System and method for robotic manipulator system

Abstract

To provide novel systems and methods for a robotic manipulator arm deployment and control system.SOLUTION: The system comprises at least a vertical mast, a mast deployment system comprising at least two cams, an elbow, an arm operable to deploy tools, one or more sensors including a non-contact sensor and a dynamic measurement unit. The cams cause the vertical mast and the arm to remain vertical during deployment into an operating space. The non-contact sensor may be used for measuring the range and bearing to objects in the operating space in polar coordinates. The dynamic measurement unit comprises accelerometers and rate sensors and is configured as a six degree of freedom three axis sensor operating in a Cartesian coordinate system. The system further comprises a controller operable to receive the polar and Cartesian coordinates from the sensors and convert them into a Cartesian coordinate system.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001]

[0001] Copyright notice This specification contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but reserves all copyright rights. The following notice applies to the software, screenshots, and data described below, as well as the following drawings and All Rights Reserved.

[0002]

[0002] Related Applications The following application claims priority to U.S. Provisional Patent Application No. 62 / 337,066, filed May 16, 2016, and is incorporated by reference in its entirety.

[0003]

[0003] The present disclosure relates to robotic systems designed to perform tasks in hazardous and / or difficult to access spaces. [Background technology]

[0004]

[0004] Certain industrial project environments are hazardous to humans, typically requiring workers to wear protective clothing and respiratory equipment to enter and operate in the workplace. Additionally, spaces and areas of certain projects are often not designed with human movement in mind, resulting in spaces that are too small, too hot, too cold, or generally difficult or impossible for humans to walk through. Some industrial project areas are so dangerous and difficult to access that human entry and repair are impractical. Remote robotic manipulators are needed to access such areas and reduce human exposure to hazardous conditions.

[0005] Currently, most off-the-shelf remote manipulators are built to a specific need and are limited in functionality and versatility. Therefore, there is a need for an all-in-one manipulator that provides increased power, versatility, and reliability for performing tasks in difficult-to-access and / or hazardous spaces.

[0006] To reduce the complexity and length of the detailed specification, applicant hereby expressly incorporates by reference the following materials, as identified in the following paragraphs: Incorporated material is not necessarily "prior art," and applicant expressly reserves the right to swear to the publication date of the incorporated material.

[0007]

[0007] The specification of U.S. Patent Application No. 62 / 337,066, filed May 16, 2016, entitled "System and Method for a Robotic Manipulator Arm," is incorporated herein by reference in its entirety, and to which this application claims priority.

[0008]

[0008] The specification of U.S. Patent Application No. 62 / 330,330, filed May 2, 2016, entitled "Tank Cleaning System," is incorporated herein by reference in its entirety.

[0009]

[0009] The entire contents of U.S. patent application Ser. No. 14 / 975,544, entitled "Systems and Methods for Chain Joint Cable Routing," filed on December 18, 2015, with a priority date of December 19, 2014, are incorporated herein by reference.

[0010]

[0010] The specification of U.S. Patent Application No. 15 / 341,985, entitled "System and Method for Inspection and Maintenance of Hazardous Spaces," filed on November 2, 2016, with a priority date of November 3, 2015, is incorporated herein by reference in its entirety.

[0011]

[0011] The specification of U.S. Patent Application No. 62 / 406,209, filed October 10, 2016, entitled "Rolatube Deployment Mechanism," is incorporated herein by reference in its entirety.

[0012] Applicant believes that the above-incorporated material is "non-essential" pursuant to 37 CFR 1.57 because it is referenced for the purpose of providing a background to the invention or for the purpose of describing the state of the art. However, if the examiner believes that any of the above-incorporated material constitutes "essential material" within the meaning of 37 CFR 1.57(c)(1)-(3), applicant will amend this specification to expressly indicate the essential material incorporated by reference as permitted by the applicable rules.

[0013] The embodiments and applications presented herein are explained below in the drawings and detailed description. Unless otherwise specified, it is intended that words and phrases in the specification and claims be given their plain, ordinary, and customary meanings to those of ordinary skill in the applicable art. The inventors fully recognize that they can be their own lexicographers, if necessary. As their own lexicographers, the inventors expressly elect to use only the plain, ordinary meanings of terms in the specification and claims unless expressly stated otherwise, and further specify a "special" definition of the term and explain how it differs from the plain, ordinary meaning. In the absence of a clear statement of intent to apply a "special" definition, the inventors intend and desire that the simple, plain, and ordinary meaning of the term be applied in interpreting the specification and claims.

[0014] The inventors also recognize the ordinary teachings of English grammar. Accordingly, where a noun, term, or phrase is intended to further characterize, specify, or narrow in any way, such noun, term, or phrase expressly includes an additional adjective, descriptive term, or other modifier in accordance with the ordinary teachings of English grammar. In the absence of the use of such adjective, descriptive term, or modifier, such noun, term, or phrase is intended to be given its plain and ordinary English meaning to one of ordinary skill in the applicable art, as defined above.

[0015]

[0015] Furthermore, the inventors fully understand the criteria and application of the special provisions of 35 U.S.C. §112, paragraph 6. Accordingly, the use of the words "function," "means," or "step" in the detailed description or drawings or claims is not intended to indicate in any way a desire to apply the special provisions of 35 U.S.C. §112, paragraph 6 to define the systems, methods, processes, and / or apparatus disclosed herein. Conversely, when the provisions of 35 U.S.C. §112, paragraph 6 are sought to be applied to define an embodiment, the claim must specifically and explicitly recite the verbatim phrase "means for" or "step for," and further set forth the term "function" (i.e., recite "means for performing the function of ..."), without reciting any structure, material, or operation that supports the function in such phrase. Thus, even if a claim recites "means for performing the function of ..." or "steps for performing the function of ...," the inventors expressly intend not to apply 35 U.S.C. §112, paragraph 6 if the claim recites any structure, material, or act in support of the means or step, or any structure, material, or act that performs the recited function. Furthermore, even if 35 U.S.C. §112, paragraph 6 is applied to define the claimed embodiments, the embodiments are not limited solely to the particular structure, materials, or acts described in the preferred embodiment, but further include any and all structures, materials, or acts that perform the claimed function as described in alternative embodiments or configurations, or any currently known or later-developed equivalent structures, materials, or acts that perform the claimed function.

