Patent Publication Number: US-11661811-B1

Title: Remote underwater robotic actuator

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation application of U.S. patent application Ser. No. 17/427,638, entitled “Remote Underwater Robotic Actuator”, filed on Jul. 31, 2021, which is a continuation of International Application No. PCT/US2020/046656 filed on Aug. 17, 2020, which claims priority from U.S. Provisional Application Ser. No. 62/888,910 filed on Aug. 19, 2019. All foregoing applications are incorporated herein by reference in their entirety. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
     Not Applicable. 
     BACKGROUND 
     This disclosure relates to the field of remotely operated apparatus. More specifically, the disclosure relates to remotely operated robotic devices used to operate certain equipment deployed in a body of water. 
     Remotely operated vehicles (ROVs) have been used in many fields ranging from underwater to interstellar applications. In the oil and gas industry, ROVs are routinely used to inspect and operate tools and equipment disposed in subsea environments. The ROVs are typically brought to the offshore site on a ship equipped with a crane to deploy the unit and equipment to control the vehicle via a tethered wire system.  FIG.  1    depicts a conventional ROV  10  suspended from a ship&#39;s  12  crane in a deployment to inspect a blowout preventer (BOP)  14  at the sea floor. 
     It is known in the art to install emergency activation panels on subsea BOP stacks. These emergency activation panels may comprise valves and stab connectors for hydraulic fluid designed to be operated by ROVs such that the BOP stack can be operated in the event of primary (surface deployed) control failure. ROVs are complex, expensive, have substantial associated equipment and require skilled operators to navigate and control the ROVs while deployed. Conventional ROVs also typically have a high power demand, requiring heavy umbilical conductors to provide the power needed to run propulsion thrusters, lights, manipulating arms, controllers, etc. 
     There is a need for improved techniques to perform unmanned remote functions, particularly in subsea environments. 
     SUMMARY 
     One aspect of the present disclosure is an underwater robotic system including a frame adapted for deployment in a body of water. The frame has guide rails and at least one movable rail movably coupled to the guide rails. An actuator module is movably coupled to the at least one movable rail. A control panel disposed proximate the frame and has a plurality of controls thereon. The plurality of controls is operable by an actuator on the actuator module. A position of each of the plurality of controls is known such that motion of the actuator module and the at least one movable rail is remotely controllable to actuate any chosen one of the plurality of controls. 
     Some embodiments further comprise a controller in signal communication with a first linear actuator for moving the movable rail and a second linear actuator for moving the actuator module, the controller comprising instructions thereon to operate the first linear actuator and the second linear actuator to position the actuator module proximate the chosen one of the plurality of controls. 
     Some embodiments further comprise at least one sensor in signal communication with the controller, the controller comprising instructions thereon to operate the first and second linear actuator to automatically move the actuator module to a chosen control in response to measurements made by the at least one sensor. 
     In some embodiments, the controller comprises instructions to move the actuator module to chosen ones of the plurality of controls in a predetermined sequence. 
     Some embodiments further comprise a signal communication channel in signal communication with the controller. The signal communication channel in is signal communication with a control system remote from the robotic system. 
     In some embodiments, the signal communication channel comprises an electrical or optical cable. 
     In some embodiments, the signal communication channel comprises an acoustic transceiver. 
     In some embodiments, the actuator is extendable and retractable with respect to the actuator module. 
     In some embodiments, the actuator is operable to rotate to cause operation of the chosen one of the plurality of controls. 
     Some embodiments further comprise a battery disposed proximate the frame and in electric power connection with a first linear actuator for moving the movable rail and a second linear actuator for moving the actuator module. 
     Some embodiments further comprise a battery disposed proximate the frame and configured to power at least one component on the frame. 
     Some embodiments further comprise an electrical power line extending from the battery to a source of electric power remote from the battery to charge the battery. 
     Some embodiments further comprise at least one articulated arm coupled to at least one of the frame and the actuator module, the articulated arm comprising jointed sections arranged to enable motion of an end of the articulated arm to a selected position with respect to the frame. 
     Some embodiments further comprise a manipulation device coupled to the end of the articulated arm. 
     In some embodiments, the frame is configured to couple to a blowout preventer. 
