Robots for use in confined spaces

Abstract

The invention relates to a robot (100) for use in confined spaces, wherein the robot (100) comprises: a body (102); a power supply coupled to the body (102); a plurality of legs (104), each leg (104) comprising: a foot (322) having a base surface (332), wherein a contact indicator (334) is arranged on the base surface (332) to indicate whether the base surface (332) is in contact with a surface.

Description

TECHNICAL AREA

[0001] The invention relates to a robot for use in confined spaces, wherein the robot comprises: a body; a power supply coupled to the body; a plurality of legs, each leg comprising: a foot having a base. BACKGROUND

[0002] Inspecting components located in remote areas or confined spaces can be expensive and, in some cases, dangerous. While drones can be used for some remote inspections, these drones are not capable of operating in confined spaces, and the demands of flight severely limit the time they can spend flying between battery recharging and the weight of the inspection tools they can carry.

[0003] In confined spaces, an externally controlled robot would be a better solution than a drone. However, a robot with multiple legs would need to be designed in such a way that the foot of each leg rests correctly on the surface it is traversing to ensure the necessary traction. SUMMARY OF THE INVENTION

[0004] The object of the present invention is to further develop a robot foot in such a way that the adhesion between the foot and the surface to be walked on is improved.

[0005] The task is solved by a robot for use in confined spaces, the robot comprising: a body; a power supply coupled to the body; a plurality of legs, each leg comprising: a foot having a base surface, the base surface having a contact indicator that shows whether the base surface is in contact with a surface.

[0006] Beneficial further training opportunities are listed in the sub-requirements.

[0007] The dependent claims list further advantages that can be combined in any way to achieve further advantages. DESCRIPTION OF THE INVENTION

[0008] A key feature of the invention is a contact indicator that actuates a spring-returned potentiometer. The contact indicator and the potentiometer are arranged in a central bore.

[0009] Furthermore, a key feature of the invention is a permanent magnet that can be magnetically neutralized by connecting a surrounding coil. When the fully actuated position is reached, the respective foot is registered as "contacted" by software. This ensures correct positioning of the magnet. If the actuation threshold is not reached, the software can react and search for a new position.

[0010] In one aspect, a robot for use in confined spaces comprises a body and a power supply that is coupled to and supported by the body.The robot also includes a variety of legs, each leg comprising a mounting element fixed to the body, a rotary element coupled to the mounting element for a pivoting movement about a first axis, a shoulder mount coupled to the mounting element for a pivoting movement about a second axis, the second axis being perpendicular and coplanar to the first axis in all operating positions of the shoulder mount and rotary element, a shoulder element coupled to the shoulder mount for a pivoting movement about a third axis, the third axis being perpendicular to the first axis and the second axis in all operating positions of the shoulder mount and shoulder element, an arm element coupled to the shoulder element for a pivoting movement about a fourth axis parallel to the third axis, and a foot coupled to the arm element for a pivoting movement about a fifth axis parallel to the third axis.The robot also includes a control system located and operable within the body to control the movement of each foot, arm element, shoulder element, shoulder support, and rotating element for each leg of the multitude of legs.

[0011] In one aspect, a robot designed for use in confined spaces comprises a body and an array of six legs. Each leg is connected to the body and includes a multitude of links arranged to define a first axis, a second axis, a third axis, a fourth axis, and a fifth axis. The first axis is perpendicular to and coplanar with the second axis, regardless of the position of the multitude of links. The robot also includes a multitude of actuators, each coupled to the leg and arranged to pivot a portion of the multitude of links around one of the first, second, third, fourth, or fifth axes.The robot also includes a power supply that is coupled to and operable with the body to power each of the multitude of actuators, and a controller that is coupled to and operable with the power supply to selectively deliver power to each actuator of each leg to move the robot.

[0012] In one aspect, a method for operating a robot involves positioning the robot within a confined space, where the robot comprises a plurality of legs. The method includes sequentially moving the legs to transport the robot from a first position to an inspection position, visually confirming that the robot is in the inspection position using an optical sensor, and coupling a non-destructive testing tool to the first leg of the plurality of legs. The method further includes positioning the non-destructive testing tool in an inspection position and performing a non-destructive test on a component.

