Safety devices for preventing ignition

Abstract

In an aspect, there is provided a power controller for providing power from a supply to a load and preventing ignition in an environment of the load. The power controller comprises a power output circuitry; and a processor, powered by the supply, configured to: receive sensor data from one or more sensors in relation to the environment; and upon determining that the sensor data indicates that ignition is prevented in the environment, activate the power output circuitry to provide the power to the load, wherein the power output circuitry is configured to gradually power the load to transition the load from an off-state to an on-state upon activation by the processor.

Description

"Safety devices for preventing ignition"Cross-Reference to Related Applications

[0001] The present application claims priority from Australian Provisional Patent Application No 2025900560 filed on 26 February 2025, the contents of which are incorporated herein by reference in their entirety.Technical Field

[0002] This disclosure relates generally to a power controller for providing power from a supply to a load and preventing ignition in an environment of the load.Background

[0003] Some environments contain explosive atmospheres, such as those found in coal mining operations and other industries, and hence, specialised equipment is used to ensure safety when handling electrical equipment. This is because the electrical equipment has the potential to provide a spark which may ignite the explosive atmosphere. Particularly, in an underground mine, the ignition of the environment may cause the mine to collapse, which may endanger the workers within the mine. Therefore, an ignition prevention device is needed to ensure electrical equipment can be operated safely within such environments.

[0004] Flameproof enclosures have been used to protect electrical equipment in these environments. However, these enclosures have limitations, particularly in extreme conditions like longwall mining systems, where enclosure failure could expose powered (e.g., energised) equipment to explosive atmospheres, leading to an explosion. Some enclosures rely on mechanical valves and the like to provide a flameproof environment within the enclosure.However, these mechanical valves are prone to failure, especially in extreme or harsh conditions, due to mechanical failure and degradation of the mechanisms over time.

[0005] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the fieldrelevant to the present disclosure as it existed before the priority date of each of the appended claims.

[0006] Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.Summary

[0007] Disclosed herein are devices for preventing ignition in an environment of a load. One embodiment of the disclosure relates to a power controller for providing power from a supply to a load and preventing ignition in an environment of the load. The power controller comprises a processor which is powered by the supply, which may enable the processor to provide or terminate power to the load dynamically.

[0008] According to an aspect of the present disclosure, there is provided a power controller for providing power from a supply to a load and preventing ignition in an environment of the load, the power controller comprising:a power output circuitry; anda processor, powered by the supply, configured to:receive sensor data from one or more sensors in relation to the environment; and upon determining that the sensor data indicates that ignition is prevented in the environment, activate the power output circuitry to provide the power to the load,wherein the power output circuitry is configured to gradually power the load to transition the load from an off-state to an on-state upon activation by the processor.

[0009] It is an advantage to gradually power the load to transition the load from the off-state to the on-state as this enables the power controller to be continuously powered while preventing any inrush currents when providing the load to prevent tripping. As such, the power controller may be useful in environments of extreme or explosive conditions, such as those found in coal mining operations.

[0010] In some embodiments, the sensor data comprises pressure data of the environment, and the processor determines that the sensor data indicates that ignition is prevented upon determining that the pressure data satisfies a pressure condition.

[0011] In some embodiments, the pressure data corresponds to absolute pressure or differential pressure.

[0012] In some embodiments, the sensor data comprises temperature data and / or humidity data of the environment, and the processor determines that the sensor data indicates that ignition is prevented upon determining that the temperature data and / or humidity data satisfies a temperature condition and / or a humidity condition.

[0013] In some embodiments, the sensor data comprises gas composition data of the environment, and the processor determines that the sensor data indicates that ignition is prevented upon determining that the gas composition data satisfies a gas composition condition.

[0014] In some embodiments, the power output circuitry is configured to provide a ramp-up voltage output to gradually power the load.

[0015] In some embodiments, the power output circuitry comprises an analogue feedback circuit.

[0016] In some embodiments, the analogue feedback circuit is configured to amplify the Miller effect to gradually power the load.

[0017] In some embodiments, power output circuitry comprises one or more of:a linear regulator;a dropping resistor;a feedback transistor;a diode; anda capacitor.

[0018] In some embodiments, the power output circuitry is configured to be intrinsically safe.

[0019] In some embodiments, the processor is configured to, upon determining that the sensor data indicates the environment is ignitable, terminate the powered load to transition the load from the on-state to the off-state.

[0020] In some embodiments, the sensor data comprises pressure data of the environment, and the processor determines that the sensor data indicates the environment is ignitable upon determining that the pressure data satisfies a pressure condition.

[0021] In some embodiments, the sensor data comprises temperature data and / or humidity data of the environment, and the processor determines that the sensor data indicates the environment is ignitable upon determining that the temperature data and / or humidity data satisfies a temperature condition and / or a humidity condition.

[0022] In some embodiments, the sensor data comprises gas composition data of the environment, and the processor determines that the sensor data indicates the environment is ignitable upon determining that the gas composition data satisfies a gas composition condition.

[0023] In some embodiments, the power controller further comprises a watchdog component configured to terminate the powered load to transition the load from the on-state to the off-state upon determining a failure or unexpected behaviour of the processor.

[0024] In some embodiments, the power controller further comprises a temperature interlock component configured to terminate the powered load to transition the load from the on-state to the off-state upon determining that the power controller exceeds a maximum junction temperature.

[0025] In some embodiments, the power controller further comprises a receiver configured to receive a communication, and the processor is further configured to perform, upon receiving the communication, one or more oftesting of the power controller;communicate data indicative of results of testing.configuration of components of the power controller; andterminate the powered load.

[0026] In some embodiments, the power controller further comprises a reverse voltage barrier component.

[0027] In some embodiments, the power controller comprises the one or more sensors, and each of the one or more sensors is a semiconductor-based sensor.

[0028] In some embodiments, the power controller comprises multiple power controller sections connected in series, each of the multiple power controller sections comprising one or more sensors and a processor.

[0029] In some embodiments, each of the multiple power controller sections further comprise a semiconductor switch configured to power or terminate the load; and for each of the multiple power controller sections, the processor is configured to power or terminate the load based on the sensor data by controlling the semiconductor switch.

[0030] According to an aspect of the present disclosure, there is provided a power output circuitry comprising a capacitor and a diode, wherein the diode and the capacitor form a feedback loop to gradually provide power to transition a load from an off state to an on state.

[0031] In some embodiments, the power output circuitry further comprises a gate configured to enable current to flow to the load and a resistor configured to be pulled low by a control signal to enable current to flow via the gate.

[0032] In some embodiments, the power output circuitry further comprises a resistor configured to be pulled high by a control signal and the power output circuitry is further configured to rapidly terminate a powered load upon the resistor being pulled high.

[0033] In some embodiments, the power output circuitry further comprises:a resistor configured to pull up a gate voltage; anda resistor configured to dissipate voltage across the capacitor.

[0034] According to an aspect of the present disclosure, there is provided an enclosure comprising the power controller of any one of the previously described embodiments, the enclosure being configured to contain a pressurised gas and a load within the enclosure.