[0016] A more complete understanding of the systems, methods, processes, and / or apparatus disclosed herein can be obtained by reference to the detailed description when considered in conjunction with the following illustrative drawings, in which like reference numerals refer to like elements or acts throughout the drawings. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 is an isometric view of one embodiment of a deployed robotic manipulator arm (RMA). [Figure 2A] FIG. 1 is an isometric view of one embodiment of an undeployed RMA. [Figure 2B] FIG. 2B is a side view of the internal components of the undeployed RMA embodiment of FIG. 2A. [Figure 3A] FIG. 1 is an isometric view of one embodiment of an RMA at the start of a deployment procedure. [Figure 3B] FIG. 3B illustrates the embodiment of FIG. 3A when the carriage is raised upward approximately 15° and the forearm enters the access point. [Figure 3C] FIG. 3B illustrates the embodiment of FIG. 3A when the carriage is raised upward approximately 45 degrees and the forearm is extended further into the access point. [Figure 3D] 3B shows the embodiment of FIG. 3A when the carriage is lowered onto the base of the frame. [Figure 3E] FIG. 3B shows the embodiment of FIG. 3A when the carriage reaches the base of the frame and reaches 90°. [Figure 3F] FIG. 3B shows the embodiment of FIG. 3A when the carriage is lifted upwards approximately 120°. [Figure 3G] 3B illustrates the embodiment of FIG. 3A when the carriage is approaching 180° relative to its original position and the elbow is in the access point. [Figure 4A] FIG. 1 illustrates one embodiment of an RMA with the mast retracted. [Figure 4B] FIG. 4B shows the embodiment of FIG. 4A with the mast extended. [Figure 5] 1 illustrates an embodiment of an elbow. [Figure 6A] FIG. 1 is an isometric view of an embodiment with the RMA elbow pointing vertically downward and both the mast and forearm fully extended. [Figure 6B] FIG. 6B is an isometric view of the embodiment of FIG. 6A with a 90 degree mast-elbow pivot actuation, lifting the forearm to a horizontal position. [Figure 6C] FIG. 6B is an isometric view of the embodiment of FIG. 6A with a 90 degree forearm-elbow pivot actuation that lifts the forearm into a vertically upward position. [Figure 7A] FIG. 13 illustrates one embodiment with the extendable RMA forearm retracted. [Figure 7B] FIG. 7B shows the embodiment of FIG. 7A when the forearm is extended. [Figure 8A] FIG. 16 is an isometric view of one embodiment of a wrist joint at 0°. [Figure 8B] FIG. 8B shows the wrist joint embodiment of FIG. 8A at −90°. [Figure 8C] FIG. 8B shows the wrist joint embodiment of FIG. 8A at +90°. [Figure 9A] 10A-10C illustrate an embodiment of an end effector coupling mechanism for coupling an end effector to a forearm. [Figure 9B] 9B illustrates an embodiment of a wrist linkage in an embodiment of a forearm, corresponding to the embodiment of the end effector linkage in FIG. 9A. FIG. [Figure 9C] 9C shows the embodiment of the linkage mechanism of FIGS. 9A and 9B when linked and the wrist is bent downwards at 90 degrees. FIG. [Figure 9D] 9C shows the embodiment of the linkage mechanism of FIGS. 9A and 9B when linked and the wrist is bent upward at 90 degrees. FIG. [Figure 10A] FIG. 1 illustrates an isometric view of one embodiment of a gripper end effector. [Figure 10B] FIG. 10B is a rear view of the embodiment of FIG. 10A. [Figure 11A] FIG. 10 is an isometric view of a variation of the RMA end effector. [Figure 11B]FIG. 10 illustrates the insertion of the end effector into the RMA. [Figure 11C] FIG. 13 shows the forearm of the RMA extending to connect to an embodiment of an end effector. [Figure 12] 10A-10C illustrate an embodiment of an end effector coupled to an RMA. [Figure 13] FIG. 1 is an isometric view of an embodiment of an end effector coupled with a water jet tool. [Figure 14] FIG. 1 illustrates an exemplary embodiment showing a virtual barrier in a workspace. [Figure 15] FIG. 1 illustrates one embodiment of a control system. [Figure 16] FIG. 1 illustrates an embodiment of a forearm with sensors. DETAILED DESCRIPTION OF THE INVENTION

[0018] Elements and operations in the figures are illustrated for simplicity and are not necessarily depicted according to any particular sequence or embodiment.

[0019]

[0053] In the following description, and for purposes of explanation, numerous specific details, process times, and / or specific formula values ​​are set forth to provide a thorough understanding of various aspects of example embodiments. However, those skilled in the art will understand that the apparatus, systems, and methods herein may be practiced without these specific details, process times, and / or specific formula values. It should be understood that other embodiments may be utilized, and structural and functional changes may be made, without departing from the scope of the apparatus, systems, and methods herein. In other instances, known structures and devices are shown or discussed more generally to avoid obscuring the example embodiments. In many cases, a description of operations is sufficient to allow various forms to be implemented, particularly when the operations are implemented in software. It should be noted that there are many different alternative configurations, devices, and technologies to which the disclosed embodiments may be applied. The full scope of embodiments is not limited to the examples described below.

[0020]

[0054] In the following examples of illustrated embodiments, reference is made to the accompanying drawings which form a part hereof, and which show, by way of illustration, various embodiments in which the systems, methods, processes, and / or apparatuses disclosed herein may be practiced. It is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention.

[0021]

[0055] A remotely operable robotic manipulator arm (RMA) is disclosed to avoid the need for workers to enter hazardous environments or environments with limited or difficult to reach spaces. The RMA can be used to remotely inspect, maintain, and clean difficult-to-access and / or hazardous spaces of various shapes, sizes, and technical constraints with little or no direct human interaction. The RMA is versatile, durable, and reusable, reducing operational risks and improving operator safety. In some embodiments, the RMA can have one or more of the following properties: radiation resistance, temperature resistance, freeze resistance, moisture resistance, chemical resistance, and earthquake / wind / weather resistance.

[0022]

[0056] In some embodiments, the RMA is designed and configured to be transported and installed at an existing location without disrupting existing infrastructure or requiring heavy machinery. In some embodiments, the RMA may be deployed within a very small area and ready for operation. In some embodiments, deployment of the RMA does not require expensive or specialized tools. During deployment and retrieval, the RMA carriage in some embodiments can follow a specific cam path that allows the manipulator to move vertically up and down through the access point. Manual deployment in some embodiments can be performed quickly and efficiently, limiting worker exposure to the work area. After the RMA completes its work, it may be washed at the site, retrieved from the work space, and removed from the site in the reverse order of installation. The RMA may be redeployed at the same site or another site.

[0023]

[0057] Terms such as "site," "tank," "compartment," "hazardous space," "work space," "work area," and "confined space" are used solely to refer to the space in which the system may perform its work and are not intended to be limiting.

[0024]

[0058] The workspace in some embodiments may contain various materials, such as ion exchange resin, sludge, waste liquid, toxic waste, and other potentially dangerous and / or difficult-to-remove materials. In some embodiments, the purpose of the RMA is to inspect the workspace, remove remaining materials, clean the workspace, and facilitate operations necessary to install or remove devices in the space or for other operations. The RMA may allow for the attachment of a variety of standard and / or customized tools that can be manipulated within the workspace to perform a variety of different operations. In an exemplary embodiment, the RMA may use a suction tool to remove bulk ion exchange material and sand while fully submerged in waste liquid.

[0025]

[0059] System Overview FIG. 1 shows an isometric view of one embodiment of a partially extended robotic manipulator arm (RMA) 100. In some embodiments, the RMA 100 is operable to perform inspection, maintenance, repair, and cleaning tasks in difficult-to-access and / or hazardous environments. In the illustrated embodiment, the RMA 100 comprises a support frame 10, a carriage 115, a mast 120, a forearm 130, an elbow 140, a wrist 150, and an end effector 160. Some embodiments may include additional components or more than one of one or more of the components shown. In some embodiments, at least one of the mast and forearm is extendable by telescoping or other means. The degrees of freedom in the illustrated embodiment are vertical mast extension / retraction, mast rotation, elbow swivel, forearm extension / retraction, wrist pitch, and wrist roll. In some embodiments, additional tools and carts may be used depending on the application and project requirements.

[0026]

[0060] In some embodiments, RMA 100 is sized and configured to be portable. In some embodiments, RMA 100 is designed to be easily maneuverable through existing rooms and doors, taking into account constraints including limited headroom, doorway access, existing equipment and infrastructure, and access points. RMA 100 can be scaled to its intended use. In one embodiment, RMA 100 has a vertical reach of 32 feet and a horizontal reach of 15 feet when fully extended. Other versions of vertical and horizontal reach are possible, depending on how the RMA is scaled to its intended use.

[0027]

[0061] In some embodiments, the integration of carbon fiber and other lightweight materials minimizes the overall weight of the RMA 100 while maintaining a high payload. In some embodiments, the payload of the RMA 100 is up to 100 pounds across the entire range and up to 150 pounds in certain orientations. The RMA 100 is scalable for different tasks and environments, thus allowing for a wide range of payloads.

