Wireless Power Transfer in Linear Cart Systems
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Solution Overview
Problem
In motion control systems with independent movers on a track, providing a portable energy source is cumbersome due to weight and space constraints, and fixed connections restrict movement and require dedicated recharging stations, limiting the flexibility and efficiency of energy supply.
Innovation Solution
A wireless power transfer system using AC voltage with both fundamental and harmonic components, where the fundamental component propels the movers along the track and the harmonic component induces a voltage in a pick-up coil, allowing for wireless energy delivery to the movers without interfering with their operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a portable energy source such as a battery is provided on the mover, then the mover can operate independently without fixed connections, but the portable energy source adds weight and takes up space on the mover
Solution Approach 1:
The patent replaces the mechanical battery-based energy storage system with an electromagnetic wireless power transfer system. The mover includes a pick-up coil that wirelessly receives power from drive coils on the track, eliminating the need for physical batteries and their associated weight and space requirements while maintaining independent operation capability
Solution Approach 2:
The drive coils on the track serve dual functions: they provide both the propulsive force for moving the mover along the track and simultaneously transfer power wirelessly to the mover through electromagnetic induction. This multi-functionality eliminates the need for separate power supply systems
2Use of energy by moving object
If a fixed connection such as an electrical conductor is provided to the mover, then power can be supplied continuously, but the motion of the mover is restricted to limit the required length of the conductor
Solution Approach 1:
The patent replaces the mechanical electrical conductor connection with an electromagnetic field-based wireless power transfer system. The pick-up coil on the mover and drive coils on the track establish power transfer through electromagnetic induction, allowing the mover to move freely along the track without any physical connection constraints
Solution Approach 2:
The electromagnetic field acts as an intermediary between the drive coils on the track and the pick-up coil on the mover, enabling power transfer without direct physical contact. This intermediary mechanism allows continuous power supply while maintaining full motion flexibility
3Duration of action of moving object
If a dedicated recharging station is provided along the track, then the portable energy source can be recharged, but the mover must stop and wait for recharging before resuming operation
Solution Approach 1:
The wireless power transfer system enables continuous power supply to the mover as it travels along the track. The pick-up coil continuously receives power from the drive coils throughout the mover's journey, eliminating the need to stop for recharging and maintaining uninterrupted operational action
Solution Approach 2:
The mover autonomously receives power throughout its entire journey along the track without requiring dedicated recharging stations or stopping. The continuous electromagnetic coupling between drive coils and pick-up coil enables the mover to service its own power needs in real-time during operation
4Use of energy by moving object
If AC voltage with harmonic components is applied to drive coils, then power can be transferred wirelessly to the mover, but the harmonic components may interfere with the fundamental propulsion function
Solution Approach 1:
The patent segments the AC voltage waveform into distinct frequency components: the fundamental frequency component provides propulsive force through interaction with permanent magnets, while harmonic frequency components provide wireless power transfer through electromagnetic induction in the pick-up coil. This segmentation allows both functions to operate independently without interference
Solution Approach 2:
The patent applies different functional qualities to different frequency components of the AC voltage: the fundamental frequency is optimized for mechanical propulsion through magnetic field interaction, while harmonic frequencies are optimized for electromagnetic power transfer. This local quality differentiation ensures each frequency component performs its specific function effectively without compromising the other
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
Enables efficient and flexible power supply to movers without the need for fixed connections or dedicated recharging, enhancing mobility and reducing weight and space requirements while maintaining system performance.
Implementation Method 1
The fundamental component of the AC voltage applied to the drive coils along the track interacts primarily with the magnetic field generated by the permanent magnets on the movers to propel the movers along the track
Implementation Method 2
the harmonic component of the AC voltage applied to the drive coils generates a moving electromagnetic field that induces a voltage in a pick-up coil mounted on the mover
Data Source
AI summary
A system for wirelessly transmitting power between a track and independent movers in a motion control system includes a pick-up coil provided proximate to the magnets on the movers. The fundamental component of the voltage applied to the drive coils interacts primarily with the magnetic field generated by the permanent magnets on the movers and not with the pick-up coil. Consequently, the pick-up coil does not interfere with desired operation of the movers but rather, interacts primarily with the harmonic components and has current and voltages induced within the pick-up coil as a result of the harmonic components. The energy captured by the pick-up coil reduces the amplitude of eddy currents on the mover. After harvesting the harmonic content, the pick-up coil may be connected to another circuit on the mover and serve as a supply voltage for the other circuit.