Rigidizable insertion tool with position adjustment

Abstract

In some embodiments, provided herein are apparatuses and methods for inspecting aircraft engines. In some embodiments, a rigidizable insertion tool includes a plurality of links arranged in a sequence. The plurality of links includes at least one structurally deformable deformable link. The rigidizable insertion tool can include a tensioning assembly configured to exert a first tensioning force on the plurality of links to actuate the plurality of links from a relaxed state to a rigidized state having a first shape. While in the rigidized state, the tensioning assembly can exert a second tensioning force on the plurality of links greater than the first tensioning force to induce structural deformation of the at least one deformable link and change the shape of the plurality of links from the first shape. The second tensioning force can change the shape from the first shape to a second shape.

Description

Technical Field

[0001] This disclosure generally relates to a tool for inspecting an environment (e.g., within the annular space of an aircraft engine) and / or performing maintenance operations on components within that environment. Background Technology

[0002] At least some aircraft engines include a compressor section, a combustor and a turbine section arranged in series. The compressor section includes a low-pressure compressor and a high-pressure compressor for compressing the air flowing through the aircraft engine. The combustor is used to mix fuel with the compressed air so that the mixture can be ignited. The turbine section includes a high-pressure turbine and a low-pressure turbine for powering the compressor section.

[0003] Within one or more sections, at least some aircraft engines define annular openings. Some of these annular openings may vary in size and shape, thus requiring a dedicated insertion tool for each opening to be used to extend around and through them. The aviation services industry continues to demand improvements in insertion tools to increase versatility and reduce the number of individual parts required on-site during maintenance operations. Attached Figure Description

[0004] This document discloses embodiments of systems, apparatus, and methods related to insertion tools. This specification includes accompanying drawings, in which:

[0005] Figure 1A These are side views and enlarged side views of a rigidifiable insertion tool in a relaxed state according to some embodiments;

[0006] Figure 1B According to some embodiments, in a rigid state Figure 1A A side view and a magnified side view of the rigidizable insertion tool in the image;

[0007] Figure 2A and Figure 2B According to some embodiments Figure 1A-1B A perspective view of an exemplary link of a rigid insertion tool in a [the document / technology].

[0008] Figure 3A and Figure 3B This is a perspective view of an exemplary link having a cross-sectional channel according to some embodiments;

[0009] Figure 3C According to some embodiments Figure 3A and Figure 3B A side view of an exemplary link in the diagram;

[0010] Figure 3D According to some embodiments Figure 3A and Figure 3BA cross-sectional view of an exemplary link in the diagram;

[0011] Figure 4 The lines and ridges between the links of a rigidifiable insertion tool according to some embodiments are shown;

[0012] Figure 5 A rigidifiable insertion tool is shown within an insertion tube according to some embodiments;

[0013] Figure 6A , 6B 6C depicts exemplary tensioning components according to some embodiments;

[0014] Figure 7 Various applied tension forces and corresponding bending radii are shown for rigidifiable insertion tools according to some embodiments;

[0015] Figure 8 Various applied tension forces and corresponding bending radii are shown for rigidifiable insertion tools according to some embodiments;

[0016] Figure 9 This is a block diagram of a rigid insertion tool system according to some embodiments;

[0017] Figure 10 A flowchart illustrating an exemplary method for operating a rigidifiable insertion tool according to some embodiments is shown;

[0018] Figure 11A Exemplary deformation compliance of a link having the link geometry shown in FIG2 according to some embodiments is illustrated;

[0019] Figure 11B It is shown that according to some embodiments, it has Figure 3A , 3B Exemplary deformation compliance of the link with the link geometry shown in 3C and 3D;

[0020] Figure 12 A rigidifiable insertion tool according to some embodiments is shown, wherein a tension gradient is used to compensate for the tool's gravity and orientation; and

[0021] Figure 13 This shows the maximum variation in tension along a given length of the insertion tool due to friction.

[0022] The elements in the figures are shown for simplicity and clarity and are not necessarily drawn to scale. For example, the size and / or relative position of some elements may be exaggerated relative to other elements to aid in understanding the various embodiments. Furthermore, common but easily understood elements that are useful or necessary in commercially viable embodiments are generally not depicted to facilitate a clearer observation of these various embodiments. Certain actions and / or steps may be described or depicted in a specific sequence of occurrence, and those skilled in the art will understand that such a specific sequence is not actually required. Unless otherwise specified herein, the terms and expressions used herein have the ordinary technical meanings that those skilled in the art would assign to them as described above. Detailed Implementation

[0023] Generally, the linkage assembly provided by this method (e.g., for a snake-arm robot) includes at least one deformable link. The use of a deformable link allows the linkage assembly to be tensioned into a tighter curve, thus allowing the linkage assembly to be more efficient, for example, when inserted into an aircraft engine and used for maintenance operations. For example, the method provided herein improves camera positioning accuracy and image quality under gravity loads and accumulated manufacturing tolerances. Therefore, the maintenance burden on the engine is reduced. Among other advantages, the method provided herein offers a simple, low-cost, and efficient inspection tool position adjustment procedure that compensates for positional deviations caused by various factors, such as structural deflection under gravity loads, accumulated manufacturing and assembly tolerances, and / or engine mounting variations.

[0024] According to various embodiments, this document provides systems, apparatus, and methods for allowing operators and / or robotic components to inspect engine cavities along defined paths. In some embodiments, a rigidifiable insertion tool includes a plurality of links arranged in sequence. The plurality of links may include at least one structurally deformable link. The rigidifiable insertion tool may include a tensioning assembly that applies a first tension force to the plurality of links to actuate the plurality of links from a relaxed state to a rigidified state having a first shape. In some embodiments, when in the rigidified state, the tensioning assembly applies a second tension force greater than the first tension force to the plurality of links to cause structural deformation of at least one link and change the shape of the plurality of links from the first shape. The second tension force may change the shape from the first shape to a second shape.