     Some embodiments further comprise a hydraulic pump configured to power at least one linear actuator. 
     A method for remotely operating a control according to another aspect of this disclosure includes deploying a frame in a body of water. The frame has guide rails. The method includes moving a first actuator to a first chosen position within a plane defined by the guide rails. The first chosen position corresponds to a known position of the control on a panel comprising a plurality of controls each at a corresponding known position on the panel. The first actuator is caused to operate the control. 
     Some embodiments further comprise repeating the moving the first actuator to at least a second chosen position and causing the first actuator to operate one of the plurality of controls associated with the at least a second position. The moving to the first and at least a second position are performed automatically such that operation of the control associated with the first and at least a second position are performed in a predetermined sequence. 
     In some embodiments, the moving to the first and at least a second position are performed automatically such that operation of the control associated with the first and at least a second position are performed automatically. 
     In some embodiments, the moving to the first and at least a second position are performed automatically such that operation of the control associated with the first and at least a second position are performed by communicating a control signal from a remote location along a signal communication channel. 
     In some embodiments, the signal communication channel comprises an electrical or optical cable. 
     In some embodiments, the signal communication channel comprises an acoustic transceiver. 
     In some embodiments, the causing the first actuator to operate the control comprises extending the first actuator from an actuator module. 
     In some embodiments, the causing the first actuator to operate the control comprises rotating the first actuator. 
     In some embodiments, substantially all power to perform the moving and causing the first actuator to operate is provided by a battery. 
     In some embodiments, the battery is charged over an electrical power cable linked to a source remote from the battery. 
     In some embodiments, the chosen position and associated control are automatically chosen in response to measurements made by at least one sensor. 
     In some embodiments, the frame is coupled to a blowout preventer disposed in the body of water. 
     Other aspects and possible advantages will be apparent from the description and claims that follow. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    shows an example deployment of a remotely operated vehicle (ROV) known in the art using a ship&#39;s crane to lower the ROV into a body of water. 
         FIG.  2    shows an example embodiment of a robotic system according to the present disclosure. 
         FIG.  3    shows an example embodiment of a control panel arrangement according to the present disclosure. 
         FIG.  4    shows an example embodiment of an actuator module that may be used with the embodiment shown in  FIG.  2   . 
         FIGS.  5 A and  5 B  show example embodiments of an actuator used to operate a knob on a control panel such as shown in  FIG.  2   . 
         FIG.  6    shows an example embodiment of a robotic system comprising associated apparatus operable by the robotic system. 
         FIG.  7    shows an example embodiment of a robotic system attached to a blowout preventer (BOP). 
     
    
    
     DETAILED DESCRIPTION 
     Illustrative embodiments of a robotic actuator are set forth in this disclosure. In the interest of clarity, not all features of any actual implementation are described. In the development of any such actual implementation, some implementation-specific features may need to be provided to obtain certain design-specific objectives, which may vary from one implementation to another. It will be appreciated that development of such an actual implementation, while possibly complex and time-consuming, would nevertheless be a routine undertaking for persons of ordinary skill in the art having the benefit of this disclosure. The disclosed embodiments are not to be limited to the precise arrangements and configurations shown in the figures and as described herein, in which like reference numerals may identify like elements. Also, the figures are not necessarily drawn to scale, and certain features may be shown exaggerated in scale or in generalized or schematic form, in the interest of clarity and conciseness. 
     Embodiments set forth in this disclosure present robotic systems configured for remote deployment and operation, in some embodiments, for deployment in a body of water. Such deployment may be used, for example, to operate equipment disposed in the water, such as on the water bottom.  FIG.  2    shows an example embodiment of a robotic system  20 . The robotic system  20  comprises a frame structure  22  including an associated control panel  24  and interconnected guide rails  26 . The frame structure may be configured to be deployed in a body of water, for example, to operate on the sea bottom to service or operate equipment associated with a subsea petroleum well. The frame structure  22  may be designed in any suitable configuration or geometric arrangement. In some embodiments, at least one surface or face of the frame structure  22  may be configured with guide rails  26  linked together in a planar configuration, i.e., that define a plane, to provide a platform for two-dimensional linear (e.g., vertical and horizontal) movement within the plane defined by the guide rails  26 . The guide rails  26  may be linked by cross-braces  27 . One such plane P 1  is shown in  FIG.  2    as extending in the x, y directions, where coordinate directions are indicated by the legend, x, y, z in  FIG.  2   . Other planes, e.g., P 2 , may be defined by other such guide rails  26  forming part of the frame structure  22 . 
