Method and apparatus for wireless power transfer to an independent moving cart

A method for wirelessly transferring power between a plurality of movers in a motion control system and a closed track along which each of the plurality of movers travels, the method comprising the steps of:

• providing power from a power supply to a primary winding mounted along the closed track, wherein the primary winding includes a primary forward conduction path and a primary reverse conduction path spaced apart from each other and extending longitudinally in a direction of travel along the closed track;
• and
• positioning a plurality of movers along the closed track, wherein each of the plurality of movers includes:
• a secondary winding having a secondary forward conduction path and a secondary reverse conduction path, wherein:
• the secondary forward conduction path and the secondary reverse conduction path are spaced apart from each other and extend along the mover in the direction of travel, and
• each of the secondary forward and reverse conduction paths are generally aligned with the primary forward and reverse conduction paths with an air gap separating the secondary forward and reverse conduction paths from the primary forward and reverse conduction paths as the mover travels along the closed track;
• and
• a power converter operative to receive power from the secondary winding mounted to the mover and to supply power to at least one electrical device mounted on the mover.

An apparatus for wireless power transfer in a motion control system, the apparatus comprising:

• a plurality of movers;
• a closed track defining a continuous path along which each of the plurality of movers travels;
• a primary winding mounted along the closed track including a primary forward conduction path and a primary reverse conduction path;
• a plurality of secondary windings, wherein:
• each secondary winding is mounted to one of the plurality of movers,
• each secondary winding includes a secondary forward conduction path and a secondary reverse conduction path, and
• each secondary winding is operative to receive power from the primary winding as the mover travels along the closed track;
• a plurality of motor drives, wherein each motor drive is mounted to one of the plurality of movers and wherein each motor drive includes:
• a rectifier section, wherein an input of the rectifier section is operative to receive power from the secondary winding mounted to the corresponding mover and an output of the rectifier section is connected to a de bus, and
• an inverter section, wherein an input of the inverter section is operative to receive power from the dc bus and wherein the motor drive is operative to provide a variable amplitude and variable frequency voltage at an output of the inverter section;
• and
• a plurality of drive coils mounted to each mover and connected to the output of the inverter section on the corresponding mover to receive the variable amplitude and variable frequency voltage.