Method for producing a system for inductively transmitting energy to a mobile part, and device for carrying out the method

Abstract

In a method for producing a system for inductively transmitting energy to a mobile part, and a device for performing the method: a stepped bore is introduced into a floor; a sealing element is introduced into the stepped bore; a ring frame is held in place in the stepped bore with the aid of an alignment unit supported on the surface of the floor, the upper edge of the ring frame in particular being aligned with the height of the floor or with the surface of a floor covering applied to the floor, i.e. the upper edge in particular being brought to the same height position as the surface of the floor or the floor covering; the ring frame is set apart from the floor so that a gap region exists between the ring frame and the floor; casting compound is filled into the gap region; the alignment unit is removed; and a primary part is accommodated in the ring frame, in particular connected with the aid of screws.

Claims

1. An apparatus for installing, in a stepped bore of a floor, a primary part of a system for inductively transmitting energy to a mobile part, comprising: a sealing element adapted to be introduced into a lower region of the stepped bore having a smaller diameter than an upper region of the stepped bore to partially extend axially into the upper region of the stepped bore; a ring frame adapted to be introduced into the upper region of the stepped bore to at least partially overlap the sealing element in an axial direction of the stepped bore; and an alignment unit detachably connectable to the ring frame and adapted to align an upper edge region of the ring frame with a surface of the floor.

2. The apparatus according to claim 1, wherein the alignment unit is adapted to space an outer periphery of the ring frame from the stepped bore to form a gap between the ring frame and the stepped bore.

3. The apparatus according to claim 1, wherein the alignment unit is detachably connectable to the ring frame by screws.

4. The apparatus according to claim 1, wherein the alignment unit includes a plurality of radially extending arms, each arm including an axially oriented adjustment screw adapted to engage the surface of the floor.

5. The apparatus according to claim 1, wherein an outer periphery of the sealing element is adapted to releasably engage a surface of the lower region of the stepped bore.

6. The apparatus according to claim 1, wherein the sealing element is toroidally shaped.

7. The apparatus according to claim 1, wherein the sealing element is inflatable and is adapted to releasably engage, in an inflated state, against a wall of the lower region of the stepped bore and against an inner circumferential surface of the ring frame.

8. The apparatus according to claim 5, wherein the outer periphery of the sealing element is adapted to releasably engage an inner circumferential surface of the ring frame.

9. The apparatus according to claim 1, further comprising a casting compound adapted to fill a gap region that extends radially between the floor and the ring frame and that extends axially between the surface of the floor and a step of the stepped bore that transitions between the upper region and the lower region.

10. The apparatus according to claim 1, further comprising a core drill adapted to introduce the stepped bore into the floor.

11. The apparatus according to claim 1, wherein the floor includes a concrete floor.

12. The apparatus according to claim 9, wherein the sealing element is adapted to engage against a wall of the lower region of the stepped bore to prevent the casting compound from flowing into the lower region of the stepped bore.

13. The apparatus according to claim 12, wherein the sealing element is adapted to be removed from the stepped bore after the casting compound has cured.

14. The apparatus according to claim 12, wherein the alignment unit is adapted to be detached from the ring frame after the casting compound has cured.

15. The apparatus according to claim 12, wherein the casting compound is adapted to retain the ring frame in the upper region of the stepped bore after the casting compound has cured.

16. The apparatus according to claim 1, further comprising a winding adapted to be arranged inside the ring frame after the ring frame is installed in the floor.

17. The apparatus according to claim 16, further comprising a cover adapted to cover the winding inside the ring frame.

18. The apparatus according to claim 17, wherein the cover is adapted to align with the surface of the floor.

19. The apparatus according to claim 17, further comprising a seal arrangeable between the cover and the ring frame to seal interior space between the cover and the ring frame.

