EP4665646A1

EP4665646A1 - Autonomous underwater vehicle power and data transfer system

Info

Publication number: EP4665646A1
Application number: EP24757472.6A
Authority: EP
Inventors: Brad HIBBARD; Jay HIBBARD
Original assignee: Individual
Current assignee: Individual
Priority date: 2023-02-14
Filing date: 2024-02-12
Publication date: 2025-12-24
Also published as: WO2024173197A1

Abstract

An autonomous underwater vehicle docking system that includes at least one power and data transfer module having a first portion and a second portion, at least one underwater autonomous vehicle (AUV), and an underwater docking station. The first portion of the transfer module is disposed on the AUV and the second portion of the transfer module is disposed on the underwater docking station. The first and second portions of the transfer module being configured to engage with one another to form an electrical connection for power and data transfer. The portions of the transfer module being formed a self-passivating transition metal having a property of forming a non-conductive passivation layer upon immersion in water and wherein a portion of the non-conductive passivation layer is removed due to scraping between the portions of the transfer module upon mating thereof.

Description

AUTONOMOUS UNDERWATER VEHICEE POWER AND DATA TRANSFER SYSTEM

RELATED APPLICATIONS

[0001] This application claims priority benefit of U.S. Provisional Application Serial Number 63/445,667 filed 14 February 2023; the contents of which are hereby incorporated by reference.

FIELD OF THE INVENTION

[0002] The present invention relates to Autonomous Underwater Vehicles (AUVs), and more particularly to an underwater AUV power and data transfer system for power and data exchange.

BACKGROUND OF THE INVENTION

[0003] Autonomous Underwater Vehicles (AUVs) may be used to conduct various underwater operations. Such operations may include, for example, military and non-military operations such as maritime reconnaissance, undersea searching, undersea surveying, submarine tracking and trailing, monitoring of various types of sea traffic, monitoring and researching animal and plant life, and communication and/or navigational aids. These and other operational capabilities make AUVs a potential option in providing a seagoing component for homeland security or other research and monitoring endeavors. In any of these scenarios, multiple AUVs could be deployed along the coasts of the country and conduct various monitoring, research, and surveillance operations.

[0004] For many of these military, non-military, security, research, and monitoring operations, it may be desirable that the AUVs remain submerged for relatively long periods of time. As such, many AUVs may include a propulsion plant that is powered by a power source that can generate a desired level of power while the AUV remains submerged, while at the same time generating a relatively low level of acoustic noise. Various types of power sources have been used and/or developed that meet one or more of these objectives. Some examples include batteries, and closed brayton cycles (CBCs) with rechargeable heat sources. Although batteries and rechargeable heat sources may be advantageous from a cost standpoint, both of these types of power sources may need periodic recharging.

[00051 In addition to the need to be periodically recharged or refueled, at some point during AUV operation, it may be desirable to retrieve various types of data from, and to supply various types of data to, the AUV. Such data can include stored intelligence and research data, data associated with equipment on-board the AUV, and data that updates AUV mission programming. [0006] In many current AUVs, the need to periodically recharge, and/or retrieve data from, and/or supply data to, the AUV may require that the AUV be periodically retrieved and taken out of service. In many instances, this results in the AUV being surfaced, and removed from the water, in order to conduct these operations. Moreover, some current AUVs may be periodically taken out of service to inspect on-board equipment to determine if maintenance should be conducted. In both instances, this can be a costly and time-consuming operation, and can reduce overall mission effectiveness.

[0007] To alleviate the need to remove the AUV from the water, submerged docking stations have been attempted. Such docking stations typically utilize mateable connectors or electromagnetic induction as a non-contact connector, both of which have significant drawbacks that have limited the use of submerged docking stations for AUVs. That is, mateable connectors require high connection forces and close tolerance alignment, which are not feasible and often lead to damaged connectors, docking stations, and/or AUVs. While non-contact connectors using electromagnetic induction solve the above-described problems associated with the mateable connectors, such non-contact connectors present their own drawbacks, namely alignment issues, slow data transfer, only one way power transfer, low power capacity, high power loss, and various other inefficiencies.

[0008] Thus, there exists a need for a submerged docking system for AUVs that provides for easy connection alignment, two-way power transfer, two-way data transfer, high power capacity, and low power loss.

