Continuous Arm Robot System

Abstract

To provide a continuum arm robot system which is a single redundant robotic system with a second continuum arm robot supporting a first continuum arm robot.SOLUTION: A continuum arm robot system comprises at least a first continuum arm robot and a second continuum arm robot, each continuum arm robot being controlled by its own actuator pack, and each actuator pack being coupled to a single control computer, in which at least the second continuum arm robot comprises a releasable connection mechanism to engage in gripping the first continuum arm robot in a workspace, so as to link at least the two continuum arm robots into a single redundant robotic system with at least the second continuum arm robot providing support for the first continuum arm robot.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to coupled continuous arm robots. In particular, the present disclosure relates to multiple jointed dual function continuous arm robots. [Background technology]

[0002] Continuous-arm and snake-arm robots are of interest in many applications because they can operate in spaces that are not easily accessible to other robotic systems or human operators. This is because the ability to manipulate the body with many degrees of freedom allows for precise and easy positioning of end tools. This positioning is controlled by actuators that operate tendons inside the robot, allowing each joint in the arm to be individually controlled with high positional accuracy.

[0003] Most arm robots have six or fewer degrees of freedom. However, for tasks requiring greater dexterity, a larger number of degrees of freedom is required. In such cases, it is necessary to increase the number of degrees of freedom. Increasing the number of degrees of freedom means that the arm can operate in tight spaces, for example, for maintenance of complex structures or for use in minimally invasive surgery. Continuous-arm robots are designed along two main lines. First, there are snake-type robots. Snake-type robots consist of multiple rigidly coupled sections connected by rigid R / U / S (Revolute / Universal / Spherical) joints or flexible joints. Each section is composed of one or more segments and is controlled independently of the other sections by on-board or remote actuation. Second, there are continuous robots. Continuous robots consist of a flexible backbone, whose local and global deformations are controlled by one or more actuators.

[0004] Current designs for functional yet highly flexible robots suffer from the large number of joints required for the robot arm. These joints result in a lower degree of stiffness for the robot arm compared to traditional six-degree-of-freedom robots. This lower stiffness reduces the load-carrying capacity and the interaction the arm may have with the environment in which it is operating. Current technologies attempt to overcome this by "freezing" the system by locking actuators or by adding stiffening means to the backbone. This can be effective for short-length robot arms. However, when employed in longer-length robots, the arm behaves like a long cantilever beam, and deflection of the beam creates significant positioning and guidance challenges. This can damage the robot and / or the object it is working on, limiting the use of such robots to light-duty tasks. Therefore, an improved continuous-arm robot system is needed to overcome these issues. Summary of the Invention

[0005] According to a first aspect of the present disclosure, there is provided a continuous arm robot system comprising at least a first continuous arm robot and a second continuous arm robot, each continuous arm robot controlled by its own actuator pack, each actuator pack being connected to a single control computer, wherein at least the second continuous arm robot comprises a releasable connection mechanism that engages with the first continuous arm robot by grasping in a workspace, thereby combining the at least two continuous arm robots into a single redundant robot system, with at least the second continuous arm robot providing support to the first continuous arm robot.

[0006] The connection mechanism may be located at the end of the second continuous arm robot.

[0007] The connection mechanism may be disposed along a continuous arm section, the end of which features a functional head.

[0008] The connection mechanism may be one of hydraulic, pneumatic, mechanical gripper, or electromagnetic.

[0009] Each continuous arm robot may include a plurality of sensors, some of which may be configured to measure the distance and relative position between the first and second continuous arms.

[0010] The clamp may feature an interlock that, if activated, prevents operation of the robotic system.

[0011] The second continuous arm robot may feature a functional tool at its tip.

[0012] One of the continuous robots may be equipped with a camera system and / or a lighting system.

[0013] The behavior of the connection mechanism may be rigid.

[0014] The connection mechanism may be flexible.

[0015] The connections may limit the system to less than six degrees of freedom.

[0016] Both of the arms may be continuous arm robots.

[0017] One of the arms may be a partially flexible robotic arm.