[0025] In some embodiments, a method for operating a rigidifiable insertion tool within a defined path of an engine includes inserting the rigidifiable insertion tool at least partially into the path of the engine while a plurality of links of the rigidifiable insertion tool are in a relaxed state. The rigidifiable insertion tool includes a plurality of links arranged in sequence and a tensioning assembly. The plurality of links may include at least one structurally deformable link. The method may include applying a first tension force to the plurality of links via the tensioning assembly to actuate the plurality of links from a relaxed state to a rigidified state having a first shape. In some embodiments, the method includes applying a second tension force greater than the first tension force to the plurality of links via the tensioning assembly in the rigidified state to cause structural deformation of at least one structurally deformable link and to change the shape of the plurality of links from the first shape. The second tension force may change the shape from the first shape to the second shape.

[0026] The following description should not be considered limiting, but is only used to describe the general principles of exemplary embodiments. In this specification, references to "an embodiment," "an embodiment," "some embodiments," "an implementation," "some implementations," and "certain applications," or similar language, mean that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one implementation of this disclosure. Therefore, the appearance of the phrases "in one embodiment," "in an implementation," "in some implementations," "in certain implementations," and similar language throughout this specification may, but not necessarily, refer to the same embodiment.

[0027] Now, referring to the attached diagram, and describing... Figure 1A-1B and Figures 6A-6C . Figure 1A Includes a side view of a rigidifiable insertion tool 100 in a relaxed state according to some embodiments. Figure 1B Including according to some embodiments Figure 1A The image shows a side view of the rigidifiable insertion tool 100 in a rigidified state. In some embodiments, the rigidifiable insertion tool 100 (also referred to as a rigidified insertion tool) includes a plurality of links 102 arranged in sequence. In some embodiments, the rigidifiable insertion tool 100 may correspond to an insertion tool that can be rigidified from a state where the tensioning assembly can apply relatively small or little or no force to a state where the tensioning assembly can apply large or greater force to push the links into a tightly coupled position.

[0028] Each of the multiple links 102 is an independent structure, and the links are arranged end-to-end along a longitudinal axis to form a link assembly (also referred to herein as multiple links 102). As described elsewhere herein, the movement and shaping of the links are controllable. Various tools, including cameras, drills, saws, etc., can be deployed at the ends of the guide links, or along the length of the rigidly insertable tool 100. In some respects, the link assembly is deployed within an aircraft engine to perform maintenance operations, including inspection and / or repair of internal engine components.

[0029] Multiple links 102 may include at least one structurally deformable link 104 (also referred to herein as a "deformable link"). In some structures described herein, a single deformable link 104 is present, while in other structures (e.g., as...) Figure 1B As shown), there are multiple deformable links 104. The number and location of these deformable links 104 are selected to achieve various shapes of the link assembly. In some embodiments, the link 104 may comprise one or more of the following: nylon, acrylonitrile-butadiene-styrene (ABS), polycarbonate, polypropylene, high-density polyethylene (HDPE), polysulfone (PSU), polybutylene terephthalate (PBT), polyvinyl chloride (PVC), and / or polytetrafluoroethylene (PTFE), to name just a few. In some embodiments, one or more of the previously discussed compressible or deformable materials may also be flexible and / or elastic materials. In some embodiments, the deformable link 104 may include compressible structural features, such as channel cutouts. In some embodiments, channel cutouts allow the deformable link 104 to bend further relative to another link without channel cutouts. For example, having a deformable portion 204 (such as...) Figure 2A , 2B The opening 304 (as shown in 3A and 3B) Figure 3C (As shown) This allows the deformable link 104 to bend further because the gap created by the opening 304 allows the tensioned portion of the deformable link 104 to move further axially until the gap narrows and the tensioned portion contacts another part of the deformable link 104.

[0030] By being deformable or compressible, it is understood that the deformable link 104 can be stretched and / or compressed in any direction, including longitudinally (along a longitudinal axis extending through a series of links), radially (outward from the longitudinal axis), or a combination of these directions. In this process, the original shape and / or dimensions of the deformable link 104 are altered. In some respects, once the deformable link 104 has been stretched and any force or actuation causing the stretching is removed, the deformable link 104 returns to its original shape and / or dimensions.

[0031] In some respects, the deformable link 104 is deformable or compressible because it is made of a material that allows deformation or compression to occur. Alternatively or additionally, physical features (e.g., channels, holes, openings, the shape of the link) may be used to facilitate or allow deformation or compression to occur. Depending on the material and / or features used, the link may undergo different deformations or compressions in different regions of the link. This can be achieved by using different materials, different concentrations of materials, and / or different physical features in different parts of the deformable link 104. For example, the distal end of the deformable link 104 may be formed of one material, and the proximal end may be formed of a different material. In other examples, the deformable link 104 is formed of a single material, and the link deforms or compresses closer to the region of the link where the force is applied.

[0032] In some respects, one link in the linkage assembly is deformable. In other respects, all links in the linkage assembly are deformable. In other examples, multiple links are deformable, so the linkage assembly consists of deformable and non-deformable links. The positioning or location of the deformable link (or links) within the linkage assembly can be selected based on various factors, such as the radius of curvature required when the linkage assembly is actuated and / or the final desired shape of the linkage assembly. For example, positioning the deformable link 104 towards the front of the linkage assembly allows the linkage assembly to bend or flex near the front of the linkage assembly. In some embodiments, the non-deformable link can be a link made of one or more materials that are high-stiffness relative to the deformable link, thereby greatly reducing the compressibility of the link when tension is applied to the linkage assembly. When the same tension is applied to the linkage assembly, the deformable link can be compressed or flexible, such as... Figure 11A and Figure 11B As shown.

