Description:TECHNICAL FIELD
[0001] Embodiments of the present disclosure generally relate to robotic systems, and more particularly relate to a pipeline maintenance robotic system. The maintenance of the pipeline may include an inspection of the pipeline and/or a cleaning of the pipeline.
BACKGROUND
[0002] Generally, inspection and maintenance of pipelines play a crucial role in ensuring an integrity and longevity of various industries, including oil, gas, water supply, chemical processing, and the like. Currently, manual inspections often take place in hazardous or hard-to-reach areas, putting human personnel at risk. Further, the manual inspections are time-consuming, expensive, and prone to human errors. Additionally, an emergence of pipe inspection robots may provide a solution to some of the challenges, however, existing pipe inspection robots may include limitations. The limitations may hinder the widespread application in diverse pipe networks, which include cable-driven systems and fixed-size inspection robots.
[0003] Cable-driven robots may commonly be used for pipe inspection; however, the cable-driven robots may encounter difficulties when navigating large pipelines with varying diameters, bends, and junctions due to limitations in cable lengths. Fixed-size inspection robots are designed for specific pipe configurations and may not accommodate changes in pipe size or geometry. These robots are often bulky and lack the flexibility needed to adapt to different pipes, thereby limiting their utility in diverse pipe networks.
[0004] Conventionally, a system provides a stereo vision combined with laser profiling systems for mapping of pipeline internal defects. The conventional system identifies and map defects or irregularities within pipelines. Another conventional system provides a flat inspection robot with two-wheel for movement. Yet another conventional system provides an actively steerable in-pipe inspection robots for underground urban gas pipelines. Another conventional system provides a pipeline cleaning robot. The conventional pipeline cleaning robot includes a radial traveling mechanism with consistent structures in its distributed traveling units, a power conversion mechanism for transmitting and converting power from a motor shaft, a pipe diameter self-adapting mechanism that uses an adjusting mechanism and connecting rod to adjust the robot's position in relation to the main shaft, and a cleaning mechanism situated at the front end of the main shaft.
[0005] However, the conventional systems may be relevant to pipeline inspection, however, the conventional systems may have limitations in terms of flexibility and adaptability to various pipeline configurations. Further, the conventional systems may be suitable for inspecting pipelines with certain geometric configurations, however, the conventional systems may face challenges when navigating within pipelines that have bends, varying diameters, or junctions. The design of the conventional systems may not be easily adaptable to different pipe sizes and shapes. Although, the conventional systems may have certain steering capabilities, however, may be limited in terms of adaptability to several types of pipelines and multifunctionality. Additionally, the conventional systems may lack customization and adaptability, in turn restricts the applications in diverse pipe networks.
[0006] Consequently, there is a need in the art for an improved, economical, configurable pipeline maintenance robotic system, to address at least the aforementioned issues in the prior arts.
SUMMARY
[0007] This summary is provided to introduce a selection of concepts, in a simple manner, which is further described in the detailed description of the disclosure. This summary is neither intended to identify key or essential inventive concepts of the subject matter nor to determine the scope of the disclosure.
[0008] An aspect of the present disclosure provides a pipeline maintenance robotic system. The pipeline maintenance robotic system includes an inspection subsystem. Further, the inspection subsystem includes a front body and a rear body. The front body and the rear body include a plurality of wheel modules, individually driven. The front body and the rear body are connected to each other via a universal joint (u-joint). Furthermore, the front body includes a direct current (DC) motor coupled to a cleaning module. The rear body includes one or more tanks for retaining one or more fluids and dispensing the one or more fluids via one or more nozzles associated with the one or more tanks. Each of the plurality of wheel modules include a pantograph mechanism. The pantograph mechanism includes a primary lever movably coupled to a fixed base of the plurality of wheel modules and a secondary lever coupled to a moving base of the plurality of wheel modules. Further, the plurality of the wheel modules performs, via the pantograph mechanism, an extraction and a retraction based on a diameter of the pipeline. Each of the plurality of moving base includes a lead screw and a threaded collar rotatably coupled to the lead screw. Further, the plurality of wheel modules with the pantograph mechanism performs at least one of an extension and a retraction based on actuation of the lead screw using a spur gear mechanism via at least two hybrid Direct Current (DC) servo motor of plurality of servo motors. Further, the inspection subsystem includes a driving unit communicatively coupled to a plurality of servo motors, configured to drive each of the plurality of wheel modules.
[0009] Further, the pipeline maintenance robotic system includes a cleaning subsystem. The cleaning subsystem includes the cleaning module, disposed at one or more sides of the front body, to remove foreign substance formed on inside surface of a pipeline. The foreign substance is removed by a rotating force generated via the DC motor, upon dispensing the one or more fluids via the one or more nozzles associated with the one or more tanks. The inspection subsystem and the cleaning subsystem is configured to perform maintenance of the pipeline comprising at least one of an inspection of the pipeline and a cleaning of the pipeline.
