ES1311263U - ROBOT FOR INSPECTION AND/OR MAINTENANCE OF FACILITIES (Machine-translation by Google Translate, not legally binding) - Google Patents

Abstract

Robot for the inspection and maintenance of installations comprising: - a basic movement module comprising motor means and traction means; - a basic control module comprising a CPU, and - a basic module for power supply of all the connected basic modules, in which each basic module comprises quick connection systems with the other basic modules; the robot comprises means for the quick connection of one or more specialized functional modules. (Machine-translation by Google Translate, not legally binding)

Description

DESCRIPTION

Robot for inspection and/or maintenance of facilities

This innovation relates to a self-propelled robot, in particular of the type used for the inspection of facilities or areas that are dangerous for humans.

Background

There are several known inspection robots, however today there is an urgent need for a robotic system that is as flexible as possible and, above all, easy to configure and operate, without requiring specialized operators and, if possible, even remotely.

Summary

The inspection robot described here is provided with different external supports and a unique “Control Panel” guidance platform that allows the operator to operate it. The robot can have both very small dimensions and dimensions suitable for supporting external devices, from a minimum of 15 cm high, 15 cm wide, 20 cm long to a maximum of 60 cm high, 60 cm wide, 80 cm long and with a weight of 2.5 kg for the less equipped “Basic” version to ~30 kg for the larger and more equipped “Plus” version. These features make the robot suitable for inspections in confined places such as piezometric wells, hydroelectric pipelines and tunnels, wind turbines and confined places in general with sections diameter from 150 mm to 6000 mm and for a maximum reach of 500 m.

In its basic configuration, the robot comprises some basic modules:

- a drive system or "basic travel module" comprising four motors for four drive wheels which can be controlled either individually or by movement in alternating pairs;

- a central CPU system with input/output ports "Basic Control Module" capable of managing the different connected modules and media;

- a "Basic Power Module" power supply system comprising a removable and rechargeable battery or an external continuous power supply, and

- a basic on-screen display module for operation, i.e. a high-resolution video camera that can be rotated 180° on one axis.

The Control Panel is an interface that allows you to manage the robot directly from your PC or smartphone using virtual buttons on the panel or via Gamepad on PCs. In addition, the latter can also be controlled remotely using software for sharing and/or monitoring the PC remotely, such as Microsoft Teams, which allows access to the local robot management device.

Technical problem solved by innovation

The purpose of this innovation is to solve the problems left in the air by the known technique, providing a robot as defined in claim 1.

Other features of this innovation are defined in the associated claims.

The main objective of the robot project according to this innovation is to develop an easy-to-use system, at any time without the need to prepare or activate auxiliary services, to carry out inspections in facilities and transmit information in real time about their health status.

Thanks to the various accessories, the robot is a tool always available in the daily life of all operators and maintenance workers.

The robot has been developed and designed to be a low cost and easy to use solution compared to the state of the art robotic technology currently available for carrying out specialist inspections of pipes or confined spaces in general.

The robot will have a target cost of less than 5,000 euros once industrialised and, thanks to its modular system, will simplify the types of assistance provided by future suppliers.

In its most complete and equipped version, the robot will allow complete control over the health status of the pipes and check the health status of the facilities, increasing and facilitating the data collection process in ArcGIS.

Other advantages, together with the characteristics and methods of use of this innovation, will be evident in the following detailed description of its preferred embodiments, presented by way of example and not limitation.

Brief description of the figures

Throughout this description reference will be made to the drawings shown in the attached figures, where:

• Figure 1 is a schematic representation of a robot according to the present innovation, in its “Basic” configuration;

• Figure 2 shows an example of a Plug&Play quick connection system;

• Figure 3 shows a basic articulated displacement module, comprising a hybrid system of non-drive magnetic wheels to increase ground adhesion.