[0033] Advantageously, the use of deformable links allows link assemblies to bend into smaller, more compact, or combined spaces or components. Link assemblies can be bent into curves with a radius centered at a point outside the link assembly. The shorter the radius, the tighter the curve of the link assembly. The larger the radius, the less capable the link assembly is of fitting into confined spaces. Using deformable links (or multiple links) allows for tighter curves, which in turn allows the link assembly to be placed in tighter spaces and precisely positioned within them.

[0034] In some embodiments, the rigidifiable insertion tool 100 includes a tensioning assembly 600. The tensioning assembly is used to change the shape of the links, including any deformable links in the link assembly. The tensioning assembly 600 can apply tension and / or pulling force on at least one line 106 to close gaps 110 between links (e.g., between link 104 and adjacent links 112) and pull them tightly together such that the plurality of links 102 can be formed into a predetermined shape. In some aspects, the line 106 may include wire and / or cable. In some embodiments, the predetermined shape may be determined by the link geometry (e.g., Figure 2A , 2B The shape of the deformable link 104 shown in 3A, 3B, 3C, and 3D is defined. For example, as... Figure 3C As shown, when the deformable link 104 is in the position as Figure 11A-11B Under the tension shown, the geometry of the link with the opening 304 through the deformable portion 204 alters the deformability of the various parts of the deformable link 104. Therefore, the opening 304 through the deformable portion 204 allows the deformable link 104 to bend further because the gap created by the opening 304 allows for further axial displacement of the portion of the deformable link 104 under tension until the gap narrows and the tensioned portion contacts another portion of the deformable link 104.

[0035] In some embodiments, at least one wire 106 may include a wire cap (not shown) located at the tip link 114 for securing at least one wire 106 in place so that the tensioning assembly 600 can apply tension in the rigidifiable insertion tool 100.

[0036] Figures 6A-6C An exemplary tensioning assembly 600 according to some embodiments is depicted (e.g., Figure 6A 602 Figure 6B 604 and Figure 6C (606). It should be understood that, Figures 6A-6C Some portions of the tensioning assembly 600 are not shown in the diagram because those skilled in the art can understand the tensioning assembly 600 in question, the corresponding portions associated with such a tensioning assembly, and how the tensioning assembly is connected to the line 106 to allow the tensioning assembly to apply tension on the plurality of links 102.

[0037] In an illustrative, non-limiting example, the tensioning component 600 may include, for example: Figure 6AThe screw / guide screw based tensioner 602 is shown. In some embodiments, the screw / guide screw based tensioner 602 may include a linear sliding mechanism 608 based on a guide screw coupled to a line 106. For example, the line 106 may be tied, connected, or coupled to a slider 610 of the screw / guide screw based tensioner 602. In some embodiments, when the guide screw 614 of the screw / guide screw based tensioner 602 is pulled back by rotating the nut 612 of the screw / guide screw based tensioner 602...

[0038] In another illustrative, non-limiting example, the tensioning component 600 may include, for example: Figure 6B The worm gear tensioner 604 is shown. In some embodiments, the worm gear tensioner 604 may include a gear 618 and a worm 616. For example, the wire 106 may be attached to the gear 618, and the tension can be set by rotating the worm 616.

[0039] In another illustrative, non-limiting example, the tensioning component 600 may include, for example: Figure 6C The diagram illustrates a motor-driven active tensioning mechanism 606. In some embodiments, the motor-driven active tensioning mechanism 606 may include a motor (e.g., a geared motor), an in-line load sensor, a ball bearing with a mounting bracket, a drive pulley, a load sensor guide, and / or a linkage adapter / receiver. In an illustrative, non-limiting example, the motor-driven active tensioning mechanism 606 includes a motor pulley assembly (e.g., a combination of a drive pulley and a geared motor), with the wire 106 attached to the drive pulley. For example, the wire 106 may be pulled / tensioned as the motor rotates to wind the wire 106 onto the drive pulley. In some embodiments, the motor can be controlled actively, or tension can be adjusted, by using position control (e.g., indirect tension control) or torque control (direct tension control) of the geared motor. In some embodiments, an in-line tension force measurement, such as an in-line load sensor, may be added to enable closed-loop control of the tension force.

[0040] In some embodiments, the tensioning assembly 600 applies a first tension force to the plurality of links 102 to move the plurality of links 102 from a slack state (e.g., Figure 1A (As shown) actuated to a rigid state having a first predetermined shape (as shown) Figure 1B (as shown in the diagram). In some embodiments, in the relaxed state, as... Figure 1A As shown, a gap 110 exists between deformable link 104 and link 112. In some embodiments, in the rigid state, relative to... Figure 1A The gap 110 shown is as follows: Figure 1BThe gap 110 shown is substantially narrowed. In some embodiments, the link 104 includes end features (e.g., protrusions and grooves), and in a rigid state, the end features of adjacent links contact and engage with each other, such that relative rotation and pivoting of the links are restricted by the end features.

[0041] In some embodiments, a tensioner 602 based on a screw / lead screw, a worm gear tensioner 604, and / or a motor-driven active tensioning mechanism 606 can apply a second tension force greater than the first tension force to multiple links 102 when in a rigid state, to cause structural deformation of at least one link 104 and to change the shape of the multiple links 102 from the first shape. Figure 7 and Figure 8 As shown, the second tension can change the shape from the first shape to the second shape. Specifically, Figure 7 and Figure 8 Various applied tension forces and corresponding bending radii of the rigidifiable insertion tool 100 are illustrated, depicting the change in shape of a plurality of links 102 from a first shape to a second shape as the applied tension forces vary. In some embodiments, the second tension force is based on a stored value of the applied force to change the shape of at least one link 104 to a predetermined shape. For example, a memory (e.g., network storage / cloud storage, hard disk drive, and / or any type of memory storage device capable of storing electronic data) can store data relating to a plurality of tension force values ​​and corresponding bending radii when these tension forces are applied to the plurality of links 102 (e.g., ...). Figure 7 and Figure 8 Various quantities of tension 702, 802 and corresponding radii 704, 804 are depicted.

