Misalignment‐tolerant integrated IPT systems for tram logistics robots featuring dual‐purpose coupler

Abstract

This study proposes a misalignment‐tolerant integrated inductive power transfer (IPT) system for tram logistics robots and presents an adapted parameter tuning method for the IPT system. A novel dual‐purpose coupler, which could undertake the responsibility of power transmission and self‐compensation is realised by substituted partially with compensation inductors of inductor–capacitor–capacitor networks, resulting in an integrated and cost‐effective system configuration. With the analysis of working principles on the IPT system and considerations of operation conditions on logistics robots, an adapted parameter tuning method is provided to maximise system misalignment tolerance and maintain high efficiency of power transfer. To demonstrate the validity and safety of the proposed system, comparative simulations and security evaluations are conducted by finite element analysis. Besides, the constant‐current output characteristic is simulated and proved. Finally, a 60.20 W experimental prototype is built. Results show that the system can operate stably with 87.31% efficiency at well‐aligned cases and the power fluctuation is confined below 9% within −120 to 120 mm x ‐misalignment, −80 to 80 mm y ‐misalignment, −50 to 12.5 mm z ‐misalignment, and −30° to 30° rotatory misalignment. It is also verified that the system could operate safely without any secondary side.