SUMMARY OF THE INVENTION

[0009] The present invention autonomous underwater vehicle docking system that includes at least one power and data transfer module having a first portion and a second portion, at least one underwater autonomous vehicle (AUV), and an underwater docking station. The first portion of the transfer module is disposed on the AUV and the second portion of the transfer module is disposed on the underwater docking station. The first and second portions of the transfer module being configured to engage with one another to form an electrical connection for power and data transfer. The portions of the transfer module being formed a self-passivating transition metal having a property of forming a non-conductive passivation layer upon immersion in water and wherein a portion of the non-conductive passivation layer is removed due to scraping between the portions of the transfer module upon mating thereof. The inventive system provides for easy connection alignment, two-way power transfer, two-way data transfer, high power capacity, and low power loss between the at least one AUV and the underwater docking station. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The present invention is further detailed with respect to the following figures that depict various aspects of the present invention.

[0011] FIG. 1 is a schematic drawing of components of an autonomous underwater vehicle docking system according to embodiments of the present disclosure;

[0012] FIG. 2 is a schematic drawing of interconnected components of an autonomous underwater vehicle docking system according to embodiments of the present disclosure;

[0013] FIG. 3 is a schematic drawing of interconnected components of an autonomous underwater vehicle docking system according to embodiments of the present disclosure;

[0014] FIG. 4 is a schematic drawing of interconnected components of an autonomous underwater vehicle docking system according to embodiments of the present disclosure;

[0015] FIG. 5 is an architecture diagram showing the interconnection of components of an autonomous underwater vehicle docking system according to embodiments of the present disclosure;

[0016] FIG. 6 is an architecture diagram showing the interconnection of components of an autonomous underwater vehicle docking system according to embodiments of the present disclosure;

[0017] FIG. 7 is an architecture diagram showing the interconnection of components of an autonomous underwater vehicle docking system according to embodiments of the present disclosure;

[0018] FIG. 8 a schematic drawing of a power and data transfer module according to embodiments of the present disclosure; [0019] FIG. 9 is a schematic drawing of an off-board bidirectional underwater charging system according to embodiments of the present disclosure;

[0020] FIG. 10 is a schematic drawing of an on-board bidirectional underwater charging system according to embodiments of the present disclosure;

[0021] FIG. 11 is a schematic drawing of an on-board bidirectional underwater charging system with a cable for mobile charging away from a power and data hub with an easily detachable and attachable connector according to embodiments of the present disclosure; and

[0022] FIG. 12 is a schematic drawing of a bidirectional underwater charging system with self- cleaning large misalignment contacts according to embodiments of the present invention.

DESCRIPTION OF THE INVENTION

[0023] The present invention has utility as an Autonomous Underwater Vehicle (AUV), docking system for power and data exchange that provides for easy connection alignment, two- way power transfer, two-way data transfer, high power capacity, and low power loss.

[0024] The present invention will now be described with reference to the following embodiments. As is apparent by these descriptions, this invention can be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. For example, features illustrated with respect to one embodiment can be incorporated into other embodiments, and features illustrated with respect to a particular embodiment may be deleted from the embodiment. In addition, numerous variations and additions to the embodiments suggested herein will be apparent to those skilled in the art in light of the instant disclosure, which do not depart from the instant invention. Hence, the following specification is intended to illustrate some particular embodiments of the invention, and not to exhaustively specify all permutations, combinations, and variations thereof. [0025] It is to be understood that in instances where a range of values are provided that the range is intended to encompass not only the end point values of the range but also intermediate values of the range as explicitly being included within the range and varying by the last significant figure of the range. By way of example, a recited range of from 1 to 4 is intended to include 1-2, 1-3, 2-4, 3-4, and 1-4.

[0026] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0027] Unless indicated otherwise, explicitly or by context, the following terms are used herein as set forth below.

[0028] As used in the description of the invention and the appended claims, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0029] Also as used herein, “and/or” refers to and encompasses any and all possible combinations of one or more of the associated listed items, as well as the lack of combinations when interpreted in the alternative (“or”).

[0030] According to embodiments, an autonomous underwater vehicle docking system 10 for power and data transfer includes a first underwater autonomous vehicle (AUV) 20 and an underwater docking station 30, also referred to herein as a stationary power and data hub.

