Robotic manipulators for in situ inspections of jet engines

Jet engines need to be inspected periodically and, in some instances, repaired. Currently, some of these maintenance operations require the engine to be removed from the wing and dismantled, which has a significant associated cost. The capability of performing some of these inspections and repairs while the engine is on-wing could lead to important cost savings. However, existing technology for on-wing operations is limited, and does not suffice to satisfy some of the needs. In this work, the problem of performing on-wing operations such as inspection and repair is analysed, and after an extensive literature review, a novel robotic system for the on-wing insertion and deployment of probes or other tools is proposed. The system consists of a fine-positioner, which is a miniature and dexterous robotic manipulator; a gross-positioner, which is a device to insert the fine-positioner to the engine region of interest; an end-effector, such as a probe; a deployment mechanism, which is a passive device to ensure correct contact between probe and component; and a feedback system that provides information about the robot state for control. The research and development work conducted to address the main challenges to create this robotic system is presented in this thesis. The work is focussed on the fine-positioner, as it is the most relevant and complex part of the system. After a literature review of relevant work, and as part of the exploration of potential robot concepts for the system, the kinematic capabilities of concentric tube robots (CTRs) are first investigated. The complete set of stable trajectories that can be traced in follow-the-leader motion is discovered. A case study involving simulations and an experiment is then presented to showcase and verify the work. The research findings indicate that CTRs are not suitable for the fine-positioner. However, they show that CTRs with non-annular cross section can be used for the gross-positioner. In addition, the new trajectories discovered show promise in minimally invasive surgery (MIS). Soft robotic manipulators with fluidic actuation are then selected as the most suitable concept for the fine-positioner. The design of soft robotic manipulators with fluidic actuation is investigated from a general perspective. A general framework for the design of these devices is proposed, and a set of design principles are derived. These principles are first applied in a MIS case study to illustrate and verify the work. Finite element (FE) simulations are then reported to perform design optimisation, and thus complete the case study. The design study is then applied to determine the most suitable design for the fine-positioner. An additional analytical derivation is developed, followed by FE simulations, which extend those of the case study. Eventually, this work yields a final design of the fine-positioner. The final design found is different from existing ones, and is shown to provide an important performance improvement with respect to existing soft robots in terms of wrenches it can support. The control of soft and continuum robots relevant to the fine-positioner is also studied. The full kinematics of continuum robots with constant curvature bending and extending capabilities are first investigated, which correspond to a preliminary design concept conceived for the fine-positioner. Closed-form solutions are derived, closing an open problem. These kinematics, however, do not exactly match the final fine-positioner design selected. Thus, an alternative control approach based on closed-loop control laws is then adopted. For this, a mechanical model is first developed. Closed-loop control laws are then derived based on this mechanical model for planar operation of a segment of the fine-positioner. The control laws obtained represent the foundation for the subsequent development of control laws for a full fine-positioner operating in 3D. Furthermore, work on path planning for nonholonomic systems is also reported, and a new algorithm is presented, which can be applied for the insertion of the overall robotic system. Solutions to the other parts of the robotic system for on-wing operations are also reported. A gross-positioner consisting of a non-annular CTR is proposed. Solutions for a deployment mechanism are also presented. Potential feedback systems are outlined. In addition, methods for the fabrication of the systems are reported, and the electronics and systems required for the assembly of the different parts are described. Finally, the use of the robotic system to perform on-wing inspections in a representative case study is studied to determine the viability. Inspection strategies are shortlisted, and simulations and experiments are used to study them. The results, however, indicate that inspection is not viable since the signal to noise ratio is excessively low. Nonetheless, the robotic system proposed, and the research conducted, are still expected to be useful to perform a range of on-wing operations that require the insertion and deployment of a probe or other end-effector. In addition, the trajectories discovered for CTRs, the design found for the fine-positioner, and the advances on control, also have significant potential in MIS, where there is an important need for miniature robotic manipulators and similar devices.Open Acces

Concentric-Tube-Eccentric-Rod: A Continuum Actuator for Macro-/Micro-Scale Translational Actuation

This paper proposes a motion de-amplification-basedactuator design, which comprises coarse and fine-stagesthat respectively achieve macro and micro-scale linearactuation. The proposed de-amplification mechanism, whichoutputs micrometer-level translation from scaling downmillimeter-level translation input, is a hybrid continuummechanism formed by embedding a many-backbone continuummechanism in a concentric tube mechanism. A simplifiedCosserat-rod-based analytical model incorporating a lumpedCoulomb friction model is derived to describe themicro-actuation input/output behavior. A prototype isfabricated and its micro-motion capabilities arecharacterized by experiments. The results demonstrate theactuator's micro-motion output possesses a travel stroke of$232.48,$$mu$m, resolution of $0.216,$$mu$m, repeatabilityof $1.92,$$mu$m (standard deviation), and output complianceamong $13.52, - 16.01,$$mu$m/N. Besides, open-looppositioning tests show a steady state error of $1.67,$$mu$m(mean). The actuator exhibits excellent performance and canbe created from off-the-shelf components using conventionalworkshop tools

Macro-continuous dynamics for hyper-redundant robots: application to locomotion bio-inspired by elongated animals

