Modular robotic manipulation system and method for operating same

Abstract

The present invention relates to the field of manipulator devices and discloses an innovative robotic technology for various industrial applications, including the inspection of assets in the oil and gas (O&G) industry. Flexible manipulators are small and have been used mainly for monitoring and manufacturing studies, with little large-scale application in the inspection of oil and gas assets. However, the inspection and maintenance of these assets are essential in this industry, which involves obstacles and areas that are difficult to access. In this context, the present invention discloses a flexible robotic manipulator as a solution to the aforementioned problem, since the manipulator is capable of adapting to adjacent structures, achieving results inaccessible to rigid robots, and presenting a lower risk to operators.

Description

MODULAR ROBOTIC MANIPULATION SYSTEM IN SYSTEMS AND ITS METHOD OF OPERATION 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 asset inspection in the Oil and Gas (O&G) industry. FUNDAMENTALS OF THE INVENTION

[0002] Flexible robotics and soft robotics solutions are still in their early stages in industry and are predominantly used in academia, where research related to manufacturing techniques, material types, actuation systems, and control strategies is more common. Currently, the latest generation of flexible manipulators are small, measuring only a few centimeters, and are mainly used to study control and manufacturing techniques, without widespread large-scale application, especially in the area of ​​oil and gas asset inspection. Therefore, the explicit use of flexible robotics for oil and gas asset inspection does not yet exist.

[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 that are difficult for humans and other remote techniques, such as teleoperated rigid robots, to access, making it difficult to inspect equipment such as collectors, production systems, and others. Ensuring the viability and safety of oil and gas inspection operations are motivating factors for... The use of flexible robotics technologies. Rigid robot solutions face difficulties navigating and performing detailed inspections with non-destructive techniques, such as vibration measurement, temperature measurement, and leak detection, in addition to posing risks to operator safety. On the other hand, manipulators based on flexible robotics show great potential, as they are able to adapt to adjacent structures and achieve results currently unavailable in the sector, as well as potentially representing less danger to those around them. Some typical use cases, little or not at all explored by current technologies in the sector, include: - Inspection of elevated areas of pipes / structures below the robot's reference plane (e.g., on top of platforms, with downward-facing view); - Inspection of elevated areas of pipes / structures above the robot's reference plane (e.g., on top of platforms, with upward-facing vision); - 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 in confined areas (e.g., storage tanks).

[0004] In order to solve the problems described above, the present invention discloses a flexible robotic manipulator that overcomes the scaling problem, facilitating access to assets at great distances / heights in hostile locations. The end effector and propulsion system allow specific instrumentation to be carried to the areas of interest. mainly at high altitudes, to carry out various inspections, such as visual inspection. STATE OF THE ART

[0005] Document WO2021178627 discloses examples related to pneumatic soft robotic spiral grippers. A fiber optic sensor can enable spiral gripper detection of, for example, an interlacing angle and the diameter of the target cylinder. In one example, a pneumatic soft robotic spiral gripper includes an elastic column with an embedded fiber optic sensor and a pneumatic spiral channel interlaced around the elastic column. The pneumatic spiral channel can be formed from a soft gripping material surrounding the elastic spine. In another example, a method of manufacturing a pneumatic soft robotic spiral gripper includes providing a gripper mold with an outer mold wall and a spiral-shaped rod positioned inside the outer mold wall.

[0006] Unlike the present invention, the above document describes an end effector in the form of a spiral pneumatic gripper made of soft material, for example cured silicone, with a hardness greater than 10 on the Shore scale. The end effector in question is designed to exert a mechanical locking action between the end effector and an object. On the other hand, the present invention describes a flexible manipulator with an end effector capable of propelling the respective part of the manipulator in order to increase its distance from the base on which the manipulator is supported by means of the reaction caused by the gas expelled during propulsion. Therefore, the present invention does not have a mechanical locking action on objects.

[0007] Document EP3058237 discloses a mechanically programmed actuator that includes at least one soft actuator body configured to bend, extend linearly, contract, twist, or combinations thereof when actuated without restriction; an actuation mechanism (e.g., a fluid pump) configured to actuate the soft actuator body; and at least one sleeve wrapped around part of the soft actuator body and configured to restrict the soft actuator body within the sleeve when actuated and cause the soft actuator body to deform where it is not covered by the sleeve.

[0008] Unlike the present invention, the above document describes a soft manipulator with fluid-based actuation. Fluid actuation influences how the manipulator body deforms, depending on the presence or absence of external gloves. The present invention uses fluid (pneumatic) to enable the propulsion of the manipulator and its elevation relative to the level of the manipulator's base, without determining, through actuation, the way in which the manipulator will deform.

[0009] Document US10639801 discloses an actuator comprising a plurality of chambers composed of a stretchable material, the chambers having inner and outer side walls, wherein at least a portion of the inner side wall is separated from an inner side wall of an adjacent chamber; and a strain-limiting base; and a channel that fluidly interconnects the plurality of chambers, in which the inner walls are configured to be more compliant than the outer walls.

