System and Method for Wirelessly Charging a Mobile Inspection Robot in a Potentially Explosive Atmosphere

Abstract

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.

Claims

1. A mobile inspection apparatus adapted for use in an explosive atmosphere, the apparatus including: a mobile inspection robot for movement along a surface in the explosive atmosphere, one or more power cells which drive movement of the mobile inspection robot within the explosive atmosphere, the one or more power cells connected to an inductive charging receiving means including a secondary coil to wirelessly receive electrical power to charge the one or more power cells; and at least one inductive charging station located in the explosive atmosphere, the at least one inductive charging station including a primary coil to allow the wireless transfer of electrical power from a power source to the secondary coil when both the primary coil and secondary coil are in electrical power transfer range and wherein the primary coil and the secondary coil are respectively enclosed in an atmosphere different from the explosive atmosphere to allow the operation and charging of the mobile inspection robot to be safely performed wholly within said explosive atmosphere.

2. The apparatus according to claim 1, wherein the atmosphere different from the explosive atmosphere in which the primary coil is located is created by an insulating first moulding material provided in a first housing of the at least one inductive charging station and on the primary coil, such that the primary coil is surrounded by the first moulding material and/or by the combination of the first housing and the first moulding material, in a substantially air-free manner.

3. The apparatus according to claim 2, wherein the atmosphere different from the explosive atmosphere in which the secondary coil is located is created by an insulating second moulding material provided in a second housing located on the mobile inspection robot and on the secondary coil, such that the secondary coil is surrounded by the second moulding material and/or by the combination of the second housing and the second moulding material, in a substantially air-free manner.

4. The apparatus according to claim 3, wherein the second housing comprises at least one peripheral wall and a bottom wall which is integrally connected to the at least one peripheral wall, and the bottom wall forms an angled and/or curved, second partition wall to separate the secondary coil from the explosive atmosphere surrounding the inspection robot.

5. The apparatus according to claim 1, wherein the power source comprises at least one solar panel for charging the power source.

6. The apparatus according to claim 1, wherein the at least one inductive charging station comprises a carrying structure, wherein the first housing of the at least one inductive charging station is connected to the carrying structure.

7. The apparatus according to claim 6, wherein the first housing is displaceable with respect to the carrying structure between an original position, in which the mobile inspection robot is positioned at a distance from the first housing, and at least one displaced position, in which the mobile inspection robot, engages with the first housing.

8. The apparatus according to claim 7, wherein the at least one inductive charging station comprises a spring between the carrying structure and the first housing which forces the first housing in a direction of the original position.

9. The apparatus according to claim 6, wherein the carrying structure is configured to accommodate at least a part of the mobile inspection robot.

10. The apparatus according to claim 1, wherein the at least one inductive charging station comprises at least one guiderail configured to guide the mobile inspection robot in a direction of the primary coil.

11. The apparatus according to claim 1, wherein the mobile inspection robot comprises at least one wheel configured to move the mobile inspection robot across the surface.

12. A system for wirelessly charging a mobile inspection robot in a potentially explosive atmosphere, comprising: at least one inductive charging station, the at least one inductive charging station comprising: at least one substantially electrically insulating first housing, at least one activatable primary coil accommodated in the at least one first housing, and at least one thermally conductive and substantially electrically insulating first moulding material provided in the at least one first housing and on the at least one primary coil, such that the at least one primary coil is surrounded by the at least one first moulding material and/or by a combination of the at least one first housing and the at least one first moulding material in a substantially air-free manner; and at least one mobile inspection robot, the at least one mobile inspection robot comprising: at least one substantially electrically insulating second housing, at least one secondary coil accommodated in the second housing, at least one thermally conductive and substantially electrically insulating second moulding material provided in the at least one second housing and on the at least one secondary coil, such that the at least one secondary coil is surrounded by the at least one second moulding material and/or by the combination of the at least one second housing and the at least one second moulding material in a substantially air-free manner; and at least one chargeable power source which is electrically connected to the at least one secondary coil for driving the electrically chargeable device, in particular the mobile inspection robot, wherein, by activating the at least one primary coil of at least one inductive charging station, electrical energy is transmitted wirelessly to the at least one secondary coil of the at least one mobile inspection robot, for charging the power source, wherein the at least one second housing comprises at least one peripheral wall and a bottom wall which is integrally connected to the at least one peripheral wall, wherein the bottom wall forms an angled and/or curved second partition wall to separate the secondary coil from the environment surrounding the electrically chargeable device, in particular the inspection robot, and wherein the at least one second housing is configured to separate the at least one secondary coil and the at least one second moulding material from the environment surrounding the electrically chargeable device, in particular the inspection robot.

