Navigation apparatus with wheel assembly having a geared wheel segment

Abstract

A navigation apparatus (102) includes a body (132), an arm (136) coupled to the body and extending outward from the body, and a wheel assembly (138) coupled to the arm. The wheel assembly (138) includes a wheel segment (152) engaged with a first side gear assembly (158) and a second side gear assembly (160). The wheel segment (152) defines a second rotational axis (WS). The first side gear assembly and the second side gear assembly (158, 160) are each independently rotatable about the axle (156) to which they are coupled defining a first rotational axis (R) and the wheel segment (152) is configured to both rotate in orbit around the first rotational axis (R) and to rotate about the second rotational axis (WS).

Description

NAVIGATION APPARATUS WITH WHEEL ASSEMBLYHAVING A GEARED WHEEL SEGMENTSTATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

[0001] This invention was made with Government support under contract number DE-AR0001328 awarded by the Advanced Research Projects Agency-Energy (ARPA-E). The Government has certain rights in this invention.BACKGROUND

[0002] The field of the disclosure relates to navigation systems and apparatuses, and more particularly to pipe navigation apparatuses including a wheel assembly with a geared wheel segment.

[0003] Pipes are commonly used to transport fluids. For example, typical pipes include a cylindrical sidewall that defines an interior cavity. During operation, fluids are transported within the interior cavity of the pipes. Sometimes, the fluids that are transported through the pipes have characteristics that can cause wear, deterioration, or otherwise affect the properties of the pipes. As a result, the pipes may require routine inspection and repair. However, the interior cavity of the pipes may be difficult to access for routine maintenance. For example, at least some known pipes are used to transport fluids having high temperatures, pressures, and / or other properties that create conditions which are inhospitable for at least some known maintenance apparatus. Moreover, at least some known pipes are difficult for at least some know n apparatus to travel through because of the pipes' size and shape and obstacles within the interior cavity.

[0004] Accordingly, it is desirable to provide a system including a motorized apparatus configured to travel through an interior cavity of the pipes and avoid obstacles within the pipes.BRIEF DESCRIPTION

[0005] In one aspect, a navigation apparatus is provided. The navigation apparatus includes a body, an arm coupled to the body and extending outward from the body, and a wheel assembly coupled to the arm. The wheel assembly includes a wheel segment engaged with the first side gear assembly and the second side gear assembly. The wheel segment defining a second rotational axis. The first side gear assembly and the second side gear assembly are each independently rotatable about the axle and the wheel segment is configured to both rotate in orbit around the first rotational axis and to rotate about the second rotational axis.

[0006] In another aspect, a wheel assembly for use with a navigation apparatus is provided. The wheel assembly includes an axle defining a first rotational axis, a first side gear assembly coupled to the axle, a second side gear assembly coupled to the axle, and a wheel segment engaged with the first side gear assembly and the second side gear assembly. The wheel segment defines a second rotational axis. The first side gear assembly and the second side gear assembly are each independently rotatable about the axle and the wheel segment is configured to both rotate in orbit around the first rotational axis and to rotate about the second rotational axis.

[0007] In yet another aspect, a method for controlling a navigation apparatus in a pipe is provided. The method includes controlling a wheel assembly of a navigation apparatus to engage an interior wall of the pipe, the navigation apparatus including a body and an arm coupled to the body and extending outward therefrom to the wheel assembly and controlling a first side gear assembly to rotate about a first rotational axis extending through an axle of the wheel assembly. The method further includes controlling a second side gear assembly to rotate, independently, about the first rotational axis. A wheel segment is engaged with the first side gear assembly and the second side gear assembly. The wheel segment defines a second rotational axis. The wheel segment is configured to both rotate in orbit around the first rotational axis and to rotate about the second rotational axis.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0009] FIG. 1 is a schematic diagram of a pipe treatment system including a navigation apparatus traveling underground;

[0010] FIG. 2 is schematic diagram of a portion of the pipe treatment system of FIG. 1. showing an end view of the navigation apparatus traveling underground in a first mode of operation;

[0011] FIG. 3 is a schematic diagram of the portion of the pipe treatment system of FIG. 2 showing the navigation apparatus rotated and in a second mode of operation;

[0012] FIG. 4 is a perspective view' of an embodiment of a w heel assembly for use with the navigation apparatus shown in FIG. 1;

[0013] FIG. 5 is an exploded view of the wheel assembly shown in FIG. 4;

[0014] FIG. 6 is a first sectional view of the wheel assembly shown in FIG. 4 and including a first drive mechanism and a second drive mechanism;

[0015] FIG. 7 is an enlarged sectional view of a portion of the wheel assembly shown in FIG. 6;

[0016] FIG. 8 is a second sectional view of the wheel assembly shown in FIG. 4;

[0017] FIG. 9 is a sectional view of an alternative wheel assembly for use with the navigation apparatus shown in FIG. 1 ;

[0018] FIG. 10 is a perspective view of another alternative wheel assembly for use with the navigation apparatus shown in FIG. 1, showing wheel segments of the wheel assembly in a first configuration;

[0019] FIG. 11 is another perspective view of the wheel assembly shown in FIG. 10, showing the w heel segments in a second configuration;

[0020] FIG. 12 is another perspective view of the wheel assembly shown in FIG. 10, showing the wheel segments in a third configuration;

[0021] FIG. 13 is a flow chart of an example method of controlling the navigation apparatus shown in FIG. 1.

[0022] Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of this disclosure. These features are believed to be applicable in a wide variety of systems including one or more embodiments of this disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.DETAILED DESCRIPTION

[0023] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.

