Extensible and deformable robotic system

Abstract

The present invention pertains to the field of manipulator devices and discloses robotic technology for various industrial applications, including asset inspection in the oil and gas (O&G) industry. The present invention relates to a soft, flexible, slender and portable robotic manipulator with electric actuation, comprising a slender robotic manipulator arm of reduced size and high deformability, made of compliant material, with a surface of low relative hardness and actuated by a set of tendons incrementally arranged along the body in intermediate sections without continuity segmentation. Its structure is arranged on a rod with the aim of increasing the reach of the manipulator without requiring the entire structure to be soft, flexible and deformable. The system further has a user operating interface associated with the robotic manipulator, giving same the ability to control and analyse the data obtained by the system.

Description

EXTENSIBLE DEFORMABLE ROBOTIC SYSTEM FIELD OF APPLICATION

[0001] The present invention applies to the field of manipulator devices. The present invention discloses a robotic technology for application in diverse industrial contexts, such as the inspection of assets in the Oil and Gas (O&G) industry, in typical onshore and offshore environments, such as pipelines, flanges, truss structures, pressure vessels and tanks. FUNDAMENTALS OF THE INVENTION

[0002] Soft robotics solutions are nascent in industry and mostly confined to the academic world, where research related to manufacturing techniques, material types, actuation systems, and control strategies is more frequent. In this sense, the soft manipulators currently in the state of the art are small (on the order of centimeters) and are primarily intended for the study of control and manufacturing techniques, without widespread large-scale applications, especially those focused on the inspection of O&G assets.

[0003] Inspection and maintenance of assets play a vital role in the oil and gas industry. In this sector, facilities present many obstacles and areas difficult to access for humans and other remote techniques, such as teleoperated rigid robots, making the inspection of equipment like manifolds, production systems, and others difficult. Ensuring the viability and safety of oil and gas inspection operations are motivating factors for the use of soft robotics technologies. Solutions using inspection rods have limited capacity to handle these challenges. with complex structures, indicating the need to increase the degrees of freedom of this type of system, such as through robotic arms. However, rigid robots, although more precise, have limitations in movement or reach, making visual inspections or those using non-destructive testing (NDT) techniques (thickness, vibration, temperature, leakage, etc.) more challenging than supposedly with soft robots, in addition to presenting risks to the safety of operators and assets. On the other hand, manipulators based on soft robotics are promising, as they can conform to adjacent structures and achieve results currently unavailable in the sector, as well as being potentially less dangerous to those around them and to the inspected assets themselves. Typical use cases, little or not at all explored by current technologies in the segment, are: • Inspection and maintenance of pipes / structures at height below the robot's reference plane (on top of platforms, looking downwards); • Navigating through narrow spaces between structures; • Detection of gas and fluid leaks in hard-to-reach environments; • Reading equipment in hard-to-reach locations; • Inspection within enclosed areas (storage tanks).

[0004] In order to solve the problems described above, the present invention discloses a soft robotic manipulator that overcomes the scaling problem, facilitating access to assets at great distances / heights. The use of a telescopic rod allows specific instrumentation to be taken to areas of interest (especially at height) for inspections. Various methods can be used (e.g., visual inspection). STATE OF THE ART

[0005] Document CN 217879677 discloses a multifunctional auxiliary tool for pipeline detection. The multifunctional auxiliary tool comprises a main rod assembly, a laser rangefinder, an auxiliary rod, a clamping device, a telescopic assembly, an underwater camera, and a clamp. The laser rangefinder is fixed to the front of the main rod assembly; the auxiliary rod is connected to the lower end of the main rod assembly. One end of the telescopic assembly is connected to the end of the auxiliary rod via the clamping device. The clamp and underwater camera are fixed to the other end of the telescopic assembly, and the underwater camera is located above the clamp.The multi-functional auxiliary tool for pipeline detection can help pipeline detection workers overcome various limiting field conditions, such as accumulated water in an inspection well, in larger and deeper well chamber pipeline detection fieldwork, and can replace detection workers at the well entry to complete various instrument operations in the inspection well.

[0006] Unlike the present invention, the document above describes only an inspection rod without a modular robotic manipulator, focusing on well and pipeline inspection. The telescopic assembly at the end of the auxiliary rod consists of a scissor mechanism that adds only one degree of freedom (extension) to the system for extending the inspection area. The length extension Using a rod is not a recommended feature. Nothing is said about other forms of inspection besides visual inspection and distance measurement.

