Modular Mechanical Avatar Assembly for Confined Space Operations
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Solution Overview
Problem
Existing methods for performing operations in confined spaces within vehicles, such as aircraft, are either time-consuming and ergonomically challenging for human workers or require large, bulky, and expensive fully automated robot assemblies that struggle with navigation and positioning.
Innovation Solution
A mechanical avatar assembly and system that includes a rail assembly with a carriage and drive system, an articulating avatar arm with mechanical links and actuators, and an image capturing device, all remotely controlled from an operator workstation outside the confined space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If fully automated robot assemblies are used to access confined spaces, then operations can be performed automatically, but the assemblies become large, bulky, and heavy requiring additional lift equipment
Solution Approach 1:
The robot assembly is divided into multiple modular segments including a base module with drive system, articulating arm modules with individual actuators, and tool modules. Each module can be independently maneuvered through the access opening and assembled inside the confined space, avoiding the need to lift a complete heavy robot assembly into the confined area.
Solution Approach 2:
The articulating arm modules are designed to nest within each other when retracted, allowing the entire robot assembly to be compacted to a small size for insertion through the access opening. The segments can be telescoped outward once positioned, enabling the robot to expand to its full operational size inside the confined space without requiring heavy lifting equipment.
2Extent of automation
If fully automated robot assemblies are used to access confined spaces, then operations can be performed automatically, but the assemblies have difficulty navigating past support structures and positioning within the confined space
Solution Approach 1:
The robot employs dynamically articulating arm segments with multiple degrees of freedom, allowing the arm to bend and flex around stringers and stiffeners. The articulating joints enable the robot to adapt its configuration in real-time to navigate complex internal geometries and position precisely at work locations within the confined space.
Solution Approach 2:
A flexible cable system serves as an intermediary to transmit actuation forces and control signals through the articulating arm segments. The cable-driven mechanism allows remote control of each joint from outside the confined space, enabling precise positioning without requiring heavy motors or complex mechanical linkages inside the robot.
3Adaptability or versatility
If human workers access confined spaces to perform operations, then flexibility and adaptability are maintained, but the process becomes time-consuming and ergonomically challenging
Solution Approach 1:
The robot assembly is equipped with self-contained actuation systems in each articulating joint, allowing the robot to position and orient itself autonomously once deployed. The onboard sensors and control systems enable the robot to navigate and perform operations without continuous human intervention, maintaining adaptability while significantly reducing operation time compared to manual methods.
Solution Approach 2:
The robot is designed with universal tool interfaces and programmable control capabilities that allow it to perform multiple different operations including inspection, sealing, painting, and fastening. This multi-functionality replaces the need for specialized equipment for each task while maintaining the flexibility to adapt to different operation types, thereby improving productivity without sacrificing versatility.
4Extent of automation
If fully automated robot assemblies are used in spark-proof environments, then automated operations are achieved, but the cost increases due to specialized sensors and controls
Solution Approach 1:
The robot employs inherently safe pneumatic actuators and mechanical cable-driven joints instead of expensive electronic sensors and motors that would require special certification for explosive environments. These simpler mechanical components are inherently spark-proof, eliminating the need for costly specialized equipment while maintaining full automation capability.
Data Source
AI summary
There is provided a mechanical avatar assembly for use in a confined space in a structure. The mechanical avatar assembly includes a rail assembly for attachment to an access opening to the confined space. The rail assembly includes two or more rail segments coupled together to form an elongated base having a rail and a gear rack extending along a length of the elongated base. The rail assembly further includes a carriage portion coupled to the rail, and movable relative to the rail, and a drive assembly coupled to the carriage portion and to the gear rack, to move the carriage portion along the rail. The mechanical avatar assembly further includes an articulating avatar arm coupled to, and movable via, the carriage portion. The mechanical avatar assembly further includes an image capturing device.