According to embodiments, power and data are supplied to the docking station 30 via off-board power and data transmission lines 32, 34 that according to embodiments extend from a remote hub 40, which may be positioned onshore, on a dock, on a submarine, or on a boat. An additional embodiment of an off-board bidirectional underwater charging station is shown in FIG. 9. According to such embodiments, an AUV or battery powered vehicle can engage with a docking station and charge on board batteries using battery charger located in the docking station while transferring data. According to some embodiments, power and data is supplied to the docking station 30 via on-board components such as a power supply and a data transmitter housed on the docking station 30. An additional embodiment of an on-board bidirectional underwater charging station is shown in FIG. 10. According to such embodiments, an AUV or battery powered vehicle can engage with a docking station and charge the AUV on-board batteries while transferring data. Alternatively, the AUV can supply power from its battery to the docking station for power or to charge another battery. The underwater AUV 20 and the underwater docking station 30 are configured to engage one another in order to undertake a power transfer and/or a data transfer operation. According to the present invention, the underwater AUV 20 and the underwater docking station 30 engage one another via a power and data transfer module 12. According to embodiments, the inventive system 10 includes a plurality of power and data transfer modules 12. Each power and data transfer module 12 includes a first portion 14 and a second portion 16 that are configured to engage with one another to form an electrical connection for power and data transfer. Notably, the power and data transfer module 12 is capable of two-way power transfer and two-way data transfer.

[0031] According to embodiments, a first portion 14 of a transfer module 12 is disposed on the AUV 20 and a second portion 16 of a transfer module 12 is disposed on the underwater docking station 30. It will be understood that either portion of a transfer module 12 may be disposed on either of the AUV 20 or the docking station 30 without departing from the present invention. In order to undertake a power and/or data transfer operation, the AUV 20 comes into proximity with the docking station 30 and the first portion 14 of the transfer module 12 disposed on the AUV 20 engages with second portion 16 of the transfer module 12 disposed on the docking station 30 to form an electrical connection for power and data transfer between the AUV 20 and the docking station 30.

[0032] According to embodiments, each power and data transfer module 12 is a self-passivating connector, meaning that the connector forms a protective layer on itself that shields it from corrosive processes. According to some embodiments, each power and data transfer module 12 is a NiobiCONN contact, which are distributed and manufactured by iCONN Systems, LLC. Niobium contacts create their own passive film when energized and exposed to water. The film acts as an insulator, electrically isolating the contact from the surrounding water and adjacent contacts. The insulating anodic film on the niobium contact mating surface is breached, providing electrical connectivity as the contacts are mated. If the niobium contact insulating anodic film is removed, then those surfaces are restored with the anodic film as soon as voltage is applied. The niobium contacts are self-healing. Niobium contacts are safe from direct contact with power applied, up to 60v. Further details regarding such embodiments of power and data transfer modules are provided in U.S. Patent No. 9,197,006 issued to Northrop Grumman Systems Corporation on November 24, 2015 and U.S. Patent No. 9,893,460 issued to Northop Grumman Systems Corporation on February 13, 2018, both of which are hereby incorporated by reference.

[0033] According to embodiments, the AUV 20 is powered by batteries, which are stored on or within a housing of the AUV 20. According to embodiments, the batteries are rechargeable, such as lithium-ion batteries. Accordingly, according to embodiments, the power transfer operation includes transferring power from the docking station 30 to the AUV 20 to recharge the batteries of the AUV 20. To accomplish this, the docking station 30 includes a power source, which according to embodiments is any of a power generator, a power cord 34 connected to a power source that is remote from the docking station 30, or an even larger pack of batteries . According to embodiments, the AUV 20 is also able to transfer power from its batteries to the docking station 30, if the need should arise.

[0034] According to embodiments, the AUV 20 includes a data processing unit, which is stored on or within the housing of the AUV 20. According to embodiments, the data processing unit (also referred to herein as a data converter) is a computer configured to store and read data. Accordingly, according to embodiments, the data transfer operation includes transferring data from the docking station 30 to the AUV 20 to exchange data between the data processing unit of AUV 20 and a data processing unit on or connected to the docking station 30. To accomplish this, the docking station 30 includes or is connected to a data processing unit of its own, which according to embodiments is any of a computer or a wireless network. According to embodiments, the AUV 20 is also able to transfer data from its data processing unit to the data processing unit of the docking station 30 if the need should arise. According to embodiments in which a data processing unit is provided with the docking station 30, data transferred from an AUV 20 or other component of the system 10 to the docking station 30 may be pre-processed so that only anomaly data is transmitted to a remote hub 40, such as an on-shore station, submarine, or other aquatic vehicle. According to embodiments, the data that is transferred between components of the inventive system 10 includes, but is not limited to, control data, mission data, diagnostic data, research data, reporting data, navigation data, and the like. [0035] According to embodiments, the AUV 20 additionally includes a second portion 16’ of a power and data transfer module 12 disposed thereon. According to embodiments, the AUV 20 may have a plurality of both first portions 14 and second portions 16 of power and data transfer modules disposed thereon Accordingly, the AUV 20 is capable of connecting with several other components of the inventive system 10 at a given time. Similarly, according to embodiments, the docking station 30 has a plurality of second portions 16 of power and data transfer modules 12 disposed thereon, so that multiple AUVs 20 or other components of the inventive system 10 may connect to the docking station 30 at a given time. According to embodiments, the docking station 30 additionally has at least one first portion 14 of a power and data transfer module 12 disposed thereon.