20. An apparatus for installing, in a stepped bore of a floor, a primary part of a system for inductively transmitting energy to a mobile part, comprising: a sealing element adapted to be introduced into a lower region of the stepped bore having a smaller diameter than an upper region of the stepped bore to partially extend axially into the upper region of the stepped bore; and a ring frame adapted to be introduced into the upper region of the stepped bore to at least partially overlap the sealing element in an axial direction of the stepped bore; wherein the ring frame includes axially-directed threaded pins adapted to engage a step of the stepped bore that transitions between the upper region and the lower region, the threaded pins adapted to align an upper edge region of the ring frame with a surface of the floor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is an exploded perspective partial cross-sectional view of a production step for producing a primary unit, in particular a charging point, of a system for an inductive transmission of energy to a mobile part, a ring frame 3 being aligned at the edge of a stepped bore with the aid of an alignment unit.

(2) FIG. 2 is an associated plan view of the assembly.

(3) FIG. 3 is an associated cross-sectional view.

(4) FIG. 4 is a perspective view through a partial cross-sectional representation of the assembly.

(5) FIG. 5 illustrates an alternative method for aligning ring frame 3.

(6) FIG. 6 is a cross-sectional view through the primary unit.

(7) FIG. 7 is a perspective partial cross-sectional view of the primary unit situated in the stepped bore, in a part-sectional view.

(8) FIG. 8 is a partial cross-sectional view of the primary unit.

(9) FIG. 9 is an exploded view of the primary unit.

(10) FIG. 10 is an exploded view of the primary unit from a different viewing angle.

(11) FIG. 11 is an exploded view of an underside of the area of winding 61 of the primary unit.

(12) FIG. 12 is a below plan view of this region when the parts are assembled.

DETAILED DESCRIPTION

(13) As illustrated in the Figures, a primary unit is situated on the floor, this primary unit having a winding 61 into which a medium-frequency current is impressed. A mobile part that is parked or turning above the primary unit, i.e. in particular the charging point, is thus inductively chargeable with energy. Toward this end, the mobile part includes a secondary winding on its underside to which a capacity is connected in parallel or in series so that the resonant frequency of the oscillating circuit formed in this manner corresponds to the frequency of the current impressed into winding 61.

(14) To produce the charging point, a core drilling is first performed in floor material 1, in particular concrete. The floor has a floor covering 8 on its top surface, on which the mobile part is able to drive.

(15) In order to keep the charging point free of barriers, i.e. not to create a tripping hazard, ring frame 3 is first aligned and held in place by an alignment unit. The alignment unit is supported at the edge of the bore.

(16) The alignment unit has a disk 4 on whose upper side arms 5 extend in the radial direction in each case. Using axially oriented adjustment screws, the alignment unit is supported at the edge region of the bore, i.e. on floor 1 or on floor covering 8 applied to floor 1.

(17) In the support on floor 1, the thickness of the floor covering is able to be taken into account with the aid of adjustment screws 20 so that arms 5 are situated at the intended height above the floor. This is so because the floor covering may be retroactively also applied to the edge region of the bore if it had not been provided at the outset already or if it was destroyed and/or at least partially removed because of the production of the stepped bore.

(18) As a result, disk 4 retained by arms 5 is able to be installed in the provided position with the aid of adjustment screws 20, which are screwed through arms 5.

(19) The stepped bore introduced into floor 1 has a step 7, and a corrugated tube 6 installed in floor 1 terminates in the region of the stepped bore situated below step 7.

(20) As illustrated in FIGS. 1 to 4, a sealing element 2 is introduced into the lower region of the stepped bore, which covers the region axially covered by the outlet region in the axial direction, i.e. in the direction of the bore axis of the stepped bore. In addition, sealing element 2 extends axially into the region axially covered by ring frame 3. As a result, the gap region that exists between step 7 and ring frame 3 is covered and casting compound 30 may be filled into this gap region. The gap region extends radially between floor 1 and ring frame 3 and axially up to step 7. Both in the radial direction and in the axial direction, ring frame 3 is set apart from floor 1, in particular from the wall of the stepped bore.