• Figure 4 shows a basic displacement module with magnetic wheels, in one of its embodiments;

• Figures 5, 6 and 7 show examples of possible magnetic wheels;

• Figure 8 shows an example of an additional module with a cart;

• Figure 9 shows a possible functional robotic arm module;

• Figure 10 shows a possible diagram of a functional module of the cleaning system; • Figure 11 shows an example of a rigid pipe with movable joints of the cleaning system;

• Figure 12 shows a possible cleaning system diagram with a rotating system with grinding disc;

• Figure 13 shows a possible LED Headlight functional module diagram;

• Figure 14 shows a possible diagram of a thickness gauge functional module;

• Figure 15 shows a possible thickness gauge probe;

• Figure 16 shows an example of the Control Panel screen for robot control; and

• Figure 17 shows a general schematic of the robot control software architecture.

Detailed description of the preferred embodiments

This innovation will be described below with reference to the figures indicated above.

The robotic platform on which this innovation is based is a platform comprising a modular system that allows for the rapid “Plug & Play” connection, both hardware and software, of different supports to carry out indoor and outdoor inspections with specialized functional modules.

As schematically illustrated in Figure 1, the robot comprises four basic modules that constitute the body of the robot and house different specialized functional modules.

The entire system and its functional modules are managed through a Control Panel. The basic modules comprise a basic travel module, a basic control module, a basic power module and a basic screen display module.

• The basic displacement module is preferably made in a moulded PLA or PVC casing, resistant to dust and water splashes, equipped with guide systems and clips for quick coupling between modules. The basic displacement module comprises an electronic circuit capable of interconnecting via I2C protocol with the basic control module and of activating and monitoring the movements of four DC motors with 12V, 62 rpm gearmotors with torque ~1.5 N*m, which in turn act directly on the drive wheels with a diameter of ~70 mm or ~110 mm.

• The basic control module is preferably manufactured in a moulded housing made of dust- and splash-proof PLA or PVC, fitted with guide and clip systems for quick coupling between modules. The basic control module comprises a CPU, for example Raspberry, two I2C Multiplexers of which one can constitute the first set of Input/Output powered at 5V, the second can read the second set of Input/Output which will have the same voltage as the battery or 7.4V or 11.1V. Finally, there are three separate power supplies for the electronic cards, one for the CPU, one for the 5V Inputs/Outputs and one for powering the other accessory cards. The control module also comprises an MPU6050 accelerometer and gyroscope which can provide further information on the handling of the robot and a fibre optic converter/Ethernet cable.

• The basic power module is made in a housing that attaches to the basic control module and comprises a 4500 mAh or 5000 mAh Li-Po battery of 7.4 V or 11.1 V and an electronic circuit capable of checking the correct operation of the module.

• The basic on-screen display module for management comprises a high-resolution video camera that can be rotated on an axis in a range of at least 180°, using a servo motor driven by the basic control module to which the basic display module is connected using the I2C protocol.

Figure 2 illustrates an example of a Plug&Play quick connection system, based on this innovation.

The Plug&Play system used for the connection and quick coupling of the basic modules and the functional modules is a system that is part of the robot and that immediately recognizes each device physically connected to the basic control module, which retrieves from its own library the pre-configurations that will generate the graphical control interface.

A Plug & Play system is understood to mean both a physical connection between supports and/or between modules using special slides, a clip system for fixing and a data and/or power connection system, as well as a software connection to read a management protocol for each basic module and each functional module into the basic control module.

For example, the mechanical connection of the supports can be made by means of slides (1,2, 3, 4, 5), guides and fixing clips. The quick-connect hardware means are preferably placed at the height of the external surfaces of the main body of the module, if possible above and below the basic modules and on the side for the optional modules.

The electrical connection is made, for example, by plugging in a 4- or 5-pin waterproof connector.

