Granted Patent B2

US 12,643,232 · App. 18/545,640 · Granted Jun 2, 2026

Inventors: Mayank Roy (Pittsburgh, PA); Edward A. Bryner (Pittsburgh, PA); Edwin H. Cho (Pittsburgh, PA); Domenic P. Rodriguez (Pittsburgh, PA); Benjamin A. Guise (Pittsburgh, PA); Ryan Dickerhoff (Pittsburgh, PA); Alberto Pinero (Pittsburgh, PA); Weston Bushyeager (Pittsburgh, PA)

Assignee: Gecko Robotics, Inc.

B25J9/1653B25J9/1674

Abstract

Claims (181)

1 . An inspection robot positioning system, comprising:

an inspection robot comprising:

a body;

an arm coupled to the body;

a payload coupled to the arm; and

an inspection surface sensor disposed in the payload and for inspecting an inspection surface;

a first position sensor configured to provide a first position value;

a second position sensor configured to provide a second position value; and

a controller configured to:

determine a position description for the inspection robot based on the first position value and the second position value, the position description comprising a robot position value of the inspection robot on the inspection surface; and

transmit the position description;

wherein at least one of the first position sensor or the second position sensor comprises an inertial measurement unit (IMU);

wherein the controller further comprises:

a component layer configured to interpret the first position value and the second position value;

a subsystem layer configured to:

process the first position value into a first position descriptor, and

process the second position value into a second position descriptor; and

a system layer configured to:

determine the position description based on:

the first position value and the second position value;

a first competence value associated with the first position value, and a second competence value associated with the second position value; and

blending a previous position description, the first position value, and the second position value;

weighting an application of each of the first position value and the second position value based on the corresponding first competence value and the second competence value; and

wherein the subsystem layer is further configured to determine the first competence value based on at least one of:

an operating region of the first position sensor;

an operating condition of the inspection robot;

an integrated error walk estimate corresponding to the first position sensor;

a fault value associated with the first position sensor;

a first correspondence value for correspondence of the first position value with the previous position description; or

a second correspondence value for correspondence of the first position value with at least one other position value.

2 . The inspection robot positioning system of claim 1 , wherein each one of the first position sensor and the second position sensor comprise at least one of:

a camera;

a range finder;

a triangulation assembly;

an encoder for at least one of a wheel or a motor of the inspection robot;

a gimbal actuator servo; or

an actuator of the inspection robot.

3 . The inspection robot positioning system of claim 1 , wherein the system layer is further configured to determine the position description based on the previous position description.

4 . The inspection robot positioning system of claim 1 , wherein:

the first position sensor comprises the IMU;

the inspection surface comprises a substantially vertical surface with respect to the Earth's center of gravity;

the IMU is structured to determine a gravity vector that points substantially towards the Earth's center of gravity; and

the controller is further configured to determine the first position value based at least in part on the gravity vector.

5 . The inspection robot positioning system of claim 4 , wherein the IMU comprises at least one of:

an accelerometer structured to generate an accelerometer output value, wherein the IMU is structured to determine the gravity vector based at least in part on the accelerometer output value; or

a gyroscope structured to generate a gyroscope output value, wherein the IMU is structured to determine the gravity vector based at least in part on the gyroscope output value.

6 . The inspection robot positioning system of claim 4 , wherein the IMU is structured to determine the gravity vector based at least in part on a relation to a normal vector of the inspection surface.

7 . The inspection robot positioning system of claim 6 , wherein the relation is based at least in part on the gravity vector forming an angle with the normal vector.

8 . The inspection robot positioning system of claim 7 , wherein the angle is between about +45° to about −45°.

9 . The inspection robot positioning system of claim 1 , wherein the robot position value comprises a position of the inspection robot on the inspection surface.

10 . The inspection robot positioning system of claim 9 , wherein the robot position value comprises an orientation of the inspection robot on the inspection surface.

11 . The inspection robot positioning system of claim 10 , wherein the robot position value comprises at least one of:

a linear velocity of the inspection robot; or

an angular velocity of the inspection robot.

12 . The inspection robot positioning system of claim 1 , wherein the robot position value comprises a position of a component of the inspection robot.

13 . The inspection robot positioning system of claim 12 , wherein the component comprises at least one of: a sensor, a sensor sled, a payload, or a payload arm.