[0036] According to embodiments, the inventive system 10 includes additional components, such as at least one additional AUV 20’ like that described above. Additional components may also illustratively include repair units, tools/sensors 50, fixed or mobile structures, retrieval vehicles, and the like that are also equipped with first 14 and or second 16 portions of power and data transfer modules 12 that allow for easy interconnection of the various system components. For example, as shown in FIG. 1, a second AUV 20’ has a first portion 14’ of a second power and data transfer module 12 disposed thereon and additionally has a second portion 16” of a third power and data transfer module disposed thereon. Given that the various components of the system 10 generally each include a first portion 14 and a second portion 16 of a power and data transfer module 12, the components of the system 10 are interchangeably interconnectable. That is, as shown in FIG. 4, the first and second AUVs 20, 20’ are configured to interconnect for a power and/or data transfer operation, in FIG. 2 either or both of the first and second AUVs 20, 20’ are configured to interconnect with the docking station 30 for a power and/or data transfer operation, and in FTG. 3 the first and second AUVs 20, 20’ are configured to interconnect with one another and also connect to the docking station 30 for a power and data transfer operation. When several AUVs are connected in series they are able to pass power nearly losslessly through each device via the on board power and data transfer modules 12 disposed thereon. Not only can power be transferred through multiple devices, but data can also be transferred through the series connected multiple AUVs.

[0037] Notably, the inventive AUV docking system 10 for power and data exchange provides for easy connection alignment, two-way power transfer, two-way data transfer, high power capacity, and low power loss, thanks in part to the unique features of the power and data transfer modules 12 utilized in the present invention. For example, as shown in Table 1, the inventive system 10 outperforms other autonomous underwater vehicle systems.

[0038] Table 1: comparison of characteristics of autonomous underwater vehicle systems.

[0039] According to embodiments, each first portion 14 of the power and data transfer modules 12 includes a first mating pin 240 formed from a self-passivating transition metal to supply power. Notably, the self-passivating transition metal has a property of forming a non-conductive passivation layer upon immersion in water. According to embodiments, the second portion 16 of the power and data transfer module 12 includes a first mating receptor R1 formed from a selfpassivating transition metal to receive the power from the first mating pin 240 in the water. Again, the self-passivating transition metal has a property of forming a non-conductive passivation layer upon immersion in water. According to embodiments, a portion of each non-conductive passivation layer is removed due to scraping between the first mating pin 240 and the first mating receptor R1 upon mating thereof.

[0040] According to embodiments, the first mating pin 240 is housed in a first mating connector and a second mating receptor is housed in a second mating connector. According to embodiments, first mating connector includes a second mating receptor to provide a return path for the first mating pin 240. According to embodiments, the second mating connector includes a second mating pin to provide a return path for the first mating receptor Rl.

[0041] According to embodiments, the self-passivating transition metal is selected from the group comprising niobium, tantalum, titanium, zirconium, molybdenum, ruthenium, rhodium, palladium, hafnium, tungsten, rhenium, osmium, and iridium.

[0042] According to embodiments, each power and data transfer module 12 additionally includes a communication source to communicate data across a conductive connection formed by mating the first mating pin 240 and the first mating receptor Rl. According to embodiments, the communication source is a radio frequency modulator that communicates data across the conductive connection via modulation of current flowing in the conductive connection.

[0043] Further details regarding the features and capabilities of the power and data transfer modules 12 utilized in the inventive autonomous underwater docking system are provided in U.S. Patent No. 9,893,460B2, U.S. Patent No. 10,868,384Bl, U.S. Patent No. 11,O69,995B1, and U.S. Patent No. 10,985,495Bl, which are incorporated by reference in their entirety.

[0044] According to some embodiments, such as that shown in FIG. 11, an inventive AUV 20 is configured to engage with a fiber optic cable 60 to transfer data to another vehicle or docking station. The cable end features a self-passivating connector, which for example is a NiobiCONN connector, which transfers power and data across the connector barrier to a fiber media convert which transmits data over a fiber. This cable 60 can be deployed with a tether management system to winch in or out the cable as the vehicle 20 moves closer or further from the origin. Additionally, the cable 60 could include power connectors so that the vehicle 20 can connect to the cable and move away from the origin while charging batteries and transferring data. The connection has very low connection force and can be repetitively connected and disconnected by the AUV 20 when the cable 60 is needed.