[0024] The singular forms ‘’a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

[0025] “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.

[0026] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary' without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and■‘substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and / or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

[0027] As used herein, the terms “processor” and “computer,” and related terms, e.g., “processing device,” “computing device,” and “controller” are not limited to just those integrated circuits referred to in the art as a computer, but broadly refers to a microcontroller, a microcomputer, an analog computer, a programmable logic controller (PLC), and application specific integrated circuit (ASIC), and other programmable circuits, and these terms are used interchangeably herein. In the embodiments described herein, “memory” may include, but is not limited to. a computer-readable medium, such as a random access memory (RAM), a computer-readable non-volatile medium, such as a flash memory. Alternatively, a floppy disk, a compact disc - read only memory (CD-ROM), a magnetooptical disk (MOD), and / or a digital versatile disc (DVD) may also be used. Also, in the embodiments described herein, additional input channels may be, but are not limited to, computer peripherals associated with an operator interface such as a touchscreen, a mouse, and a keyboard. Alternatively, other computer peripherals may also be used that may include, for example, but not be limited to, a scanner. Furthermore, in the example embodiment, additional output channels may include, but not be limited to. an operator interface monitor or heads-up display. Some embodiments involve the use of one or more electronic or computing devices. Such devices typically include a processor, processing device, or controller, such as a general purpose central processing unit (CPU), a graphics processing unit (GPU), a microcontroller, a reduced instruction set computer (RISC) processor, an ASIC, a PLC, a field programmable gate array (FPGA), a digital signal processing (DSP) device, and / or any other circuit or processing device capable of executing the functions described herein. The methods described herein may be encoded as executable instructions embodied in a computer readable medium, including, without limitation, a storage device and / or a memory device. Such instructions, when executed by a processing device, cause the processing device to perform at least a portion of the methods described herein. The above examples are exemplary only, and thus are not intended to limit in any way the definition and / or meaning of the term processor and processing device.

[0028] Embodiments described herein relate to a pipe navigation system including a navigation apparatus that includes a wheel assembly including a plurality of geared wheel segments. The apparatus includes a body and an arm coupled to the body and extending outward therefrom. The wheel assembly is coupled to the arm and includes an axle defining a first rotational axis, a first side gear assembly coupled to the axle, a second side gear assembly coupled to an axle. The wheel segment further includes a wheel segment engaged with the side gear assemblies and defining a second rotational axis. The first side gear assembly and the second side gear assembly are each independently rotatable about the axle and the wheel segment is configured to both rotate in orbit around the first rotational axis and to rotate about the second rotational axis. As a result, the wheel assembly allows for the navigation apparatus to be driven in a “straight drive” mode and to be driven in a “spin drive mode”, whereby the navigation apparatus, including the body and the arms, are rotated within the pipe, thereby increasing maneuverability of the navigation apparatus within the pipe. Thus, the navigation apparatus may be maneuvered within the pipe to avoid obstacles in the pipe such as foreign objects, obstructions, or structural features of the pipe such as an opening in a “T-joint” of the pipe. Additionally, the wheel assembly provides improved traction with the pipe by providing a transverse force across the wheel in addition to a thrust force during drive mode operations, allowing for the navigation apparatus to be spun within the pipe without decreasing traction.

[0029] FIG. 1 is a schematic diagram of a pipe navigation system 100, alternatively referred to herein as a “system” including a navigation apparatus 102. also referred to herein as a “crawler,” traveling underground. For example, navigation apparatus 102 is configured to travel through a pipe 106. In other embodiments, navigation apparatus 102 may be configured to travel along any suitable drive surface. Pipe 106 may be any enclosed path through a material. For example, pipe 106 may be a conduit or a tunnel and may have a circular or non-circular cross-section. Pipe 106 includes an interior wall 108 having an interior surface 110 defining an interior cavity 112.

[0030] System 100 includes a controller 116 communicatively coupled to navigation apparatus 102. In the example embodiment, controller 116 is configured to provide instructions to move navigation apparatus 102 through pipe 106 and / or to perform inspection or repair operations. Controller 116 includes a transceiver 124, a processor 126,and a memory 128. In some embodiments, controller 116 is positioned remotely from navigation apparatus 102, e.g., controller 116 is located at a base station that enables an operator on an exterior of pipe 106 (shown in FIG. 1) to interact with navigation apparatus 102, and / or controller 116 can be at least partly incorporated into and located on board navigation apparatus 102. Transceiver 124 is communicatively coupled with navigation apparatus 102 and is configured to send information to and receive information from a transceiver of navigation apparatus 102. In some embodiments, transceiver 124 and a transceiver on navigation apparatus 102 communicate wirelessly. In alternative embodiments, navigation apparatus 102 and controller 116 communicate in any manner that enables system 100 to operate as described herein. For example, in some embodiments, controller 116 and navigation apparatus 102 exchange information through a wired link extending between navigation apparatus 102 and controller 116 e.g., by a tether 149, described in further detail below.

[0031] In addition, in some embodiments, controller 116 is at least partly located on board navigation apparatus 102 and is configured to execute instructions for controlling components of navigation apparatus 102, such as a maintenance tool and drive systems. For example, controller 116 executes instructions that cause navigation apparatus 102 to move in a selected direction. In alternative embodiments, navigation apparatus 102 includes any controller that enables system 100 to operate as described herein. In some embodiments, controller 116 is not located on board navigation apparatus 102.