[0035] In some embodiments, the enclosure meets the Ex-p certificate standard.Brief Description of Drawings

[0036] An example will be described with reference to the following drawings:

[0037] Fig. 1 illustrates an example embodiment of a system comprising a power controller.

[0038] Fig. 2a illustrates an example embodiment of a system comprising an enclosure.

[0039] Fig. 2b illustrates a variation of the embodiment of Fig. 2a.

[0040] Fig. 2c illustrates a further variation of the embodiment of Fig. 2a.

[0041] Fig. 3a illustrates an enclosure according to an embodiment of the present disclosure.

[0042] Fig. 3b illustrates a variation of the embodiment of Fig. 3a.

[0043] Fig. 4a illustrates an example embodiment of the power controller disclosed herein.

[0044] Fig. 4b illustrates a variation of the embodiment of Fig. 4a.

[0045] Fig. 5 illustrates an example embodiment of the power controller disclosed herein comprising multiple additional safety components.

[0046] Fig. 6a illustrates an example embodiment of the disclosed power controller comprising multiple power controller sections.

[0047] Fig. 6b illustrates a variation of the embodiment of Fig. 6a.

[0048] Fig. 7 illustrates an example embodiment of the power output circuitry disclosed herein, configured to gradually provide power to a load.

[0049] Fig. 8 illustrates another example embodiment of the power output circuitry disclosed herein, configured to rapidly terminate a powered load.

[0050] Fig. 9 illustrates a circuit diagram of a power controller according to an embodiment of the present disclosure.

[0051] Fig. 10 illustrates an example of the power controller according to an embodiment of the present disclosure.

[0052] Fig. Ila shows a top view of a power controller according to an embodiment of the present disclosure.

[0053] Fig. 1 lb shows a bottom view of the power controller of Fig. Ila.

[0054] Fig. 12a shows an isometric exploded view of a power controller according to an embodiment of the present disclosure.

[0055] Fig. 12b shows an isometric (assembled) view of the power controller of Fig. 12a.Description of Embodiments

[0056] Disclosed herein are devices for preventing ignition in an environment of the load. Some embodiments relate to a power controller which comprises a processor (such as a microprocessor or the like) to provide or terminate power to a load in a safe manner e.g., to prevent ignition of an environment. The processor may be powered by the same power supply that provides power to the load. In this way, the processor may always be powered, as opposed to only being powered when power is being provided to the load. This enables more functionality and control of the power to the load, enabling the load to be powered when the environment is safe and terminating the power when the environment is unsafe (e.g., compromised, or ignitable). The disclosed power controller may determine when the environment is safe or unsafe.

[0057] Some embodiments of the power controller enable the load to be powered in a safe manner e.g., in a manner that does not produce sparks that may ignite the environment of the load. Further, embodiments of the power controller may enable the load to be powered in a manner that does not trip any fuses when powering (or energising) the load. In particular, for some applications, such as mining operations, some loads use power provided at a high voltage and / or current which may trip some safety fuses. Embodiments of the power controller disclosed herein address this by providing a power output circuitry that gradually powers the load (e.g., over time), rather than providing the load in an instantaneous manner.

[0058] Ex d enclosures with Equipment Protection Level (EPL) Mb ratings (i.e., a rating that indicates a device has a high level of protection against ignition in a mine) according to the International Electrotechnical Commission (IEC) 60079 standard have been used to protect electrical equipment in explosive atmospheres. IEC 60079 is a series of international standards that cover the safe installation and use of electrical equipment in potentially explosive atmospheres. Ex d is a certification that indicates an enclosure is flameproof or explosion-proof.

[0059] However, Ex d enclosures are generally unsuitable for some areas of longwall mining installations, because they may not withstand physical stresses and debris, maintenance is difficult and costly, and their flameproof integrity is hard to ensure. These enclosures may rely on regular inspection and effective ventilation for hazardous gases, are heavy and bulky, and thus impractical in confined spaces. The disclosed power controller extends protection to these challenging scenarios.

[0060] Some embodiments of the power controller may be used by an enclosure, wherein the enclosure is configured to contain a pressurised gas and a load within the enclosure. The disclosed power controller may operate on the Ex p principle, which involves controlling the atmosphere within electrical enclosures by pressurising them with an inert gas (e.g., nitrogen) to exclude oxygen. Such a power controller comprising a processor may enable rapid and reliable detection of pressure-loss events in pressurised enclosures. As such, the disclosed power controller may provide additional safety of some enclosures by the principles of intrinsic safety (Ex ib) to create a single, versatile module that can be certified as Ex p for a wide range of enclosures previously uncertifiable (such as enclosures formed from plastics or other synthetic materials). Intrinsic safety refers to a protection technique used to ensure the safe operation of electrical equipment in hazardous areas by limiting the energy (both electrical and thermal) available for ignition.

[0061] For a pressurised enclosure, the disclosed power controller may provide continuous, real-time pressure monitoring and rapid response capabilities, unlike mechanically controlled pressure switch-based systems. The processor may replace mechanical or pneumatic solutions, such as mechanical pressure switches, pressure gauges, pressure ports, and mechanical valves which may be prone to wear and tear. As such, the power controller may provide an electronic solution to preventing ignition of an environment, as compared to mechanical valves and the like. Compared to mechanical systems, the disclosed power controller undergoes less frequentmaintenance, which may potentially lower operational costs and downtime. As such, using a processor offers improved longevity and reliability.

[0062] The pressurisation provided by an enclosure, combined with the intrinsic safety features of the disclosed power controller may enable for: use in Zone 1 and Zone 2 hazardous areas under Standards Australia and Standards New Zealand requirements (Zone 1 is where explosive atmospheres may occasionally occur during normal operations, while Zone 2 is an area where an explosive atmosphere is not likely to occur during normal operations, but if it does, it will only persist for a short period); fail-safe operation when enclosure integrity is compromised; and increased speed in developing and deploying sensors and systems in potentially explosive environments, and significantly reduces the size and complexity of enclosures, making it adaptable to a variety of hazardous environments. Moreover, the disclosed power controller may be certified as Ex ib pxb according to IEC standards 60079-0, 60079-2, and 60079-11. Ex ib pxb is an IEC marking that indicates a piece of equipment is intrinsically safe internally and externally, and uses an X-type purge system (i.e., a system that is fully automatic and performs critical purging, pressurisation and monitoring of the protected enclosure).

[0063] The disclosed safety devices may be useful in many areas with potential explosive atmospheres including in the oil and gas sector, such as offshore drilling platforms, onshore refineries, natural gas processing plants, liquefied natural gas (LNG) facilities, pipeline compressor stations, storage tanks, and fuel terminals; in chemical manufacturing sector such as petrochemical plants, organic solvent production, paint and coating manufacturing, adhesive and sealant production, plastic and rubber manufacturing, and fertiliser plants; the mining industry such as in underground coal mines, mineral processing plants, coal preparation plants, and underground hard rock mines; the grain and food processing industry including grain elevators, flour mills, sugar refineries, and powdered milk production.; the wood and paper industry which includes sawmills, paper mills, and furniture manufacturing; automotive and aerospace sectors including paint spray booths, fuel system manufacturing, battery production for electric vehicles, and rocket fuel handling; in industries involving energy storage and distribution such as hydrogen production, fuel cell manufacturing, biogas plants, and power-to-gas facilities; and in gas production includes acetylene generation, hydrogen filling stations, and industrial gas manufacturing.Systems

[0064] Fig. 1 illustrates an example embodiment of a system (denoted as system 100). Fig. 1 is one example of a configuration of system 100. However, system 100 is not strictly limited to this configuration and this may be one possible embodiment of system 100. It is noted that system 100 of Fig. 1 is only meant to illustrate an example system.

