In industrial AGV applications, the deployment of wireless charging modules needs to take into account electromechanical integration, space utilization and maintenance convenience. The core installation methods are divided into two major units: vehicle-end receiving and ground transmission, supplemented by the positioning system to work in coordination.

Integration of vehicle-end receiving modules

The mainstream solution adopts chassis embedded installation: The receiving coil (with a diameter of 150-300mm) and the magnetic shielding component are embedded in the middle of the AGV chassis, 30-50mm above the ground, and the module thickness is controlled at 20-35mm (including a 3mm aluminum-magnesium alloy protective layer). The power management unit is installed nearby in the equipment compartment and is directly connected to the coil through a waterproof connector. The cable length does not exceed 0.8 meters. For AGVs with limited chassis space (such as submersible models), a side-mounted lifting structure can be adopted: the receiving module is externally attached to the side of the vehicle body, equipped with a hydraulic or lead screw adjustment mechanism (±15mm lifting range), and an IP67-level stamped stainless steel protective cover is added to resist collisions.

Ground launch module deployment

Embedded installation is suitable for new construction scenarios: excavate an 80mm deep trench on the ground and pour a resin concrete base; Lay the epoxy resin-encapsulated transmitting coil and temperature sensor; The surface is covered with 5mm thick polycarbonate pressure-resistant board (with a load-bearing capacity of ≥5 tons), and the height difference from the floor is controlled within ±0.3mm. The wiring is connected to the control cabinet through galvanized steel pipes, and the maximum transmission distance does not exceed 10 meters.

The flat-laid installation is suitable for renovation scenarios: The 25mm thick integrated protective module (with built-in coils and heat sinks) is directly anchored to the ground and fixed by both chemical anchor bolts and structural adhesives. The edge of the module adopts a 10° anti-crushing slope design, and the surface is treated with diamond sand spraying, with a friction coefficient of ≥0.8 (meeting the DIN51130 anti-slip standard).

High-precision positioning supporting solution

- Triple positioning guarantee: Anti-metal RFID tags are embedded in the ground (positioning accuracy ±3mm), UWB transceivers are installed under the vehicle to calibrate position offset in real time, and a laser reflector can be optionally equipped to assist in compensation

- Safety interlock mechanism: A 2D safety scanner (adjustable detection distance of 0.5 to 3 meters) is deployed at the boundary of the charging area, which is linked with the AGV dispatching system to control the electromagnetic lock. When the system detects an offset greater than ±15mm or foreign objects invade, it will automatically cut off the power

- Status monitoring system: The ground fault monitoring unit (response threshold ≤5mA) is linked with the temperature sensor. When the coil temperature exceeds 65℃, the power operation is immediately reduced

Key points of project implementation

The actual case of a certain auto parts factory shows that after the AGV chassis was embedded and installed, the ground clearance of the entire vehicle was only reduced by 3mm (from the original 45mm to 42mm). The embedded ground module, in combination with ±12mm dynamic positioning compensation, achieved a system efficiency of 92% (6cm air gap, 20kW power). Before installation, the underground pipeline network needs to be scanned to avoid magnetic field shielding. The intervals between multiple modules should be maintained at least 1.5 times the coil diameter (usually ≥450mm). It is recommended to clean the accumulated iron filings in the core gap every six months for maintenance to prevent the coupling efficiency from decaying by more than 10%.

This solution supports the rapid deployment of a single workstation within 3 hours, and the modular design reserves 30% redundancy for future power upgrades. Practical data has proved that the system combined with the off-peak charging strategy can increase the average daily effective operating time of AGVs by 17%. The charging process is fully integrated into the material handling process, achieving a true "operation - energy replenishment integration" closed loop.