#robotic complexes
BATANOV Alexander Fedorovich
GRITSYNIN Sergey Nikolaevich
MURKIN Sergey Vladimirovich
ROBOTIC SYSTEMS FOR APPLICATION IN EMERGENCY SITUATIONS
Source: magazine «Special Equipment«
Man-made accidents and disasters, the probability of which is quite high due to the increasing complexity of production using energy-intensive technologies, radioactive and toxic substances, are becoming almost inevitable in the current state of the country's economy, characterized, in particular, by high wear and tear of fixed assets and the lack of financial support for scheduled repairs and replacement of worn-out equipment, a decrease in the exactingness and efficiency of supervisory bodies and state inspection, a decline in technological and production discipline, and a decrease in the level of qualification of service personnel.
In this situation, chemical and nuclear industry facilities pose a particular danger. Operating worn-out equipment is a constant threat to the health of service personnel, and any abnormal operating situation can lead to an accident or disaster. The damaging factors that arise in this case create extreme conditions for the survival of not only those being rescued, but also the rescue personnel eliminating the consequences of accidents.
The degree of human participation in work in hazardous conditions can be reduced by using remotely controlled equipment. In this regard, the creation of robotic systems designed to carry out work to prevent or eliminate the consequences of abnormal situations is very relevant.
Currently, the robotics division is equipped with remotely controlled machines BROKK (Holmhed Systems AG, Sweden), MV-3 and MV-4 (Telerob, Germany), in addition, it is planned to accept mobile robots MRK-25M and MRK-46M (Bauman Moscow State Technical University, Russia) for supply.
The specified robotics are designed for:
- performing work in hazardous areas (reconnaissance, sampling, excavation, dismantling and destruction of building structures and industrial equipment, transportation of hazardous items);
- performing work during the liquidation of consequences of emergency situations (inspection of accident sites, dismantling and destruction of damaged structures, manipulation of radioactive and highly toxic substances, fire fighting);
- conducting explosive works (search, extraction, transportation and rendering harmless or destruction of explosive objects and unexploded ordnance; blasting works).
The scope of application of the RTS models under consideration is limited:
a) local accidents at chemically hazardous facilities with complete or partial (with the formation of relatively small cracks and holes) destruction of containers with toxic chemical substances (TCS), with the spillage of TCS onto the surface of the earth or into a tray (substrate) with the formation of primary and secondary clouds of TCS and local fires;
b) local accidents (within one building or structure) at radiation hazardous facilities with the destruction of process equipment with the release (output) of ionizing radiation into the environment.
MV-3 and MV-4 are designed for reconnaissance and elimination of consequences of local accidents at nuclear cycle enterprises.
The MV-3 (photo 1) includes a transport module, a manipulator, and a control panel. Additionally, the complex can include various types of attachments and a transport container.
Photo 1. Mobile robot MV-3.
Simulation of loading a radioactive object into a special container.
The transport module has a tracked mover with four tracked groups. Each individual tracked group has its own drive, independent of the other three. The ability to change the geometry of the mover allows for multiple movement positions. The robot is set in motion, as well as the inclination of the tracked groups, by built-in electric motors with gearboxes. The four-quadrant control system used ensures high maneuvering accuracy. The surmountable height of the steps of a flight of stairs is 300 mm without track adjustment and 600 mm with track adjustment. The surmountable steepness of the stairs is up to 45°. The running wheels in the tracked groups have independent suspension and shock absorption. Automatic safety brakes instantly block the robot when the power is turned off.
The manipulator has six degrees of freedom, with the ability to rotate in the horizontal plane by 360°. The opening of the gripping device is 300 mm, the lifting capacity is up to 80 kg. The manipulator can move vertically by 100° and downwards by 80° relative to the body. To protect against overloads, all manipulator drives are equipped with fuses.
The manipulator is controlled by individual degrees of mobility with smooth adjustment of the speed of movement. The speed of movement is proportional to the angle of deviation of the control handle.
The control system consists of a control panel, a video monitor, a power supply unit, and a radio data transmission channel unit. A special feature of the robot control system design is the presence of a serial data bus. Commands issued from the control panel are sent to all components connected to the bus. Each node determines the commands and data intended for it and executes them. The control panel is also connected to this bus. Communication between the robot and the control panel can be carried out via a duplex serial bus, either by radio or by cable.
The control panel systems are mounted on a manual two-wheeled trolley with a manual drive. The control panel has a device for transmitting sound, including a microphone and a loudspeaker.
The robot is equipped with three video cameras. The overview video camera is mounted on a pan-tilt head. The other two cameras provide a view forward and backward. Each camera has its own spotlight for illumination.
For quick delivery of the MV-3 to the place of use, the robot is placed in a specially equipped transport container, based on a 10-foot sea container and corresponding to the standards, requirements and criteria for type A containers, which allows transporting a robot contaminated with radioactive substances. The container can be loaded with a crane or a forklift and transported on a tractor with a replaceable loading system or by rail.