[0010] Unlike the present invention, the document The above describes the use of pneumatic chambers as actuators for moving sections of soft robot bodies in a curved direction relative to the manipulator body section, whereas the present invention utilizes pneumatic channels whose purpose is to propel the manipulator to overcome gravity by means of reaction force caused by the jets of compressed air emitted by the device.

[0011] Document US10576643 discloses a soft robotic device with one or more sensors. The sensor may be embedded in the soft body of the soft robotic device, attached to the soft body of the soft robotic device, or otherwise connected to the soft body of the soft robotic device.

[0012] Unlike the present invention, the above document describes a soft robotics device composed of pressurization chambers and soft sensors to provide information about the states of the soft device. In contrast, the present invention presents a pneumatic actuator without necessarily soft parts, which obtains flotation by means of compressed air outlets, without sensors involved. SUMMARY OF THE INVENTION

[0013] The present invention applies to the field of manipulator devices and discloses an innovative robotic technology for various industrial applications, including asset inspection in the Oil and Gas (O&G) industry. Currently, flexible robotics is in its early stages in industry, being explored more in academia for research in manufacturing techniques, materials, actuation, and control. Flexible manipulators are small and have been used primarily for control studies and... Manufacturing, with little large-scale application in the inspection of oil and gas assets. However, the inspection and maintenance of these assets are essential in this industry, which presents obstacles and areas of difficult access. In this context, the present invention discloses a flexible robotic manipulator as a solution to the aforementioned problem, since the manipulator is able to adapt to adjacent structures, achieve results inaccessible to rigid robots, and represent less risk for operators. BRIEF DESCRIPTION OF THE FIGURES

[0014] Figure 1 illustrates the operating principle of the present invention.

[0015] Figure 2 illustrates the modular robotic manipulation system of the present invention.

[0016] Figure 3 illustrates a soft polymer coating.

[0017] Figure 4 illustrates a prototype of the manipulator of the present invention with an end-drive propulsion system with a length of 1.2 m.

[0018] Figure 5 illustrates the flowchart of operation of the robotic system.

[0019] Figure 6 illustrates the ability to overcome obstacles in the operating area due to the end-effector propulsion system. DETAILED DESCRIPTION OF THE INVENTION

[0020] The invention can be better understood through the following detailed description, in conjunction with the attached figures.

[0021] The present invention discloses a modular robotic manipulation system for use in industrial systems.

[0022] As illustrated in Figure 1, in general terms, the modular robotic manipulation system has as its structure a support bench (S) for a base (B) connected to a manipulator body (C) and a pneumatic unit (P), where along the manipulator body (C) there are actuation segments (A) and at its end there is an end effector (11) connected to a camera (12).The support bench (S) supports the physical apparatus; the base (B) serves as a spatial reference for the manipulator (C); the manipulator body (C) performs movements in various directions and with many degrees of freedom due to compressed air propulsion in the end effector (11) and the drive cables (3) at the end of each segment, the combination of both being responsible for controlling the position and orientation of the body; the pneumatic unit (P) supplies compressed air to the end effector (11); the actuation segments (A) provide controllability for the manipulator body; the end effector (11) provides propulsion capability for the manipulator body and the possibility of varying the angle of the air jet in relation to the surface from a mechanical system actuated by a cable passing through the body and a motor in the base; and the camera (12) provides visual feedback for inspections.

[0023] As illustrated in Figure 2, the manipulator body (C) comprises a plurality of deformable segments (1), a plurality of hollow structural discs (2) interspersed with the deformable segments (1), which are used to guide the drive cables (3). Each cable (3) has an individual conduit / sheath (4) for passage to the base of the actuation section (A) of a module (M1, M2). The cables (3) are actuated by Motors (5) on the base (B), and wound on pulleys (6). For actuation of the compressed air propulsion in the end effector, a pressure conductor (7) comes out of a pneumatic unit (P), couples to a dedicated electronic pressure valve (8) and runs the entire length of the manipulator, to the end effector (11). This end effector (11) has air outlets and, at least, one camera (12) for visual inspection. The system is powered by a power supply board (10) connected to a power source (9).

[0024] The modular robotic manipulation system can be configured to comprise at least two modules (M1, M2), where the first module (M1) functions as the first actuation section via cables of the manipulator body (C) comprising three actuation cables, hollow structural discs and deformable segments, and the second module (M2) functions as the second actuation section via cables of the manipulator body (C) comprising three actuation cables, hollow structural discs, deformable segments and the end effector (11). The manipulator body (C) allows more modules to be added to the device, following the configuration of modules M1 and M2, to increase its reach, provided that the last module contains the end effector (11).

[0025] The modularity provided for in the mechanical design allows for the progressive increase in length of the manipulator body, with the addition of deformable segments (1) and hollow structural discs (2).

[0026] The body (C) of the modular robotic manipulation system can be covered by a soft polymeric sheath, as shown in Figure 3, which protects the manipulator's interactions with the environment. Furthermore, the modular robotic manipulation system can be coupled to fixed or mobile bases.