[0010] To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the disclosure and are therefore not to be considered limiting in scope. The disclosure will be described and explained with additional specificity and detail with the appended figures.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0011] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described, by way of example only, and with reference to the accompanying figures, in which:
[0012] FIG. 1 illustrates a perspective view of a pipeline maintenance robotic system, in accordance with some embodiments of the present disclosure;
[0013] FIG. 2 illustrates a side view of an inspection subsystem associated with the pipeline maintenance robotic system such as those shown in FIG. 1, in accordance with some embodiments of the present disclosure;
[0014] FIG. 3 illustrates an isometric view of an inspection subsystem (a) at a point of insertion into pipeline, (b) movement through vertical pipelines, (c) movement through an L bent pipeline, in accordance with some embodiments of the present disclosure;
[0015] FIG. 4 illustrates a block diagram of a pipeline maintenance robotic system, in accordance with some embodiments of the present disclosure;
[0016] FIG. 5A illustrates a side view of a (a) universal joint holder, an isometric view of a (b) swivel, and a side view of a (c) complete universal joint (u-joint), in accordance with some embodiments of the present disclosure;
[0017] FIG. 5B illustrates a side view of a wheel module (a) depicting a main lever length and a secondary lever length, (b) in the fully retracted position, (c) in complete expanded position, in accordance with some embodiments of the present disclosure;
[0018] FIG. 5C illustrates an auxiliary view (a) and (c), and a top view (b) of a threaded collar, in accordance with some embodiments of present disclosure;
[0019] FIG. 5D illustrates an auxiliary view (a) and (c), and a top view (b) of a rotating holder associated with a cleaning module, in accordance with some embodiments of present disclosure; and
[0020] FIG. 5E illustrates an auxiliary view (a) and (c), and a top view (b) of a plurality of pre-defined shaped extrusions associated with a cleaning module, in accordance with some embodiments of present disclosure.
[0021] Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.
DETAILED DESCRIPTION
[0022] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure. It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof.
[0023] In the present document, the word “exemplary” is used herein to mean “serving as an example, instance, or illustration”. Any embodiment or implementation of the present subject matter described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.
[0024] While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.
[0025] The terms “comprises”, “comprising”, “includes”, “including” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device or method that includes a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or method.
[0026] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
[0027] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
[0028] A description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the invention. In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
[0029] In the present disclosure, terms such as “upper”, “lower”, “left”, “right”, “front”, “rear”, “vertical”, “horizontal”, “side”, “bottom”, and the like, may refer to an orientation or a positional relationship based on that shown in the drawings, and are merely relational terms, which are used for convenience in describing structural relationships of various components or elements of the present invention, and do not denote any one of the components or elements of the present disclosure, and are not to be construed as limiting the present invention.
[0030] In the present disclosure, terms such as “fixedly attached”, “movably coupled”, “connected”, “coupled”, and the like are to be construed broadly and refer to either a fixed connection, or a movable, or an integral or removable connection; can be directly connected or indirectly connected through an intermediate medium. The specific meaning of the terms in the present disclosure can be determined according to circumstances by a person skilled in the relevant art or the art and is not to be construed as limiting the present disclosure.
[0031] Embodiments of the present disclosure provides a pipeline maintenance robotic system. The pipeline maintenance robotic system incorporates an inspection subsystem, which may include a front body and a rear body. The front body and the rear body include individually driven wheel modules. The front body and the rear body may be interconnected by universal joints (u-joints). Additionally, the front body is equipped with a direct current (DC) motor linked to a cleaning module, while the rear body including one or more tanks for storing and dispensing fluids through associated nozzles. Each wheel module features a pantograph mechanism, comprising a primary lever attached to the fixed base and a secondary lever connected to the moving base of the wheel modules. This pantograph mechanism may facilitate the extension and retraction of the wheel modules, adapting to the pipeline's diameter. Each moving base includes a lead screw and a threaded collar that rotates around it. The wheel modules, in conjunction with the pantograph mechanism, extend or retract based on the actuation of the lead screw through a spur gear mechanism driven by a hybrid Direct Current (DC) servo motor. The inspection subsystem may be coupled to a driving unit that communicates with the multiple servo motors, enabling it to control each of the wheel modules.
[0032] Furthermore, the pipeline maintenance robotic system includes a cleaning subsystem. This subsystem incorporates the cleaning module, positioned on one or more sides of the front body, to eliminate foreign substances present on the interior surface of the pipeline. The DC motor generates a rotating force for the removal of these substances, using the fluids dispensed through the associated nozzles from the tanks. The inspection subsystem and the cleaning subsystem are configured to conduct maintenance tasks on the pipeline, such as inspection and cleaning procedures, ensuring pipeline upkeep.
[0033] Referring now to the drawings, and more particularly to FIGs. 1 through FIG. 5E where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments, and these embodiments are described in the context of the following exemplary system and/or method.
[0034] FIG. 1 illustrates a perspective view of a pipeline maintenance robotic system 100, in accordance with some embodiments of the present disclosure. According to FIG. 1 the pipeline maintenance robotic system 100 includes an inspection subsystem 102, and a cleaning subsystem 104. The inspection subsystem 102 may assess and examine the condition of a pipeline. The cleaning subsystem 104 may be responsible for the removal of foreign substances or deposits present on the inside surface of the pipeline (not shown in FIG. 1). The maintenance of the pipeline may include an inspection of the pipeline and/or a cleaning of the pipeline. For example, the pipeline may include, but are not limited to, oil and gas pipelines, water supply pipelines, natural gas pipelines, chemical processing pipelines, sewer pipelines, mining slurry pipelines, renewable energy pipelines, yellow stone pipelines, biomethane pipelines, Atacama pipeline, colonial pipelines, any other pipelines, and combinations thereof. In an example, the pipeline maintenance robotic system 100 may include, but are not limited to, inspection robots, cleaning robots, repair and maintenance robots, crawling, or tracked robots, modular robots, teleoperated or remote-controlled robots, autonomous robots. The pipeline maintenance robotic system 100 may include a level of autonomy including, but is not limited to, semi-autonomous, autonomous, and the like, or combinations thereof. The other levels of autonomy of the pipeline maintenance robotic system 100 may include, assistive, teleported, collaborative, swarm, learning robots, and the like, and combinations thereof. Further, the pipeline maintenance robotic system 100 may be configurable, and adjustable based on a pipeline geometry and/or a pipeline configuration.
