SBIR Phase II: In-Motion Capacitive Wireless Charging System for Material Handling Vehicles

The broader/commercial impact of this Small Business Innovation Research (SBIR) Phase II project is the development of a high-power wireless charging technology that enables autonomous mobile robots to recharge while operating within their normal workflows, eliminating charging downtime, increasing robot utilization, and reducing the total cost of ownership of robotic fleets. Where opportunity charging is beneficial, the technology substantially lowers initial robotic system costs by reducing fleet size, battery capacity requirements, and charging infrastructure. Where conductive contact charging is used, the technology eliminates maintenance associated with conductive charging contacts, a major operational cost for many automated warehouses. By replacing complex, expensive magnetic-coil wireless charging systems with simple, affordable metal-plate wireless charging systems, the technology also has the potential to reduce manufacturing costs and accelerate adoption of wireless charging across industrial automation applications. Successful commercialization will improve supply chain efficiency and support the continued growth of warehouse automation. The project will also advance scientific understanding of high-frequency capacitive wireless power transfer, enabling broader application of this technology to future industrial electric vehicles and other electrified transportation systems. This Small Business Innovation Research (SBIR) Phase II project will advance a patented capacitive wireless charging system from a successful proof-of-concept into a pilot-ready commercial technology for industrial mobile robots. The research focuses on scaling wireless power transfer to 2 kW and beyond while achieving at least 90% DC-DC efficiency through continued research in resonant matching network optimization, high-quality-factor passive components, high-frequency power electronics, thermal management, electromagnetic compatibility, and closed-loop system control. The project will also improve manufacturability, reliability, and industrial integration through development of production-grade hardware, communication interfaces, and pilot-ready systems. Successful completion of the proposed research will retire the remaining technical risks associated with high-power capacitive wireless charging and establish the technical foundation required for commercial deployment in automated warehouse environments. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.