The software connection is made by recognition of the functional module by a main CPU, which scans the input/output ports “I/O Port” of the basic control module through the I2C Multiplexers (single-channel system allowing multi-channel reading) capable of scanning the possible I2C addresses to compare the basic modules and/or functional modules detected with those that can be managed since they are preconfigured in the CPU.

have a modular system that is easily and quickly modifiable and adaptable according to different needs

Alternative or augmented modules

The basic modules that make up the robot can benefit from specific supports applicable as localized upgrades. Each of the modules can always be quickly replaced thanks to a Plug & Play system for connection to the basic control module, such as the basic travel module that can provide different traction systems using different technologies or designs, such as magnetic wheels (8), tracks or with larger dimensions to support functional modules of more than 15 cm in length, 15 cm in width and 20 cm in height.

For example, the following variants of the basic displacement module can be envisaged.

• Articulated basic displacement-traction module (figure 3), with dimensions of 15 cm long, 15 cm wide and 9 cm high, the system consists of a PVC or PLA casing with two 12V, 62 rpm motors, with a 2 cm wide articulated mesh and a total length of approximately 60 cm made of rubber. The control card comprises an electronic circuit capable of interacting via I2C protocol with the basic control module and of activating and monitoring the movements of the 2 DC motors. In addition, this basic module also comprises non-driven magnetic wheels (8) to increase adherence to the ground.

• Basic displacement-traction module with magnetic wheels (figure 4), the system consists of a molded PLA or PVC casing resistant to dust and water splashes, equipped with guide and clip systems for quick coupling between modules. The basic displacement module comprises an electronic circuit capable of interconnecting via I2C protocol with the Control Module and of activating and monitoring the movements of the four DC motors with 12V, 62 rpm geared motor with torque ~1.5 N*m in figure 4, which in turn act directly on the magnetic traction wheels, according to different possible configurations, three of which are shown as an example in figures 5, 6 and 7. In other words, if possible the structure of the magnetic wheel is mainly configured for flat surfaces, but other magnetic wheel solutions are disclosed that can be configured for environments with different environmental conditions as in figures 5, 6 and 7.

• Basic Plus Displacement Module: traction system with overall dimensions of 60 cm long, 60 cm wide and 50 cm high, the system consists of a casing and a frame made of molded PLA or PVC resistant to dust and splashes of water, equipped with guide and clip systems for quick coupling between basic modules and functional modules. The Basic Displacement Module includes an electronic circuit capable of interconnecting via I2C protocol with the Control Module and of activating and monitoring the movement of four DC motors with 12V, 45/60 rpm gearmotor with torque ~15 N*m.

In accordance with this innovation, the robot can also comprise for its own benefit an additional module with a cart, towable as a cart and which can be attached with a metal ring to the basic robot that will move it on its two axes and four free wheels, as in figure 8. The cart is composed of a casing and a frame made of moulded PLA or PVC resistant to dust and water splashes, equipped with guide systems and clips for the quick coupling of the functional modules.

Functional modules

Functional modules are all the supports that can be installed in Plug & Play mode on the appropriate supports of the robot. Functional modules are designed to increase the functions of the robot, allowing it to obtain more information during inspection and to carry out specialized inspections in environments that are difficult for personnel to access. All systems have been designed respecting the fundamental characteristics of the robot, i.e. small and easy-to-use systems.

Below is an example description of some possible specialized functional modules.

• Robotic arm: The functional module of the robotic arm comprises a system of joints controlled by at least two motors that allow movement on a minimum of two axes as in figure 9. The motors used will have a power of 3.9 and 5.9 N*m with a voltage of 7.4V and will receive direct power from the basic control module. The robotic arm can function as an individual functional module or as an extension and support for other functional modules, allowing it to reach more than 15 cm from the robot housing. It will also be possible to enjoy a small LED light system with a power of ~3 watts and a 4K HD camera. All systems can be controlled remotely through the control panel once interconnected to the doors of the basic control module.

• Surface cleaning system: this system (figure 10) comprises two components that can be operated separately with the corresponding control buttons from the Control Panel. The first system is an installation that includes a CO<2> tank, for example, consisting of four mini CO<2> cylinders (15) connected by means of an automated flow regulation system to a dispensing system as in figure 11. The dispensing system consists of a rigid pipe with movable joints fixed at the head to the mechanical arm by means of a special support.