     The frame structure  22  may include one or more movable rails  28  movably disposed between corresponding guide rails  26  as shown in  FIG.  2   . The guide rails  26  and movable rails  28  may have any suitable cross-sectional shape, e.g., may be round (i.e., rod-shaped) or square cross-section. The movable rails  28  can move up or down along the guide rails  26  independently of one another. In  FIG.  2   , one of the movable rails can move within plane P 1 . Another one of the movable rails  28  may move within another plane P 2  defined by guide rails  26  and corresponding cross-braces  27 . In some embodiments, such as the one shown in  FIG.  2   , the frame structure  22  may be implemented with one or more vertically movable rails  28  configured to move vertically along the plane(s) P 1 , P 2  defined by the guide rails  26 . Each movable rail  28  may include thereon an actuator module  30  configured to move back and forth along the length of the respective movable rail  28  (e.g., horizontally, from side-to-side in the embodiment of  FIG.  2   ). The robotic system  20  may also comprise an articulated arm  31  coupled at one end to one or more of the actuator modules  30 . The articulated arm  31  may be configured with a manipulation device  33  at the other end. The articulated arm  31  may be configured with jointed and/or telescoping sections  31 A that allow the articulated arm  31  to move and rotate to various directions and positions. Conventional articulated arms  31  as used in ROVs may be used to implement the embodiments of this disclosure. The manipulation device  33  may be configured to perform any function or combination of functions as known in the art for example and without limitation, a gripper, light, camera, probe, sensor, fastener tool, cutter, torch, etc. 
     The movable rails  28  may be moved along the respective guide rails  26  by a linear actuator (not shown separately) which may comprise any suitable device known in the art for linear motion, including, without limitation, a linear electric motor, hydraulic cylinder and ram, gear and rack combination, worm gear and ball nut combination and sheave and cable system. A corresponding linear actuator (not shown) may be provided to move each actuator module  30  along its respective movable rail. In combination, the linear actuator for the movable rail  28  and corresponding linear actuator for the actuator module  30  enables each actuator module  30  to be positioned at any chosen location within its respective plane P 1 , P 2 . 
     The control panel  24  may include a plurality of controls, such as valves. knobs or switches  32 . The valves, knobs or switches  32  may be arranged on the control panel  24  in an ordered grid pattern.  FIG.  3    depicts an example control panel  24  face with the knobs or switches  32  arranged in an ordered grid pattern identified as columns A-C and rows 1-3. Behind the control panel  24 , the valves, knobs or switches  32  may be configured with conduits, cables, and wiring of types known in the art used for coupling to the objects to be controlled or activated via the knobs or switches. Some embodiments may be implemented with control panel(s)  24  equipped with switches  32  comprising conventional electric toggle-type switches. Some embodiments may be implemented with switches  32  and actuator modules  30  providing other types of activation/trigger modes as known in the art (e.g., LED, infrared sensors, etc.). Some embodiments may be implemented with control panel(s)  24  equipped with valves  32  comprising conventional fluid regulating valves (e.g., ball valves). The positions of the various valves, knobs or switches  32  in any embodiment of the control panel  24  need not be regularly spaced; in some embodiments, the positions of each of the valves, or knobs  32  are known or determinable within the respective plane, e.g., P 1  in  FIG.  2     
       FIG.  4    depicts a side view of an example embodiment of an actuator module  30 . The actuator module  30  may be configured with an extendable and retractable pin  34 . The control panel  24  is mounted on the frame  22  at a predetermined distance from the actuator module  30  to allow the pin  34  to make contact with the control knobs or switches  32  when the pin  34  is extended from the actuator module  30 . With this configuration, if it desired to operate the switch  32  in a chosen control panel grid position (e.g., B- 2  in  FIG.  3   ), the movable rail  28  and actuation module  30  respectively move vertically and horizontally to position the pin  34  directly over the switch  32  (in the B- 2  position in this example). Once in position, the pin  34  is extended from the actuator module  30  to depress and/or toggle the chosen switch  32 . The pin  34  is then retracted into the actuator module  30 , ready for another switch or knob operation. The pin  34  may be extended and retracted using any suitable mechanism, including without limitation, a solenoid, hydraulic cylinder, spring (and magnet/coil to retract) and screw drive/nut. In some embodiments, the pin  34  may comprise one or more geometric features (not shown) to engage corresponding feature(s) on the switch or knob  32 , for example, splines, to enable operation of the switch or knob  32  by rotating the pin  34  as will be further explained with reference to  FIGS.  5 A and  5 B . 
