Systems and methods for a BIO-inspired inspection robot

Abstract

Examples of a robotic platform include an elongated body having a plurality of members interconnected via a plurality of rotator components, as well as a plurality of gripper members in communication a sensing system. The device mimics the friction-based mobility of lizards enabling it to navigate and maneuver effectively on tubular structures. The sensing system can include passive ultrasound sensing for acoustic emission monitoring that does not require the use of couplants integrated into the gripper members, allowing for accurate and efficient inspection of tubular metallic structures. A dry couplant phased array transducer can be integrated into each gripper for inspection of pipeline and tubular components and joints. The sensing system can employ a combination of through-transmission and pulse-echo techniques, allowing the utilization of a network of sensors to image plate-like and cylindrical structures without the need for comprehensive scanning.

Description

SYSTEMS AND METHODS FOR A BIO-INSPIRED INSPECTION ROBOTGOVERNMENT SUPPORT

[0001] This invention was made with government support under DE- FE0031649 awarded by the Department of Energy. The government has certain rights in the invention.CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This is a PCT Patent Application that claims benefit from U.S. Provisional Application Serial No. 63 / 597,938 filed on November 10, 2023, which is herein incorporated by reference in its entirity.FIELD

[0003] The present disclosure generally relates to robotic platforms and associated technologies; and in particular to a bio-inspired robotic platform for bioinspired robotic inspection.BACKGROUND

[0004] Tubular structures play a critical role in boilers and heat exchangers, but their exposure to extreme conditions, such as high temperatures and stress loads, often leads to corrosion, cracks, and stress corrosion cracks. Regular inspection of these components is crucial to prevent tube leakages, which can result in extended outages. However, conventional inspection methods can be challenging, time-consuming, and sometimes infeasible. While the implementation of robots for inspection purposes has emerged as a promising solution to overcome these challenges, traditional robotic systems face limitations when operating in complex environments.

[0005] It is with these observations in mind, among others, that various aspects of the present disclosure were conceived and developed.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIGS. 1A-1 D are a series of illustrations showing a robot for improved traversal and inspecting of tubular structure networks;

[0007] FIGS. 2A and 2B are a pair of illustrations showing rotation of an end rotator assembly of the robot of FIGS. 1A-1 D;

[0008] FIGS. 3A and 3B are a pair of illustrations showing rotation of a linkage rotator assembly of the robot of FIGS. 1A-1 D;

[0009] FIGS. 4A and 4B are a pair of illustrations showing rotation of an intermediate linkage rotator assembly of the robot of FIGS. 1A-1D;

[0010] FIGS. 5A-5D are a series of illustrations showing a gripper assembly of the robot of FIGS. 1 A-1 D;

[0011] FIGS. 6A-6H are a series of illustrations showing a first example locomotive sequence of the robot of FIGS. 1A-1 D;

[0012] FIGS. 7A-7I are a series of illustrations showing a second example locomotive sequence of the robot of FIGS. 1A-1 D;

[0013] FIGS. 8A-8E are a series of illustrations showing a third example locomotive sequence of the robot of FIGS. 1A-1 D;

[0014] FIG. 9 is an illustration showing an example embodiment of the robot of FIGS. 1A-1 D that includes a tail; and

[0015] FIG. 10 is a simplified diagram showing an example computing device for implementation of a controller device of the robot of FIGS. 1A-1 D.

[0016] Corresponding reference characters indicate corresponding elements among the view of the drawings. The headings used in the figures do not limit the scope of the claims.DETAILED DESCRIPTION

[0017] The present disclosure relates to examples of a platform for a robotic platform and methods thereof for bio-inspired robotic inspection. In general, the robotic platform includes a backbone having a plurality of members interconnected along a plurality of gearboxes comprising one or more servo motors that accommodate changes in position and orientation of the plurality of members for unique movement and mobility of the robotic platform as described herein. The robotic platform further includes a plurality of gripper members along the backbone configured to engage a surface (of, e.g., a tubular structure), and a sensing system that provides passive in-motion inspection of the surface. The robotic platform (or robot) is designed to mimic the friction-based mobility of lizards, enabling it to navigate and maneuver effectively on tubular structures. This unique feature enhances the robot's ability to access and inspect hard-to-reach areas.

[0018] In some examples, the sensing system defines a couplant-free ultrasound sensing system that does not require the use of couplants. This system is seamlessly integrated into the robot's gripper members, allowing for accurate and efficient inspection of tubular metallic structures. In addition, the robotic platform can combine the benefits of mobility and advanced ultrasound imaging techniques. By leveraging the robot's mobility capabilities, it can efficiently detect and evaluate corrosion and cracks in tubular components, thereby enhancing inspection accuracy and speed. By specific example, dry couplant phased array transducers can be integrated into the gripper members for inspection of pipeline and tubular components and joints. Passive ultrasound sensing for acoustic emission monitoring can also be integrated. Acoustic data in the motion strategy can be used to better localize the source of anomalies in the pipeline structures including leakages.

