Compact magnetic crawler vehicle with anti-rocking supports

• US 10,343,276 B2
• Filed: 07/12/2017
• Issued: 07/09/2019
• Est. Priority Date: 07/12/2017
• Status: Active Grant

• Current Assignee: Saudi Arabian Oil Company (Government of Saudi Arabia)
• Original Assignee: Saudi Arabian Oil Company (Government of Saudi Arabia)
• Inventors: Carrasco Zanini, Pablo, Abdellatif, Fadl, Arab, Abdullah, Parrott, Brian
• Primary Examiner(s): Hurley, Kevin
• Application Number:
  US15/647,332
• Publication Number:
  US 20190015971A1
• Time in Patent Office: 727 Days
• CPC Class Codes: B25J 5/007 mounted on wheels
• CPC Class Codes: B60B 19/006 Magnetic wheels
• CPC Class Codes: B62D 53/028 Having only coupling joints other than directional articulated frames B62D21/186 and B62D55/10
• CPC Class Codes: B62D 57/024 specially adapted for moving on inclined or vertical surfaces endless-track vehicles for ascending or descending stairs B62D55/075; hand-carts with provision for travelling up or down stairs B62B5/02
• CPC Class Codes: B62D 57/028 having wheels and mechanical legs B62D57/024 takes precedence; ground-engaging vehicle fittings for supporting, lifting or manoeuvring the vehicle, wholly or in part B60S9/00
• CPC Class Codes: G01N 29/34 Generating the ultrasonic, sonic or infrasonic waves , e.g. electronic circuits specially adapted therefor

Abstract

A robotic vehicle for traversing surfaces is provided. The vehicle is comprised of a chassis supporting a magnetic drive wheel for driving and steering the vehicle and a stabilization mechanism. The magnetic wheel comprises two flux concentrator yokes and an axially magnetized hub extending therebetween. The hub includes a central housing configured to house a sensor probe and enhance the magnetic pull force of the wheel by providing a continuous pathway of high magnetic permeability material for magnetic flux to flow axially through the drive wheel. The stabilization mechanism comprises a front and rear facing support element moveably coupled to the chassis and configured to contact the surface and move symmetrically relative to the chassis thereby maintaining the vehicle and probe normal to the surface and providing stability to the vehicle while traversing surfaces regardless of surface curvature and vehicle orientation.

Claims

1. A magnetic robotic crawler vehicle for traversing a surface, comprising:

a chassis;

a magnetic drive wheel mounted to the chassis, wherein the drive wheel extends in a lateral direction and comprises;

two spaced apart flux concentrating yokes that rotate about a rotational axis and are configured to be driven independently thereby driving and steering the vehicle along the surface, wherein a longitudinal axis of the vehicle extends perpendicularly to the lateral, rotational axis in a front and back direction and through the midpoint between the two yokes; and

an axially magnetized hub extending laterally between the two yokes; and

a stabilization mechanism coupled to the chassis, the stabilization mechanism comprising;

a first and a second support element configured to contact and move along the surface during normal operation of the vehicle, the first and second support elements being positioned on opposite sides of the drive wheel relative to the rotational axis, and wherein the first and second support elements are positioned symmetrically with respect to the longitudinal axis; and

a support mechanism moveably coupling the first and second support elements to the chassis, wherein the support mechanism is configured to move the first and second support elements relative to the chassis in at least an up and down direction, wherein the up and down direction is generally perpendicular to both the longitudinal axis and the rotational axis,

wherein the support mechanism is passive in nature and moves the first and second support elements in the up and down direction in response to a curvature of the surface thereby maintaining the first and second support elements in contact with the surface.

2. The magnetic robotic crawler vehicle of claim 1, wherein the axially magnetized hub comprises:

one or more axially magnetized magnets; and

a housing extending along the rotational axis,

wherein the housing is shaped to define open chamber therein and at least one opening, wherein the chamber is provided at the midpoint between the two yokes and wherein the housing has a fixed position relative to the yokes such that the at least one opening faces downward toward the surface during normal operation of the vehicle.

3. The magnetic robotic crawler vehicle of claim 2, wherein the a housing comprises a ferromagnetic material and includes a left wall, an opposing right wall and a one or more lateral walls extending therebetween along the rotational axis, the walls of the housing being shaped to define the chamber and the one or more lateral walls being shaped to define the at least one opening therethrough.

4. The robotic vehicle of claim 3, further comprising:

a sensor probe assembly disposed at least partially within the chamber; and

a sensor support moveably coupling the sensor probe assembly to one or more of the housing and the chassis, wherein the sensor support assembly is configured to passively move the probe assembly relative to the housing in at least the up and down direction in response to the curvature of the surface thereby maintaining the probe assembly in contact with the surface.

5. The magnetic robotic crawler vehicle of claim 4, wherein the sensor probe assembly comprises:

a dry coupled wheel probe configured to passively roll generally in a direction of travel of the vehicle along the surface.

