Abstract: A two-wheel compact magnetic crawler vehicle for traversing and inspecting surfaces. The crawler comprises a chassis. Two independently actuated magnetic drive wheels are spaced apart in a lateral direction and mounted to the chassis by a hinged joint enabling each wheel to tilt in response to the surface curvature. A probe wheel is provided at the midpoint between the two drive wheels and laterally in line therewith. A spring-assisted probe carrier passively moves the probe wheel vertically relative to the chassis in response to changes in the surface curvature. Additionally, the vehicle includes a probe angle normalization mechanism comprising spring-loaded, vertically moveable, ball casters positioned symmetrically about the probe wheel. The combined utilization of the probe carrier and the caster carrier passively maintain the probe contacting the surface, the chassis level, and the probe normal to the surface irrespective of changes in the surface curvature with vehicle movement.

Abstract: An automated system for performing multiple operations on one or more weld joints of a pipe string includes a main controller including a user interface; and a first robotic device that is in communication with the main controller and is configured to controllably travel inside of the pipe string and detect and uniquely identify each weld joint within the pipe string based on a vision-based weld detection module that is executed on a first onboard computer. The vision-based weld detection module provides at least one of: (1) images captured within the pipe string and (2) a live video feed within the pipe string that is displayed on the user interface for allowing a user to review and approve detection of the weld joint, whereupon once the user confirms the approval, the first robotic device automatically positions itself a predefined distance from the detected weld joint and automatically begins to perform at least one operation on the weld joint.

Abstract: Cable-driven robotic platform systems and methods of operation are disclosed. The system includes a robotic platform suspended by a system of overhead cables, motorized cable reels and pulleys. A master control computer coordinates operation of the motorized cable system as a function of sensor data captured by navigation sensors on-board the platform so as to move the robotic platform inside an industrial plant. The system is configured to maneuver around pipings and avoid obstacles in the plant in order to maximize the effective workspace that the robotic platform can reach to perform operations including inspection or repair. Additionally, a robotic “wire jacket” device can be attached to suspension cables and configured to crawl along a cable. The wire-jacket can be selectively positioned on a cable to provide an intermediate cable suspension point that improves platform mobility within congested spaces and avoids obstacles.

Abstract: A robotic vehicle for traversing surfaces comprises a chassis having a plurality of wheels mounted thereto. Two magnetic drive wheels are spaced apart in a lateral direction and rotate about a rotational axis while a stabilizing wheel is provided in front of or behind the two drive wheels. The drive wheels are configured to be driven independently, thereby driving and steering the vehicle along the surface. The vehicle also includes a sensor probe assembly that is supported by the chassis and configured to take measurements of the surface being traversed. In accordance with a salient aspect, the vehicle includes a probe normalization mechanism that is configured to determine the surface curvature and adjust the orientation of the probe transducer as a function of the curvature of the surface, thereby maintaining the probe at the preferred inspection angle irrespective of changes in the surface curvature with vehicle movement.

Abstract: A two-wheel compact magnetic crawler vehicle for traversing and inspecting surfaces is disclosed. The crawler comprises a chassis. Two independently actuated magnetic drive wheels are spaced apart in a lateral direction and mounted to the chassis by a hinged joint enabling each wheel to tilt in response to the surface curvature. A probe wheel is provided at the midpoint between the two drive wheels and laterally in line therewith. A spring-assisted probe carrier passively moves the probe wheel vertically relative to the chassis in response to changes in the surface curvature. Additionally, the vehicle includes a probe angle normalization mechanism comprising spring-loaded, vertically moveable, ball casters positioned symmetrically about the probe wheel. The combined utilization of the probe carrier and the caster carrier passively maintain the probe contacting the surface, the chassis level, and the probe normal to the surface irrespective of changes in the surface curvature with vehicle movement.