[0019] In addition, the concepts outlined herein can be designed for the integration of other non-destructive testing (NDT) and also repair methods. Eddy current testing, magnetic flux testing, infrared imaging, and tap testing can be seamlessly integrated into the gripper members and other components of the robot, resulting in a versatile and multi-functional inspection and repair platform. In summary, the bio-inspired robotic inspection platform presented offers an innovative approach to tube inspection. By combining bio inspired mobility, advanced ultrasound imaging, and the potential for integrating multiple NDT and repair methods, the platform aims to significantly improve the efficiency, accuracy, andversatility of tube inspection and repair processes. The robotic platform is designed to revolutionize tube inspection processes by eliminating the need for laborious point-by-point scanning of tube surfaces for crack and corrosion detection and provides efficient and comprehensive inspection capabilities for tubular structures.Introduction & Development:

[0020] Inspiration for the concepts outlined herein can be drawn from organisms like lizards and snakes that navigate such environments effectively. Bioinspired robotics aims to incorporate principles from biological organisms' movement into robotics to enhance their capabilities. Among organisms, lizards are known fortheir versatility, possessing an exceptionally effective attachment system that allows them to swiftly and reversibly cling to surfaces with diverse chemistry and topography. In this context, the present robotic platform is lizard-inspired and can be equipped with custom frictional pads that enable efficient climbing of tubes, regardless of their surface texture.

[0021] The power generation industry faces a significant challenge in detecting and characterizing corrosion and cracks on tubular structures. Ultrasound techniques have emerged as a viable approach for measuring remaining wall thickness and detecting cracks. However, traditional contact ultrasound testing using bulk waves requires laborious point-by-point scanning with the use of couplant and prepared surfaces. Recent advancements in couplant-free ultrasonic testing and the imaging algorithm such as total focusing method and development of Lamb wavebased imaging offer a promising solution by eliminating the need for couplant and enabling the inspection of a line between two transducers instead of scanning the entire cross-section of a tube. The present concept explores two mechanisms for generating and receiving Lamb waves: high voltage ultrasound generation with pressurized contacted interfaces and electro-magnetic acoustic transducers.

[0022] In recent years, efforts have been made to combine ultrasonic Lamb waves with imaging algorithms, such as tomography, for the detection and localization of damage in tubular structures. Notably, Professor Ehsan Dehghan-Niri proposed and successfully tested a multi-helical ultrasonic imaging (MHUI) approach for corrosion detection and characterization in cylindrical structures. This approach utilized an array of permanently installed piezoelectric transducers to generate andreceive high-order helical guided waves, increasing the ray density / resolution without the need for numerous sensors. One key advantage of this method is its ability to reconstruct ultrasound images using a few distributed point sources, eliminating the need for point-by-point scanning. Furthermore, these point sources can be strategically located on one side of the cylinder / tube / pipe to image the entire area among and around them. This unique advantage allows the lizard-inspired robot to utilize its multi-functional gripper members for comprehensive corrosion detection and evaluation.

[0023] In addition, the current platform can include a dry couplant phased array that can provide detailed information of the areas of damage. Furthermore, passive acoustic monitoring sensing of the robotic platform allows the integration of acoustic data into the motion strategy and movement. This novel approach allows the robotic platform to better localize the source of anomalies such as leakage.

[0024] In addition to corrosion location estimation, two methods were developed for estimating thickness reduction and area of corrosion. Notably, a new method called the "distributed circle method" allows for the estimation of corrosion location even with fewer point omnidirectional transducers.

[0025] While the multi-helical ultrasound imaging (MHIII) technique is primarily based on through transmission and does not rely on scattered or reflected waveform information, there is a need for higher resolution and increased sensitivity in crack detection. Synthetic Aperture Focusing Technique (SAFT) imaging, initially developed for airborne radar mapping systems and later adopted in medical imaging using bulk ultrasound, provides a solution. SAFT has evolved into Total Focusing Method (TFM), which creates an image by combining signals obtained from multiple transmitters and receivers through a process called full matrix capture (FMC). However, TFM presents a challenge in that there is no unique referenced signal as the reference changes with the variation of transmitter transducer coordinates. Recently, a Lamb wave-based TFM method was developed for crack detection and evaluation. The coverage of different combinations of transducers was estimated for various crack orientations, further enhancing the capabilities of the bio-inspired robotic inspection platform. In summary, the above mentioned developments serve as the foundation for the development of the bio-inspired tube inspector robotdescribed herein, integrating mobility, advanced ultrasound imaging, and the potential for multi-functional capabilities in the field of tubular structure inspection.Technical Solution (Example Robotic Platform):

[0026] Referring to FIGS. 1A-1D, a robotic platform (“robot 100”) is configured for robotic inspection to accommodate efficient and comprehensive inspection of tubular structures. The robot 100 includes an elongated body 102 including a first end unit 110A and a second end unit 110B connected by a linkage unit 140. As shown in FIGS. 1A and 1B, the robot 100 includes gripper members that enable the robot 100 to grasp and traverse pipe structures. Further, the gripper members can be outfitted with sensors that enable passive in-motion inspection of the surface and a surrounding environment by the robot 100. Notably, components of the robot 100 include a plurality of rotator components that enable the robot 100 to better traverse pipe networks and other complex structures. The arrangement of the first end unit 110A, the second end unit 110B, and the linkage unit 140 in addition to the plurality of rotator components enables the robot 100 to pivot and move around complex structures that accommodate changes in position and orientation of the plurality of members for forward motion and maneuvering on flanges and elbows of different angles, such as 45, 90, and 180 degrees. FIG. 1C shows an underside view of the robot 100. FIG. 1D shows a side view of the robot 100 with gripper members of the first end unit 110A and the second end unit 110B rotated sideways (in contrast to the view shown in FIG. 1A).