[0007] Document CN 110993382 discloses a pole-climbing, free-standing, multi-functional operating rod of the FTU power distribution automation type, and the operating rod comprises: a multi-functional operating head comprising a rhombic handle operating part, and a triangular key and a fixed-value dial contact that are detachable and connected to the rhombic handle operating part; a telescopic rod made of an insulating material and provided with at least two telescopic joints, wherein the upper end of the telescopic rod is connected to a multi-functional operating head and the lower end of the telescopic rod is connected to an operating handle; and a Wi-Fi camera used to transmit the filmed video to a smart terminal for ground workers in real time.By adopting the telescopic insulating operating rod and the removable multi-functional operating head, in terms of safety, the telescopic insulating operating rod can be positioned at the required height in a telescopic manner, making operation convenient, the size small, transport convenient, and the risk of electric shock avoided. In terms of practicality, the rhombic handle operating part, the triangular key operating head, and the fixed-value dial contact are integrated, saving time and making operation convenient.

[0008] Unlike the present invention, the document above describes a rod with specific application in maneuvering and Verification of power systems, such as electrical distribution poles, does not include other forms of inspection besides visual inspection. Furthermore, there is a focus on the efficiency of electrical protection for operators at high voltages, without the need for multiple degrees of freedom through the use of a robotic manipulator.

[0009] Document CN 220035193 discloses a safety inspection instrument for a telescopic bridge pole, and aims to solve the problems that in the prior art the cost is high when using a bridge inspection vehicle for auxiliary inspection, some relatively low pillars and supports are wasted when the bridge inspection vehicle is used and, meanwhile, the space under a bridge is usually the original ground and is uneven; in order to overcome the defects that a ladder cannot be properly fixed and potential safety hazards are easily caused, the following scheme is provided, the ladder fixing device comprises an electric telescopic pole, a pole body is disposed on the electric telescopic pole, a placement structure is fixedly connected to the electric telescopic pole, a sliding groove is formed on the underside of the placement structure and an adjustment mechanism is rotatably installed in the sliding groove.The inspection device is simple in structure and easy to transport. It can observe the condition of parts such as a beam plate, a support, a box girder, a cover beam, a web plate, and a wet joint. It can be used on the ground in relation to a ladder support and a bridge inspection vehicle. It presents no potential safety risks, has a low cost, and can be recycled.

[0010] Unlike the present invention, the document above describes an inspection instrument focused on bridge inspection, which only features rotational movements for camera adjustment, but does not feature bending movements or movements intended to deform on the structure and inspect hard-to-reach points.

[0011] Document CN 211902390 discloses a periscope device for detecting defects in the piping of an eccentric inspection well, in order to perform the detection of the eccentric inspection well. According to the technical diagram, the periscope device for detecting defects in the piping of the eccentric inspection well is characterized by comprising a vertical telescopic rod, a transverse electric telescopic rod and a probe device of the QV equipment, the upper portion of the vertical telescopic rod being connected with a stabilizing support capable of being supported on the mouth of the inspection well.The lower end of the vertical telescopic rod is connected to the transverse electric telescopic rod in a rotating manner; one end of the transverse electric telescopic rod is connected to the upper end of the QV equipment's probe device in a rotating manner; and the vertical telescopic rod is equipped with a tilt angle adjustment mechanism capable of adjusting the tilt angle of the transverse electric telescopic rod. The signaling equipment is located at the upper end of the vertical telescopic rod and connected to the transverse electric telescopic rod and the QV equipment's probe device via signal lines, and the signaling equipment is in communication connection with a panel. This operation is used to control the electric telescopic transverse rod and probe device of the QV equipment.

[0012] Unlike the present invention, the above document describes an inspection device designed for eccentric wells, focusing solely on underground inspections. This device has some degrees of freedom to compensate for the eccentricity of the inspection locations, but these are limited, not approaching the dexterity of a soft manipulator, which is capable of conforming to existing structures, thus limiting the inspection of narrow and irregular locations.

[0013] Document EP 3266571 discloses a robotic manipulator arm deployment and control system. The system comprises at least one vertical mast, a mast deployment system comprising at least two cams, an elbow, an arm on which the arm is operable for deploying tools, and one or more sensors including a non-contact sensor and a dynamic measurement unit. The cams cause the vertical mast and arm to remain vertical during deployment in an operational space. The non-contact sensor can be used to measure range and orientation for objects in the operational space in polar coordinates. The dynamic measurement unit comprises accelerometers and rate sensors and is configured as a three-axis sensor with six degrees of freedom operating in a Cartesian coordinate system.The system also includes an operable controller to receive the polar and Cartesian coordinates from the sensors and convert them into a Cartesian coordinate system.

[0014] Unlike the present invention, the document The above description describes a manipulator with multiple degrees of freedom, capable of bending, extending, and rotating; however, it is a rigid manipulator, unable to adapt to the structures being inspected. The system lacks the ability to inspect distant locations because it is not coupled to a rod, thus being only a manipulator with many degrees of freedom.