[0035] In an embodiment, the inspection subsystem 102 includes a front body 106 and a rear body 108. The front body 106 and the rear body 108 may be connected to each other via a universal joint (u-joint) 112. The u-joint 112 may be attached and detached via a locking mechanism comprising a swivel (not shown in FIG. 1). Further, the front body 106 and the rear body 108 may be spaced apart from a pivotal axis of the u-joint 112 around, which the front body 106 and the rear body 108 may be in angular freedom, based on at least one of a type of the pipeline, a curvature of the pipeline, a joint of a pipeline, and a diameter of the pipeline.
[0036] Further, the front body 106 and the rear body 108 may include a plurality of wheel modules 110-1, 110-2, 110-3, 110-4, …..,110-N (individually referred to as the wheel module 110, and collectively referred to as the wheel modules 110 or the plurality of wheel modules 110). The plurality of wheel modules 110 may be individually driven. In the plurality of wheel modules 110, at least three of the wheel modules 110 may be attached to a circumference of each of the front body 106 and the rear body 108, with pre-defined degrees apart. Further, in the plurality of wheel modules 110, at least one wheel module is configured to retract, and at least two-wheel modules 110 with decreased angle (i.e., retract) is used for inspecting horizontal surfaces.
[0037] In an embodiment, the front body (106) includes a direct current (DC) motor coupled to a cleaning module 114 associated with the cleaning subsystem 104. The rear body 108 inlcudes one or more tanks 116 for retaining one or more fluids. The one or more fluids may include, but is not limited to, water, hydraulic fluid, coolant or antifreeze fluid, lubricating oil, fuel, chemical solutions, transmission fluid, adhesives or sealants, pneumatic fluid (compressed air), and the like, and combinations thereof. The one or more tanks 116 may dispense the one or more fluids via one or more nozzles 118 associated with the one or more tanks 116. The one or more tanks 116 may be refilled with the one or more fluids via a one or more external source through a thin tubular structure. The external source may include, but is not limited to, water supply devices, water tanks, water pumps, water wells, rainwater harvesting systems, reservoirs, water storage tanks, water distribution networks, any other fluid/liquid source, and combinations thereof.
[0038] Each of the plurality of wheel modules 110 include a pantograph mechanism. Further, the pantograph mechanism may include a primary lever movably coupled to a fixed base (not shown in FIG. 1) of the plurality of wheel modules 110, and a secondary lever may be coupled to a moving base (not shown in FIG. 1) of the plurality of wheel modules 110. The pantograph mechanism may be a linkage system composed of interconnected rods and joints designed to replicate and amplify movements. The pantograph mechanism may operate on the principle of maintaining a geometrically symmetric parallelogram as its key feature. The interconnected links within the pantograph form this parallelogram, providing a framework for consistent and proportional motion transmission. As one point in the mechanism undergoes a specific movement, the connected point reproduces the motion, albeit with a proportional change in size. This inherent scaling property makes pantographs particularly useful in applications where replicating or resizing motions is required.
[0039] In an embodiment, the plurality of the wheel modules 110 may be configured to perform, via the pantograph mechanism, an extraction and a retraction based on a diameter of the pipeline. Each of the plurality of moving base may include a lead screw (not shown in FIG. 1) and a threaded collar (not shown in FIG. 1) rotatably coupled to the lead screw. Further, the plurality of wheel modules 110 with the pantograph mechanism may be configured to perform at least one of an extension and a retraction. The extension and the retraction may be based on actuation of the lead screw using a spur gear mechanism via a hybrid Direct Current (DC) servo motor of plurality of servo motors 120. The spur gear mechanism may include a controlled rotation of the lead screw, and a longitude motion of the moving base. Further, the spur gear mechanism may include a diametrical adjustment of the plurality of wheel modules 110, by adjusting the fixed base and the moving base.
[0040] For example, the spur gear mechanism may be a gearing system comprising of cylindrical gears with straight teeth that run parallel to the axis of rotation. The spur gears may include straight-toothed design, extending radially from the center of the gear. The spur gears may allow a direct transfer of a rotational motion between parallel shafts. Spur gears are particularly efficient in transmitting power and motion between parallel shafts. The direction of rotation in meshing gears is opposite; if one gear turns clockwise, its mating gear turns counterclockwise. The spur gear mechanism may include, but is not limited to, an external spur gear, an internal spur gear (ring gear), a parallel spur gear, a non-parallel or crossed spur gear, a helical spur gear, a double helical gear (herringbone gear), a straight cut spur gear, a skew spur gear, a ground spur gear, a plastic spur gear, a metal spur gear, a cluster gear, a compound spur gear, a planetary gear (epicyclic gear), a rack and pinion, an idler gear, a zero backlash gear, a variable tooth thickness gear, a zero bevel gear, and the like.