The MV-4 robot (photo 2) differs from the MV-3 model only in the design of the caterpillar drive.
Photo 2. Mobile robot MV-4.
Loading an explosive object (anti-personnel mine) into an explosion-proof container.
A series of remotely controlled small-sized machines BROKK 330, 110D and Mini Cut were developed by the Swedish company Holmhed Systems AG for carrying out dangerous work on the destruction of building structures, dismantling nuclear reactors, cleaning the surfaces of foundry boilers, for excavating soil, etc.
The compact design of these machines, combined with electric drive and remote control, allows them to be used in confined spaces and hazardous environments. To protect against aggressive environments, the machines are painted with a special epoxy paint that is resistant to harmful effects.
BROKK 330 is a self-propelled, remote-controlled, tracked, electro-hydraulic, full-turning machine equipped with a manipulator, a control system, and a set of replaceable equipment and tools (photo 3).
Photo 3. Remotely controlled machine BROKK 330.
An electric motor, electrical cabinet, hydraulic pump, hydraulic tank, oil radiator, distributor and rotary gearbox are mounted on a full-swing platform. The platform is rotated by a hydraulic motor located on it. The hydraulic axial piston pump with adjustable working volume is powered by an electric drive and provides a flow rate of 0 to 100 l/min. It is equipped with a pressure and flow regulator, which allows for more efficient use of the drive electric motor power.
The BROKK 330 MRK is powered by a stationary electric power source or a mobile three-phase 380 V generator.
The manipulator design consists of three arms, which provides better “maneuverability” and increases the ability to perform work in confined spaces. The boom design allows for long-term operation under dynamic loads. The maximum permissible weight of the hydraulic equipment is 550 kg. Pressure feedback control ensures optimal coordination of boom movement. Each valve position corresponds to a lever position.
All machine systems are controlled via radio or cable from a portable control panel. The radio control range in the line of sight is up to 200 m.
The video surveillance and control system consists of two black-and-white television cameras and a monitor. One camera is mounted on a stand and is equipped with a 60 m long cable. The second camera is installed on the platform bracket.
The following are used as replaceable attachments:
— a hydraulic hammer with replaceable working bodies of the “peak” and “chisel” type;
— a standard bucket with a capacity of 250 l and a width of 800 mm;
— full-rotation grab bucket with a capacity of 300 l;
— full-rotation gripping device;
— full-rotation hydraulic shears for the destruction of reinforced concrete products, with a force on the working element of 400 kN, which ensures the cutting of reinforcement with a diameter of up to 30 mm.
Fast delivery of the machine to the place of its use is carried out in a specially equipped 20-foot transport container, providing protection against corrosion and the safety of the machine during transportation.
BROKK 110D (photo 4) is structurally similar to the 330th and differs from it in lower power and the use of a diesel engine mounted on a rotating platform as an energy source.
Photo 4. Remotely controlled machine BROKK 110D.
The BROKK 110D uses a hydraulic axial piston pump with adjustable working volume, powered by an electric drive and providing a flow rate of 1 to 61 l/min. The hydraulic pump is equipped with a pressure and flow regulator, which allows for more efficient use. The hydraulic pressure changes depending on the functions performed.
The boom of the manipulator is three-section, which provides better maneuverability, especially in cramped conditions. The boom design allows it to be used for a long time under dynamic loads (for example, when working with a hydraulic hammer). There is a quick-release connection to speed up the process of replacing attachments. The maximum permissible weight of hydraulic equipment is 150 kg.
All machine systems are controlled via a radio channel or cable from a portable control panel, which can be installed on the operator's waist belt or on a stand. Communication between the control panel and the MR is carried out using a digital coded signal and is adapted for radio control. The radio control range in the line of sight is up to 200 m. Radio signal power @ 10 mW.
The machine's operation is monitored using a monitor and one black-and-white TV camera installed on the platform bracket.
The set of replaceable attachments includes:
— a hydraulic hammer with replaceable working bodies of the «pick» and «chisel» type;
— a standard bucket with a volume of 80 l and a width of 800 mm;
— full-rotation grab bucket with a capacity of 70 l;
— full-rotation gripper;
— full-rotation hydraulic shears for breaking reinforcement with a diameter of up to 15 mm.
The compact BROKK Mini Cut (photo 5) is designed for emergency work mainly in closed spaces.
Photo 5. Remotely controlled machine BROKK Mini Cut.
The design of Mini Cut is similar to the older models — a three-section manipulator, an electric motor, an electrical cabinet, a hydraulic pump, an oil tank, a valve block and a hydraulic motor that ensures the rotation of the platform are mounted on a rotary platform.
In the robot BROKK Mini Cuta hydraulic axial piston pump with adjustable working volume, powered by an electric drive and providing a flow rate of 0.1 to 11 l/min, is used.
For more efficient use, the pump is equipped with a pressure and flow regulator.
