Submersible robotically operable vehicle system for infrastructure maintenance and inspection

• US 20120215348A1
• Filed: 02/19/2011
• Published: 08/23/2012
• Est. Priority Date: 02/19/2011
• Status: Active Grant

• Current Assignee: Richard Arthur Skrinde
• Original Assignee: Richard Arthur Skrinde
• Inventors: Skrinde, Richard Arthur
• Granted Patent: US 8,805,579 B2
• Time in Patent Office: Days
• US Class Current: 700/245
• CPC Class Codes: B08B 9/049 having self-contained propelling means for moving the cleaning devices along the pipes , i.e. self-propelled
• CPC Class Codes: B25J 11/008 Manipulators for service tasks
• CPC Class Codes: B25J 11/0085 Cleaning
• CPC Class Codes: B25J 3/00 Manipulators of master-slave type, i.e. both controlling unit and controlled unit perform corresponding spatial movements
• CPC Class Codes: B25J 9/0084 comprising a plurality of manipulators
• CPC Class Codes: B25J 9/08 characterised by modular constructions
• CPC Class Codes: B25J 9/163 learning, adaptive, model based, rule based expert control
• CPC Class Codes: B25J 9/1661 characterised by task planning, object-oriented languages
• CPC Class Codes: B25J 9/1676 Avoiding collision or forbidden zones
• CPC Class Codes: B25J 9/1689 Teleoperation
• CPC Class Codes: F16L 2101/12 Cleaning
• CPC Class Codes: F16L 55/32 being self-contained
• CPC Class Codes: Y10S 901/05 Machine driven lead through

Abstract

A configurable robotic apparatus and system is disclosed that is remotely operable in difficult, hazardous, subterranean, or submerged environs. The apparatus merges diverse disciplines to effect inspecting, cleaning, treating, repairing or otherwise maintaining a wide variety of materials and conditions. Deployment environments include power, municipal water and wastewater plants, surface and submerged infrastructures (pipes, lines, conduits), and like industrial applications. Extensible and articulating modules, configurable through standardized and interchangeable connectors, provide unique flexibility, scalability and versatility to accommodate a wide range of shapes, surfaces, and obstacles. In-module intelligence and instrumentation eliminates the need for constant manual control through autonomous operation capable of simultaneous optimization and synchronization of multiple work processes, but manual override and remote control is provided to overcome unanticipated limitations. Benefits include improved efficiency, cost, and safety over prior art. High-performance, one-pass operation reduces facility downtime while incorporating environmentally responsible debris recovery.

Claims

1. An apparatus for inspecting, cleaning, and maintaining a work surface, said apparatus comprising:

a plurality of interconnected modules, including at least;

a frame module comprising;

a proximal end, a center, and a distal end, with each end able to separately flex and twist with respect to the center;

external connection means for connecting to an umbilical and a debris line;

signal aggregating and distributing means for aggregating and distributing signals to a plurality of interchangeable modules via a bus;

power distribution means for distributing power to the plurality of interchangeable modules;

inter-module connection means for connecting mechanically to the plurality of interchangeable modules and for conveying power and signals via the bus, said inter-module connection means being mediated by standardized interfaces; and

,

means for detecting and monitoring the configuration, identification, status, connection, resource requirements, and functional capabilities of the plurality of connected modules;

a shoulder module means for controllable rotation around a central axis and having interface means for interconnection to the plurality interchangeable modules;

an articulation module means configurable for any combination of controllable extension, radial orientation, multi-axis articulation, and structural bracing;

a hand module means for controllably connecting to any of a plurality of interchangeable tools comprising a propulsion tool for providing controllable propulsion means to the apparatus, a debris removal tool for providing means to controllably remove material from a surface, a debris recovery tool for providing means to controllably recover debris from area of the surface, and an inspection tool providing sensor means to sense the environment of the apparatus;

each of said plurality of connected modules further comprising;

an embedded intelligence means;

means for sending signals descriptive of identification, configuration, status, and functional capabilities to any other module to which it is connected;

means for interconnecting resources and signals;

means for sensing position, orientation, and motion responsive to control signals; and

,

means for obstacle avoidance;

said frame module having means for controllably coordinating the motion and functions of, and signals produced by sensors within, the plurality of interchangeable modules;

said umbilical;

connected to a remote control means; and

.

providing power to and control signals both to and from the frame module;

said debris line connected to debris removal means for removing debris from the environment of the apparatus;

said remote control means providing the ability to monitor and control the position, orientation, movement and functions of the apparatus; and

,

said frame module having the means for autonomously navigation, inspection, and remediation of the work surface via control and coordination of the plurality of interchangeable modules and the debris removal means.

