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Marinization Concept for the TRICEPT TR600 Robot

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Marinization Concept for the TRICEPT TR600 Robot FORSCHUNGSZENTRUM RECEIVED Marinization concept for I16V-1J31988 the TRICEPT TR600 robot OSTl ¥ * ¥ ¥ BRITE ¥ ¥EURAM ¥ « VS&S®® % ** ^GKSS FORSCHUNCSZEMTRUIW NEOS fl^©|g©?[](§g General Authors: Robotics A. Meyer E. Aust Limited H.-R. Niemann R. Hammerin K.-E. Neumann D. Gibson ■ J. F. dos Santos NATIONAL.HYPERBARIC CENTRE GKSS 98/E/14 ISSN 0344-9629 DISCLAIMER Portions of this document may be illegible in electronic image products. Images are produced from the best available original document. GKSS 98/E/14 ( Marinization concept for the TR1CEPT TR600 robot Authors: A. Meyer E. Aust H.-R. Niemann (GKSS, Institute for Materials Research, Geesthacht, Germany) R. Hammerin K.-E. Neumann (Neos Robotics AB, Taby, Sweden) D. Gibson (The National Hyperbaric Centre, Aberdeen, United Kingdom) J. F. dos Santos (GKSS, Institute for Materials Research, Geesthacht, Germany) GKSS-Forschungszentrum Geesthacht GmbH • Geesthacht • 1998 Die externen Berichte der GKSS werden kostenlos abgegeben. The delivery of the external GKSS reports is free of charge. Anforderungen/Requests: GKSS-Forschungszentrum Geesthacht GmbH Bibliothek/Library Postfach 11 60 D-21494 Geesthacht Als Manuskript vervielfaltigt. Fur diesen Bericht behalten wir uns alle Rechte vor. GKSS-Forschungszentrum Geesthacht GmbH • Telefon (04152)87-0 Max-Planck-Stralle • D-21502 Geesthacht / Postfach 11 60- D-21494 Geesthacht *DEO12010707 * GKSS 98/E/14 Marinization concept for the TRICERT TR600 robot A. Meyer, E. Aust, H.-R. Niemann, R. Hammerin, K.-E. Neumann, D. Gibson, J. F. dos Santos 96 pages with 39 figures and 5 tables Abstract The need for automated welding repair systems of marine structures, ship hulls and nuclear installations had lead to an increasing demand for subsea robots. Considering the application of friction welding to perform underwater repairs, a TRICEPTTR600 robot has been identified as the most suitable system to withstand the high reaction forces characteristic of this process. This study reviews initially the research and development work carried out at GKSS to modify and test a Siemens-MANUTEC robot. After a description of the TRICERT TR600 robot a marinization concept is presented and discussed in detail. Problems of galvanic corrosion in seawater are addressed in a separate chapter. The deflection of the robot endeffector in subsea water currents is estimated with a worst-case calculation. Modifikationskonzept fur einen TRICEPT TR600-Roboter Zusammenfassung Der Wunsch, Roboter auch unter Wasser einsetzen zu konnen, wachst mit steigendem Interesse nach automatisierten SchweilSverfahren fur Reparaturen an marinen Bauwerken, Schiffsrumpfen und in Kernenergieanlagen. Fur den Einsatz von ReibschweiBverfahren fur diese Reparaturen wurde der TRICEPT TR600-Roboter ausgewahlt, da dieser auch den charakteristisch hohen ProzeBkraften widerstehen kann. Die notwendigen Modifikationen und Prufungen werden beispielhaft anhand des bei der GKSS modifizierten Siemens-MANUTEC-Roboters vorgestellt. Nach einer Beschreibung des TRICEPT-Roboters werden die notwendigen UmbaumaRnahmen detailliert dargestellt und diskutiert. Auf die Problematik der galvanischen Korrosion in Seewasser wird in einem gesonderten Kapitel naher eingegangen. Zusatzlich wird eine mdgliche Ablenkung des Roboters durch Wasserstromung uberschlagig berechnet. Manuscript received/ Manuskripteingang in der Redaktion: 8. Juni 1998 PREAMBLE Underwater fatigue cracks in offshore steel structures, ships and nuclear installations are a well known problem in repair and maintenance for these industries. Repairs are often required in areas which are either hazardous or costly for human intervention. Ships usually require dry docking for underwater repairs, reactors may need to shut down and divers, operating from support ships, are required for offshore platform repairs. This European Commission sponsored project "Affordable Underwater Robotic Welding Repair System" (ROBHAZ) will develop equipment and methods for remotely operated underwater welding using the Friction Stitch Welding technique deployed and operated from Remotely Operated Vehicles (ROV's). Friction stitch welding was developed at The Welding Institute in Cambridge on a project supported by various organisations from the oil, nuclear and construction industries. Two of these sponsors are now partners in a new project to develop the process for underwater repairs. This new BRITE-EURAM III project started in June 1997 and includes participants from five European countries. The contributors are: The National Hyperbaric Centre in Aberdeen, United Kingdom, which co-ordinates the project and provides testing facilities with its hyperbaric chambers and test tank. Stolt