[0013] The foregoing has provided a rather broad outline of the technical features of the present disclosure, so that the person skilled in the art may better understand the following detailed description. The following describes additional features and advantages of the disclosure that are the subject of the claims. The person skilled in the art will be aware that they can readily use the concept and specific embodiments disclosed as a basis for modifying or designing other structures to achieve the same purposes of the present disclosure. The person skilled in the art will also recognize that such equivalent constructions do not deviate from the spirit and scope of the disclosure in its broadest form.

[0014] Before we proceed with the detailed description below, it should be understood that this patent document provides various definitions for certain words and phrases, and that the average person skilled in the art will understand that such definitions apply in many, if not most, cases to both past and future uses of such defined words and phrases. While some terms may encompass a variety of embodiments, the accompanying claims may expressly limit these terms to specific embodiments.

[0015] Before any embodiments of the invention are explained in detail, it should be understood that the invention is not limited in its application to the details of the design and arrangement of components set forth in this description or illustrated in the following drawings. The invention is capable of other embodiments and can be practiced or implemented in various ways. It should also be understood that the phrases and terminology used herein serve descriptive purposes and should not be considered limiting.

[0016] It should also be understood that the words or phrases used herein should be interpreted broadly unless explicitly restricted in some examples. For instance, the terms "inclusive," "having," and "comprehensive," and derivatives thereof, mean inclusion without restriction. The singular forms "a," "an," and "the" are also meant to include the plural forms unless the context indicates otherwise. Furthermore, the term "and / or," as used here, refers to and includes all possible combinations of one or more of the related listed elements. The term "or" is inclusive, meaning and / or, unless the context clearly indicates otherwise.The terms "connected to" and "associated with" and derivatives thereof can mean that they include, are enclosed, are connected to each other, contain, are contained, connect with, link to, couple with, are communicable, cooperate, nest, place side by side, be near, be bound to, have, possess a property of, or the like. Furthermore, although several embodiments or constructions may be described herein, all features, methods, steps, components, etc., described in relation to one embodiment are equally applicable to other embodiments unless specifically stated otherwise.

[0017] Although the terms “first,” “second,” “third,” and so on may be used here to refer to different elements, information, functions, or actions, these elements, information, functions, or actions should not be limited by these terms. Rather, these numerical adjectives are used to distinguish different elements, information, functions, or actions from one another. For example, a first element, piece of information, function, or action could be referred to as a second element, piece of information, function, or action, and similarly, a second element, piece of information, function, or action could be referred to as a first element, piece of information, function, or action, without deviating from the scope of the present disclosure.

[0018] Furthermore, the term "adjacent to" can mean that an element is relatively close to another element but does not touch it, or that the element is in contact with the other element, unless the context clearly indicates otherwise. Additionally, the phrase "based on" is intended to mean "at least partially on" unless explicitly stated otherwise. The terms "over," "substantially," or "similar" are intended to cover variations in a value that are within industry-standard manufacturing tolerances for that dimension. Where no industry standard is available, a 20 percent deviation would fall within the meaning of these terms unless otherwise specified. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] An embodiment of the invention will be explained in more detail below with reference to the following figures.

[0020] The properties, features and advantages of this invention described above, as well as the manner in which they are achieved, will become clearer and more easily understood in connection with the following description of the exemplary embodiments, which are explained in more detail in conjunction with the drawings.

[0021] Identical components or components with the same function are marked with the same reference numerals.

[0022] Exemplary embodiments of the invention are described below with reference to the drawings. These drawings are not intended to be drawn to scale; rather, where helpful for explanation, they are presented in a schematic and / or slightly distorted form. For further details regarding the teachings directly apparent from the drawings, reference is made to the relevant prior art.

