280

IEEE Transactions on Power Delivery, Vol. PWRD-1, No. 3, July 1986

"ROBOTIC MAINTENANCE OF OVERHEAD TRANSMISSION LINES"

John H. Dunlap Senior Member Electric Power Research Institute Palo Alto CA

Joseph M. Van Name Senior Member Philadelphia Electric Company Philadelphia, PA

Jerry A. Henkener Southwest Research Institute San Antonio, TX

Abstract - This paper covers the design, assembly, and field testing of the TOMCAT Component TOMCAT is an acronym for Evaluation Unit (CEU). for and Teleoperator Operations, Maintenance, The unit Construction using Advanced Technology. was developed in the performance of Phase 2 of EPRI Project No. RP14967-1, "Remote Controlled Maintenance Device" system developmerit program. The objective of this effort was to design, fabricate, and evaluate a remotely controlled assemble, manipulator system for the maintenance and repair of overhead transmission lines based the upon utilization of as many off-the-shelf components as The major intent was to develop the practical. design information necessary for a field operable The component evaluation unit was prototype. assembled and then evaluated under energized and deenergized conditions. Information gathered from the evaluation will form the design criteria for the follow-on prototype system.
INTRODUCTION

Company (PECO), and A. B. Chance in conducting the Phase 1 effort. The objectives for the Phase 1 feasibility study were (1) Develop requirements for maintaining high voltage (138 kV to 765 kV) overhead transmission lines; (2) Determine the technical and economic feasibility of developing a system to meet the requirements; (3) Develop a system conceptual The Phase 1 objectives were met and the design. results were documented in EPRI final report EL3296, dated November 1983. EPRI continued the contract with SwRI and PECO for Phase 2 in which the major objective of the work was to design, assemble, and evaluate a functional, remotely operated system. The system was named TOMCAT (Teleoperator for Operations, Maintenance, and Construction using Advanced Technology). Figure 1 shows the completed Component Evaluation Unit (CEU) assembly. The emphasis in Phase 2 was to utilize off-the-shelf to the components greatest extent possible. Development efforts were divided into seven tasks. This Paper summarizes the accomplishments of the Phase 2 effort.

The maintenance of overhead transmission line systems is routinely performed by experienced linemen who make use of a wide variety of special and adhere to tools strict, well-developed Most of these tools and procedures procedures. cannot be employed during inclement weather conditions. Maintenance of the more complex, higher voltage systems can be taxing even for experienced linemen. In heavily populated areas load levels are increasing and the compacting of transmission lines A remote is being given serious consideration. maintenance system for use in these conditions is very attractive since differential energy costs associated with an out of service line can be In an effort to augment prohibitively expensive. the lineman's working ability and to give him the ability to work during inclement weather, especially in an emergency, the Electric Power Research Institute (EPRI) initiated a research program aimed at developing a remotely controlled manipulator work The basic concept was demonstrated by system. Philadelphia Electric in 1979 on a de-energized line using an available manipulator. After the interest generated by that demonstration, EPRI proceeded with the first Phase of their research program by with Southwest Research Institute contracting (SwRI). SwRI was teamed with Philadelphia Electric

Component

Unit MIanipul.tor

EvdIuati 1n

86 WM 163-0 A paper recommended and approved by the IEEE Transmission and Distribution Committee of the IEEE Power Engineering Society for presentation at the IEEE/PES 1986 Winter Meeting, New York, New York, February 2 - 7, 1986. Manuscript submitted September 3, 1985; made available for printing November 12, 1985.

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stupplied by PECO j
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Figure 1.