[0018] According to a second aspect of the present disclosure, there is provided a method of operating the above-mentioned robot system, comprising the steps of inserting the first continuous arm robot and inserting the second continuous arm robot into a workspace; connecting the first continuous arm robot and the second continuous arm robot to combine the robots to form a robot system; performing a desired task using at least the first continuous arm robot; disconnecting the first continuous arm robot and the second continuous arm robot; and withdrawing the continuous arm robot from the workspace.

[0019] The first and second continuous robots may be moved to a predetermined setting and may approach each other under controlled relative positioning to connect the first and second arms.

[0020] Those skilled in the art will understand that, except where mutually exclusive, a feature described in connection with any one of the above embodiments may be applied mutatis mutandis to any other embodiment. Furthermore, except where mutually exclusive, any feature described herein may be applied to any embodiment and / or may be combined with any other feature described herein.

[0021] Embodiments will now be described, by way of example only, with reference to the drawings in which: [Brief explanation of the drawings]

[0022] [Figure 1A] FIG. 1a shows a prior art example of a cross section of a continuous arm robot. [Figure 1B] FIG. 1B shows an example of a joint in a continuous robotic arm. [Figure 2] FIG. 2 shows an illustration of a continuous arm robotic system according to the present disclosure. [Figure 3] FIG. 3 shows a schematic diagram of the operation of a continuous arm robot according to the present disclosure. [Figure 4]FIG. 4 illustrates an example of a control system that may be used to control an at least two arm continuous arm robotic system according to the present disclosure. [Figure 5] FIG. 5 shows a flowchart of the operation of the articulated continuous arm robotic system of the present disclosure. [Figure 6] FIG. 6 shows an example of a three-robot continuous system according to the present disclosure. [Figure 7] FIG. 7 shows an example of a clamping mechanism between the second continuous arm robot and the first continuous arm robot shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0023] Aspects and embodiments of the present disclosure are described with reference to the accompanying drawings, and further aspects and embodiments will be apparent to those skilled in the art.

[0024] FIG. 1a shows a prior art example of a cross section of a continuous arm robot. The prior art continuous arm robot includes a continuous arm robot section 101, which is permanently integrated into and extends from an actuator pack 102. The actuator pack 102 houses multiple independent actuators 103. These actuators are used to adjust tension in tendons that run through the continuous arm 101. The tendons are associated with joints within the arm. Each of these joints is designed to operate in response to tension or relaxation of the tendons associated with the joint. Thus, tension or relaxation of the tendons causes the joint to contract or extend, thereby allowing the continuous arm to bend. The actuator pack is shown mounted on a rail or support 104 located near the part to be inspected. The actuators are also provided with multiple power and signal cables 105, which are used to power and address the actuators. Individual signals across the range of the actuators provide control of the joints, thereby allowing the continuous arm 101 to be oriented. Although not shown in Figure 1, a computing device coupled to the actuator is also required, along with an operator carrying the computing device to control the operation of the continuous arm and perform the desired task. Because the continuous arm is permanently integrated into the actuator pack, if a separate tool is required, a complete continuous arm robot system including the actuator must be used. The computing device connected to the prior art actuator can be any suitable computer system, such as a laptop computer, capable of controlling the continuous arm, featuring the necessary operating software for the robot and a control input such as a joystick.

