Wireless CAN Retrofit for Underground Drill Communication Reliability

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Solution Overview

Problem

Conventional underground production drill control systems face challenges with CAN bus cables being easily damaged due to the harsh operating environment, making them difficult to protect.

Innovation Solution

A wireless communication system is retrofitted onto existing CAN bus control systems, comprising slave and master units with protocol converters and transceivers, enclosed in impact-resistant and thermally-conductive materials, to establish a wireless Controller Area Network between the control system and actuators.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If CAN bus cables are used for control system communication, then reliable wired communication is achieved, but the cables are easily damaged and difficult to protect in the harsh underground drilling environment

Engineering Contradiction:

Improvecommunication reliabilityVSAvoidcable damage from environmental factors

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical CAN bus cable system with a wireless communication system. The slave unit and master unit use wireless transceivers to communicate control signals and data without physical cable connections, eliminating the mechanical vulnerability of cables to damage from the harsh underground drilling environment while maintaining communication reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces wireless communication technology as an intermediary between the control system and actuators. The slave unit contains a wireless transceiver that mediates communication between the hydraulic actuator and the master control unit, replacing the direct cable connection with a wireless signal transmission medium that is not susceptible to physical damage

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If wireless communication components are added to the system, then cable damage is eliminated, but device complexity increases

Engineering Contradiction:

Improveprotection from environmental damageVSAvoidsystem complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into the slave unit: the CAN bus interface for wired communication compatibility, the wireless transceiver for wireless communication, and the protocol converter for protocol translation, all integrated into a single encapsulated unit that interfaces with the existing hydraulic actuator. This merging approach manages complexity by providing a unified interface rather than separate components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The slave unit is designed with multi-functionality to handle both CAN bus communication and wireless communication protocols, allowing it to serve as a bridge between the existing wired control system and the new wireless communication infrastructure, thereby managing complexity through versatile component design

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If battery and power controller are encapsulated in thermally-conductive fire retardant material, then safety is improved, but heat dissipation requirements increase

Engineering Contradiction:

ImprovesafetyVSAvoidheat dissipation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent uses composite material encapsulation that combines fire retardant properties with thermal conductivity. The encapsulant material provides both safety benefits (fire resistance) and thermal management benefits (heat dissipation), resolving the contradiction by finding a material that satisfies both opposing requirements simultaneously

Inventive Principle:

Principle #40Composite materials

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 system protects the communication infrastructure from damage and environmental ingress, maintaining seamless operation of the drill without disrupting the existing control system.

Implementation Method 1

the controller and battery encapsulated in a thermally-conductive fire retardant material

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12483638B2Underground production drill communication system

Publication Date: 2025.11.25 BCI MINING TECH PTY LTD

AI summary

A communication system (10) for an underground production drill (8), comprising a slave unit (12) comprising a CAN bus interface (14) and an electrical power controller (16) and rechargeable battery (18), said controller (16) configured to monitor a status and regulate charging of said battery (18). The controller (16) and battery (18) encapsulated in a thermally-conductive fire retardant material (10). The slave unit (12) includes a first protocol converter (24) and powered via the power controller (16) and configured to convert between wireless network and CAN bus protocols, and a first wireless transceiver (26) arranged in signal communication with the power controller (16) and first protocol converter (24) and configured to transceive the wireless network protocol and transmit the status of the battery (18). System (10) includes a master unit (28) comprising a CAN bus interface (14), a second protocol converter (30) and a second wireless transceiver (32).