13. The system as claimed of claim 12, wherein the at least one inductive charging station includes a first control unit and wherein the at least one mobile inspection robot includes a second control unit.

14. The system as claimed in claim 13, wherein the first control unit is at least partly surrounded by the at least one first moulding material and/or by the combination of the at least one first housing and the at least one first moulding material in a substantially air-free manner.

15. The system as claimed in claim 13, wherein the second control unit is at least partly surrounded by the at least one second moulding material and/or by the combination of the at least one second housing and the at least one second moulding material in a substantially air-free manner.

16. The system as claimed in claim 13, wherein the first control unit is coupled to an identity sensor, the identity sensor configured to detect the identity of the at least one mobile inspection robot, wherein the second control unit is coupled to a second identity sensor, the second identity sensor configured to detect the identity of the at least one inductive charging station, and wherein the first control unit and the second control unit are programmed in such a manner that an electrical energy transferred from the at least one primary coil to the at least one secondary coil and/or charging the power source only takes place if detected identities of the at least one inductive charging station and the at least one mobile inspection robot corresponds to a predefined identity.

17. The system as claimed in claim 13, wherein the first control unit and the second control unit are programmed to compare an amount of energy produced by the at least one primary coil and an energy received by the at least one secondary coil and, depending on the result of this comparison, continue or interrupt a transmission of electrical energy from the at least one primary coil to the at least one secondary coil and/or the charging of the power source of the at least one mobile inspection robot.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0072] The invention will be explained by means of non-limiting illustrative embodiments illustrated in the figures below, in which:

[0073] FIG. 1a shows a diagrammatic plan view of an inductive charging station and a mobile inspection robot according to the invention;

[0074] FIG. 1b a shows a cross section of the inductive charging station and the mobile inspection robot as illustrated in FIG. 1a,

[0075] FIG. 1c shows a detailed representation of a part of the cross section as illustrated in FIG. 1b,

[0076] FIGS. 2a and 2b show a possible embodiment of an inductive charging station according to the invention,

[0077] FIGS. 3a and 3b show a possible embodiment of a mobile inspection robot according to the invention, and

[0078] FIG. 4 shows an assembly of an inductive charging station and a mobile inspection robot according to the invention.

DESCRIPTION OF THE INVENTION

[0079] FIGS. 1a-c show a system for wirelessly charging a mobile inspection robot (101) in a potentially explosive atmosphere according to the invention. In these figures, similar or corresponding parts are denoted by identical reference numerals.

[0080] FIG. 1a shows a plan view of an inductive charging station (102) and a mobile inspection robot (101). The inductive charging station (102) comprises a carrying structure (111) in the form of a covering (111) which partly surrounds the inspection robot (101). In the illustrated embodiment, the mobile inspection robot (101) is provided with running wheels (119) which are surrounded by caterpillar tracks (110a, 110b). The inspection robot (101) comprises a third housing (103) and an electric motor (104) accommodated in the third housing (103) for driving the inspection robot (101). At the location of the electric motor (104), the housing (103) is provided with ventilation openings (105).

[0081] FIG. 1b shows a cross section of the assembly along the line A-A′, as shown in FIG. 1a. The inductive charging station (102) comprises a substantially electrically insulating first housing (114) which is accommodated in the carrying structure (111). This first housing (114) contains a primary coil (107) for generating, for example, a magnetic veld. Further details of the first housing (114) and the primary coil (107) contained therein are illustrated in FIG. 1c, which shows a detailed representation of selection B.

[0082] The mobile inspection robot (101) comprises a substantially electrically insulating second housing (108). The second housing (108) contains a secondary coil (109) which can be coupled magnetically with the primary coil (107) of the charging station (102). Further details of the second housing (108) and the secondary coil (109) contained therein are also illustrated in FIG. 1c.