[0025] Figure 1B shows an example of a continuous-arm robot's joints. The arm has multiple joints, requiring at least two cables per joint. For example, a system with three joints and four tendons per joint requires 12 actuators for actuation. Increasing the number of joints requires either increasing the number of actuators or reducing the number of tendons per joint. The highlighted joints 106, 107, and 108 can be manipulated to move in three dimensions. The joints are configured as follows: joints 106 and 108 can bend in the same plane relative to the center of the arm. Meanwhile, the plane in which joint 107 can move is offset by 90° relative to joints 106 and 108. In this way, alternating joint angles allow each to move in a different orthogonal plane, allowing the arm to be manipulated in three dimensions. Each joint in the arm has a limit to the amount of bend it can perform. This is determined by the arm's design and the materials used. The bend limit at each joint sets characteristics such as the minimum bend radius and the torque required to effect change at the joint. The space within the joints allows for joint movement and allows for flexibility, resulting in lower stiffness of the arm compared to other robotic arms of the same length. This is because the structural behavior of a snake-type robot manipulator can be likened to that of a loaded cantilever beam. This is because one end of the system is fixed to a base with an actuation puck, and the remaining arm is used to guide the arm through the surrounding environment without any other contact points. In this condition, loads, including the snake's own weight, on the body and / or tip of the snake-type robot force it to deflect significantly from its ideal posture. The end of the arm is typically equipped with a tool or probe designed to perform one or more functions after the continuous arm is in place. The head of a continuous-arm robot is typically equipped with an optical system, allowing an operator to view the head as it is inserted into a part and control it as it performs its task. The optical system is often coupled to an illumination system.Control cables for tools, power connectors to lighting systems, and optical cables may typically run through the center of the joints in the continuous arm. This has the advantage of protecting the cables from potential damage. All of these components, as well as the arm structure, are permanently connected to the actuators. This means that if the arm breaks down or experiences problems, the entire continuous arm robot must be replaced.

[0026] FIG. 2 shows an image of a continuous arm robot system according to the present disclosure. The continuous arm robots may be the same size. Alternatively, the continuous arm robots may have different lengths and / or thicknesses. The continuous arm robot system features a first continuous arm robot 201 and a second continuous arm robot 202. Although described as continuous arm robots, one of the arms may be a partially flexible robot arm robot. The continuous arm robots are controlled by their own respective actuator packs coupled to a single computer and program. The first continuous arm robot is attached to an actuator pack that performs the desired task to be performed by the robot system. The second continuous arm robot features a connection mechanism 203 (shown at the end of the arm in FIG. 2) at a location along the continuous arm robot section. This connection mechanism is configured to grip and support the first continuous arm robot in the appropriate location while the first continuous arm robot performs its desired task. Thus, the second continuous arm robot can be moved to the appropriate position to support the first continuous arm robot, while allowing the system to compensate for loads across multiple channels. Therefore, the continuous-arm robot system does not suffer from the large deflections that a single continuous-arm robot system would. Using two continuous-arm robots fixedly connected to each other can improve the static and dynamic behavior of the system. Because both continuous-arm robots are mobile, an operator can move the gripping position of the first continuous-arm robot to any suitable position to perform the task. For example, the suitable position can be near the tip of the first continuous-arm robot or many articulated sections away from the tip. The presence of a second robot arm provides an additional advantage to the system, as it allows additional tools to be brought into the area that could not be brought through the channels of a single snake-arm robot. Tool feeding can occur through the core of the articulated section of the continuous-arm robot.This allows the system to be used to deliver multiple supplies, such as air or various gases, to a desired area in a single operation. Similarly, using multiple continuous arm robots in a system allows for additional sensors that would not be present using a single arm robot. The length of the robots can be any suitable length. In one embodiment, the connection between two continuous arm robots occurs after the first 6 DoF from the end. This provides optimal performance enhancement.

[0027] The head of a continuous-arm robot may be equipped with sensors such as ultrasound, cameras, and depth sensors. Alternatively, mechanical tools such as grinding or milling tools, or electrical tools such as lasers, or gas-based cutting equipment may be equipped. By utilizing multiple continuous-arm robots, it is possible to have a free end effector dedicated to an operation on a first continuous-arm robot while moving some of the sensors on a "holding" second continuous-arm robot. This potentially allows for more operations or reduces the overall diameter of both robots. Depending on how the robots are connected, the connected robots can also be used to supply compressed air / liquid, gas, or electricity to the tools at the end of the continuous arms. The purpose of using coupled continuous-arm robots is to increase the rigidity and / or payload capacity by connecting them together. Additional advantages of coupling continuous arms include the possibility of "driving / pulling" one main continuous arm with another to increase its range / precision, and the possibility of supplying more tools than a single robot would allow through a single access corridor.