[0041] In an embodiment, the inspection subsystem 102 may include a driving unit (not shown) communicatively coupled to a plurality of servo motors 120. The driving unit may be configured to drive each of the plurality of wheel modules 110. At least two servo motors of the plurality of servo motors 120 may include at least two hybrid Direct Current (DC) servo motors. The hybrid DC servo motor may include at least one quadrature encoder, configured to vary diameter of the pipeline maintenance robotic system 100, by actuating the spur gear mechanism to actuate the pantograph mechanism. The lead screw includes external threads driven by the plurality of servo motors 120 for controlled longitudinal motion of the threaded collar translated into radial expansion of the plurality of wheel modules 110 through the pantograph mechanism. Further, the controlled longitudinal motion of the threaded collar may be translated into a radial expansion of the plurality of wheel modules 110.
[0042] In an embodiment, the cleaning subsystem 104 may include the cleaning module 114. The cleaning module 114 may include a plurality of pre-defined shaped extrusions with a one or more cleaning materials attached to a top end of each of the pre-defined shaped extrusions. The cleaning subsystem 104 may be disposed at one or more sides of the front body 106, to remove foreign substance formed on inside surface of a pipeline, by a rotating force generated via the DC motor, upon dispensing the one or more fluids via the one or more nozzles 118 associated with the one or more tanks 116. In an embodiment, the inspection subsystem 102, and the cleaning subsystem 104 may be configured to perform maintenance of the pipeline. The maintenance of the pipeline may include an inspection of the pipeline and/or a cleaning of the pipeline.
[0043] Further, the pipeline maintenance robotic system 100 may be implemented by way of a single device or a combination of multiple devices that may be operatively connected or networked together. The pipeline maintenance robotic system 100 may be implemented in hardware or a suitable combination of hardware and software. The pipeline maintenance robotic system 100 may include one or more hardware processor(s) (not shown), and a memory (not shown). The memory may include a plurality of modules (not shown). The pipeline maintenance robotic system 100 may be a hardware device including the hardware processor executing machine-readable program instructions for the pipeline maintenance tasks. Execution of the machine-readable program instructions by the hardware processor may enable the proposed pipeline maintenance robotic system 100 to maintain the pipeline. The “hardware” may comprise a combination of discrete components, an integrated circuit, an application-specific integrated circuit, a field-programmable gate array, a digital signal processor, or other suitable hardware. The “software” may comprise one or more objects, agents, threads, lines of code, subroutines, separate software applications, two or more lines of code, or other suitable software structures operating in one or more software applications or on one or more processors.
[0044] The hardware processor may include, for example, microprocessors, microcomputers, microcontrollers, digital signal processors, central processing units, state machines, logic circuits, and/or any devices that manipulate data or signals based on operational instructions. Among other capabilities, hardware processor may fetch and execute computer-readable instructions in the memory operationally coupled with the pipeline maintenance robotic system 100 for performing tasks such as data processing, input/output processing, and/or any other functions. Any reference to a task in the present disclosure may refer to an operation being or that may be performed on data.
[0045] The hardware processor(s), as used herein, means any type of computational circuit, such as, but not limited to, a microprocessor unit, microcontroller, complex instruction set computing microprocessor unit, reduced instruction set computing microprocessor unit, very long instruction word microprocessor unit, explicitly parallel instruction computing microprocessor unit, graphics processing unit, digital signal processing unit, or any other type of processing circuit. The hardware processor(s) may also include embedded controllers, such as generic or programmable logic devices or arrays, application-specific integrated circuits, single-chip computers, and the like.
[0046] The memory may be a non-transitory volatile memory and a non-volatile memory. The memory may be coupled to communicate with the hardware processor, such as being a computer-readable storage medium. The hardware processor may execute machine-readable instructions and/or source code stored in the memory. A variety of machine-readable instructions may be stored in and accessed from the memory. The memory may include any suitable elements for storing data and machine-readable instructions, such as read-only memory, random access memory, erasable programmable read-only memory, electrically erasable programmable read-only memory, a hard drive, a removable media drive for handling compact disks, digital video disks, diskettes, magnetic tape cartridges, memory cards, and the like. In the present embodiment, the memory includes the plurality of modules stored in the form of machine-readable instructions on any of the above-mentioned storage media and may be in communication with and executed by the hardware processor.
[0047] Though few components and subsystems are disclosed in FIG. 1, there may be additional components and subsystems which is not shown, such as, but not limited to, instruments, remote controllers, mobile devices, user devices, network devices, facility equipment, image capturing devices, Augmented Reality (AR) devices, Virtual Reality (VR) devices, Metaverse based devices, speakers, sensors, water supply devices, any other devices, and combination thereof. The person skilled in the art should not be limiting the components/subsystems shown in FIG. 1.
[0048] Those of ordinary skilled in the art will appreciate that the hardware depicted in FIG. 1 may vary for particular implementations. For example, other peripheral devices such as an optical disk drive and the like, local area network (LAN), wide area network (WAN), wireless (e.g., wireless-fidelity (Wi-Fi)) adapter, graphics adapter, disk controller, input/output (I/O) adapter also may be used in addition or place of the hardware depicted. The depicted example is provided for explanation only and is not meant to imply architectural limitations concerning the present disclosure.
[0049] Those skilled in the art will recognize that, for simplicity and clarity, the full structure and operation of all data processing systems suitable for use with the present disclosure are not being depicted or described herein. Instead, only so much of the robotic system 100 as is unique to the present disclosure or necessary for an understanding of the present disclosure is depicted and described. The remainder of the construction and operation of the robotic system 100 may conform to any of the various current implementations and practices that were known in the art.