[0027] Referring to FIGS. 2A and 2B, the first end unit 110A can include a first coaxial portion 112A having a first gripper assembly 120A and a second coaxial portion 114A having a first end rotator assembly 130A of the plurality of rotator components. The first end rotator assembly 130A is operable for rotating the second coaxial portion 114A about a first end pivot point relative to the first coaxial portion 112A responsive to a first end control signal (e.g., received from a controller device).

[0028] While FIGS. 2A and 2B show rotation of the first end unit 110A around the first end pivot point, the same can be applied to the second end unit 110B. The second end unit 110B can include a first coaxial portion 112B having a second gripper assembly 120B and a second coaxial portion 114B having a secondend rotator assembly 130B of the plurality of rotator components. The second end rotator assembly 130B is operable for rotating the second coaxial portion 114B about a second end pivot point relative to the first coaxial portion 112B responsive to a second end control signal (e.g., received from a controller device).

[0029] As shown in FIGS. 3A and 3B, the linkage unit 140 connects the first end unit 110A with the second end unit 11 OB, and can include a first linkage section 142A and a second linkage section 142B connected by an intermediate linkage section 144. The first linkage section 142A can be connected to the first end unit 110A by a first linkage rotator assembly 150A of the plurality of rotator components. The first linkage rotator assembly 150A is operable for rotating the first end unit 110A about a first linkage pivot point relative to the first linkage section 142A (or vice-versa) responsive to a first linkage control signal. The first linkage pivot point can have an axis that is perpendicular to the first end pivot point.

[0030] While FIGS. 3A and 3B show rotation of the first linkage section 142A relative to the first end unit 110A, the same can be applied to the second linkage section 142B with respect to the second end unit 110B. The second linkage section 142B can be connected to the second end unit 110B by a second linkage rotator assembly 150B of the plurality of rotator components. The second linkage rotator assembly 150B is operable for rotating the second end unit 110B about a second linkage pivot point relative to the second linkage section 142B (or vice-versa) responsive to a second linkage control signal. The second linkage pivot point can have an axis that is perpendicular to the second end pivot point.

[0031] Referring to FIGS. 4A and 4B, the intermediate linkage section 144 can include an intermediate linkage rotator assembly 160 of the plurality of rotator components that increases or decreases an intermediate linkage angle between the first linkage section 142A and the second linkage section 142B responsive to an intermediate linkage control signal. The intermediate linkage rotator assembly 160 can define an intermediate linkage pivot point having an axis that is parallel to the first linkage pivot point.

[0032] As further shown in FIGS. 5A-5C, the first gripper assembly 120A (as well as the second gripper assembly 120B) can include a gripper member pair 122 associated with a gripper motor 124. The gripper motor 124 can be operable for opening or closing the gripper member pair 122 around a cylindrical surface (e.g., a tube or pipe) responsive to a gripper motor control signal. Incomparison with previous examples that employ one motor per gripper member, each gripper member pair 122 can share a gripper motor 124 that enables the gripper member pair 122 to open (FIG. 5B) or grasp slowly and close (FIG. 5C) around pipes of different sizes. Each gripper member pair 122 can be equipped with friction pads, enabling them to securely grip tubes of various sizes and surface conditions, including smooth or corroded surfaces.

[0033] Further, the first gripper assembly 120A (as well as the second gripper assembly 120B) can include one or more gripper sensors 126 positioned along the gripper member pair 122. The one or more gripper sensors 126 are operable for capturing sensor data associated with the surface. In an example shown in FIG. 5B, a gripper member of a gripper member pair 122 can include one or more coupling keys 128 that removably couple the one or more gripper sensors 126 along the gripper member pair 122 such that the one or more gripper sensors 126 can be switched out for another gripper sensor 126 which may be of the same type (e.g., in case of failure) or a different type.

[0034] The fabrication of a robot associated with the robot 100 can involve a combination of machining and rapid prototyping techniques. Methods such as 3D printing, laser cutting, and hybrid deposition manufacturing (HDM) can be utilized. Specifically, the gripper members can be fabricated using the HDM technique, which enables precise construction. In some examples, the gripper members can be manufactured from aluminum or another strong but lightweight material. The friction pads, responsible for increasing grip and friction, can be created using soft lithography with miniature features using materials like PDMS (Polydimethylsiloxane) and Polyurethane. To overcome the limitations of traditional couplant based ultrasound transmission, a couplant-free ultrasound transmission approach that include phased array can be implemented. This technique enables ultrasound transmission through the gripper's surface, even with PDMS pads present to increase friction.

[0035] As shown in FIGS. 6A-8E, the arrangement of the plurality of rotator components enable the robot 100 to traverse various pipe configurations.

[0036] FIGS. 6A-6H show a first example locomotive sequence of the robot 100 of FIGS. 1A-1D where the robot 100 moves forward along a horizontal pipe structure and where gray lines show positions of components of the robot 100for an immediately preceding configuration (e.g., where gray lines in FIG. 6B show a preceding configuration of FIG. 6A).

[0037] FIG. 6A shows an example starting configuration where gripper member pairs 122 of the first gripper assembly 120A open to disengage itself from the pipe structure.

[0038] FIG. 6B shows rotation of the first linkage rotator assembly 150A, the second linkage rotator assembly 150B, and the intermediate linkage rotator assembly 160 of the elongated body 102 to lift the first end unit 110A away from the pipe structure and draw the first end unit 110A towards the second end unit 110B.