[0023] They show: Fig. 1. A perspective view of a robot with a body and multiple legs, Fig. 2 is a bottom view of the robot from Fig. 1, Fig. Figure 3 is a perspective view of the first leg of the robot. Fig. 1 with one foot, Fig. Figure 4 is a side view of part of the leg. Fig. 3, which shows the foot with a contact indicator DESCRIPTION OF THE EXECUTION FORMS

[0024] Fig. shows a robot 100 that is suitable for use in many locations, but is particularly suitable for carrying out inspections in confined spaces.

[0025] As used herein, "confined space" refers to a space or area that is difficult for a person to access or that poses a danger to some part of the access. Difficult spaces include small spaces within machines, components, or equipment. Hazardous spaces include areas where the atmosphere is hazardous, where radiation exposure may be present, where there are high or exposed areas, or where other hazards may be present. In addition to confined spaces, the Robot 100 is also well-suited for use in remote areas where on-site inspection can be costly due to travel or other requirements.

[0026] The robot 100 comprises a body 102 and a plurality of legs 104 extending from the body 102. In the illustrated construction, the robot 100 comprises six legs 104. However, other constructions could include fewer legs 104 or more than six legs 104, as might be required.

[0027] The robot 100 includes, in particular, two optical sensors 106, which are connected to the body 102. The optical sensors 106 are designed to capture video images, which can be stored by the robot 100 and / or transmitted by the robot 100 to another location. A single optical sensor 106 could be used instead of the two optical sensors 106, if desired. However, providing two optical sensors 106, positioned apart from each other, offers two different perspectives of the scene in front of the optical sensors 106. The two views can be combined to provide a stereo or 3D image of the scene in front of the optical sensors 106. Other designs could include different sensors instead of, or in conjunction with, the optical sensors 106, if desired.For example, infrared sensors could be used as optical sensors 106 or in conjunction with the optical sensors 106.

[0028] The Fig. Figure 2 shows a bottom view of the robot 100, which better illustrates the body 102. In the depicted design, the body 102 comprises a frame 206 that defines and protects the interior. The frame 206 has a multitude of hexagonal openings that reduce the weight of the frame 206 without significantly reducing its strength and rigidity. Of course, other designs can also include a solid frame or incorporate different sizes and arrangements of openings, depending on requirements.

[0029] The frame 206 is extended in one direction to define a longitudinal axis that runs along a centerline of the body 102. The frame 206 includes a plurality of attachment points 208, each attachment point 208 being arranged to receive and support one of the multiple legs 104. Four of the attachment points 208 are located near the corners of the frame 206, with the remaining two attachment points 208 being located approximately at the center of the longitudinal axis of the frame 206.

[0030] The internal structure is dimensioned and shaped to house, support, and protect components including a power supply, such as a battery, preferably a rechargeable battery 202, and a controller 204. The rechargeable battery 202 is selected and sized to provide power for all necessary operations of the robot 100 for a desired period of time. For example, some rechargeable batteries 202 may provide one hour of operation, while others may provide more or less power depending on the power requirements of the robot 100 and the tools used by the robot 100.

[0031] The controller 204 is preferably a microprocessor-based controller comprising a processor, a memory, and a data storage unit arranged such that the processor can control all aspects of the operation of the robot 100, either with user intervention and control (e.g., steering or steering the robot 100) or autonomously. In some designs, the data storage unit is dimensioned to provide sufficient data storage for programming the operation of the robot 100, while other designs include additional data storage units to enable the storage of data that could be acquired by the robot 100 (e.g., data from the optical sensors 106, inspection data, path data, etc.).

[0032] In addition to the rechargeable battery 202 and the controller 204, the frame 206 can also support and protect other components, such as a transmitter, receiver, transceiver, antenna, other communication devices, and other power supplies, such as an AC power connector, and the like. The frame 206 is therefore dimensioned to support all the necessary components for a desired application while simultaneously protecting those components that require additional protection.