[0042] In some embodiments, the first tension force may correspond to the initial tension of the line 106 from a relaxed state to a rigidified state. The second tension force may correspond to a tension force applied to deform the plurality of links 102 into a specific shape with a specific radius (e.g., applying a tension force of 10 Newtons (N) corresponds to bending the plurality of links 102 into a shape with a radius of 210 millimeters (mm), such as...). Figure 8 (As shown). In some embodiments, a single tension force can be applied to stiffen the line 106 from a relaxed state to a stiffened state that forms a specific shape.

[0043] In some embodiments, one or more subsequent tension forces are applied until the multiple links 102 reach a desired shape to perform maintenance, repair, and / or inspection operations. In one example, a single subsequent tension force is applied, and the final desired shape and curvature of the link is achieved by applying this single force. In another example, multiple tension forces are applied, causing the link 102 to progressively move from an initial shape and curvature to an intermediate shape and curvature, and then to the final desired shape and curvature.

[0044] For example, the stored force values ​​can include multiple tension forces 702, each with a corresponding radius 704, such as... Figure 7 As shown. Each radius 704 is an approximation of the radius obtained when a corresponding tension force 702 is applied. In some embodiments, the resulting radius may take into account the corresponding radius as well as at least one or both of gravity and friction acting on the rigidifiable insertion tool. This radius corresponds to a given curvature of the closest assumed curve of the link 102 when a specific tension force is applied to the link 102. The radius is measured from a predetermined point selected by the user. Figure 7 The diagram illustrates links in positions with different radii, where different radii are achieved by applying different forces to link 102. Generally, the larger the achieved radius, the less rigid the curvature of link 102; conversely, the smaller the achieved radius, the greater the curvature (the tighter the curvature). Figure 7 As shown, a radius of 330 mm is obtained when a force of 28.2 N is applied to link 102. In some respects, a smaller radius can be achieved by applying a larger force, and a larger radius can be achieved by applying a smaller force. The force can be applied using the devices and mechanisms described elsewhere in this document. It should be understood that when a specific tension force is applied based on the desired result, those skilled in the art will understand and know how to select or choose the radius of curvature based on the curvature of the bend achieved by link 102.

[0045] In some embodiments, each stored force value may be associated with a corresponding predetermined shape of a plurality of links 102 in a rigid state. The corresponding predetermined shape may be defined by a corresponding radius 704. For example, as... Figure 7 As shown, when multiple links 102 are rigidified to have corresponding radii 704, a predetermined shape can be formed. Alternatively, as... Figure 8 As shown, the stored force values ​​can include multiple tension forces 802, each tension force having a corresponding radius 804. Similarly, when multiple links 102 are rigidified to have, as Figure 8 A predetermined shape can be formed when the corresponding radius 804 is shown. Each radius 804 is an approximation of the radius achieved when the corresponding tension force 802 is applied. In some embodiments, the resulting radius may take into account the corresponding radius as well as at least one or both of gravity and friction acting on the rigidifiable insertion tool. For example, the predetermined shape may be defined by the corresponding radius 804. In an illustrative, non-limiting example, the tensioning assembly 600 may be configured as described above. Figure 7 and Figure 8 The stored values ​​are based on the repeatability of the tension force position correlation (e.g., each of tension forces 702, 802 is subsequently applied until the desired shape of the plurality of links 102 is achieved) and / or based on one or more tool position sensors described herein (e.g., Figure 9 The tool position sensor 920 detects real-time feedback information to apply subsequent tension.

[0046] Figure 9 A block diagram of a rigidifiable insertion tool system 100 according to several embodiments is shown. In some embodiments, the rigidifiable insertion tool system 100 may include a controller 902 and / or a memory 904. For example, stored values ​​of forces for changing the shape of at least one link 104 to a predetermined shape may be stored in the memory 904.

[0047] In some embodiments, controller 902 may include one or more processors, microcontrollers (MCUs), microprocessors, programmable logic controllers (PLCs), and / or application-specific integrated circuits (ICs) designed for control purposes, to name just a few. In some embodiments, the rigidifiable insertion tool system 100 may include one or more tool position sensors 920. For example, one or more tool position sensors 920 may include a camera 906, a light detection and ranging (LIDAR) sensor 908, an inertial measurement unit (IMU) sensor 910, a structured light measurement sensor 912, a three-dimensional (3D) stereo camera 914, and / or a laser distance sensor 916. In some embodiments, controller 902 may use sensor data (i.e., feedback data) output to controller 902 by one or more tool position sensors 920 via communication network 918 to determine whether an applied second tension force (or subsequent tension force) changes the shape of the plurality of links 102 from a first shape to a second shape. In some embodiments, communication network 918 may include the Internet, a wired network, and / or a wireless network.

[0048] exist Figure 9 In one example of the system's operation, controller 902 causes tensioning assembly 600 to apply subsequent tension based on feedback data received from one or more tool position sensors 920. For example, controller 902 processes the feedback data and determines that the desired predetermined shape of the multiple links 102 has not yet been achieved because the bending radii of the multiple links 102 are determined to be smaller than the corresponding bending radii. In some embodiments, applying a second tension may cause the multiple links 102 to bend radially between 60% and 100% of the original or initial radius of the rigid insertion tool 100. In some embodiments, the value of the second tension may include a range between 100% and 500% of the first tension. In some embodiments, controller 902 can continuously change the tension applied by tensioning assembly 600 based on the length of the rigid insertion tool 100 deployed into the cavity of the part being inspected, thereby allowing the tip of the rigid insertion tool 100 to travel a complex three-dimensional path while the tool is inserted into the part being inspected. In some embodiments, such as Figure 12As shown, the controller 902 can sequentially change the tension applied by the tensioning assembly 600 (e.g., starting from the minimum tension) according to the tension 702 and / or the tension 802 until the desired shape of the multiple links 102 is achieved.