[0028]

[0062] Support frame FIG. 2 shows one embodiment of RMA 100 housed in support frame 10. In some embodiments, RMA 100 fits entirely within support frame 10 when fully folded, enhancing maneuverability of the system during deployment and retrieval and reducing storage footprint. In some embodiments, support frame 10 may include wheels or other such mechanisms for ease of transportation and positioning. In some embodiments, support frame 10, once positioned, may be attached to external supports 105 to enhance stability of the system during deployment of the manipulator arms. In some embodiments, support frame 10 may provide containment for at least one of operation, cleaning, and transportation.

[0029]

[0063] carriage In some embodiments, such as the embodiment shown in FIGS. 2A and 2B, a carriage 115 can be used to couple the RMA 100 to the support frame 10 during operation. In some embodiments, the carriage 115 can integrate a cam path 112 and / or a rotary actuator to control the alignment of the RMA 100 as it is deployed. In some embodiments, the rotary actuator is hydraulic. In some embodiments, the carriage 115 may include control components for operation and control of the RMA 100, such as an electric wire rope winch, position feedback, and a motor for mast extension and / or rotation. In some embodiments, the carriage 115 further serves cable management purposes.

[0030]

[0064] Deployment / Return 3A-3H illustrate one embodiment of the RMA 100 deployment process.

[0031]

[0065] 3A shows RMA 100 at the beginning of deployment with the working end of the manipulator arm inserted into an access point. In the illustrated embodiment, the access point is located below RMA 100. It should be apparent that in some embodiments, RMA 100 may be configured to deploy through an access point located within a wall, ceiling, or other structure. In some embodiments, RMA 100 may be deployed in an open environment.

[0032]

[0066] 3B-3E show the RMA 100 as the forearm 130 enters the access point. In some embodiments, cams and cam paths can be used to control the angle at which the RMA 100 is deployed into the access point. In the illustrated embodiment, cams and cam paths are used to keep the manipulator vertical as it enters the access point below. In the illustrated embodiment, a cam mechanism is used to rotate the carriage 115 upward as the forearm 130 is deployed into the access point. In the illustrated embodiment, the mast is first rotated upward 90° (FIGS. 3B and 3C) and then lowered to the bottom of the frame 10 (FIGS. 3D and 3E).

[0033]

[0067] 3F and 3G show the RMA 100 as the elbow 140 is about to enter the access point and the carriage 115 is rotated upward another 90°. In the illustrated embodiment, the carriage 115 rotates 180° during the deployment process. Once the carriage 115 is 180° from its initial position, the mast can be deployed through the access point, as shown in FIGS. 4A and 4B.

[0034]

[0068] In some embodiments, RMA 100 utilizes a cart for ease of transport and / or installation. The cart can allow RMA 100 to be placed on its side (horizontal) and may optionally include a bar linkage or other such mechanism to assist in moving RMA 100 from horizontal to vertical and vice versa. Once the optional bar linkage is in place, it can be actuated to power one or more on-board hydraulic cylinders. When the frame is in the upright (vertical) position and positioned over the workspace, the cart can be removed.

[0035]

[0069] In some embodiments, the frame of RMA 100 incorporates several wheels and / or one or more other mobility-facilitating mechanisms to allow for transporting and positioning RMA 100. RMA 100 can be positioned manually or using a remote control. In some embodiments, the installation cart may include one or more drive mechanisms that allow for remote movement of the cart for proper positioning.

[0036]

[0070] In some embodiments, RMA 100 can be mounted to existing infrastructure or other support to increase stability during manipulator deployment. In some embodiments, RMA 100 includes a mounting plate that can be secured to existing infrastructure. For example, the mounting plate may be secured to the floor for a floor access point such that the load path is directed to the floor through the mounting plate rather than the frame.

[0037]

[0071] For deployment, the manipulator in some embodiments may use an overhead A-frame gantry beam and chain fall or other lift mechanism. The RMA 100 may be deployed to the access point while powered or unpowered. Some embodiments include cams and cam paths to control the deployment operation for difficult access points. In some embodiments, during deployment, the carriage of the RMA 100 can follow a specific cam path that allows the manipulator to move linearly to the access point.

[0038]

[0072] mast FIG. 4A shows one embodiment of the mast 120 in a retracted position. In some embodiments, the mast 120 can include one or more telescoping tubes. In some embodiments, the mast 120 can be extended or retracted depending on the desired depth / height, as shown in FIG. 4B. In some embodiments, the tube or tubes are formed from a lightweight material, such as carbon fiber. In some embodiments, the tube or tubes are constructed from a metal, such as stainless steel. To enable rotation of the mast 120, the outermost tube can be coupled to a gear or slewing ring, which can be driven by a motor, in some embodiments. The mast 120 can be rigidly attached to the carriage 115 by a mounting ring and bearings coupled to the outermost tube. In some embodiments, the mast 120 can rotate 360°. In some embodiments, the innermost tube can include a hydraulic cylinder that can form or be coupled to an elbow mechanism. In the illustrated embodiment, the hydraulic cylinder is double-acting.

[0039]

[0073] elbow FIG. 5 shows one embodiment of an elbow 140 that can be used to connect the mast 120 to the forearm 130. In some embodiments, the elbow 140 has two actuation stages. In some embodiments, the elbow 140 allows a total of −10° to +180° of movement from a vertically downward orientation. In some embodiments, the elbow's mast-to-elbow pivot 141 allows 90° of movement, allowing the elbow linkage to point downward or horizontally. In some embodiments, the forearm-to-elbow pivot 142 allows 100° of movement, for example, −10° to +90° of actuation.

[0040]

[0074] FIG. 6A shows one embodiment of the elbow 140 pointed straight down. FIG. 6B shows a 90° actuation of the mast-elbow pivot 141, raising the forearm 130 to a horizontal position. FIG. 6C shows an example of a 90° actuation of the forearm-elbow pivot 142, raising the forearm 130 to a vertical position. A combination of these actuations can enable the RMA 100 to reach the full range of its workspace. In some embodiments, each stage is actuated using a single hydraulic cylinder, and each pivot pin incorporates a resolver for position feedback. In some embodiments, stage actuation can require multiple hydraulic cylinders.

[0041]

[0075] In some embodiments, a double-acting hydraulic cylinder is mounted within the internal mast 120 to provide pivoting motion for the first elbow joint 141. The hydraulic cylinder assembly may comprise a stainless steel rod and cylinder weldment. In some embodiments, the hydraulic cylinder may be attached to the end of the mast 120 by a pin.

[0042]

[0076] The RMA 100 may include one or more joints. In some embodiments, all joints act in the same plane. In some embodiments, the joints may be offset to act in different planes or at different angles relative to one another. Different joint types, such as ball joints and chain joints, having different ranges of motion may be implemented. Chain joints are described in co-pending U.S. patent application Ser. No. 14 / 975,544, entitled "Systems and Methods for Chain Joint Cable Routing," filed Dec. 18, 2015, with a priority date of Dec. 19, 2014, which is incorporated herein by reference in its entirety. In some embodiments, one or more joints may be hydraulically actuated.

[0043]

[0077] forearm In some embodiments, the forearm 130 is similar in design to a mast. In some embodiments, the forearm 130 comprises one or more telescoping tubes. In some embodiments, the one or more tubes may be constructed from carbon fiber. In some embodiments, the one or more tubes are constructed from a metal, such as stainless steel. FIG. 7A shows the forearm 130 in a retracted position, and FIG. 7B shows the forearm 130 in an extended position. The telescoping forearm 130, in some embodiments, can be extended and retracted using one or more hydraulic cylinders that can be moved together to allow simultaneous movement. The cylinder rods may be hollow to minimize the number of hydraulic lines required to run through the forearm 130. In some embodiments, forearm pivot actuation is provided by one or more elbows.