[0033] The Fig. Figure 3 shows a perspective view of a first leg 300, which better illustrates its details. It is understood that each of the legs 104 is similar to the first leg 300, with only minor differences between them. The first leg 300 comprises a variety of linkages or components arranged such that adjacent linkages can move or rotate relative to one or more of the first axes 302, a second axis 304, a third axis 306, a fourth axis 308, and a fifth axis 310.

[0034] A mounting element 312 is arranged to firmly attach the first leg 300 to one of the mounting points 208 of the frame 206, thereby securing the first leg 300 to the body 102 of the robot 100. In the illustrated design, the mounting element 312 has four openings arranged to receive fasteners that firmly attach the mounting element 312 to the frame 206. A first actuator 336 is rigidly connected to the mounting element 312, so that the first actuator 336 does not move relative to the mounting element 312 during operation. Of course, other arrangements of the mounting element 312 or fastening arrangements are also possible.

[0035] A rotary element 314 is pivotally coupled to the mounting element 312 to allow pivoting rotation about the first axis 302 relative to the mounting element 312. The first actuator 336 is coupled to the rotary element 314 such that actuation of the first actuator 336 generates a rotational movement of the rotary element 314 about the first axis 302 relative to the mounting element 312. A second actuator 338 is fixedly connected to the rotary element 314 so that the second actuator 338 does not move relative to the rotary element 314 during its operation. Arrangements of the rotary element 314 that differ from the one shown in Figure 3 are also possible.

[0036] A shoulder bracket 316 is pivotally coupled to the rotary element 314 to allow pivoting rotation about the second axis 304 relative to the rotary element 314. The second actuator 338 is coupled to the shoulder bracket 316 such that actuation of the second actuator 338 generates a rotational movement of the shoulder bracket 316 about the second axis 304 relative to the rotary element 314. A third actuator 340 is fixedly attached to the shoulder bracket 316 so that the third actuator 340 does not move relative to the shoulder bracket 316 during its operation. A different arrangement of the shoulder bracket 316 than that shown in Fig. The 3 shown is also possible.

[0037] A shoulder element 318 is pivotally coupled to the shoulder bracket 316 to allow pivoting rotation about the third axis 306 relative to the shoulder bracket 316. The third actuator 340 is coupled to the shoulder element 318 such that actuation of the third actuator 340 generates a rotational movement of the shoulder element 318 about the third axis 306 relative to the shoulder bracket 316. A different arrangement of the shoulder element 318 than that shown in Fig. The 3 shown is also possible.

[0038] An arm element 320 is pivotally coupled to the shoulder element 318 to allow rotation about the fourth axis 308 relative to the shoulder element 318. A fourth actuator 342 is fixedly connected to the arm element 320, so that the fourth actuator 342 does not move relative to the arm element 320 during operation. The fourth actuator 342 is also coupled to the shoulder element 318, so that actuation of the fourth actuator 342 produces a rotation of the arm element 320 relative to the shoulder element 318 about the fourth axis 308. A fifth actuator 344 is also fixedly connected to the arm element 320, so that the fifth actuator 344 does not move relative to the arm element 320 during operation. Arrangements of the arm element 320, which are from the in Fig. Differences from the 3 shown are also possible.

[0039] The arm element 320 comprises a first end through which the fourth axis 308 passes, and a second end through which the fifth axis 310 passes. A foot 322 is pivotally coupled to the arm element 320 for a pivoting movement about the fifth axis 310. A foot linkage 324 couples the foot 322 to the arm element 320 at a second pivot axis 346 between the first end and the second end of the arm element 320. The fifth actuator 344 is coupled to the foot linkage 324 to generate a rotational movement of the foot linkage 324 about the second pivot axis 346.

[0040] The foot linkage 324 comprises an upper linkage 326, a middle linkage 328, and a lower linkage 330. The upper linkage 326 has a first end connected to the fifth actuator 344 such that actuation of the fifth actuator 344 rotates the upper linkage 326 about the second pivot axis 346. The middle linkage 328 has a first end pivotally connected to a second end of the upper linkage 326 and a second end pivotally connected to a first end of the lower linkage 330. A second end of the lower linkage 330 is fixedly connected to the foot 322. In some designs, the lower linkage 330 and the foot 322 are formed as a single unit.

[0041] The Fig. Figure 4 shows an embodiment of the foot 322 according to the invention. The foot 322 comprises a base surface 332 and a contact indicator 334. The contact indicator 334 is designed such that it detects whether the base surface 332 is correctly positioned on a surface. Tilting or misalignment should be prevented. The foot 322 is optimally positioned when the contact indicator 334, which can move in a linear direction 415, disappears completely into the base surface 332. The contact indicator 334 is mechanically connected to a linear potentiometer 410, so that a signal is generated which depends on the position of the foot 322 relative to the surface.

[0042] To ensure optimal contact between the foot 322 and the surface, a permanent magnet 411 is arranged around the contact indicator 334. This permanent magnet 411 establishes a durable and secure connection with a suitable surface. If the foot 322 is to be moved again, the magnetic forces of the permanent magnet 411 must be effectively switched off. This is achieved primarily by neutralizing the magnetic forces. For this purpose, a switchable magnet with an opposite magnetic polarity to that of the permanent magnet 411 is arranged around the permanent magnet 411. This is accomplished by a neutralizing coil 412, which is arranged around the permanent magnet 411. As soon as a suitable current flows through the neutralizing coil 412, the foot 322 can be lifted from the surface, since no net magnetic force remains in the direction of the surface.

[0043] The arrangement of the various axes is chosen to simplify the movement of the first leg 300 and, in particular, the programming of the movement. The first axis 302 extends in a first or "X" direction, with the second axis 304 arranged perpendicular to the first axis 302, so that the second axis extends in a second or "Y" direction. The first axis 302 and the second axis 304 are positioned so that they intersect at a single point that does not change during the movement of the first leg 300. More precisely, regardless of the position or configuration of the first leg 300, the relationship and the point of intersection of the first axis 302 and the second axis 304 do not change.This arrangement allows the two joints to be considered as one omnidirectional joint, rather than two unidirectional joints, thereby greatly simplifying the kinematic layout, which also greatly simplifies the programming movement of the first leg 300.

[0044] The third axis 306, the fourth axis 308, and the fifth axis 310 are parallel to each other and perpendicular to the first axis 302 and the second axis 304. Thus, the third axis 306, the fourth axis 308, and the fifth axis 310 extend in a third or "Z" direction with respect to the first axis 302 and the second axis 304. The second axis of rotation 346 is also parallel to the third axis 306, the fourth axis 308, and the fifth axis 310.

[0045] The position of foot 322, and in particular the position of the fifth actuator 344, is the mirror image of the positions of the third actuator 340 and the fourth actuator 342, such that foot 322 remains parallel to the body 102 and the floor or component on which the robot 100 is positioned. However, this arrangement can be offset to accommodate movements on convex / concave surfaces or when required during the transition from a surface in a first plane to a second surface in another plane (e.g., from horizontal to vertical).

[0046] As already mentioned, the first leg 300 is exemplary for the remaining legs 104, which are in the robot 100 of the Fig. 1 and Fig.Figure 2 is shown. While fewer than six legs 104 could be used as six, six legs 104 enable safe climbing of a vertical surface, where at least four legs 104 can always maintain magnetic contact with the wall. It is desirable that the magnets 402 are selected such that two magnets 402 can support the full weight of the robot 100.

[0047] As discussed, the robot 100 comprises five actuators 336, 338, 340, 342, and 344. Each actuator 336, 338, 340, 342, and 344 can include an electric motor, such as a DC motor, a geared motor, a servo motor, a stepper motor, or another type of actuator, which can be operated to generate precise rotary movements to position each of the various linkages as required.