[0039] FIG. 6C shows rotation of the first linkage rotator assembly 150A and the intermediate linkage rotator assembly 160 of the elongated body 102 to continue to lift the first end unit 110A away from the pipe structure and draw the first end unit 110A towards the second end unit 110B.

[0040] FIG. 6D shows rotation of the first linkage rotator assembly 150A and the intermediate linkage rotator assembly 160 of the elongated body 102 to lower the first end unit 110A onto the pipe structure while continuing to draw the first end unit 110A towards the second end unit 110B.

[0041] FIG. 6E shows rotation of the first linkage rotator assembly 150A and the intermediate linkage rotator assembly 160 of the elongated body 102 to lower the first end unit 110A onto the pipe structure. Further, FIG. 6E shows gripper member pairs 122 of the first gripper assembly 120A closing around and engaging the pipe structure.

[0042] FIG. 6F shows rotation of the the second linkage rotator assembly 150B, and the intermediate linkage rotator assembly 160 of the elongated body 102 to lift the second end unit 110B away from the pipe structure and push the second end unit 110B away from the first end unit 110A. Further, FIG. 6F shows gripper member pairs 122 of the second gripper assembly 120B opening to disengage itself from the pipe structure.

[0043] FIG. 6G shows rotation of the first linkage rotator assembly 150A, the second linkage rotator assembly 150B, and the intermediate linkage rotator assembly 160 of the elongated body 102 to lower the second end unit 110B towards the pipe structure and push the second end unit 110B away from the first end unit 110A.

[0044] FIG. 6H shows rotation of the first linkage rotator assembly 150A, the second linkage rotator assembly 150B, and the intermediate linkage rotator assembly 160 of the elongated body 102 to lower the second end unit 110B towards the pipe structure and push the second end unit 110B away from the first end unit 110A. Further, FIG. 6F shows gripper member pairs 122 of the second gripper assembly 120B closing around and engaging the pipe structure.

[0045] FIGS. 7A-7I show a second example locomotive sequence of the robot 100 of FIGS. 1A-1D where the robot 100 moves forward along a pipe structure having a 90-degree bend, where the robot 100 has already descended from a vertical portion of the pipe structure and is to move forward along a horizontal portion of the pipe structure. Similarly, gray lines show positions of components of the robot 100 for an immediately preceding configuration (e.g., where gray lines in FIG. 7B show a preceding configuration of FIG. 7A).

[0046] FIG. 7A shows an example starting configuration where the first end unit 110A of the robot 100 is engaged along the vertical portion of the pipe structure and the second end unit 110B is engaged along the horizontal portion of the pipe structure.

[0047] FIG. 7B shows rotation of the first linkage rotator assembly 150A to rotate the first end unit 110A of the robot 100 away from the vertical portion of the pipe structure. FIG. 7B also shows gripper member pairs 122 of the first gripper assembly 120A opening to disengage itself from the pipe structure.

[0048] FIG. 7C shows rotation of the second linkage rotator assembly 150B to continue to rotate the first end unit 110A of the robot 100 away from the vertical portion of the pipe structure.

[0049] FIG. 7D shows rotation of the intermediate linkage rotator assembly 160 (and optionally the first linkage rotator assembly 150A and the second linkage rotator assembly 150B) to bend the elongated body 102 and “stack” the first end unit 110A above the second end unit 110B.

[0050] FIG. 7E shows rotation of the second end rotator assembly 130B to swivel the first end unit 110A and the linkage unit 140 away from the vertical portion of the pipe structure.

[0051] FIG. 7F shows rotation of the second linkage rotator assembly 150B to “straighten out” the linkage unit 140 and to lower the first end unit 110Atowards the horizontal portion of the pipe structure and away from the second end unit 110B.

[0052] FIG. 7G shows rotation of the intermediate linkage rotator assembly 160 to continue to “straighten out’’ the linkage unit 140 and to lower the first end unit 110A towards the horizontal portion of the pipe structure and away from the second end unit 11 OB.

[0053] FIG. 7H shows rotation of the first linkage rotator assembly 150A and the intermediate linkage rotator assembly 160 to continue to “straighten out” the linkage unit 140 and to lower the first end unit 110A towards the horizontal portion of the pipe structure and away from the second end unit 110B.

[0054] FIG. 7I shows rotation of the intermediate linkage rotator assembly 160 to continue to “straighten out” the linkage unit 140 and to lower the first end unit 110A along the horizontal portion of the pipe structure. FIG. 7I also shows gripper member pairs 122 of the first gripper assembly 120A closing around and engaging the pipe structure.

[0055] FIGS. 8A-8E show a third example locomotive sequence of the robot 100 of FIGS. 1A-1D where the robot 100 is moving along a pipe structure having an upper vertical portion and a lower vertical portion connected by a horizontal portion, where the upper vertical portion and the lower vertical portion are laterally offset from one another as shown. Similarly, gray lines show positions of components of the robot 100 for an immediately preceding configuration (e g., where gray lines in FIG. 8C show a preceding configuration of FIG. 8A).

[0056] In this example, starting with FIGS. 8A and 8B where FIG. 8B shows a side view of the configuration of FIG. 8A, the robot 100 is shown hanging by the first end unit 110A from the upper vertical portion of the pipe structure and is to move towards the lower vertical portion of the pipe structure. As shown FIGS. 8A and 8B, the second end unit 110B had previously been decoupled from the pipe structure and the intermediate linkage rotator assembly 160 had “bent” the linkage unit 140 such that the second end unit 110B positioned away from the pipe structure.