[0049] In some embodiments, such as Figure 13 As shown, the controller 902 can generate an electronic control signal and send it to the tensioning assembly 600. This electronic control signal controls / causes the tensioning assembly 600 to continuously change the tension force applied by the tensioning assembly 600 according to the length of the rigidizable insertion tool 100 deployed into the cavity, to generate a continuously varying tension force gradient along the deployment length of the rigidizable insertion tool 100, compensating for the orientation of the deployment portion of the rigidizable insertion tool 100 relative to gravity, thereby allowing the rigidizable insertion tool 100 to have a desired shape, such as a simple circle with a desired radius. At a given length of the rigidizable insertion tool 100... The maximum change in tension in line 106 (upper line) It depends on the coefficient of friction between line 106 and connecting rod 102. And the angle of line 106 along the length of the rigid insertion tool 100 The change. For those with a circular arc radius. The maximum change in tension of the rigid insertion tool 100 is given by the following formula: .

[0050] For an arc, length ,therefore For example, for a given link compliance, the required change in tension per unit length can be calculated using the free-body diagram of each link 102 to obtain a rigidifiable insert tool with a specific radius of curvature. It is necessary to evaluate the rate of change of the line tension, and in some cases, it may be necessary to select materials or coatings for one or both of the links 102 and the line 106 to obtain a sufficient coefficient of friction at their interface to maintain the required linear rate of change of the line tension over a given length of the rigidifiable insert tool 100.

[0051] Now for reference Figure 2A and 2B , described Figure 1A-1B A perspective view of opposite ends of the same exemplary link of a rigid insertion tool. In some embodiments, Figure 2A and 2B One or more features shown are common to links (deformable and non-deformable links). In some embodiments, Figure 2A and 2BOne or more features shown apply only to deformable links. This document specifically describes those features that apply only to deformable links. As shown, link 104 includes one or more wire channels 202 extending axially within a deformable portion 204 of link 104. In some embodiments, the deformable portion 204 may correspond to a more deformable portion of the deformable link relative to the rest of the deformable link due to the link geometry present in the deformable link portion. In some embodiments, tensioning assembly 600 includes one or more wires 106 extending through one or more wire channels 202 of link 104 to apply tension. In some embodiments, a first end 206 of link 104 includes one or more protrusions 208 to engage with one or more grooves 210 of adjacent link 112, thereby aligning link 104 with adjacent link 112 and restricting relative movement between link 104 and adjacent link 112 when a first tension is applied to rigidify the tool. Alternatively or additionally, link 104 may include a protruding portion 220 of a pivot feature and a sleeve portion 214 of a pivot feature. In some embodiments, the protruding portion 220 is located at a first end 206 of link 104, while the sleeve portion 214 is located at a second end 212 of link 104. In some embodiments, in a series arrangement of each link 104 in the rigidifiable insertion tool 100, the second end 212 of each of the plurality of links 102 faces the tensioning assembly 600, while the first end 206 of each link 104 faces away from the tensioning assembly 600 or towards the distal end of the rigidifiable insertion tool 100. In some embodiments, in the series arrangement of each link 104 in the rigidizable insertion tool 100, the first end 206 of each link 104 of the plurality of links 102 faces the tensioning assembly 600, while the second end 212 of each link 104 faces away from the tensioning assembly 600 or faces the distal end of the rigidizable insertion tool 100.

[0052] Alternatively or additionally, link 104 may include cavity 216. In some embodiments, cavity 216 may receive a connector (e.g., fluid, electrical, torque, and / or data connection) for an instrument such as camera 906, light detection and ranging (LIDAR) sensor 908, inertial measurement unit (IMU) sensor 910, structured light measurement sensor 912, three-dimensional (3D) stereo camera 914, and / or laser distance sensor 916. In some embodiments, the instrument may include maintenance or repair tools, such as spray tools, lasers, cameras, brushes, drilling tools, grinding tools, light sources, or liquid dispensing heads.

[0053] Now for reference Figure 4 . Figure 4A rigidifiable insertion tool 100, comprising a line 106 and a ridge 402, is illustrated according to some embodiments. In some embodiments, the ridge 402 may pass through the ridge channel 404 of a link 104 and the ridge channel 404 of an adjacent link 112. For example, the ridge 402 may pass through all the ridge channels 404 of all links 104 of a plurality of links 102. In some embodiments, the ridge 402 may continuously hold links in the plurality of links 102 in place.

[0054] Now for reference Figure 3A , 3B 3C and 3D. Figure 3A and 3B This is a perspective view of opposite ends of an exemplary link 104 having a cross-sectional channel 302 according to some embodiments. Figure 3C According to some embodiments Figure 3A and 3B A side view of an exemplary link 104 in the diagram. Figure 3D According to some embodiments Figure 3A and 3B A cross-sectional view of an exemplary link 104. In some embodiments, Figure 3A , 3B One or more features shown in 3C and 3D are common to the link (deformable and non-deformable link). In some embodiments, Figure 3A , 3B One or more features shown in 3C and 3D are only applicable to deformable links, such as Figure 3D The cross-sectional channel 302 and opening 304 described herein. In some embodiments, a portion of one or more line channels 202 includes an opening (e.g., cross-sectional channel 302 and / or opening 304) extending into a cavity 216 of at least one deformable link 104. Those features are specifically described herein only for deformable links. In some embodiments, the cross-sectional channel 302 and opening 304 allow the deformable link 104 to bend further relative to another link that does not have one or more of these features. For example, having a section through the deformable portion 204 (e.g., Figure 2A , 2B The opening 304 (as shown in 3A and 3B) Figure 3C (As shown) allows the deformable link 104 to bend further because the gap created by the opening 304 allows the tensioned portion of the deformable link 104 to move further axially until the gap narrows and the tensioned portion contacts another portion of the deformable link 104. Alternatively or additionally, the link 104 may include a cross-sectional channel 302 extending laterally through the link 104. In some embodiments, the cross-sectional channel 302 may include an opening 304 through the deformable portion 204. Alternatively or additionally, a portion of one or more of the line channels 202 (e.g., in) Figure 2A and 2B The shown link geometry and / or Figure 3A , 3B The linkage geometry shown in 3C and 3D diagrams may include an opening 306 extending into a cavity 216 of the linkage 104. In some embodiments, the opening 306 exposes a portion of one or more wire channels 202. In some embodiments, a plurality of linkages 102 having at least one linkage 104 including a cross-sectional channel 302 may be based on Figure 8 Multiple tension forces 802 and corresponding radii 804 are tensioned to one or more predetermined shapes. In some embodiments, multiple links 102 having at least one link 104 excluding the cross-sectional channel 302 can be based on Figure 7 Multiple tension forces 702 and corresponding radii 704 are tensioned to one or more predetermined shapes.