     In some implementations, the switches or knobs  32  are configured to rotate to make graduated adjustments (e.g., to make pressure or level adjustments). Some embodiments of the actuator module  30  may therefore be configured with pins  34  that extract, retract, and rotate in either direction in a controlled manner as explained above. Pin  30  embodiments may be configured with the pin end having a specific shape or pattern to engage with the corresponding shape or pattern formed on the knob or switch  32  on the control panel  24 .  FIG.  5 A  depicts such an embodiment, with an actuator (e.g., a pin)  34  having a pair of protrusions  36  extending from the pin end to engage with corresponding holes  38  formed on the knob  32  surface.  FIG.  5 B  depicts an actuator (pin)  34  having a splined end  40  to engage with a corresponding splined opening  42  formed in the knob  32  surface. These example configurations enable positive engagement of the pin  34  with and controlled rotation of the knob(s)  32 . It will be appreciated that any particular pin-knob embodiments may be configured with other matching patterns, protrusions, or shapes as desired. 
     The movable rails  28  and actuator modules  30  may be implemented using conventional components and hardware as known in the art. For example, conventional computer numerical control (CNC) framing structures, controllers, electronics, and components may be used to implement some embodiments according to this disclosure. Commercially available components designed for underwater applications may be used to implement the disclosed embodiments. In some implementations, custom designed waterproofing may be required, e.g., for certain water depths, which can be performed using any suitable techniques as known in the art. For example, conventional linear motion bearings can be configured with seals to resist water invasion for underwater applications. Robotic system  20  components may also be formed of non-metallic materials such as plastics, composites, or synthetic materials. 
     Referring once again to  FIG.  2   , some embodiments may include a power supply  44 , a controller  46 , and an acoustic transceiver  48  (e.g., in signal communication with the controller  46 ). The controller  46  may comprise any suitable microcomputer, field programmable gate array, microprocessor or any similar device and may be programmed to activate and run certain components on the robotic system  20  as desired according to the particular application of the robotic system  20 . The power supply  44  may be implemented, for example, using conventional batteries configured for underwater use as known in the art. In some embodiments, a power/communication line  50  may be coupled to the controller  46  or another component on the system to provide a hardwired power and/or data transfer and communication link to the robotic system  20 . In some embodiments, the power/communication line  50  may have current carrying capacity only sufficient to recharge the batteries in the power supply  44  while the robotic system  20  is idle, wherein the power supply  44  itself provides sufficient power to operate the robotic system  20  (e.g., the controls, acoustic transceiver, etc.) in its intended use. In such way, providing a high current capacity power line to surface may be avoided. The power/communication line  50  may, for underwater operations, extend to the surface (e.g., to provide direct real time control/data transfer functionality) or to another module on the robotic system  20 , or to another tool or device in the vicinity of the system (e.g., another remote robotic system), depending on the desired application. Communication and data signal transfer can also be carried out via the acoustic transceiver  48  as known on the art. In some implementations where direct operator control is desired (e.g., to make selective adjustments or activations using the articulated arm  31 ) an operator on a ship at the water surface or elsewhere can communicate and direct the robotic system  20  by communicating suitable control signals, along the power/communication line  50  and/or the acoustic transceiver  48 . In some embodiments, the controller  46  can be programmed to perform autonomous activations by suitable operation of the actuation module  30  and/or the articulated arm  31 . 