For grinding operations on the upper arm, a rotary system comprising a motor (23) with grinding disc (25) can be installed as shown in figure 12. The control of the functional module will follow the I2C communication system, which will enable it to communicate with the basic control module.

• LED Headlight: The LED Headlight functional module (figure 13) is a system comprising a plate (27) 15 cm wide by 15 cm long arranged to house two 50 watt LED sensors (28) with their respective heat sinks. The plate is connected to a Plug & Play support through a hinge that allows, thanks to the use of a servomotor of approximately 2 N*m at 7.4V, to rotate more or less 100°. The LED Headlight is preferably powered autonomously through a 4500 mAh LiPo battery (26) mounted on the Plug & Play connection system. The entire system is managed by the Control Panel, which allows both the inclination of the light beam on an axis and the intensity of the light to be regulated. This functional module is designed to be able to direct the light beam of the headlight allowing, thanks to the combined use of this functional module with the driving camera that can also move with the same degrees of freedom, to drive the robot both forwards and backwards while maintaining the same driving comfort.

• Lidar: The Lidar functional module is a system equipped with a YDLIDAR-X4 sensor, i.e. a sensor capable of scanning the environment around the robot at 360° and able to return a medium-resolution point cloud. The main features of this functional module are the measurement capacity from 0.12m to 10m, communication via USB or internal I2C protocol, adjustable scanning frequency from 6 to 12 Hz and angular resolution of 0.63°. The functional module comprises a Plug & Play connection system to the robot and is made in a PLA or PVC housing that protects the lower part of the sensor. The Lidar functional module uses an electronic card so that the YDLIDAR-X4 sensor can interact with the basic control module. In addition, to reduce consumption, a battery can be added to the Li-Po (26) to give the functional module more autonomy compared to the robot unit.

• Thermal Camera: The Thermal Camera functional module can also be mounted on the Robotic Arm functional module and provides for the use of an AMG8833 sensor, comprising an 8x8 array of IR thermal sensors with a temperature measurement range of 0°C to 80°C, housed within a molded PLA housing. The system monitored and managed via the Control Panel is directly interfaced with the ports of the Basic Control Module, which allows communication via I2C protocol with a 10Hz update rate and supplies power.

• Thickness gauge: The system (figure 14) comprises three main systems, a probe system that can be mounted on the Robotic Arm functional module, a system for dispensing the contact gel (34) between the probe (33) and the metal surface, an electronic card (21) for communication between the sensors and the basic control module.

As shown in Figure 15, the probe (33) is a system that allows to emit and receive ultrasounds with a frequency between 2 and 5 MHz, said information is transmitted by cable to an electronic card that interprets the information and retransmits it to the basic control module.

The probe can be mounted on the top of the Robotic Arm functional module. The latter requires a gel or contact liquid dispensing system for proper operation.

The gel dispensing system comprises a tray containing the liquid and a small motorized pump that pushes it through a small flexible PVC tube towards the extruder located next to the ultrasonic probe.

The electronic card allows the data from the probe to be classified, enabling the display and management of commands from the Control Panel. It also regulates the emission of gel under the probe and supplies power to the entire thickness gauge functional module thanks to an external Li-Po battery.

Control Panel

The Robot Control Panel, shown in Figure 16, is a software interface comprising a set of graphical units attributable to each basic module and/or functional module connected to the basic control module, from which we can view information and give them orders. The Control Panel is generated from the control logic of the basic control module based on the basic modules and functional modules it finds connected when the robot starts up. The software can be used from any device with access to the browser, as long as it is connected to the same local network. The Control Panel has been designed to use a dynamic configuration capable of displaying both graphical objects related to the connected basic modules and functional modules and fixed graphical objects to help with the handling of the robot such as the “Help” section to offer assistance on the main functions, “Telemetry” for information to help with the handling of the robot such as roll and pitch, temperature and remaining battery and “Settings” to customize some driving functions.