[0044]

[0078] In some telescoping embodiments, bushings can be utilized to prevent the mast and / or forearm tubes from rotating relative to one another. In some embodiments, the tubes can include dual keys and mating key slots in the bushings to prevent each section from rotating independently. In some embodiments, the bushings can have machined slots to allow for the flow of washwater. Hard stops can be incorporated into one or more tubes to prevent overextension or over-retraction. In some embodiments, hard retraction stops are threaded into the top of each keyway. In some embodiments, one or more interfaces between the telescoping tool and other components can be coated or constructed with a low-friction material to facilitate movement.

[0045]

[0079] In some embodiments, the telescoping mast and / or forearm can extend using gravity. In some embodiments, the mast and / or forearm can be retracted using a rope, tether, or other flexible attachment that can be connected to a winch or hoist mechanism. In some embodiments, retraction can be accomplished using one or more electric wire rope hoists. In some embodiments, the mast and / or forearm includes one or more redundant wire rope hoists for disaster recovery. Each hoist can retract by itself if another fails. The wire rope hoists can position the mast and / or forearm along the stroke as desired by the operator.

[0046]

[0080] wrist In some embodiments, the RMA 100 includes a wrist joint 150 at the working end of the forearm 130. FIGS. 8A-8C illustrate an exemplary range of motion for the wrist 150. In some embodiments, the wrist 150 can be capable of one or more actuations, including wrist pitch and wrist roll. In some embodiments, the wrist 150 can include one or more rotary actuators to enable wrist roll and wrist pitch. Wrist pitch, in some embodiments, can be actuated using a hydraulic rotary actuator for +90° of movement in the vertical plane. Wrist roll, in some embodiments, can utilize a hydraulic rotary actuator and is capable of 180° of rotation. In some embodiments, each joint of the wrist 150 is capable of up to 180° of rotation. In some embodiments, the wrist 150 includes a master tool changer assembly. In some embodiments, the wrist 150 can include a versatile grip or other mechanism to enable deployment of various tools and / or end effectors.

[0047]

[0081] End Effector In some embodiments, there is a matching interface between the end effector, forearm, or wrist and a tool or other end effector to accommodate multiple end effectors in different orientations. Some embodiments can incorporate a universal coupling mechanism between various tools and / or end effectors and the working end of the RMA. In some embodiments, the coupling mechanism can be configured for end effector exchange. FIG. 9A shows a rear isometric view of an embodiment of a gripper 160 including an embodiment of an end effector coupling mechanism 165 that can be used to connect and secure an end effector to the forearm 130. FIG. 9B shows a front isometric view of the forearm 130 including an embodiment of a forearm coupling mechanism 155 that connects and secures the end effector 160 to the forearm 130. In some embodiments, the coupling mechanism is adapted for quick attachment and detachment to enable rapid end effector changeover. In some embodiments, the coupling mechanism can include one or more of mechanical, electrical, and hydraulic connections. In some embodiments, the coupling mechanism can include a means for inserting and removing material, such as tubing, from the workspace. In some embodiments, the linkage is adapted to provide power, control, and material transfer capabilities to a variety of different end effectors.

[0048]

[0082] Figure 9C shows the embodiment of the linkage mechanism of Figures 10A and 10B when coupled and the wrist is bent downward by 90°, and Figure 9D shows the embodiment of the linkage mechanism of Figures 10A and 10B when coupled and the wrist is bent upward by 90°.

[0049]

[0083] In some embodiments, the working end of the forearm 130 can be equipped with one or more sensors and / or an end effector, such as a gripper or tool. FIGS. 10A and 10B show front and back isometric views of one embodiment of a gripper 160. The gripper 160 can grasp objects and deploy various tools. In some embodiments, the jaws 161 can be connected to a linkage 162 to keep them parallel while opening and closing. In some embodiments, in the event of a hydraulic failure, the gripper 160 can fail in an "in place" position. In the event of a loss of pressure, the jaws 161 become flexible and can move when a predetermined load is applied to the jaws 161. In some embodiments, a piston with a reduced stroke is used for a smaller access point to prevent the gripper 160 from opening beyond a predetermined limit.

[0050]

[0084] Gripper 160 can employ a wide variety of tools that can be used in different applications. In some embodiments, gripper 160 may be used in combination with another tool, end effector, and / or one or more sensors. This may be useful in instances where gripper 160 is used to grasp infrastructure and provide stability to a tool or other end effector. Some embodiments may include other tool / end effector / sensor configurations as needed for the desired task.

[0051]

[0085] In some applications, the end effector may be a specific tool, hi some embodiments, the end effector is actuated by one or more of mechanical, electromechanical, hydraulic, electrohydraulic, pneumatic, magnetic, piezoelectric, and linear motor actuators.

[0052]

[0086] In some embodiments, each tool or end effector includes a mounting interface that allows it to be grasped by gripper 160 in one or more different orientations. One such interface is shown and described in co-pending U.S. patent application Ser. No. 15 / 341,985, entitled "System and Method for Inspection and Maintenance of Hazardous Spaces," filed Nov. 2, 2016, with a priority date of Nov. 3, 2015, which is incorporated herein by reference in its entirety.

[0053]

[0087] tool The RMA 100 can perform many different tasks by deploying a variety of different tools and end effectors. Tools deployed by the RMA 100 can, in some embodiments, include off-the-shelf tools that can be modified for remote deployment. The RMA 100 can be equipped with any one or more of a water jet tool, an inflatable bag tool, a grouting tool, a shear tool, an eductor bulk return tool, a jet wash tool, a scoop / scraper tool, a swabbing tool, a gamma monitor, and other tools, end effectors, and sensors for performing one or more of inspection, maintenance, repair, and cleaning. Many other tools are possible, including simple tools such as rakes, trowels, and shovels.

[0054]

[0088] 11A-11C illustrate one embodiment of a tool change process. The end effector 160 is inserted under the RMA 100 using the tool handling system 210. In this embodiment, the end effector 160 is aligned with the retracted forearm 130. When the mast 120 and / or forearm 130 are extended, the wrist linkage 155 engages the end effector linkage 165, securing the end effector 160 to the forearm 130. FIG. 12 illustrates one embodiment of the RMA 100 coupled to the end effector 160. FIG. 13 illustrates an isometric view of the end effector 160 and forearm 130 coupled to a water jet tool 180.

[0055]

[0089] In some embodiments, tools can be deployed to the workspace through separate access points that can be offset from the main access point. In some embodiments, additional tools or end effectors can be placed in the workspace before the RMA enters. In some embodiments, tools and end effectors can be changed outside of the workspace.

[0056]

[0090] In some embodiments, a hoist and / or pulley system can be used to lower tools and end effectors into the workspace. In some embodiments, a wire rope or other such connector can be used to secure a tool or end effector to the RMA 100 and allow it to be pulled and retracted by the RMA 100 as needed. The wire rope or other such connector may also be used to return the end effector. The wire rope or other such connector may be wound on a spring-loaded spool, which may be powered and / or manual. The spring reel may be provided with several tension ranges to accommodate various tool or end effector weights.

[0057]

[0091] Hydraulic Power Unit In some embodiments, the RMA includes one or more hydraulic power units (HPUs) for powering one or more hydraulic actuators, including, among others, one or more of elbow rotation, forearm extension, wrist pitch, wrist roll, and gripper open / close.