[0032] In some embodiments, navigation apparatus 102 includes one or more sensors. An operator interface 130 is configured to display information relating to the characteristics detected by navigation apparatus 102 for interpretation by the operator. Operator interface 130 may be included on a remote computing device (not shown) and / or may be incorporated with controller 116. Operator interface 130 may include, among other possibilities, a web browser and / or a client application. For example, in some embodiments, operator interface 130 displays images of interior surface 110 based on received signals. In some embodiments, operator interface 130 allows an operator to input and / or view information relating to control of navigation apparatus 102. In the example embodiment, operator interface 130 is configured to display information relating to the state of one or more of a maintenance tool and a power source for interpretation by the operator. For example,state information may include a position of navigation apparatus 102 along a length of pipe 106.

[0033] In various embodiments, processor 126 translates operator inputs into steering, tool motion, camera control, sensor control, sensor motion, and / or any other commands and sends information via transceiver 124 to navigation apparatus 102 via a transceiver of navigation apparatus 102. In some embodiments, operator control of navigation apparatus 102 is in real time, such as through a joystick, a keyboard, a touchscreen, a remote motion capture system, and / or a wearable motion capture system or other interface having similar function. In other embodiments, navigation apparatus 102 is controlled partially or wholly according to a pre-programmed routine. In further embodiments, navigation apparatus 102 is at least partially automated. In some embodiments, an operator inputs information such as operation goals or conditional directions. In further embodiments, information, such as information received by controller 116 from navigation apparatus 102, control data sent to navigation apparatus 102, and additional operator inputs or state information (e.g., location, time, orientation, datalink quality, battery levels, repair material levels, failure mode indicators), is logged into memory 128.

[0034] Moreover, in the example embodiment, controller 116 is positioned on the exterior of pipe 106 and communicates with navigation apparatus 102 positioned within interior cavity 112 of pipe 106. For example, controller 116 is configured to send information to navigation apparatus 102 relating to the propulsion and / or steering of navigation apparatus 102 while navigation apparatus 102 is moving within interior cavity7112 of pipe 106 through a wireless connection and / or tether 149. In alternative embodiments, controller 116 and navigation apparatus 102 are configured in any manner that enables system 100 to operate as described herein.

[0035] Navigation apparatus 102 includes a body 132 that is configured to fit within interior cavity 112 and travel along the length of pipe 106. Accordingly, navigation apparatus 102 facilitates inspection and / or repair of pipe 106. Moreover, navigation apparatus 102 includes a drive assembly 134 coupled to body 132. Navigation apparatus 102 is self-propelled by drive assembly 134, meaning that navigation apparatus 102 moves withininterior cavity 112 without external propulsion (e.g., a mechanical push or pull force) acting on navigation apparatus 102.

[0036] Drive assembly 134 includes a plurality of arms 136 extending from body 132. In the example, each of the arms 136 includes at least two links pivotably connected to body 132 with a wheel assembly 138 attached to distal ends of each link. In other embodiments, arms 136 may include any suitable number of links and in some embodiments, include a single link. Arms 136 extend at least partially radially outward from body 132 such that wheel assemblies s 138 engage interior surface 110 to propel navigation apparatus 102 along pipe 106. Arms 136 position body 132 of navigation apparatus 102 centrally within pipe 106, such that a central axis of navigation apparatus 102 is generally colinear with a central axis of pipe 106. In the example embodiment, navigation apparatus 102 includes three arms 136 each having a corresponding wheel 138. In other embodiments, navigation apparatus 102 includes any suitable number of arms 136 and wheels 138.

[0037] Body 132 includes a first or “distal” end 140 and an opposed second or “proximal” end 142. During operation, for example, navigation apparatus 102 may be positioned within interior cavity 112 through an opening 144 in pipe 106, with first end 140 oriented into opening 144 and second end 142 trailing first end 140. In the illustrated embodiment, navigation apparatus 102 travels in a travel direction 146 into pipe 106 from opening 144.

[0038] In some embodiments, navigation apparatus 102 includes a tool (not shown) configured to perform a maintenance operation within pipe. The tool may include for example, and without limitation, any of the following: a spray nozzle, an applicator, a drill, a grinder, a heater, a welding electrode, an optical sensor (e.g., visible, infrared, and / or multi-spectral sensor), a mechanical sensor (e.g., stylus profilometer, coordinate measurement probe, load transducer, linear variable differential transformer), a thermal sensor (e.g., pyrometer, thermocouple, resistance temperature detector), a magnetic sensor, an acoustic sensor (e.g., piezoelectric, microphone, ultrasound), and an electromagnetic sensor (e g., eddy current, potential drop, x-ray).

[0039] In addition, in some embodiments, navigation apparatus 102 includes a light source (not shown) configured to irradiate at least a portion of interior cavity 112 to facilitate visual or non- visual steering of navigation apparatus 102 and / or to allow a navigation apparatus to capture images, for example. The light source may be coupled to body 132 and, in some embodiments, may be positionable relative to body 132. In alternative embodiments, navigation apparatus 102 includes any light source that enables navigation apparatus 102 to operate as described herein.

[0040] In the example embodiment, tether 149 is coupled to navigation apparatus 102, proximate to or at second end 142, and extends from navigation apparatus 102 through pipe 106 and to the surface at opening 144 of pipe 106. In some embodiments, tether 149 provides at least one of power, communications, (e.g., control communications, sensor signals, video signals, etc.) and supply of a fluid for a fluid treatment to navigation apparatus 102. For example, in embodiments where navigation apparatus 102 includes a spray nozzle, tether 149 may include a fluid supply line coupled in fluid communication with the spray nozzle for providing a fluid treatment to interior surface 110 of pipe 106. In other embodiments, tether 149 and a fluid supply line may be separate independent lines coupled to body 132.

