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.

What is claimed is: 
     
         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.