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Design and Analysis of a Robotic Duct Cleaning System by Siamak Ghorbani Faal A thesis Presented to Sharif University of Technology, International Campus, Kish Island in partial fulfillment of the requirements for the degree of Master of Science in Mechanical Engineering (Mechatronics) Supervisor: Prof. Gholamreza Vossoughi Co-supervisor: Dr. Kambiz Ghaemi Osgouie Kish Island, Iran, 2011 © Siamak Ghorbani Faal, 2011 i Sharif University of Technology International Campus, Kish Island This is to certify that the Thesis Prepared, By: Siamak Ghorbani Faal Entitled: Design and Analysis of a Robotic Duct Cleaning System and submitted in partial fulfillment of the requirements for the Degree of Master of Science complies with the regulation of this university and meets the accepted standards with respect to originality and quality. Signed by the final examining committee: Supervisor: Co-Supervisor: External Examiner: Internal Examiner: Session Chair: ii AUTHOR'S DECLARATION I hereby declare that I am the sole author of this thesis. The work described in this thesis has not been previously submitted for a degree in this or any other university, and unless otherwise referenced it. This is a true copy of the thesis, including any required final revisions, as accepted by my examiners. I understand that my thesis may be made electronically available to the public. iii Abstract Design and Analysis of a Robotic Duct Cleaning Siamak Ghorbani Faal, M.Sc. Sharif University of Technology, International Campus, Kish Island, 2011 Supervisor: Prof. Gholamreza Vossoughi Co-supervisor: Dr. Kambiz Ghaemi Osgouie Delivering high quality and clean air into occupied spaces is the main goal of Heating, Ventilation and Air Conditioning (HVAC) systems. HVAC systems draw supply air which usually contains fungi and moisture. Fungi and moisture plus organic materials create a good bed for mold growth. Studies prove that duct cleaning process can definitely reduce the amount of pollutants present in the ducts. Hence, it has positive impact on human lives both regarding psychological and physical points of view. Duct cleaning method‟s application difficulties and ducts‟ unreachable environments motivated duct cleaning firms to employ robots for duct cleaning tasks. Although there are considerable numbers of Duct Cleaning Robots (DCRs) available on the market, they are not dexterous enough to be widely used by the companies requiring this service. The main reason is that they are unable to maneuver in vertical ducts. This thesis focuses on designing a novel DCR which doesn‟t have the limitations of current DCRs. First, a literature review on DCRs is presented in order to find their requirements and limitations. Additionally, a literature review on climbing robots is presented in order to find an appropriate structure serving as a DCR. By considering different duct conditions and DCRs requirements, a conceptual design of a climbing DCR (named as Duct-Sweeper) is proposed. Moreover, an optimization problem is formulated and solved to find the optimal robot geometry. The results of the optimization are used to design a prototype. Finally, different maneuvers and path plantings of the robot are discussed. iv Although the introduced robot is designed to serve as HVAC DCR, small changes to the adhesion system and wheeled locomotion system of the robot can make it suitable for industrial duct systems as well. Key words: Duct cleaning robots, Climbing robots, Conceptual design, Design optimization, Prototype design, Path planning v Acknowledgements This dissertation would not have been possible without the guidance and help of several individuals who contributed their valuable assistance throughout this study. Foremost, I would like to express my sincere appreciation to my supervisor Prof. Gholamreza Vossoughi for his patience, motivation and immense knowledge. His guidance and support helped me throughout this research and the preparation of this thesis. My special thanks also go to my Co-Supervisor Dr. Kambiz Ghaemi Osgouie for his support, motivation and knowledgeable guidance. My sincere thanks also go to my friends in Sharif University of Technology, International Campus-Kish Island: Mozhgan Azimpour Kivi, Kaveh Bidarmaghz and Navid Kermanshahi who always took the time to listen to me and share their knowledge. Last but not the least; I would like to thank my parents, Maghsoud Ghorbani Faal and Nasrin Basharkhah, for their endless support and love they have provided me throughout my life. I would also like to thank them for encouraging and supporting me to pursue my Master‟s study. My brother, Babak Ghorbani Faal, and my sister, Parisa Ghorbani Faal, deserve my wholehearted thanks as well. vi Dedication This thesis is dedicated to my parents who have never failed to give us financial and moral support and for showing me the worth of knowledge. It is also dedicated to all my teachers throughout my life that helped me to pursue my studies. Finally, this thesis is dedicated to all those who never stop believing in the richness of learning. vii Table of Contents Sharif University of Technology ............................................................................................... ii AUTHOR'S DECLARATION ................................................................................................. iii Abstract .................................................................................................................................... iv Acknowledgements .................................................................................................................. vi Dedication ............................................................................................................................... vii Table of Contents ................................................................................................................... viii List of Figures ........................................................................................................................... x List of Tables ........................................................................................................................... xii List of Abbreviations .............................................................................................................. xiii Chapter 1 Introduction ............................................................................................................... 1 1.1 The necessity of duct cleaning ........................................................................................ 1 1.2 Proposed method ............................................................................................................. 3 1.3 Chapter organization ....................................................................................................... 4 Chapter 2 Literature review of current duct cleaning and climbing robots ............................... 5 2.1 Literature review on duct cleaning robots ....................................................................... 5 2.2 Literature review on climbing robots .............................................................................. 9 Chapter 3 Conceptual Design .................................................................................................. 15 3.1 Structure concept of the Duct-Sweeper ......................................................................... 15 3.2 Duct-Sweeper waist mechanism‟s workspace requirements ......................................... 16 3.3 Conceptual design of the waist mechanism ................................................................... 22 3.4 Conceptual design of wheeled locomotion .................................................................... 26 3.5 Conceptual design of adhesion system .......................................................................... 28 3.5.1 Duct construction materials .................................................................................... 28 3.5.2 Adhesion technology suitable for Duct-Sweeper ................................................... 29 3.5.3 Vacuum system design ........................................................................................... 30 3.5.4 Adhesion system leveling mechanism .................................................................... 36 3.6 Summary of Duct-Sweeper‟s conceptual design ........................................................... 37 Chapter 4 Kinematics and static force analysis of Duct-Sweeper ........................................... 39 4.1 Kinematic analysis of Duct-Sweeper ............................................................................ 39 4.1.1 Solving waist‟s kinematics using SSM .................................................................. 39 4.1.2 Mapping PP kinematics to SSM ............................................................................. 41 4.1.3 Forward and inverse kinematics of the waist ......................................................... 43 4.1.4 Velocity analysis .................................................................................................... 47 viii 4.2 Jacobian and static force analysis .................................................................................. 49 4.3 Suction cup force analysis ............................................................................................. 50 Chapter 5 Design optimization and prototype design ............................................................. 55 5.1 Definition of parameters