[0065] System 100 comprises power controller 110, according to an embodiment of the present disclosure. Power controller 110 may be a printed circuit board (PCB) or the like. Power controller 110 provides power from supply 120 to load 130 and prevents ignition in environment 140 of load 130. Supply 120 may be any type of power supply, such as a connection from a mains power grid and may comprise a transformer or voltage regulator, such as a buck / boost converter. Supply 120 may also be, but not limited to, a power centre, a diesel generator, a portable substation and a battery. Supply 120 may be configured to provide a high voltage, such as 220V / 110V or a low voltage, such as 12V as alternating current (AC) or direct current (DC). In Fig. 1, load 130 is depicted as a device which is powered by supply 120. However, it is noted that load 130 may be an electrical load. More specifically, load 130 may be an electrical component or portion of a circuit that consumes (active) electric power, such as an electrical appliance, device or electrical equipment.

[0066] “Environment” in the context of the present disclosure may generally refer to the surroundings or vicinity of load 130. Environment 140 may encompass load 130, a sensor 141 as well as the air (including gases) and other particulates near load 130. In some embodiments, load 130 may be contained within an enclosure, thereby also containing environment 140. Under some conditions, environment 140 may be ignitable (i.e., may be able to catch fire). “Ignitable” in the present context may also refer to environment 140 as being combustible, flammable, inflammable, incendiary, burnable or the like, due to the presence of one or more of fuel (e.g. methane, hydrogen), oxidiser (e.g. oxygen) or heat. It can also be said that environment 140 may be explosive. However, it is noted that power controller 110 may be used if environment 140 is non-igni table.

[0067] Power controller 110 comprises power output circuitry 111, which is configured to gradually power load 130 to transition the load from an off-state to an on-state upon activation. “Gradually” in the context of the present disclosure may refer to load 130 being powered slowly or softly, rather than (effectively) instantaneously. In some embodiments, gradually may refer to load 130 being powered incrementally, in which the power to load 130 increases in increments or discretely. These increments may be equal, in some examples, but in other examples, theincrements may be non-equal. Gradually may refer to load 130 being powered linearly or exponentially over time. In essence, gradually may refer to load 130 being powered over a period of time, rather than (effectively) instantaneously. In this sense, power output circuitry 111 can be said to provide an additional impedance between supply 120 and load 130 to slow the change from off to on state compared to what it would be based on the output impedance of the supply 120 and the input impedance of the load 130. At the same time, power output circuitry 111 may be configured to transition from on to off state instantaneously. In some examples, power output circuitry 111 may be rated at about 3A and 15.5V.

[0068] Power output circuitry 111 enables a soft start function to load 130 to reduce inrush currents to enable the system to be used with a wide range of power supplies with stringent output current limit. Such inrush currents may exceed the safety standard for intrinsic safety. For example, an inrush current of a maximum of 2.5A may be provided at 10V. Power output circuitry 111 may be comprised one or more of: a linear regulator; a resistor (such as a pulling or dropping resistor, as well as resistors that provide other functionality); a transistor (such as a feedback transistor); a diode; and a capacitor. In some examples, power output circuitry 111 may be configured to activate upon receiving power from supply 120. In further examples, power output circuitry 111 may be configured to activate upon receiving a command from processor 112 (such as through a control line).

[0069] Power output circuitry 111 may be configured to provide a ramp-up voltage output to gradually power the load. Ramp up voltage is a voltage that gradually increases over time. When the ramp up voltage is below a threshold value, the output voltage increases with the ramp up voltage. When the ramp up voltage is above the threshold value, the output voltage remains stable. In some embodiments, power output circuitry 111 comprises an analogue feedback circuit, which gradually powers load 130. This analogue feedback circuit may comprise a diode and a capacitor. In other examples, the analogue feedback circuit may comprise one or more resistors. In some examples, minimum ramp up time provided by power output circuitry 111 may be configurable based on specific component selection (e.g., the resistor, capacitor, diode etc).

[0070] The feedback circuit (e.g., the analogue feedback circuit) may be configured to amplify the Miller effect to gradually power the load. The Miller effect is a phenomenon in electronics where the input capacitance of an amplifier appears significantly larger than its actual value due to the amplification of the capacitance between the input and output terminals of the amplifier,essentially causing a “magnified” capacitance at the input. “Amplify the Miller effect” may also refer to amplifying an input capacitance (e.g., using the Miller effect) and to gradually power the load".

[0071] Preferably, power output circuitry 111 is configured to be intrinsically safe. Intrinsically safe electronics are designed to prevent the release of energy that could ignite flammable gasses or vapours. Intrinsically safe electronics limit the amount of electrical and thermal energy they produce. They are designed to not produce enough heat or sparks to ignite an explosive atmosphere, even if they are damaged. The definition of intrinsic safety used in the relevant IEC apparatus standard IEC 60079-11 is a “type of protection based on the restriction of electrical energy within apparatus and of interconnecting wiring exposed to the potentially explosive atmosphere to a level below that which can cause ignition by either sparking or heating effects”. In particular, it is noted that the power provided by supply 120 may or may not be intrinsically safe. However, power output circuitry 111 is configured to be intrinsically safe despite power provided by supply 120 being intrinsically safe or not.

[0072] Power controller 110 comprises processor 112, which is powered by supply 120.Processor 112 may be a microcontroller, microprocessor, central processing unit (CPU), or the like. Software, that is, an executable program, may cause processor 112 to perform methods for providing or terminating power to a load. While the singular of “processor” is used herein, it is meant to also encompass multiple processors that are individually or together configured (e.g., programmed) to perform the methods disclosed herein. As such, processor 112 may refer to multiple CPUs and / or graphical processing units (GPUs) that are configured to collectively perform the methods disclosed herein.

[0073] Processor 112 is configured to receive sensor data (such as, but not limited to, pressure data, temperature data, humidity data and gas composition data) from sensors 141, 142 in relation to environment 140. Sensor data may refer to one or more measurements obtained by sensors 141, 142. In some examples, a sensor may be in relation to environment 140 if the sensor is within environment 140 (such as sensor 141 depicted in Fig. 1). However, a sensor may be in relation to environment 140 if the sensor is outside of environment 140 by near or proximal to environment 140 (such as sensor 142 depicted in Fig. 1).