[0041] FIG. 2 shows an end view of navigation apparatus 102 within pipe 106 and in a “straight drive” mode of operation. As shown in FIG. 2, navigation apparatus includes body 132 and three arms 136 each radiating out from body 132 and towards pipe wall 108. Wheel assemblies 138 are each coupled to a respective arm 136 at distal ends thereof. In the example embodiment, navigation apparatus 102 includes three wheel assemblies 138 and three arms 136 each substantially circumferentially spaced around body 132. In other embodiments, navigation apparatus 102 includes any suitably number of wheel assemblies 138 and arms 136.

[0042] In the example embodiment, each of the wheel assemblies 138 includes a plurality of wheel segments 152 that are rotated about a rotational axis Ri, R2, R3 of the respective wheel assembly 138 to drive the navigation apparatus 102 forward within pipe 106. The wheel segments 152 are each substantially identical to one another. In the example embodiment, wheel segments 152 are discrete segments on the wheel assemblies 138 that are circumferentially spaced from one another and which collectively define adiscontinuous wheel circumference. For example, in the embodiment of FIG. 2, each of the wheel assemblies 138 include four wheel segments (three wheel segments 152 for each wheel assembly are visible in FIG. 3). The wheel segments 152 are spaced substantially circumferentially the same from one another on the wheel assemblies 138. In the example embodiments, each of the wheel assemblies 138 are tireless wheels.

[0043] The wheel segments 152 are configured to rotate around a respective rotational axis Ri, Ry R3, of the wheel assemblies 138 to drive navigation apparatus 102 within pipe 106. For example, as shown in FIG. 2, the navigation apparatus 102 is in a “straight drive mode’’, in which each of the wheel assemblies 138 drive the navigation apparatus forward in a generally constant rotational orientation within the pipe 106. Specifically, in the “straight drive mode’’ as shown in FIG. 2, the navigation apparatus 102 is driven within the pipe by rotating the wheel segments 152 about the rotational axes of their respective wheel assemblies 138, while an orientation of the wheel segments 152 on the wheel assemblies 138 is held constant (i.e., the wheel segments 152 are not spun about wheel segment axes WSi, shown in FIG. 6).

[0044] In the example embodiment, navigation apparatus 102 is operable in a second drive mode, referred to herein as a “spin drive mode”, in which the navigation apparatus 102 may be spun within the pipe 106 about a central axis Ci (extending into the page in FIG. 2) of the navigation apparatus 102. In the example embodiment, the rotational axis Ci extends longitudinally through the navigation apparatus 102 and is positioned at an approximate radially center of the pipe 106.

[0045] FIG. 3 shows navigation apparatus 102 in the “spin drive mode”. As shown in FIG. 3, navigation apparatus 102 is rotated approximately 60 degrees clockwise, in the direction of arrow 154, within pipe 106. Spinning navigation apparatus 102 within pipe 106 may be used to avoid obstructions, sensitive or low traction surfaces, or other obstacles within pipe. As an example, some pipes include a junction, such as a T-junction, the forms an opening on the interior surface of pipe 106. Spinning navigation apparatus 102 may be used to move arms 136 and / or wheel assemblies 138 out of alignment with such openings.

[0046] In the spin drive mode, each of the wheel segments 152 of at least one or more of the wheel assemblies 138 are rotated about respective rotational axes WSi (shown in FIG. 6) of the wheel segments 152. In the example of FIG. 3, all wheel segments 152 of all wheel assemblies 138 are rotated approximately 45 degrees from the “straight drive mode” shown in FIG. 2. Each of the wheel assemblies 138 may be controlled independently to have different degrees of rotation of wheel segments 152 and drive different movements of the navigation apparatus 102 within pipe. After and / or while the segments 152 are rotated, the wheel assemblies 138 are controlled to rotate the wheel segments 152 around the respective rotational axes Ri, R2, R3 of the wheel assemblies 138 to drive navigation apparatus 102 forward. In the example embodiment, the w heel segments 152 are each rotated in the spin drive mode to the orientation shown in FIG. 3 and continue driving rotation. As used herein in reference to wheel segments 152. terms such as “spin” or “spinning rotation” refer to rotation of the wheel segments 152 about respective rotational axes WSi of the wheel segments 152. Terms such as “driving rotation” with reference to the wheel segments 152 refer to orbital rotation of the wheel segments 152 around the wheel assembly 138 (i.e., rotation around rotational axes Ri, R2, R3).

[0047] FIG. 4 is a perspective view of an example wheel assembly 138 for use with the navigation apparatus 102 shown in FIGS. 1-3. As shown in FIG. 4, the wheel assembly 138 includes an axle 156, a first side gear assembly 158, a second side gear assembly 160, and a plurality of wheel segments 152 positioned between the first side gear assembly 158 and the second side gear assembly 160.

[0048] First side gear assembly 158 and second side gear assembly 160 are each coupled to, and specifically are mounted on, axle 156. First side gear assembly 158 and second side gear assembly 160 are each independently rotatable on axle 156 for spinning wheel segments 152.