[0083] FIG. 1b furthermore shows that the mobile inspection robot (101) comprises two running wheels (119) which are positioned one behind the other and which are surrounded by the caterpillar track (110). Two running wheels (119) which are situated on opposite sides of the inspection robot (101) project with respect to a part the second housing (108) positioned between the running wheels (119). Furthermore, the inspection robot (101) comprises a chargeable electrical power source (106) which is connected to the secondary coil (109). This chargeable electrical power source (106) functions as a power supply for the electric motor (104). Furthermore, the electrical power source (106) and/or the electric motor (104) are coupled to further electrical components (118), such as for example a converter. The inspection robot (101) is provided with an inspection unit (117). The inspection unit (117) is for example configured for visual, thermographic, odorous and/or auditory inspection.

[0084] FIG. 1c shows a detailed representation of selection B as shown in FIG. 1b. The inspection robot (101) comprises a second housing (108) and a secondary coil (109) which is accommodated in the second housing (108) and which can be magnetically coupled to the primary coil (107) of the inductive charging station (102) for charging the chargeable electrical power source (106). The secondary coil (109) is in this case surrounded by the substantially electrically insulating second moulding material (112) in a substantially air-free manner. The thermally conductive and substantially electrically insulating second moulding material (112a) is, for example, a synthetic resin and/or a pouring rubber. The second moulding material (112a) is initially introduced in the second housing (108) in a liquid state. The moulding material (112) has the advantage that it is readily moldable, due to its low viscosity. As a result thereof, the risk of air inclusions in the resulting hardened moulding material (112a) after the moulding material (112a) has been introduced in a liquid state, is minimal. The secondary coil (109) may be arranged, for example, in the second housing (108), after which the moulding material (112a) is subsequently provided in a liquid state, in such a way that the space present in the second housing (108) around the secondary coil (109) is filled by the second moulding material (112) in an air-free manner. The moulding material (112a) may subsequently be at least partly hardened. The air-free filling of the environment of the secondary coil (109) is essential in order to be able to ensure safe use in a potentially explosive atmosphere. The presence of air, gas and/or other impurities may result in a risk of explosion in combination possibly internally present electrical energy and/or static electricity. Embedding the secondary coil (109) in the moulding material (112a) offers a solution to this problem. The mobile inspection robot (101) also comprises a second electronic control unit (113). In the illustrated embodiment, the second electronic control unit (113) is also surrounded by the second housing (108) and the thermally conductive and substantially electrically insulating moulding material (112) in a substantially air-free manner. However, it is also conceivable for the second electronic control unit (113) to be surrounded only by the moulding material (112a) in a substantially air-free manner. Embedding the secondary coil (109) and the second electronic control unit (113) in the moulding material (112a) provides resistance to influences from the environment. Embedding ensures that if the inspection robot (101) is situated in a potentially explosive atmosphere, the potentially explosive atmosphere cannot be ignited, neither by sparks from the secondary coil (109) and/or the electronic control unit (113), nor by heating inside the molded casing of moulding material (112a). The second housing (108) is preferably made of a chemically non-aggressive thermoplastic polymer. It is advantageous if the second housing (108) is electrically insulating so as to be able to prevent any disruption and/or reduction in the efficiency of the charging process. In the illustrated embodiment, the second housing (108) comprises different wall thicknesses. A wall portion (108a), in particular a bottom wall (108a), or second partition wall (108a), of the second housing (108) near the secondary coil (109) is relatively thin-walled, for example having a thickness of 1 mm, which ensures that the secondary coil is exposed to a substantial part of the magnetic field created during charging. Furthermore, the second housing (108) comprises a peripheral wall (108b) and a bottom wall (108a) which is integrally connected to the at least one peripheral wall (108b), wherein the bottom wall (108a) of the at least one integrally formed second housing (108) forms an angled and second partition wall (108a) for separating the secondary coil (109) from the environment surrounding the electrically chargeable device (101), in particular the inspection robot (101). The second housing (108) as such is in this case configured to separate the secondary coil (109) and the second moulding material (112a) from the environment surrounding the electrically chargeable device (101), in particular the inspection robot (101). The second housing (108), and in particular the partition wall (108a), is preferably at least partly made of polyvinylidene fluoride (PVDF) or a derivative thereof. In addition to the advantage of great strength and good resistance to chemicals and UV light, PVDF bonds with the moulding material (112) used. The bonding may be improved by using a primer (layer) between the PVDF and the moulding material.