[0055] In some embodiments, each of the plurality of links 102 may include a cross-sectional channel 302. In some embodiments, only a subset of the plurality of links 102 includes a cross-sectional channel 302, while other links (e.g., link 104 in FIG. 2) do not have a cross-sectional channel 302. In some embodiments, due to the link geometry present in the deformable link portion, such as the cross-sectional channel 302 and the opening 304, the deformable portion 204 may correspond to a portion of the deformable link that is more deformable than the rest of the deformable link.

[0056] Now for reference Figure 5 . Figure 5 A rigidifiable insertion tool 100 within an insertion tube 502 according to some embodiments is illustrated. An illustrative, non-limiting example of the insertion tube 502 may include a proximal end (not shown) and a distal end 510, and has a length and / or curvature sufficient to guide a plurality of links 102 into the engine cavity. In some embodiments, the insertion tube 502 may include a tubular sliding plane bearing feature positioned at least partially along the wall of the insertion tube 502 to prevent the plurality of links 102 from becoming misaligned or twisted off-orientation during insertion through the insertion tube 502.

[0057] In some embodiments, multiple links 102 can be moved via an insertion tube 502. The insertion tube 502 can hold the links within it in various shapes, while the shape of the links extending out of the insertion tube is determined by tension. In some embodiments, a rigidifiable insertion tool 100 can be coupled to an end effector 504. In some embodiments, the end effector 504 may include a camera 506 and / or an LED 508, to name just a few. In some embodiments, the end effector 504 may include a jetting tool, a laser, a camera, a brush, a drilling tool, a grinding tool, a light source, or a liquid dispensing head. In some embodiments, the end effector 504 may be one or more fixed and / or detachable attachments to facilitate inspection and / or repair of engine interiors (e.g., aircraft engines and / or any engine with chambers). In some embodiments, the end effector 504 may be attached to or coupled to multiple links 102, such as... Figure 1A The tip link 114 shown is positioned at the front and remains outside the insertion tube 502. For example, the tip link 114 may correspond to a link among a plurality of links 102, at a distance of 600 from the tensioning assembly. Figure 1A The furthest link.

[0058] Now for reference Figure 10 . Figure 10 A flowchart of an exemplary method 1000 for operating a rigid insertion tool 100 within a defined path of an engine, according to some embodiments, is shown. In some embodiments, method 1000 includes step 1002, inserting the rigid insertion tool 100 at least partially into the path of the engine while a plurality of links 102 of the rigid insertion tool 100 are in a relaxed state. The rigid insertion tool 100 may include a plurality of links 102 arranged in sequence. In some embodiments, the plurality of links 102 includes at least one structurally deformable link 104. Alternatively or additionally, the rigid insertion tool 100 may include a tensioning assembly 600.

[0059] In some embodiments, method 1000 includes step 1004, applying a first tension force to a plurality of links 102 by a tensioning assembly 600 to actuate the plurality of links 102 from a relaxed state to a rigid state having a first shape.

[0060] In some embodiments, method 1000 includes step 1006, in a rigidified state, applying a second tension force greater than a first tension force to a plurality of links 102 via tensioning assembly 600, to cause structural deformation of at least one link 104 and to change the shape of the plurality of links 102 from a first shape. As described herein, the second tension force can change the shape from the first shape to a second shape. In some embodiments, one or more subsequent tension forces may be applied, which can further change the shape of the plurality of links 102 from the second shape to one or more subsequent shapes. In some embodiments, when the rigidifiable insertion tool 100 is pulled out of the engine, the rigidifiable insertion tool 100 can be withdrawn from the engine by gradually reducing the tension force applied by tensioning assembly 600.

[0061] Now for reference Figure 11A and 11B . Figure 11A An exemplary deformation compliance 1100 of a deformable link 104 having the link geometry shown in FIG2 according to some embodiments is depicted. Figure 11A As shown, when in the line channel 202 surrounding the link 104 ( Figure 2A , 2B Line 106 (3A and 3B) applies load force Figure 1A When tension or pulling force is applied in the link 104 (as shown), the portion 1102 of the link 104 with the least deformation faces the middle portion, while the portion 1104 of the link 104 with the greatest deformation faces the second end 212 of the link 104. The portion 1102 with the least deformation is the place where the link 104 is bent, compressed, or stretched by the least amount (compared to a position where it is not bent, compressed, or stretched). The portion with the greatest deformation is the place where the link 104 is bent, compressed, or stretched by the greatest amount (compared to a position where it is not bent, compressed, or stretched). In some embodiments, such as Figure 11A and 11B As shown, the bottom of the link deforms the most compared to the top, which may be due to the presence of the line channel 202 (the area where the load force is applied to the line 106) and the link geometry (e.g., cross-sectional channel 302 and / or opening 304).