[0049] Referring to FIG. 5, wheel assembly 138 includes six wheel segments 152 that each extend radially outward of the wheel assembly 138 rotational axis Ri and are spaced circumferentially around the axle 156. The wheel assembly rotational axis Ri extends through a radial center of the axle 156 of the wheel assembly 138. Each of the wheel segments 152 includes a spider gear 162, a wheel pad 164, and a neck 166 extending from the spider gear 162 to the wheel pad 164. The wheel pad 164 includes an outer segmentsurface 168 that contacts the interior wall 108 of pipe 106 (shown in FIG. 1 ), or more broadly, any other suitable drive surface, during operation. In the example embodiment, the wheel pads 164 each include treads 170 on the outer segment surface 168. In other embodiments, the wheel pads 164 may include any suitable surface traction features that enable the wheel segments 152 to operate as described herein.

[0050] As shown in FIG. 5, the first side gear assembly 1 8 and the second side gear assembly 160 are substantially the same as one another and each include a driven gear 172 and a driving gear 174. In the example embodiment, the driven gear 172 and driving gear 174 are formed as a single piece (i.e., unitarily formed). In other embodiments, driven gear 172 and driving gear 174 may be formed as distinct and separable components.

[0051] Driven gear 172 includes a plurality of circumferentially arranged driven gear teeth 176 that are oriented generally parallel to the rotational axis Ri of the wheel assembly 138. Driven gear teeth 176 are configured to mate with corresponding features (not shown) of the respective drive mechanisms 178, 180, illustrated schematically in FIG. 6.

[0052] Referring to FIG. 6, wheel assembly 138 further includes a first drive mechanism 178 and a second drive mechanism 180. First drive mechanism 178 is configured to drive rotation first side gear assembly 158 on axle and second drive mechanism 180 is configured to drive rotation of second side gear assembly 160 on axle independent of rotation of first side gear assembly 158. In some embodiments, each of the drive mechanisms 178, 180 includes a worm gear and a motor (not shown) configured to rotate the worm gear. The drive mechanisms 178, 180 are independently controllable (e.g., by controller 116 shown in FIG. 1) to independently rotate the first side gear assembly 158 and the second side gear assembly 160, respectively. The worm gears may each include threads (not shown) configured to mate with driven gear teeth 176 (shown in FIG. 5) for driving rotation of the first side gear assembly 158 and the second side gear assembly 160. In other embodiments, first drive mechanism 178 and second drive mechanism 180 include any suitable gear and motor combination that enables rotation of side gear assemblies 158, 1 0 as described herein.

[0053] As shown in FIG. 5, the driving gears 174 each include an outer sidewall 182 that flares, at least in part, radially outward from driven gear 172 to an interior end 184 of driving gear 174. A plurality of driving gear teeth 186 are arranged on the interior end 184 and extend generally radially, as described in greater detail below, relative to the rotational axis Ri of the wheel assembly 138. The driving gear teeth 186 of the first side gear assembly 158 and the second side gear assembly 160 are oriented inwards to face one another and are configured to mate with corresponding teeth 188 of the spider gears 162 of wheel segments 152.

[0054] Referring to FIG. 6, the first side gear assembly 158 and the second side gear assembly 160 are each rotatable about the axle 156 for rotating the wheel segments 152 around the axle 156 (i.e., around the wheel assembly rotational axis Ri,). The first drive mechanism 178 and second drive mechanism 180 are operable to independently rotate the first side gear assembly 158 and the second side gear assembly 1 0, respectively, to rotate wheel segments 152 about rotational axes WSi, WS2 of the wheel segments 152. In FIG. 6, a first wheel segment 190 and second wheel segment 192 are shown. A first wheel segment rotational axis W S 1 extends through the first wheel segment 190 and a second wheel segment rotational axis WS2 extends through the second wheel segment 192. The first wheel segment rotational axis WSi and the second wheel segment rotational axis WS2 are colinear in the example embodiment, as the first wheel segment 190 and second wheel segment 192 are positioned at a 180-degree offset from one another circumferentially about the axle 156.

[0055] When operating in the “straight drive mode”, the first drive mechanism 178 and the second drive mechanism 180 synchronously drive rotation of the first side gear assembly 158 and the second side gear assembly 160, respectively, such that the first side gear assembly 158 and the second side gear assembly 160 rotate on the axle 156 in the same rotational direction and at substantially the same rotational velocity. Synchronous rotation of the first side gear assembly 158 and the second side gear assembly 160 causes each of the wheel segments 152 to rotate around the wheel assembly rotational axis Ri without spinning the wheel segments 152 about their respective rotational axes WSi, WS2. During the “spin drive mode” operation, first drive mechanism 178 controls first side gear assembly 158 to rotate asynchronously (i.e., at a different rotational velocity and / or direction relative) relative second side gear assembly 160. The different rotation of first sidegear assembly 158 and second side gear assembly 160 causes each of the wheel segments 152 to spin about the respective wheel segment rotational axes WSi, WS2.

[0056] In the example embodiment, wheel assembly 138 further includes a housing 194 that includes a first housing segment 196 and a second housing segment 198 (shown in FIG. 5). As shown in FIG. 5, the first housing segment 196 and the second housing segment 198 are coupled to one another by a plurality of fasteners 200 and are positioned on the first side gear assembly 158 and the second side gear assembly 160, respectively, and for rotation therewith. When assembled, the housing 194 defines a plurality of apertures 202 (shown in FIG. 6) through which at least a portion of the wheel segments 152 extend through.

