Wireless Power Revolutionizing Modern Manufacturing: Efficiency, Safety, and Growth

Modern manufacturing plants are going wireless at an unprecedented pace. In a revolution that some call “Industry 4.0,” factories are implementing industrial internet-of-things (IIOT) technologies that allow for real-time, data-driven methods and strategies. And on the factory floor, wireless technology is more prevalent and profitable than ever before.

But with new forms of integration come new challenges. As IIoT technologies become increasingly commonplace, manufacturers are required to solve a different set of problems. These new devices require power, and it’s not always clear how to deliver this power in an effective way. To address this challenge and bring the Industry 4.0 revolution to its peak, manufacturing plants are turning to long-range wireless charging. 

Dynamic Demands 

As data and analytics become more essential to manufacturing, a growing number of factory owners are deploying devices and technologies to maximize efficiency, speed and quality. Many rely on some of the following:

• Asset trackers. Manufacturing and distribution centers can be large, sprawling compounds. So knowing where inventory is at all times can be a challenge. Asset trackers are small devices designed to solve this problem and utilize intuitive, unobtrusive technology. With an asset tracker, a manufacturer can instantly determine where tracked items are at any given moment.
• Handheld scanners. These devices are used by team members to scan items as they move through the production process: receiving, assembly, QA, shipping, etc. Handheld scanners are designed to be flexible and can be programmed to scan for numerous purposes. 
• IIoT sensors. Modern manufacturing systems use a variety of sensors to perform their primary functions. For example, these sensors may monitor factors such as pressure or temperature, the activity of a forklift or the velocity of a robotic arm. In some cases, these sensors are built directly into devices. Other times, sensors may be attached later for increased flexibility.
• Mobile workstations. In many manufacturing settings, team members can be assigned to flexible, moveable workstations. Each workstation, often including height-adjustable work surfaces, can be customized to provide the tools, integrations and functions necessary for daily tasks. 

By using IIoT wireless technologies, these different devices are able to seamlessly communicate. "It's not just about the sensors and the data conductivity,” says Steven Martin, chief digital officer of power at General Electric. “It's understanding the value and then making decisions on how to optimize that hardware based on the economic reality."

Flexible Power

There’s one universal demand on the factory floor: power. Indeed, it wasn’t until the advent of steam engines that factories themselves became a common mode of construction. While the source of power has changed, the same concept applies.

The vast majority of these IoT devices are portable and flexible. Manufacturers can place the devices where they need them or keep them handheld, depending on the situation. In order to keep these devices powered, factory floors turn high-efficiency batteries as a solution, or try to route wires and power cords.

But over time, even powerful batteries have these noticeable drawbacks:

• Cost. Many manufacturers may have significant numbers of devices, from handheld scanners to asset trackers. If each device requires a fresh set of replacement batteries, the costs associated with those batteries can become astronomical. 
• Downtime. Batteries will need to be replaced or recharged. When this happens, the device in question can’t be in use, creating a significant opportunity cost. 
• Limited charge. Even the highest efficiency battery can only provide so much power so quickly. Having to rely on this limited charge can restrict the capabilities of devices. A manufacturer may not be able to take full advantage of IoT on their factory floor running only on battery power. And devices designed to run solely on batteries may not have the capabilities required by modern manufacturing. For example, a manufacturer may want a sensor to report information every fifteen minutes, but battery management may limit the transmission of data to once every 60 minutes. That can impact the overall efficiency of the assembly line or effectiveness of any data-driven approach.

Some manufacturers have taken to using alternative power sources to alleviate these energy concerns. The most popular option thus far has been solar paneling, but even it has some major drawbacks. First, solar panels can only derive so much energy from electric lighting. Second, the size of the panels are usually limited by the surface area on the device they’re intended to power (devices which get more compact all the time). 

Wireless Power Presents a Solution

A growing number of manufacturers are turning to an innovative technology to solve this problem: long range wireless power. By using energy that is beamed from a distance, modern long range wireless charging systems can power a wide range of devices safely and efficiently — without interfering with production priorities — and unleash the full potential of Industry 4.0.

Here’s how the technology works. Master transmitters are installed periodically throughout the factory or workplace. Any device that needs power can then be hooked into this charging network via a simple wireless power receiver. 

There are several candidate technologies for long-range wireless power, but a very promising one is using infrared light. This invisible energy source can safely and efficiently deliver substantial power from a distance, and offers several key advantages for manufacturers:

• Long range. The charging signal can be transmitted across a factory floor or large warehouse. 
• Safety. Because infrared light is prevalent in nature and in everyday devices such as TV remote controls, its safety profile is excellent: meaningful levels of energy can be sent while staying well within consumer and industrial safety limits.
• Power. Because wireless power provides never-ending energy, manufacturers can use devices that have greater power demands, increase reporting rates, add local sensor intelligence and many other features.
• Integration. IIoT devices are designed to help manufacturing in a number of ways, and are especially helpful for gathering and utilizing data. But that can be difficult when batteries or corded power supplies get in the way. Long range wireless technology can be easily integrated into existing systems, making installation simple for any manufacturer.
• Flexibility. Unlike when they are connected to static cables, sensors can move freely within the enterprise, receiving energy practically wherever they are.

The Benefits of Wireless Charging

For manufacturers looking to keep their process lean, agile and profitable, wireless charging presents several powerful benefits, which include:

• Saved time and money. Changing batteries costs time and money--not only in terms of opportunity cost (a device in need of a battery change is not contributing to the manufacturing process), but also simply in terms of absolute costs. Wireless charging helps drastically reduce both of those. 
• Greater flexibility. Devices that use wireless charging can offer manufacturers a significant boost in agility and customizability. Devices aren’t restricted by proximity to a charging outlet or a weak wireless signal, for example. With wireless charging, devices can be placed anywhere within line of sight of the charging transmitter and still receive power. This means that manufacturers can place devices based on their assembly needs and processes.
• Added sensor capabilities. Many device capabilities are capped due to power consumption. By introducing long range wireless charging, manufacturers can invest in sensors with more capabilities. Sometimes this means the ability to track temperature, pressure, or flow more often. In other situations, it may simply mean greater range or more integration. That kind of performance requires power, however, and wireless charging can produce the necessary energy to improve performance.

With long-range wireless charging in place, manufacturers can focus on using IIoT to innovate — and customize factory floors for a data-driven future.

Yuval Boger is chief marketing officer at Wi-Charge.