[0045] According to some embodiments, the self-passivating contacts of each power and data transfer module 12 are self-cleaning and provide large contacts that do not require precise alignment, as shown in FIG. 12. That is, the power and data contacts 12 self clean by mechanically sliding one contact along another by face to face contact or by a brush/wiper to face contact. Alternatively, cleaning is achieved by electrification of the contact surfaces.

[0046] Patent documents and publications mentioned in the specification are indicative of the levels of those skilled in the art to which the invention pertains. These documents and publications are incorporated herein by reference to the same extent as if each individual document or publication was specifically and individually incorporated herein by reference.

[0047] The foregoing description is illustrative of particular embodiments of the invention but is not meant to be a limitation upon the practice thereof. The following claims, including all equivalents thereof, are intended to define the scope of the invention.

Claims

1. An autonomous underwater vehicle docking system comprising: a first power and data transfer module comprising a first portion and a second portion, the first portion and the second portion configured to engage with one another to form an electrical connection for power and data transfer; a first underwater autonomous vehicle (AUV) having the first portion of the first transfer module disposed thereon; an underwater docking station having the second portion of the first transfer module disposed thereon.

2. The autonomous underwater vehicle docking system of claim 1 wherein the first AUV is powered by batteries stored thereon.

3. The autonomous underwater vehicle docking system of claim 2 wherein the batteries are rechargeable.

4. The autonomous underwater vehicle docking system of any one of claims 1 to 3 wherein the first AUV contains a data processing unit.

5. The autonomous underwater vehicle docking system of any one of claims 1 to 3 wherein the first AUV has a second portion of a second power and data transfer module disposed thereon.

6. The autonomous underwater vehicle docking system of any one of claims 1 to 3 wherein the underwater docking station contains a data processing unit.

7. The autonomous underwater vehicle docking system of any one of claims 1 to 3 wherein the underwater docking station has a plurality of second portions of a plurality of transfer modules disposed thereon.

8. The autonomous underwater vehicle docking system of claim 1 further comprising a second AUV.

9. The autonomous underwater vehicle docking system of claim 8 wherein the second AUV has a first portion of a second power and data transfer module disposed thereon.

10. The autonomous underwater vehicle docking system of claim 9 wherein the first portion of the second power and data transfer module is configured to engage with all of the second portion of the first transfer module on the underwater docking station, any of the plurality of second portions of a plurality of transfer modules on the underwater docking station, and the second portion of the second power and data transfer module on the first AUV.

11 . The autonomous underwater vehicle docking system of claim 9 wherein the second AUV has a second portion of a third transfer module disposed thereon.

12. The autonomous underwater vehicle docking system of claim 1 wherein the first portion of the first power and data transfer module comprises a first mating pin formed from a selfpassivating transition metal to supply power, the self-passivating transition metal having a property of forming a non-conductive passivation layer upon immersion in water and wherein the second portion of the power and data transfer module comprises a first mating receptor formed from a self-passivating transition metal to receive the power from the first mating pin in the water, the self-passivating transition metal having a property of forming a non-conductive passivation layer upon immersion in water, wherein a portion of each non-conductive passivation layer is removed due to scraping between the first mating pin and the first mating receptor upon mating thereof.

13. The autonomous underwater vehicle docking system of claim 12 wherein the first power and data transfer module additionally comprises a communication source to communicate data across a conductive connection formed by mating the first mating pin and the first mating receptor.

14. The autonomous underwater vehicle docking system of claim 13 wherein the communication source is a radio frequency modulator that communicates data across the conductive connection via modulation of current flowing in the conductive connection.

15. The autonomous underwater vehicle docking system of claim 12 wherein the selfpassivating transition metal is selected from the group comprising niobium, tantalum, titanium, zirconium, molybdenum, ruthenium, rhodium, palladium, hafnium, tungsten, rhenium, osmium, and iridium.

16. The autonomous underwater vehicle docking system of claim 12 wherein the first mating pin is housed in a first mating connector and a second mating receptor is housed in a second mating connector.

17. The autonomous underwater vehicle docking system of claim 16 wherein the first mating connector includes a second mating receptor to provide a return path for the first mating pin.

18. The autonomous underwater vehicle docking system of claim 16 wherein the second mating connector includes a second mating pin to provide a return path for the first mating receptor.

19. The autonomous underwater vehicle docking system of claim 1 wherein the power and data transfer module is a self-passivating connector.