[0028] FIG. 3 shows a schematic diagram of the operation of connected continuous arm robots. In this illustration, a first continuous arm robot 301 is inserted through an access passage 305. After the first continuous arm robot is positioned, or simultaneously with insertion, a second continuous arm robot 302 can be fed through a second access passage 306. This allows both continuous arm robots to reside within the same workspace 307. The second continuous arm robot is then oriented toward the first continuous arm robot. The second continuous arm robot can then be clamped or connected to the first continuous arm robot via a connection mechanism 303. With the first and second continuous arm robots coupled, the actuator head of the first continuous arm robot can use its tool or gripper to machine an object 304. In addition to typical continuous robot tasks, collaboration enhances certain machinability and manipulation tasks. Collaboration can also be utilized for inspection tasks requiring force interaction with the surrounding environment (e.g., ultrasonic inspection). Coupling the first and second continuous-arm robots means that the first continuous-arm robot is supported during machining, resulting in less deformation than if it were operating alone. To remove the first and second continuous-arm robots, the clamp between the robots is released. This allows the first and second continuous-arm robots to be removed along their respective access paths. While the illustration shows the use of two access ports, these could be, for example, borescope holes in a gas turbine engine or other complex system. However, the robot arms could be used with any suitable access port into the system. Furthermore, the two robot arms do not need to use different access paths; they could be inserted into the system adjacent to each other. Using a coupled continuous-arm robot means that access to the work area can be less than 50 mm. The only size requirement is that the continuous arm be large enough to fit through. This means that a coupled continuous-arm robot can be used in areas that are inaccessible to larger industrial robots.As such, the system can be used in aerospace, nuclear, oil and gas, and communications technologies, all of which have access challenges for robots and human technicians. Those skilled in the art will appreciate that this is a non-exhaustive list and that the technology can be extended for use in any suitable location.

[0029] A camera system may be employed on the first and / or second continuous arm robot to guide the second continuous arm robot toward the first continuous arm robot. This allows an operator to orient the head of the second continuous arm robot toward the first continuous arm robot. Alternatively or additionally, positioning sensors may be employed on both continuous arm robots to provide feedback on relative position information to the operator. This allows the operator to manipulate the robots relative to each other so that they can establish proper coupling. Suitable sensors may be cameras or depth sensors for guidance, used individually or in combination. Magnetic sensors may also be incorporated. Additionally or alternatively, optical fibers may be used for shape sensing. This may be possible by coupling sensors to each of the first and / or second continuous arm robots. This allows the robots to provide the operator with accurate position data regarding their positions. Relative position control is available when the two robot arms are close to each other. Before coupling, the two robot arms can move independently of each other. However, after coupling, they are controlled as a single system. Once connected, control of the robot system is achieved through synchronization / coordination control. Independent movement is possible because they have their own actuators. This allows for precise positioning of the second continuous arm robot. This is necessary because the connection point between the first and second continuous arm robots determines the stiffness of the system. Additionally, control of the level of movement possible for the head of the first continuous arm robot is also available. This control of movement is achieved by connecting the second continuous arm robot closer to the end of the first continuous arm robot and limiting the movement between the connection point and the end. In this way, if the operator connects the second robot closer to the head of the first continuous arm robot, the degrees of freedom of movement possible for the first continuous arm robot are reduced, but the deflection of the system is also reduced.This means greater positional control over the head, allowing it to be used to move heavier objects or in processes where the head generates reaction forces, such as media spraying. In this way, the system can operate in tight spaces where contact with the side of the object could damage it. Alternatively, this process can be used to lock the degrees of freedom, restricting the head to movement in a single plane (similar to an artist grasping their wrist to create a straight line). However, connecting the first continuous arm away from the head increases flexibility and degrees of freedom. This allows the continuous-arm robot system to operate with greater control in areas requiring greater dexterity. As mentioned above, the arms can be connected in a "hand-to-hand" fashion, providing additional support for the arm performing the task. This allows a continuous-arm robot of the same size to perform heavier and stronger tasks than would be possible without it. Having such a system allows the head to be supported during tasks where forces are exerted on the arm's head during the task, such as spraying. In such cases, the presence of an auxiliary arm acts as a support. Using such a system may prevent the robot head from damaging the surrounding area while performing such tasks.