14 . The inspection robot positioning system of claim 1 , wherein:

the first position sensor comprises the IMU; and

the second position sensor comprises an encoder for at least one of a wheel or a motor of the inspection robot.

15 . The inspection robot positioning system of claim 14 , further comprising:

a third position sensor providing a third position value;

wherein:

the controller is further configured to determine the position description based on the third position value; and

the third position sensor comprises a triangulation rangefinder.

16 . An inspection robot positioning system, comprising:

an inspection robot comprising:

a body;

an arm coupled to the body;

a payload coupled to the arm; and

an inspection surface sensor disposed in the payload and for inspecting an inspection surface;

a first position sensor configured to provide a first position value;

a second position sensor configured to provide a second position value; and

a controller configured to:

determine a position description for the inspection robot based on the first position value and the second position value, the position description comprising a robot position value of the inspection robot on the inspection surface; and

transmit the position description;

wherein at least one of the first position sensor or the second position sensor comprises an inertial measurement unit (IMU);

wherein the controller further comprises:

a component layer configured to interpret the first position value and the second position value;

a subsystem layer configured to:

process the first position value into a first position descriptor, and

process the second position value into a second position descriptor; and

a system layer configured to:

determine the position description based on:

the first position value and the second position value;

a first competence value associated with the first position value, and a second competence value associated with the second position value; and

blending a previous position description, the first position value, and the second position value;

at least partially resetting the position description based on the one of the first competence value or the second competence value and the corresponding first position value or the second position value; and

wherein the subsystem layer is further configured to determine the first competence value based on at least one of:

an operating region of the first position sensor;

an operating condition of the inspection robot;

an integrated error walk estimate corresponding to the first position sensor;

a fault value associated with the first position sensor;

a first correspondence value for correspondence of the first position value with the previous position description; or

a second correspondence value for correspondence of the first position value with at least one other position value.

17 . The inspection robot positioning system of claim 16 , wherein each one of the first position sensor and the second position sensor comprise at least one of:

a camera;

a range finder;

a triangulation assembly;

an encoder for at least one of a wheel or a motor of the inspection robot;

a gimbal actuator servo; or

an actuator of the inspection robot.

18 . The inspection robot positioning system of claim 16 , wherein the system layer is further configured to determine the position description based on the previous position description.

19 . The inspection robot positioning system of claim 16 , wherein:

the first position sensor comprises the IMU;

the inspection surface comprises a substantially vertical surface with respect to the Earth's center of gravity;

the IMU is structured to determine a gravity vector that points substantially towards the Earth's center of gravity; and

the controller is further configured to determine the first position value based at least in part on the gravity vector.

20 . The inspection robot positioning system of claim 16 , wherein the robot position value comprises a position of the inspection robot on the inspection surface.

21 . The inspection robot positioning system of claim 20 , wherein the robot position value comprises an orientation of the inspection robot on the inspection surface.

22 . The inspection robot positioning system of claim 21 , wherein the robot position value comprises at least one of:

a linear velocity of the inspection robot; or

an angular velocity of the inspection robot.

23 . The inspection robot positioning system of claim 16 , wherein the robot position value comprises a position of a component of the inspection robot.

24 . The inspection robot positioning system of claim 23 , wherein the component comprises at least one of: a sensor, a sensor sled, a payload, or a payload arm.

25 . The inspection robot positioning system of claim 16 , wherein:

the first position sensor comprises the IMU; and

the second position sensor comprises an encoder for at least one of a wheel or a motor of the inspection robot.

26 . The inspection robot positioning system of claim 25 , further comprising:

a third position sensor providing a third position value;

wherein:

the controller is further configured to determine the position description based on the third position value; and

the third position sensor comprises a triangulation rangefinder.

27 . A method for localizing an inspection robot, the method comprising:

determining a first position value via a first position sensor disposed on the inspection robot, wherein the inspection robot includes a body, an arm coupled to the body, a payload coupled to the arm, and an inspection surface sensor disposed in the payload and for inspecting an inspection surface;

determining a second position value via a second position sensor disposed on the inspection robot;

determining, via a controller and based on the first position value and the second position value, a position description for the inspection robot, the position description comprising a robot position value of the inspection robot on the inspection surface; and

transmitting the position description;

wherein at least one of the first position sensor or the second position sensor comprises an inertial measurement unit (IMU);

interpreting the first position value and the second position value via a component layer of the controller;

