Wireless Charging System for Assembly Line Pallets
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Solution Overview
Problem
Assembly lines face inefficiencies in maintaining power and charge for sensors and electronic devices on pallets, as manual battery replacement and recharging are time-consuming for large numbers of devices.
Innovation Solution
An automated wireless charging system using near-field magnetic resonance to wirelessly power and charge sensors and electronic devices on pallets, incorporating impedance matching networks and a charging algorithm to optimize power transfer and prolong energy storage component life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual battery replacement and recharging is used for sensors and electronic devices on pallets, then the devices can be powered, but the process is time-consuming and reduces productivity
Solution Approach 1:
The patent replaces manual mechanical battery replacement with an automated wireless power transfer system using electromagnetic fields. The transmitter coil generates an alternating magnetic field that inductively couples with the receiver coil on the pallet, automatically transferring power without human intervention, thus eliminating the time-consuming manual battery replacement process while maintaining continuous power supply.
Solution Approach 2:
The system enables self-service power replenishment by equipping pallets with receiver coils and energy storage devices that automatically couple with transmitter coils at charging stations. The pallets self-charge during their journey through the assembly line without requiring manual intervention, allowing continuous operation and maintaining productivity.
2Quantity of substance
If hundreds to thousands of sensors and electronic devices are deployed on assembly line pallets, then monitoring and data collection capabilities are enhanced, but the complexity of maintaining power to all devices increases significantly
Solution Approach 1:
The patent implements a universal wireless power transfer infrastructure where transmitter coils are strategically positioned throughout the assembly line to serve multiple pallets simultaneously. Each transmitter can power multiple receiver coils on different pallets, and each pallet can pass through multiple charging zones, creating a multi-functional system that handles power distribution to hundreds or thousands of devices through a standardized wireless interface, greatly simplifying power management complexity.
3Extent of automation
If wireless charging systems are implemented on assembly lines, then automated power supply is achieved, but the system complexity and infrastructure requirements increase
Solution Approach 1:
The patent divides the wireless charging system into modular segments: transmitter coils are installed at specific charging stations along the conveyor path rather than requiring complete coverage. Each transmitter-receiver coupling represents an independent charging zone, allowing the system to be implemented incrementally and maintained as discrete units, reducing overall infrastructure complexity while achieving automated power supply.
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 enables continuous, efficient power supply to devices on assembly lines, reducing manual intervention and extending the lifespan of energy storage components by minimizing charge levels.
Implementation Method 1
a transmitter coil is provided at a charging station located at a fixed position along the conveyor path. The transmitter coil is configured to generate an alternating magnetic field
Implementation Method 2
An automated wireless charging system using near-field magnetic resonance to wirelessly power and charge sensors and electronic devices on pallets
Data Source
Figure 1A~1B
Figure 1C~3
Figure 4A~4B
AI summary
An assembly line includes a conveyor belt and an energy charging system. The energy charging system includes (i) a resonator having a TX resonator disposed along the conveyor belt and a RX resonator mounted on and transported by the conveyor belt, (ii) an impedance matching network in communication with the resonator, (iii) and an energy storage device in communication with at least one of the resonator and the impedance matching network. Vmin is a minimum voltage of the energy storage device, and Vcap is a voltage across the energy storage device measured in real time. Energy is transferred from the TX resonator to the RX resonator when the Vcap is less than Vmin of the energy storage device.