Wireless Sensor Power Control for Machine Tool Battery Charging

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Solution Overview

Problem

Current power supply systems for wireless sensors in machine tools require frequent battery replacement or charging, leading to machine tool downtime, safety concerns, and reduced productivity due to the need for manual intervention and potential sensor damage from cutting fluids and chips.

Innovation Solution

A power supply control system that includes a power receiving antenna, conversion unit, charging unit, and power supply control unit, enabling wireless power transmission and concurrent communication, allowing sensors to operate without interruption and be safely charged within the machine tool.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If battery replacement or charging is performed manually, then the battery can be recharged, but the machine tool must be stopped and productivity decreases

Engineering Contradiction:

Improvebattery operation continuityVSAvoidmachine tool productivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The sensor performs self-charging through wireless power transmission. The power receiving antenna in the sensor automatically receives power from the power supply antenna in the control system without manual intervention, enabling the sensor to maintain operation continuously without stopping the machine tool for battery replacement or charging

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system enables continuous power supply to the sensor by establishing wireless power transmission between the power supply antenna and power receiving antenna. This allows the sensor to operate without interruption and maintains machine tool productivity while ensuring the battery is continuously charged

Inventive Principle:

Principle #20Continuity of useful action

2Adaptability or versatility

If multiple sensors are deployed, then measurement coverage increases, but the frequency of battery replacement or charging increases and management becomes complicated

Engineering Contradiction:

Improvesensor measurement coverageVSAvoidbattery management complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The control system provides a universal power supply solution that can simultaneously charge multiple sensors through wireless power transmission. The power supply antenna can transmit power to multiple power receiving antennas in different sensors, eliminating the need for separate charging operations for each sensor and simplifying management while expanding measurement coverage

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Measurement precision

If the sensor is placed inside the machine tool, then measurement accuracy improves, but safety risks increase due to exposure to cutting fluids and chips

Engineering Contradiction:

Improvemeasurement accuracyVSAvoidsensor damage from cutting fluid and chips

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The system replaces wired power connection with wireless power transmission using electromagnetic fields. The power receiving antenna in the sensor receives power wirelessly from the power supply antenna, eliminating the need for physical cable connections that could introduce contaminants into the sensor while maintaining the sensor's position inside the machine tool for accurate measurement

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 allows for easy and safe charging of sensors, reducing downtime, maintaining power transmission efficiency, and preventing sensor damage, thereby enhancing productivity and safety.

Implementation Method 1

a power receiving antenna that acquires a radio wave for transmitting power to the electronic device

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a conversion unit that converts the radio wave received by the power receiving antenna to power

Methodology Applied

Scientific EffectElectromagnetic energy conversion: Electromagnetic Induction

Data Source

PatentUS20230387731A1Power supply control system and control system

Publication Date: 2023.11.30 METROL CO LTD

AI summary

Provided are: a power supply control system to simply and safely charge a power source for a sensor installed in a machine tool. Power supply control system 1 supplies power to an electronic device 30 and comprises: the electronic device 30 which comprises a battery 33 to drive 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.