Wireless Charging Coils in Explosive Atmospheres

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Charging electrically powered inspection robots in potentially explosive atmospheres is risky and inefficient due to the risk of ignition from hot surfaces, sparks, and static electricity, making it difficult to maintain and recharge these devices in hazardous environments like oil and gas fields.

Innovation Solution

A wireless inductive charging system using electrically insulating and thermally conductive moulding materials to surround the coils, preventing sparks and heat accumulation, allowing for safe and efficient charging of inspection robots without direct electrical connections, and incorporating identity sensors for secure energy transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrically powered inspection robots are charged in potentially explosive atmospheres using traditional wired charging methods, then the devices can be recharged, but the risk of ignition from sparks, hot surfaces, and static electricity increases significantly

Engineering Contradiction:

ImprovesafetyVSAvoidignition risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical wired charging system with a wireless inductive charging system. The charging station uses a primary coil to generate a magnetic field that induces current in a secondary coil within the robot, eliminating physical electrical connections and the associated spark and static electricity hazards in explosive atmospheres

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates an inert environment by completely encapsulating both the primary coil in the charging station and the secondary coil in the robot with electrically insulating and thermally conductive moulding material. This encapsulation prevents any interaction between electrical components and the explosive atmosphere, effectively creating a safe charging interface

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Reliability

If inspection robots are removed from hazardous environments for charging, then safety is improved, but productivity and efficiency decrease due to downtime

Engineering Contradiction:

ImprovesafetyVSAvoidusability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent introduces a wireless charging station as an intermediary device that can be positioned at a safe distance from the hazardous area while still enabling charging of robots that operate in explosive atmospheres. The inductive coupling allows energy transfer through a non-conductive barrier, maintaining safety while enabling continuous operation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

By replacing wired charging with wireless inductive charging, the system eliminates the need to physically connect cables that could conduct sparks or static electricity into hazardous zones, allowing robots to be charged in or near explosive atmospheres without compromising safety

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Use of energy by moving object

If traditional wired charging connections are used in explosive atmospheres, then electrical energy can be transferred, but the risk of sparks and static electricity ignition increases

Engineering Contradiction:

Improveenergy transferVSAvoidsparks and static electricity

Core Design Contradiction:

Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The patent substitutes the mechanical electrical connection system with an electromagnetic field-based wireless energy transfer system. The primary coil generates a time-varying magnetic field that induces current in the secondary coil, transferring energy without physical contact and eliminating spark generation from plugging and unplugging connectors

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnetic field serves as an intermediary medium for energy transfer between the charging station and the robot. This field-based mediation allows energy transmission without direct electrical contact, preventing the generation of sparks and static electricity that would occur with traditional wired connections

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of operation

If coils are exposed during charging operations, then wireless energy transfer is enabled, but heat accumulation and ignition risk increase

Engineering Contradiction:

Improvewireless charging capabilityVSAvoidheat accumulation

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The patent uses composite encapsulation consisting of electrically insulating material combined with thermally conductive properties. The moulding material acts as a thermal pathway to conduct heat away from the coils while simultaneously providing electrical insulation, thus managing heat accumulation without compromising wireless charging functionality

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The encapsulating moulding material serves as a thermal intermediary that conducts heat away from the coils to safer areas. This material layer manages thermal energy distribution, preventing localized heat accumulation that could lead to ignition while allowing the wireless charging process to continue

Inventive Principle:

Principle #24Intermediary (Mediator)

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 wireless charging of inspection robots in potentially explosive atmospheres, increasing their usability and efficiency by eliminating the need for removal from hazardous environments and reducing the risk of ignition.

Implementation Method 1

by activating at least one primary coil of at least one inductive charging station, electrical energy can be transmitted wirelessly to at least one secondary coil of at least one electrically chargeable device

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

at least one thermally conductive and substantially electrically insulating first moulding material which is provided in the first housing and on the primary coil... at least one thermally conductive and substantially electrically insulating second moulding material which is provided in the second housing and on the secondary coil

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11518256B2System and method for wirelessly charging a mobile inspection robot in a potentially explosive atmosphere

Publication Date: 2022.12.06 EXROBOTICS BV

AI summary

The invention relates to a system for wirelessly charging an electrically chargeable device, in particular a mobile inspection robot, in a potentially explosive environment. The invention also relates to a charging station for use in such a system according to the invention. The invention further relates to an electrically chargeable device, in particular an inspection robot, for use in such a system according to the invention. In addition, the invention relates to a method for wirelessly charging an electrically chargeable device, in particular a mobile inspection robot, by using such a system according to the invention.