ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS
20230219644 · 2023-07-13
Inventors
- Clayton Eduardo Rodrigues (Rio de Janeiro, BR)
- Andre Koebsch (Rio de Janeiro, BR)
- Paulo Henrique Giusti (Rio de Janeiro, BR)
- Doglas Negri (Joinville, BR)
- Ismael Secco (Joinville, BR)
- Diego De Souza (Joinville, BR)
- Walter Kapp (Joinville, BR)
- Marco Shawn Meireles Machado (Joinville, BR)
- Felipe Faria (Joinville, BR)
- Luiz Felipe Baldo Marques (Joinville, BR)
Cpc classification
B60G7/02
PERFORMING OPERATIONS; TRANSPORTING
B60G2300/50
PERFORMING OPERATIONS; TRANSPORTING
B05C5/02
PERFORMING OPERATIONS; TRANSPORTING
International classification
B25J5/00
PERFORMING OPERATIONS; TRANSPORTING
B25J11/00
PERFORMING OPERATIONS; TRANSPORTING
B60K7/00
PERFORMING OPERATIONS; TRANSPORTING
B60G7/02
PERFORMING OPERATIONS; TRANSPORTING
B60B19/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present invention aims at developing a robot for applying coating in regions called “difficult access areas” of offshore platforms and ships, such as curved, vertical surfaces, or surfaces with negative inclination angles. The design concept was developed based on a low-weight painting system, integrated into a vehicle with magnetic shoes (104), which produces a constant magnetic force on the metallic surface, capable of guaranteeing the support of the vehicle in the different areas of application. The floating magnetic system aims at ensuring that the wheels (102) have the necessary friction for the vehicle to move. The use of the equipment allows greater productivity, with agility and speed in the application of coatings, reduction of coating losses during the process, repeatability and guarantee of the thickness of the applied layer, in addition to allowing the application of the coating on vertical surfaces, with negative inclinations or curves, without the need for access using scaffolding, dispensing with scaffolding assembly and disassembly services and the use of ropes by professionals for work on the sea, with the consequent reduction in the number of workers on the sea and the reduction of exposure of the man in unhealthy environments.
Claims
1- A ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS, characterized in that it comprises: powertrain (1), magnetic shoe (2), omnidirectional wheel (3), chassis (4), robotic manipulator (5), electrical panel (6), suspension (7), and process effector (8).
2- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 1, characterized in that it is equipped with three (six) powertrains (1), which consist of a motor (101), brake, reducer and drive shaft.
3- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 2, characterized in that each powertrain (1) has an omnidirectional wheel (102).
4- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 3, characterized in that each omnidirectional wheel (102) has nine equally spaced mecanum rollers (103) and two magnetic shoes (104).
5- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 4, characterized in that each shoe (104) is positioned next to a side face of the wheel (102), being inserted within the wheel envelope.
6- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 4, characterized in that each shoe (104) consists of a permanent magnet in the shape of a horseshoe.
7- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 1, characterized in that the suspension (7) is a set of tubular elements and machined components connected by rotating joints, connecting the axles (411 and 412) to the sprung chassis (402).
8- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 7, characterized in that the suspension (7) is articulated for distribution of traction forces for a redundant system of six mecanum wheels (102) adaptable to any surface in a rigid way.
9- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 1, characterized in that the chassis (4) is subdivided into a sprung chassis (402) and an unsprung subchassis (401) articulated that adapts to the surface.
10- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 9, characterized in that the sprung chassis (402) supports the robot load and the manipulator arm (5).
11- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 1, characterized in that the chassis (4) has a central shaft (403) connected to two triangles (414) by their bases and at the opposite vertex of this triangle pivots orthogonal (413) to the central shaft (403), which are connected to the end axles (404), which are parallel to the central shaft (403).
12- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 11, characterized in that the gauge of the central shaft (403) is greater than the gauge of the end axles (404).
13- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 1, characterized in that the subchassis (401) has a central articulation (413) that allows a different height of the end axles (404) in relation to the center shaft (403).
14- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 1, characterized in that the chassis (4) has pivots at the tips of the triangles (414), where the end axles (404) pivot on a longitudinal axis, allowing the three axles to work in a non-parallel manner.
15- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 1, characterized in that the force component normal to the sprung chassis (402) is transferred to the central pivot (413) of the end axles (404) by the links (405) that connect the corners of the chassis (4) to the pivot (410) of the triangles (414) of the unsprung subchassis (401).
16- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 1, characterized in that the force in the longitudinal direction is transferred from the sprung chassis (402) to the central shaft (403) through a double opposite triangle type mechanism (414), where a triangular base (414) is fixed to the sprung chassis (402) and the other base is fixed to the central shaft (403), the two triangles (414) being joined by a nearly spherical ball joint (413) at the apex opposite the bases.
17- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 16, characterized in that, on the central shaft (403), the force is divided between the end axles (404) through the unsprung subchassis (401).
18- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 16, characterized in that the parallel force applied to the sprung chassis (402) is transferred to the central shaft (403) through a double rigid quadrilateral (406), articulated by its parallel bases.
19- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 16, characterized in that the rolling force applied to the sprung chassis (402) is transferred to the central shaft (403) through a double rigid quadrilateral (406), articulated by its parallel bases, the same responsible for the transverse forces.
20- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 1, characterized in that the pitch moment component applied to the sprung chassis (402) is transferred to the central pivot (413) of the end axles (404) by the links (405) that connect the corners of the chassis (4) to the pivot (410) of the triangles (414) of the subchassis (401).
21- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 20, characterized in that the moment applied to the end axles (404) by the wheels (102) is transferred to the unsprung subchassis (401) by a set of offset double bushings (405).
22- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 20, characterized in that the moment applied to the central shaft (403), by the wheels (102), is transferred to the sprung chassis (402) by means of a double opposing triangle type mechanism (414), where a triangular base is fixed to the sprung chassis (402) and the other base fixed to the central shaft (403), the two triangles (414) are joined by a nearly spherical ball joint (413) at the apex opposite the bases.
23- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 20, characterized in that the axial force generated by the wheels (102) is canceled within the axles/shaft themselves (central shaft (403) and end axles (404)).
24- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 1, characterized in that the chassis (4) is geometrically sprung and consists of aeronautical aluminum structural tubes and a fixation base for the robotic manipulator (5).
25- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 24, characterized in that the robotic manipulator (5) plays the role of applying the coating.
26- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 1, characterized in that the electrical panel (6) is mounted on the upper part of the chassis (4), on the opposite side to which the manipulator (5) is mounted, in order to balance the center of gravity of the set.
27- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 26, characterized in that an umbilical bundle containing electrical and pneumatic power and communication connections reaches the inside of the panel via cable glands.
28- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 26, characterized in that a static DC-DC converter lowers the input supply voltage, internally distributing the DC voltages that supply other electrical devices, such as controllers, drivers, communication interfaces, relays, etc.
29- THE ROBOT WITH MAGNETIC SHOES APPLIED TO THE METALLIC SURFACES COATING PROCESS according to claim 27, characterized in that the umbilical bundle contains electrical power and communication for the vehicle panel, the power and command cables of the manipulator (5), and a supply of compressed air for actuating the coating tool (502), coupled to the effector of process (501).
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The present invention will be described in more detail below, with reference to the attached figures which, in a schematic way and not limiting the inventive scope, represent examples of its realization. In the drawings:
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
DETAILED DESCRIPTION OF THE INVENTION
[0034] There follows below a detailed description of a preferred embodiment of the present invention, by way of example and in no way limiting. Nevertheless, it will be clear to a technician skilled on the subject, from reading this description, possible additional embodiments of the present invention still comprised by the essential and optional features below.
[0035] The invention seeks to solve or reduce the limitations found in the State of the Art of the coating process in oil extraction offshore plants, through the development of a mechatronic system capable of operating, at least, by teleoperation. The main pillars of the development of the invention are: [0036] Adherence: the equipment must be able to adhere to the ferromagnetic metallic surfaces of the target structures of the coating; [0037] Movement: the equipment must be able to move with the maximum possible degrees of freedom on the surface to which it is adhered; [0038] Accessibility: the equipment must, through its adherence and movement capabilities, be able to reach difficult access places that normally cannot be accessed by industrial climbers; [0039] Dexterity: the equipment must be able to apply the coating with greater dexterity, precision and repeatability compared to manual application mode; [0040] Productivity: the equipment must be able to perform the application of the coating with greater productivity, in square meters per hour (m.sup.2/h) in relation to the manual application mode; [0041] Adaptability: the equipment must be capable of mechanically adapting or overcoming, in terms of positioning and movement, the geometric variations of the application surface, such as curvature radii, sheet steps, weld beads, etc.
[0042] The robot of the present invention has the ability to access difficult access areas, allowing the application of coating in places where the industrial climber is currently unable to reach, either due to physical impediment or safety standards.
[0043] The high repeatability of the industrial manipulator of this invention allows for greater uniformity of the applied coating layer, ensuring a more homogeneous and higher quality result, since it is possible to parameterize and control the movement of the manipulator, in order to optimize the process of application.
[0044] The concept of omnidirectional movement of the vehicle of this invention allows rapid repositioning and displacement on the work surface, thus increasing productivity in relation to the application of coating performed by an industrial climber.
