Abstract:
An embodiment of the invention is directed to an electronic caliper which combines positioning and measurement in one unit without the use of hydraulics for subsea use. In certain embodiments, several attachments can be affixed to accommodate a range of measurement tasks. In a preferred embodiment, one jaw is adjustable and the other, or opposing, jaw is fixed, e.g. by bolting it on to a mounting structure. The jaws typically allow for the removal and replacement of other attachments. In another embodiment, the unit communicates to computer software for position control, precise indication and clamping for adjustment. In a preferred embodiment, computer software displays all feedback via laptop computer on surface. The caliper is maneuvered to a position proximate an object and used to measure a predetermined physical characteristic of the object. The measurement can be displayed, e.g. at the surface, using a computer with control software.

Description:
RELATION TO PRIOR APPLICATIONS 
       [0001]    This application is a continuation of pending and approved U.S. patent application Ser. No. 12/243,536 filed Oct. 1, 2008 and claims priority in part through U.S. Provisional Application 60/977,825 filed Oct. 5, 2007 and U.S. Provisional Application 61/032,552 filed Feb. 29, 2008. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The controllable caliper is adapted to measure an object&#39;s physical dimension. In a preferred embodiment, the digital caliper is adapted for use subsea to measure objects having a physical dimension ranging between around 0 inches to around 16 inches. In a further embodiment, the controllable caliper is a digital caliper. 
       BACKGROUND OF THE INVENTION 
       [0003]    There is a need to obtain and provide measurements of subsea objects to determine strain of parts or corrosion, but not limited to these circumstances. Traditionally, subsea operators have attempted to take physical, lineal measurements of physical features subsea by using laser line scans, photogrammetry or simple, non-adjustable, “go/no-go” gauges. Often, they have not had the accuracy necessary to measure quantities such as strain due to load (stress) or thickness change due to corrosion. These methods also were difficult to use, had to be adjusted on the surface, or required “post-processing” of the information to yield a measurement. What has been needed for some time is a way to take an accurate linear measurement subsea, in realtime, using a tool that is designed for integration with an ROV control system. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]      FIG. 1  is a planar side view of an exemplary embodiment; 
           [0005]      FIG. 2  is a block diagram of an exemplary portion of an exemplary embodiment illustrating a portion of the control system; 
           [0006]      FIG. 3  is an exemplar of a computer graphic interface to a control system; and 
           [0007]      FIGS. 4-7  illustrate exemplary embodiments of the claimed tool in an open position and gauging various objects. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0008]    Referring now to  FIG. 1 , in an embodiment, tool  100  provides for measuring a physical dimension of an object such as a subsea object. Tool  100  comprises first rail  22 ; jaws  2   a  and  2   b  disposed about first rail  22 , at least one jaw  2   a,   2   b  being adjustable in a predetermined plane; positioner  30  operatively connected to an adjustable jaw  2   a;  measurement sensor  9  operatively in communication with positioner  30 ; pressure balancing compensator  20  connected to positioner  30 ; data link connector  10 ; and power source link connector  11 . 
         [0009]    Rail  22  is typically machined from a corrosion-resistant material, e.g. stainless steel, to afford a smooth sliding/running fit (no play) with jaws  2   a,   2   b.  In a preferred embodiment, one end of rail  22  terminates at block  23   a  and an opposing end terminates at block  23   b.    
         [0010]    At least one of first or second jaws  2   a,   2   b  is adjustable in a predetermined plane with respect to the other of the jaws  2   a,   2   b  such as by being movably mounted along rail  22 . In a preferred embodiment, a predetermined one of the jaws e.g. jaw  2   b,  is fixedly attached to a structure such as block  23   b  and the other jaw, e.g. opposing jaw  2   a,  is slidably mounted to rail  22 . In certain embodiments, fixedly attached jaw  2   b  is further adapted to allow removal and replacement of one or more attachments  5 . 
         [0011]    Jaws  2   a,   2   b  are typically machined from aluminum and can be fitted with wear resistant inserts, e.g. inserts made from stainless steel or carbide. Jaws  2   a,   2   b  are also typically shaped to fit the intended application. For example, if the diameter of a hole is to be measured, jaws  2   a,   2   b  can be machined so that the measuring surfaces face outward. If a chain link or a plate thickness were to be measured, jaws  2   a,   2   b  would face inward. Combinations of shapes are also contemplated. 
         [0012]    Positioner  30  is typically adapted to effect virtually stepless movement of adjustable jaw  2   a.  However, in alternative embodiments, positioner  30  may effect discrete step movement of adjustable jaw  2   a.  In a preferred embodiment, positioner  30  comprises actuator  1 , motor controller  51  ( FIG. 2 ), position monitor  3 , motor  7 , lead screw  8 , and measurement sensor  9 . In a currently preferred embodiment, position monitor  3  and motor controller  51  are in located the same housing. 
