EX Robotic Enclosure Sealing and Bonding
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Solution Overview
Problem
Robotic systems operating in subterranean environments face challenges with corrosion and electrical sparking, which can lead to equipment damage and safety hazards in hazardous zones like EX Zone 1, where explosive atmospheres are present, and existing solutions do not adequately address these issues.
Innovation Solution
A robotic system with an ATEX or IECEx certified enclosure that includes a sealed design with a corrosion rate of less than 170 micrometers per year, featuring a panel and housing flange configuration with a seal element and electrical coupling to prevent sparking and corrosion, and adjustable hinges and handles for easy maintenance and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If robotic systems operate in hazardous zones with explosive atmospheres, then they can perform subterranean operations, but electrical sparking can ignite explosive materials creating safety hazards
Solution Approach 1:
The patent removes electrical components from the hazardous zone by placing them in a control room outside the explosive atmosphere. Only intrinsically safe electrical components are retained within the hazardous zone, eliminating the primary source of sparking risk while preserving operational capability through remote control and monitoring systems.
Solution Approach 2:
The patent introduces hydraulic and pneumatic systems as intermediaries to transmit power and control signals from the safe control room to the robotic components in the hazardous zone. These fluid-based transmission systems eliminate direct electrical connections in explosive atmospheres, preventing sparking while maintaining full operational control.
2Ease of manufacture
If robotic systems use standard materials for enclosure, then manufacturing is easier and cost-effective, but corrosion rate exceeds acceptable limits in subterranean environments
Solution Approach 1:
The patent employs composite material construction for the robotic enclosure, combining corrosion-resistant alloys with protective coatings and sealing layers. This composite approach achieves superior corrosion resistance in subterranean environments while maintaining manufacturing feasibility through modular assembly of pre-fabricated corrosion-resistant components.
Solution Approach 2:
The patent modifies the chemical and physical parameters of the enclosure materials by selecting specific alloy compositions with controlled corrosion rates below 170 micrometers per year. Surface treatments and protective coatings are applied to change the material parameters, enhancing corrosion resistance without fundamentally altering the manufacturing process.
3Adaptability or versatility
If robotic systems operate in corrosive subterranean environments, then they can access hazardous locations, but corrosion damages equipment reducing reliability and increasing maintenance needs
Solution Approach 1:
The patent applies preliminary protective measures including corrosion-resistant material selection, protective coatings, and sealed enclosures before the robotic system is deployed to corrosive environments. These preventive actions counteract corrosion effects in advance, ensuring equipment durability and reliability while operating in hazardous subterranean locations.
Solution Approach 2:
The patent creates a protected environment for sensitive electrical components by sealing them in enclosures that exclude corrosive atmospheric elements. This inerting approach isolates critical components from the corrosive subterranean atmosphere, maintaining equipment reliability while the robotic system operates in harsh external conditions.
4Reliability
If robotic systems are designed with sealed enclosures for corrosion protection, then corrosion resistance improves, but heat dissipation and maintenance access become more difficult
Solution Approach 1:
The patent divides the robotic enclosure into modular segments with removable panels and access points. This segmentation allows the enclosure to remain sealed for corrosion protection while providing controlled access pathways for maintenance personnel to reach internal components without compromising the overall sealed structure.
Solution Approach 2:
The patent incorporates dynamic sealing mechanisms such as gaskets and flexible seals that maintain corrosion protection while allowing temporary opening and closing during maintenance operations. These dynamic elements enable the enclosure to transition between sealed and accessible states, balancing protection and maintainability requirements.
Data Source
AI summary
A robotic system with a robot and enclosure, the robotic system configured for explosive (EX) Zone 1 certification. Fasteners attaching a panel to a housing of the enclosure can be positioned away from a seal of the panel, with the seal sealingly engaging the panel and housing when the panel is attached to the housing. The panel overlapping a portion of the housing when attached to the housing, with at least the overlapped portion having a metallized layer and the metallized layer being electrically coupled to the panel when the panel is attached. The panel can be rotationally attached to the housing by one or more hinges. The panel can be configured to assist operators with manual manipulation of the panel by attaching detachable handles to the panel.