Network architecture for remote robot with interchangeable tools

• US 20060074525A1
• Filed: 10/01/2004
• Published: 04/06/2006
• Est. Priority Date: 10/01/2004
• Status: Active Grant

• Current Assignee: RedZone Robotics, Inc.
• Original Assignee: RedZone Robotics, Inc.
• Inventors: Close, Eric, Slifko, Adam, Hudson, Edison T., Genise, Ronald G.
• Granted Patent: US 7,720,570 B2
• Time in Patent Office: Days
• US Class Current: 700/245
• CPC Class Codes: B25J 9/1617 Cellular, reconfigurable manipulator, e.g. cebot
• CPC Class Codes: G05B 2219/33189 Optical, glass fiber
• CPC Class Codes: G05B 2219/33192 Radio link, wireless
• CPC Class Codes: G05B 2219/40099 Graphical user interface for robotics, visual robot user interface
• CPC Class Codes: G05B 2219/45233 Repairing pipelines, tubes

Abstract

Systems, methods and devices for the remote control of a robot which incorporates interchangeable tool heads. Although applicable to many different industries, the core structure of the system includes a robot with a tool head interface for mechanically, electrically and operatively interconnecting a plurality of interchangeable tool heads to perform various work functions. The robot and tool head may include several levels of digital feedback (local, remote and wide area) depending on the application. The systems include a single umbilical cord to send power, air, and communications signals between the robot and a remote computer. Additionally, all communication (including video) is preferably sent in a digital format. Finally, a GUI running on the remote computer automatically queries and identifies all of the various devices on the network and automatically configures its user options to parallel the installed devices. Systems according to the preferred embodiments find particular application in the pipeline arts. For example, interchangeable tool heads may be designed to facilitate inspection, debris clearing, cleaning, relining, lateral cutting after relining, mapping, and various other common pipeline-related tasks.

Claims

1. A robotic control system, comprising:

a robot that includes an attachment interface;

an attachment coupled to said robot by said attachment interface, wherein said attachment is interchangeable with a plurality of additional attachments of different types, wherein said robot and/or said attachment include a plurality of sensors and/or control devices;

a computer located remote from said robot; and

a communications network which transfers digitized information from said plurality of sensors and control devices to said remote computer.

2. The control system of claim 1, wherein said attachment is a tool head.

3. The control system of claim 1, wherein said attachment is a sensor.

4. The control system of claim 1, wherein said communications network is wireless.

5. The control system of claim 1, wherein said communications network is wired.

6. The control system of claim 5, further comprising:

an umbilical cable interconnecting said remote computer to said robot such that all resources required to operate said attachment exist in said umbilical cable.

7. The control system of claim 6, wherein said umbilical cable includes electrical power lines.

8. The control system of claim 6, wherein said umbilical cable includes pneumatic air lines.

9. The control system of claim 1, further comprising:

a software system that automatically enumerates and identifies each of said plurality of sensors and control devices and which automatically configures a graphical user interface running on said remote computer to include a corresponding interface for monitoring and controlling each of said sensors, control devices and tool heads.

10. The system of claim 1, wherein said plurality of sensors includes at least one imaging sensor, further wherein said communications network conveys continuous video data from said sensor that has been digitized at or near said imaging sensor.

11. The system of claim 1, further comprising:

a second remote computer, wherein said communications network further transfers data from said second remote computer to said robot.

12. The system of claim 1, wherein said communications network transmits data according to IEEE-1394a, IEEE-1394b, Firewire, IEEE P802.3z Gigabit Ethernet, ad USB 2.0.

13. The system of claim 1, wherein said plurality of sensors includes a sensor for modeling a pipe.

14. The system of claim 13, wherein said sensor for modeling a pipe is a laser.

15. The system of claim 1, wherein said sensors indicate the state of the robot relative to a gravity field in a pipe, said sensors including tilt and incline sensors.

16. The system of claim 2, wherein said tool head is capable of performing a pipeline rehabilitation function selected from the group consisting of cutting, inspecting, marking, cleaning, mapping, spraying, pumping, vacuuming, and sealing.

17. The system of claim 1, wherein a functionality of said plurality of sensors is selected from the group consisting of observing, guiding, digitizing, and encoding.

18. The system of claim 1, wherein said robot incorporates sensors that indicate the state of an environment within and outside of the robot and attachment, said state selected from the group consisting of pressure, temperature, humidity and flow.

19. The system of claim 1, wherein said robot incorporates sensors that monitor the state of the electrical and mechanical systems of the robot and attachment, said state selected from the group consisting of voltage and current of a robot power supply, motor drivers, encoder positions, travel sensors, payout sensors, digital I/O, and analog I/O.

20. The system of claim 1, wherein said communication network is fiber optic.

21. The system of claim 1, wherein said communications network is wire-based.

22. A method of performing rehabilitation on a pipeline including a main pipe and at least one feature of interest in said main pipe, comprising the steps of:

inserting a robotic device into said main pipe;

using said robotic device to mark the location of said at least one feature of interest with a marking device; and

using said robotic device to sense said marking device from within said main pipe.

23. The method of claim 22, wherein said marking device can be sensed by an electromagnetic method.

24. The method of claim 22, further comprising the step of:

relining said main pipe, said relining step obscuring a line of sight between said robot and said marking device.

25. The method of claim 23, wherein said electromagnetic methods include magnetics, radio frequency (RF), light, radiation, thermal, and/or eddy current.

26. The method of claim 23, wherein said at least one feature of interest is marked by at least two marking devices, said marking devices being placed relative to said feature of interest.