         [0013]    Actuator  1  is typically operatively connected to adjustable jaw  2   a  and motor controller  51  is operatively connected to the actuator  1 . In certain embodiments, actuator  1  has an operative stroke length of around 8 inches with an actuator force of around 100 lbs. maximum. In certain embodiments, actuator  1  is an electronic linear actuator with position feedback. In these embodiments, electronic linear actuator  1  further comprises stepper motor  7  and measurement sensor  33 . 
         [0014]    In a currently preferred embodiment, positioner  30  comprises lead screw  8  operatively in communication with motor  7 . Lead screw  8  may be actuated by motor  7 , which can be a stepper or servo motor operating through a gearbox. Vendors for such motors include Pacific Scientific, Baldor, Pittman, and Danaher. Vendors for such gearboxes include Bayside and Harmonic Drive Technologies. 
         [0015]    In typical embodiments, position monitor  3  comprises a position control module, i.e. a microprocessor or its equivalent and software or its equivalent, operative to allow position monitor  3  to effect controlling the position of jaw  2   a  along rail  22 . 
         [0016]    Measurement sensor  9  may be contained at least partially within the same housing as lead screw  8 . In preferred embodiments, measurement sensor  9  is a linear potentiometer operatively in communication with motor  7 , lead screw  8 , or a combination thereof. In a further preferred embodiment, measurement sensor  9  is a linear, absolute measurement device such as a Linear Variable Differential Transformer or a Linear Potentiometer. Vendors of such measurement sensors  9  include Lucas-Schaevitz for LVDTs and Bourns manufactures Linear potentiometers. 
         [0017]    Measurement sensor  9  may also comprise feedback sensor  33  ( FIG. 2 ). Measurement sensor  9  is adapted to measure a predetermined physical dimension of an object disposed in-between the jaws  2   a,   2   b.    
         [0018]    For subsea operations, data link connector  10  is typically a remotely operated vehicle compatible (ROV) data link connector. Data link connector  10  allows data communication between positioner  30  and measurement sensor  9 , e.g. feedback sensor  33  ( FIG. 2 ). Data link connector  10  allows further data communication between computer  50  ( FIG. 2 ), positioner  30 , and measurement sensor  9 . Data are typically communicated using a standard protocol such as RS233 at supportable data rates. In a preferred embodiment, data are transmitted at 19200 baud in an 8-bit no parity format with 1 stop bit, although other data rates and protocols are supportable. 
         [0019]    Power link connector  10  may be present to accept power from a source such as ROV  60  ( FIG. 2 ). In a preferred embodiment, power link connector  10  is coterminous with data link connector  10 . For subsea operations, power source link connector  10  is typically an ROV  60  compatible power link connector. 
         [0020]    Referring back to  FIG. 1 , in a further embodiment, tool  100  comprises first rail  22 ; first jaw  2   a  and second jaw  2   b  disposed about the first rail  22 , at least one of the first or second jaws  2   a,   2   b  being adjustable in a predetermined plane with respect to the other of the jaws  2   a,   2   b  along the first rail  22 ; an electronic positioner  30  operatively connected to at least one of the first jaw  2   a  and the second jaw  2   b;  positioning sensor  9  operatively in communication with the electronic positioner  30 ; measurement sensor  33  operatively in communication with the electronic positioner  30 ; pressure balancing compensator  4 ; data link  10  to ROV  60  ( FIG. 2 ); and power link  11  to ROV  60 . 
         [0021]    In contemplated embodiments, actuator attachment  5  may be attached to at least one of the jaws  2   a,   2   b  at a predetermined actuator attachment point  6 . Typically, actuator attachment  5  is attached to adjustable jaw  2   a  and comprises strainable member  199 , where strainable member  199  is capable of handling mechanical strains of a predetermined magnitude. For example, a metal foil or fiber optic strain gauge can be affixed to actuator  1  so as to indicate the force being applied by the jaws to the object being measured so as to give a positive indication that the jaws are fully contacting the work surface. Similarly, an indication of adequate jaw loading could be afforded by using a small switch to monitor strain of the linear actuator on a mount which incorporates a spring loaded, limited travel slide. 
         [0022]    For subsea use, tool  100  is typically constructed of materials sufficient to support a depth rating of around 10000 feet and handle objects ranging from around 0 inches to around 16 inches with a preferred range of around 0 inches to around 13 inches. 