Comex Seaway AS in Haugesund, Norway who provide the expertise and resources for offshore repairs and ROV operation. General Robotics in Milton Keynes, United Kingdom, who will develop the man machine interface. Pressure Products Group in Aberdeen, United Kingdom, who are developing the Friction Stitch Welding Head. Neos Robotics in T_by, Sweden who will build the submersible robot for deploying the welding head. Institute De Soldadura e Qualidade in Lisbon, Portugal, who will provide expertise in ship repair and test the system for this application. GKSS-Forschunaszentrum in Geesthacht, Germany, who are providing expertise on the design of electric robots for underwater use, repairs for nuclear applications and will perform the initial weld testing. The project will be completed in the first quarter of 2000. TABLE OF CONTENTS 1. INTRODUCTION 9 1.1 The Offshore Industry 9 1.2 The ROBHAZ project 14 2. MODIFICATION OF A MANUTEC R15: A REVIEW 18 2.1 Project background 18 2.2 The MANUTEC r15 20 2.3 Modifications 20 2.3.1 Compensation Fluid 21 2.3.2 Optical encoder 21 2.3.3 Brakes 22 2.3.4 Casing 23 2.3.5 Joint sealing 23 2.3.6 Limit switches 24 2.3.7 Electrical connections 24 2.3.8 Control unit 24 2.4 Test Programme 25 2.4.1 Pressure Tests 25 2.4.2 Power consumption 25 2.4.3 Positioning accuracy 25 2.4.4 Sensor feedback 26 2.4.5 Frequency analysis 26 2.4.6 Inspection 26 2.5 Industrial Application and Certification 27 2.5.1 Offshore relevant work 27 2.5.2 Certification 28 2.6 Discussion 28 3. TRICEPT TR600 30 3.1 General Description 30 3.2 Axes Definition 31 3.3 General Features 32 3.3.1 Technical Data of the TRICEPT Robot 32 3.3.2 Work envelope / Pressing capacity 33 3.4 Functional Description 33 3.4.1 General Movement 33 3.4.2 Axes Position Measurement System 34 3.5 Mechanical Description 36 3.5.1 Linear Axes 37 3.5.2 Centre Axis 37 3.5.3 Wrist Assembly 39 3.6 Electrical Connection 41 4. THE MARINE ENVIRONMENT 42 4.1 Galvanic Corrosion 43 4.2 Material Selection 44 5. MARINIZATION CONCEPT 46 5.1 Linear Axes 1,2 and 3 47 5.1.1 Motor Unit 47 5.1.2 Linear Actuators 48 5.1.3 Cardanic Joints 49 5.2 Centre Tube and Axis 4 49 5.2.1 Motor Unit 49 5.2.2 Housing and Centre Tube 50 5.2.3 Cross Roller Bearing 50 5.3 Wrist (Axes 5/6) 51 5.3.1 Claw and Axis 5 51 5.3.2 Axis 6 51 5.4 Structure 51 6. HYDRODYNAMIC FORCES 52 6.1 Idealisation of components 52 6.2 Calculation 53 7. OPERATION OF THE ROBHAZ SYSTEM 56 7.1 Delivery Systems 56 7.1.1 Observation ROV 56 7.1.2 Workclass ROV 57 7.1.3 Tether Management System 59 7.1.4 Operational Limitations 59 7.2 Inspection Methods and Tools 60 7.2.1 Eddy Current Inspection 61 7.2.2 Magnetic Particle Inspection 61 7.2.3 Ultra Sonic Inspection 62 7.2.4 Radiographic Imaging 62 7.2.5 Video Systems 62 7.2.6 Crack Finding and Refinding 62 7.3 Possible Repair Scenario 63 7.3.1 Launch of the ROV 63 7.3.2 Attachment to the repair site 64 7.3.3 Delivery of the ROBHAZ System 64 7.3.4 Crack Finding 65 7.3.5 Drilling and Welding 65 7.3.6 Checking and Documentation 65 7.3.7 Recovery 66 8. DISCUSSION 67 9. REFERENCES 69 10. APPENDIX A 72 10.1 Harmonic Drive 72 10.1.1 The Components 72 10.1.2 The Principle of Operation 72 10.1.3 Advantages of Harmonic Drive Gears 73 10.2 Calculation of the additional pressure inside the actuators 74 11. APPENDIX B 76 -9- 1. INTRODUCTION 1.1 The Offshore Industry The development and implementation of new technology has been the driving force of the offshore oil and gas industry as it has evolved from its early days in the Gulf of Mexico in the 1940s. This focus on technology was driven by the need to search for oil and gas resources in ever deeper and more hostile environments (Figure 1). The first platforms were installed in less than 10 metres water depth in US waters. Development there continued throughout the 1960s and in the 1970s and 80s attention shifted to the North Sea where many large steel and concrete platforms were designed and put in operation. Other areas of the world also saw the development of new and innovative technologies, in particular the deepwater structures off the coast of Brazil. Water depths in metres Figure 1: Offshore production platform milestones, USA/1/ - 10- Today there are more than 6,500 oil and gas platforms world-wide, located on the continental shelf of some 53 countries. Many different types of platforms and Floating Production Systems (FPS) exist as each one is uniquely designed for the particular reservoir conditions, the location where it will be installed (e.g. water depth, wind, wave and current conditions, and seabed characteristics) and the method of installation. The majority of platforms are steel structures rigidly fixed to the seabed with thick steel pipes 1-2 metres in diameter that penetrate as much as 100 metres into the seabed, Figure 2a. More than 30 piles may be required in some cases.
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