[0030] While the connection is made at the head of the second continuous arm robot in the example shown in FIG. 3 , the connection can be made at any suitable point along the length of the second and first continuous arms. The connection point can be determined before inserting the device. Alternatively, an operator can determine the connection point while positioning the continuous arm robot within the workspace. This allows a combined continuous arm robot to have separately functioning heads with increased rigidity due to the combined arms. Connections at points along the arms can be implemented, for example, by having electromagnetic clamps at points along the continuous arm robot. This allows, for example, one head to perform repair tasks such as spraying, while the second head provides a lighting system and a camera system. Alternatively, two heads can provide complementary functions such as cleaning and repair. The presence of two continuous arms in the system also increases the supply to the work area, as fluids can be piped along the center or periphery of the arms. Similarly, optical systems such as lighting and camera systems can be supplied to the work area. Therefore, by connecting arms further down from the head, two heads can be independently controlled within the system. Because of this, they maintain the full functionality of the end of the continuous arm from the moment the two arms are connected. Having two heads that can perform different tasks in the same system increases the functionality of the robotic system. This also means that multiple processes can be carried out simultaneously. This can reduce maintenance times in complex equipment, and therefore its downtime.

[0031] The robot arms can be connected by many different options. The connection system can be achieved by magnetically or adhesively coupling the continuous arms together. Alternatively or additionally, the connection system can be achieved by a mechanical, pneumatic, or hydraulic clamping system. The connection system's controller is coupled to a connection control unit on the actuator pack. Upon a signal from the control computer program, the actuator pack activates and initiates the process for connecting the second continuous arm robot to the first continuous arm robot. For example, in the case of a hydraulic and pneumatic connection system, the connection controller controls the fluid supply to the clamps to close them around the first continuous arm robot. In an alternative example utilizing an electromagnetic coupling, the connection control unit supplies the necessary current to the electromagnetic clamps to engage them.

[0032] To control at least two continuous-arm robot systems such as that shown in FIG. 4, a control system is required. The control system features a computer 401 having a processor and memory suitable for executing an appropriate control program. The computer also has a means for user input. This can be a USB port connected to a joystick that the operator moves to control the robot's movement. Additional computer functionality is desirable. This can include a second user input device, such as a keyboard, or through commands entered via a touchscreen device. Additional functionality, such as a mouse, can also be used. The computer also needs a means for connecting with the actuator packs associated with the different continuous-arm robots. This connection can be physical, using cables, or wireless.

[0033] The first continuous arm robot 402 and the second continuous arm robot 403 are controlled by a computer program used to control the actuator packs of each continuous arm robot. This computer program is installed on the continuous arm system computer. The computer operates a kinematic model of the motion of a single continuous arm and the coupled continuous arm system to control the motion of the continuous arm robot. The computer program may treat one continuous arm as the master and the other continuous arm robot as the slave. Alternatively, the computer program may treat both as a pair. The computer control program must adapt kinematic models to model multiple manipulators in the system as well as continuous arm robots without coupling. This is because gripping of the arms changes the control and position of the arms. For example, when a first continuous robot is gripped by a second continuous robot, there is less associated deflection of the work head when performing the associated task. Therefore, the program's motion modeling must adapt to changes in the stiffness of the robot system. Precision camera systems and / or position sensors may be employed to improve control of the continuous arms as they perform desired tasks. This provides the computer program and the operator with accurate time information regarding the positions of at least the first and second continuous arm robots. Output from the computer program is utilized to control actuators connected to tendons that control each of the robot arms. The computer program may also control signals provided to the connection system. The computer program may be able to take signals from sensors that may be located on the arms to determine the movement and operation of the connection system. The computer program may also receive signals from the connection system to ensure sufficient pressure is applied to the connection system and to provide information to the operator that the connection is properly engaged. Additionally and / or alternatively, the robot system may be provided with a connection interlock.Thus, if a signal from a connection is lost, the system will stop with the task until the connection signal is restored. The computer program is coupled to a user's input, allowing an operator to control the continuous arm robot. The program may be coupled to an imaging device, if present, on one or more of the continuous arm robots. For example, one or more of the arms may have a fiber optic camera, the output of which is fed to a decoder. The decoder's signal is provided to the computer and program, allowing the operator to view a live real-time display of the operation of the continuous arm robot, from which the operator can maneuver the robot into position. The computer program also has inputs that allow it to operate the connection system when desired. The computer program can operate each continuous robot individually. It may also be possible to operate two or more continuous robots simultaneously. Output from the computer program is then sent to an actuator to control the output of the continuous robot.

