Rail-Mounted Inspection Robot With In-Motion Charging
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Solution Overview
Problem
Deploying robots in hazardous environments, such as explosion-proof areas in process automation plants, poses challenges due to the risk of igniting flammable substances and the inefficiency of battery charging methods, which can be costly and cumbersome.
Innovation Solution
Implementing rail-mounted robots with battery charging capabilities that draw power from embedded wireless or conductive power sources along the rail, allowing charging while in motion, and using location indicia for precise localization, ensuring safe operation and efficient data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the robot charges the battery at a base charging station before operation, then the battery size can be limited, but the robot's operational efficiency decreases and requires stationary charging stops
Solution Approach 1:
The robot charges the battery continuously while moving along the rail through in-motion charging stations positioned at intervals. This eliminates stationary charging stops and maintains continuous operational flow, transforming the charging process from a discrete interrupt to a continuous background operation that occurs during normal transit.
Solution Approach 2:
The patent replaces the mechanical connection-based charging system (physical plugging into base stations) with wireless power transfer technology. This allows charging to occur without mechanical contact or stationary stops, enabling the robot to charge while moving along the rail through electromagnetic field-based power transmission.
2Use of energy by moving object
If exposed power terminals are used for charging, then power transfer is efficient, but the risk of ignition in hazardous areas increases
Solution Approach 1:
The patent replaces exposed conductive power terminals with wireless power transfer technology that uses electromagnetic fields to transmit power through the air gap between the rail-mounted transmitter and the robot's receiver. This eliminates the need for exposed electrical contacts that could generate sparks, while maintaining efficient power transfer through optimized electromagnetic coupling.
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary medium to transfer power between the rail infrastructure and the mobile robot. This intermediary allows power transmission without direct electrical contact, eliminating the spark generation risk associated with exposed terminals while maintaining the efficiency of electrical power transfer through controlled electromagnetic coupling.
3Productivity
If wireless charging infrastructure is deployed throughout the plant, then continuous charging is enabled, but the infrastructure complexity and cost increase significantly
Solution Approach 1:
The patent integrates wireless power transmission functionality into the existing rail infrastructure, allowing the same rail system to serve both as the guide/path for the robot and as the power delivery network. This multi-functional design eliminates the need for separate wireless charging infrastructure, reducing overall system complexity while enabling continuous charging capability.
Solution Approach 2:
The patent combines the guidance rail and power transmission rail into a single integrated infrastructure system. The rail serves dual purposes: providing physical guidance for the mobile robot and simultaneously transmitting wireless power to the robot during motion. This merging of functions reduces the number of separate infrastructure components needed and simplifies deployment.
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
Enables safe and efficient operation of robots in hazardous areas by preventing ignition risks and optimizing battery charging, reducing human error, and enhancing data exchange without the need for extensive wireless infrastructure.
Implementation Method 1
a charger to draw power from a power terminal integral with the rail while the rail-mounted robot is in motion, and to charge the battery using the drawn power
Implementation Method 2
the charger takes the form of a conductive wheel or capacitive coupling pad that draws power from the exposed conductive trace
Implementation Method 3
the charger may take the form of a radio frequency (RF) power antenna, and the power terminal integral with the rail takes the form of a plurality of RF power transmitters distributed along a length of the rail
Implementation Method 4
an actuator to propel the rail-mounted robot along a rail
Implementation Method 5
one or more onboard sensors configured to generate one or more sensor signals that are usable to inspect the plant
Data Source
AI summary
Implementations are described herein for operating rail-mounted robots in hazardous conditions. In various implementations, a rail-mounted robot configured to inspect a plant with an explosion proof area may include: an actuator to propel the rail-mounted robot along a rail; a battery to provide power to the actuator; a charger to draw power from a power terminal integral with the rail while the rail-mounted robot is in motion, and to charge the battery using the drawn power; and logic to localize the rail-mounted robot based on readings from location indicia distributed along the rail.