TOMCAT Component Evaluation Unit Assembly

0885-8977/86/0007-0280$01.001986

IEEE

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SYSTEM DESIGN
The selection of an appropriate manipulator for the TOMCAT System was the first task of the Phase 2 effort. The major goal was to conduct an engineering trade-off analysis, and select the most appropriate manipuilator based upon the criteria defined during Phase 1 and the manufacturer's willingness to participate in the program on a cooperative basis. Candidates were reevaluated in terms of the requirements as shown in Table 1. Kraft Ocean Systems was the manufacturer that most nearly satisfied the TOMCAT CEU system requirements. The selected manipulator operates in a masterThe manipuslave, spatially correspondent mode. lator was developed for use in the harsh, undersea environment and has a proven track record for reliability under the rough treatment of offshore The operations. was manipulator especially attractive for transmission line applications because of the robotic features. It is controlled by a computer with the ability to remember the motion sequence of each joint in a "teach mode." The motion sequences can then be repeated in a robotic fashion. This feature can be especially important for repetitive work tasks and other repetitive movements such as retrieving or stowing special tools. A major modification over conventional manipulators is the use of fiber optics to provide safe electrical isolation between the operator and the manipulator when the manipulator is energized at line potential. The fiber optic components were powered by a 12 Vdc lead-acid battery. A schematic of the manipulator control system is shown in Figure 2. The prototype includes a hydraulic powered alternator to minimize battery weight. Television was used for operator feedback. The TV camera pan and tilt mechanism was controlled through the use of three position (spring-loaded center off) toggle switches for both the pan and tilt functions. Hydraulic control for each function was obtained by use of four-way (center position The pan and tilt locked) 12 Vdc solenoid valves. system was designed to communicate over a single link fiber communications from the operator's control panel to the boom end control box.

Table

I.

Manipulator Requirements

Highly Desired Features

o
o o

Master-slave design Force and position feedback All weather, waterproof design Externally "clean" design to
corona

o o o o
o

o o

o o
o

Minimum of 7 degrees of freedom (6 plus grip) Hydraulically powered Weight less than 300 lb. Reach at least 5 ft. Positional accuiracy of 1/8 in. Grip opening of 4 to 6 in. Corona shielding to 765 kV Grip force 100 lb. minimum Wrist torque 50 ft-lb. Arm lifting capability 100 lb. Position hold in event of power loss 1000 hr mtbf (mean time between fail]ure) 12 hr mttr (mean time to repair) 48 hr mtbm (mean time between maintenance)

discharge

prevent/reduce

o o

o o

o o o o o

Symmetric working envelope User friendliness (quick to learn and easy for novice to perform relatively complex tasks, a natural extension to the human hand) Interchangeable end effectors Able to be reconfigured in different lengths in the field Low power consumption Variable force feedback at each joint Some degree of programmability or computer assist for repetitive tasks Nonconducting outer skin Modular design for ease of maintenance

KMC 900-HT

Figure 2.

Evaluation Unit Manipulator Control

System

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The operator control components consist of a manipulator master, a manipulator hand terminal, a control panel with pan control and tilt control switches, dual TV monitors, and a control box for housing the main printed circuit board for data transmission. These components are located in the back of the bucket truck. Each TV camera was mounted in a sealed aluminum housing for shielding and protection purposes. The camera was powered by the 12 Vdc battery. At the beginning of this Phase 2 effort, it was decided that only one of the cameras required a pan and tilt capability. The decision was made to assemble a hydraulic pan and tilt mechanism using readily available 12 Vdc 4-way solenoid valves and twin rotary actuators for the two degrees of freedom. The mechanism was not optimal for the application but functioned sufficiently well to learn the critical requirements needed for the future prototype system in which electric powered units will be used. COMPONENT EVALUATION UNIT

functionally checked prior to the final, total system assembly at PECO. An insulated bucket truck was provided by PECO for test purposes. It should be noted that the goal of the TOMCAT system is to be modular, and therefore adaptable to various truck configurations or other types of host platforms such as conductor carts. The basic subsystem elements, except for the insulator change-out tools, are shown in the test assembly system configuration in Figure
The boom mounted components were initially designed to be held in place by an aluminum mounting structure. The mounting structure was purposely made as a bolt-together construction to allow for relatively easy modifications. The aluminum frame was designed to straddle the boom and be pinned to a solid steel shaft that connects to the boom The levelling system maintains levelling system. the manipulator in a vertical position regardless of the boom position. A mounting structure was designed to house the batteries and control box on either side of the boom. The cameras were initially mounted behind the manipulator. A tool rack was mounted off to the left side of the manipulator. The initial structural design proved to be too bulky. Modifications made to reduce the size included: side brackets shortened, battery mounted on the same plate as the manipulator, control box relocated to a position behind the battery.

3.