6. The magnetic robotic crawler vehicle of claim 5, wherein the sensor support comprises one or more shafts supporting an axle of the wheel probe and being coupled to one or more of the housing and the chassis by at least one mount, wherein the at least one mount is configured to allow the one or more shafts to move relative to the housing in at least the up and down direction;

and

one or more spring elements configured exert a force between at least the sensor probe assembly and one or more of the chassis and the housing, and wherein the force urges the wheel probe downward through the at least one opening of the housing and into contact with the surface.

7. The magnetic robotic crawler vehicle of claim 1, wherein the first and second support elements are equidistant from the rotational axis of the drive wheel, and wherein the first and second support elements are one or more of:

positioned in line with the longitudinal axis of the vehicle, and evenly spaced apart from the longitudinal axis on opposite sides thereof.

8. The magnetic robotic crawler vehicle of claim 1, wherein the stabilization mechanism includes one or more linkages mechanically coupling the first and second support elements, wherein the one or more linkages are configured to move the first and second support elements symmetrically relative to the drive wheel in at least the up and down direction thereby maintaining the first and second support elements in contact with the surface and the vehicle substantially normal to the surface.

9. The magnetic robotic crawler vehicle of claim 8, wherein the one or more linkages are configured to move the first and second support elements symmetrically relative to the drive wheel in the front and back direction and in the up and down direction such that the first and second stabilization elements move along a respective curved path.

10. The magnetic robotic crawler vehicle of claim 8, the further comprising:

one or more spring elements configured to exert a force between at least one of the one or more linkages and one or more of the chassis, the drive wheel and another linkage, wherein the force urges the front and rear support elements into contact with the surface thereby urging the first chassis sections into a normal position relative to the surface.

11. The magnetic robotic crawler vehicle of claim 4, wherein the stabilization mechanism includes one or more linkages mechanically coupling the first and second support elements and is configured to move the first and second support elements symmetrically relative to the drive wheel in one or more directions, wherein the stabilization mechanism is configured to maintain a prescribed relationship between the motion of the first and second support elements and the motion of the probe assembly in the up and down direction.

12. The magnetic robotic crawler vehicle of claim 1, wherein the support mechanism comprises a first linkage supporting the first support element and a second linkage supporting the second support element, wherein the first and second linkages are moveably coupled to the chassis by one or more mounts, and wherein the first and second linkages are mechanically coupled so as to synchronize the motion of the first and the second support elements in at least one direction relative to the chassis thereby maintaining the first and second support elements in contact with the surface and the vehicle substantially normal to the surface.

13. The magnetic robotic crawler vehicle of claim 12, wherein the one or more mounts are selected from the group consisting of:

a linear bearing configured to allow one of the first and second linkages to slide linearly with respect to the chassis in one or more directions, and

a pivot configured to allow the one of the first and second linkages to rotate about the pivot.

14. The magnetic robotic crawler vehicle of claim 13, wherein the first and second linkages are rigidly joined together such that the first and second support elements move in parallel.

15. The magnetic robotic crawler vehicle of claim 13, wherein the first and second linkages are mechanically coupled using one or more spur gears configured to synchronize the motion of the first and second support elements in one or more directions relative to the chassis and in one or more directions relative to each other.

16. The magnetic robotic crawler vehicle of claim 1, further comprising:

one or more position sensors attached to one or more of the stabilization mechanism, the chassis and the drive wheel and configured to measure a relative position between the stabilization mechanism and either the drive wheel or the chassis; and

a processor configured to calculate, based on a known geometry of the stabilization mechanism and the drive wheel and the relative position measured using said one or more sensors during execution of a prescribed maneuver of the robotic crawler vehicle on the surface, one or more of;

a) an orientation of the robotic crawler vehicle relative to the surface based on a known geometry of the surface, and b) a curvature of the surface.

17. The robotic crawler vehicle of claim 4, further comprising:

one or more position sensors attached to one or more of the sensor probe assembly, the chassis and the drive wheel, wherein the one or more position sensors are configured to measure a relative position between the sensor probe assembly and the drive wheel; and

a processor configured to calculate, based on a known geometry of the sensor probe assembly and the drive wheel and the relative position measured using said one or more sensors during execution of a prescribed maneuver of the robotic crawler vehicle on the surface, one or more of;

a) an orientation of the robotic crawler vehicle relative to the surface based on a known geometry of the surface, and b) a curvature of the surface.