[0085] As has already been described above, the charging station (102) comprises a primary coil (107) for generating a magnetic field. The charging station (102) comprises a first housing (114) which contains the primary coil (107). In the illustrated embodiment, the primary coil (107) is in this case surrounded by the first housing (114) and a thermally conductive and substantially electrically insulating first moulding material (112b) in a substantially air-free manner. However, it is also possible for the primary coil (107) to be surrounded substantially completely by the first moulding material (112b). The first moulding material (112b) is substantially identical to the second moulding material (112a) of the inspection robot (101) as a result of which the use of the first moulding material (112b) for embedding the primary coil (107) in the first housing (114) therefore has the same advantages as described above for the mobile inspection robot (101). The charging station (102) also comprises a first electronic control unit (115) which is connected to the primary coil (107). The first electronic control unit (115) is also surrounded by the first housing (114) and the thermally conductive and substantially electrically insulating first moulding material (112b) in a substantially air-free manner. A wall portion (114a), or the first partition wall (114a), of the first housing (114) near the primary coil (107) is in this case also thinner than a wall portion (114b) of the first housing (114) at a distance from the primary coil (107).

[0086] FIG. 1c shows a possible position of the inspection robot (101) in the charging station (102) during the wireless charging of the inspection robot (101). The primary coil (107) is in this case situated at a distance from the secondary coil (109). In particular, the first partition wall (114a) is situated at a distance from the second partition wall (108a). Between the primary coil (107) and the secondary coil (109), and in particular between the first partition wall (114a) and the second partition wall (108a), a free space (116) or air gap (116) is present. The distance between the primary coil (107) and the secondary coil (109), and in particular the distance between the first partition wall (114a) and the second partition wall (108a) at the location of the primary and secondary coil (107, 109), respectively, is preferably between 0 and 6 mm. Upon activation of the primary coil (107) of the inductive charging station (102), this facilitates the wireless transmission of electrical energy to the secondary coil (109) of the mobile inspection robot (101) in order to charge the power source (106) of the aforementioned mobile inspection robot (101).

[0087] FIGS. 2a and 2b show a diagrammatic representation of a possible embodiment of an inductive charging station (202) according to the invention for use in a system for wirelessly charging a mobile inspection robot (not shown) in a potentially explosive atmosphere according to the invention. In these figures, identical or corresponding parts are denoted by identical reference numerals. The inductive charging station (202) comprises a first housing (214) and an activatable primary coil (not shown) which is accommodated in the first housing (214). The charging station (202) furthermore comprises a carrying structure (211) or covering (211) for at least partly surrounding an inspection robot (not shown). An advantage of the covering (211) is that it offers protection against influences from outside for the mobile inspection robot during the wireless charging of the aforementioned inspection robot.

[0088] In the illustrated embodiment, the first housing (214) is displaceably and also rotatably accommodated in the charging station (202). It is conceivable for a part of the covering 211 which—in a coupled position—is positioned above the inspection robot, not to be used. The first housing (214) is in this case rotatable about a rotation point (221). However, it is also possible for the first housing (214) and/or the carrying structure (211) to comprise one or several resilient parts and/or pressure elements in order to facilitate the alignment of the primary coil with respect to the secondary coil, and thus achieving (optimum) contact with the inspection robot to be charged. The charging station (202) also comprises a guiderail (220) for guiding a mobile inspection robot in the direction of the primary coil. In the illustrated embodiment, the guiderail (220) because a sloping orientation. The slope of the guiderail (220) is, for example, between 5 and 15 degrees. It is conceivable for the running wheels and/or the (caterpillar) tracks of the inspection robot to be charged fall on both sides of the guiderail (220), viewed from the direction of guiding. The guiderail (220) may, for example, make contact with a part of the frame and/or the housing of the inspection robot during guiding of the inspection robot in the direction of the primary coil. However, it is also conceivable for the guiderail (220) to serve as a drive-on ramp for an inspection robot. The primary coil of the inductive charging station (202) is connected to an electrical power source (206), in particular a chargeable power source (206), of the inductive charging station (202) in order to activate the primary coil. In the illustrated embodiment, the inductive charging station (202) also comprises a solar panel (222) which is connected to the power source (206) for charging the power source (206). In the illustrated embodiment, the solar panel (222) is positioned on a side of the carrying structure (211) facing away from the second housing (214). Obviously, it is also possible for the inductive charging station (202) to comprise another power supply and/or for the inductive charging station (202) to be coupled to a non-chargeable power source.