[0045] The ability to teleoperate the vehicle ensures that the operator is not subjected to the dangerous environment to which the industrial climber is usually exposed, allowing the process to be performed on longer journeys, since the operator will work in a more ergonomic and less aggressive position.
[0046] All the above-mentioned features of the invention, when combined, not only allow for a more efficient, safe and effective coating process, but also enable the optimization of plant occupancy in an offshore environment, since the process is performed by fewer people and in a shorter period.
[0047] The robot is able to adhere and move on surfaces of ferromagnetic metal sheets of at least 8 millimeters thick at inclinations of 0 up to 180 degrees in relation to a horizontal reference. It has a suspension that allows the vehicle to adapt to curved surfaces of at least 1 meter radius (concave or convex). It is capable of overcoming rectangular obstacles of at least 22 millimeters in height in frontal approaches, in which case the obstacle line is perpendicular to the X axis of the vehicle (see
[0048] Considering alternative applications for the invention, it is feasible, in the face of minor modifications (without direct impact on the concept of the invention), the use of tools other than coating, both on the handle of the robot manipulator and replacing the manipulator itself. The invention ends up providing a mobile platform, allowing the implementation of process and inspection modules in its structure, enabling the transfer of technology to other applications, respecting, of course, the previously imposed restrictions.
[0049] According to
[0058] The vehicle is equipped with three powertrains (1), which consist of motors (101) (
[0059] In
[0060] As the mechanical adherence depends not only on the coefficient of friction of the rollers (103), but also on the magnitude of the normal force in relation to the ferromagnetic surface, each omnidirectional wheel (102) has two magnetic shoes (104), each of which shoe (104) is positioned alongside a side face of the wheel (102). The magnetic shoes (104) consist of permanent magnets enclosed by a sleeve of non-magnetic material, which in turn is attached to a ferromagnetic core that provides the optimized induction of the magnetic field between the shoe (104) and the ferromagnetic substrate, which consequently generates the normal magnetic force necessary to ensure the adhesion of the vehicle to the surface.
[0061] The suspension (7) is a set of tubular elements and machined components connected by rotating joints, designed to connect the powertrains (1) to the chassis (4) and provide the vehicle with the necessary magnetic adhesion force to overcome possible abrupt dihedral changes, or simply adapt, in a reactive way, to the irregularities of the ferromagnetic surface. The principle of the mechanism is given by the up and down movement (translation) of the central powertrain, while the adjacent powertrains have a complex movement (translation and rotation), which aims at ensuring that their respective magnetic shoes remain parallel to the magnetic surfaces of each dihedral. The chassis (4) is rigid and has no relative movement.
[0062] Connected to the suspension (7) by means of rotational joints, the chassis (4) is geometrically sprung and consists of aeronautical aluminum structural tubes and a fixation base for the robotic manipulator (5). Its primary function is to resist loads imposed during service and ensure the stiffness and dynamic stability necessary for the robotic manipulator (5) to correctly perform the coating operation, according to previously parameterized physical variables, guaranteeing the quality of the applied coating (layer thickness and surface finishing). In addition, it provides an appropriate place for fixing the power/electrical panel (6).
[0063] The electrical panel (6) is mounted on the top of the chassis (4), on the opposite side to which the manipulator (5) is mounted, in order to balance the center of gravity of the assembly. An umbilical bundle containing electrical and pneumatic power and communication connections reaches the inside of the panel via cable glands. A DC-DC static converter lowers the input supply voltage, internally distributing the DC voltages that supply other electrical devices, such as controllers, drivers, communication interfaces, relays, etc. There are, then, smaller cable glands through which the motor control cables (101) are distributed throughout the vehicle, being fixed to the chassis (4) and suspension (7) of the vehicle.
[0064] The umbilical bundle contains electrical power and communication for the vehicle panel, the power and command cables of the manipulator (5), and a supply of compressed air for actuating the coating tool (502), as shown in
[0065] The omnidirectional displacement on any surface requires three degrees of movement, namely: two orthogonal translations and an orientation with a rotation axis normal to the surface. The mecanum wheels (102) allow this type of displacement from the control of two axles, each with a pair of wheels with opposite roller helices (left and right). That totals four wheels needed for three degrees of freedom of movement. However, this minimum condition works well provided that the traction capacity is balanced between each of the wheels, which is only possible on almost flat horizontal surfaces, or with some type of surface adaptive suspension.