2. The apparatus of claim 1 further comprising:

means for stably positioning the frame module with respect to the work surface.

3. The apparatus of claim 1 further comprising the steps of:

stabilizing the position of the umbilical and the debris line with respect to the work surface;

undocking the frame module from the umbilical and debris line;

performing a function under autonomous control of the frame module;

docking the frame module to the umbilical and debris line; and

,

subsequent to the step of docking, moving the position of the umbilical and the debris line with respect to the work surface.

4. The apparatus of claim 1 further comprising:

downloading from the remote control means to at least one specific module a control template means for translating high-level operational command strings into a correlated set of low-level command streams targeted to a specific module, the specific module being connected to the frame module.

5. The apparatus of claim 1 further comprising:

downloading from the remote control means to at least one specific module a control template means for translating between internal signals from a sensor in the specific module to a data format for inter-module communication and for communication to the remote control means, the specific module being connected to the frame module.

6. The apparatus of claim 1 wherein the embedded intelligence means and the remote control means are integrated in a distributed control system (‘

DCS’

), said DCS further comprising;

computing means for each of a plurality of modules to acquire signals from sensors and control actuators;

computing means for each SROV to monitor, control, and coordinate signals from sensors and to actuators within the plurality of modules; and

,

computing means for remote control, monitoring, and coordination the functionality of multiple simultaneously deployed instances of the apparatus.

7. The apparatus of claim 6 wherein the DCS further comprises:

means for registering, and acquiring data from, a plurality of sensors;

means for detecting, registering, and controlling a plurality of actuators;

means for developing plans and responses to data about surface and infrastructure conditions, said plans comprising positioning and orientations commands;

means for navigating the apparatus and the plurality of modules responsive to position and orientation signals;

means for detecting and controlling the position and orientation of the apparatus and the plurality of modules;

means for coordination and control of debris removal, recovery, and reclamation;

means for designing, storing, retrieving, and executing solution patterns, control templates, and work processes; and

,

means for human-operable interface for design and operation.

8. The apparatus of claim 7 wherein the interface means integrates into a overlaid output a combination of sensor data, simulation of the movement of the apparatus, and previously recorded data.

9. An apparatus for any of inspecting, cleaning, repairing, or maintaining a constructed surface which is not open for human access during normal operation, said surface being any of submersed, buried, and interior to a structure, said apparatus comprising:

an Operations Center (‘

OC’

) having a network, and a human-usable monitoring and operations station;

a Mobilization Platform (‘

MP’

), connected to the OC through the network, having at least one distal Plug, at least one umbilical connecting to said MP through said at least one umbilical, and at least one monitoring and operational control station for said at least one umbilical;

said umbilical providing both extension of a network among the OC and the MP for communication to and from the SROV, and power from the MP to the SROV;

at least one Submersible Robotically Operable Vehicle (‘

SROV’

), connected via a proximal Socket on the SROV through said at least one umbilical to said MP'"'"'s distal Plug, said SROV further being comprised of

a Bus connecting to said network and said power via said umbilical to the MP,

said Bus further connecting within the SROV to;

at least one actuator;

at least one sensor for the external environment;

at least one sensor for the SROV'"'"'s internal status;

at least one embedded intelligence, further comprising;

at least one logic processing unit;

memory; and

, programming concerning the SROV'"'"'s operational status and goals;

a frame module with at least one proximal Plug, at least one distal Socket, a proximal end, a center, and a distal end, with each end able to separately flex and twist with respect to the center, said Bus connecting the proximal Socket to the distal Plug and thus with said umbilical and MP;

a shoulder module with a controllably rotating frame around a central shaft, at least one proximal Plug and at least one distal Socket, a Bus connecting said proximal Plug to said distal Socket and thus connecting with said Bus and said frame module;

at least one proximal Plug for the SROV; and

,

at least one modular component connected via a proximal Plug on the modular component to the SROV'"'"'s distal Socket, said at least one modular component further comprising;