[0058]

[0092] In some embodiments, the HPU can be automatically controlled by a control system during operation. The control system, in some embodiments, can automatically activate the hydraulic supply upon hydraulic demand and automatically control the HPU cooling system according to hydraulic fluid temperature. The HPU may include basic manual controls in addition to the automatic controls to provide flexible control as needed. In some embodiments, local manual control of the HPU can be provided to allow recovery in the event of a control system failure.

[0059]

[0093] In the exemplary embodiment, the HPU supplies hydraulic fluid to all hydraulic actuators at a maximum pressure of 2.9 ksi and a maximum flow rate of 3.96 gallons per minute. Other pressures and flow rates are possible. In some embodiments, hydraulic fluid levels can be monitored to detect leaks.

[0060]

[0094] Cleaning In some embodiments, the RMA includes an integrated cleaning system designed to remove contaminants from the RMA. In some embodiments, cleaning occurs when the RMA is retracted from the workspace, capturing contaminants within the workspace. In some embodiments, the cleaning system can include one or more separate cleaning rings located within the RMA that allow pressurized water to be sprayed onto the RMA surface. Some embodiments incorporate three cleaning rings: one located at the top of the mast, one at the base of the mast, and one located inside the forearm. During return, in some embodiments, each cleaning ring can be pressurized in sequential steps to ensure thorough cleaning of all components. In some embodiments, a high-pressure water supply can be used to operate the cleaning system.

[0061]

[0095] In some embodiments, at least a portion of the electrical components may be maintained to an Ingress Protection Rating (IP) of 64 or higher to protect against overspray and liquids in the work space. In some embodiments, all overspray and overflow may be captured by the support frame containment cover and drained out the bottom of the wash pan into the work space. In the event of a drain blockage, floating objects may automatically shut off the wash water in some embodiments.

[0062]

[0096] Cable Management The cables may extend inside and / or outside the RMA. The term "cable" is intended to include electrical wiring, hydraulic hoses, air hoses, fiber optic cables, communication cables, or any other cables, wires, or lines, and bundles thereof. The cables may be used to transfer / transmit data related to sensing and / or control of the system or any extensions attached to the system. Additionally, cables for transporting materials into and out of the workspace may be included.

[0063]

[0097] In some embodiments, one or more feeds may run internally through one or more of the mast, elbow, and forearm. In some embodiments, cable management can be achieved using one or more of an external tension reel system, a pulley system, and an internal cable chain. The pulley system, in some embodiments, can be under constant tension using a system such as a constant force gas spring. In some embodiments, additional umbilical cables can be included for tools requiring separate power or control systems or additional sensor or signal cables. The cable management system, in some embodiments, can allow the cable to be moved in and out of the mast during extension and retraction. In some embodiments, this can be achieved using a set of pulleys, which can be tensioned with a pneumatic cylinder. Some embodiments may include one or more cable shrouds to prevent the lines and cables from becoming pinched during operation.

[0064]

[0098] One embodiment of a cable management system for an RMA can incorporate a RolaTube® attached to a tether near the RMA, similar to the deployment / recovery tool disclosed in co-pending U.S. patent application Ser. No. 15 / 341,985, entitled "System and Method for Inspection and Maintenance of Hazardous Spaces," filed Nov. 2, 2016, with a priority date of Nov. 3, 2015, which is incorporated herein by reference in its entirety. Some embodiments can include a tether that includes a supply section and material transfer lines between sections to support the tether. This can reduce the force required to move the tether and prevent entanglement with internal infrastructure within the workspace.

[0065]

[0099] In some embodiments, one or more sensors or other devices may utilize wireless communication technologies such as near field communication (NFC) and Bluetooth. Wireless sensors and other devices can reduce the amount of cabling required, thereby increasing the range, capability, and mobility of the system.

[0066]

[0100] Detection and Control Control of the RMA is initiated by a control system. The control system can be one of a local control system and a remote control system for the RMA and workspace. Monitoring and control operations may be performed locally, remotely, and / or mobile. Mobile monitoring and control may be performed using one or more mobile devices, such as smartphones, laptops, mobile desktop computer workstations, tablets, and wearable computing devices. In some embodiments, one or more operators may be equipped with one or more wearable or other mobile devices that provide feedback to the operator. For example, vibration and / or audible alerts may be used to provide warnings to the operators.

[0067]

[0101] In some embodiments, control can be affected by a master-slave manipulation system, including a "man-in-the-loop" system. In such embodiments, an operator can control a master system remotely relative to the workspace. As the operator moves to control the master system, the slave system (the RMA) can respond immediately and accurately. One or more sensors located on at least one of the workspace and the RMA can provide feedback to the operator. In some embodiments, one or more sensors on the RMA can provide tactile and other feedback to the operator to simulate any resistance or other forces acting on the RMA. In some embodiments, the RMA may not respond if the master instructs it to perform an impossible task or a task that would damage the RMA or the workspace. For example, if the master instructs the RMA to move outside of its operating range or workspace, the RMA moves into the operating range or workspace and cannot move any further. Some embodiments can incorporate additional safety mechanisms, such as a slave not responding if the master is moved too quickly. In some embodiments, the master system is an exact replica of the slave system, which can be scaled in size. In some embodiments, the master system is wearable, for example on the operator's wrist.

[0068]

[0102] In some embodiments, a preliminary inspection is performed before performing other operations. The preliminary inspection can generate data that can be used to pre-program the RMA to automatically perform operations. In some embodiments, an operator can program other predetermined data sets into the RMA to automatically perform operations. In some embodiments, the workspace can be inspected after operations for quality control or other purposes. Control of the end effector and / or tool can be integrated into the RMA and / or standalone control.

[0069]

[0103] Virtual Barrier In some embodiments, one or more sensors can be used to scan the workspace prior to operations to collect data that can be used to generate an electronic three-dimensional map of the workspace. When two or more sensors are used to collect data regarding the geometry of the workspace, the data can be combined using sensor fusion techniques known in the art. Alternatively, or in addition, the three-dimensional map of the workspace can be generated manually using known information about the geometry of the space. In some embodiments, the three-dimensional map can be viewed by an operator on a user interface and / or stored in memory. The operator can set a global coordinate system and one or more local coordinate systems within the space. The purpose of the three-dimensional map of the workspace is to define the boundaries of the workspace and any infrastructure or objects within the space that may limit the operational range of the RMA within the space. Knowledge of the geometry of the workspace can be used to preprogram the RMA to automatically perform tasks within the space and to avoid impacting objects within the space when manually performing tasks.

[0070]

[0104] One or more virtual barriers can be generated to prevent equipment from contacting surfaces and / or objects within the workspace, protecting the integrity of both the RMA and the workspace. A three-dimensional map of the workspace defines the actual physical boundaries of the workspace. The virtual barriers define one or more virtual operating areas, offset from the physical boundaries, where work can be safely performed within the workspace without damaging the space or the RMA. Virtual barriers are invisible "walls" that are automatically generated by the control system using predetermined offset values ​​and / or manually programmed or edited by the operator. The offsets of the virtual barriers can be programmed in a manner similar to programming the working area of ​​a CNC machine.

[0071]

[0105] An exemplary virtual barrier embodiment is shown in FIG. 14. In some embodiments, an impermeable virtual barrier 905 can be offset from one or more of the surfaces 900a, 900b within the workspace 950 and can act to prevent the RMA from approaching the one or more surfaces 900a, 900b. In some embodiments, the impermeable virtual barrier 905 can be set at a minimum allowable distance from the one or more surfaces 900a, 900b at which an operation can be safely performed. In the illustrated embodiment, the virtual barrier is offset from the walls 900a and objects 900b within the workspace 950. In some embodiments, a permeable virtual barrier 915 can be offset from the impermeable virtual barrier 905 or one or more surfaces 900a, 900b within the workspace 950 and can act to provide haptic feedback and / or a warning to the operator when encountered. The warning may be one of tactile, auditory, and / or visual. In some embodiments, the warning may intensify as the RMA progresses further into the permeable virtual barrier 915.