[0074] Further, processor 112 is configured to, upon determining that the sensor data indicates that ignition is prevented in environment 140, activate power output circuitry 111 to provide thepower to load 130. In other words, processor 112 may determine that environment 140 is non-ignitable (e.g., non-combustible, non-flammable or the like). “Ignition is prevented” may also refer to environment 140 being safe i.e., safe (e.g., without a high probability of ignition) to activate power output circuitry 111 to provide the power to load 130. “Ignition is prevented” may also refer to environment 140 having suitable environmental conditions e.g., temperature and pressure, such that there is a very low possibly of ignition in environment 140. “Ignition is prevented” may also refer to environmental conditions meeting predefined safety thresholds such that ignition risk is below a predetermined level. Processor 112 may determine that the sensor data indicates that ignition is prevented in environment 140 by determining that the sensor data satisfies one or more conditions. As such, power output circuitry 111 gradually powers load 130 to transition load 130 from an off-state to an on-state upon activation by processor 112. In some embodiments, upon determining that the sensor data indicates that ignition is prevented in environment 140, processor 112 provides power from supply 120 to power output circuitry 111. For example, processor 112 may close a switch positioned between supply 120 and power output circuitry 111.

[0075] In some embodiments, power controller 110 comprises memory, which may comprise non-volatile memory and / or volatile memory, for example. Processor 112 may communicate with the memory by communicating with the non-volatile memory and / or the volatile memory. The non-volatile memory may be a non-transitory computer readable medium and may be an optical disk drive, hard disk drive, solid-state drive, flash memory, storage server, cloud storage or another equivalent type of memory. The volatile memory may be cache, RAM or another equivalent type of memory. Processor 112 may store the sensor data, among other things, on the memory, for example.

[0076] Fig. 2a illustrates another example embodiment of a system (denoted as system 200), which comprises a power controller according to an embodiment of the present disclosure (denoted as power controller 210). Elements of Fig. 2a may be equivalent elements of Fig. 1. However, Fig. 2a comprises enclosure 250, which contains load 230. As such, enclosure 250 also contains environment 240. In some embodiments, enclosure 250 may be configured to contain a pressurised gas, such as an inert gas (e.g., nitrogen). In some embodiments, enclosure 250 may be associated with power controller 210 or may comprise power controller 210. For example, power controller 210 may be attached (or connected) to enclosure 250 internally, in the sense that power controller 210 sits within enclosure 250 and environment 240. In these embodiments, power controller 210 may comprise one or more sensors (such as sensor 241). In otherembodiments, power controller 210 may be attached (or connected) to enclosure 250 externally, in the sense that power controller 210 sits outside of enclosure 250 and environment 240. In these embodiments, power controller 210 may comprises one or more sensors (such as sensor 242).

[0077] Although it is depicted in Fig. 2a that power controller 210 is located externally to enclosure 250, it is noted that in some embodiments, power controller 210 may be located within enclosure 250. Further, although Fig. 2a depicts one sensor within enclosure 250 (i.e., sensor 241) and one sensor external to enclosure 250 (i.e., sensor 242), other embodiments of system 200 may have different sensor configurations. For example, some embodiments may have each sensor located externally to enclosure 250, while other embodiments may have each sensor located within enclosure 250. As such, consider the example embodiment of system 200 shown in Fig. 2b, where power controller 210 is located (or situated) within enclosure 250 and is connected to an internal sensor (i.e., sensor 241) and an external sensor (i.e., 242). Further, consider the example embodiment of system 200 shown in Fig. 2c, where power controller 210 is located (or situated) within enclosure 250 and is connected to an internal sensor (i.e., sensor 241) only (e.g., there is no external sensor). The embodiment of Fig. 2c may be useful for static pressurisation, using sensor 241 to determine an absolute measurement. It noted that other configurations of system 200 are equally possible.

[0078] In some embodiments, enclosure 250 meets the Ex-p certificate standard. The Ex-p certificate standard (which may be referred to as Ex p EN 60079-2 by the IEC) relates to equipment that provided protection by pressurised enclosure. In other words, the equipment meets the requirements for protection methods based on using a protective gas and excluding the formation of an explosive gas or dust atmosphere in an enclosure.

[0079] Embodiments of the power controller disclosed herein will now be discussed with reference to Fig. 1. However, it is noted that these embodiments are equivalent to embodiments of the power controller depicted in Fig. 2a, and vice versa, as well as other embodiments of the disclosed power controller described herein.

[0080] In some embodiments, the sensor data comprises pressure data of environment 140. For example, sensors 141, 142 may be a pressure sensor, such as a capacitive, strain gauge, piezoelectric or vacuum sensor. Processor 112 may then determine that the sensor data indicates that ignition is prevented upon determining that the pressure data satisfies a pressure condition.For example, the pressure condition may be that the pressure of environment 140 is below a pressure threshold (for example, 0.5 atm). With reference to Fig. 2a, enclosure 250 may contain a pressurised gas at a fixed pressure (at around 0.5 mbar (50 Pascals) above ambient pressure, for example). Sensor 241 may be a pressure sensor and determine that the pressure (such as the absolute pressure) of environment 240 is at or about this fixed pressure, which may correspond to the pressure condition. Therefore, processor 212 may determine that the sensor data indicates that ignition is prevented upon determining that the pressure data is at or about this fixed pressure.

[0081] In some embodiments, the pressure data corresponds to absolute pressure or differential pressure. For example, with reference to Fig. 2a, sensors 241, 242 may both be pressure sensors, wherein sensor 241 measures the pressure of environment 240 within enclosure 250 (e.g., the absolute pressure) and sensor 242 measure the pressure of the environment external to enclosure 250. Processor 212 may determine the differential pressure using the pressure data determined from sensors 241, 242 e.g., processor 212 may determine a difference between the pressure data measure by sensor 241 and the pressure data measured by sensor 242. In some examples, the pressure condition may comprise an absolute pressure condition and / or a differential pressure condition. In some examples, one or sensors 241, 242 may be an absolute pressure sensor (such as the MS8607 sensor, for example). One or sensors 241, 242 maybe a differential pressure sensor (such as sensors in the XGZP6877Dx series, or a gauge style sensor).

[0082] In some embodiments, with reference to Fig. 1, the sensor data comprises temperature data and / or humidity data of environment 140. For example, sensors 141, 142 may be a temperature sensor such as a thermocoupler, thermistor, resistance temperature detector (RTD), infrared sensor, and an integrated circuit (IC) temperature sensor. Moreover, sensors 141, 142 may be a humidity sensor, such as a resistive, capacitive, thermal conductivity, electrochemical, and displacement sensor.

[0083] Processor 112 may determine the sensor data indicates that ignition is prevented upon determining that the temperature data and / or humidity data satisfies a temperature condition and / or a humidity condition, respectively. For example, a temperature condition may be a temperature of less than 50°C and hence, processor 112 determines that the sensor data indicates that ignition is prevented upon determining that the temperature data is less than 50°C. In another example, a humidity conditions may be high humidity (above 60% humidity, for example) andhence, processor 112 determines that the sensor data indicates that ignition is prevented upon determining that the humidity data is above 60% humidity.