[0050] FIG. 2 illustrates a side view of an inspection subsystem 102 associated with the pipeline maintenance robotic system 100, such as those shown in FIG. 1, in accordance with some embodiments of the present disclosure. The pipeline maintenance robotic system 100 may include the inspection subsystem 102 for inspection and surveillance in constrained conditions. The pipeline maintenance robotic system 100 may be configured and adjusted to different terrains and environments, based on specific requirements for navigating and inspecting constrained conditions, such as size, mobility, and sensor capabilities, of the pipeline maintenance robotic system 100. Position based servo motors may be used to drive the wheels while a DC motor of, for example, 100 Revolutions Per Minute (RPM) may be used to control the operation of the cleaning module 114. Further, a hybrid DC servo motor of, for example, 10 RPM with inbuilt quadrature encoder may be used to vary the overall diameter of the robotic system 100 by actuating the spur gear mechanism. The spur gear mechanism in turn actuates the pantograph mechanism that varies the overall diameter of the robotic system 100. For example, the spur gear mechanism may include 3 driven gears and 1 driving gear.
[0051] Additionally, the quadrature encoder may measure position, speed, and direction of rotation of a shaft with high precision. The quadrature encoder may include an encoder disc mounted on a rotating shaft, including evenly spaced slots or holes around its circumference. Positioned on opposite sides of the encoder disc are light-emitting diodes (LEDs) and photodetectors. As the shaft rotates, the slots or holes in the disc allow light to pass through, creating a pattern of light and dark regions. The two output channels generated by the photodetectors are known as Channel A and Channel B. These channels produce electrical signals that are in quadrature, meaning they are offset by a quarter of a cycle and are 90 degrees out of phase with each other. This phase shift may be crucial for determining both the direction and the speed of rotation. As the shaft moves, the encoder generates pulses on the A and B channels. The sequence of these pulses and the order in which they occur indicate the direction of rotation, providing valuable feedback for control systems. The number of pulses per revolution, determined by the resolution of the encoder, offers information about the distance traveled or the speed of rotation.
[0052] In another example, a wireless communication unit (not shown in FIG. 2) (e.g., Wireless-Fidelity (Wi-Fi) module) and an (RGB – Red, Green, Blue) and depth information (D) (RGBD) camera may be embedded in the inspection subsystem 102 to operate in a teleoperated mode (human control). In another example, a power source such as a Lithium Polymer (LiPo) battery may be implemented in the system 100.
[0053] In an example, the front body 106 and the rear body 108 may be a length of 190 mm and three-wheel modules 110 may be arranged in 120 degrees apart. Each wheel module 110 may be designed to accommodate complex and constrained conditions. The wheel module 110 may include the pantograph mechanism that can extend and retract based on the actuation of the lead screw using the spur gear mechanism. The spur gear mechanism may be actuated by the hybrid DC motor. In addition, the u- joint 112 may be attached and detached via a specialized locking mechanism such as the swivel (not shown in FIG. 2).
[0054] FIG. 3 illustrates an isometric view of an inspection subsystem 102 (a) at a point of insertion into pipeline 302-1, (b) movement through vertical pipelines 302-2, (c) movement through an L bent pipeline 302-3, in accordance with some embodiments of the present disclosure. For example, frictional characteristics may be provided to the system 100. The pipeline may be horizontal section and a vertical pipe connected by a L bent. The working of the wheel module may be based on a pre-defined wheel velocities which may be a constant (0.1m/s) at the straight pipelines and differential velocities at the L bents of the pipeline. During a movement of the robotic system 100, in the vertical pipelines there may be a wall press mechanism to avoid slippage. Using two main driving units, the combined effect may help the robotic system 100 to move in vertical pipes without considerable slippage.
[0055] FIG. 4 illustrates a block diagram of a pipeline maintenance robotic system 100, in accordance with some embodiments of the present disclosure. In an embodiment, the pipeline maintenance robotic system 100 may include the inspection subsystem 102, the cleaning subsystem 104. The pipeline maintenance robotic system 100 may further include a driving unit 402, one or more image capturing units 404, one or more sensor units 406, wireless communication unit(s) 408, a processing unit 410, other units 412. The inspection subsystem 102 may assess and examine the condition of a pipeline 302. The cleaning subsystem 104 may be responsible for the removal of foreign substances or deposits present on the inside surface of the pipeline 302.
[0056] In an embodiment, the driving unit 402 may be communicatively coupled to a plurality of servo motors 120. The driving unit 402 may be configured to drive each of the plurality of wheel modules 110 through the plurality of servo motors 120. The one or more image capturing units 404 may be configured to capture multimedia content of the inside surface of the pipeline 302. The multimedia content may include, but not limited to, video, image, audio, and the like. Further, the one or more sensor units 406 configured to detect one or more attributes within the inside surface of the pipeline 302. The one or more attributes may include, but not limited to, a corrosion, cracks or fractures, a material thickness, foreign objects, temperature variations, pressure changes, pipeline diameter, surface irregularities, pipeline contaminants, coating integrity, and the like, and combinations thereof.