a device for inspecting, cleaning, repairing, or maintaining a constructed surface, which if said device is merely for inspecting the same, comprises at least one sensor of environmental information, but which if said device is for cleaning, repairing, or maintaining the same, further comprises an actuator and tool suited to the task;

at least one sensor for monitoring the modular component'"'"'s internal status;

a Bus within said modular component;

intelligence and instrumentation within the modular component connecting with said Bus, further comprising;

at least one memory unit, a processing logic unit, a stored program for the module suited to the processing logic unit, and any sensor and any output device in the modular component;

with each of the MP, SROV, and modular component connected through standardized module interconnectivity by a unified method of hardware interconnection and software interconnection through its respective Bus to provide to each modular component power, communication, and control, and to receive from each modular component feedback;

said SROV further comprising a standardized control and feedback architecture encapsulating at each of the OC, MP, SROV, and modular component computer memory, processing capacity, sensory and actuating hardware, and module-specific software, needed to effect autonomic operation of that module subject to tasking and guidance of a hierarchy of human operators, OC, MP, SROV, and any module.

10. An apparatus as in claim 9, wherein the Operations Center'"'"'s human-usable monitoring and operations station further comprises:

a self-contained, enclosed structure large enough inside to include all of the OC'"'"'s functional and operable components;

environmental conditioning to protect human operators and sensitive equipment;

a connection with any of a set of power and communication sources and carrying devices that will, subject to the override control of the OC, provide the necessary power, monitoring, and control for any SROV being operated through that OC;

a central control unit which a human operator in the OC can use to control the operations and actions, and monitor the status and performance, of an SROV being operated through that OC, said central control unit further comprising;

at least one input device configured for human use by which control commands may be sent to the SROV;

at least one output device configured for human use by which status reports may be received from the SROV;

means for programming any SROV, and any subordinate portion of any SROV, for autonomous performance of any of a task, activity, or goal; and

means for monitoring the autonomous performance by any SROV or any subordinate portion thereof, including;

means for receiving any status report;

means for storing any received status report; and

,

means for reviewing any set of received and stored status reports with a controllable time element allowing the review to be independent of the temporal linkage of the reports within that set.

11. An apparatus as in claim 9, further comprising:

means for extending and retrieving the umbilical;

umbilical positioning means for extending and retrieving the umbilical;

umbilical placement means for managing the rotational and directional position of the umbilical, or a subportion thereof;

a debris removal line;

debris removal line positioning means for extending and retrieving the debris removal line;

debris removal line placement means for managing the rotational and directional position of the debris removal line, or a subportion thereof;

debris removal line operating means for activating, operating, and shutting down the debris removal line;

means for directing the output from the debris removal line into a targeted deposit area or volume; and

,

means for monitoring the status of the umbilical, the debris removal line, the debris removal line positioning means, the debris removal line placement means, the debris removal line operating means, and the targeted deposit area or volume;

thereby enabling a feedback-linked control from the MP over each of the umbilical and debris removal lines.

12. An apparatus as in claim 9, wherein the frame module further comprises:

an environmentally protected, tubular frame enclosing the Bus and interior sub-assemblies that further comprise on-board processing, sensors, distribution, navigation and fail-safe elements;

a proximal Multi-Way Joint Assembly connecting the proximal Plug to the proximal end of the frame module;

a distal Multi-Way Joint Assembly connecting the distal Socket to the distal end of the frame module;

thereby permitting articulation of the frame module as a whole.

13. An apparatus as in claim 12, further comprising a Fail-safe Unit within the frame module, comprising:

a back-up battery bank for powering SROV emergency procedures when the umbilical-provided power fails;

on-board memory, processing, and program components comprising the control and operating management device to implement automated operation of pre-programmed, situation-specific tasks as best match up with the last signal inputs stored and received before the loss of umbilical-provided power; and

,

a set of programmed activities stored in the on-board memory and triggered on detection of signals, against which the on-board processing component compares stored signals and received signals to determine and activate the best matching response, using the same stored signals and received signals, and situational constraints on the selection.