The CEU consisted of an insulated bucket truck, manipulator, structural mounting system, television viewing system, control system, insulator change-out tools, and hydraulic power supply. The above seven subsystems were individually designed, purchased and

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Component Evaluation IJnit Assembly

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The Kraft seven-function manipulator was bolted to the structure at the end of the boom. The only modification to the standard manipulator arm was the addition of special jaws specifically designed to handle the tools. Initially, the manipulator was mounted at a 15 bias angle to permit the manipulator to easily reach a tool rack without requiring the tool rack structure to be forward of the arm in its folded position. The manipulator was later mounted straight when the tool rack concept was modified. The television viewing system utilized two Charge Couple Device (CCD) cameras with automatic A 16 mm (0.63 in) iris and fixed focus lenses. lense was used for close viewing and an 8.5 mm (0.35 in) lense was used to provide an overall picture. The 16 mm camera was mounted on a hydraulically operated pan and tilt mechanism while the 8.5 mm Each camera had its own monitor camera was fixed. with a single fiber cable linking each camera with it's monitor. The operator's control panel also housed the fiber optic transmitter and receiver for the controls and the switches for manipulator controlling pan and tilt and the electro-optical receivers for both television cameras.

Stability of the CEU was reviewed. It was not a problem during this Phase since the maximum height off the ground for the manipulator was only 35 to 40 For transmission line field conditions, feet. however, the manipulator height could easily be 150 to 200 feet. At these heights, wind and boom repositioning will undoubtedly cause the manipulator to sway. Under these situations, one or two stabilizing arms may be desirable. One arm is prefered to minimize the manipulator handling effort. These stabilizing arms can also be integrated with the lock-on feature when operating at line potential or under close clearances. It is likely the stabilizing arm will be most effective if it can telescope out from the mounting structure. If this is the case, then the stabilizing arm would be designed to clamp on to the conductor or other part when working energized. When working on the cold end clamping to the pole arm or tower structure would provide stability.

CONCLUSIONS

FIELD EVALUATION
After the basic functional checkout of the CEU assembly, de-energized testing was conducted primarily in the following study areas: reach, dexterity, and stability; tool and task interface; insulator work procedure; change-out tool development; TV camera placement; system demonstration. Reach and dexterity tests were conducted in a subjective manner with emphasis placed on the change out of a vertical 230 kV insulator string. For most the operations, manipulator appeared to have sufficient reach. For the operation at the PECO test site, it was relatively easy to reposition the boom. Applications where large, fully extended booms will be used may be more difficult. In those applications, an additional one to two foot longer reach could be beneficial, especially when operating on the hot end. The possibility of adding one or two additional degrees of freedom to the manipulator mounting frame was explored, but was considered to be an unnecessary complexity for the CEU. Provision for adding the additional degrees of freedom at a later date will be part of the prototype mounting structure. The basic philosophy for the CEU was to simplify the tools and procedures to permit functioning without force feedback. Manipulator dexterity appeared adequate in terms of having position feedback only. One of the tasks requiring significant dexterity was the pulling of the cotter When adequate vision could be provided, the key. key could be pulled as shown in Figure 4. There is no doubt that the addition of force feedback will significantly enhance the operators ability to This maneuver parts and to control the work tools. will lead to significant improvements in dexterity and efficiency when force feedback is used. This approach also provides the option to use a less expensive system if a utility can justify reduced efficiency or has less complex work tasks in mind.

EPRI development The program for remote transmission line maintenance is now in the middle of Phase 3, the prototype phase. The conclusions of Phase 1 were that such a system was technically feasible and could be economically justified for routine and emergency useage if the system cost was held to around $300k. During the Phase 2 component evaluation phase technical was feasibility demonstrated and the potential problem areas were identified where the bulk of the prototype development effort needs to be concentrated. These major areas are (1) the viewing system, (2) tool handling and modification, (3) minimization of weight and size; response to boom movements, and (14) field effective from electric shielding interference. It was demonstrated that the use of multiple arms would be too bulky as well as It was also significantly increasing the cost. demonstrated that many conventional hot stick tools could be used without the fiberglass poles. Every operation, however, is likely to require some special tools that are unique and designed to A interface with the transmission line hardware. major conclusion from the Phase 2 effort was to demonstrate that a lineman could operate the system to change out a string of 230 kV vertical insulators under field-simulated conditions. The objectives of the Prototype Phase now underway is to prove that the system can operate in the field under the expected rugged abuse and harsh environmental conditions.

FUTURE WORK

Design and construction of the field-operable prototype is well underway and should be ready for After field evaluations in the fall of 1985. complete testing for mechanical and electrical performance, the prototype TOMCAT will be made available to EPRI member utlities to evaluate the potential uses in transmission line activities.

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Figure 4.

Manipulator Pulling Cotter Key on Cold End