[0062] Figure 11B It is shown that according to some embodiments, it has Figures 3A-3D The exemplary deformation compliance 1100 of the link 104 with the shown link geometry. Figure 11B As shown, when in the line channel 202 surrounding the link 104 ( Figure 2A , 2B Line 106 (3A and 3B) applies load force Figure 1A When tension or pulling force is applied in the part shown, the parts of connecting rod 104 with the smallest and largest deformation are... Figure 11A Similar. However, Figure 11B The maximum deformation amplitude of connecting rod 104 in the middle is significantly greater than Figure 11A The deformation amplitude in the figure illustrates the influence of the connecting rod geometry on the connecting rod deformation. For example, unlike the case where only the cross-sectional channel 302 exists, Figure 11B The connecting rod contains a cross-sectional channel 302 and an opening 304, which allows Figure 11B The deformation of the middle connecting rod 104 is relatively more significant.

[0063] Return to reference Figure 1A and 1B After the rigidifiable insertion tool 100 is formed, one or more wires 106 under tension are used to apply compressive loads to each link 104. Therefore, the wires 106 can induce structural deformation in each link 104 (e.g., Figure 11A and 11B As shown), this accumulates into the available global shape / positional changes of the insertion tool 100. In an illustrative, non-limiting example, when at least one line 106 transitions from a relaxed state to a tensioned state (e.g., tensioning assembly 600 applies tension in line 106 or initiates a pulling action), at least one line 106 closes the gap 110 between all links 104 (deformable and non-deformable links), thereby forming and / or shaping the rigidifiable insertion tool 100. Alternatively or additionally, after the gap 110 between links 104 is closed, increasing the tension in at least one line 106 may induce compressive loads between the links 104. Such tension-dependent compressive loads may cause structural deformation of each link 104, which may superimpose on significant (e.g., exceeding 1, 3, 5, 10 degrees, etc.) global shape and / or positional changes of the insertion tool 100 (e.g., as shown). Figure 7 and Figure 8 (As shown). In some embodiments, the geometry or structure of the deformable link 104 may be specifically designed to increase compliance, thereby increasing its sensitivity to tension position adjustment. In some embodiments, tension control may be required to adjust the tension to a target value related to deployment and inspection positions. Furthermore, when out-of-plane deviations are present, the in-plane position adjustment mechanism described herein can be combined with a simple rotation mechanism along the insertion axis of the pipe mirror port to provide a low-cost 2-DOF adjustment solution for both in-plane and out-of-plane deviations.

[0064] When the tension-position correlation exhibits good repeatability, the tension-based position adjustment described herein can operate in an open-loop manner after calibration. Alternatively or additionally, the tension-based position adjustment described herein can utilize one or more tool position sensors 920 described herein (e.g., Figure 9(As shown) The embodiment described herein obtains and / or uses the feedback data captured therein to operate. The embodiments described herein provide a simple, low-cost, and effective method for adjusting the position of an inspection tool that can compensate for positional deviations caused by various factors: (1) structural deflection under gravity loads, (2) accumulation of manufacturing and assembly tolerances, and / or (3) engine mounting variations. Furthermore, combining the rigidizable insert tool 100 described herein with simple out-of-plane adjustments, such as rotation along the insertion axis of the duct mirror port, can also achieve multi-degree-of-freedom (DOF) positional compensation capabilities. For example, the rigidizable insert tool 100 described herein provides accurate and repeatable positioning of the camera to the inspection station. In addition, the rigidizable insert tool 100 described herein provides improved camera positioning accuracy and image quality under gravity loads and accumulation of manufacturing tolerances. Therefore, one or more advantages provided by the rigidizable insert tool 100 are reduced maintenance burden in engine inspections and low cost of achieving positional compensation.

[0065] Further aspects of this disclosure are provided by the subject matter of the following clauses:

[0066] A rigidifiable insertion tool includes: a plurality of links arranged in sequence, the plurality of links including at least one deformable link that is structurally deformable; and a tensioning assembly configured to apply a first tension force to the plurality of links to actuate the plurality of links from a relaxed state to a rigidified state having a first shape, wherein the tensioning assembly is further configured to apply a second tension force greater than the first tension force to the plurality of links in the rigidified state to cause structural deformation of the at least one deformable link and change the shape of the plurality of links from the first shape to a second shape.

[0067] The rigidifiable insertion tool according to any one of the preceding clauses, wherein the second tension is based on a stored value of a force applied to change the shape of the at least one deformable link to a predetermined shape.

[0068] The rigid insertion tool according to any one of the preceding clauses further includes an insertion tube, wherein the plurality of links are movable through the insertion tube.

[0069] The rigid insertion tool according to any one of the preceding clauses further includes a controller configured to continuously change the tension force applied by the tensioning assembly according to the length of the deployed rigid insertion tool.

[0070] The rigid insertion tool according to any one of the preceding clauses, wherein the at least one deformable link includes one or more wire channels extending axially within a deformable portion of the at least one deformable link, and wherein the tensioning assembly includes one or more wires extending through the one or more wire channels of the at least one deformable link to apply tension.

[0071] The rigid insertion tool according to any one of the preceding clauses, wherein a portion of the one or more wire channels includes an opening extending into a cavity of the at least one deformable link.

[0072] The rigid insertion tool according to any one of the preceding clauses, wherein the value of the second tension force includes a range between 100% and 500% of the first tension force.

[0073] The rigid insertion tool according to any one of the preceding clauses, wherein applying the second tension force causes the radial bending of the plurality of links to be between 60% and 100% of the original radius of the rigid insertion tool.

[0074] The rigid insertion tool according to any one of the preceding clauses, wherein the end of the at least one deformable link includes one or more protrusions configured to engage with one or more grooves of an adjacent link to align the at least one deformable link with the adjacent link and restrict relative movement of the at least one deformable link and the adjacent link when the first tension force is applied.