[0057] In an embodiment, the wireless communication unit 408 may transmit the multimedia content associate with the one or more image capturing units 404, and the detected one or more attributes associated with the one or more sensor units 406, to a remote-control unit (not shown), communicatively coupled to the wireless communication unit 408. The remote-control unit for the pipeline maintenance robotic system 100 may serve as a vital interface between operators and the robotic system 100, enabling efficient and safe control from a distance. Equipped with wireless connectivity, the remote-control unit may establish a communication link with the robotic system 100, allowing operators to navigate through pipelines 302 and perform maintenance tasks in challenging or hazardous environments. The remote-control unit may be input devices such as joysticks, control panels, or touchscreens, providing an intuitive interface for operators to command the robotic system's 100 movements, adjust speed, and control specialized tools or sensors. Real-time feedback, including live video feeds from onboard cameras and sensor data, enhances the operator's situational awareness, facilitating informed decision-making during remote operation. Additionally, the remote-control unit may allow operators to perform a range of tasks such as navigating pipelines, adjusting speeds, and executing maintenance procedures remotely.
[0058] In an embodiment, the wireless communication unit 408 may receive one or more control signals from the remote-control unit, to control a plurality of operational modes of the inspection subsystem 102 and the cleaning subsystem 104. The plurality of operational modes may include distinct configurations or states in which the inspection subsystem 102 and the cleaning subsystem 104 of the pipeline maintenance robotic system 100 may operate. The operational modes are subject to control signals transmitted from the remote-control unit via the wireless communication unit 408. The control signals received from the remote-control unit guide and dictate the specific functions and behaviors of both the inspection and cleaning subsystems. The operational modes may include, but is not limited to, variations in movement, speed, sensor activation, tool deployment, or other functionalities, allowing the robotic system to adapt to different tasks and operational requirements.
[0059] In an embodiment, the processing unit 410 may control operation of the DC motor, and/or the plurality of servo motors 120, based on the received one or more control signals, the one or more attributes, and the diameter of the pipeline. Further, the processing unit 410 may control the inspection subsystem 102 and the cleaning subsystem 104 based on the plurality of operational modes.
[0060] FIG. 5A illustrates a side view of a (a) universal joint holder, (b) swivel, (c) complete universal joint (u-joint) 112, in accordance with some embodiments of the present disclosure. In an example, two segments such as the front body 106 and the rear body 108 of the pipeline maintenance robotic system 100 may be connected through the u-joint 112. The u-joint 112 may provide flexibility to the pipeline maintenance robotic system 100 when navigating turns and T-joints of the pipeline 302, while avoiding any collision between the driving units 402 in the front body 106 and the rear body 108. As, the u-joint 112 allows for angular freedom, the u-joint 112 may prevent longitudinal movement between the segments and mitigates the risk of damage to the components associated with the robotic system 100. Moreover, the u-joint 112 may provide stability, as the front body 106 or the rear body 108 (lower body) may prevent the robotic system 100 from slipping within the pipeline 302, if the rear body 108 or the front body (i.e., the body ahead loses traction. Accordingly, the u-joint 112 may provide the flexible joint between the segments, with ability to provide the required flexibility while maintaining stability and preventing damages to the components of the robotic system 100.
[0061] FIG. 5B illustrates a side view of a wheel module 110 (a) depicting a primary lever 504 and a secondary lever 506, (b) in fully retracted position, (c) in complete expanded position, in accordance with some embodiments of the present disclosure. For example, the robotic system 100 may include six-wheel modules 110, with three attached to each of the front body 106 and the rear body 108. Each wheel module 110 may include the pantograph mechanism with the primary lever 504 connected to a fixed base 508 and a secondary lever 506 coupled to a moving base 510. The primary lever 504 may include the wheels 516, and the moving base 510 is coupled to wheel module base 518.
[0062] Further, a hybrid DC motor (not shown in FIG. 5B) may actuate the spur gear mechanism for controlled rotation of a lead screw 512, which enables the longitudinal motion of the moving base 510 via a threaded collar 514. The longitudinal motion of the moving base 510 enables a controlled diametrical adjustment of the wheel modules 110. The longitudinal motion of the moving base 510 may be translated into radial expansion of the wheel modules 110 through the pantograph mechanism. In an example, all the three-wheel modules 110 may be coupled to the circumference of the front body 106 and/or the rear body 108, pre-defined degrees apart (e.g., 120). When inspecting horizontal surfaces of the pipeline 302, the robotic system 100 may retract one of the wheel modules 110 and use other two-wheel modules 110 in the front body 106 and/or the rear body 108. This is to increase usability of the system 100 in other fields and optimize power consumption during inspections. Further, the wheel modules 110 with adjustability may provide stability and maneuverability when traversing through challenging terrains. FIG. 5C illustrates an auxiliary view (a) and (c), and a top view (b) of a threaded collar 514, in accordance with some embodiments of present disclosure.
[0063] FIG. 5D illustrates an auxiliary view (a) and (c), and a top view (b) of a rotating holder 520 associated with the cleaning module 114, in accordance with some embodiments of present disclosure. FIG. 5E illustrates an auxiliary view (a) and (c), and a top view (b) of a plurality of pre-defined shaped extrusions 522 associated with the cleaning module 114, in accordance with some embodiments of present disclosure. For example, position-based servo motors may be used to drive the wheels 516, while a DC motor of for example, 100 RPM may be used to control the operation of the cleaning module 114. The robotic system 100 may include the cleaning module 114 which may include the rotating holder 520 and a combination of pre-defined shaped extrusions 522 (e.g., L shape, T shape and the like) coupled to the rotating holder 520. The extrusions 522 may be equidistant from each other that have a sponge attached to each of a top end of the extrusions 522. The cleaning module 114 associated with the cleaning subsystem 104 may rotate in both clockwise as well as anticlockwise directions. Further, the tanks 116 may embedded on the robotic system 110 to store the necessary liquids required in order to clean the pipeline 302. Dispensing of the liquid is via the nozzle 118 provided on the tanks 116. The tanks 116 may be connected to an external source via thin tubular structures for constant refilling purposes of the liquids/fluids.