[0057] Referring to FIG. 6, wheel assembly 138 further includes a bearing assembly 204 rotatably coupling wheel segments 152 to axle 156. Beanng assembly 204 includes a first bearing lock 206 coupled to a second bearing lock 208 (e.g., by fasteners) and a bearing pad 210 positioned betw een the first bearing lock 206 and the second bearing lock 208. The bearing assembly 204 is positioned on and extends circumferentially around axle 156. The bearing assembly 204 defines a notch 212 therein that is sized to receive a proximal projection 214 of wheel segments 152, as shown in FIG. 7. Bearing assembly 204 is configured to rotatably couple wheel segments 152 to axle 156 and allow for rotation of wheel segments 152 about rotational axes WSi, WS2 of wheel segments 152.

[0058] FIG. 7 is an enlarged view of the cross section shown in FIG. 6 showing the first w heel segment 190 of the wheel assembly 138. As shown in FIG. 7, the driving gears 174 of first side gear assembly 158 and second side gear assembly 160 are engaged along a gear wheel interface 216. In particular, the driving gear teeth 186 are oriented to extend in part radially and in part axially relative to rotational axis Ri of wheel assembly 138. Spider gear teeth 188 are shaped in correspondence with driving gear teeth 186. The gear-wheel interface 216 extends along an interface axis IAi that is oriented obliquely relative to the wheel assembly rotational axis Ri and the wheel segment rotational axis WSi. The interface axis IAi and the wheel segment rotational axis WSi form an oblique interface angle, indicated at 0. The interface angle 0 is between 10 degrees and 80 degrees, betw een 15 degrees and 60 degrees, or between 20 degrees and 40 degrees. In the example embodiment, the interface angle 0 is approximately 30 degrees.

[0059] FIG. 8 shows another cross-sectional view of the wheel assembly 138 shown in FIG. 4, taken perpendicular to the cross section shown in FIG. 6. As shown in the example embodiment, each of the wheel segments 152 are arranged such that the rotational axes WSi, WS2. WS3, WS4, WS5, WSe of the wheel assembly 138 are generally perpendicular to the wheel assembly rotational axis Ri and each intersect at the wheel assembly 138 rotational axis Ri.

[0060] FIG. 9 is a schematic cross section showing an alternative wheel assembly 338 for use with the navigation apparatus 102 shown in FIGS. 1-3. The wheel assembly 338 is substantially the same as the wheel assembly 138 shown in FIGS. 4-8 except as otherwise described. In particular, in the example embodiment, each of the wheel segments 352 are oriented at an offset such that the rotational axes WSi. WS2, WS3, WS4, WS5. WS6do not intersect w ith each of the other wheel segment rotational axes and do not intersect with the wheel assembly rotational axis Ri. Additionally, driving gear teeth and spider gear teeth (not shown) of wheel assembly 338 may be configured (e.g., shaped) differently from driving gear teeth 186 and spider gear teeth 188 of wheel assembly 138 to impart rotation of the wheel segments 352 about the offset rotational axes WSi, WS2, WS3, WS4, WS5, WS6

[0061] In the example embodiment, each of the wheel segments 352 are oriented at substantially the same offset. In some embodiments, the wheel segments 352 are oriented at an increased offset such that the rotational axes WSi, WS2, WS3, WS4, WS5, WS6 do not intersect the axle 356. Each of the rotational axes WSi, WS2, WS3, WS4, WS5, WSe extend through a midpoint of the respective wheel segment 352 and are oriented generally perpendicular to interior ends 305 of the wheel segments 352.

[0062] The wheel segments 352 each include a projecting end 301 that projects radially outwards on the wheel segments 352 and an opposed recessed end 303 that is radially recessed relative to the first end 301. A spacer 311 (alternatively referred to herein as a “shield’7) extends circumferentially around the wheel assembly 338 and is shown schematically by the circle. In the example embodiment, the spacer 311 is sized and shaped such that the spacer 311 covers approximately half of the outer surface of w heel segments 352 and aligns with rotational axes WSi, WS2, WS3, WS4, WS5, WSe at an approximate midpoint of the outer surface wheel segments 352.

[0063] As shown in FIG. 9, the spacer 311 shields portions of the wheel segments 352 positioned radially within the spacer 311, such as recessed ends 303, from contacting the drive surface (i.e., interior wall 108). The projecting end 301 contacts the interior wall 108 of pipe 106 (shown in FIG. 1), while at least a portion of recessed end 303 is spaced from, and does not contact, the interior wall 108. During operation, when wheel segments 352 are rotated in the “spin drive mode”, the portion of the wheel segment 352 that is in contact with the pipe 106, and defines the projecting end 301, changes. As the wheel segment 352 is rotated and the portion of wheel segment 352 in contact with pipe changes, a thrust is created (e.g.. in the direction of into and / or out of the page in FIG. 9) and a reciprocal force is applied on the wheel segment 352 by the pipe 106 which imparts spinning motion to the navigation apparatus 102 (shown in FIG. 1).

[0064] FIGS. 10-13 show an alternative embodiment of a wheel assembly 538 for use with the navigation apparatus 102 of FIGS. 1 -3. The wheel assembly 538 is substantially the same as the wheel assembly 138, shown in FIGS. 4-8, except as described below-. In particular, the wheel segments 552 of the wheel assembly 538 do not include wheel pads 164 and instead include rollers 501 which are arranged to contact the interior w all 108 of the pipe 106 (showm in FIG. 1 ).