The Control Panel application can be accessed once the robot has been turned on via a web browser such as Explorer, Firefox or Chrome by accessing the robot's IP address (written into the robot or verifiable via devices connected to the included router via the address: e.g. 192.168.1.56:5000). Once logged into the Control Panel, we can view and manage in real time the information coming from the modules, while orders can be given with the mouse by clicking on the buttons on the Control Panel, with the keyboard and/or with the Gamepad. In addition, the software thanks to its simple interface allows to export the screen that can be seen on the PC, also on a VR display system.

The Control Panel system has been designed through HTML programming language code strings capable of interacting with the robot's central unit programmed through the Python3 language.

The robot can be managed remotely using PC remote control programs. Thus, through a remotely connected PC, it will always be possible to use both the gamepad and the VR system.

The robot can be fitted with a number of accessories to facilitate its operation both on-site and remotely, such as the Gamepad and VR glasses. The robot can be controlled with any wireless PC Gamepad by connecting its wireless dongle to a USB port on the PC where the Control Panel is displayed. By running the JoyToKey program on the inspection PC, the gamepad commands are automatically converted into keyboard commands and the use of the robot becomes more flexible thanks to the personal reconfiguration of the commands.

Additionally, to provide a more comfortable viewing of the control panel, a VR headset can be used as a PC screen extender via the HDMI port.

Control Accessories Specifications:

<o>Gamepad: Any gamepad compatible with PC (Windows 7/8/10) and PS3 can be used, with Wireless Dongle 2.4Ghz connectivity with at least 600mAh battery and double joypad

<o>VR headset: Any device with a screen resolution >2K, with HDMI input, 4000mAh battery and a minimum field of view of 100° can be used.

Control logic

Referring to Figure 17, the robot software architecture is divided into two main programs “Flask Server” and “Central”, and some interface programs with the Modules and Payload written through HTML, C++ and Pyton3 programming languages. Flask Server contains the Flask micro-framework that allows the connection between the graphical environment of the Control Panel in HTML and the robot management environment regarding the basic modules and the functional modules in Python3. The Flask Server system allows both the communication with the two functional modules such as video cameras and the graphical interface between the Control Panel and the “WebSocket” system present on the Raspberry CPU as a bridge with the Central system. The Flask Server program enables the Dashboard graphics by transferring the commands received to the WebSocket system which in turn transfers them to the Central program as in figure 27. WebSocket is responsible for both making the information from the basic modules and/or the functional modules available in the Dashboard, and for transferring the commands to the Central by managing the maximum number of users who can access the robot information. The code is prepared to manage the Dashboard, if desired, through a direct system via the web. Central is the operating core of all the logic, with its algorithms it manages the communication with the basic modules and/or the functional modules independently of the connection to the I/O ports on the control module, giving rise to the Plug & Play system. Each basic module and/or functional module is preconfigured by individual codes defined as "Class" and always present in the CPU, all communications between the Classes and the Modules are managed through the I2C protocol. Central is therefore tasked with initially scanning the connected modules, creating the web-to-module dialog paths, managing the I2C resource by mutual exclusion between the reading phase and the command sending phase to the basic modules and/or to the functional modules. It is also responsible for managing all the errors that may be generated during the use of the robot.

All the programs in Figure 17, except those for the modules, are stored in the microprocessor of the basic control module, while the programs for the modules are located in each module on a microcontroller. This configuration by parts makes each module autonomous, so that the failure of the microprocessor of the control module does not imply instability in other modules.

Browser: This interface can be opened on PC, tablet or smartphone.

CPU (Raspberry pi4): This software and hardware structure is installed inside the inspection robot.

Payload Module: Payloads and modules can be connected to the CPU module using Plug and Play sockets.

Logic for Plug & Play system

The Plug & Play system, generated by algorithms in Central and Web, makes the software dynamic and open to the insertion of infinite new basic modules and/or functional modules. In fact, the Control Panel itself is dynamic because of its flexibility to display only the modules actually connected to the robot.