[0089] FIGS. 3a and 3b show a diagrammatic representation of a possible embodiment of an inspection robot (301) according to the invention for use in a system for wirelessly charging the inspection robot (301) in a potentially explosive atmosphere according to the invention. In these figures, identical or corresponding parts are denoted by identical reference numerals.

[0090] The inspection robot (301) comprises a second housing (308) and a secondary coil (not shown) which is accommodated in the second housing (308) and which can be coupled magnetically with the primary coil of the charging station (not shown), for charging a chargeable electrical power source (not shown). The inspection robot (301) furthermore comprises a thermally conductive and substantially electrically insulating second moulding material (not shown) which is provided in the second housing (308) and on the secondary coil, in particular a synthetic resin and/or a pouring rubber, wherein the secondary coil is surrounded by the second moulding material and/or by the combination of the second housing (308) and the second moulding material in a substantially air-free manner. The secondary coil is also electrically connected to a chargeable power source (not shown) and electric motor (not shown) for driving the mobile inspection robot (301).

[0091] The inspection robot (301) relates to a mobile inspection robot (310) which, in the illustrated embodiment, is provided on both sides with running wheels (319) which are placed one behind the other and which are surrounded by caterpillar tracks (310a, 310b). Two running wheels (319) situated on opposite sides of the inspection robot (301) project with respect to a part of the second housing (308) positioned between the running wheels (319). The inspection robot (301) comprises an inspection camera (323) for inspection purposes and an antenna (324) for receiving and/or transmitting signals, such as for example radio-frequency signals. It is conceivable for the inspection robot (301) to comprise a plurality of sensors, for example a light sensor, a temperature sensor, a humidity sensor, an air sensor, a gas sensor and/or an electronic nose. In the shown embodiment, the second housing (303) is provided with optional cooling ribs (330). It is also conceivable that the first housing of the charging station is provided with cooling ribs. In the illustrated embodiment, the inspection robot (301) comprises a third housing (303) in order to protect, for example, the electrical power source and/or the electric motor. However, it is also possible for the second housing (308) and the third housing (303) to be mutually integrated and/or for the third housing (303) to form part of the second housing (308).

[0092] FIG. 4 shows an assembly of an inductive charging station (402) and an inspection robot (401) according to the invention. The inspection robot (401) and the inductive charging station (402) each have substantially the same components and functionality as the embodiments described in FIGS. 1-3. FIG. 4 shows the cooperation between the inductive charging station (402) and the mobile inspection robot (401) during the wireless transmission of electrical energy. In the illustrated embodiment, the first housing (414) of the inductive charging station (402) comprises an angled first partition wall (414a) for separating the primary coil from the environment surrounding the inductive charging station (402). The second housing (408) of the inspection robot (401) comprises an angled second partition wall (408a) for separating the secondary coil from the environment surrounding the inspection robot (401). In this case, a plane enclosed by the primary coil is situated substantially parallel to at least a part of the first partition wall (414a), wherein a plane enclosed by the secondary coil is situated substantially parallel to at least a part of the second partition wall (408a). The first partition wall (414a) and the second partition wall (408a) are configured to engage with one another, with the first partition wall (414a) and the second partition wall (408a) substantially having a complementary design. This results in a desired alignment of the secondary coil with respect to the primary coil, which may significantly aid the efficiency of the charging process. In this case, the first housing (414) is partly accommodated in a part of the second housing (408). The charging station (402) also comprises a first control unit (not shown) which is coupled to a first identity sensor (417) for detecting the identity of the mobile inspection robot (401), wherein the first control unit is programmed in such a way that the transmission of electrical energy from the primary coil to the secondary coil and/or the charging of the power source of the inspection robot only takes place if a detected identity of the mobile inspection robot (401) corresponds to a predefined identity. However, it is also conceivable for the inspection robot (401) to comprise an identity sensor for detecting the identity of an inductive charging station according to an identical principle.

[0093] It will be clear that the invention is not limited to the exemplary embodiments illustrated and described here, but that countless variants are possible without departing from the scope of the attached claims and that these will be obvious to the person skilled in the art. In this case, it is conceivable for different inventive concepts and/or technical measures of the above-described variant embodiments to be fully or partly combined without moving away from the inventive idea described in the attached claims.

[0094] The verb ‘comprise’ and conjugations thereof used in this patent are understood to mean not only ‘comprise’, but also the expressions ‘contain’, ‘substantially consist’, ‘formed by’, and conjugations thereof.