         [0023]    Referring additionally to  FIG. 2 , control software is resident in computer  50  and is adapted to effect a change in positioner  30  based on data from the measurement sensor  33 . In a preferred embodiment, control software comprises a position control software module adapted to create data representative of a precise indication of displacement of the adjustable jaw  2   a,  e.g. from data obtained via data link connector  10 , as well provide control signaling to adjust displacement of adjustable jaw  2   a.  Control software may further comprise a feedback display software module adapted to create feedback information for display such as to computer display  52 . 
         [0024]    Referring now to  FIG. 3 , an exemplary computer display controlled by the control software, range scale buttons  102  may be selected in agreement with a mechanical tool configuration of tool  100 . For example, where the actuator range is 8 inches, the control software may utilize the actuator range value in combination with the actual, real-time actuator reading to produce a correct measurement of object larger than 8 inches. In experimental operations, best results were obtained with a speed value set to 0.2 inches/second. 
         [0025]    Force may be user selectable, e.g. in steps of 1%. As shown in the exemplary embodiment in  FIG. 3  at  104 , a maximum force may be chosen, e.g. one that equates to 100 lbs. 
         [0026]    Tool  100  may be calibrated by using objects of known dimensions, pre- and/or post-dive. Zero button  106  can be used to perform relative measurements, such as when jaws  2   a,   2   b  ( FIG. 1 ) are set at a known reference distance. 
         [0027]    Water detect alarms may have an indicator to indicate dry (normal) or wet conditions. Water detect circuits are typically built into the electronics which drive motor  7  and read the LYDT or Linear Potentiometer. For example, when there is detectable water level, in a preferred embodiment graphical user interface elements (buttons, light emitting diodes, screen display elements, or the like, or combinations therefore) illuminate to indicate and alarm condition. 
         [0028]    In the operation of exemplary embodiments, as shown in  FIG. 2  and exemplified in  FIGS. 4-7 , position control module, e.g.  50 , sends a signal to actuator  1  ( FIG. 1 ) which, in turn, controls positioner  30  ( FIG. 1 ) which, as illustrated, may comprise lead screw  8  ( FIG. 2 ). In this embodiment, actuator  1 , which may be a linear actuator, extends or retracts a position of jaw  2   a  ( FIG. 1 ) to a required location via actuator  1 , e.g. motor  7 , e.g. a stepper motor, translates the request into linear motion through lead screw  8 . When actuator  1  stops, the location of jaw  2   a  along rail  22  ( FIG. 1 ) is relayed through position control module  33  and displayed at the surface through computer  50  with the control software. 
         [0029]    Measurement of a physical dimension of a device, e.g. one located subsea, may be obtained by maneuvering tool  100  ( FIGS. 4-7 ) to a position proximate object  200 , tool  100  comprising a set of jaws  2   a,   2   b.  Jaws  2   a,    2   b  are either already in an opened position or are opened upon locating tool  100  proximate object  200 . 
         [0030]    A signal is sent from position control module  50  ( FIG. 2 ) to actuator  1  ( FIG. 1 ) operatively in communication with position controller  3  ( FIG. 1 ) where position controller  3  is operatively in communication with at least one of the set of jaws  2   a,    2   b.    
         [0031]    A state of actuator  1  ( FIG. 1 ) is changed, e.g. extended or contracted, to a desired state using stepper motor  7  ( FIG. 2 ) translated to linear motion through lead screw  8  ( FIG. 2 ). This changing of the state of actuator  1  preferably occurs in a preselected discrete step. In certain embodiments, the changing of the state of actuator  1  continues occurs until a feedback measurement reaches a predetermined value. 
         [0032]    Actuator  1  is stopped and the location of jaws  2   a,   2   b,  relayed through position control module  3 . 
         [0033]    Additionally, a change in a predetermined physical characteristic may be measured during the changing of the state, e.g. compression or tension. Tool  100  typically has a plurality of measurement ranges, with a typical spread of jaws  2   a,   2   b  ranging from around 0 inches to around 13.3 inches. 
         [0034]    The location may then be observed, e.g. displayed, at the surface such as by using control software within computer  50  ( FIG. 2 ). 
         [0035]    Tool  100  calibration is typically obtained manually, either pre-, post-, or both pre- and post-use such as by comparison to a known object size. 
         [0036]    Position monitor  3  may further provide a pre-selected amount of force to exert on jaws  2   a,   2   b  or attachment  6  from 0-100% of available force. 
         [0037]    The foregoing disclosure and description of the inventions are illustrative and explanatory. Various changes in the size, shape, and materials, as well as in the details of the illustrative construction and/or an illustrative method may be made without departing from the spirit of the invention.