The Development of Robot System for Pressurizer Maintenance in Npps 3

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The development of robot system for pressurizer maintenance in NPPs

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- IV - S UMMARY

I. Project Title The development of robot system for pressurizer maintenance in NPPs

II. Objective and Necessity of the Project

The robot has been widely applied to manufacturing system in the areas of automobile and electrical industry by the help of the progress of precise machine, semiconductor technology, and control technology. Nowadays, the area is widened to the non manufacturing industry such as nuclear power plant, space project, underwater exploring system, medical system, service system, agricultural & aquatic-products industry, construction and so on. Especially, the development of robot for nuclear power plant is much required, since it is very dangerous for the human to perform the task such as monitoring, maintenance, atomic pile disassembly, waste recycling, treatment of atomic fuel, assembly and disassembly of contaminated system, disposal of contaminated matter, washing the high voltage power line. The development of the robot for nuclear power plant monitoring and maintenance can replace the expensive system from abroad and reinforce the national competence in this area. Recently the developed countries attempt to make other countries technical colony through patent, royalty, copyright. Therefore we should develope the high technology to get out of the technical dependency. In modern civilization, there exist many extreme situations such as nuclear power plant, deep sea task, space developing project, tasks in high voltage, high pressure, high radiation environment. It is very hard for human to work in these environments and people don't like to 3-D (Dangerous, Dirty, Difficult) work in these dangerous environment even thought the task is very important. The robot for extreme hazard environment of nuclear power plant can reduce the possibility of danger and perform the extreme task quickly and efficiently. Also, efficient monitoring and maintenance of extreme environment using robot can improve the safety of nuclear power plant.

- v - III. Contents and Scope of the Project

O Design and producing of articulated manipulator • Analysis of task, design of robot structure • Simulation of controller for the performance test • Concept design using graphic representation

O Inspection task simulation using graphic simulation • 3D task environment modeling • Development of task procedure simulation module

O Design of electrical controller • Analysis of electrical device characteristic in radiation environment • Design of processor board and multi axis servo controller • Design of distributed remote control system and PWM amplifier • Production of electrical actuator controller

O Development of system management control part • Design of management control system and main program study. • Console design for remote control.

O Etc. • Composition of the manual and installation guide book. • Composition of the task procedure guide book. • Composition of robot maintenance manual.

IV. Results of the Project

In this project, the study of main element technology and the development of system construction technology for application to the atomic field has been performed. Based on the previous results, articulated robot manipulator was designed and manufactured. Also, the underwater robot system was built to be able to perform the task in the pressurizer filled with water. Development results of robot system considering water-filled and non water-filled pressurizer are

- vi - summarized as follows.

1. Non water-filled system development for surveillance/inspection in pressurizer

(1) Design and building of articulated robot manipulator the developed robot system is composed of a 2D0F link, a portable gripper using a steel wire, and a controller.

(2) Inspection graphic simulator Simulation has been performed using ROBCAD to analyze the interference of a manhole when a robot was injected into the pressurizer.

(3) Electrically manipulated controller design This method is used for security of control block by use of diode. In circuit, the role of diode is recharging which suppies rechargible battery with rectified voltage normally and cutting supply voltage when the main power system problem occurs. So it can be safely said that more stability and safety of motor via using direction of voltage is acquired.

(4) Development of position and rigid body vibration control algorithm and vision processing algorithm

Modelling of robot system for pressurizer maintenance ,control algorithm, processing of sensor information, and checking by cameras are developed. The result of this research also includes the position control and vibration control of rigid body and development of processing visual information for vision sensor.

2. Water-filled system inside of pressurizer for surveillance and maintenance

The robot system is designed and developed which composed of 4 actuator for forward/backward, left/right, up/down movement and camera unit for surveillance and maintenance of buoyance so that the reasonable depth is maintained.

- VI1 - V. The Application of the Results

The high-tech teleoperation must be secured urgently for unmanned surveillance of facilities preventing abnormal operation of nuclear power plant as soon as possible. Multi-purpose, radiation-proof robot for extreme situation can be developed via organically composing composite hi-tech and engineering because it has the property of repercussions of technology and high added value. And by that reason, the developed countries are preventing outflow of these technologies. Therefore if this technology is accomplished the base in which the level of the technology is raised up to the one of developed country is constructed and it is able that we can export the technology. And the necessity of this technology is raised as in our country the quality of the man power is admirable and the development of the high technology is entrusted. As the frail technology with respect to developed country is developed the velocity of the development can be accelerated.

