Design and Control of an Articulated Robotic Arm Using Visual Inspection for Replacement Activities

Design of robotic systems and their control for inspection and maintenance tasks is highly complex activity involving coordination of various sub-systems. In application like inspections in fusion reactor vessels and deep-mining works, a regular off-line maintenance is necessary in certain locations. Due to the hostile environments inside, robotic systems are to be deployed for such internal observations. In this regard, current work focuses on the methodology for maintenance of the first wall blanket modules in a fusion reactor vessel using a manipulator system. A design is proposed for wall tile inspections in an ideal environment in which vacuum and temperature conditions are not accounted and wall surface curvature is not accounted initially. The entire design has four important modules: (i) mathematical modelling (ii) control system design (iii) machine vision and image processing, (iv) hardware development and testing. A five- axis articulated manipulator equipped with a vision camera in eye-to-hand configuration is designed for performing the pick and place operations of the defected tiles in a systematic manner. Kinematic and dynamics analysis of the system are first carried-out and a scaled prototype is fabricated for testing various operating issues. Forward kinematics of manipulator allows in estimation of robot workspace and in knowing the singular regions during operation, while the inverse kinematics of the manipulator would be needed for real time manipulator control task. Dynamics of manipulator is required for design of model-based controllers. Interactive programs are developed in Matlab for kinematics and dynamics and three-dimensional manipulator assembly configuration is modelled in SolidWorks software. Motion analysis is conducted in ADAMS software in order to compare the results obtained from the classical kinematics. Two types of model-based control schemes (namely Computed Torque Control and Proportional Derivative-Sliding Mode Control approach) with and without external disturbances are implemented to study trajectory tracking performance of the arm with different input trajectories. A disturbance observer model is employed in minimizing the tracking errors during the action of external disturbances such as joint friction and payload. In order to experimentally understand the inspection and replacement activities, a test set-up is developed using vision camera and microcontroller platform to guide the robot joint servos so as to perform defected object replacement activity. Presence of crack and the coordinate of the region are indicated with the use of image-processing operations. Using a high resolution Basler camera mounted at fixed distance from the tile surface, the surface images are acquired and image processing module identifies the crack details using edge detection algorithms. Necessary motion of the end-effector will be provided based on the pose calculations using coordinate transformations. Both visual inspection and joint guidance are combined in a single application and the results are presented with a test case of tile replacement activity. The results are presented sequentially using a test surface with uniform rectangular tiles

From plain visualisation to vibration sensing: using a camera to control the flexibilities in the ITER remote handling equipment

Thermonuclear fusion is expected to play a key role in the energy market during the second half of this century, reaching 20% of the electricity generation by 2100. For many years, fusion scientists and engineers have been developing the various technologies required to build nuclear power stations allowing a sustained fusion reaction. To the maximum possible extent, maintenance operations in fusion reactors are performed manually by qualified workers in full accordance with the "as low as reasonably achievable" (ALARA) principle. However, the option of hands-on maintenance becomes impractical, difficult or simply impossible in many circumstances, such as high biological dose rates. In this case, maintenance tasks will be performed with remote handling (RH) techniques. The International Thermonuclear Experimental Reactor ITER, to be commissioned in southern France around 2025, will be the first fusion experiment producing more power from fusion than energy necessary to heat the plasma. Its main objective is “to demonstrate the scientific and technological feasibility of fusion power for peaceful purposes”. However ITER represents an unequalled challenge in terms of RH system design, since it will be much more demanding and complex than any other remote maintenance system previously designed. The introduction of man-in-the-loop capabilities in the robotic systems designed for ITER maintenance would provide useful assistance during inspection, i.e. by providing the operator the ability and flexibility to locate and examine unplanned targets, or during handling operations, i.e. by making peg-in-hole tasks easier. Unfortunately, most transmission technologies able to withstand the very specific and extreme environmental conditions existing inside a fusion reactor are based on gears, screws, cables and chains, which make the whole system very flexible and subject to vibrations. This effect is further increased as structural parts of the maintenance equipment are generally lightweight and slender structures due to the size and the arduous accessibility to the reactor. Several methodologies aiming at avoiding or limiting the effects of vibrations on RH system performance have been investigated over the past decade. These methods often rely on the use of vibration sensors such as accelerometers. However, reviewing market shows that there is no commercial off-the-shelf (COTS) accelerometer that meets the very specific requirements for vibration sensing in the ITER in-vessel RH equipment (resilience to high total integrated dose, high sensitivity). The customisation and qualification of existing products or investigation of new concepts might be considered. However, these options would inevitably involve high development costs. While an extensive amount of work has been published on the modelling and control of flexible manipulators in the 1980s and 1990s, the possibility to use vision devices to stabilise an oscillating robotic arm has only been considered very recently and this promising solution has not been discussed at length. In parallel, recent developments on machine vision systems in nuclear environment have been very encouraging. Although they do not deal directly with vibration sensing, they open up new prospects in the use of radiation tolerant cameras. This thesis aims to demonstrate that vibration control of remote maintenance equipment operating in harsh environments such as ITER can be achieved without considering any extra sensor besides the embarked rad-hardened cameras that will inevitably be used to provide real-time visual feedback to the operators. In other words it is proposed to consider the radiation-tolerant vision devices as full sensors providing quantitative data that can be processed by the control scheme and not only as plain video feedback providing qualitative information. The work conducted within the present thesis has confirmed that methods based on the tracking of visual features from an unknown environment are effective candidates for the real-time control of vibrations. Oscillations induced at the end effector are estimated by exploiting a simple physical model of the manipulator. Using a camera mounted in an eye-in-hand configuration, this model is adjusted using direct measurement of the tip oscillations with respect to the static environment. The primary contribution of this thesis consists of implementing a markerless tracker to determine the velocity of a tip-mounted camera in an untrimmed environment in order to stabilise an oscillating long-reach robotic arm. In particular, this method implies modifying an existing online interaction matrix estimator to make it self-adjustable and deriving a multimode dynamic model of a flexible rotating beam. An innovative vision-based method using sinusoidal regression to sense low-frequency oscillations is also proposed and tested. Finally, the problem of online estimation of the image capture delay for visual servoing applications with high dynamics is addressed and an original approach based on the concept of cross-correlation is presented and experimentally validated