[0034] The actuator packs associated with the first continuous arm robot 404 and the second continuous arm robot 405 each feature inputs that can be coupled to a computer. This can be a cable jack for inserting a network cable, a wireless transmission card, or both. These are connected to a processor within the actuator pack. The processor is connected to encoders used to control the actuator's operation. The actuators within an actuator bank of an actuator pack can be paired. The actuators must be capable of generating sufficient torque and precisely controlled movement to operate the tendons and joints within the continuous arm. The actuators can be brushless servo motors. Such servo motors offer the advantage of being lightweight yet providing the torque and precision dynamic control required for precise positioning of the continuous arm robot. Alternatively, the actuators can be any other suitable actuators apparent to those skilled in the art. The actuators can be mounted on a frame that allows the actuators to be connected to the bank. When combined with another pair of actuators on the frame, the bank can be combined to form an actuator pack. The actuator's drive electronics are connected to the actuator to control its operation. The actuator pair can also be equipped with a load cell. The load cells measure the load on the actuators and can feed back the associated load signals to the servo drives used to control the individual actuators. Thus, precise control of the actuators can be obtained. The movement of the actuators sets the tension within the tendons in the arm. Controlling the tension results in movement of each joint in the arm, causing the arm to bend from a straight state. This allows the robot and head to be manipulated into the appropriate position. The second continuous arm robot also features a connection controller mechanism that allows the second continuous arm robot to be connected to the first continuous arm robot, such that the second continuous arm robot and its actuators are different from those of the first continuous arm actuators.Additionally, continuous-arm robots may feature positioning sensors that allow an operator to determine the distance and position relative to one another so that the two snakes can be properly guided toward one another. These sensors feed signals back to actuators, which in turn relay the signals to a computer program that controls the actuators. It is important that the control of both the actuators and the controlling computer program be synchronized to a common clock to allow coordinated movement of the continuous-arm robots. While examples of cable-operated continuous-arm robots have been described, it is also possible to use non-cable-driven systems, such as continuous-arm robots controlled by pneumatic, hydraulic, or electric motors.

[0035] Once the arms are locked, the operator can control the continuous arm robot while it performs the task. If a second robot arm is connected at the head, no or minimal control of the second continuous arm is required until the two robots are disengaged. However, if the second continuous arm has a functional tool on its end, the second continuous arm robot can be controlled simultaneously with or separately from the control of the first continuous arm robot. After performing the task, the operator can provide a command to disengage the connection system, disengaging the two robots. The two continuous arm robots can then be controlled separately and removed from the workspace without damage to themselves or any equipment within the workspace.

