactless energy transmission is achieved, but the construction becomes very complex
Solution Approach 1:
The coil core is divided into multiple U-shaped or C-shaped sections arranged around the winding. Each section can be independently positioned and contributes to the overall magnetic flux path, allowing the complex function to be distributed across simpler modular components rather than requiring a single complex core structure
Solution Approach 2:
The U-shaped or C-shaped coil core acts as an intermediary magnetic flux conductor between the primary and secondary windings. This intermediate magnetic path structure enables efficient coupling without requiring direct contact or complex mechanical alignment mechanisms between the rotating windings
2Reliability
If a closed inner surface of the coil core is produced on the inside of the coil core, then the entire flux can be routed from the inside out, but production complexity increases
Solution Approach 1:
Instead of manufacturing a single complex closed-core structure, the core is segmented into multiple U-shaped or C-shaped sections. These segments can be manufactured using simpler processes and then assembled together to form the complete magnetic flux path, reducing individual component manufacturing complexity while achieving the same functional result
Solution Approach 2:
Multiple U-shaped or C-shaped coil core sections are combined around the winding to create the complete magnetic flux routing structure. By merging these simpler individual components, the system achieves effective flux containment and routing without requiring each component to be complex
3Ease of manufacture
If a specially shaped rotary pot is used for the coil core, then production can be carried out more quickly and easily, but material is not optimally utilized
Solution Approach 1:
The U-shaped or C-shaped core sections provide concentrated magnetic flux paths exactly where needed around the winding, rather than distributing material uniformly throughout a complete rotary pot structure. This localizes the magnetic material to areas of high flux density need, improving material utilization efficiency
Solution Approach 2:
By changing the geometric parameters of the coil core from a complete closed structure to open U-shaped or C-shaped sections, the system achieves a balance between manufacturing simplicity and material efficiency. The open structure allows easier production while the strategic placement of sections ensures optimal material utilization in the critical flux path regions
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 system achieves simple, cost-effective, and efficient contactless energy transmission with constant magnetic flux and reduced material usage, enabling power transfer of over 1 kW and interference-free data transmission.
Implementation Method 1
the magnetic field lines can be conducted through the core and thus a strong inductive coupling between the windings can be provided
Implementation Method 2
a parallel resonant circuit being provided on the secondary side, the resonant frequency of which is tuned to the medium frequency
Data Source
Figure 1a~1d
Figure 2a~2d
Figure 3
AI summary
System for the contactless transmission of power, comprising a primary winding and a secondary winding which is arranged such that it can rotate in relation to the primary winding, with a coil core being provided on the primary winding and the sectional shape of said coil core being formed in a U-shape or C-shape around the winding region of the primary winding in at least one sectional plane which includes the axis of rotation.