The present innovation has been described so far with reference to its preferred embodiments. It should be understood that each of the technical solutions implemented in the preferred embodiments, described here by way of example, can be advantageously combined, in a manner different from that described, with the others, to give rise to other embodiments, which belong to the same inventive core and which, in any case, fall within the scope of protection of the claims indicated below.

Legend of numerals:

1. CPU module slider

2. Feed module slide

3. Slide module slide

4. Feed and displacement module slide

5. Coupling the modules with a slide

6. Fixing the modules using a tab

7. Inserting the plug

8. Magnetic wheels

9. Magnetic wheel with thick magnets

10. Soft rubber

11. Magnets

12. 3M double-sided adhesive

13. PVC or PLA rim

14. Vulcanized rubber

15. CO2 bombs

16. Multiple CO2 cylinder collector

17. Solenoid valve

18. Flexible line

19. Mouthpiece

20. Dispenser

21. Electronic interface card with the control module 22. Input/Output

23. Engine

24. Plug and play coupling system

25. Rotating head with grinding disc

26. Li-Po Battery

27. LED headlight plate

28. LED sensor with heatsink

29. LED tilt motor

30. Power line

31. Data line

32. Liquid contact thickness gauge probe

33. 2-5 MHz probe

34. Contact gel dispenser

35. Gel reservoir

36. External power line

37. Line of control

38. Hydraulic gel line

39. Probe control line - thickness gauge

40. Magnetic wheel with thin magnets

Claims (17)

1. Robot for inspection and maintenance of facilities comprising: • a basic displacement module comprising drive means and traction means; • a basic control module comprising a CPU, and • a basic power supply module for all the connected basic modules, in which each basic module comprises quick connection systems with the other basic modules; The robot comprises means for rapid connection of one or more specialized functional modules. 2. Robot according to claim 1, wherein said means for quick connection comprise devices for mechanical connection between modules and/or devices for electrical connection between modules. 3. Robot according to claim 2, wherein said devices for mechanical connection comprise guides, slides and/or clips placed along the surfaces of said basic and/or specialized modules. 4. Robot according to one of the preceding claims, wherein the basic movement module comprises one or more DC motors with geared motors acting on the respective traction members. 5. Robot according to the preceding claim, wherein said motors are powered at 12V and have a rotation speed between 40 and 70 rpm with a torque between 1.5 N*m and 15 N*m, preferably 1.6 N*m and 10 N*m. 6. Robot according to claim 4 or 5, wherein said traction members comprise rubber tracks with a mesh of about 2 cm wide and a total length of about 60 cm. 7. Robot according to claim 4 or 5, wherein said traction members comprise magnetic drive wheels. 8. Robot according to one of the preceding claims, wherein said basic movement module is an articulated traction module comprising a hybrid traction system, which comprises rubber tracks and non-drive magnetic wheels. 9. Robot according to one of the preceding claims, wherein said basic control module also comprises an MPU6050 accelerometer and gyroscope capable of providing further information on the driving of the robot. 10. Robot according to one of the preceding claims, further comprising an additional module with a towable cart, provided with quick connection means for one or more specialized functional modules. 11. Robot according to one of the preceding claims, wherein one of said specialized functional modules is a robotic arm with two or more degrees of freedom. 12. Robot according to the preceding claim, wherein said robotic arm is prepared for the coupling of other specialized functional modules. 13. Robot according to one of the preceding claims, wherein one of said specialized functional modules is a surface cleaning system. 14. Robot according to the preceding claim, wherein said surface cleaning system comprises a CO<2> tank and a dispensing system, which in turn comprises a rigid pipe with movable joints. 15. Robot according to one of the preceding claims, wherein one of said specialized functional modules is a LIDAR scanning system. 16. Robot according to the preceding claim, wherein said thermal camera uses an AMG8833 sensor, comprising an 8x8 array of IR thermal sensors with a temperature measurement range of 0 °C to 80 °C. 17. Robot according to one of the preceding claims, wherein one of said specialized functional modules is a thickness gauge.