[0084] In some embodiments, the sensor data comprises gas composition data of environment 140. For example, sensors 141, 142 may be a gas sensor such as a semiconductor, electrochemical, catalytic, infrared, and thermal conductivity sensor. Sensors 141, 142 may determine the concentration of certain gases (such as oxygen, nitrogen, hydrogen, methane and other hydrocarbons) in environment 140. The gas composition may indicate the composition and / or concentration of various gases in environment 140. Processor 112 may determine that the sensor data indicates that ignition is prevented upon determining that the gas composition data satisfies a gas composition condition. For example, the gas composition condition may be less than 16% oxygen and hence, processor 112 may determine that the sensor data indicates that ignition is prevented upon determining that the gas composition data indicates that there is less than 16% oxygen in environment 140. The gas composition condition may comprise multiple gas composition conditions for each gas e.g., oxygen, nitrogen, hydrogen, methane etc.

[0085] It is noted that in some embodiments, one or more sensors (such as sensors 141, 142) measure pressure data, temperature data, humidity data and gas composition data or some combination thereof. As such, processor 112 may determine that the sensor data indicates that ignition is prevented upon determining that the sensor data satisfies each of the corresponding conditions. As such, if the sensor data does not satisfy one of the conditions, then processor 112 may not activate power output circuitry 111 to power load 130. In some examples, the conditions may be based on environment 140, load 130 or the place where load 130 is implemented. For example, the conditions may be different for an underground mine compared to an offshore oil rig.

[0086] Some embodiments of the power controller disclosed herein prevent ignition of environment 140 by determining whether environment 140 is ignitable (e.g., compromised) and as a result, terminates power being provided to load 130 (or de-energises load 130). This minimises the potential of a spark forming that may ignite environment 140 in the situation where environment 140 is ignitable. As such, in some embodiments, processor 112 is configured to, upon determining that the sensor data indicates the environment is ignitable, terminate the powered load to transition load 130 from the on-state to the off-state. For example, processor 112 may open one or more switches situated between supply 120, power output circuitry 111 andload 130 to terminate power to load 130. “Terminate the powered load” may refer to terminate powering of the load, for example.

[0087] In some embodiments, the sensor data comprises pressure data of environment 140, and processor 112 determines that the sensor data indicates environment 140 is ignitable upon determining that the pressure data satisfies a pressure condition. For example, the pressure condition may be that the pressure of environment 140 is above a pressure threshold (for example, 0.5 atm). With reference to Fig. 2a, enclosure 250 may contain a pressurised gas at a fixed pressure (at around 0.5 mbar (50 Pascals) above ambient pressure, for example). Sensor 241 may be a pressure sensor and processor 212 may determine changes to the fixed pressure, which may indicate that enclosure 250 is compromised (e.g., gases external to enclosure 250 have entered environment 240), which may indicate that environment 240 is ignitable. For example, the pressure condition which indicates that environment 240 is ignitable may be that the absolute pressure of environment 240 is below 0.4 mbar or above 0.6 mbar.

[0088] In some embodiments, the sensor data comprises temperature data and / or humidity data of environment 140, and processor 112 determines that the sensor data indicates the environment is ignitable upon determining that the temperature data and / or humidity data satisfies a temperature condition and / or a humidity condition. For example, a temperature condition may be a temperature of greater than 50°C and hence, processor 112 determines that the sensor data indicates that environment 140 is ignitable upon determining that the temperature data is greater than 50°C. In another example, a humidity conditions may be low humidity (below 60% humidity, for example) and hence, processor 112 determines that the sensor data indicates that environment 140 is ignitable upon determining that the humidity data is below 60% humidity.

[0089] In some embodiments, the sensor data comprises gas composition data of environment 140, and processor 112 determines that the sensor data indicates environment 140 is ignitable upon determining that the gas composition data satisfies a gas composition condition. For example, the gas composition condition may be greater than 16% oxygen and hence, processor 112 may determine that the sensor data indicates that environment 140 is ignitable upon determining that the gas composition data indicates that there is greater than 16% oxygen in environment 140.

[0090] Some examples for the pressure data, temperature data, humidity data and the gas composition data for determining that ignition is prevented may be equivalent examples for thepressure data, temperature data, humidity data and the gas composition data for determining that environment 140 is ignitable. It is noted that in some embodiments, one or more sensors (such as sensors 141, 142) measure pressure data, temperature data, humidity data and gas composition data or some combination thereof. As such, there may be multiple conditions that indicate environment 140 is ignitable. In some embodiments, processor 112 may determine that the sensor data satisfies at least one of these multiple conditions and terminate the powered load as a result.

[0091] In some embodiments, processor 112 cross checks its own functioning (and the functioning of other components of power controller 110) each time it operates (e.g., every time it turns on). Upon determining a fault (either it its own functioning or the functioning of any other components), processor 112 may prevent load 130 from being powered, even if ignition is prevented in environment 140.Enclosure

[0092] Fig. 3a illustrates an enclosure according to an embodiment of the present disclosure (denoted as enclosure 350). Enclosure 350 comprises power controller 310, which may be similar to power controller 110 of Fig. 1 or another embodiment of disclosed power controller described herein. As depicted in Fig. 3a, power controller 310 is placed externally to enclosure 350 and connected to load 330. Enclosure 350 is configured to contain a pressurised gas and load 330. As such, it may be said that enclosure 350 contains (or encloses) an environment of load 330. Power controller 310 comprises input port 321 which may be connected to a supply to provide power to load 330 within enclosure 350 (as well as powering a processor of power controller 310). In some examples, enclosure 350 may be formed from a metal or metal alloy, such as stainless steel. However, given that enclosure 350 comprises power controller 310, enclosure 350 does not necessarily need to be formed from a rigid material, such as stainless steel. In some examples, enclosure 350 may be formed from a plastic material or the like.

[0093] Fig. 3b illustrates a variation of the embodiment of Fig. 3a. Enclosure 350 comprises power controller 310. However, power controller 310 is situated within enclosure 350 i.e., within the environment of load 330. It is noted that with the embodiments depicted in Figs. 3a and 3b, power controller 310 is attached (adhered or affixed) to enclosure 350. However, in other examples, power controller 310 may be remote from enclosure 350 or detachable.Power controller

[0094] Fig. 4a illustrates an example embodiment of the power controller disclosed herein (denoted as power controller 410). Elements of power controller 410 (such as processor 412 and power output circuitry 411) may be similar to elements of power controller 110 depicted in Fig.1 or other embodiments of the disclosed power controller described herein. Fig. 4a illustrates power controller 410 comprising multiple ports. In particular, power controller 410 comprises input port 420, which may be configured to connect to a supply (not shown) such that power controller 410 receives power to power processor 412 and provide power to power output circuitry 411. Power controller 410 also comprises output port 430, which may be configured to connect to a load (not shown). Power controller 410 also comprises sensor ports 440, which may be configured to connect to one or more sensors configured to determine sensor data of an environment comprising a load.

[0095] Fig. 4b illustrates a variation of the embodiment of Fig. 4a. As depicted in Fig. 4b, power controller 410 comprises sensors 441, 442, rather than having sensor ports. For example, power controller 410 may be a PCB and sensors 441, 442 may be soldered on to the PCB. In some examples, sensors 441, 442 may be semiconductor-based sensors. A semiconductor-based sensor is a type of sensor that utilises the electrical properties of semiconductor materials (like silicon or gallium arsenide) to detect and measure changes in physical parameters. In some applications, semiconductor-based sensors are more sensitive, faster, and reliable than mechanical sensors, making them better for early detection and prevention of ignition. They are also compact, versatile, and cost-effective, with lower power consumption and fewer maintenance needs. Moreover, they may be intrinsically safe.