[0072]

[0106] In some embodiments, the haptic feedback may be in the form of resistance. For example, as the RMA traverses a permeable virtual barrier 915, the resistance may increase until the RMA encounters an impermeable virtual barrier 905 or cannot overcome the resistance. In some embodiments, the one or more virtual barriers may be generated automatically using predetermined values ​​and / or manually by an operator. The offset of the virtual barriers from the surface and from each other may be uniform or variable throughout. In the illustrated embodiment, the virtual barrier is offset farther from the object 900b than the wall 900a. The one or more virtual barriers may be visible on the display.

[0073]

[0107] interface One embodiment of a control system 1000 is shown in FIG. 15. The RMA 100 can comprise one or more sensors 1700, one or more actuators 1730, one or more transceivers 1745, and the control system 1000. The control system 1000 can include one or more processors 1710, one or more user interfaces 1720, one or more transceivers 1740, one or more programmable controllers 1750, memory 1760, and one or more remote control stations 1770. The programmable controller 1750 provides flexible means of operation of the RMA 100 and / or tools, enabling an optimal control solution for the equipment. The one or more remote control stations 1770 can provide a custom operator interface. The one or more interfaces 1720 can include one or more of a display, touchscreen, joystick, buttons, toggles, switches, and voice input for equipment control. In some embodiments, the interface 1720 can be designed to allow an operator to operate the RMA from within a virtual 3D map of the workspace.

[0074]

[0108] Further details of possible control system and actuator embodiments are described in U.S. Patent Application No. 14 / 975,544, entitled "Systems and Methods for Chain Joint Cable Routing," filed December 18, 2015, with a priority date of December 19, 2014, which is incorporated herein by reference in its entirety.

[0075]

[0109] In some embodiments, the control system may require one or more forms of authentication from an operator in order to function. In some embodiments, if the control system loses confidence that the operator has been properly authenticated, such as not being given a task within a predetermined period of time, the control system may require the operator to re-authenticate.

[0076]

[0110] Operation Mode In some embodiments, the control method can include one or more of joint-by-joint actuation and inverse kinematic actuation. Inverse kinematics allows the operator to control the gripper / tool ​​position, and the control system determines the joint movements to achieve that position. In some embodiments, the control is operator-initiated individual variable speed joint control. In some embodiments, the joint control can be either a push-and-hold type or a bump time-based type depending on the operation being performed.

[0077]

[0111] In some embodiments, the control system 1000 can have a flexible and robust control interface. The interface can have two or more control modes that appropriately control a variety of normal and potentially abnormal behaviors of the equipment. A key design constraint that provides the control system 1000 with the ability to potentially perform a variety of high-level functions can be integrated position feedback on the RMA axes. With knowledge of the RMA configuration, the control system can perform inverse kinematics and kinetic calculations. The two basic operating modes of the control system are joint control mode and inverse kinematics control mode.

[0078]

[0112] In some embodiments, the joint control mode can provide open-loop control for a single axis. The operator can select the desired axis for control on the control interface. Control of the selected axis may be provided by a joystick or other input device and / or interface. The joint control mode can be used during recovery operations, calibration operations, and non-normal operations where inverse kinematics control would interfere with the operator's ability to perform a task. The open-loop joint control mode allows for removal of the RMA in the event of a position sensor failure.

[0079]

[0113] In some embodiments, a closed-loop inverse kinematics control mode can simultaneously provide the operator with x / y / z control of the tool / end effector. Inverse kinematics control allows the operator to control the orientation of the tool / end effector relative to the floor or other fixed infrastructure in the workspace, and allows the operator to control the position (Cartesian coordinate frame) of the tool / end effector within the workspace.

[0080]

[0114] The RMA and tools can be operated manually or automatically. In some embodiments, some functions are automatic and some are manual. In some embodiments, the RMA can provide variable speed control for each joint over an adjustable maximum speed.

[0081]

[0115] Interlock In some embodiments, the RMA may include one or more interlocks to ensure efficient, proper, and safe equipment operation. In some embodiments, these interlocks vary in severity and the awareness presented to the operator. In some embodiments, there are three types of interlocks, including alarm, warning, and operational.

[0082]

[0116] In some embodiments, an alarm may halt system operation that may jeopardize the health of the equipment and typically trigger some type of visual, tactile, and / or auditory feedback to the operator. The alarm condition of the control system may, in some embodiments, be visually displayed in a system alarm interface and status provided. In some embodiments, an alarm may require operator acknowledgement and resolution before the system can become operational again. In some embodiments, if an existing alarm condition is active, the alarm may remain active and non-resettable.

[0083]

[0117] In some embodiments, the warning may include visual, tactile, and / or auditory feedback to the operator, but may not cause the RMA to interrupt operation. Operational interlocks may be executed by the control system to ensure proper equipment health during normal operation. In some embodiments, operational interlocks may not be discernible to the operator and typically execute in the background. For example, a hydraulic power unit may incorporate a cooling interlock that activates / deactivates a fan depending on the fluid temperature. This interlock may occur in the system's normal operating logic.

[0084]

[0118] The control system can provide equipment interlocks as needed (considering desired control options and equipment feedback) to improve equipment health and operability. In some embodiments, control system interlocks can be separated into three main levels: Equipment effective interlock - Interlock for the normal operation of all operations (e.g. emergency stop) Equipment normal operation interlocks - interlocks for normal operation but which may not be needed for non-normal operation (e.g., low fluid pressure levels) Equipment action specific interlocks – interlocks for specific sub-actions (e.g., during the initial deployment action to lock the gripper in a closed position during deployment)

[0085]

[0119] In some embodiments, the control system can include an emergency shutdown system that removes all power from the equipment once activated. In some embodiments, the emergency shutdown system does not remove power from the control and monitoring equipment. In some embodiments, the emergency shutdown system can allow operational feedback during an emergency shutdown condition. After an emergency shutdown, an operator may be required to reset the system to function. Although the equipment may stop or shut down, the control system can remain operational in some embodiments, allowing for alerts and troubleshooting actions. In some embodiments, the control system design provides an electrical disconnect switch at the electrical supply input point to allow for equipment isolation. The control system can meet electrical codes to ensure equipment safety and provide fail-safe for electrical, hydraulic, and mechanical components in the event of a supply loss.

[0086]

[0120] Sensor In some embodiments, the RMA 100 may include one or more sensors. The one or more sensors may include one or more of contact sensors, non-contact sensors, capacitive sensors, inductive sensors, 3D imagers, cameras, thermal imagers, thermometers, pressure sensors, accelerometers, inertial measurement units (IMUs), rotary encoders, resolvers, string encoders, radiation detectors, LIDAR, microphones, force sensors, load sensors, strain sensors, etc. In some embodiments, the one or more sensors may be used to determine the position of a deployed tool during operation. In some embodiments, the one or more sensors may be used to monitor at least one of strain, torque, pressure, and environmental conditions at one or more locations in the system as a safety mechanism to prevent catastrophic failure.