18. A magnetic robotic crawler vehicle for traversing a surface, comprising:

a chassis;

a magnetic drive wheel mounted to the chassis, wherein the drive wheel extends in a lateral direction and comprises;

two spaced apart flux concentrating yokes that rotate about a rotational axis and are configured to be driven independently thereby driving and steering the vehicle along the surface, wherein a longitudinal axis of the vehicle extends perpendicularly to the rotational axis in a front and back direction and through the midpoint between the two yokes; and

an axially magnetized hub extending laterally between the two yokes; and

a stabilization mechanism coupled to the chassis, the stabilization mechanism comprising;

a first and a second support element configured to contact and move along the surface during normal operation of the vehicle, the first and second support elements being positioned on opposite sides of the drive wheel relative to the rotational axis, wherein the first and second support elements are positioned symmetrically across the rotational axis of the drive wheel and are positioned symmetrically with respect to the longitudinal axis;

a support mechanism moveably coupling the first and second support elements to the chassis, wherein the support mechanism is configured to move the first and second support element relative to the chassis in at least an up and down direction, wherein the support mechanism is configured to move the first and second support elements in a passive manner in the up and down direction in response to a curvature of the surface thereby maintaining the support elements in contact with the surface.

19. The robotic vehicle of claim 18, the axially magnetized hub comprising:

one or more axially magnetized magnets; and

a housing shaped to define an open chamber therein and at least one opening through the housing that faces the surface during normal operation, wherein the chamber is provided at the midpoint between the two yokes and has a fixed position relative to the chassis,

wherein the housing includes a left wall, a right wall and a one or more sidewalls extending therebetween, wherein the left wall and the right wall are each adjacent to a wheel component.

20. The robotic vehicle of claim 18, wherein the a housing is composed of a ferromagnetic material, and includes a left wall, a right wall and a one or more sidewalls extending therebetween, the one or more sidewalls having the at least one opening therethrough.

21. A magnetic robotic crawler vehicle for traversing a surface, comprising:

a chassis;

a magnetic drive wheel mounted to the chassis, wherein the drive wheel extends in a lateral direction and comprises;

two spaced apart flux concentrating yokes that rotate about a rotational axis and which are configured to be driven independently thereby driving and steering the vehicle along the surface, wherein a longitudinal axis of the vehicle extends perpendicularly to the rotational axis in a front and back direction and through the midpoint between the two yokes,

an axially magnetized hub extending laterally between the two yokes including,

one or more axially magnetized magnets, and

a housing composed of a ferromagnetic material and including a left wall, an opposing right wall and a one or more lateral walls extending therebetween along the rotational axis, the walls of the housing being shaped to define an open chamber therein and the one or more lateral walls being shaped to define at least one opening therethrough, wherein the chamber is provided at the midpoint between the two yokes and wherein the housing has a fixed position relative to the yokes such that the at least one opening faces downward toward the surface during normal operation of the vehicle; and

a sensor probe assembly disposed at least partially within the chamber, the sensor probe assembly comprising;

a dry coupled wheel probe configured to passively roll generally in a direction of travel of the vehicle along the surface, and

a sensor support moveably coupling the wheel probe to one or more of the housing and the chassis, wherein the sensor support assembly is configured to passively move the wheel probe relative to the housing in at least an up and down direction in response to the curvature of the surface thereby maintaining the probe in contact with the surface during normal operation of the vehicle; and

a stabilization mechanism coupled to the chassis, the stabilization mechanism comprising;

a first and a second support element configured to contact and move along the surface during normal operation of the vehicle, the first and second support elements being positioned on opposite sides of the drive wheel relative to the rotational axis, wherein the first and second support elements are positioned symmetrically across the rotational axis of the drive wheel and are positioned symmetrically with respect to the longitudinal axis, and

a support mechanism moveably coupling the first and second support elements to the chassis, wherein the support mechanism is configured to move the first and second support element relative to the chassis in at least the up and down direction, wherein the support mechanism is passive in nature and moves the first and second support elements in at least the up and down direction in response to a curvature of the surface thereby maintaining the first and second support elements in contact with the surface.

22. The magnetic robotic crawler vehicle of claim 21, wherein the sensor support comprises one or more shafts supporting an axle of the wheel probe and being coupled to one or more of the housing and the chassis by at least one mount, wherein the at least one mount is configured to allow the one or more shafts to move relative to the housing in at least the up and down direction;

and

one or more spring elements configured exert a force between at least the sensor probe assembly and one or more of the chassis and the housing, and wherein the force urges the wheel probe downward through the at least one opening of the housing and into contact with the surface.

23. The magnetic robotic crawler vehicle of claim 21, wherein the first and second support elements are positioned equidistant from the rotational axis of the drive wheel, and one or more of:

in line with the longitudinal axis of the vehicle, and evenly spaced apart from the longitudinal axis on opposite sides thereof.

24. The magnetic robotic crawler vehicle of claim 21, wherein the stabilization mechanism comprises:

one or more linkages mechanically coupling the first and second support elements, wherein the one or more linkages are configured to move the first and second support elements symmetrically relative to the drive wheel in at least the up and down direction; and

one or more spring elements configured exert a force between at least one of the one or more linkages and one or more of the chassis, the drive wheel and another linkage, and wherein the force urges the front and rear support elements into contact with the surface thereby urging the first chassis sections into a normal position relative to the surface.