[0096] Fig. 5 illustrates an example embodiment of the power controller disclosed herein (denoted as power controller 510). Elements of power controller 510 (such as processor 512 and power output circuitry 511) may be similar to elements of power controller 110 depicted in Fig.1. It is noted that elements (or components) of power controller 510 may be elements (or components) of other embodiments of the disclosed power controller. However, the embodiment of Fig. 5 comprises comprising multiple additional safety components, as will be described below.

[0097] Power controller 510 comprises watchdog component 551 (which may also be referred to as a watchdog timer or simply a watchdog), which may be configured to detect a failure ofprocessor 512. As such, watchdog component 551 may be configured to terminate a powered load to transition the load from the on-state to the off-state upon determining a failure or unexpected behaviour of processor 512. For example, watchdog component 551 may detect that processor 512 is out of control, operating incorrectly or inefficiently, or has stopped operating all together. As such, watchdog component 551 may act as a “fail-safe” in the event that processor 512 malfunctions. Watchdog component 551 may terminate a powered load by opening one or more switches situated between input port 520, power output circuitry 511 and output port 530, for example.

[0098] Power controller 510 comprises temperature interlock component 552, which may be configured to determine whether power controller 510 exceeds a maximum junction temperature. A “maximum junction temperature” may refer to the highest temperature that a semiconductor device, like a transistor or integrated circuit, can safely operate at without experiencing damage or significant performance degradation. The maximum junction temperature may be around 150°C or around 175°C or between 150°C and 175°C. As such, temperature interlock component 552 may be configured to terminate the powered load to transition the load from the on-state to the off-state upon determining that power controller 510 exceeds a maximum junction temperature. As such, temperature interlock component 552 may act as a “fail-safe” in the event that processor 512 (or other components of power controller 510) degrades due to high temperature. Such high temperature may be common in some applications involving power controller 510, such as an underground mine, for example. Temperature interlock component 552 may terminate a powered load by opening one or more switches situated between input port 520, power output circuitry 511 and output port 530, for example.

[0099] Power controller 510 comprises reverse voltage barrier component 553, which may provide an electrical potential barrier created when a reverse voltage is applied. This effectively preventing current from flowing through the diode in the opposite direction of its intended operation. In essence, reverse voltage barrier component 553 acts as a blocking mechanism against reverse current flow, protecting the circuit from damage caused by reversed polarity, reverse voltage barrier component 553 may comprise a diode (such as a semiconductor diode). When the diode is reverse biased (positive voltage applied to the negative terminal), the depletion region within the junction widens, creating a strong electric field that repels majority charge carriers, significantly hindering current flow. While reverse voltage barrier component 553 is depicted to be between power output circuitry 511 and output port 530, reverse voltage barrier component 553 may be situated at other locations within power controller 510.

[0100] Power controller 510 comprises communication interface 560 configured to receive and transmit communication to and from processor 512. Power controller 510 comprises input / output (I / O) port 561, which may be connected to a computer system or computation device. For example, power controller 510 (and more specifically, processor 512) may be connected to a computer via I / O port 561, and processor 512 may receive or transmit communication (such as data or commands) to and from the computer via I / O port 561 across communication interface 560. Power controller 510 may connect to the computer (or other computation device) via Ethernet, USB, Thunderbolt or any other wired communication.

[0101] Power controller 510 also comprises antenna 562. As such, power controller 510 (and more specifically, processor 512) may receive or transmit communication (such as data or commands) to another device (such as a computer) wirelessly via antenna 563. For example, power controller 510 may communicate with another device using the Internet according to the IEEE 802.11 protocol, Bluetooth and electromagnetic radiation, such as infrared communication or radio. In some examples, antenna 562 may simply be receiver, such as an infrared (IR) receiver, which is configured to receive communication from an external device wirelessly. In some embodiments, VO port 561 and antenna 562 may be directly connected to processor 512.

[0102] In some embodiments, processor 512 is configured to, upon receiving a communication via I / O port 561 or antenna 562, one or more of: perform testing of power controller 510; communicate data indicative of results of testing; configure components of power controller 510; and terminate the powered load. This is useful, particularly if power controller 510 is inaccessible once deployed (e.g., within an enclosure containing a pressurised gas) or to remotely control power controller 510 so that a worker does not need to enter a dangerous area. In another example, the system comprising power controller 510 can be tested remotely without having to disassemble the whole system.

[0103] Processor 512 may perform testing of power controller 510 and its components thereof. For example, processor 512 may run diagnostics on itself, power output circuitry 511, and / or the one or more sensors connected to power controller 510 to ensure these components are operating as expected. Processor 512 may determine results from performing the testing (in the form of data) and may communicate the results (i.e., the data) to an external device (such as a computer) via I / O port 561 or antenna 562 across communication interface 560.

[0104] In some embodiments, power controller 510 may comprise one or more light emitting diodes (LEDs) of various colours, which are in communication with processor 512. Processor 512 may control each of the one or more LEDs and create patterns or sequences of LED illumination to represent different functionalities of power controller 510. For example, the LEDs may indicate that the load is powered. In other examples, the sequence of LED illumination may represent an error message, such as a fault of one of the sensors or another fault detected by processor 512.

[0105] Fig. 6a illustrates an example embodiment of the disclosed power controller (denoted as power controller 610). In this embodiment, power controller 610 comprises power controller sections 610, 620 connected in series. Each of multiple power controller sections 610, 620 comprise a processor (e.g., power controller section 610 comprises processor 612) and one or more sensors (e.g., power controller section 610 comprises sensors 614). It is noted that Fig. 6a depicts two power controller sections. However, in other embodiments, there may be more than two power controller sections. These power controller sections enable redundancy to be implemented in the power controller disclosed herein, increasing reliability of the power controller, as will be discussed. In other words, this embodiment provides multiple systems that cross check in series. Such multiple redundancy may satisfy one of the safety standards of the IEC.

[0106] Power controller sections 610, 620 further comprise switches 615, 625, respectively configured to power or terminate a load. Switches 615, 625 may be a semiconductor switch such as an insulated-gate bipolar transistor (IGBT), a metal-oxide-semiconductor field-effect transistor (MOSFET), or a power diode. Semiconductor switches may have similar benefits to semiconductor-based sensors, particularly in extreme or dangerous areas like an underground mine, as faster, and reliable than mechanical switches, while also being compact, versatile, and cost-effective. Moreover, the semiconductor switches may be less prone to degradation and intrinsically safe. As depicted in Fig. 6a, switches 615, 625 are connected in series, meaning that both switches are to be closed to provide power to the load, whereas only one switch is to be open to terminate or prevent power to the load. In this embodiment, power output circuitry 630 may be configured to activate upon receiving power from the supply (i.e., when both switches 615, 625 are closed).