Abstract: An in-pipe apparatus for pipe inspection or maintenance using a probe or tool includes: a lateral deployment mechanism including a perpendicular deployment mechanism and a linear actuator configured to deploy the perpendicular deployment mechanism in a lateral direction toward a target point to contact an inner wall of the pipe and passively deploy a probe or tool perpendicularly on or at the target point; and a rotational deployment mechanism coupled to the lateral deployment mechanism and including a motor configured to rotationally deploy the lateral deployment mechanism about the inner circumference with respect to a rotation axis that differs from the pipe axis, to align the lateral deployment mechanism in the lateral direction. The perpendicular deployment mechanism includes: a pivot member to pivot the perpendicular deployment mechanism about a pivot axis parallel to the rotation axis; and a probe or tool holder coupled to the pivot member.

Abstract: An apparatus for automated inspection or maintenance is provided. The apparatus includes a dual slider mechanism for deploying a probe. The dual slider mechanism comprises: a frame; a probe slider configured to attach the probe; a probe linear guide coupled to the frame and configured to guide the probe slider and attached probe in a linear direction; a spring having one end attached to the probe slider; a spring slider attached to another end of the spring; and a spring linear guide coupled to the frame and configured to guide the spring slider and attached spring in the linear direction, in order to guide the probe slider and attached probe in the linear direction along the probe linear guide using the guided spring.

Abstract: Cable-driven robotic platform systems and methods of operation are disclosed. The system includes a robotic platform suspended by a system of overhead cables, motorized cable reels and pulleys. A master control computer coordinates operation of the motorized cable system as a function of sensor data captured by navigation sensors on-board the platform so as to move the robotic platform inside an industrial plant. The system is configured to maneuver around pipings and avoid obstacles in the plant in order to maximize the effective workspace that the robotic platform can reach to perform operations including inspection or repair. Additionally, a robotic “wire jacket” device can be attached to suspension cables and configured to crawl along a cable. The wire-jacket can be selectively positioned on a cable to provide an intermediate cable suspension point that improves platform mobility within congested spaces and avoids obstacles.

Abstract: An automated system for performing multiple operations on one or more weld joints of a pipe string includes a main controller including a user interface; and a first robotic device that is in communication with the main controller and is configured to controllably travel inside of the pipe string and detect and uniquely identify each weld joint within the pipe string based on a vision-based weld detection module that is executed on a first onboard computer. The vision-based weld detection module provides at least one of: (1) images captured within the pipe string and (2) a live video feed within the pipe string that is displayed on the user interface for allowing a user to review and approve detection of the weld joint, whereupon once the user confirms the approval, the first robotic device automatically positions itself a predefined distance from the detected weld joint and automatically begins to perform at least one operation on the weld joint.

Abstract: An in-pipe apparatus for pipe inspection or maintenance is provided. The apparatus includes: a rotational deployment mechanism to rotationally deploy a probe or tool about an inner circumference of a pipe with respect to an axis of rotation; a radial deployment mechanism to radially deploy the probe or tool in a radial direction from the axis of rotation toward a target point on the inner circumference; and a passive centering mechanism to passively align the axis of rotation with the axis of the pipe. In some embodiments, the rotational deployment mechanism includes a motor to rotate the radial deployment mechanism about the axis of rotation. In some embodiments, the apparatus further includes a longitudinal deployment mechanism to longitudinally deploy the probe or tool along the pipe axis, with the passive centering mechanism passively maintaining alignment of the axis of rotation with the pipe axis during the longitudinal deployment.

Abstract: An in-pipe apparatus for pipe inspection or maintenance is provided. The apparatus includes: a rotational deployment mechanism to rotationally deploy a probe or tool about an inner circumference of a pipe with respect to an axis of rotation; a radial deployment mechanism to radially deploy the probe or tool in a radial direction from the axis of rotation toward a target point on the inner circumference of the pipe; and a passive centering mechanism to passively align the axis of rotation with the axis of the pipe. In some embodiments, the rotational deployment mechanism includes a motor to rotate the radial deployment mechanism about the axis of rotation. In some embodiments, the apparatus further includes a longitudinal deployment mechanism to longitudinally deploy the probe or tool along the axis of the pipe, with the passive centering mechanism passively maintaining alignment of the axis of rotation with the pipe axis during the longitudinal deployment.