[0057] FIG. 8C shows rotation of the first end rotator assembly 130A to swivel the linkage unit 140 and the second end unit 110B and position the second end unit 110B adjacent to the lower vertical portion of the pipe structure.

[0058] FIGS. 8D and 8E show rotation of the second end rotator assembly 130B to position the gripper member pairs 122 of the second gripperassembly 120B of the second end unit 11 OB such that they can securely close around and engage the pipe structure onto the lower vertical portion of the pipe structure as shown, and also shows rotation of the intermediate linkage rotator assembly 160 to “straighten out” the linkage unit 140 and position the second end unit 11 OB against the lower vertical portion of the pipe structure as shown.

[0059] In an example shown in FIG. 9, to enhance stability and inspection capabilities, the robot 100 can include a tail 170. The tail 170 can include one or more members 172, one or more motors 174 that move the one or more members 172 relative to one another, and one or more tail sensors 176 such as a borescope and additional sensors, enabling inspection at challenging locations that may be inaccessible to the robot 100 itself. In some examples, the tail 170 can include using one or more coupling keys (similar to coupling keys 128 associated with gripper sensors 126 as in FIG. 5D) that removably couple the one or more tail sensors 176 along the tail 170 such that the one or more gripper sensors 126 can be switched out for another gripper sensor 126 which may be of the same type (e.g., in case of failure) or a different type.Controlling the Robot

[0060] In a further aspect, the robot 100 can include or otherwise communicate with a computing device 200 which can be in operative communication with the plurality of rotator components of the robot 100. The computing device 200 can include a processor 220 in communication with a memory 240, the memory 240 including instructions executable by the processor 220 to apply one or more control signals to one of the plurality of rotator components (e.g., one or more of the first end rotator assembly 130A, the second end rotator assembly 130B, the first linkage rotator assembly 150A, the second linkage rotator assembly 150B, and the intermediate linkage rotator assembly 160) to enable the robot 100 to traverse an environment.

[0061] The memory 240 can further include instructions executable by the processor 220 to apply one or more control signals to a gripper motor 124 which causes a gripper member pair 122 of the first gripper assembly 120A (or the second gripper assembly 120B) to grasp slowly and close around pipes of different sizes.

[0062] In a further aspect, the memory 240 can further include instructions executable by the processor 220 to apply one or more gripper sensorcontrol signals to the one or more gripper sensors 126 to capture sensor data by the one or more gripper sensors 126. Similarly, the memory 240 can further include instructions executable by the processor 220 to one or more tail sensor control signals to the one or more tail sensors 176 to capture sensor data by the one or more tail sensors 176.

[0063] The processor 220 can access the sensor data captured by the one or more gripper sensors 126 (and / or the one or more tail sensors 176) for various tasks including recording the sensor data, communicating the sensor data to another device, and autonomously controlling actuating components of the robot 100 to capture better or additional sensor data based on previously-acquired sensor data. The robot 100 can sequentially repeat sensor data capture by positioning the robot on a plurality of locations on the surface. In some examples, the memory 240 can include instructions executable by the processor 220 to construct an image based on the sensor data using a multi-helical ultrasound imaging method.

[0064] In some examples, the memory 240 can further include instructions executable by the processor 220 to apply one or more control signals to the plurality of rotator components based on the sensor data captured by the one or more gripper sensors 126 (and / or the one or more tail sensors 176). The computing device 200 can facilitate autonomous or semi-autonomous operation of the robot 100. For example, the robot 100 may be operable to autonomously adjust its position to obtain better sensor data (e.g., and resultant images) based on previously- acquired sensor data (e.g., and resultant images).

[0065] The robot 100 and / or the computing device 200 can include or otherwise communicate with manual controllers (not shown) that facilitate semi- autonomous or manually-controlled operation of the robot 100. However, depending on the mission requirements, data and power can be transmitted wirelessly or through a tether.

[0066] The control signals applied to the robot 100 enables the robot 100 to utilize bending of the elongated body 102 for traveling along the surface by lifting a gripper member pair of a gripper assembly (e.g., first gripper assembly 120A or second gripper assembly 120B) away from a first position associated with a first region of the surface and repositioning the gripper member pair of a gripper assembly to engage second positions associated with a second region of the surface. The robot 100 can continually capture sensor data with each “step”, e.g,first sensor data for the first region and second sensor data for the second region, and can combine the sensor data into an image or other representation.

[0067] FIG. 10 is a schematic block diagram of an example computing device 200 that may be used with one or more embodiments of the robot 100 described herein.

[0068] Computing device 200 comprises one or more network interfaces 210 (e.g., wired, wireless, PLC, etc.), at least one processor 220, and memory 240 interconnected by a system bus 250, as well as a power supply 260 (e.g., battery, plug-in, etc.).

[0069] Network interface(s) 210 include the mechanical, electrical, and signaling circuitry for communicating data over the communication links coupled to a communication network. Network interfaces 210 are configured to transmit and / or receive data using a variety of different communication protocols. As illustrated, the box representing network interfaces 210 is shown for simplicity, and it is appreciated that such interfaces may represent different types of network connections such as wireless and wired (physical) connections. Network interfaces 210 are shown separately from power supply 260, however it is appreciated that the interfaces that support PLC protocols may communicate through power supply 260 and / or may be an integral component coupled to power supply 260.