[0107] The processor for power controller sections 610, 620 (e.g., processor 612) may be configured to power or terminate the load based on the sensor data (for sensors 614, for example)by controlling respective switch 615, 625. For example, to power the load, the processor of each power controller section 610, 620 determines that the sensor data indicates that ignition is prevented in the environment containing the load. This may involve processor 612 comparing the sensor data to thresholds stored by processor 612. For example, if the sensor data for all sensors meet the thresholds for preventing ignition, processor 612 powers up the load, such as by changing a low-active output signal to low or a high active output signal to high and the output signal is connected to switches 615, 625 or power output circuitry disclosed herein. Else, processor 612 powers down the load.

[0108] Upon determining that the respective sensor data indicates that ignition is prevented in the environment, and in response to the change in the output signal, power controller sections 610, 620 may close their respective switch to enable a payload from a supply connected to input port 631 to power output circuitry 630, thereby powering a load connected to output port 632. However, if one or both power controller section 610, 620 do not determine that the sensor data indicates that ignition is prevented in the environment (i.e., determines that the environment is ignitable), then the respective processor may leave the respective switches open, thereby preventing the load from being powered. This enables redundancy in power controller 600 as one of power controller section 610, 620 (or components thereof) may fail to determine that ignition is prevented in the environment.

[0109] In a similar manner, when a load is being powered, the processors may terminate the powered load (i.e., terminate the payload to power output circuitry 630) by controlling the respective switches. For example, both processors may determine that the respective sensor data indicates the environment is ignitable and open their respective switches, thereby terminating the powered load to transition the load from the on-state to the off-state. However, it is noted that only one of power controller sections 610, 620 may determine environment is ignitable to terminate the powered load, given that switches 615, 625 are connected in series. As such, this enables redundancy in power controller 600 in the event one of power controller sections 610, 620 fail to determine that the environment is ignitable, thereby also providing further safety functionality.

[0110] Fig. 6b illustrates a variation of the embodiment of Fig. 6a. As depicted in Fig. 6b, each power controller section 610, 620 is connected to power output circuitry 630. In this embodiment, both power controller sections 610, 620 may determine that ignition is prevented in the environment containing the load. Upon determining that ignition is prevented, both powercontroller sections 610, 620 (more specifically, the respective processors) may activate power output circuitry 630 to provide the power to the load. However, in this embodiment, both processors should determine that ignition is prevented. As such, power output circuitry 630 may rely on communication (i.e., a signal) from each processor of power controller sections 610, 620 to activate.Power output circuitry

[0111] Fig. 7 illustrates an example embodiment of the power output circuitry disclosed herein (denoted as power output circuit 730). Power output circuitry 730 may be used in the embodiments of the power controller disclosed herein. Power output circuitry 730 comprises input port 731 configured to connect to a supply (i.e., a power supply) and output port 732 configured to connect to a load. Power output circuitry 730 also comprises diode 733, capacitor 734 (about IpF, for example) and resistor 735 (about lOk , for example) which are arranged to gradually provide power to a load. Resistor 735 may be considered to be a pull-down resistor, as will be explained later. Power output circuitry 730 further comprises transistor 736 configured to enable (and disable) current to flow from input port 731 to output port 723. Transistor 736 may be a metal oxide field effect transistor (MOSFET) and may be a p-channel enhancement mode MOSFET, for example. Power output circuitry 730 further comprises resistor port 737 to provide (electrical) connection to resistor 735. Power output circuitry 730 is configured to be intrinsically safe in that it does not generate sparks, increased temperature or other conditions that could induce an ignition.

[0112] Power output circuitry 730 is configured to provide a ramp-up voltage output (at output port 732) to gradually power the load. As will be discussed, diode 733 and capacitor 734 form a feedback loop (which may be referred to as a feedback circuit) to gradually provide power to transition a load from an off state to an on state. This feedback loop may be considered to be an analogue feedback loop, in the sense that it may not require any input from a digital processor, for example. Further, the feedback circuit (e.g., the analogue feedback circuit) is configured to amplify the Miller effect to gradually power the load.

[0113] Power output circuitry 730 gradually provides power in the following process. When the control signal (provided by a processor, for example) at resistor 735 is pulled low, it begins discharging the gate of transistor 736, causing the gate-to-source voltage (VGS) to become more negative with respect to input port 731. Once the gate voltage crosses the threshold voltage oftransistor 736, transistor 736 starts to conduct, thereby enabling current to flow from input port 731 to output port 732. As the voltage at output port 732 rises, it is coupled back to the gate of transistor 736 through diode 733 and capacitor 734, forming a feedback loop (particularly, an analogue feedback loop) that smooths the transition and ramps up the voltage at output port 732 gradually by pulling up the gate voltage. Capacitor 734 acts as additional drain-gate capacitance of transistor 736, slowing the gate charge and controlling the turn-on speed. Diode 733 may ensure that capacitor 734 remains part of the feedback loop during turn-on, creating the controlled ramp-up at output port 732. Further, when the signal at port 737 to changes to high, transistor 736 turns off and due to diode 733, no feedback occurs to slow the transistor 736 in turning off. Therefore, turning off is instantaneous. It is noted that an n-channel MOSFET with a pull-up resistor could also be used.

[0114] Fig. 8 illustrates another example embodiment of the power output circuitry disclosed herein (denoted as power output circuit 830). Power output circuitry 830 may be used in the embodiments of the power controller disclosed herein. Power output circuitry 830 may be similar to the embodiment described with reference to Fig. 8. For example, power output circuitry 830 may be configured to gradually power a load in a similar manner. However, power output circuitry 830 comprises additional resistors 838, 839 which may enable power output circuitry 830 to provide a rapid turn-off sequence (or termination) of a provided load even if port 837 is not changed to high but is left floating. As such, power output circuitry 830 may be configured to rapidly terminate a powered load. “Rapidly” in this context may refer to (effectively) instantaneously.

[0115] Power output circuitry 830 rapidly terminates a powered load in the following process. When a control signal at resistor 835 is released (pulled high or floating), the gate voltage is quickly pulled up toward input port 831 by resistor 839 (about lOkQ, for example). Diode 833 blocks current from flowing back through capacitor 834 into the drain, preventing the capacitance at of gate 836 from being influenced by the rising output voltage at output port 832. This high-impedance path created by diode 833 prevents gate 836 from being pulled down slowly through the feedback loop, enabling gate 836 to turn off rapidly. Resistor 838 (about lOOkQ, for example) ensures that the voltage across on capacitor 834 is dissipated.Other embodiments of the power controller

[0116] Fig. 9 illustrates a circuit diagram of a power controller according to an embodiment of the present disclosure. The power controller represented by the circuit diagram of Fig. 9 comprises processor 912 and power output circuitry 930 configured to gradually power a load with power from a supply connected at input 931 to a load connected at output 932. Power output circuitry 930 may also be configured to rapidly terminate power to a load. As such, power output circuitry 930 may be similar to the embodiments described with reference to Figs. 7 and 8. Fig. 9 shows an example of the components (i.e., transistor, diode, capacitor and resistors) that may be used in embodiments of the power controller (and power output circuit) disclosed herein. However, it is noted that the specific components are not limited to what is shown in Fig. 9. For example, alternative resistors may be used to achieve similar configurations.