[0027] The end effector (11) allows the coupling of various types of sensors for the execution of specific inspection tasks, such as non-destructive testing (NDT) sensors like ultrasonic probes for thickness measurement and other graphic inspection technologies like thermal and hyperspectral cameras.

[0028] The constituent elements are structures printed by additive manufacturing, as described below. For example, the polymeric coating for the manipulator body (C) is preferably made of silicone or thermoplastic polyurethane (TPU).

[0029] The structure of the robotic system, including its base, deformable segments, and structural discs, can be produced using additive manufacturing technology, with materials selected from the group comprising: polyamide 12 (PA12), polypropylene (PP), or thermoplastic polyurethane (TPU).

[0030] The robotic system's operating method comprises the following steps: (a) Energize the system by connecting the power cables to an electrical source; (b) Actuate the proportional pneumatic valve from a variable DC control signal between 0 and 10 V, allowing linear control of the compressed air pressure in relation to the input signal and enabling the actuator to reach the desired height from the horizontal surface; (c) Activate the motors that control the movement cables of the manipulator body relative to modules M1 and M2 in order to achieve the positioning desired by the implementer; (d) Activate motor that controls cable for adjusting air jet orientation in the end effector relative to the horizontal surface in order to achieve the desired orientation. (e) To take pictures with the camera. Examples Example 1: Evaluation of the propulsion concept in a manipulator.

[0031] This evaluation was carried out with a prototype test having two modules (M1 and M2) of 60 cm (total of approximately 1.2 m), as shown in figures 4 and 5.

[0032] The experiment consisted of raising the manipulator to a height above its resting position by means of the propulsive action of the end effector. The manipulator body was partially at rest on the test bench, attached to a perpendicular base. The experiment consisted of varying, via the pneumatic valve, the level of compressed air pressure supplied to the system, in order to observe the gradual elevation of the end effector, and consequently of the manipulator body, through the propulsion provided by the end effector. The end effector reached a certain height, from which the pressure level was reduced to return the manipulator to its resting position. In another round of the experiment, propulsion was used in combination with the actuation of the cables in modules M1 and M2 to overcome an obstacle, as shown in Figure 6.

[0033] The manipulator body of the actuator reached a height of 60 cm measured from the surface of the workbench to a Compressed air pressure of 4.5 bar. For greater heights with this configuration, a higher compressed air pressure is required. The movement provided by the cables of the modules combined with the controlled propulsion of the actuator was sufficient to overcome an obstacle with lateral movements.

[0034] 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. Deformable segments 2. Hollow structural discs 3. Movement drive cables 4. Individual conduit / cover 5. Engines 6. Pulleys 7. Pressure conduit 8. Dedicated electronic pressure valve 9. Source 10. Power supply board 11. Effector 12. Camera for visual inspection S - Support bench B - Base A - Business segments C - Manipulator body P - Pneumatic unit Ml - First module M2 - first module

Claims

CLAIMS 1. Modular robotic manipulation system characterized by comprising a support bench (S); a base (B); a manipulator body (C), covered by a polymeric sheath, separated by modules (M1, M2), wherein more modules can be added to increase the length of the body; a pneumatic unit (P); actuation segments (A); an end effector (11) connected to the end of the manipulator body (C); a camera (12) connected to the end effector (11); drive cables (3); motors (5); pulleys (6); a pressure conduit (7); a dedicated electronic pressure valve (8), wherein said support bench (S) supports the base (B), which connects to the manipulator body (C) and a pneumatic unit (P).

2. System, according to claim 1, CHARACTERIZED in that the manipulator body (C) performs rotational and translational movements from the actuation of the actuation segments (A), formed by the set of deformable segments (1), hollow structural discs (2), actuation cables (11) and end effector (11).

3. System, according to claims 1 or 2, CHARACTERIZED in that the pneumatic unit (P) supplies compressed air to the actuator (11), through the pressure conduit (7), which extends along the manipulator body (C), wherein the released compressed air is controlled by the pressure valve (8).

4. System, according to any one of claims 1 to 3, CHARACTERIZED in that the end effector (11) has a propulsion mechanism that uses compressed air jets.

5. System according to claims 1 or 2, CHARACTERIZED by the fact that the drive cables for the movement (3) comprise an individual conduit / sheath (4) for passage to the base of the actuation section (A) of a module (M1, M2) inside openings of the hollow structural discs (2), where the cables (3) are controlled by the motors (5) and wound on pulleys (6).

6. Method of operation of the modular robotic manipulation system in systems, as defined in claims 1 to 5, CHARACTERIZED by comprising the steps of: i. Energizing the system by connecting the power cables to an electrical source; ii. Actuating the proportional pneumatic valve to control the compressed air pressure; iii. Actuating the motors (5) that control the cables (3) to adjust the orientation of the air jet in the end effector (11) relative to the horizontal surface in order to reach the desired position of the manipulator body (C); iv. Recording images with the camera.

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