[0036] FIG. 5 shows a flowchart of the operation of linked continuous-arm robots. In step 1, multiple separate continuous-arm robots enter the workspace through one or more access areas. The access area can be an access port, such as a borescope in a gas turbine engine, or another confined space access area. Two or more continuous-arm robots can be inserted separately or simultaneously. After the robots enter the workspace, one or more operators orient them toward the work object. This orientation brings the two or more snake-arm robots into close proximity in the workspace. In step 2, the two or more continuous-arm robots connect to each other. The two or more continuous-arm robots move in a predetermined configuration until the final distance between them is covered. This is controlled by the relative positioning of the arms. Proximity and positioning sensors and / or optical systems allow the operator to view the status. After the continuous-arm robots are in place, the operator can engage the connection system, which mechanically connects the continuous arms to each other. The connection system can be equipped with sensors such as pressure sensors. This allows the operator to confirm full connection between two or more continuous arm robots, so the operator knows to proceed with the required task. This system can be coupled to an interlock system, so that if it determines that the first continuous arm robot is no longer gripping, the interlock system will stop the operation of the first continuous arm robot until sufficient connection is re-established. Step 3 is performing the desired task. In this step, the first continuous arm robot, and possibly another continuous arm robot, are moved into position within the workspace so that they are correctly positioned to perform the desired task. With the continuous arms in position, they can be manipulated to perform the required task, such as debris removal or repair tasks.When multiple continuous arm robots are used for a task, it may be necessary to first position a first continuous arm robot arm to perform its task and then be able to remove the first continuous arm robot arm before moving a second continuous arm robot into position to perform its associated task. Alternatively, if the systems are complementary, both may be moved into position before performing the task. After performing the task, the multiple continuous arms may be moved to a desired safe position. Once they are positioned in the desired safe position, step 4 may be performed, which is disengaging at least the first and second continuous arm robots. When three or more continuous arm robots are used, there may be a desired order for disengaging the continuous arm robots so that maximum support is still provided to the first continuous arm robot. Disengaging the continuous arm robots involves releasing the connection system and may further include moving the continuous arm robot to a safe distance from the first continuous arm robot. Once the continuous arm robots are disengaged, the operator may reposition them within the work area so they can be used in a different section of the part as needed. In this case, the process is repeated as described above. Step 6 is to remove at least the first and second continuous arm robots from the access ports, which may be done one continuous arm robot at a time or simultaneously.

[0037] FIG. 6 shows an example of a three-robot system. In this illustration, a first continuous-arm robot 601 extends from its actuator pack, located outside the workspace, to a tip 604 where it is needed to perform the robot system's required tasks. A second continuous-arm robot 602 extends from a different access port. Similarly, the actuator pack is located outside the workspace, and the continuous-arm robot extends into the workspace at its tip. The second continuous-arm robot has a two-part clamp 605 that is used to engage around the body of the first continuous-arm robot and clamp it in place. In this example, a third continuous-arm robot 603 is also present. The presence of the third continuous-arm robot provides additional support for the first continuous-arm robot, allowing it to support a larger load than it could by itself or with the second continuous-arm robot alone. Like the first and second continuous-arm robots, the actuator pack of the third continuous-arm robot is outside the workspace. The third continuous arm robot is shown extended to the first continuous arm robot in a position where it clamps / grabs the first continuous arm robot using an electromagnetic clamping mechanism 606 that engages the magnetic section of the first continuous arm robot 607. The tip of the first continuous arm robot is therefore free to perform the required work task within the workspace. An alternative to the third robot system is for the first and third continuous arm robots to have functional heads that can be used for certain purposes, while the second continuous arm robot features two clamps that can engage the first and third continuous arm robots. Thus, the second continuous arm robot acts as a support for the first and third continuous arm robots.

[0038] FIG. 7 shows an example of a clamping mechanism between the second and first continuous arm robots shown in FIG. 6 . The clamping mechanism 703 is located at the end of the second continuous arm robot 702. While the second continuous arm robot moves closer to the first continuous arm robot 701, the operator ensures that the connection system is in an open state. This ensures that the connection system can be positioned relative to the first continuous arm robot without damaging the first continuous arm robot. This also means that the connection system is already in place to connect to the first continuous arm robot. After the connection system is positioned around the first continuous arm robot, the operator can activate a signal to close the connection system so that the first continuous arm robot is held by the second continuous arm robot. A sensor, such as a pressure sensor, can be applied to the connection system to notify the operator that contact exists at one or more points on the connection system and that the connection system can be safely closed. To release, the operator issues a command to release the connection system, which causes the second continuous arm robot to release the first continuous arm robot. The behavior of the connection system can be rigid. In this case, a highly rigid connection can be achieved. Alternatively, the connection system may be flexible, resulting in reduced stiffness but high flexibility, resulting in elastic behavior. Furthermore, the connection may be limited to fewer than six degrees of freedom, allowing for one or more modes of relative motion between the robots. In this case, rather than behaving as a fixed fixture, the connection may be equivalent to a revolute, universal, spherical, prismatic, or other joint. As noted above, one of the continuous-arm robots may be a partially flexible robot arm rather than a flexible robot. In this case, it may still be associated with its own actuator pack and operate similarly as if it were a continuous-arm system, except with less control over its own positioning and movement.