[0070] Memory 240 includes a plurality of storage locations that are addressable by processor 220 and network interfaces 210 for storing software programs and data structures associated with the embodiments described herein. In some embodiments, device 200 may have limited memory or no memory (e.g., no memory for storage other than for programs / processes operating on the device and associated caches). Memory 240 can include instructions executable by the processor 220 that, when executed by the processor 220, cause the processor 220 to implement aspects of the robot 100 and associated methods outlined herein.

[0071] Processor 220 comprises hardware elements or logic adapted to execute the software programs (e.g., instructions) and manipulate data structures 245. An operating system 242, portions of which are typically resident in memory 240 and executed by the processor, functionally organizes device 200 by, inter alia, invoking operations in support of software processes and / or services executing on the device. These software processes and / or services may include robotic sensing platform processes / services 290, which can include aspects of methods and / orimplementations of various modules described herein. Note that while robotic sensing platform processes / services 290 is illustrated in centralized memory 240, alternative embodiments provide for the process to be operated within the network interfaces 210, such as a component of a MAC layer, and / or as part of a distributed computing network environment.

[0072] It will be apparent to those skilled in the art that other processor and memory types, including various computer-readable media, may be used to store and execute program instructions pertaining to the techniques described herein. Also, while the description illustrates various processes, it is expressly contemplated that various processes may be embodied as modules or engines configured to operate in accordance with the techniques herein (e.g., according to the functionality of a similar process). In this context, the term module and engine may be interchangeable. In general, the term module or engine refers to model or an organization of interrelated software components / functions. Further, while the robotic sensing platform processes / services 290 is shown as a standalone process, those skilled in the art will appreciate that this process may be executed as a routine or module within other processes.Sensing Methods

[0073] Two mechanisms can be implemented for couplant-free ultrasound transmission: Electromagnetic Acoustic Transducer (EMAT) and / or high- power excitation of piezoelectric transducers. The couplant-free ultrasound transducers can be integrated with Lamb wave and bulk wave excitation capabilities. For imaging purposes, an imaging technique is contemplated, allowing the utilization of a network of sensors (the robot's gripper members) to image plate-like and cylindrical structures without the need for comprehensive scanning. The control system of the robot is designed not only based on dynamic stability and mobility requirements but also tailored to targeted inspection needs. The imaging method employs a combination of through-transmission and pulse-echo techniques, utilizing the data captured by the robot's multiple gripper positions. At each location, the gripper members may move and adopt different configurations. In a round-robin fashion, one gripper excites guided ultrasound waves while the other gripper receives the resulting waveforms. This process is repeated to capture data from multiple positions. The imaging method is based on guided wave total focusingmethod (TFM) and Multi-Helical Ultrasound imaging (MHUI) techniques, enabling the detection and evaluation of cracks and corrosion. As the robot progresses, collecting new sets of data at each new location, the imaging algorithm updates the image of the covered area. This scanning approach allows for rapid and versatile inspection without the need for sensors to visit every single position on the material's surface. When the rough estimate of the damaged area is identified, dry compliant phased array transducer can be used to image and scan the entire area between the gripper members.

[0074] In one example summary, the concepts outlined herein include a bio-inspired robotic inspection platform with dexterous gripper members, a tailored elongated body (e.g., a backbone) for mobility, a tail for additional stability and inspection, couplant-free ultrasound transmission capabilities, passive monitoring and algorithm for source localization, dry phased array, and a multi-sensor imaging method based on through transmission and pulse-echo techniques. These components and techniques work together to enable efficient and comprehensive inspection of tubular structures, allowing for rapid and precise detection and evaluation of cracks and corrosion.

[0075] The bio-inspired robot presented offers a versatile and adaptive solution for inspecting tubular structures. It exhibits exceptional maneuverability, enabling it to navigate challenging scenarios such as 90 and 180 degree elbows, flanges, and various types of tubes with different surface textures and geometries. The robot's capabilities encompass handling both curved and flat surfaces, and nonferromagnetic or ferromagnetic materials. With its ability to traverse rough surfaces and complex geometries, the bio-inspired robot has significant commercial potential, providing an efficient and reliable solution for tube inspection in industries such as power generation, oil and gas, and manufacturing.

[0076] Example aspects of the robot 100 include:1. Unique Robot Design: Introduces a novel robot design equipped with gripper members capable of navigating and maneuvering through a wide range of challenging scenarios. These include effectively handling 90 and 180-degree elbows, traversing flanges, and climbing various types of tubes, even those with non-ideal surface conditions such as corrosion. The robot's design enables it to tackle complex geometries and surfaces, making it highly adaptable for inspection tasks.2. Multi-functional Bio-Inspired Gripper members: The gripper members integrated into the robot's design exhibit multifunctionality by combining both sensing and gripping capabilities. This innovation allows for simultaneous inspection and secure attachment to the inspected tubular structures. The integration of sensing within the gripper members enhances inspection efficiency by eliminating the need for separate sensor deployment mechanisms.3. Continuous Inspection Capability: A distinctive aspect of the concepts outlined herein is the ability to conduct continuous inspection of the entire tube while the robot is in motion. This is achieved through the utilization of Multi-Helical Ultrasonic Imaging (MHUI) and Total Focusing Method (TFM) techniques. By employing these advanced imaging methods, the robot can construct comprehensive images of the inspected tube, enabling efficient and thorough evaluation of potential defects such as cracks and corrosion.