     The robotic system  20  according to this disclosure may be used as stand-alone unit or it may be incorporated or used with other systems, tools, or equipment to be remotely deployed.  FIG.  6    depicts a system positioned on the sea floor and linked to sensors  52  and other equipment  54  via conduits (cables or hoses)  56 . The control knobs and switches  32  on the control panel  24  in the present example embodiment are linked to the sensors  52  and other equipment  54  to activate and control features and functions on the sensors  52  and equipment  54  as desired. The robotic system  20  may be anchored at the sea floor using techniques as known in the art. In some embodiments, the power supply  44  or the power/communication line  50  may be configured to power a hydraulic pump  57  disposed on the unit, which in turn may be configured to power the linear actuators or other components. Pressurized fluid from the hydraulic pump  57  is conveyed to the controls  32  via a fluid line  61 . 
       FIG.  7    depicts a robotic system  20  integrated with a BOP assembly  58  at the sea floor. In some embodiments, the frame structure  22  may be secured to the BOP assembly  58  such that the BOP assembly  58  may be deployed (e.g., attached to a subsea wellhead) with the robotic system  20  coupled in place to the BOP assembly prior to deployment in the water. The robotic system  20  may include components that link with the BOP assembly&#39;s  58  hydraulic, pneumatic, and electronic systems to provide system-specific controllability. In addition to the actuator module  30  calibrated to the control panel  24 , the robotic system  20  of  FIG.  7    may include a pair of articulated arms  31  (as described with reference to  FIG.  2   ) configured to perform multiple operations. The articulated arms  31  may be configured with jointed sections  31 A that allow the articulated arms  31  to move and rotate to various directions and positions. The base of each articulated arm  31  is configured to move in linear motion along the rails  22 . 
     With the robotic system  20  incorporated with the BOP  58 , the control panel  24  and articulated arms  31  may be used to perform multiple functions remotely. For example, the system  20  may be used to open and close components on the BOP (e.g., valves), vent systems (e.g., accumulators), provide backup/emergency operations, perform arm-disarm functions, perform refill operations (e.g., via a hydraulic fluid reservoir  60  or compressed air tank  62  with an extendable stab). The articulated arms  31  may also be configured with cameras and lights to record unit operation and/or facilitate viewing by a remote operator. In some embodiments, the system  20  can be coupled to the BOP&#39;s  58  multiplex (MUX) cable  64  for subsea communication and data transfer to and from the surface. With such embodiments, an operator can directly and remotely control the robotic system&#39;s  20  knobs  32 , switches  32 , and articulated arms  31  as desired. In some embodiments the system  20  can also be linked to receive electrical power from the BOP&#39;s power supply  66 . 
     It will be appreciated that embodiments of the disclosed robotic system  20  may be implemented for use in numerous subsea applications and operations, in the oil and gas industry and in other fields of endeavor. In light of the principles and example embodiments described and illustrated herein, it will be appreciated that the example embodiments can be modified in arrangement and detail without departing from the scope of the present disclosure. The foregoing description is made with reference to particular embodiments, but other configurations are also within the scope of this disclosure. In particular, even though expressions such as in “an embodiment,” or the like are used herein, these phrases are meant to generally reference embodiment possibilities, and are not intended to limit the disclosure to particular embodiment configurations. As used herein, these terms may reference the same or different embodiments that are combinable into other embodiments. For purposes of defining the scope of this disclosure, any embodiment referenced herein is freely combinable with any one or more of the other embodiments referenced herein, and any number of features of different embodiments are combinable with one another, unless expressly stated otherwise. 
     This disclosure describes one or more embodiments wherein various operations are performed by certain systems, applications, modules, components, etc. In alternative embodiments, however, those operations could be performed by different components. Also, items such as applications, modules, components, etc., may be implemented as software constructs stored in a machine accessible storage medium, such as an optical disk, a hard disk drive, etc., and those constructs may take the form of applications, programs, subroutines, instructions, objects, methods, classes, or any other suitable form of control logic; such items may also be implemented as firmware or hardware, or as any combination of software, firmware and hardware, or any combination of any two of software, firmware and hardware. It will also be appreciated by those skilled in the art that embodiments may be implemented using conventional processors and memory in applied computing systems. 
     Although only a few examples have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible within the disclosed examples. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims.