Wireless Sensor Battery Charging Control in Machine Tools
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Solution Overview
Problem
Existing wireless sensors in machine tools require frequent battery replacement or charging, leading to machine tool downtime, safety concerns, and reduced productivity due to battery failures and maintenance complications.
Innovation Solution
A power supply control system that uses wireless power transmission and communication between a receiver and electronic device, allowing battery charging without interrupting machine tool operation, with separate antennas for power and communication and controlled timing to avoid interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery replacement or charging is performed, then the battery can be replaced or recharged, but the machine tool must be stopped and productivity decreases
Solution Approach 1:
The system performs preliminary action by automatically charging the battery before it is completely depleted. The control unit monitors battery status and initiates wireless charging in advance, ensuring the battery is recharged before replacement would be necessary, thus preventing machine tool stoppage.
Solution Approach 2:
The patent replaces the mechanical system of manual battery replacement with a wireless electromagnetic charging system. The wireless power transmission unit uses electromagnetic fields to transmit power to the battery without physical contact, eliminating the need for machine tool stoppage and manual intervention.
2Adaptability or versatility
If multiple sensors are used, then measurement capability is improved, but the number of batteries increases and replacement/charging becomes more complicated
Solution Approach 1:
The control unit serves multiple functions: it monitors battery status, controls wireless power transmission, and manages charging timing for multiple sensors. This multi-functional approach simplifies the overall system by using a single control unit to manage all battery-related operations across multiple sensors, reducing management complexity.
Solution Approach 2:
Each sensor equipped with a battery performs self-service through automatic wireless charging. The sensor's control unit autonomously monitors its own battery status and initiates charging when needed, eliminating the need for manual monitoring and management of multiple batteries.
3Ease of operation
If battery replacement is performed inside the machine tool, then maintenance can be done in-place, but the risk of sensor failure from cutting fluid or chips increases
Solution Approach 1:
The patent replaces manual battery replacement operations with automatic wireless charging. The wireless power transmission unit delivers power through electromagnetic fields without requiring physical access to the sensor interior, eliminating the risk of cutting fluid or chips entering the sensor during maintenance.
Solution Approach 2:
The wireless power transmission unit acts as an intermediary between the power source and the battery. It transmits power through electromagnetic fields without direct physical contact or opening the sensor housing, thus protecting the sensor from contamination while still enabling battery recharging.
4Ease of operation
If operator enters the machine tool for maintenance, then maintenance tasks can be performed, but safety risks increase
Solution Approach 1:
The system performs self-service maintenance through automatic wireless charging, eliminating the need for operators to enter the machine tool for battery replacement. The control unit autonomously monitors battery status and initiates charging, keeping operators out of hazardous areas.
Solution Approach 2:
The patent replaces manual maintenance operations requiring operator entry with automatic wireless charging. The wireless power transmission system delivers power without physical contact, eliminating the need for operators to access the machine tool interior and thereby removing safety risks associated with operator entry.
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 easy, safe, and efficient battery charging of sensors in machine tools, reducing downtime and improving productivity by allowing concurrent power supply and communication without interference.
Implementation Method 1
a power receiving antenna that receives a radio wave for wirelessly transmitting power
Data Source
Figure 1A~1B
Figure 1C
Figure 2
AI summary
Provided are: a power supply control system with which it is possible to simply and safely charge a power source for a sensor installed in a machine tool; and a control system. Provided is a power supply control system 1 that supplies power to an electronic device 30 and that comprises: the electronic device 30 which comprises a battery 33 that is for driving the electronic device 30, a power reception antenna 31 that acquires a radio wave for transmitting power to the electronic device 30, a conversion unit 34 that converts the radio wave received by the power reception antenna 31 into power, and a charging unit 35 that charges the battery 33 with the power converted by the conversion unit 34; and a power supply control unit 44 which controls the conditions in which power is transmitted to the power reception antenna 31 such that the operation of the electronic device 30 is not affected.