Rotating Bendable Insertion Tool for 3D Path Access
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Solution Overview
Problem
Existing insertion tools face limitations in maneuvering complex tool paths due to their inability to simultaneously extend, bend, and rotate in multiple planes, making it difficult to access intricate areas within devices like jet engines.
Innovation Solution
The insertion tool incorporates a bendable section with a rotation interface, allowing the tip to extend, bend, and rotate relative to the tool's axis, enabling it to traverse curves in multiple planes, facilitated by a tensioning assembly and a rotation interface with a cam and follower mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional rigid insertion tool is used, then the tool structure is simple and easy to manufacture, but the tool cannot reach difficult areas with complex geometries
Solution Approach 1:
The insertion tool is divided into multiple rigidizable links connected by nonplanar hinges, allowing each segment to independently adjust its orientation. This segmentation enables the tool to navigate complex 3D paths and access difficult areas while maintaining a relatively simple overall structure compared to fully articulated robotic tools.
Solution Approach 2:
The tool transitions from a static rigid structure to a dynamic system where links can be rigidized at specific orientations using a tensioning assembly. This dynamic capability allows the tool to adapt its shape and path in real-time during insertion, enabling access to complex geometries without requiring an overly complex mechanical structure.
2Adaptability or versatility
If the tool tip is made rigid for stability, then the tool provides good structural stability, but the tool cannot bend and rotate in multiple planes to follow complex paths
Solution Approach 1:
The tool employs a dynamic rigidification mechanism where links transition from flexible to rigid states based on operational requirements. During insertion, links remain flexible to allow bending and rotation in multiple planes, while the tensioning assembly can rigidize specific links to provide structural stability when needed, thus resolving the contradiction between adaptability and stability.
Solution Approach 2:
Different portions of the tool have different mechanical properties - the proximal portion maintains flexibility for maneuvering, while distal portions can be locally rigidized through the tensioning assembly to provide stability during inspection or servicing operations. This local differentiation of mechanical properties allows simultaneous achievement of both adaptability and stability.
3Adaptability or versatility
If a planar bending mechanism is used, then the tool structure is simple, but the tool cannot traverse curves in multiple planes (3D paths)
Solution Approach 1:
The tool employs nonplanar (asymmetric) hinges instead of conventional planar joints, allowing links to rotate about axes that are not confined to a single plane. This asymmetric joint design enables 3D path traversal by combining rotations in multiple planes, achieving complex spatial maneuvering without requiring a fully robotic 6-DOF mechanism.
Solution Approach 2:
The patent merges the bending and rotating functions into a single nonplanar hinge mechanism, eliminating the need for separate planar bending joints and rotation joints. This combined mechanism achieves 3D path capability through a more compact and less complex structure compared to using multiple independent planar joints to achieve the same motion.
4Manufacturing precision
If the tool is designed for precise positioning, then the tool achieves accurate inspection and servicing, but the tool cannot maneuver through confined spaces with limited access
Solution Approach 1:
The segmented link structure with nonplanar hinges allows the tool to navigate confined spaces by flexing and reconfiguring its shape, while the tensioning assembly can then rigidize the appropriate segments to achieve precise positioning. This two-stage process (maneuvering in flexible state, then rigidizing for precision) resolves the contradiction between maneuverability and positioning accuracy.
Solution Approach 2:
The tool performs preliminary maneuvering in a flexible state to reach confined spaces, then uses the tensioning assembly to rigidize the path and position the tip accurately. This preliminary action of flexible insertion followed by rigidification ensures both ease of operation in confined spaces and manufacturing precision for inspection and servicing.
Data Source
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AI summary
An insertion tool (100) includes a housing (106), an elongated section (108) at least partially within the housing (106), a bendable section (120) coupled to the elongated section (108), and an actuator (102). The actuator (102) is configured to actuate the bendable section (120), via causing an axial displacement (154) of the elongated section (108) within the housing (106), from a retracted state at least partially positioned within the housing (106) to an extended state outside of the housing (106). The insertion tool (100) also includes a tensioning assembly (112) configured to tension the bendable section (120) into a predefined shape in the extended state. The elongated section (108) is coupled to the housing (106) via a rotation interface (104) configured to cause a rotation (162) of the bendable section (120) during the actuation of the bendable section (120) from the retracted state to the extended state.