Climbing Track Robot Suspension for Surface Adaptability

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Solution Overview

Problem

Existing mobile climbing systems for inspecting ferrous structures face challenges in accommodating surface irregularities, distributing adhering forces effectively, and minimizing parasitic motions in inspection transducers, leading to safety hazards, increased costs, and reduced inspection efficiency.

Innovation Solution

A climbing endless track vehicle with a multi-link suspension apparatus and a reconfigurable transducer manipulator that distributes climbing loads optimally and isolates undesirable motions, allowing the system to operate on flat, inverted, and vertical surfaces while carrying nondestructive examination tools.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual inspection is performed by trained technicians, then inspection quality and reliability are maintained, but safety hazards increase and inspection costs rise

Engineering Contradiction:

Improveinspection qualityVSAvoidsafety hazards

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent creates a robotic replica of the inspection process that copies the functions performed by human technicians. The mobile climbing vehicle carries nondestructive examination tools and can perform inspections in hazardous environments, effectively copying the inspection capability without the safety risks associated with human operators working at heights or in dangerous conditions.

Inventive Principle:

Principle #26Copying

2Stability of the object's composition

If rigid track guides are used to constrain the endless track, then structural stability is improved, but adaptability to non-uniform climbing surfaces deteriorates

Engineering Contradiction:

Improvestructural stabilityVSAvoidsurface adaptability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent employs a flexible endless track system that can conform to non-uniform climbing surfaces. The track is designed to be flexible enough to adapt to surface irregularities while maintaining its structural integrity, allowing the vehicle to climb various surfaces without requiring rigid guides that would limit adaptability.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The endless track system incorporates dynamic elements that allow it to adjust its configuration in response to varying surface conditions. The track can flex and adapt its shape dynamically as the vehicle moves across different geometries, maintaining both stability and adaptability through controlled flexibility.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If magnets are placed on a track without guide or mechanism between end wheels, then ease of manufacture is improved, but climbing force distribution deteriorates due to localized loads

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidclimbing force distribution

Core Design Contradiction:

Ease of manufactureVSForce

Solution Approach 1:

The patent introduces an intermediary mechanism between the magnets and the track structure that distributes climbing forces more effectively. This intermediary element acts as a force-distributing component that prevents localized loading on individual magnets while maintaining the simple trackless configuration, thereby improving force distribution without significantly complicating manufacturing.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables remote and safer inspections with improved payload-to-weight ratio, enhanced surface adaptability, and reduced control requirements, facilitating efficient and reliable inspections across various structural geometries.

Implementation Method 1

Wheeled or endless track devices that make use of magnetic forces include the following. U.S. Pat. Nos. 3,764,777, 5,853,655, 6,627,004, 5,809,099 and Fisher, Tache and Siegwart (2008) show variations of climbing vehicles with magnetic wheels

Methodology Applied

Scientific EffectMagnetic forces: Magnetism

Implementation Method 2

Wheeled or endless track devices making use of vacuum pressure include the following. U.S. Pat. Nos. 7,520,356 and 7,076,335 show vehicles that use wheels or endless tracks with the vacuum seal devices attached to the frame of the vehicle

Methodology Applied

Scientific EffectVacuum pressure forces: Vacuum

Data Source

PatentUS10315715B2Mobile, climbing endless track robotic system to perform remote inspections on structures

Publication Date: 2019.06.11 BEARD JAMES

AI summary

An endless-track type mobile climbing vehicle containing a suspension apparatus, transducer manipulator and surface cleaning system to perform non-destructive examination of structures while traversing the structure in all positions. The invention is able to conform to large range of irregularities of the climbing surface while maintaining contact between the track and adhering members and uniformly distributing the climbing loads on the adhering members giving the system a high payload to weight ratio. The invention is moves the inspection transducer over the surface while maintaining correct alignment of the tool relative to the surface. The invention allows an operator to perform an inspection on structures that require cleaning or other preparation prior to inspection. The invention allows an operator to perform an inspection remotely.