- VI11 - CONTENTS

Chapter 1. Introduction l

Chapter 2. Overview of the State-of-the Technology 3

Section 1. State-of-the Art 3

Section 2. Overview of Technologies 3

Chapter 3. Contents and Results of Project 6

Section 1. Robot Design Criteria and Pressurizer Modelling 6

1. Robot Design Criteria 6 2. Pressurizer Modelling 7

Section 2. Pressurizer inner part Inspection and Maintenance for Water Shunk 9

1. System Composition 9 2. Robot Conceptual Design 16 3. Robot Base Frame Stress Analysis 21 4. Robot Criteria and Manufacture 23 5. Robot Path Planing, Control and vision Inspection system for Tele-Manipulation 26

- ix - Section 3. Pressurizer Inner Part Inspection and Maintenance for Water Filled 46

1. System Composition 46 2. Robot Conceptual Design 51 3. Performance Evaluation and Field Test of Robot System..54

Chapter 4. Achievements and Contributions 60

Chapter 5. Applications and Future Plans 61

Chapter 6. References 62

Appendix A. Robot Drawing of Pressurizer inner part Inspection and Maintenance (Water Shunk)

Appendix B. Robot Drawing of Pressurizer inner part Inspection and Maintenance (Water Filled)

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7|§^i£# !§••& $_*} sjol^afl ^\o]"t journal of Control, Automation and Systems Engineering, Vol.3. No.l, pp.23-31, Feb. 1997 16. J.W.Auernig, and H. Troger, "Time optimal control of overhead cranes with

- 62 - hoisting of the load", Automation, Vol.23, no.4, pp.437-447, 1987 17. F. Boustany and B. Andrea-Novel, "Adaptive control of non-completely controlled mechanical systems using dynamic feedback linearization and estimation design", Int. J. Adaptive Control and Signal Processing, Vol. 6, pp. 589-610, 1992 18. I. Morishita, "A new control algorithm for the grab swing elimination in the automation operation of traveling cranes", ^I^HMM^I fe^HJCH-g-), Vol. 14, no.6, pp. 127-132, 1978 19. Y. Sakawa and Y. Shindo, "Optimal control of container cranes", Automation, vol. 18, no. 3, pp.257-266, 1982 20. Chang Woo Park, Jaehoon Kim, Cheol Kwon, Mignon Park, "Tracking Control of a Robot Manipulator Using Sliding Mode Controller with Fast and Accurate Performance", Proc. of IROS'99, pp. 305-310, October 17-21, 1999

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^(electric heater)^- ^TT^I(spray) ^f-^ 7}'#7)(pressurizer)fe BIBLIOGRAPHIC INFORMATION SHEET Performing Org. Sponsoring Org. Stamdard Report No. IMS Subject Code Report No. Report No. KAERI/RR-1953-98 Tide / Subtitle J The development of robot system for pressurizer maintenance in NPP's

Project Manager Seungho Kim (Advanced Robotics Team) and Department Changhoi Kim("), Seungho Jung("), Yongchil Seo{"), Youngkwang Lee(") Researcher and Byungyung Go(Seungri Co), Kwangwon Lee(") Department Sang 111 Lee("), Jongyeon Yun("), Hyungsoon Lee(") Mignon Park(Yonsei University),Changwoo Park("), Kwon Cheol(")

Publication Taejon Publisher KAERI Publication 1999. 12 Place Date Page 111. & Tab. Yes( 0 ), No ( ) A4 Size Note Classified Open( 0 ), Restricted( ), Report Type Research Report Class Document Contract No. Sponsoring Org. Abstract (15-20 Lines)

The pressurizer that controls the pressure variation of primary coolant system, consists of a vessel, electric heaters and a spray, is one of the safety related equipments in nuclear power plants. Therefore it is required to inspect and maintain it regularly. Because the inside of pressurizer is contaminated by radioactivity, when inspectin and repairing it, the radiation xposure of workers is inevitable. In this research two robot system has been developed for inspection and maintenance of the pressurizer for the water filled case and the water sunken case. The one robot system for the water filled case consists of two links, movable gripper using wire string, and a support frame for the attachment of robot. The other robot is equipped propeller in order to navigate on the water. It also equiped high performance water resistance camera to make inspection possible. The developed robots are designed under several constraints such as its weight and collision with pressurizer wall. To verify the collision free robot link length and accessibility to the any desired rod heater it is simulated by 3-dimensional graphic simulation software(RobCad). For valuation stress of the support frame finite element analysis is performed by using the ANSYS code. Subject Keywords Pressurizer, movable gripper, Link part, Robot control part (About 10 words) Thruster, resistance camera 3-dimensional graphic simulation 1.

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