generating, via a subsystem layer of the controller and based at least in part on the first position value, a first position descriptor;

generating, via the subsystem layer and based at least in part on the second position value, a second position descriptor;

determining, via a system layer of the controller based at least in part on the first position value and the second position value, the position description;

determining, via the subsystem layer, a first competence value associated with the first position value;

determining, via the subsystem layer, a second competence value associated with the second position value;

wherein determining, via the system layer of the controller based at least in part on the first position value and the second position value, the position description, is based on the first competence value and the second competence value; and

determining, via the controller, a competence factor, wherein:

determining, via the subsystem layer, a first competence value associated with the first position value is based on the competence factor, wherein the competence factor is at least one of:

an operating region of the first position sensor;

an operating condition of the inspection robot;

an integrated error walk estimate corresponding to the first position sensor;

a fault value associated with the first position sensor;

a first correspondence value for correspondence of the first position value with a previous position description; or

a second correspondence value for correspondence of the first position value with at least one other position value;

wherein determining, via the system layer of the controller based at least in part on the first position value and the second position value, the position description comprises blending, via the subsystem layer, the previous position description, the first position value, and the second position value; and

wherein determining, via the system layer of the controller based at least in part on the first position value and the second position value, the position description further comprises weighting application of each of the first position value and the second position value based on the corresponding first competence value and the second competence value.

28 . The method of claim 27 further comprising:

determining, via the controller, the previous position description for the inspection robot, wherein determining, via the system layer of the controller based at least in part on the first position value and the second position value, the position description, is based on the previous position description.

29 . The method of claim 27 , wherein:

the first position sensor comprises the IMU;

the method further comprises determining, via the IMU, a gravity vector with respect to the Earth's center of gravity; and

determining, via the controller and based on the first position value and the second position value, a position description for the inspection robot is based at least in part on the gravity vector.

30 . A method for localizing an inspection robot, comprising:

determining a first position value via a first position sensor disposed on the inspection robot, wherein the inspection robot includes a body, an arm coupled to the body, a payload coupled to the arm, and an inspection surface sensor disposed in the payload and for inspecting an inspection surface;

determining a second position value via a second position sensor disposed on the inspection robot;

determining, via a controller and based on the first position value and the second position value, a position description for the inspection robot, the position description comprising a robot position value of the inspection robot on the inspection surface; and

transmitting the position description;

wherein at least one of the first position sensor or the second position sensor comprises an inertial measurement unit (IMU);

interpreting the first position value and the second position value via a component layer of the controller;

generating, via a subsystem layer of the controller and based at least in part on the first position value, a first position descriptor;

generating, via the subsystem layer and based at least in part on the second position value, a second position descriptor;

determining, via a system layer of the controller based at least in part on the first position value and the second position value, the position description;

determining, via the subsystem layer, a first competence value associated with the first position value;

determining, via the subsystem layer, a second competence value associated with the second position value;

wherein determining, via a system layer of the controller based at least in part on the first position value and the second position value, the position description, is based on the first competence value and the second competence value; and

determining, via the controller, a competence factor, wherein:

determining, via the subsystem layer, a first competence value associated with the first position value is based on the competence factor, wherein the competence factor is at least one of:

an operating region of the first position sensor;

an operating condition of the inspection robot;

an integrated error walk estimate corresponding to the first position sensor;

a fault value associated with the first position sensor;

a first correspondence value for correspondence of the first position value with a previous position description; or

a second correspondence value for correspondence of the first position value with at least one other position value;

wherein determining, via the system layer of the controller and based at least in part on the first position value and the second position value, the position description comprises blending, via the subsystem layer, the previous position description, the first position value, and the second position value; and

wherein determining, via a system layer of the controller based at least in part on the first position value and the second position value, the position description further comprises:

partially resetting the position description based on one of the first competence value or the second competence value and the corresponding first position value or the second position value.

31 . The method of claim 30 , further comprising:

determining, via the controller, the previous position description for the inspection robot, wherein determining, via the system layer of the controller based at least in part on the first position value and the second position value, the position description, is based on the previous position description.

32 . The method of claim 30 , wherein:

the first position sensor comprises the IMU;

the method further comprises determining, via the IMU, a gravity vector with respect to the Earth's center of gravity; and

determining, via the controller and based on the first position value and the second position value, a position description for the inspection robot is based at least in part on the gravity vector.

Assignments (1)

Continuity (2)

References Cited (400)