Abstract: An in-pipe apparatus for pipe inspection or maintenance using a probe or tool includes: a lateral deployment mechanism including a perpendicular deployment mechanism and a linear actuator configured to deploy the perpendicular deployment mechanism in a lateral direction toward a target point to contact an inner wall of the pipe and passively deploy a probe or tool perpendicularly on or at the target point; and a rotational deployment mechanism coupled to the lateral deployment mechanism and including a motor configured to rotationally deploy the lateral deployment mechanism about the inner circumference with respect to a rotation axis that differs from the pipe axis, to align the lateral deployment mechanism in the lateral direction. The perpendicular deployment mechanism includes: a pivot member to pivot the perpendicular deployment mechanism about a pivot axis parallel to the rotation axis; and a probe or tool holder coupled to the pivot member.

Abstract: An apparatus for automated inspection or maintenance is provided. The apparatus includes a dual slider mechanism for deploying a probe. The dual slider mechanism comprises: a frame; a probe slider configured to attach the probe; a probe linear guide coupled to the frame and configured to guide the probe slider and attached probe in a linear direction; a spring having one end attached to the probe slider; a spring slider attached to another end of the spring; and a spring linear guide coupled to the frame and configured to guide the spring slider and attached spring in the linear direction, in order to guide the probe slider and attached probe in the linear direction along the probe linear guide using the guided spring.

Abstract: An in-pipe apparatus for pipe inspection or maintenance is provided. The apparatus includes: a rotational deployment mechanism to rotationally deploy a probe or tool about an inner circumference of a pipe with respect to an axis of rotation; a radial deployment mechanism to radially deploy the probe or tool in a radial direction from the axis of rotation toward a target point on the inner circumference of the pipe; and a passive centering mechanism to passively align the axis of rotation with the axis of the pipe. In some embodiments, the rotational deployment mechanism includes a motor to rotate the radial deployment mechanism about the axis of rotation. In some embodiments, the apparatus further includes a longitudinal deployment mechanism to longitudinally deploy the probe or tool along the axis of the pipe, with the passive centering mechanism passively maintaining alignment of the axis of rotation with the pipe axis during the longitudinal deployment.

Abstract: An in-pipe inspection or maintenance apparatus comprises: a single rotational and radial deployment mechanism to both rotationally deploy a probe or tool about an inner circumference of a pipe with respect to the axis of the pipe and radially deploy the probe or tool to first and second target points on the inner circumference; and a single actuator to automatically actuate the rotational and radial deployment mechanism to perform both the rotational and radial deployments of the probe or tool. The rotational and radial deployment mechanism is further configured to: rotate the probe or tool and radially extend the probe or tool to the first target point in response to the single actuator actuating the rotational and radial deployment mechanism; and rotate the probe or tool from the first target point to the second target point in response to the single actuator further actuating the rotational and radial deployment mechanism.

Abstract: A robotic vehicle for traversing surfaces comprises a chassis having a plurality of wheels mounted thereto. Two magnetic drive wheels are spaced apart in a lateral direction and rotate about a rotational axis while a stabilizing wheel is provided in front of or behind the two drive wheels. The drive wheels are configured to be driven independently, thereby driving and steering the vehicle along the surface. The vehicle also includes a sensor probe assembly that is supported by the chassis and configured to take measurements of the surface being traversed. In accordance with a salient aspect, the vehicle includes a probe normalization mechanism that is configured to determine the surface curvature and adjust the orientation of the probe transducer as a function of the curvature of the surface, thereby maintaining the probe at the preferred inspection angle irrespective of changes in the surface curvature with vehicle movement.