[0117] Fig. 10 illustrates an example of the power controller according to an embodiment of the present disclosure (denoted as power controller 1000). In this example embodiment, power controller 1000 comprises two power controller sections comprising semiconductor switches controlled by a respective processor to turn the payload on or off. In this example embodiment, power controller 1000 is connected to pressure and temperature sensors, which continuously monitors the environment containing the load. As previously discussed, in some embodiments, the sensors could measure internal or external relative or absolute pressure, temperature, humidity or gas composition.

[0118] Initially, output 1032 (denoted by H2) is deenergised (i.e., does not provide power to a load connected to output 1032). On providing power from a supply (either from an intrinsically safe or non-intrinsically safe power supply), each power controller section (in series), checks for all relevant (flexible, manufacturer defined) safety related parameters to be met (i.e., determines that ignition is prevented and components are working expectedly). On success, the output on that power controller section is energised. If both stages are active, the load connected to H2 may be energised. In this state, if one of the safety related parameters is no longer met (e.g., a processor determines that the environment is ignitable, such as over temperature or depressurisation, as well as any other fault such as unexpected behaviour of the processor), each power controller section that detects a fault is de-energised, thereby removing power from H2, thus safely deenergising the payload.

[0119] Fig. Ila shows a top view of a power controller according to an embodiment of the present disclosure. In particular, the power controller of this embodiment is a printed circuit board (PCB) with two power controller sections (labelled as Channel 1 and Channel 2), whichare identical. Fig. 1 lb shows a bottom view of the power controller of Fig. Ila. Fig. 12a shows an isometric exploded view of a power controller according to an embodiment of the present disclosure. In particular, Fig. 12a shows the power controller as a PCB board that is enclosed within a housing. Fig. 12b shows an isometric (assembled) view of the power controller of Fig.12a, in which the PCB representing the power controller is enclosed in the housing. The PCB with the housing may itself be considered to be a power controller according to an embodiment of the present disclosure.

[0120] It will be appreciated by persons skilled in the art that numerous variations and / or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

CLAIMS:

1. A power controller for providing power from a supply to a load and preventing ignition in an environment of the load, the power controller comprising:a power output circuitry; anda processor, powered by the supply, configured to:receive sensor data from one or more sensors in relation to the environment; and upon determining that the sensor data indicates that ignition is prevented in the environment, activate the power output circuitry to provide the power to the load,wherein the power output circuitry is configured to gradually power the load to transition the load from an off-state to an on-state upon activation by the processor.

2. The power controller of claim 1, wherein the sensor data comprises pressure data of the environment, and the processor determines that the sensor data indicates that ignition is prevented upon determining that the pressure data satisfies a pressure condition.

3. The power controller of claim 2, wherein the pressure data corresponds to absolute pressure or differential pressure.

4. The power controller of any one of the preceding claims, wherein the sensor data comprises temperature data and / or humidity data of the environment, and the processor determines that the sensor data indicates that ignition is prevented upon determining that the temperature data and / or humidity data satisfies a temperature condition and / or a humidity condition.

5. The power controller of any one of the preceding claims, wherein the sensor data comprises gas composition data of the environment, and the processor determines that the sensor data indicates that ignition is prevented upon determining that the gas composition data satisfies a gas composition condition.

6. The power controller of any one of the preceding claims, wherein the power output circuitry is configured to provide a ramp-up voltage output to gradually power the load.

7. The power controller of any one of the preceding claims, wherein the power output circuitry comprises an analogue feedback circuit.

8. The power controller of claim 7, wherein the analogue feedback circuit is configured to amplify the Miller effect to gradually power the load.

9. The power controller of any one of the preceding claims, wherein power output circuitry comprises one or more of:a linear regulator;a dropping resistor;a feedback transistor;a diode; anda capacitor.

10. The power controller of any one of the preceding claims, wherein the power output circuitry is configured to be intrinsically safe.

11. The power controller of any one of the preceding claims, whereinthe processor is configured to, upon determining that the sensor data indicates the environment is ignitable, terminate the powered load to transition the load from the on-state to the off- state.

12. The power controller of claim 11, wherein the sensor data comprises pressure data of the environment, and the processor determines that the sensor data indicates the environment is ignitable upon determining that the pressure data satisfies a pressure condition.

13. The power controller of any one of the preceding claims, wherein the sensor data comprises temperature data and / or humidity data of the environment, and the processor determines that the sensor data indicates the environment is ignitable upon determining that the temperature data and / or humidity data satisfies a temperature condition and / or a humidity condition.

14. The power controller of any one of the preceding claims, wherein the sensor data comprises gas composition data of the environment, and the processor determines that the sensor data indicates the environment is ignitable upon determining that the gas composition data satisfies a gas composition condition.

15. The power controller of any one of the preceding claims, wherein the power controller further comprises a watchdog component configured to terminate the powered load to transition the load from the on-state to the off-state upon determining a failure or unexpected behaviour of the processor.

16. The power controller of any one of the preceding claims, wherein the power controller further comprises a temperature interlock component configured to terminate the powered load to transition the load from the on-state to the off-state upon determining that the power controller exceeds a maximum junction temperature.

17. The power controller of any one of the preceding claims, wherein the power controller further comprises a receiver configured to receive a communication, and the processor is further configured to perform, upon receiving the communication, one or more of:testing of the power controller;communicate data indicative of results of testing.configuration of components of the power controller; andterminate the powered load.

18. The power controller of any one of the preceding claims, wherein the power controller further comprises a reverse voltage barrier component.

19. The power controller of any one of the preceding claims, wherein the power controller comprises the one or more sensors, and each of the one or more sensors is a semiconductorbased sensor.

20. The power controller of any one of the preceding claims, wherein the power controller comprises multiple power controller sections connected in series, each of the multiple power controller sections comprising one or more sensors and a processor.

21. The power controller of claim 20, whereineach of the multiple power controller sections further comprise a semiconductor switch configured to power or terminate the load; andfor each of the multiple power controller sections, the processor is configured to power or terminate the load based on the sensor data by controlling the semiconductor switch.

22. A power output circuitry comprising a capacitor and a diode, wherein the diode and the capacitor form a feedback loop to gradually provide power to transition a load from an off state to an on state.

23. The power output circuitry of claim 22, wherein the power output circuitry further comprises a gate configured to enable current to flow to the load and a resistor configured to be pulled low by a control signal to enable current to flow via the gate.

24. The power output circuitry of claim 22 or 23, wherein the power output circuitry further comprises a resistor configured to be pulled high by a control signal and the power output circuitry is further configured to rapidly terminate a powered load upon the resistor being pulled high.

25. The power output circuitry of claim 24, wherein the power output circuitry further comprises:a resistor configured to pull up a gate voltage; anda resistor configured to dissipate voltage across the capacitor.

26. An enclosure comprising the power controller of any one of claims 1 to 21, the enclosure being configured to contain a pressurised gas and a load within the enclosure.

27. The enclosure of claim 26, wherein the enclosure meets the Ex-p certificate standard.

Images