EU DEMO Remote Maintenance System development during the Pre-Concept Design Phase

During the EU DEMO Pre-Concept Design Phase, the remote maintenance team developed maintenance strategies and systems to meet the evolving plant maintenance requirements. These were constrained by the proposed tokamak architecture and the challenging environments but considered a range of port layouts and handling system designs. The design-driving requirements were to have short maintenance durations and to demonstrate power plant relevant technologies. Work concentrated on the in-vessel maintenance systems, where the design constraints are the most challenging and the potential impact on the plant design is highest. A robust blanket handling system design was not identified during the Pre-Concept Design Phase. Novel enabling technologies were identified and, where these were critical to the maintenance strategy and not being pursued elsewhere, proof-of-principle designs were developed and tested. Technology development focused on pipe joining systems such as laser bore cutting and welding, pipe alignment, and on the control systems for handling massive blankets. Maintenance studies were also conducted on the ex-vessel plant to identify the additional transport volumes required to support the plant layout. The strategic implications of using vessel casks, and of using containment cells with cell casks, was explored. This was motivated by the costs associated with the storage of casks, one of several ex-vessel systems that can drive the overall plant layout. This paper introduces the remote maintenance system designs, describes the main developments and achievements, and presents conclusions, lessons learned and recommendations for future work

Development of Remote Handling Technologies Tolerant to Operation Ready Fusion Reactor Conditions

The International Thermonuclear Experimental Reactor (ITER) will be the next step towards fusion power plants, featuring deuterium-tritium plasma to generate 500 MW of fusion power. Using tritium will result in the activation of the vacuum vessel materials, requiring robotic manipulators to carry out the maintenance of the machine. One of these robots must perform inspection tasks, such as carrying the ITER In-Vessel Viewing System (IVVS), and will need to be deployed in conditions as close as possible to the operating machine; the vacuum inside the vessel should be kept clean, the wall temperature and radiation level will be high, and the toroidal magnetic field should still be on. The robot should be able to place the probe within view of a good percentage of the plasma-facing wall covering the whole vacuum vessel. This study aims to provide technical solutions for every system of a robotic manipulator in this environment. The effects of the magnetic field on the different systems of a robot will be investigated, from the fundamentals of theory to practical experimentation, using a specially designed magnetic field generator. Solutions for actuation, sensing, logic system, and command that are tolerant of the magnetic field or actively use it to enhance the performance of the robotic manipulator are provided. A preliminary design of a robot using the technical solutions developed in this thesis as per the specifications of the IVVS is presented. The design is meant to demonstrate the feasibility of a robotic manipulator featuring multiple degrees of freedom within the constraints considered. Guidelines for geometry, actuation, sensing and logic systems design are provided that should allow the robotic manipulator to place its probe for it to view more than 99% of the first wall. Finally, a summary of the major contributions of the thesis is given in conclusion. The major effects of a magnetic field on robot components are listed with guidelines on how to cope with them in the design. This chapter also sums up the different technologies, their advantages, and their limitations

DTT - Divertor Tokamak Test facility - Interim Design Report

The “Divertor Tokamak Test facility, DTT” is a milestone along the international program aimed at demonstrating – in the second half of this century – the feasibility of obtaining to commercial electricity from controlled thermonuclear fusion. DTT is a Tokamak conceived and designed in Italy with a broad international vision. The construction will be carried out in the ENEA Frascati site, mainly supported by national funds, complemented by EUROfusion and European incentive schemes for innovative investments. The project team includes more than 180 high-standard researchers from ENEA, CREATE, CNR, INFN, RFX and various universities. The volume, entitled DTT Interim Design Report (“Green Book” from the colour of the cover), briefly describes the status of the project, the planning of the design future activities and its organizational structure. The publication of the Green Book also provides an occasion for thorough discussions in the fusion community and a broad international collaboration on the DTT challenge