International audienceThis article presents a unified dynamic modeling approach of continuum robots. The robot is modeled as a geometrically exact beam continuously actuated through an active strain law. Once included into the geometric mechanics of locomotion, the approach applies to any hyper-redundant or continuous robot devoted to manipulation and/or locomotion. Furthermore, exploiting the nature of the resulting models as being a continuous version of the Newton-Euler models of discrete robots, an algorithm is proposed which is capable of computing the internal control torques (and/or forces) as well as the rigid overall motions of the locomotor robot. The efficiency of the approach is finally illustrated through many examples directly related to the terrestrial locomotion of elongated animals as snakes, worms or caterpillars and their associated bio-mimetic artifacts

Modeling, Analysis, Force Sensing and Control of Continuum Robots for Minimally Invasive Surgery

This dissertation describes design, modeling and application of continuum robotics for surgical applications, specifically parallel continuum robots (PCRs) and concentric tube manipulators (CTMs). The introduction of robotics into surgical applications has allowed for a greater degree of precision, less invasive access to more remote surgical sites, and user-intuitive interfaces with enhanced vision systems. The most recent developments have been in the space of continuum robots, whose exible structure create an inherent safety factor when in contact with fragile tissues. The design challenges that exist involve balancing size and strength of the manipulators, controlling the manipulators over long transmission pathways, and incorporating force sensing and feedback from the manipulators to the user. Contributions presented in this work include: (1) prototyping, design, force sensing, and force control investigations of PCRs, and (2) prototyping of a concentric tube manipulator for use in a standard colonoscope. A general kinetostatic model is presented for PCRs along with identification of multiple physical constraints encountered in design and construction. Design considerations and manipulator capabilities are examined in the form of matrix metrics and ellipsoid representations. Finally, force sensing and control are explored and experimental results are provided showing the accuracy of force estimates based on actuation force measurements and control capabilities. An overview of the design requirements, manipulator construction, analysis and experimental results are provided for a CTM used as a tool manipulator in a traditional colonoscope. Currently, tools used in colonoscopic procedures are straight and exit the front of the scope with 1 DOF of operation (jaws of a grasper, tightening of a loop, etc.). This research shows that with a CTM deployed, the dexterity of these tools can be increased dramatically, increasing accuracy of tool operation, ease of use and safety of the overall procedure. The prototype investigated in this work allows for multiple tools to be used during a single procedure. Experimental results show the feasibility and advantages of the newly-designed manipulators

On the Statics, Dynamics, and Stability of Continuum Robots: Model Formulations and Efficient Computational Schemes

This dissertation presents advances in continuum-robotic mathematical-modeling techniques. Specifically, problems of statics, dynamics, and stability are studied for robots with slender elastic links. The general procedure within each topic is to develop a continuous theory describing robot behavior, develop a discretization strategy to enable simulation and control, and to validate simulation predictions against experimental results.Chapter 1 introduces the basic concept of continuum robotics and reviews progress in the field. It also introduces the mathematical modeling used to describe continuum robots and explains some notation used throughout the dissertation.The derivation of Cosserat rod statics, the coupling of rods to form a parallel continuum robot (PCR), and solution of the kinematics problem are reviewed in Chapter 2. With this foundation, soft real-time teleoperation of a PCR is demonstrated and a miniature prototype robot with a grasper is controlled.Chapter 3 reviews the derivation of Cosserat rod dynamics and presents a discretization strategy having several desirable features, such as generality, accuracy, and potential for good computational efficiency. The discretized rod model is validated experimentally using high speed camera footage of a cantilevered rod. The discretization strategy is then applied to simulate continuum robot dynamics for several classes of robot, including PCRs, tendon-driven robots, fluidic actuators, and concentric tube robots.In Chapter 4, the stability of a PCR is analyzed using optimal control theory. Conditions of stability are gradually developed starting from a single planar rod and finally arriving at a stability test for parallel continuum robots. The approach is experimentally validated using a camera tracking system.Chapter 5 provides closing discussion and proposes potential future work

Task and Configuration Space Compliance of Continuum Robots via Lie Group and Modal Shape Formulations

Continuum robots suffer large deflections due to internal and external forces. Accurate modeling of their passive compliance is necessary for accurate environmental interaction, especially in scenarios where direct force sensing is not practical. This paper focuses on deriving analytic formulations for the compliance of continuum robots that can be modeled as Kirchhoff rods. Compared to prior works, the approach presented herein is not subject to the constant-curvature assumptions to derive the configuration space compliance, and we do not rely on computationally-expensive finite difference approximations to obtain the task space compliance. Using modal approximations over curvature space and Lie group integration, we obtain closed-form expressions for the task and configuration space compliance matrices of continuum robots, thereby bridging the gap between constant-curvature analytic formulations of configuration space compliance and variable curvature task space compliance. We first present an analytic expression for the compliance of a single Kirchhoff rod. We then extend this formulation for computing both the task space and configuration space compliance of a tendon-actuated continuum robot. We then use our formulation to study the tradeoffs between computation cost and modeling accuracy as well as the loss in accuracy from neglecting the Jacobian derivative term in the compliance model. Finally, we experimentally validate the model on a tendon-actuated continuum segment, demonstrating the model's ability to predict passive deflections with error below 11.5\% percent of total arc length