[0065] Referring to FIG. 10, a first wheel segment 590 includes a first roller 501. The roller 501 is configured to freely rotate about a free rotation axis FRi that extends through a first end 509 and opposed second end 511 of the roller 501. In the example embodiment, the rollers 501 each include an outer roller body 507 and an interior aperture (not shown) that receives a wheel segment axle (not shown) defining the free rotation axis FRi. The roller body 507 is rotatably mounted on the wheel segment axle. Each of the wheel segments 552 of wheel assembly 538 include substantially identical rollers 501 thereon. During operation, the rollers 501 of wheel segments 552 contact the wall 108 of pipe 106 (shown in FIG. 1). In the example embodiment rollers 501 each include a resilient material (e.g., rubber). In other embodiments, rollers may be formed of any suitable material.

[0066] In the example embodiment, each of the wheel segments 552 are rotatable about wheel segment rotation axes (e.g., similar to WSi, WS2, WSs, WS4, WS5, WS6shown in FIG. 8) in substantially the same manner as described with respect to wheel assembly 538, shown in FIGS. 4-8. Rotation of wheel segments 552 causes wheel assembly538 to change wheel configurations and / or direction of spin on navigation apparatus 102 and relative to a wheel plane. The wheel plane extends through the axle 556 and each of the wheel segments 552.

[0067] For example, as shown in FIG. 10, wheel segments 552 are each oriented in an “omni wheel configuration.” In the omni wheel configuration, wheel segments 552 are oriented such that the free rotation axis FRi of at least one of the wheel segments 552 is oriented parallel to the direction of travel 146 (shown in FIG. 1) of the navigation apparatus 102. In the omni wheel configuration, each of the wheel segments 552 are oriented generally tangentially to, and in alignment with, a rotational circumference of the wheel assembly 138 and are coplanar with the wheel plane.

[0068] Referring to FIG. 11. in the example embodiment, wheel segments 552 are each rotated from the “omni wheel” configuration shown in FIG. 10 to a “first mecanum wheel” configuration. In the example embodiment, wheel segments 552 are moved to the “first mecanum wheel” configuration by rotating the first side gear assembly 558 in a first rotational direction, indicated by the arrow 505, and rotating the second side gear assembly 560 in an opposite second rotational direction, indicated by the arrow 507. In the “first mecanum wheel" configuration, the wheel segments 552 are each oriented at an offset (e.g., about 45 degrees) relative to the wheel plane in a first rotational direction.

[0069] Referring to FIG. 12, the wheel assembly 538 is shown in a “second mecanum wheel" configuration. The wheel assembly 538 may be moved to the “second mecanum wheel” configuration from the “omni wheel” configuration by rotating the first side gear assembly 558 in the second rotational direction 507, and rotating the second side gear assembly 560 in the first rotational direction, indicated by the arrow 505. Other suitable asynchronous control of the side gear assemblies 558, 560 may be used to rotate wheel segments 552 between the “omni wheel” and “mecanum wheel” configurations. As shown in FIGS. 10-12, the wheel segments 552 are rotated in unison such that each of the wheel segments 552 is oriented substantially the same relative to the wheel plane in each configuration of the wheel assembly 538.

[0070] FIG. 13 is a flow chart of an example method 1300 for controlling the navigation apparatus 102 in a pipe 106 (shown in FIG. 1). In reference to FIGS. 1-12, method 1300 includes controlling 1302 a wheel assembly 138, 338, 538 of a navigation apparatus 102 to engage an interior wall 108 of the pipe 106. The navigation apparatus 102 includes a body 132 and an arm 136 coupled to the body 132 and extending outward therefrom to the wheel assembly 138. Method 1300 further includes controlling 1304 a first side gear assembly 158, 558 to rotate about a first rotational axis Ri extending through an axle 156, 356, 556 of the wheel assembly 138, 338, 538.

[0071] Method 1300 further includes controlling 1306 a second side gear assembly 160, 560 to rotate, independently, about the first rotational axis Ri. A wheel segment 152. 352, 552 is engaged with the first side gear assembly 158, 558 and the second side gear assembly 160, 560 . The wheel segment 152, 352, 552 defines a second rotational axis WSi and the wheel segment 152, 352, 552 is configured to both rotate in orbit around the first rotational axis Ri and to rotate about the second rotational axis WSi.

[0072] An example technical effect of the methods, systems, and apparatus described herein includes at least one of: (a) improving maneuverability of a navigation apparatus within a pipe; (b) increasing traction with the pipe; (c) improving travel distance of navigation apparatus; (d) increasing load capacity of navigation apparatus, at least in part due to the increased traction; (e) improving travel distance of navigation apparatus; (f) improving ability to traverse complex pipe geometries including obstructions or other obstacles.

[0073] Example embodiments of systems and methods for use in pipe maintenance operations are described above in detail. The methods and systems are not limited to the specific embodiments described herein, but rather, components of systems and / or steps of the methods may be utilized independently and separately from other components and / or steps described herein. For example, the method may also be used in combination with other components, and are not limited to practice only with pipes as described herein. Rather, the example embodiment can be implemented and utilized in connection with many other applications.

[0074] Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and / or claimed in combination with any feature of any other drawing.

[0075] This written description uses examples to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

WHAT IS CLAIMED IS:

1. A navigation apparatus comprising: a body; an arm coupled to said body and extending outward from said body; and a wheel assembly coupled to said arm, said wheel assembly comprising: an axle defining a first rotational axis; a first side gear assembly coupled to said axle; a second side gear assembly coupled to an axle; and a wheel segment engaged with said first side gear assembly and said second side gear assembly, said wheel segment defining a second rotational axis, wherein said first side gear assembly and said second side gear assembly are each independently rotatable about said axle, and wherein said wheel segment is configured to both rotate in orbit around the first rotational axis and to rotate about the second rotational axis.