[0075] The rigid insertion tool according to any one of the preceding clauses, wherein the tensioning component is further configured to apply a subsequent tensioning force based on at least one of repeatability or feedback information related to tension position.

[0076] The rigid insertion tool according to any one of the preceding clauses, wherein the feedback information is based on at least one of the following: one or more images captured by a camera and sensor data from one or more of a light detection and ranging (LIDAR) sensor, an inertial measurement unit (IMU) sensor, a structured light measurement sensor, a three-dimensional (3D) stereo camera, and a laser distance sensor.

[0077] The rigid insertion tool according to any one of the preceding clauses, wherein the at least one deformable link includes a cross-sectional channel extending laterally through the at least one deformable link.

[0078] The rigid insertion tool according to any one of the preceding clauses, wherein the cross-sectional channel includes an opening through a deformable portion of the at least one deformable link.

[0079] A method for operating a rigidifiable insertion tool within an engine in a defined path, the method comprising: inserting the rigidifiable insertion tool at least partially into the path of the engine while a plurality of links of the rigidifiable insertion tool are in a relaxed state, wherein the rigidifiable insertion tool comprises: the plurality of links arranged in sequence and a tensioning assembly, wherein the plurality of links includes at least one deformable link that is structurally deformable; applying a first tension force by the tensioning assembly to the plurality of links to actuate the plurality of links from the relaxed state to a rigidified state having a first shape; and in the rigidified state, applying a second tension force greater than the first tension force by the tensioning assembly to the plurality of links to cause structural deformation of the at least one deformable link and change the shape of the plurality of links from the first shape, wherein the second tension force changes the shape from the first shape to a second shape.

[0080] According to any one of the preceding clauses, the second tension force is based on a stored value of a force applied to change the shape of the at least one deformable link to a predetermined shape.

[0081] The method according to any one of the preceding clauses, wherein the rigidifiable insertion tool further comprises an insertion tube, and wherein the plurality of links are movable through the insertion tube.

[0082] The method according to any one of the preceding clauses further includes continuously changing the tension force applied by the tensioning assembly by a controller communicatively connected to the tensioning assembly according to the length of the deployed rigidizable insertion tool.

[0083] The method according to any one of the preceding clauses, wherein the at least one deformable link includes one or more wire channels extending axially within a deformable portion of the at least one deformable link, and wherein the tensioning assembly includes one or more wires extending through the one or more wire channels of the at least one deformable link to apply tension.

[0084] The method according to any one of the preceding clauses, wherein the value of the second tension includes a range between 100% and 500% of the first tension.

[0085] According to any one of the preceding clauses, the application of the second tension force causes the radial bending of the plurality of links to be between 60% and 100% of the original radius of the rigidifiable insertion tool.

[0086] The method according to any of the foregoing clauses further includes the application of a subsequent tensioning force by the tensioning component based on at least one of repeatability or feedback information related to the tension position.

[0087] The method according to any one of the preceding clauses, wherein the feedback information is based on at least one of the following: one or more images captured by a camera and sensor data from one or more of a light detection and ranging (LIDAR) sensor, an inertial measurement unit (IMU) sensor, a structured light measurement sensor, a three-dimensional (3D) stereo camera, and a laser distance sensor.

[0088] According to any one of the preceding clauses, in the method, the end of the at least one deformable link includes one or more protrusions configured to engage with one or more grooves of an adjacent link to align the at least one deformable link with the adjacent link and restrict relative movement of the at least one deformable link and the adjacent link when the first tension force is applied.

[0089] Those skilled in the art will recognize that various other modifications, alterations, and combinations can be made to the above embodiments without departing from the scope of this disclosure, and such modifications, alterations, or combinations should be considered within the scope of the inventive concept.

Claims

1. A rigid insertion tool, characterized in that, include: A plurality of links arranged in sequence, the plurality of links including at least one deformable link that is structurally deformable; and A tensioning assembly configured to apply a first tension force to the plurality of links to actuate the plurality of links from a relaxed state to a rigidified state having a first shape. The tensioning component is further configured to apply a second tension force greater than the first tension force to the plurality of links in the rigid state, so as to cause structural deformation of the at least one deformable link and change the shape of the plurality of links from the first shape to the second shape.

2. The rigid insertion tool according to claim 1, characterized in that, in, The second tension is based on a stored value of the force applied to change the shape of the at least one deformable link to a predetermined shape.

3. The rigid insertion tool according to claim 1, characterized in that, It further includes an insertion tube through which the plurality of links are movable.

4. The rigid insertion tool according to claim 1, characterized in that, It further includes a controller configured to continuously change the tension applied by the tensioning assembly based on the length of the deployed rigidizable insertion tool.

5. The rigid insertion tool according to claim 1, characterized in that, in, The at least one deformable link includes one or more wire channels extending axially within a deformable portion of the at least one deformable link, and wherein the tensioning assembly includes one or more wires extending through the one or more wire channels of the at least one deformable link to apply tension.

6. The rigidifiable insertion tool according to claim 5, characterized in that, in, A portion of the one or more line channels includes an opening that extends into a cavity of the at least one deformable link.

7. The rigid insertion tool according to claim 1, characterized in that, in, The value of the second tension includes a range between 100% and 500% of the first tension.

8. The rigid insertion tool according to claim 1, characterized in that, in, Applying the second tension force causes the radial bending of the plurality of links to be between 60% and 100% of the original radius of the rigid insertion tool.

9. The rigid insertion tool according to claim 1, characterized in that, in, The end of the at least one deformable link includes one or more protrusions configured to engage with one or more grooves of an adjacent link to align the at least one deformable link with the adjacent link and restrict relative movement between the at least one deformable link and the adjacent link when the first tension force is applied.

10. The rigid insertion tool according to claim 1, characterized in that, in, The tensioning component is further configured to apply subsequent tension force based on at least one of repeatability or feedback information related to tension position.

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