Exemplary scenario 1:
[0064] Consider a scenario of oil and gas pipeline inspection in remote area. In a vast and remote oil and gas field, a pipeline maintenance robotic system 100 equipped with advanced inspection subsystem 102 and cleaning subsystem 104 may be deployed. The robotic system 100 may be transported to the site and carefully lowered into the pipeline entrance. In case of semi-autonomous, the remote-control unit may be operated by a technician stationed at a central control hub. In another case, the robotic system 100 may be autonomous mode of maintaining the pipeline 302. Further, in semi-autonomous mode, the technician may select the inspection mode, allowing the robotic system 100 to autonomously navigate through the pipeline 302, collecting data on structural integrity and detecting any signs of corrosion or defects. Real-time video feeds and sensor data are transmitted back to the control hub, providing the operator with a comprehensive view of the pipeline's 302 condition. Upon identifying areas that require cleaning, the operator switches to the cleaning mode, activating the cleaning subsystem 104 to remove debris and contaminants. The robotic system efficiently completes the inspection and cleaning tasks, significantly reducing the need for manual intervention in the challenging and remote pipeline environment.
Exemplary scenario 2:
[0065] Consider a scenario of water treatment pipeline maintenance in urban area. In an urban area with an extensive water treatment pipeline network, a pipeline maintenance robotic system 100 may be employed for routine inspection and cleaning. The system 100 may be transported to a water treatment plant and carefully inserted into the pipeline through a designated access point. The operator, situated at a control station within the facility, utilizes the remote-control unit (in case of semi-autonomous) to initiate the inspection mode. The robotic system 100 navigates through the intricate network of pipelines 302, using its sensors to assess the interior condition of the pipelines 302. The operator observes real-time video feeds and sensor data, identifying areas with sediment build-up and potential blockages. Upon detecting such areas, the operator switches to the cleaning mode, activating the cleaning subsystem 104 to remove sediment and ensure the efficient flow of water. The versatility of operational modes, controlled remotely, allows for a proactive and targeted approach to pipeline maintenance, ensuring the reliability and longevity of the water treatment infrastructure in the urban environment.
[0066] Embodiments of the present disclosure provides a pipeline maintenance robotic system. The maintenance of the pipeline may include an inspection of the pipeline and/or a cleaning of the pipeline. The present disclosure provides a low-cost semi-autonomous pipeline inspection and cleaning robotic device. The present disclosure provides a robotic system to incorporate a modular framework that allows for effortless customization and expansion, overcoming the limitations of fixed-size robots. The ability to adapt to distinct pipe sizes and configurations is a pivotal feature, enabling the robot to navigate through a wide range of pipes, including those with bends, junctions, and varying diameters. This design flexibility not only streamlines maintenance and repair procedures, however, also introduces replaceable or upgradable components, enhancing the overall usability and longevity of the robot.
[0067] Due to merging of inspection and cleaning functions in multiple modes of operations, the present disclosure averts hazardous manual inspections, enhances operational efficiency, detects defects in real-time, and encourages proactive maintenance. The modular design facilitates component replacement or upgrades, reducing downtime and improving overall efficiency. Moreover, the adaptive structure accommodates various pipe sizes, curbing the limitations of fixed-size robots.
[0068] The utility and market potential of this modular and adaptable pipe inspection and cleaning robotic system are significant across various industries reliant on pipeline infrastructure. The robot provides an efficient and automated solution for inspecting pipelines while simultaneously cleaning them, eliminating the need for manual inspections in hazardous or hard-to-reach areas. Industries such as oil and gas, water and wastewater, chemical processing, and infrastructure utilities stand to benefit from its versatility. The modular framework, universal joint connector, improved maintenance processes, and integration of a cleaning module collectively enables the robotic system to address the challenges posed by diverse pipe networks.
[0069] The written description describes the subject matter herein to enable any person skilled in the art to make and use the embodiments. The scope of the subject matter embodiments is defined by the claims and may include other modifications that occur to those skilled in the art. Such other modifications are intended to be within the scope of the claims if they have similar elements that do not differ from the literal language of the claims or if they include equivalent elements with insubstantial differences from the literal language of the claims.
[0070] A description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the invention. When a single device or article is described herein, it will be apparent that more than one device/article (whether they cooperate) may be used in place of a single device/article. Similarly, where more than one device or article is described herein (whether or not they cooperate), it will be apparent that a single device/article may be used in place of the more than one device or article or a different number of devices/articles may be used instead of the shown number of devices or programs. The functionality and/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/features. Thus, other embodiments of the invention need not include the device itself.
