Patent ID: 12233544

DETAILED DESCRIPTION CERTAIN OF EMBODIMENTS OF THE DISCLOSURE

According to one or more embodiments, systems for deploying mobile robotic inspection crawlers onto elevated steel assets and structures is disclosed. The system can comprise an extendable telescopic pole useable to deploy the mobile robotic inspection crawler (“crawler” or “robot”) onto an elevated structure, such as a pipe, as well as retrieve it. The crawler can be designed in a way that is compatible with the telescopic pole for successful deployment and re-docking of the crawler. Further described herein are exemplary designs and variations of the telescopic pole, its end effector, which can include a docking station where the crawler can be held and be deployed from, an optional base carrier provided on the ground and configured to hold the telescopic pole, as well as other features.

An example embodiment of the mobile robot deployment system100is shown inFIG.1. The system100includes an extendable pole105. The pole is, for example, a telescopic pole that is adjustable in length. The pole has a proximal end and a distal end and, in an example configuration, is intended to be held by an operator at a proximal end. Provided at the distal end of the pole is a docking station150within which the crawler120can be positioned.

In an embodiment, the pole105can be coupled to the docking station150using any of a variety of known mechanical couplings mechanisms. For example, as shown inFIG.1, the joint comprises a ball and socket joint115, wherein the socket is mounted to the proximal side of the docking station and a ball provided at the end of the pole is held in the socket and configured to rotate within the socket. The ball and socket joint115thus can enable the end frame to pivot and rotate relative to the pole and facilitates coupling the docking station to the asset130.

The magnetic inspection crawler120is just one example of a crawler that is useable with the system100. A magnetic crawler with magnetic wheels can allow it to move in inverted fashioned along the bottom side of a horizontal pipe, and stay fixed to a platform within the docking station even while it is deployed in an inverted fashion along the bottom side of a horizontal pipe. It should be understood that mobile robotic inspection crawlers are well known in the art and various types of inspection crawler can be used with the various deployment systems described herein. More generally, where certain elements of the present embodiments can be partially or fully implemented using known components, only those portions of such known components that are necessary for an understanding of the present embodiments are described, and detailed descriptions of other portions of such known components are omitted so as not to obscure the embodiments.

The docking station150can comprise an end-effector frame155that provides a housing that encompasses an interior volume of the docking station and provides structure for supporting the various components of the docking station. As shown inFIG.1, the frame155can be shaped to define two legs175that extend distally away from a main body of the frame coupled to the pole105. A magnetic foot180is mounted at the distal end of each of the two legs175. The magnetic feet180are used to anchor the frame to the elevated asset130with the metallic platform, as further described herein, positioned against the elevated structure. The magnetic feet can be moveably joined to the legs of the end-effector frame using a mechanical coupling. For example, the coupling can comprise a through bolt or pin157configured to allow the foot180to pivot relative to the frame155and thus adapt to curved or uneven surfaces of the asset. Other suitable mechanical couplings could be used.

In certain embodiments, the frame155can be configured to house components therein but otherwise lack an interior volume but still can engage with the crawler when the crawler is docked.

In an embodiment, the magnetic feet180comprise switchable magnets that can be switched on or off to respectively couple and uncouple the docking station to the asset130. Although not shown, buttons or any suitable switching mechanism for operating the switchable magnet system, as would be understood by those in the art, can be provided near the proximal end of the pole. It should be understood that, although the embodiment ofFIG.1depicts two magnetic legs, any number of such magnetic legs can be provided (e.g. four or eight) depending on the size of the crawler and surface curvature of the asset(s) intended to be inspected.

Mounted to the frame155a metallic platform160. The metallic platform is a generally planar metallic plate-like structure that the crawler120can be magnetically held against while within the docking station, and that the crawler can maneuver off-of and back onto during use. For example, the crawler120could have magnetic wheels (as shown inFIG.1) or a magnetized chassis that enable it to magnetically couple to the ferromagnetic platform160. The frame155is also shaped to define at least one open side of the docking station, so as to allow the crawler to enter into or exit the docking station.

As an example, the platform160can be mounted to the frame155using a spring-biased mounting mechanism that provides for passive self-adjustment of the height of the platform relative to the frame depending on the contour of the surface of the asset130. This mounting mechanism can allow the docking station to conform to assets that do not have uniformly flat surfaces (e.g., curved pipes) thereby facilitating the magnetic coupling between the docking station and the asset and enabling the robot to more easily drive off and on the platform160. For instance, as shown inFIG.1, the distal end of four support shafts165are coupled to the interior surface of the platform160. The support shafts extend perpendicularly from the interior surface of the platform160(in the “normal” direction) toward the frame where they are coupled to the frame155. Each shaft can be coupled to the frame155using a suitable mechanical coupling that allows the shaft to slide relative to the frame in the normal direction. For example, the coupling can comprise a linear bearing that allows the shaft to slide linearly therethrough (i.e., in the normal direction) and thus moving the platform closer to or further away from the frame155.