[0087]

[0121] In some embodiments, the RMA 100 can include one or more imaging sensors. The one or more imaging sensors may comprise one or more of a 3D imager, a 2D distance sensor, a camera, a thermal imager, a radiation detector, and the like. The one or more imaging sensors can be used to provide inspection and monitoring capabilities to a remote operator. Signals from the one or more imaging sensors can be displayed in real time, recorded for later review, and / or recorded for work documentation. In some embodiments, one or more imaging devices can be mounted on or proximate to the end effector to enable a close-up view of the work. In some embodiments, one or more imaging devices can be mounted in the workspace. Any one or more imaging devices can be one of a fixed type or a pan-tilt-zoom type. Any one or more imaging devices can be remotely controlled or preset by an operator to follow input motion patterns or rules.

[0088]

[0122] An operator can select and manage a desired imaging device view for a task while controlling the imaging devices with associated control functions such as pan, tilt, zoom (PTZ), focus, and light. In some embodiments, one or more imaging devices can provide complete visual coverage of the task within the workspace. One or more imaging devices can be used for visual collision avoidance during the task. Auditory feedback to the operator may be provided from any one or more positions within the workspace and / or from one or more positions on the RMA 100.

[0089]

[0123] One or more sensors may be included in RMA 100 to detect contact with infrastructure and / or other surfaces within the workspace. In some embodiments, the one or more sensors may be a six-axis sensor that can communicate the direction and magnitude of an impact to an operator and / or other personnel. In some embodiments, the one or more sensors may function as a proximity warning system to prevent contact with infrastructure and / or other surfaces within the workspace. In some embodiments, the control system may not process inputs that could cause damage to the equipment or workspace.

[0090]

[0124] In some embodiments, the extension and / or velocity of extendable components in the system, such as the forearm and / or mast, can be measured using one or more string potentiometers. Mast rotation, in some embodiments, can be driven by an electric geared motor mounted on a turntable bearing and can use a resolver for position feedback. In some embodiments, lighting can be provided at one or more locations within the workspace and / or at each imaging device location.

[0091]

[0125] In some embodiments, such as the embodiment shown in FIG. 16 , the RMA 100 includes a dynamic measurement unit 1010, which includes one or more accelerometers and one or more rate sensors. In some embodiments, the RMA 100 includes one or more non-contact sensors attached to at least one of the forearm 130, the mast, and the elbow. In the illustrated embodiment, the non-contact sensors are collocated with the dynamic measurement unit 1010 on the forearm 130. The dynamic measurement unit 1010 may be configured as a six-degree-of-freedom, three-axis sensor configured to operate in a Cartesian coordinate system. In some embodiments, the dynamic measurement unit 1010 includes three accelerometers and three rate sensors, with each pair of accelerometers and rate sensors oriented along a respective axis of the Cartesian coordinate system.

[0092]

[0126] In some embodiments, one or more non-contact sensors (not shown) mounted on at least one of the forearm 130, mast, and elbow report object measurements as distance and azimuth angles or orientations to objects and / or surfaces in the workspace in a polar reference coordinate frame. In some embodiments, the control system 1000 calculates and displays objects and / or surfaces in the workspace in an x, y, and z Cartesian reference coordinate frame. This is done to allow the operator to view the workspace in three dimensions more intuitively, making it easier to understand and visualize. Thus, in some embodiments, the non-contact sensor data is transformed into a Cartesian reference coordinate frame before it is used.

[0093]

[0127] The standard transformation from a polar reference frame to a Cartesian reference frame is x m =r m cosθ m and y m =r m sinθ m , (1) where r m and θ m are the range and azimuth of the sensor target in the polar reference coordinate frame, respectively, and x m and y m are the downrange and cross range coordinates in the transformed Cartesian coordinate frame, respectively. However, when dealing with measurements, mean and variance statistics, the above formulas cannot be used to directly convert from the polar coordinate frame to the Cartesian coordinate frame.

[0094]

[0128] However, if measurement uncertainty is a concern in terms of variance in the distance and bearing measurements, additional steps in the transformation should be considered. In the case of variance in the transformation, the standard transformation will not produce a perfect elliptical error envelope. To do so, there may be a debiased correction term that can be subtracted from (Equation 1) to obtain better values ​​of the distance and bearing measurements.

[0095]

[0129] Removing the bias of standard transformations is generally well understood, published, and explained in the art. The following equation gives the bias-removing transformation from a polar coordinate frame to a Cartesian coordinate frame:

number

number

[0096]

[0130] Covariance matrix R for downrange and cross-range coordinates a teeth,

number

[0097]

[0131] Starting up the device Upon power up, the control system may, in some embodiments, start up in an equipment start safe state. Once power is up, initiation of equipment control may require an operator start or emergency stop system reset and alarm reset in the operator interface. Operator initiation of the system may ensure personnel are aware of the equipment status and condition before work begins.

[0098]

[0132] Equipment shutdown In some embodiments, the control system can trigger an emergency stop circuit to shut down the equipment in an active safe state. The control system design in some embodiments ensures that the equipment shuts down in a safe state upon removal of power or electrical supply by the emergency stop circuit. A fail-safe design in the absence of power allows for hard equipment shutdown, such as electrical disconnection or isolation.

[0099]

[0133] recovery In some embodiments, the control system can turn off normal operation mode for recovery operations in the event of a failure. Recovery of the equipment via the user interface can be the primary mode of equipment recovery when access to the operating area is difficult. If recovery of the equipment via the user interface is not possible (e.g., if the programmable controller fails), the operator can provide hydraulic or manual mechanical means for recovery.

[0100]

[0134] Non-transitory computer-readable medium

[0135] The various operations of the methods described above may be performed by any suitable means capable of performing an operation, such as various hardware and / or software components, circuits, and / or modules. In general, any operation illustrated in the figures may be performed by a corresponding functional means capable of performing the operation.

[0101]

[0136] The various example logic blocks, modules, and circuits described in this disclosure may be implemented or performed with a general-purpose processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA) or other programmable logic device (PLD), discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor may be a microprocessor, but alternatively, the processor may be any commercially available processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of two computing components, e.g., a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors in combination with a DSP core, or any other such configuration.

[0102]

[0137] In one or more aspects, the functions described may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions may be stored on or transmitted over as one or more instructions or code on a computer-readable medium. Computer-readable media includes both computer storage media and communication media, including any medium that facilitates transfer of a computer program from one place to another. Storage media may be any available medium that can be accessed by a computer. By way of example, and not limitation, such computer-readable media may include RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage, or any other medium that can be used to execute or store desired program code in the form of instructions or data structures and that can be accessed by a computer. Also, any connection is properly termed a computer-readable medium. For example, if the software is transmitted from a website, server, or other remote source using coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of medium. As used herein, disk and disc include compact discs (CDs), laser discs, optical discs, digital versatile discs (DVDs), floppy disks, and Blu-ray discs, where disks typically reproduce data magnetically and discs reproduce data optically with a laser. Thus, in some respects, computer-readable medium may include non-transitory computer-readable medium (e.g., tangible media).Additionally, in some aspects computer-readable media may comprise transitory computer-readable media (e.g., a signal). Combinations of the above should also be included within the scope of computer-readable media.

[0103]

[0138] The methods disclosed herein include one or more steps or actions for achieving the described method. Method steps and / or actions may be interchanged with one another without departing from the scope of the claims. In other words, unless a specific order of steps or actions is specified, the order and / or use of specific steps and / or actions may be changed without departing from the scope of the claims. Processes or steps described in one implementation may be combined with steps of other described implementations as appropriate.

[0104]

[0139] The functions described may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions may be stored as one or more instructions on a computer-readable medium. A storage medium may be any available medium accessible by a computer. By way of example, and not limitation, such computer-readable media may include RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage, or any other medium that can be used to execute or store desired program code in the form of instructions or data structures and that can be accessed by a computer. As used herein, disk and disc include compact discs (CDs), laser discs, optical discs, digital versatile discs (DVDs), floppy disks, and Blu-ray discs; discs typically reproduce data magnetically, while discs reproduce data optically with a laser.