[0066] In the case of the application of the robot of this invention, the surfaces will have any orientation in relation to the vector of gravity, being mostly vertical surfaces. In this specific case, as the center of mass of the robot with its pay load will never be on the surface, but away from it, the moment of the weight force with that distance to the surface unbalances the normal force of the wheels against the surface, reducing the contact force and consequently the traction of the upper wheels in relation to the vector of gravity. For that reason, the robot has three axles/shaft with a pair of mecanum wheels (102) with opposite helices on each axle. Thus, in the case where the longitudinal direction of the vehicle is aligned with the gravity vector, the central shaft maintains an average load, the lower axle has its load increased and the upper axle has its load reduced, but there will always be two axles/shaft with two pairs of wheels with full traction capacity. In the case where the transverse axis of the vehicle is aligned with the vector of gravity, all the moment of displacement of the center of gravity is applied to the central shaft (403), which has a wheel with increased traction capacity, and the pair opposite lightened, but in this condition the two end axles (404) are pivoted and do not receive the moment of the displaced center of mass and these two end axles keep the control of the vehicle. In this unique way, the mecanum wheels (102) are likely to be used for traction on vertical surfaces, with no other known application of these wheels for this type of surface.
[0067] The robot of the present invention has an articulated suspension (7) for distribution of traction forces for a redundant system of six mecanum wheels (102) adaptable to any surface. The robot has six points of contact that must be rigidly adapted to any surface, so that it can carry out precise tasks. For this, the robot structure, shown in
[0068] To adapt to a surface that is not flat in any way, it is necessary to articulate the six points of contact, so that three virtual points of contact remain, and the way to make the reduction from six points to three is to insert three joint pivots (degrees of freedom), which in sequence are linearly independent.
[0069] In this design, the three pivots were arranged as follows, as detailed in
[0070] As the gauge of the central shaft (403) is greater than the gauge of the end axles (404), if the cylindrical surface has six axles orthogonal to the robot axles, the central articulation (413) allows a different height of the end axles (404) in relation to the central shaft (403), shown in
[0071] The pivots (410) of the tips of the triangles (414), where the end axles (404) pivot on a longitudinal axis, allow the three axles/shaft to work in a non-parallel way, adapting a helix surface (twisted) (
[0072] Compositing any overlapping cylindrical surfaces with various axis directions with a helix surface, there will be a fully generic surface shape, and this adaptation mechanism will be compatible.
[0073] The suspension (7) is capable of distributing the vehicle forces among all the wheels. The component of force normal to the sprung chassis (402) is transferred to the central pivot of the end axles (404) by the links (405) that connect the corners of the chassis (4) to the pivot of the triangles (414) of the unsprung subchassis (401). Only the end axles receive this type of force.
[0074] The force in the longitudinal direction is transferred from the sprung chassis (402) to the central shaft (403) through an opposing double triangle type mechanism, where a triangular base is attached to the sprung chassis (402) and the other base is attached to the central shaft. The two triangles (414) are joined by a nearly spherical ball joint at the apex opposite the bases. From the central shaft (403), this force is shared with the end axles (404) through the unsprung subchassis (401).
[0075] The parallel force applied to the sprung chassis (402) is transferred to the central shaft (403) through a double lower transverse quadrilateral (406), articulated by its parallel bases. From the central shaft (403), this force is shared with the end axles (404) through the unsprung subchassis (401).
[0076] The rolling force applied to the sprung chassis (402) is transferred to the central shaft (403) through a double rigid quadrilateral, articulated by its parallel bases, the same responsible for the transverse forces. The rolling force of the sprung chassis (402) is integrally applied to the central shaft (403).
[0077] In the force of the pitch moment of the chassis, the pitch moment component applied to the sprung chassis (402) is transferred to the central pivot (413) of the end axles (404) by the links (405) that connect the corners of the chassis (4) to the pivot (410) of the triangles (414) of the subchassis (401). Only the end axles receive this force.
[0078] In the force of the yaw moment of the chassis, the pitch moment component applied to the sprung chassis (402) is transferred to the central pivot (413) of the end axles by the links that connect the corners of the chassis to the pivot of the triangles (414) of the subchassis (401). From this pivot, the forces are divided between the end axles and the central shaft through the unsprung subchassis (401).
[0079] The moment applied to the end axles (404) by its wheels (102) is transferred to the unsprung subchassis (401) by a set of offset double bushings (or corner links) (405). The opposing moments in each subchassis (401) generate opposite reaction forces in the pivots of the unsprung subchassis (401) and in the pivots (413) coinciding with the central shaft (403), which generates a homogeneous distribution of forces in all wheels (102).
[0080] The moment applied to the central shaft (403) by its wheels (102) is transferred to the sprung chassis (402) by means of a double opposing triangle type mechanism, in which a triangular base is attached to the sprung chassis (402) and the other base fixed to the central shaft (403). The two triangles (414) are joined by a nearly spherical ball joint at the apex opposite the bases.
[0081] The axial force generated by the mecanum wheels (102) is canceled within the axles/shafts themselves (central shaft (403) and end axles (404)), since the wheels (102) always associated with a given axle have the roller helices (103) opposite (left and right).