Past Projects

ULC ROBOTICS R&D

ULC Robotics works on an array of Research & Development projects. We develop simple hand tools, process redesigns, and complex robotic systems in addition to taking over failing projects to make them a success. We’d like to share with you a small sampling of R&D projects performed at ULCR.

SAMPLE PROJECTS

Please Note: All designs, fabrications, field testing and commercialization performed for each project are executed exclusively by ULCR resources.

CAST IRON JOINT SEALING ROBOTS (CISBOT):

THE CISBOT CAST IRON PIPE JOINT SEALING ROBOT SEALS JOINTS IN LIVE CAST IRON GAS MAINS.

Working for two of the country’s largest Utility Companies, ULC Robotics took two struggling prototype robots, built by another firm, and turned them into a commercial success.

Two of the country’s largest utility companies invested heavily in the development of robots to seal joints in live, in service, cast iron gas mains. When the original manufacturer failed to deliver field ready units, they hired ULC Robotics to debug, re-engineer and commercialize the systems. ULCR licensed the technology from the utility companies and now provides live robotic cast iron joint sealing services throughout the Northeast US.

WORK PERFORMED

• Performed Critical Analysis of Mechanical, Electrical and Pneumatic Systems to Assess System Deficiencies

• Completed a Variety of Activities Designed To Increase the Functionality and Reliability of the . Mechanical, Electrical, Pneumatic And Pump Systems

• Performed Field Deployments of Robotic Systems in Live Gas Mains In Order To Demonstrate . System Operability and Commercial Readiness

• Currently Perform Contracted Services for Multiple Utility Companies

MICRO MAGNETIC CASED PIPE INSPECTION ROBOT (MMC):

THE MICRO MAGNETIC CASED PIPE INSPECTION ROBOT (MMC) PROVIDES VIDEO AND SENSOR DATA FOR CRITICAL ANALYSIS OF GAS MAINS BURIED WITHIN CASED PIPE IN HIGH CONSEQUENCE AREAS.

Reacting to new federally mandated pipeline integrity rules, a consortium of US utility companies hired ULC Robotics to solve a critical problem: Gather important data about the condition of underground gas mains buried inside casings – and do it inside spaces as small as 1 ¼” and up to hundreds of feet long.

New federal pipeline integrity rules require utility companies to evaluate thousands of gas mains buried beneath highways, railroad tracks and airport runways – each and every one cased inside a larger pipe. ULCR imagined, designed and built a solution. The Micro-Magnetic Cased Pipe Inspection Robots defy gravity by magnetically attaching to the metallic casing pipe enabling them to crawl hundreds of feet into tight annular spaces. Front and rear mounted video cameras provide real-time, full motion video of the outer surface of the gas main. Pitch and roll sensors allow for remote navigation and provide the precise location of defects and anomalies. Temperature and humidity sensors continually monitor the environment inside the casing. An ultrasonic thickness sensor can be deployed to take spot wall thickness measurements. Using two forward projecting lasers, a video based measurement system may be used to take measurements of defects or objects within the casing annulus.

WORK PERFORMED

• Ground Up Design of Two Unique, Ultra Compact, Robotic Systems

• Complete Design of User Interface, Control And Drive Systems, Custom Tether And Mechanical Design

• Integration of Ultrasonic Thickness Gauge Capable Of Remotely Measuring Wall Thickness Through Coal Tar Coating At Distances Over 200 Ft

• Development, Fabrication and Test of On board Sensor System (Pitch, Roll, Temperature And Humidity)

• Successful Development of 2500 Cps Ultrasonic Couplant Pumping System; Operates At Over 700 Psi

VARIABLE GEOMETRY CRAWLER (VGC):

THE VARIABLE GEOMETRY CRAWLERS PROVIDE INSPECTION CAPABILITIES UNDER LIVE GAS CONDITIONS.

Four of the country’s largest utility companies asked ULC Robotics to go where no man could ever go – inside live large diameter gas mains. ULCR did – by building and commercializing two unique pipeline inspection robots.

A group of four Northeast US utility companies own and maintain thousands of miles of large diameter cast iron gas mains installed between the mid 1800’s and mid 1900’s. At their request, ULC Robotics conceived of, designed, built and commercialized two highly specialized pipeline robots, and companion launch systems, which provide critical data regarding the structural integrity of these mains. This data is used to react to problems and issues within the mains and to inform the selection of repair and rehabilitation methods.

WORK PERFORMED

• Ground Up Design Of Two Unique Robotic Systems Capable Of Vertical Entry Into Live Gas Mains Through Extremely Small Tap Holes

• Design and Fabrication of All Mechanical Systems; Including Remotely Telescoping Track System

• Development of Electrical Controls, Video and Drive Systems

• Custom Miniature Pan and Tilt Camera System Development

• Development of No Blow Vertical Launch System Designed To Eliminate the Escape Of Gas Into The Environment During Operation

HIGH PRESSURE GAS CAMERAS:

THE HIGH PRESSURE GAS CAMERA (PRX250/PRX250K) IS A UNIQUE, INTERNAL INSPECTION TOOL DEVELOPED TO ALLOW GAS UTILITY COMPANIES TO INSPECT 4” – 12” DIAMETER LIVE GAS PIPE.

ULC Robotics advanced the state of the art in small diameter live gas main inspection by developing the first remote controlled camera system capable of launching vertically through keyholes. The rugged PRX250K is in wide spread use by many of the country’s largest utility companies.

WORK PERFORMED

• Electrical and Mechanical Design of Water Tight Miniature Camera and Self Deploying Centering System

• Development of No Blow Vertical Launch System Designed To Eliminate the Escape Of Gas Into The Environment During Operation

• Control and Video System Development; Designed For Quick Deployment in Harsh Field Conditions

• Design and Integration of a Flexible, Vertically Launching 16 Hz Locating Transmitter Sonde

EXPLORER I:

THE EXPLORER I ROBOT WAS DESIGNED TO PROVIDE GAS DISTRIBUTION COMPANIES WITH LIVE, HIGH-RESOLUTION VIDEO INSPECTION IN STEEL AND CAST IRON GAS MAINS.

Working for a premier research and development project management organization, ULC Robotics debugged and performed a commercialization assessment of a wireless live gas pipeline inspection robot developed by one of the country’s leading universities.

WORK PERFORMED

• Design and Construct Testing Facility

• Critical Analysis of Mechanical, Electrical and Wireless Communication and Control Systems

• Debugging of System Control and Robot Electronics

• Performed a Variety of Activities Designed To Increase The Functionality And Reliability Of Mechanical, Electrical And Wireless Systems

• Performed Field Deployments of Robotic System In Live Gas Mains In Order To Demonstrate System Operability And Commercial Readiness