In an embodiment, the sliding of the shafts165and thus movement of the platform relative to the frame can be biased or assisted using springs. For example,FIG.1depicts the frame155comprising four spring housings170that the four shafts165are respectively received within. The spring housings can each contain a compressed spring (not shown) configured to exert a force that urges a respective shaft out toward the platform160.

FIG.2is a process flow diagram illustrating an example routine200for deploying a crawler120using the deployment system100. The method200begins at step205with the pole in an initial retracted configuration. At step210, the crawler is securely positioned with the docking station150. For instance, the crawler can be magnetically secured and attached to the metal platform160. At step215, the telescopic pole105is extended in length and the docking station is positioned in proximity to the portion of the asset to be inspected. At step220, the magnetic feet180of the docking station150are magnetically attached to the asset130by turning the switchable magnets180on. For instance, the switchable magnets can be turned on or off by the user or controller activating embedded servo motors that switch the switchable magnets on or off. Alternatively, the switchable magnets could be turned on and off mechanically by twisting the pole using a suitable mechanical linkage. Once the pole is attached to the asset, at step225, the crawler is deployed for inspection. After completion of the inspection, at step230, the crawler returns into the docking station and re-docks therewith by attaching magnetically to the platform160. At step235, the magnetic feet180are deactivated by the operator, for instance, by actuating the servos to turn off the switchable magnets. At this point, the telescopic pole can be moved to a different location, retracted back to its initial position, and one or more steps of routine200(e.g., steps215-235) can be repeated.

Another example configuration of a mobile robot deployment system300is shown inFIGS.3A-3B. The system300comprises a telescopic pole305having a similar configuration to the pole of system100. System300further comprises an end-effector355that is coupled to the distal end of the pole305by way of a ball joint315. System300can also comprise a crawler320configured to be selectively attached to or detached from the end-effector355. In an embodiment, the top side of the crawler can comprise a magnet317, a switchable magnet, or a magnetic receptive material (e.g., a ferrous material). The end effector355can comprise a switchable magnet357. As shown inFIG.3B, the switchable magnet357can be provided in the center of the end effector355. Thus, the crawler320can be mounted to the end effector355so as to allow the crawler320to be positioned on an asset130by magnetically coupling the magnet317of the crawler with the switchable magnet357. To deploy the crawler320using the system300, the switchable magnets357can be turned off once the magnetic crawler is attached to the asset being inspected thereby detaching the end effector355from the crawler320.

Another example configuration of a mobile robot deployment system400is shown inFIG.4. The system400comprises a telescopic pole405having a similar configuration to the pole of system100. System400further comprises an end-effector455that is provided at the distal end of the pole405. System400can also comprise a crawler420configured to be selectively attached to or detached from the end-effector455using a mechanical coupling mechanism. In an embodiment, the coupling mechanism can comprise a latch457provided at the distal end of the end effector455and the top side of the crawler can comprise a complementary slot417within which the latch457can be received. Thus, the crawler420can be mounted to the end effector455so as to allow the crawler420to be positioned on an asset130by inserting the latch with the slot and matingly engaging the latch and slot. To deploy the crawler420using the system400, the latch can be actuated so as to disengage it from the slot417, thereby releasing the crawler420from the end effector455.

As should be understood other types of user-actuated mechanical coupling mechanisms could be used to selectively attach or detach the crawler420and the end effector455. Another example configuration of a mobile robot deployment system500is shown inFIG.5. The system500comprises a telescopic pole505having a similar configuration to the pole of system100. System500further comprises an end-effector555that is provided at the distal end of the pole505. System500can also comprise a crawler520configured to be selectively attached to or detached from the end-effector555using a mechanical coupling mechanism. In an embodiment, the coupling mechanism can comprise a threaded bolt557extending from the distal end of the end effector555. The coupling mechanism further comprises a complementary threaded nut517that is provided on the top side of the crawler and that the threaded bolt557can be threaded into. Thus, the crawler520can be mounted to the end effector555so as to allow the crawler520to be positioned on an asset130by inserting and threading the bolt557into the threaded nut517. To deploy the crawler520using the system500, the threaded bolt can be backed out of the threaded nut517, thereby releasing the crawler520from the end effector555. The bolt557can be threaded into or backed out of the threaded nut through manual rotation or motorized rotation of the bolt using a motor (not shown) provided within the pole505or end effector555.