[0048] In operation, the Robot 100 is programmed to perform a desired task in a specified confined space or other location. During a single use, the Robot 100 is remotely controlled by a user. The Robot 100 transmits data collected by its optical sensors 106 to the user, allowing the user to see the area around the Robot 100 and thus improving control. The Robot 100 is pre-programmed to move in specific directions, so the user simply operates a joystick or other input device to guide the Robot 100. Specifically, the movement of the legs 104 is pre-programmed to translate simple user inputs into complex and coordinated movements of the various legs 104.Once the robot 100 is in the desired position, data can be acquired using a tool, sensor, or instrument. For example, in a design, the robot 100 is positioned next to a component, and an ultrasonic probe is placed on the component to inspect it for damage.

[0049] In another application, the robot 100 is programmed to move between waypoints and perform inspections at specific points. In this configuration, the user has little to no input during the operation of the robot 100.

[0050] Although the invention has been illustrated and described in detail by the preferred embodiment, the invention is not limited by the disclosed examples and other variations can be derived by the person skilled in the art without leaving the scope of protection of the invention.

Claims

[1] Robot (100) for use in confined spaces, the robot (100) comprising: a body (102); a power supply coupled to the body (102); a plurality of legs (104), each leg (104) comprising: a foot (322) having a foot base (332) wherein a contact indicator (334) is arranged on the foot base (332) to indicate whether the foot base (332) is in contact with a surface. [2] Robot (100) according to claim 1, wherein the contact indicator (334) has a movable button projecting from the foot (322), which can be moved towards the surface by moving the foot (322) and generates a signal. [3] Robot (100) according to claim 2, wherein the button is coupled to a linear potentiometer (410) such that the position of the button can be determined. [4] Robot (100) according to claim 2 or 3, wherein a permanent magnet (411) is arranged around the button, which ensures adhesion to the surface. [5] Robot (100) according to claim 4, with a neutralizing coil (412) arranged around the permanent magnet (411), wherein the neutralizing coil (412) is designed such that a magnetic adhesion of the permanent magnet (411) to the surface can be neutralized. [6] Robot (100) according to any of the preceding claims, for use in confined spaces, the robot comprising: a body (102); a power supply coupled to the body (102); a plurality of legs (104), each leg (104) comprising: a mounting element (312) fixedly connected to the body (102); a pivoting element (314) coupled to the mounting element (312) to enable pivoting about a first axis (302); a shoulder support (316) coupled to the mounting element (312) to enable pivoting about a second axis (304), the second axis (304) being perpendicular and coplanar to the first axis (302) in all operating positions of the shoulder support (316) and the pivoting element (314);a shoulder element (318) coupled to the shoulder support (316) to perform a pivoting movement about a third axis (306), the third axis (306) perpendicular to the first axis (302) and the second axis (304) in all operating positions of the shoulder support (316) and the shoulder element (318); an arm element (320) coupled to the shoulder element (318) to enable a pivoting movement about a fourth axis (308) parallel to the third axis (306); and a foot (322) coupled to the arm element (320) for a pivoting movement about a fifth axis (310) parallel to the third axis (306);and a control (204) arranged and operable within the body (102) to control the movement of each foot (322), arm element (320), shoulder joint (318), shoulder support (316) and pivot element (314) for each leg (104) of the plurality of legs, each leg (104) comprising: a foot (322) having a base surface (332) wherein a contact indicator (334) is arranged on the base surface (332) indicating whether there is contact between the base surface (332) and a surface. [7] Robot (100) according to one of the preceding claims, wherein the plurality of legs (104) is six. [8] Robot (100) according to one of the preceding claims, further comprising an optical sensor (106) which is connected to the body and can be actuated to capture a visual image. [9] Robot (100) according to claim 6, 7 or 8, wherein the contact indicator (334) has a movable button projecting from the foot (322) which can be moved towards the surface by moving the foot (322) and generates a signal. [10] Robot according to one of claims 6 to 9, wherein a permanent magnet (411) is arranged around the button, which ensures adhesion to the surface. [11] Robot according to claim 10, with a neutralizing coil (412) arranged around the permanent magnet (411), wherein the neutralizing coil (412) is designed such that a magnetic adhesion of the permanent magnet (411) to the surface can be neutralized.

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