[0015] The present invention differs from prior art documents by revealing a soft manipulator at the rod end, adding more degrees of freedom of movement; a modular end effector designed with sensing / maintenance capabilities for industrial assets; the possibility of rotating the end effector for positioning and orienting inspection sensors on structures; actuation by motor-driven tendons; a user interface with control of manipulator movement, camera visualization and other sensors; access to delicate structures without the possibility of damaging them, with the presence of a protective cover. SUMMARY OF THE INVENTION

[0016] The present invention applies to the field of manipulator devices and discloses a robotic technology for various industrial applications, including asset inspection in the Oil and Gas (O&G) industry. The present invention relates to a soft, flexible, slender, and portable electrically driven robotic manipulator, comprising a slender robotic arm with reduced size, high deformability, composed of compliant material, with a relatively low hardness surface, and actuated by a set of tendons incrementally arranged along the body in Intermediate sections without segmentation of continuity. Its structure is positioned on a rod with the aim of increasing the reach of the manipulator without requiring the entire structure to be soft, flexible, and deformable. Associated with the robotic manipulator, the system has a user operation interface, giving the user the ability to control and analyze the data obtained by the system. BRIEF DESCRIPTION OF THE FIGURES

[0017] Figure 1 illustrates the soft manipulator.

[0018] Figure 2 illustrates the manipulator along with the data, control, and interface cable.

[0019] Figure 3 illustrates the soft polymer coating.

[0020] Figures 4 through 9 illustrate the applications and uses of the robotic manipulator. DETAILED DESCRIPTION OF THE INVENTION

[0021] The invention can be better understood through the following detailed description, in conjunction with the attached figures.

[0022] The present invention discloses a soft robotic manipulator for asset inspections in the Oil and Gas (O&G) industry.

[0023] The soft, flexible, slender, and portable electrically driven robotic manipulator is illustrated in Figure 1. The manipulator comprises a slender robotic arm (1) less than 1 meter in length, with deformability capability, composed of compliant material, preferably PA12, and others such as ABS (Acrylonitrile Butadiene Styrene), PETG (Polyethylene Terephthalate Glycol), nylon, Acrylonitrile Styrene Acrylate (ASA), polyoxymethyl ethylene (POM), PSU (polysulfone) and resins, manufactured by additive manufacturing, with a relatively low hardness surface, and actuated by a set of tendons incrementally arranged along the body in intermediate sections without segmentation of continuity. The manipulator structure is positioned on a tubular rod (h) in order to increase its reach, as illustrated in figures 4 to 9, without requiring the entire structure to be soft, flexible and deformable.

[0024] As illustrated in Figure 1, the robotic manipulator is formed by deformable segments (a), interspersed with hollow structured sections / discs (b) used to guide drive cables for movement. (c) . Each cable is routed to the base (g) . The cables are driven by motors (g) at the base (d) , and wound onto pulleys (e) , specifically designed for the manipulator. The base (d) is coupled to the rod coupler (f), which fits into the tubular rod (h). At least one camera for visual inspection is coupled to the manipulator end effector, but NDT sensors (ultrasound, magnetic, eddy current) for thickness measurement and defect detection, gas sensors; vibration sensors; temperature sensors; distance sensors; mechanical cleaning actuators; and chemical sprayers may also be coupled.

[0025] As illustrated in Figure 2, a user operating interface (M) is coupled to the robotic manipulator, giving the user the ability to analyze the data obtained by the system. The motors can be coupled to the interface (M) via the data cable (k). The control (j) gives the user the ability to control the manipulator and is connected to the interface (m), which is powered by the battery (L).

[0026] The soft manipulator is between 20 and 80 cm long and, when coupled to the rod (h) extended to its maximum, reaches lengths that can vary from 2 to 10 m, depending on the rod used, considering ergonomic limits of human loading.

[0027] The manipulator body can be covered by a soft polymer sheath, as shown in Figure 3, which protects the manipulator from its interactions with the environment. EXAMPLES Example 1: Evaluation of the concept of a soft manipulator coupled to a rod for visual inspection at height.

[0028] This evaluation was performed using a tested prototype of a 45 cm soft manipulator, with a reach of 3.45 m using the telescopic rod, as shown in Figure 2.

[0029] The experiment consisted of using the manipulator to inspect elevated structures as shown in Figures 4 and 5. The telescopic rod was extended by the operator to reach the top of the equipment being inspected.

[0030] The soft manipulator reached the desired structures and tilted over them, allowing for easy visualization of different points of the structure. For greater inspection heights, a longer reinforced rod is necessary. Example 2: Evaluation of the concept of a soft manipulator coupled to a rod for reading equipment in hard-to-reach locations.