In an embodiment, to avoid needing a user to hold the telescoping pole, the telescopic pole can be mounted on a base carrier resting on the ground.FIG.6depicts a system600in which the exemplary pole105, as shown and described in connection withFIG.1, is mounted at a proximal end thereof to a base carrier605. The base carrier605can provide a rolling base on wheels to assist with transporting the system from one location to another. The pole105can be attached to the base carrier605via a coupling610having one or more degrees of freedom. As shown inFIG.6, the coupling610can be configured to provide multiple degrees of freedom. Preferably, the degrees of freedom include at least a first degree of freedom, tilt, and a second degree of freedom, pan and tilt, as these would provide sufficient adjustability for most scenarios. As shown, for example, the pole is mounted directly to the coupling610by a through-bolt so as to enable the pole to tilt relative to the coupling. Additionally, the coupling610can be rotatably mounted to a top surface of the base carrier605so as to provide the panning degree of freedom. To enable a long pole to be mounted stably onto the base carrier, a weighted counterbalance (not shown) can be provided inside the carrier for stability. Alternatively, stability can be achieved through a friction joint coupling the pole to the base carrier and a suitably heavy base carrier. In an embodiment, movement of the pole in the one or more degrees of freedom could be manually controlled. In an embodiment, movement of the pole in the one or more degrees of freedom could be actively controlled using a suitable motor and electronic controller provided within the base carrier. Such an automated positioning system can be configured to operate automatically or semi-automatically based on user controls input to the controller.

In an embodiment, the telescopic pole can be configured to be a smart device.FIG.7depicts an exemplary configuration of a deployment system700including a telescopic pole705having a smart-device configuration. More specifically, pole705can be fitted with an electronic controller707, such as a microcontroller, computer device or other suitable processing unit. Pole can also be fitted with one or more of a variety of sensors724that are in wired or wireless communication with the controller and that facilitate placement of the pole, effector and robot in proximity to the asset and facilitate automated or semi-automated operation of the pole. For instance, sensor724can be a sophisticated sensor system such as, a Light Detection and Ranging (LIDAR) sensor. By way of further example, other distance-measuring sensor technology can be used such as light, laser or ultrasonic proximity sensors. Thus, the control unit707can be configured to, based on the sensor data, automatically control one or more motors712arranged to, for example, elongate the pole and rotate the pole to align the end effector755with the asset130and attach it to the surface of the asset to be inspected. A camera sensor726can also be integrated into the head of the pole near the crawler such that it can be used to guide the pole's extension towards an asset for easy deployment.

As noted above, extending, manipulating and/or attaching the end effector to the asset can be performed manually, automatically by the controller, or semi-autonomously by the controller under command of an operator. For instance, the switchable magnetic feet780can be turned on or off by the user actuating the appropriate switches722connected to the controller707. More specifically, the controller707can be configured to, in response to the user input, activate an embedded servo motor (not shown) that serves to switch the switchable magnets on or off. It should be understood various operations of the pole can controlled by the user via one or more user input devices (e.g., switches722) that are communicatively coupled to the controller707including for example, extending the pole, rotating the end effector, actuating the end effector (e.g., latching/unlatching a latch, rotating the screw end, switching a magnet on/off) and the like.

Additionally, the controller707of the smart telescopic pole can comprise a wireless communication connection such that an operator can remotely control the pole705and other aspects of the system700system by transmitting control commands from a remote control station (not shown) over a communication link. These features could also be integrated into a base carrier (e.g., carrier605) if needed. Furthermore, although pole705is fitted with a docking station755similar to the system described inFIG.1, it should be understood that other example configurations of poles can similarly be fitted with sensors, electronic controllers, motors and the like.

The described techniques herein can be implemented using a combination of sensors, transmitters, and other devices including computing or other logic circuits configured (e.g., programmed) to carry out their assigned tasks. These devices are located on or in (or otherwise in close proximity to) the pole705or carrier base (not shown). In some example embodiments, the control logic is implemented as computer code configured to be stored on a computer-readable storage medium and executed on a computing circuit (such as a microprocessor) to perform the control steps that are part of the technique. For ease of description, this processing logic (e.g., ASIC, FPGA, processor, custom circuit, or the like) will be referred to as a controller throughout. For further ease of description, this control circuit will be programmable by code to perform the control logic (or otherwise customize the circuit to perform its intended purpose).

