Wireless Tool Head with Onboard Battery and Charging
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Solution Overview
Problem
Existing systems for industrial tool heads, such as those used in clinching or welding operations, face challenges in maintaining high operating autonomy while avoiding the use of power-supply cables, which leads to wear and increased maintenance stoppages due to the need for frequent replacement of electrical wiring.
Innovation Solution
A system with a data-acquisition and transmission module of small dimensions, equipped with an energy storage device for autonomous electrical supply, allowing for wireless data transmission and charging, thereby eliminating the need for electrical wiring and reducing maintenance stoppages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power-supply cables are used to supply electrical energy to sensors on the tool head, then the sensors can be continuously powered, but the electrical wiring is subject to considerable wear and must be replaced periodically, causing productivity losses
Solution Approach 1:
The patent extracts the power supply function from the external cable system and places it directly on the tool head through an energy storage device (battery). This eliminates the electrical wiring that connects the tool head to the robot, removing the source of wear and maintenance stoppages while maintaining continuous power supply to sensors and other electrical components.
Solution Approach 2:
The tool head becomes self-sufficient in terms of power supply through the integrated energy storage device. The battery on the tool head autonomously provides electrical energy to all onboard devices without requiring external wiring or periodic cable replacement, enabling the tool head to service its own power needs.
2Device complexity
If wireless transmission units are added to enable wireless control and monitoring, then constructional complications from wiring are reduced, but the device dimensions and complexity increase
Solution Approach 1:
The patent merges multiple functions into the control module: the wireless transmission unit, the energy storage device, and the sensor interface are all integrated into a single compact module mounted on the tool head. This consolidation achieves wireless operation while minimizing the increase in tool head volume compared to adding separate discrete components.
3Productivity
If electrical wiring is eliminated for tool head replacement, then replacement operations become faster and productivity increases, but a reliable power supply to sensors must be maintained without cables
Solution Approach 1:
The energy storage device (battery) is pre-installed on the tool head before replacement operations. This preliminary placement of the power source ensures that when the tool head is quickly swapped onto the robot, power supply to sensors is immediately restored without requiring cable connection or adjustment, maintaining power reliability while enabling rapid replacement.
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 operation with reduced maintenance needs, increased productivity, and rapid replacement of tool heads, while providing simultaneous supply and monitoring of multiple sensors, enhancing operational autonomy and flexibility.
Implementation Method 1
mounted on the tool head is a device for storing electrical energy that provides autonomously for electrical supply of the sensor, of the data-acquisition unit, and of the wireless-transmission unit
Implementation Method 2
The system comprises wireless charging means for charging the device for storing electrical energy
Data Source
AI summary
A system for performing industrial operations comprises at least one tool head provided with a tool and at least one sensor associated to the tool head. The system further comprises a control module mounted on the tool head including a data-acquisition unit connected to the sensor configured for acquiring the data coming from said at least one sensor, and a wireless transmission unit connected to the acquisition unit for receiving the aforesaid acquired data and for transmitting the data acquired to a receiving unit in a wireless mode. The module further comprises a device for storing electrical energy for electrical supply of the control module. The system further comprises a wireless charging system for charging the device for storing electrical energy comprising a first charging device carried by the tool head and connected to the energy-storage device and a second charging device associated to a stationary workstation.