[0105]

[0140] Accordingly, certain aspects may include a computer program product for performing the operations presented herein. For example, such a computer program product may include a computer-readable medium having stored (and / or encoded) instructions, the instructions being executable by one or more processors to perform the operations described herein. In certain aspects, the computer program product may include packaging materials.

[0106]

[0141] Software or instructions may be transmitted over a transmission medium. For example, if the software is transmitted from a website, server, or other remote source using coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of transmission media.

[0107]

[0142] Furthermore, it should be understood that modules and / or other suitable means for performing the methods and techniques described herein may be downloaded and / or obtained by a user terminal and / or base station, where applicable. For example, such devices may be coupled to a server to facilitate the transfer of means for performing the methods described herein. Alternatively, the various methods described herein may be provided via storage means (e.g., RAM, ROM, physical storage medium such as a CD (compact disk) or floppy disk, etc.) such that the user terminal and / or base station can obtain the various methods when coupling or providing the storage means to the device.

[0108]

[0143] It is to be understood that the claims are not limited to the precise configuration and components described above. Various modifications, changes and variations can be made in the arrangement, operation and details of the methods and apparatus described above without departing from the scope of the claims.

[0109]

[0144] For convenience, operations are described as various interconnected functional blocks or separate software modules, although this is not required, and these functional blocks or modules may equivalently be aggregated into a single logical device, program, or operation having indistinct boundaries. In any event, the functional blocks and software modules or described features may be implemented by themselves or in combination with other operations in either hardware or software.

[0110]

[0145] While the principles of the systems, methods, processes, and / or apparatus disclosed herein have been described and illustrated in preferred embodiments thereof, it will be apparent that the systems, methods, processes, and / or apparatus may be changed in arrangement and detail without departing from such principles. The claims cover all modifications and variations that come within the spirit and scope of the appended claims. [Explanation of symbols]

[0111] 10...Support frame, 100...RMA, 105...External support, 112...Cam path, 115...Carriage, 120...Mast, 130...Forearm, 140...Elbow, 141...Mast-elbow pivot, 142...Forearm-elbow pivot, 150...Wrist, 155...Forearm linkage, wrist linkage, 160...End effector, gripper, 161...Jaw, 162...Link mechanism, 165...End effector linkage, 180...Water jet tool, 210...Tool handling link 900a...surface, 900b...surface, 905...impermeable virtual barrier, 915...permeable virtual barrier, 950...work space, 1000...control system, 1010...dynamic measurement unit, 1700...sensor, 1710...processor, 1720...user interface, 1730...actuator, 1740...transceiver, 1745...transceiver, 1750...programmable controller, 1760...memory, 1770...remote control station.

Claims

1. 1. A robotic arm deployment and control system, comprising: a robotic arm comprising at least two segments connected by one or more elbows, a first segment configured to operate as a telescoping mast and a second segment configured to operate to deploy a tool from a working end; a mast deployment system including a cam path for controlling deployment into the workspace; one or more sensors; 1. A processor-based controller, comprising: identifying one or more surfaces defining the workspace with the one or more sensors; generating a three-dimensional map of the workspace based at least in part on the one or more surfaces defining the workspace; establishing an impermeable virtual barrier offset from the one or more surfaces within the workspace, the offset of the impermeable virtual barrier being at least one of variable and uniform; a controller configured to establish a permeable virtual barrier offset from the impermeable virtual barrier; A system comprising:

2. The system of claim 1 , wherein the one or more sensors comprise at least one of a dynamic measurement unit and / or a non-contact sensor, the non-contact sensor being attached to the working end of the second segment.

3. The system of claim 2 , wherein the one or more sensors are operatively oriented along respective axes of a local Cartesian coordinate system.

4. The system of claim 2 , wherein the one or more sensors include at least one dynamic measurement unit and at least one non-contact sensor, the dynamic measurement unit being co-located with the non-contact sensor.

5. The system of claim 1 , wherein the one or more sensors comprise three accelerometers and three rate sensors, one accelerometer and one rate sensor oriented along each axis of a local Cartesian coordinate system.

6. The system of claim 1 , wherein the processor-based controller is further configured to be operable to combine data received from the one or more sensors.

7. The system of claim 1 , wherein the offset of the impermeable virtual barrier is the minimum allowable distance at which an operation can be performed.

8. 10. The system of claim 1, wherein the permeable virtual barrier transmits at least one of a warning and / or haptic feedback to the operator when the robotic arm approaches, the haptic feedback being in the form of increasing resistance as the robotic arm approaches the impermeable virtual barrier.

9. The system of claim 1 , wherein the impermeable virtual barrier prevents the robotic arm from advancing beyond the impermeable virtual barrier.

10. The system of claim 1 , wherein the processor-based controller is configured to enable remote control of the robotic arm by an operator.

11. 1. A robotic arm deployment and control system, comprising: a robotic arm comprising at least two segments connected by one or more elbows, a first segment configured to operate as a telescoping mast and a second segment configured to operate to deploy a tool from a working end; a telescoping mast deployment system including a cam path for controlling deployment into the workspace; one or more sensors, a non-contact sensor attached to the second segment and configured to measure distance and orientation in polar coordinates to objects contained within the workspace; a dynamic measurement unit attached to the working end of the second segment, the dynamic measurement unit comprising at least three accelerometers and three rate sensors, the dynamic measurement unit configured to be operable as a six-degree-of-freedom, three-axis sensor configured to operate in a local Cartesian coordinate system; one or more sensors comprising:

1. A processor-based controller, comprising: applying a global Cartesian reference frame to the workspace; receiving the polar coordinates from a first local position of the non-contact sensor and the Cartesian coordinates from a second local position of the dynamic measurement unit; converting the polar coordinates to a Cartesian coordinate form and relating the converted coordinates from the non-contact sensor and the Cartesian coordinates from the dynamic measurement unit to the global Cartesian reference coordinate frame; identifying the one or more surfaces defining the workspace with the one or more sensors; generating a three-dimensional map of the workspace based at least in part on the one or more surfaces defining the workspace; establishing an impermeable virtual barrier offset from the one or more surfaces within the workspace, the offset of the impermeable virtual barrier being at least one of variable and uniform; a controller operatively configured to establish a permeable virtual barrier offset from the impermeable virtual barrier; A system comprising:

12. The system of claim 11 , wherein the non-contact sensor is attached to the working end of the second segment.

13. The system of claim 11 , wherein the non-contact sensor and the dynamic measurement unit are operatively oriented along respective axes of the local Cartesian coordinate system.

14. The system of claim 11 , wherein the dynamic measurement unit is collocated with the non-contact sensor.

15. The system of claim 11 , wherein one accelerometer and one rate sensor are oriented along each axis of the local Cartesian coordinate system.

16. The system of claim 11 , wherein the processor-based controller is further configured to be operable to combine data received from the one or more sensors.

17. The system of claim 11 , wherein the offset of the impermeable virtual barrier is the minimum allowable distance at which an operation can be performed.

18. 12. The system of claim 11, wherein the permeable virtual barrier transmits at least one of a warning and / or haptic feedback to the operator when the robotic arm approaches, the haptic feedback being in the form of increasing resistance as the robotic arm approaches the impermeable virtual barrier.

19. The system of claim 11 , wherein the impermeable virtual barrier prevents the robotic arm from advancing beyond the impermeable virtual barrier.

20. The system of claim 11 , wherein the processor-based controller is configured to enable remote control of the robotic arm by an operator.

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