[0031] The experiment consisted of using the same prototype presented for structural inspection. lower, to reach and view equipment displays.

[0032] The movement of the end effector, facilitated by cable actuation, allowed for reaching viable positions to view the measurements of a set of industrial gauges using a camera, considering that this inspection point was located below the operators, as shown in Figure 6. Example 3: Evaluation of the concept of a soft manipulator coupled to a rod for entry into hard-to-reach and / or confined spaces.

[0033] The experiment consisted of using the same prototype presented to enter difficult-to-access structures, such as a pressure vessel through one of its openings, as shown in Figure 7. The experiment consisted of verifying the movement of the manipulator inside the vessel and evaluating the inspection capabilities of this structure.

[0034] The movement of the soft manipulator and its slender construction allowed for easy entry into the interior of the vessel, so that the camera could visualize the integrity of this industrial component without the need for personnel to enter the interior. Example 4: Evaluation of the concept of a soft manipulator coupled to a rod for equipment integrity inspection.

[0035] The experiment consisted of using the same prototype described to inspect the integrity of the welds, flanges, and walls of a chemical processing equipment, having the manipulator lean on the structure and evaluating the manipulator's dexterity in assembling the structure for support and inspection, as described above. shown in figure 8.

[0036] The high level of dexterity and degrees of freedom of the present invention allowed it to adapt to the shape of the structure, enabling detailed inspection, especially behind the equipment flange. The adaptability to the structure allowed the manipulator to be supported on the equipment, assisting the operator. The horizontal inspection capability of this system, capable of reaching points in different positions and orientations, is also noteworthy. Experiment 5: Evaluation of the concept of a soft manipulator coupled to a rod for use in non-destructive thickness measurement techniques.

[0037] The experiment consisted of using the same prototype described for measuring thickness at points on an industrial equipment, as shown in Figure 9. The experiment in question aimed to perform point thickness measurements using the pulsed eddy current (PEC) sensor by positioning the end effector over the desired locations.

[0038] The manipulator's movement allowed it to reach the desired points with the PEC sensor attached to the end effector, returning the thicknesses of important points on the tested equipment.

[0039] The present invention has been disclosed in this descriptive report in terms of its preferred embodiment. However, other modifications and variations are possible from the present description, and are still within the scope of the invention disclosed herein. List of references 1. Robotic arm a. Polymer casing b. Deformable segments c. Hollow structural discs d. Movement drive cables e. Base f. Pulleys g. Rod coupler h. Motors i. Tubular rod j. Modular end effector k. Control L. Battery M. Interface

Claims

CLAIMS 1. Soft and extendable robotic system CHARACTERIZED by comprising a robotic arm (1), covered by a polymeric sheath (2); a base (d); pulleys (e); rod coupler (f); motors (g); tubular rod (h); end effector (i); control (j); data cable (k); battery (L); interface (M).

2. System, according to claim 1, CHARACTERIZED in that the robotic arm is made of compliant material, which may be composed of PA12, ABS (Acrylonitrile Butadiene Styrene), PETG (Polyethylene Terephthalate Glycol), nylon, Acrylonitrile Styrene Acrylate (ASA), polyoxymethyl ethylene (POM), PSU (polysulfone) and resins, preferably composed of PA12, has a length of 20 to 80 cm, has deformability capacity and comprises deformable segments (a), interspersed with hollow structural discs (b) that guide movement actuation cables (c), wherein the hollow structural discs (b) and the movement actuation cables (c) are the actuators of the system.

3. System according to claim 1, CHARACTERIZED in that the base (d) is coupled to the rod coupler (f), wherein the rod coupler (f) has a length of 2 to 10 meters.

4. System according to claim 1, CHARACTERIZED in that the drive cables for the movement (c) are routed to the base (d) and driven by motors (g) positioned on the base (d), wherein each cable is wound around a pulley (e).

5. System according to claim 1, CHARACTERIZED in that the modular end effector (i) can be Coupled with a camera for visual inspection, NDT sensors (ultrasound, magnetic, eddy current) for thickness measurement and defect detection, gas sensors, vibration sensors, temperature sensors, distance sensors, mechanical cleaning actuators, and chemical sprayers, the elements can only be coupled one at a time, depending on the operation's needs.

6. System, according to claim 1, CHARACTERIZED in that the user operating interface (M) is powered by a battery (L), being coupled to the manipulator, the control (j) and the motors (g) via the data cable (k), and is responsible for analyzing system data relating to the operation performed by the manipulator.

7. System, according to claim 1, CHARACTERIZED in that the definition of the manipulator position is performed by the user through control (j).

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