Collaborative Robot Control for Gas Turbine Maintenance
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Solution Overview
Problem
The maintenance of gas turbine engines is time-consuming and costly due to the need for disassembly to access worn or damaged internal components, which can be efficiently addressed by enabling collaboration between physically separate robots within the engine system.
Innovation Solution
A method and apparatus for controlling at least one first robot and a second robot to collaborate within a system, where the second robot's position and orientation are determined using sensed data, and a control signal is provided to perform actions such as movement, clamping, or machining, with the first robot, utilizing three-dimensional scanners, magnetic fields, and ultrasonic waves to facilitate coordinated operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual inspection and repair methods are used, then operators can directly access and repair components, but the gas turbine engine requires time-consuming disassembly to access internal components
Solution Approach 1:
The system divides the maintenance task into two separate robotic entities: a first robot for inspection and a second robot for repair operations. This segmentation allows each robot to be optimized for its specific function and enables parallel operation, eliminating the need for time-consuming disassembly while maintaining access to internal components.
Solution Approach 2:
The patent introduces a controller as an intermediary that coordinates between the first robot, second robot, and the gas turbine engine. The controller receives sensed data from the first robot, determines appropriate repair actions, and directs the second robot to perform repairs, enabling automated maintenance without manual disassembly.
2Adaptability or versatility
If a single robot is used for both inspection and repair, then the system structure is simpler, but the robot cannot perform multiple functions simultaneously with optimal performance
Solution Approach 1:
The system separates inspection and repair functions into two distinct robots. The first robot is specialized for inspection with sensors and scanning capabilities, while the second robot is specialized for repair with manipulation tools. This functional segmentation allows each robot to be optimized for its specific task while the controller manages the overall coordination.
Solution Approach 2:
The controller serves as a universal coordinating entity that manages both the first robot and second robot, enabling the system to perform multiple functions (inspection, repair, coordination) through a single controlling intelligence. This allows functional versatility without requiring each individual robot to be universally capable of all tasks.
3Productivity
If robots are placed physically close to each other for collaboration, then coordination is easier, but the robots cannot access different areas of the engine simultaneously
Solution Approach 1:
The controller acts as an intermediary that enables coordination between physically separate robots. It receives sensed data from the first robot's position in the engine, determines appropriate repair actions, and directs the second robot to the correct location and timing for repair operations, facilitating parallel operation despite physical separation.
Solution Approach 2:
The system implements feedback through the controller receiving sensed data from the first robot about component conditions and positions. This feedback loop allows the controller to make real-time decisions about when and where the second robot should perform repair operations, enabling coordinated parallel work from different engine areas.
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
This collaboration enables efficient inspection, machining, and repair of internal components within the gas turbine engine, reducing the need for disassembly and lowering maintenance costs by allowing robots to work together optimally within the engine's complex structure.
Implementation Method 1
Controlling an emitter to emit electromagnetic waves, the sensed data being received from an electromagnetic wave sensor
Implementation Method 2
Controlling an ultrasonic transducer to emit ultrasonic waves, the sensed data being received from the ultrasonic transducer
Implementation Method 3
Controlling a magnetic transmitter arrangement to provide one or more magnetic fields, the second robot being at least partially positioned within the one or more magnetic fields, the sensed data being received from a magnetic field sensor mounted on the second robot
Data Source
AI summary
A method of controlling at least one of a first robot and a second robot to collaborate within a system, the first robot and the second robot being physically separate to one another, the method including: receiving sensed data associated with the second robot; determining position and/or orientation of the second robot using the received sensed data; determining an action for the second robot using the determined position and/or orientation of the second robot; and providing a control signal to the second robot to cause the second robot to perform the determined action to collaborate with the first robot.