The set of replaceable attachments includes a hydraulic hammer, a standard 12-liter bucket, and a full-rotation gripper.
In 1986-1987, to eliminate the consequences of the Chernobyl accident, the Bauman Moscow State Technical University created the remotely controlled Mobot Ch-HV and Mobot Ch-HV2 machines., equipped with a manipulator and a special tool, which in the zone of extremely high radiation were able to perform such complex operations as reconnaissance and measurement of the power of ionizing radiation, cleaning the roof from radioactive debris, installing formwork for concreting the roof, evacuating one damaged robot by another at radiation levels of up to 10,000 r/hour.
Taking into account the experience of successful use of mobile robotic complexes at Bauman Moscow State Technical University, the mobile robotic complex MRK-46M was developed(Photo 6), which is designed to carry out work to eliminate the consequences of local radiation accidents.
Photo 6. Mobile robots MRK-46M (left) and Mobot-CHHV2 (right).
The MRK-46M is a self-propelled, remotely controlled vehicle with a caterpillar drive, equipped with a manipulator, a front loader, two movable television cameras, an automatic cable layer, and control and monitoring equipment. The robot is controlled and powered via cable.
The robot vehicle has a welded, dust- and moisture-proof body on which all the equipment devices, units, and assemblies of the MR are mounted.
The robot has an independent torsion bar suspension symmetrical relative to the longitudinal axis of the machine with coupled parallel torsion bars. There are six support rollers on each side. The vehicle transmission is electromechanical, structurally designed in the form of motor-stars.
The track consists of eight polyurethane reinforced elements, fastened together with pins.
The power plant includes a transformer and rectifier units. The transformer is a three-phase, dry type, designed to convert the supply three-phase voltage of 380 V, 50 Hz into supply voltages required for the operation of the equipment and mechanisms of the MR.
A cable-rope is used to supply power, transmit command signals to the MR, and transmit video signals and telemetry from the MR to the operator's station.
The robot's manipulator has five degrees of mobility and is designed for loading and transporting lump and piece goods, aiming the gamma radiation power detection unit at controlled objects, and working with additional technological equipment.
The working element of the manipulator is a gripping device — a two-fingered gripper. The maximum opening of the gripper is 300 mm. Instead of a two-fingered gripper, a clamshell gripper can be installed, allowing work with bulk material.
A front loader is used to perform transport and loading and unloading operations. The working element of the loader is a bucket mounted on an articulated frame.
The control system of the mobile robot consists of two parts — an on-board part and an operator's station.
The mobile television installation consists of a television camera, a light source and a two-stage electromechanism that allows changing and fixing the position of the television camera and light source in the longitudinal and horizontal planes. The angular movement in the horizontal plane is ± 180°, in the vertical longitudinal plane — ± 60° from the average (initial) position.
The equipment of the operator's post includes the following devices: operator's console, power supply and distribution unit, loudspeaker unit, two video viewing devices, transceiver controller unit.
A special container is used for transporting and storing the robot.
The mobile robotic complex MRK-25M (photo 7) is designed to carry out work to eliminate the consequences of local radiation and chemical accidents on concrete, asphalt and dense soil areas, as well as to carry out pyrotechnic work.
Photo 7. Mobile robot MRK-25M.
The complex includes:
- mobile robot;
- remote control post;
- communication channel;
- additional equipment.
The MRK-25M is a tracked vehicle with a variable geometry drive, the body of which contains the control system units, the onboard part of the communication channel and two batteries, a manipulator or other technological equipment is mounted on the robot body, the composition of which varies depending on the type of task being performed.
The MR is equipped with a television system, a lighting system, and an acoustic feedback unit. All actuators are electromechanical with DC motors.
The MR is controlled from a control stand consisting of a control panel, video control devices (monitors), video tuners with an acoustic feedback unit and a battery. The components of the control stand are mounted on a wheeled trolley, which ensures high mobility when deploying the complex. The control panel is removable. It can be controlled manually with direct observation of the MR.
Control is carried out via cable.
The robot's chassis is a tracked chassis with variable track geometry and consists of drive motor sprockets, polyurethane tracks, balance bogies of support rollers, mechanisms for changing the track geometry and the body.
The MR body is welded from aluminum alloy, dust- and moisture-proof. The body contains batteries for power supply and control system units. The chassis elements and mounted process equipment are fixed to the body.
The manipulator has five degrees of mobility:
- manipulator rotation around the vertical axis;
- swinging of the arm;
- swinging of the end link;
- rotation of the gripper;
- compression of the gripper jaws.
The MRK-25M prototype was successfully used in the liquidation of the consequences of the accident in Sarov in 1997.
A number of mobile robots designed to eliminate the consequences of chemical and radiation accidents were developed on its basis. These robots will be supplied to the Leader Center to perform operational tasks.
The use of robots in emergency rescue and special operations is a fundamentally new direction in the development of the Russian Emergencies Ministry.