(21) Since ring frame 3 is held by the compensation device, i.e. disk 4, in particular with the aid of connecting screws 21, casting compound 30 is able to be filled into the gap surrounding ring frame 3. Sealing element 2 prevents casting compound 30 from flowing into the region of the stepped bore.

(22) Once casting compound 30 has cured, the compensation device, in particular disk 4 including arms 5, is therefore able to be removed. Ring frame 3 is thus retained in an integral fashion with the aid of casting compound 30 and is therefore connected to floor 1.

(23) Sealing element 2 has a centrally situated axially uninterrupted hole so that it is easily removable from the area of the stepped bore using a finger.

(24) Sealing element 2 is made from a foamed material, in particular plastic, and has a toroidal shape, in particular. Alternatively, sealing element 2 is hollow and provided with a skin of rubber or plastic as the surface, and it is inflatable by compressed air and when inflated, it nestles against the wall of the stepped bore situated axially below step 7 of the stepped bore and also rests against ring frame 3 while restricting the gap. After casting compound 30 has been filled in, the air is released from sealing element 2.

(25) FIG. 5 shows an alignment of ring frame 3 at the stepped bore as an alternative to the arrangement illustrated in FIGS. 1 to 4.

(26) In this instance, ring frame 3 has axially directed threaded bores at its circumference, into which threaded pins 50 may be screwed so that they allow ring frame 3 to be supported on step 7 of the stepped bore.

(27) As a result, the position of ring frame 3, in particular the height of ring frame 3, is determined by an adaptation of threaded pins 50 with the aid of screws. The axially upper edge region of ring frame 3 is brought to the level of floor covering 8, similar to the arrangement illustrated in FIGS. 1 to 4, so that ring frame 3 is situated at the intended height, at the latest once floor covering 8 has been repaired or applied.

(28) Subsequently, casting compound 30 is introduced in the arrangement according to FIG. 5 as well. Threaded pins 50 remain in casting compound 30.

(29) FIG. 6 is a cross-sectional view of the charging point to be produced after casting compound 30 has cured and sealing element 2 has been removed.

(30) A spiral-shaped rectangular winding 61 is accommodated in a groove that has a corresponding spiral-shaped rectangular shape and is situated on the underside of a cover part 62. Cover part 62 functions as winding carrier for winding 61.

(31) Cover part 62 has a circular, i.e. circular cylindrical, outer circumference.

(32) Cover part 62 is connected to a receiving part 63. A ferrite layer 60 is accommodated in receiving part 63, which substantially fills a space region in the shape of a circular plate, i.e. a circular cylindrical space region, the ferrite layer being composed of small, adjacently placed cuboidal ferrite parts, for example.

(33) Thus, ferrite layer 60 is situated between cover part 62 and receiving part 63. The space region filled by ferrite layer 60 is restricted by cover part 62 and receiving part 63.

(34) Receiving part 63 is connected to frame part 3 with the aid of screws 69 that penetrate cover part 62 and receiving part 63. Toward this end, frame part 3 has corresponding axially directed threaded bores into which screws 69 are at least partially screwed.

(35) The underside of receiving part 63, i.e. the side of receiving part 63 facing away from cover part 62, is covered by a lower part 64, in particular a lower cover part. An annular space region in which a circuit board 67 is situated is developed between receiving part 63 and lower part 64. The annular space region is developed circumferentially in the circumferential direction, i.e. arranged without any interruption in the circumferential direction.

(36) Capacitors, which are connected in parallel or in series to winding 61, are placed on circuit board 67. The resonant frequency of the oscillating circuit produced in this manner corresponds to the frequency of the current impressed into the winding by a feeder device.

(37) The supply of the current from the feeder device is carried out via a line 66, i.e. cable, which is routed to circuit board 67 through corrugated tube 6 and through a cable gland 65. The housing of cable gland 65 is situated on the underside of lower part 64, i.e. on the side of lower part 64 facing away from receiving part 63.