[0039] Although the above example shows the system as having two connected continuous arms, it is possible for the system to have three or more connected continuous arms. By increasing the number of arms in the system, the system can have greater functionality.

[0040] It will be understood that the present invention is not limited to the above-described embodiments, and that various modifications and improvements can be made without departing from the concepts described herein. Any of the features may be employed separately or in combination with other features, except where mutually exclusive. The present disclosure extends to and includes all combinations and subcombinations of one or more features described herein.

Claims

1. 1. A continuous arm robot system comprising at least a first continuous arm robot and a second continuous arm robot, each continuous arm robot controlled by its own actuator pack, comprising: at least the first continuous arm robot has a head configured to receive a tool; the second continuous arm robot includes a releasable connection mechanism; the connection mechanism engages the first continuous arm robot by grasping in a workspace to combine at least two of the continuous arm robots into a single redundant robot system, with at least the second continuous arm robot providing support to the first continuous arm robot, the connection mechanism being located at an end of the second continuous arm robot; an end of the first continuous arm robot has a structure different from an end of the second continuous arm robot at least in that the connecting mechanism is not disposed thereon; a processor configured to control the first continuous arm robot and the second continuous arm robot, the second continuous arm robot configured to releasably and directly engage the first continuous arm robot at a distance from the head of the first continuous arm robot, each actuator pack coupled to a single control processor; Continuous arm robot system.

2. The connection mechanism is disposed along a continuous arm section; the end of the continuous arm section is characterized by a functional head having at least one tool selected from the group consisting of a sensor, a mechanical tool, an electrical tool, and a cutting device; The continuous arm robot system of claim 1 .

3. 3. The continuous-arm robot system of claim 2, wherein the second continuous-arm robot is characterized by a functional tool having at least one tool selected from the group consisting of a sensor, a mechanical tool, an electrical tool, and a cutting device at its tip.

4. the connecting mechanism is one of a hydraulic gripper type, a pneumatic gripper type, a mechanical gripper type, or an electromagnetic gripper type; The continuous arm robot system of claim 1 .

5. 5. The continuous-arm robot system of claim 4, wherein the connection mechanism is an electromagnetic gripper type.

6. Each continuous arm robot comprises a plurality of sensors; The continuous arm robot system of claim 1 .

7. 7. The continuous arm robot system of claim 6, wherein some of the sensors are configured to measure distances and relative positions between the first continuous arm robot and the second continuous arm robot.

8. the clamp features an interlock that, when activated, prevents operation of the continuous arm robotic system; The continuous arm robot system of claim 1 .

9. One of the continuous arm robots is equipped with a camera system and / or a lighting system. The continuous arm robot system of claim 1 .

10. The continuous-arm robotic system of claim 1 , wherein the connection mechanism is rigid.

11. The continuous arm robotic system of claim 1 , wherein the connection mechanism is flexible.

12. 10. The continuous arm robotic system of claim 1, wherein the connection mechanism limits the single redundant robotic system to less than six degrees of freedom.

13. 10. A method of operating a continuous-arm robotic system according to claim 1, comprising: inserting the first continuous arm robot and the second continuous arm robot into the workspace; combining the first continuous arm robot and the second continuous arm robot to form the single redundant robot system by connecting the first continuous arm robot and the second continuous arm robot, the second continuous arm robot releasably and directly engaging the first continuous arm robot at a distance from the head of the first continuous arm robot; performing a desired task using at least the first continuous arm robot; disconnecting the first continuous arm robot from the second continuous arm robot; withdrawing the first continuous arm robot and the second continuous arm robot from the workspace; A method for providing the above.

14. 14. The method of claim 13, wherein the first continuous arm robot and the second continuous arm robot move towards a predetermined setting and approach each other under controlled relative positioning to connect the first continuous arm robot with the second continuous arm robot.

Images