[0077] These novel aspects demonstrate significant advancements in robot design, gripper functionality, and inspection techniques, positioning it as an innovative and promising solution for comprehensive tubular structure inspection.

[0078] In addition, advantages include:1. Enhanced Mobility and Flexibility: Existing robots often face limitations in terms of mobility and flexibility. Many of these robots rely on wheel-based approaches, which restrict their maneuverability and limit their application to simple geometries and smooth surfaces. Furthermore, the use of magnets for attachment poses a challenge for inspecting tubes made of non-ferromagnetic materials. In contrast, the bio inspired robot presented overcomes these limitations by employing friction and / or adhesion-based mobility. This innovative approach significantly enhances the robot's flexibility and maneuverability, enabling it to access components of interest for inspection, even in areas with restricted access or complex geometries. This robot can effectively move on tubes with various surface conditions, including rough surfaces, curved and flat surfaces, and tubes made of both ferromagnetic and non-ferromagnetic materials.2. Advanced Imaging Capability: Current robots typically carry measurement tools specific to a particular non-destructive testing (NDT) method, such as ultrasound testing (UT). However, these methods often require smooth and prepared surfaces, limiting their applicability and inspection capabilities. Point- by-point inspections for thickness measurements, for example, necessitate accessibility to the tube's surroundings, which is often challenging due to limited circumferential access in boiler tubes. Additionally, circumferential UT techniques struggle to effectively map pitting corrosion and circumferential cracks. In contrast, the presented platform incorporates an advanced imaging method based on Lamb wave technology. This enables the robot to employ Multi Helical Ultrasound Imaging (MHUI) and Lamb wave-based Total Focusing Method (TFM) techniques. By integrating couplant-free ultrasoundsensing within the robot's gripper members and = utilizing advanced Lamb wave imaging methods, the robot can image the entire cross- section of a tube between and around its multi-functional gripper members. This imaging capability remains effective when the robot is both stationary and in motion, enabling comprehensive inspection and mapping of defects, including pitting corrosion and circumferential cracks.

[0079] The advantages offered by the robotic platform includes enhanced mobility, flexibility, and advanced imaging techniques have a significant impact on tubular structure inspection. They overcome existing limitations, such as restricted access and surface conditions, and enable comprehensive inspections with precise defect mapping. The potential commercial impact is substantial, as it enhances inspection efficiency, accuracy, and versatility, reducing downtime, preventing failures, and optimizing the performance and lifespan of tubular components in various industries.

[0080] The commercial potential of the concepts outlined herein extend beyond tubular structures, as the scientific and engineering knowledge developed can be applied to the development of similar robots for various applications, including steam, gas, and wind turbine inspections, as well as high-power generator inspections. It is important to note that while the current project focuses on the inspection aspect, the bioinspired robot can be easily adapted with additional components, such as a welding tip, to enable robotics enabled repairs.

[0081] The robot presented offers distinct advantages over available alternatives. Its enhanced mobility, flexibility, and advanced imaging capabilities allow for efficient inspection of tubular structures, even in complex scenarios. The integration of couplant-free ultrasound sensing and the ability to image the entire tube while in motion set the robot apart from existing technologies, positioning it as a promising solution with significant commercial potential in industries requiring comprehensive and reliable inspection of tubular components.

[0082] In other examples, the technology is a bio-inspired robotic inspection system designed to revolutionize tube inspection processes by eliminating the need for laborious point-by-point scanning of tube surfaces for crack and corrosion detection. One key objective of this versatile bio-inspired robot is to provide efficient and comprehensive inspection capabilities for tubular structures. By combining bio-inspired mobility, advanced ultrasound imaging, and the potential for integrating multiple NDT and repair methods, the system aims to significantlyimprove the efficiency, accuracy, and versatility of tube inspection and repair processes.• Designed to mimic the friction-based mobility of lizards, enabling it to navigate and maneuver effectively on tubular structures. This unique feature enhances the robot's ability to access and inspect hard-to-reach areas.• Lightweight ultrasound sensing system that does not require the use of couplants integrated into the robot's gripper members, allowing for accurate and efficient inspection of tubular metallic structures.• can efficiently detect and evaluate corrosion and cracks in tubular components• dry couplant phased array transducer will be integrated into the gripper for inspection of pipeline and tubular components and joints• passive ultrasound sensing for acoustic emission monitoring• Eddy current testing, magnetic flux testing, infrared imaging, and tap testing can be seamlessly integrated into the gripper members and other components of the robot• tail carries a borescope and additional sensors, enabling inspection at challenging locations that may be inaccessible to the robot• Imaging technique employs a combination of through-transmission and pulseecho techniques, allowing the utilization of a network of sensors to image plate-like and cylindrical structures without the need for comprehensive scanning

[0083] It should be understood from the foregoing that, while particular embodiments have been illustrated and described, various modifications can be made thereto without departing from the spirit and scope of the inventive concept as will be apparent to those skilled in the art. Such changes and modifications are within the scope and teachings of this inventive concept as defined in the claims appended hereto.