(38) A further space region in which a controllable illumination device may be provided is centrally situated between receiving part 63 and lower part 64. As a result, it is possible to display information through the illumination device, for which purpose a bore that passes axially through the receiving part has to be created, and the cover part is either produced from a transparent plastic, or a region of the cover part situated above the bore is produced from a transparent material. The bore is filled, for example, with a transparent material. The illumination device is able to be controlled such that the illumination device may be switched on or off, and/or so that the color of the illumination device is controllable. This makes it possible to display different operating states or other information as well.

(39) According to example embodiments, winding 61 is arranged as a flat ring winding. The ring winding has the form of a circular spiral. In this manner, the mobile part is rotatable on the charging point during the transmission of energy, without any fluctuation in the inductive coupling between winding 61 and the secondary winding that is provided on the mobile part and is, for example, likewise implemented as a flat ring winding in the form of a circular spiral. The time required for changing the steering angle of a mobile part having a track drive or some other omnidirectional drive may thus be used for an inductive energy transmission to the mobile part.

(40) Lower part 64 is fastened to receiving part 63 with the aid of screws 68.

(41) As illustrated in FIG. 8, a seal 81, which is situated at a greater diameter than ferrite layer 60 and winding 61, is disposed between cover part 62 and receiving part 63. Seal 81 is, for example, arranged as an O-ring.

(42) A seal 80, which seals the space region accommodating circuit board 67 from the outer environment, is also provided between lower part 64 and receiving part 63.

(43) As illustrated in FIG. 9 and FIG. 10, ferrite layer 60 is situated in a depression 100 provided on receiving part 63. This depression is located on the upper side of receiving part 63, i.e. on the side facing cover part 62.

(44) Receiving part 63 has two axially uninterrupted recesses 90, which are set apart from each other so that connection lines such as feed line 66 are able to be fed through to circuit board 67.

(45) Recesses 63 terminate on the upper side of receiving part 63 in depression 100.

(46) Lower part 64 has a circumferential ring wall 101 in the circumferential direction, which restricts the space region situated in a centered manner between lower part 64 and receiving part 63.

(47) In addition, lower part 64 has a further circumferential ring wall 104 in the circumferential direction, which is radially set apart from ring wall 101. As a result, the space region accommodating circuit board 67 is restricted by ring wall 101 and ring wall 104.

(48) Lower part 64 is fastened to receiving part 63 with the aid of screws 68, for which purpose receiving part 63 has axially directed threaded bores.

(49) As illustrated in FIG. 11, cover part 62 has on its side facing receiving part 63, i.e. its underside, groove 113, which extends in a rectangular, spiral-type form and into which winding 61 is inserted.

(50) The ends of the winding wire of winding 61 arranged as a flat winding are guided out toward adapter boards 111 on which an electrical connection part 112 is mounted in each case. An easy electrical connection is therefore provided. Adapter boards 111, i.e. circuit boards, are screw-fitted, and thus are electrically connected to current bars 110, which are electrically connected to circuit traces of circuit board 67.

(51) Current bars 110 are situated on the side of the ferrite layer that faces away from cover part 60.

(52) Seal 81 may be arranged as a foam seal.

(53) Ring walls 101 and 104 premolded on lower part 64 are situated on the side of lower part 64 that faces receiving part 63. Ring walls 101 and 104 touch receiving part 63 so that the annular space region in which circuit board 67 is situated is provided radially between them.

LIST OF REFERENCE NUMERALS

(54) 1 floor, in particular concrete 2 sealing element 3 ring frame 4 disk, in particular circular disk 5 arm 6 corrugated tube 7 step of the stepped bore 8 floor covering 20 adjustment screw 21 connecting screw 30 casting compound 50 threaded pin 60 ferrite layer 61 winding, in particular rectangular winding 62 cover part as winding carrier 63 receiving part 64 lower part, in particular lower cover part 65 housing of the cable gland 66 feed line 67 circuit board 68 screw 69 screw 80 seal 81 seal 90 recess 100 depression 101 ring wall 102 depression 103 depression 104 ring wall 110 bus bar 111 adapter board 112 electrical connection part 113 groove, in particular groove having the shape of a rectangular winding