2. The navigation apparatus of Claim 1 , wherein synchronous rotation of said first side gear assembly and said second side gear assembly causes said wheel segment to rotate in orbit around the first rotational axis and drives forward movement of said navigation apparatus within a pipe, and wherein asynchronous rotation of said first side gear assembly and said second side gear assembly causes said wheel segment to rotate about the second rotational axis to spin said navigation apparatus within the pipe.

3. The navigation apparatus of Claim 1 further comprising a first drive mechanism comprising a first motor drivingly coupled to said first side gear assembly and a second drive mechanism comprising a second motor drivingly coupled to said second side gear assembly.

4. The navigation apparatus of Claim 3, wherein said first drive mechanism and said second drive mechanism are configured to be operated synchronously in a first mode of operation to drive forward movement of said navigation apparatus within a pipe, and wherein said first drive mechanism and said second drive mechanism are configured to be operated asynchronously in a second mode of operation to spin said navigation apparatus within the pipe.

5. The navigation apparatus of Claim 1, wherein said wheel segment comprises a pad configured to contact a drive surface, and wherein said pad is oriented at an offset relative to said axle such that the second rotational axis does not intersect the first rotational axis.

6. The navigation apparatus of Claim 1. wherein said wheel segment comprises a pad configured to contact a drive surface, and wherein said pad is oriented such that the second rotational axis intersects the first rotational axis.

7. The navigation apparatus of Claim 1 wherein said first side gear assembly and said second side gear assembly each comprise a driving gear on interior ends thereof, said driving gears each comprising a plurality7of driving gear teeth, said wheel segment comprising a spider gear comprising a plurality of spider gear teeth, and wherein said spider gear teeth are interdigitated with said driving gear teeth of each of said first side gear assembly and said second side gear assembly.

8. The navigation apparatus of Claim 7, wherein said driving gear teeth are oriented to extend radially, at least in part, relative to said first rotational axis.

9. The navigation apparatus of Claim 7, wherein said driving gear teeth are engaged with said spider gear teeth along an interface, and wherein the interface is oriented at an oblique angle relative to the second rotational axis.

10. The navigation apparatus of Claim 1, wherein said yvheel segment comprises a roller, said roller pivotable in orientation based on rotation of said wheel segment about the second rotational axis.

11. The navigation apparatus of Claim 10, wherein said wheel segment comprises a first wheel segment of a plurality of wheel segments of said wheel assembly, each wheel segment of said plurality of wheel segments engaged with said first side gear assembly and said second side gear assembly and configured to rotate about a respective rotational axis.

12. The navigation apparatus of Claim 11, wherein said plurality of wheel segments are configured to rotate into a first orientation in which said wheel assembly is configured as a mecanum wheel and a second orientation in which said wheel assembly is configured as an omni wheel.

13. A wheel assembly for use with a navigation apparatus, said wheel assembly comprising: an axle defining a first rotational axis; a first side gear assembly coupled to said axle; a second side gear assembly coupled to said axle; and a wheel segment engaged with said first side gear assembly and said second side gear assembly, said wheel segment defining a second rotational axis, wherein said first side gear assembly and said second side gear assembly are each independently rotatable about said axle and said wheel segment is configured to both rotate in orbit around the first rotational axis and to rotate about the second rotational axis.

14. The wheel assembly of Claim 13. wherein synchronous rotation of said first side gear assembly and said second side gear assembly causes said wheel segment to rotate in orbit around the first rotational axis and drives forward movement of said navigation apparatus, and wherein asynchronous rotation of said first side gear assembly and said second side gear assembly causes said wheel segment to rotate about the second rotational axis to spin said navigation apparatus.

15. The wheel assembly of Claim 13 further comprising a first drive mechanism comprising a first motor drivingly coupled to said first side gear assembly and a second drive mechanism comprising a second motor drivingly coupled to said second side gear assembly.

16. The wheel assembly of Claim 15, wherein said first drive mechanism and said second drive mechanism are configured to be operated synchronously in a first mode of operation to drive forward movement of said navigation apparatus, and wherein said first drive mechanism and said second drive mechanism are configured to be operated asynchronously in a second mode of operation to spin said navigation apparatus.

17. The wheel assembly of Claim 13. wherein said wheel segment comprises a pad configured to contact a pipe, and wherein said pad is oriented at an offset relative to said axle such that the second rotational axis does not intersect the first rotational axis.

18. The wheel assembly of Claim 13. wherein said wheel segment comprises a roller, said roller pivotable in orientation based on rotation of said wheel segment about the second rotational axis.

19. A method for controlling a navigation apparatus in a pipe, said method comprising: controlling a wheel assembly of a navigation apparatus to engage an interior wall of the pipe, the navigation apparatus including a body and an arm coupled to the body and extending outward therefrom to the wheel assembly; controlling a first side gear assembly to rotate about a first rotational axis extending through an axle of the wheel assembly; and controlling a second side gear assembly to rotate, independently, about the first rotational axis, wherein a wheel segment is engaged with the first side gear assembly and the second side gear assembly, the wheel segment defining a second rotational axis, and wherein the wheel segment is configured to both rotate in orbit around the first rotational axis and to rotate about the second rotational axis.

20. The method of claim 19, wherein synchronous rotation of the first side gear assembly and the second side gear assembly causes the wheel segment to rotate in orbit around the first rotational axis and drives forward movement of the navigation apparatus within the pipe, and wherein asynchronous rotation of the first side gear assembly and the second side gear assembly causes the wheel segment to rotate about the second rotational axis to spin the navigation apparatus within the pipe.

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