It should be understood that various combination, alternatives and modifications of the present embodiments could be devised by those skilled in the art. The present disclosure is intended to embrace all such alternatives, modifications and variances that fall within the scope of the appended claims.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

Terms of orientation are used herein merely for purposes of convention and referencing and are not to be construed as limiting. However, it is recognized these terms could be used with reference to a viewer. Accordingly, no limitations are implied or to be inferred. In addition, the use of ordinal numbers (e.g., first, second, third) is for distinction and not counting. For example, the use of “third” does not imply there is a corresponding “first” or “second.” Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

The term “communication link,” as used in this disclosure, means a wired or wireless medium that conveys data or information between at least two points. The wired or wireless medium can include, for example, a metallic conductor link, a radio frequency (RF) communication link, an Infrared (IR) communication link, or an optical communication link. The RF communication link can include, for example, Wi-Fi, WiMAX, IEEE 802.11, DECT, 0G, 1G, 2G, 3G, 4G or 5G cellular standards, or Bluetooth.

The terms “controller,” “computer” or “computing device,” as used in this disclosure, means any machine, device, circuit, component, or module, or any system of machines, devices, circuits, components, or modules which are capable of manipulating data according to one or more instructions, such as, for example, without limitation, a processor, a microprocessor, a graphics processing unit, a central processing unit, a general purpose computer, a super computer, a personal computer, a laptop computer, a palmtop computer, a notebook computer, a desktop computer, a workstation computer, a server, a server farm, a computer cloud, or an array of processors, microprocessors, central processing units, general purpose computers, super computers, personal computers, laptop computers, palmtop computers, notebook computers, desktop computers, workstation computers, or servers.

The term “computer-readable medium,” as used in this disclosure, means any storage medium that participates in providing data (for example, instructions) that can be read by a computer. Such a medium can take many forms, including non-volatile media and volatile media. Non-volatile media can include, for example, optical or magnetic disks and other persistent memory. Volatile media can include dynamic random access memory (DRAM). Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, an EPROM, a FLASH-EEPROM, any other memory chip or cartridge, a carrier wave, or any other medium from which a computer can read. The computer-readable medium can include a “Cloud,” which includes a distribution of files across multiple (for example, thousands of) memory caches on multiple (for example, thousands of) computers.

Various forms of computer readable media can be involved in carrying sequences of instructions to a computer. For example, sequences of instruction (i) can be delivered from a RAM to a processor, (ii) can be carried over a wireless transmission medium, or (iii) can be formatted according to numerous formats, standards or protocols, including, for example, Wi-Fi, WiMAX, IEEE 802.11, DECT, 0G, 1G, 2G, 3G, 4G, or 5G cellular standards, or Bluetooth.

The term “network,” as used in this disclosure means, but is not limited to, for example, at least one of a local area network (LAN), a wide area network (WAN), a metropolitan area network (MAN), a personal area network (PAN), a campus area network, a corporate area network, a global area network (GAN), a broadband area network (BAN), a cellular network, or the Internet, any of which can be configured to communicate data via a wireless or a wired communication medium. These networks can run a variety of protocols not limited to TCP/IP, IRC or HTTP.

The term “transmission,” as used in this disclosure, means the conveyance of signals via electricity, acoustic waves, light waves and other electromagnetic emissions, such as those generated with communications in the radio frequency (RF) or infrared (IR) spectra. Transmission media for such transmissions can include coaxial cables, copper wire and fiber optics, including the wires that comprise a system bus coupled to the processor.

Devices that are in communication with each other need not be in continuous communication with each other unless expressly specified otherwise. In addition, devices that are in communication with each other may communicate directly or indirectly through one or more intermediaries.

Although process steps, method steps, or algorithms may be described in a sequential or a parallel order, such processes, methods and algorithms may be configured to work in alternate orders. In other words, any sequence or order of steps that may be described in a sequential order does not necessarily indicate a requirement that the steps be performed in that order; some steps may be performed simultaneously. Similarly, if a sequence or order of steps is described in a parallel (or simultaneous) order, such steps can be performed in a sequential order. The steps of the processes, methods or algorithms described in this specification may be performed in any order practical.

When a single device or article is described, it will be readily apparent that more than one device or article may be used in place of a single device or article. Similarly, where more than one device or article is described, it will be readily apparent that a single device or article may be used in place of the more than one device or article. The functionality or the features of a device may be alternatively embodied by one or more other devices which are not explicitly described as having such functionality or features.

While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. Therefore, the scope of the invention is indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.