Claims

CLAIMSWhat is claimed is:

1. A robotic platform, comprising: an elongated body including a first end unit and a linkage unit; the first end unit including a first coaxial portion having a first gripper assembly and a second coaxial portion having a first end rotator assembly of a plurality of rotator components; the first end rotator assembly being operable for rotating, responsive to a first end control signal, the second coaxial portion about a first end pivot point relative to the first coaxial portion; the linkage unit including a first linkage section and a second linkage section connected by an intermediate linkage section; the first linkage section being connected to the first end unit by a first linkage rotator assembly of the plurality of rotator components, the first linkage rotator assembly being operable for rotating, responsive to a first linkage control signal, the first linkage section relative to the first end unit about a first linkage pivot point having an axis that is perpendicular to the first end pivot point; and the intermediate linkage section including an intermediate linkage rotator assembly of the plurality of rotator components that increases or decreases an intermediate linkage angle between the first linkage section and the second linkage section responsive to an intermediate linkage control signal, the intermediate linkage rotator assembly defining an intermediate linkage pivot point having an axis that is parallel to the first linkage pivot point.

2. The robotic platform of claim 1 , the elongated body further comprising: a second end unit connected to the second linkage section;the second end unit including a first coaxial portion having a second gripper assembly and a second coaxial portion having a second end rotator assembly of the plurality of rotator components; the second end rotator assembly being operable for rotating, responsive to a second end control signal, the second coaxial portion about a second end pivot point relative to the first coaxial portion; and the second linkage section being connected to the second end unit by a second linkage rotator assembly of the plurality of rotator components, the second linkage rotator assembly being operable for rotating, responsive to a second linkage control signal, the second linkage section relative to the second end unit about a second linkage pivot point having an axis that is perpendicular to the second end pivot point.

3. The robotic platform of claim 1 , further comprising: a computing device in operative communication with the plurality of rotator components of the robotic platform, the computing device including a processor in communication with a memory, the memory including instructions executable by the processor to apply one or more control signals to the plurality of rotator components.

4. The robotic platform of claim 1 , the first gripper assembly comprising: a gripper member pair associated with a gripper motor, the gripper motor being operable for opening or closing the gripper member pair around a surface responsive to a gripper motor control signal.

5. The robotic platform of claim 4, the first gripper assembly comprising: one or more gripper sensors positioned along the gripper member pair, the one or more gripper sensors being operable for capturing sensor data associated with the surface.

6. The robotic platform of claim 5, the gripper member pair including a coupling key that removably couples the one or more gripper sensors along the gripper member pair.

7. The robotic platform of claim 5, further comprising: a computing device including a processor in communication with a memory, the memory including instructions executable by the processor to: apply one or more gripper sensor control signals to the one or more gripper sensors; and access sensor data captured by the one or more gripper sensors.

8. The robotic platform of claim 7, the memory including instructions executable by the processor to: apply one or more control signals to the plurality of rotator components based on the sensor data captured by the one or more gripper sensors.

9. The robotic platform of claim 7, the memory including instructions executable by the processor to: construct an image based on the sensor data using a multi-helical ultrasound imaging method.

10. The robotic platform of claim 1 , further comprising: a tail including one or more tail sensors being operable for capturing sensor data.11 . The robotic platform of claim 10, further comprising: a computing device including a processor in communication with a memory, the memory including instructions executable by the processor to: apply one or more tail sensor control signals to the one or more tail sensors; and access sensor data captured by the one or more tail sensors.

12. A method, comprising: positioning a robotic platform at a first location along a surface, the robotic platform comprising an elongated body including a first end unit and a second end unit connected by a linkage unit; the first end unit including a first coaxial portion of the first end unit having a first gripper assembly and a second coaxial portion of the first end unit being rotatable relative to the first coaxial portion of the first end unit by a first end rotator assembly of a plurality of rotator components, the first gripper assembly including one or more gripper member pairs having one or more gripper sensors; and the linkage unit including one or more linkage rotator assemblies of the plurality of rotator components that are operable for rotating one or more linkage sections of the linkage unit relative to one another or relative to the first end unit; capturing, at a processor, first sensor data from the first location along the surface using the one or more gripper sensors as signals are applied through the surface using the one or more gripper sensors; positioning the robotic platform at a second location along the surface by actuation of one or more of the plurality of rotator components of the robotic platform; capturing, at a processor, second sensor data from the second location along the surface using the one or more gripper sensors; and combining the first sensor data and the second sensor data into an image.

13. The method of claim 12, the second end unit including a first coaxial portion of the second end unit having a second gripper assembly and a second coaxial portion of the second end unit being rotatable relative to the first coaxial portion of the second end unit by a second end rotator assembly of the plurality of rotator components, and the linkage unit including one or more linkage rotator assemblies of the plurality of rotator components that are operable for rotating one or more linkage sections of the linkage unit relative the second end unit.

14. The method of claim 12, further comprising: applying one or more tail sensor control signals to one or tail sensors of a tail of the robotic platform; and capturing sensor data captured by the one or more tail sensors.

15. The method of claim 12, constructing the image based on the first sensor data and the second sensor data incorporating a multi-helical ultrasound imaging method.

16. The method of claim 12, each gripper member pair being associated with a gripper motor, the gripper motor being operable for opening or closing the gripper member pair around the surface responsive to a gripper motor control signal.

17. The method of claim 16, further comprising: applying one or more gripper motor control signals to the gripper motor to open or close the gripper member pair around the surface.

18. The method of claim 17, further comprising: applying one or more control signals to the plurality of rotator components based on the sensor data captured by the one or more gripper sensors.

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