14. An apparatus as in claim 9, wherein the shoulder module further comprises:

a plurality of internal sensors for position of the Shoulder Module, or for each sensor a subportion thereof specific to that sensor;

a plurality of internal sensors for the orientation of the Shoulder Module, or for each sensor a subportion thereof specific to that sensor;

a Rotary Joint Assembly mounted around the central shaft and having a plurality of Sockets;

with at least one Articulation Module attached to at least one Socket;

with a Bus Splitter routing the Bus out of the central shaft and distributing the Bus separately to each Socket through said Rotary Joint Assembly;

thereby enabling a plurality of Articulation Modules to be configured onto the Shoulder Module, and to have their orientation and position linked to, even while separably monitored and controlled, the orientation and position of the Shoulder Module and the SROV as superior parts to said Articulation Modules.

15. An apparatus as in claim 9, wherein the umbilical further comprises:

a standardized orientation and placement for each conductor within the umbilical on both distal and proximal connections, from any of SROV, MP, and OC to any other of SROV, MP, and OC;

at least one power conductor for transmitting power from the proximal to the distal end, said power conductor being insulated against leakage to any unintended target of signal, interference, and power within the SROV, MP, and OC; and

,

at least one communication conductor for communicating signals from the proximal to the distal end, said communication conductor being shield against signal loss, interference, and power; and

,

at least one signal and one power connector within said umbilical connecting at least indirectly with the computers, instrumentation, intelligence, sensors, and actuators of any of SROV, MP, and OC to which the umbilical connects.

16. An apparatus as in claim 9, wherein the Bus further comprises:

a standardized orientation and placement for each connector within the Bus on both distal and proximal connections, from any of umbilical, SROV, module, assembly, and tool, to any other of umbilical, SROV, module, assembly, and tool;

a plurality of power conductors for conveying power from the proximal to the distal end, each said power conductor being insulated against environment, leakage, interference, and power loss within the Bus, module, and SROV;

a plurality of communication conductors for conveying signals from the proximal to the distal end, said communication conductors being insulated against environment, leakage, interference, and power loss within the Bus, module, and SROV.

17. An apparatus as in claim 15, wherein at least one power conductor further comprises a connector transmitting any of hydraulic pressure, mechanical power, pneumatic pressure, and electrical power.

18. An apparatus as in claim 15, wherein at least one communication conductor is a fiber optic cable.

19. An apparatus as in claim 9, wherein the a unified method of hardware connection and software connection connecting each of the MP, SROV, and modular component connected through standardized interfaces further comprises:

a Bus with a preferred rotational orientation;

for the proximal end of each connection;

a Socket further comprising a Bus; and

, an external connector;

for the distal end of each connection;

a Plug further comprising a Bus; and

, an external connector;

wherein the physical dimensions and points of connection for the external connector for the Socket matches and mirrors each the external connector for the Plug for at least those portions of the Socket and the Plug that are in physical contact when mated;

surrounding said Bus at least one insulating and shielding layer;

surrounding said insulating and shielding layer an outer surface suited for mechanical interaction with at least one interior rotational and orientation positioner; and

,

wherein each of the proximal and distal faces of said Bus having the standardized placement of each connector identical as to location, orientation, and type thereof.

20. An apparatus for any of inspecting, cleaning, repairing, or maintaining a surface, said surface being any of submersed, buried, exterior to a structure, and interior to a structure, said apparatus comprising:

means for robotic control of at least one autonomous function;

means for remote-control of at least one remotely-controlled function;

a plurality of interconnectable and interchangeable modules, each module comprising embedded intelligence for controlling at least one actuator and for acquiring data from at least one sensor;

standardized means for mechanically interconnecting and interchanging the plurality of interconnectable and interchangeable modules, said standardized means comprising at least one plug and at least one socket;

standardized means for interconnecting signals among the plurality of interconnectable and interchangeable modules, said standardized means comprising the at least one plug and the at least one socket;

standardized means for a first module, upon being interconnected to a different module, to provide said different module with identification of the first module and some portion of the first module'"'"'s functions, mechanical parameters, operational parameters, and capabilities.

means for intelligently coordinating and synchronizing the plurality of interconnectable and interchangeable modules responsive to instructions for achieving a common function of the apparatus and signals from sensors;

means for propulsion and locomotion of the apparatus;

means for navigation, positioning, and orientation of the apparatus; and

,

means for downloading instructions to any module.