Intrinsic-Safe Electromagnetic Coils for Higher Power Density
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Solution Overview
Problem
Current intrinsically safe (IS) electromagnetic devices for hazardous environments lack the mechanical power and power density required for efficient operation in explosive atmospheres, due to energy limitations that restrict their power delivery and size, making them unsuitable for applications like small unmanned aerial vehicles.
Innovation Solution
Design of IS electromagnetic devices with multiple independent safe wire coils wound around ferromagnetic cores, each with electrical insulator layers, connected to independent power supplies, ensuring maximal voltage and short-circuit current remain below ignition limits, allowing for increased mechanical power and power density while preventing ignition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If energy limitation is applied to ensure intrinsic safety in explosive atmospheres, then ignition risk is prevented, but mechanical power and power density are reduced
Solution Approach 1:
The electromagnetic device is divided into multiple independent coils, each connected to a separate power supply. Each coil operates within intrinsic safety limits individually, but collectively they can deliver higher total power than a single coil could provide while maintaining safety standards.
Solution Approach 2:
Multiple intrinsically safe coils are combined in a single electromagnetic device to achieve cumulative power output that exceeds what a single intrinsically safe coil could provide, while the device as a whole maintains intrinsic safety through proper isolation and design of each coil circuit.
2Power
If multiple independent safe wire coils are used to increase mechanical power, then power density is improved, but device complexity increases
Solution Approach 1:
The device uses multiple independent coils that can be designed as modular units. Each coil assembly can be standardized and replicated, which while increasing component count, allows for simplified manufacturing and assembly processes through modularity.
Solution Approach 2:
Each safe wire coil is designed to perform the same function and can be interconnected in different configurations (series, parallel, or combinations) to achieve different power and voltage requirements, making the basic coil unit a universal building block that reduces overall design complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables IS devices to safely deliver greater mechanical power and power density, enhancing their operational capabilities in hazardous environments without risking ignition, thus overcoming the limitations of existing IS devices.
Implementation Method 1
The present invention includes types of intrinsically safe (IS) electromagnetic devices for use in explosive atmosphere zones
Data Source
AI summary
Disclosed is a design approach for intrinsically safe electromagnetic devices such as electrically actuated valves, motors, generators, or transformers intended for and capable of safe operation in explosive atmospheres or environments. The design employs a plurality of electrically insulated, intrinsically safe circuits cooperating to induce, or in the case of a generator, create a relatively large magnetic flux in the ferromagnetic core, or iron, of these devices. A method to construct such intrinsically safe devices is disclosed. These devices can be practically used in machines, mechanisms, valves, and manned or unmanned vehicles intended for safe operation in hazardous environments, for example underground coal mines or ATEX or EX classified facilities.