[0071] The illustrated steps are set out to explain the exemplary embodiments shown, and it should be anticipated that ongoing technological development will change the manner in which particular functions are performed. These examples are presented herein for purposes of illustration, and not limitation. Further, the boundaries of the functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternative boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed. Alternatives (including equivalents, extensions, variations, deviations, etc., of those described herein) will be apparent to persons skilled in the relevant art(s) based on the teachings contained herein. Such alternatives fall within the scope and spirit of the disclosed embodiments. Also, the words “comprising”, “having”, “containing”, and “including”, and other similar forms are intended to be equivalent in meaning and be open-ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
[0072] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter. It is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
, Claims:CLAIMS:
We claim:
1. A pipeline maintenance robotic system (100) comprising:
an inspection subsystem (102) comprising:
a front body (106) and a rear body (108) comprising a plurality of wheel modules (110) individually driven, wherein the front body (106) and the rear body (108) are connected to each other via a universal joint (u-joint) (112),
wherein the front body (106) comprises a direct current (DC) motor coupled to a cleaning module (114), and wherein the rear body (108) comprises one or more tanks (116) for retaining one or more fluids and dispensing the one or more fluids via one or more nozzles (118) associated with the one or more tanks (116),
wherein each of the plurality of wheel modules (110) comprise a pantograph mechanism with a primary lever movably coupled to a fixed base of the plurality of wheel modules (110) and a secondary lever coupled to a moving base of the plurality of wheel modules (110),
wherein the plurality of the wheel modules (110) is configured to perform, via the pantograph mechanism, an extraction and a retraction based on a diameter of the pipeline,
wherein each of the plurality of moving base comprises a lead screw and a threaded collar rotatably coupled to the lead screw, and
wherein the plurality of wheel modules (110) comprising the pantograph mechanism is configured to perform at least one of an extension and a retraction based on actuation of the lead screw using a spur gear mechanism via one or more hybrid Direct Current (DC) servo motors of a plurality of servo motors (120); and
a driving unit communicatively coupled to the plurality of servo motors (120), configured to drive each of the plurality of wheel modules (110); and
a cleaning subsystem (104) comprising:
the cleaning module (114), disposed at one or more sides of the front body (106), to remove foreign substance formed on inside surface of a pipeline, by a rotating force generated via the DC motor, upon dispensing the one or more fluids via the one or more nozzles (118) associated with the one or more tanks (116), wherein the inspection subsystem (102) and the cleaning subsystem (104) is configured to perform maintenance of the pipeline comprising at least one of an inspection of the pipeline and a cleaning of the pipeline.
2. The pipeline maintenance robotic system (100) as claimed in claim 1, further comprising:
one or more image capturing units configured to capture multimedia content of the inside surface of the pipeline;
one or more sensor units configured to detect one or more attributes within the inside surface of the pipeline;
a wireless communication unit configured to:
transmit the multimedia content associate with the one or more image capturing units and the detected one or more attributes associated with the one or more sensor units, to a remote-control unit communicatively coupled to the wireless communication unit; and
receive one or more control signals from the remote-control unit, to control a plurality of operational modes of the inspection subsystem (102) and the cleaning subsystem (104).
3. The pipeline maintenance robotic system (100) as claimed in claim 2, further comprising:
a processing unit configured to:
control operation of at least one of the DC motor, the plurality of servo motors (120), the plurality of servo motors (120), based on the received one or more control signals, the one or more attributes, and the diameter of the pipeline; and
control the inspection subsystem (102) and the cleaning subsystem (104) based on the plurality of operational modes.
4. The pipeline maintenance robotic system (100) as claimed in claim 1, wherein the spur gear mechanism corresponds to controlled rotation of the lead screw, and longitude motion of the moving base, and diametrical adjustment of the plurality of wheel modules (110), by adjusting the fixed base and the moving base.
5. The pipeline maintenance robotic system (100) as claimed in claim 1, wherein in the plurality of servo motors (120) at least two servo motors corresponds to hybrid DC servo motors, and wherein the hybrid DC servo motors comprises at least one quadrature encoder, configured to vary diameter of the pipeline maintenance robotic system (100), by actuating the spur gear mechanism to actuate the pantograph mechanism.
6. The pipeline maintenance robotic system (100) as claimed in claim 1, wherein the lead screw comprises external threads driven by the servo motors (120) for controlled longitudinal motion of the threaded collar translated into radial expansion of the plurality of wheel modules (110) through the pantograph mechanism.
7. The pipeline maintenance robotic system (100) as claimed in claim 6, wherein the controlled longitudinal motion of the threaded collar is translated into a radial expansion of the plurality of wheel modules (110).
8. The pipeline maintenance robotic system (100) as claimed in claim 1, wherein the cleaning module (114) comprises a plurality of pre-defined shaped extrusions with a one or more cleaning materials attached to a top end of each of the pre-defined shaped extrusions.
9. The pipeline maintenance robotic system (100) as claimed in claim 1, wherein, in the plurality of wheel modules (110), at least three of the wheel modules (110) are attached to a circumference of each of the front body (106) and the rear body (108), with pre-defined degrees apart.
10. The pipeline maintenance robotic system (100) as claimed in claim 1, wherein, in the plurality of wheel modules (110), at least one wheel module is configured to retract, and at least two-wheel modules (110) with decreased angle is used for inspecting horizontal surfaces.
11. The pipeline maintenance robotic system (100) as claimed in claim 1, wherein the u-joint (112) is attached and detached via a locking mechanism comprising a swivel.
12. The pipeline maintenance robotic system (100) as claimed in claim 1, wherein the one or more tanks (116) is refilled with the one or more fluids via a one or more external source through a thin tubular structure.
13. The pipeline maintenance robotic system (100) as claimed in claim 1, wherein the front body (106) and the rear body (108) are spaced apart from a pivotal axis of the u-joint (112) around, which the front body (106) and the rear body (108) are in angular freedom, based on at least one of a type of the pipeline, a curvature of the pipeline, a joint of a pipeline, and a diameter of the pipeline.
Dated this 07th day of December 2023