Infinity Drone | Haile wu

Infinity X

Drone for welding at height

2024 Spring | work in progress

"Infinity X" is a modular drone integrated with a robotic arm that performs high-altitude welding during maintenance.

Design Background

Hazardous Working Environment

"Falling on the ground" is the top industrial accident during construction.

35,295 falling accidents happened in Japan in 2022.

Source: MHLW (Japan)

Number of casualties in accidents caused by constructing equipment in Japan

Welding is a common yet risky maintenance task.

"1 in 250" construction workers face a fatal injury during welding.

The dangers of working at heights and intense welding conditions increase the risk of accidents.

OSHA studies

What is Working at height?

• In general, working at height refers to working more than a height of 4 feet.

• The risk of falling and getting injured increases as the working height elevated due to the mental and physical challenges involved during the construction.

Pain Point

Worker Safety

Welders working at heights face significant risks of falls, exposure to hazardous fumes, and potential injuries from handling heavy equipment.

Equipment Complexity

Labor Cost & Environment

The need for multiple workers to set up, operate, and supervise the welding process increases labor costs. Prolonged setup contributes to construction pollution and noise.

Setting up scaffolding or aerial work platforms for welding at height is time-consuming and requires significant manpower and equipment.

Design statement

In order to enhance safety and improve accessibility during the maintenance of structures at height, I want to minimize human involvement in potentially hazardous situations by integrating unmanned aerial vehicle (UAV) technology.

Why INFINITY X?

Sequence Model | Stakeholder Map

Improved Working Flow

UAV technology simplify traditional welding at height working flow.

Stake Holder Mapping

The updated working pattern brings benefits to all stake holder involved during the process.

There's a great opportunity to develop a drone designed for specific industrial tasks.

1. Simplifying traditional complex welding workflows, reducing the time it takes to set up equipment
2. Minimizing the potential risks associated with people working at height
3. Reducing the labor costs of the implements

4. Maintaining a good living environment for the occupants by reducing construction pollution and noise.

Positive effects on skill variety and use can be expected whenever technology takes over the “dull, dirty, and dangerous” tasks.

Walsh & Strano,2018, p. xix

Ideation

Mood Board

//Robust // Color Contrast // Tech Savvy

Material List

Final

Part name: Propeller

Material: PC

Finished: Matte

PANTONE B 6U

Part name: Upper Cover

Material: Aluminum Alloy

Finished: Powder Coated

PANTONE 137U

Part name: Battery

Material: PC

Finished: Matte

PANTONE CG 4U

Part name: Lower Cover

Material: PC

Finished: Matte

PANTONE B 6U

Part name: Fixer Arm

Material: PPS

Finished: Matte

PANTONE B 6U

Part name: Suction Cups (OGVM)

Material: Silicone Rubber

Finished: Matte

PANTONE B 6U

Infinity X mainly use PC and aluminum alloy to minimize electromagnetic interference from welding while ensuring exceptional hardness. The contrasting orange and black color scheme makes the whole design energetic and tech-savvy.

How it works?

Artifact Model

Infinity X welding system involves the coordination of two operators. The first operator, the Drone Pilot, focuses on flying the drone to the target location. After arrival, the drone scans the environment and sends the data to a PC. The second operator, the Welder, sets the welding path based on the 3D model, adjusts welding parameters, and sends the instructions back to the drone. Meanwhile, the weld platform car sends the necessary gas, laser filler, and electrical power to the drone for welding.

Stabilization & Flexibility

To meet the need for welding precision, the UAV is designed to be able to carry a laser welding robot arm as well as a perch module. They work in tandem to ensure that drone is flexible and stable enough to perform high altitude welding.

Explore More Details ...

Gripping Module

This module will help to anchor the drone to a specific surface, providing a stable platform for subsequent welding.

Robotic Arm Module

This module is connected to the welding car and performs welding tasks after the drone flies to the destination.

5-axis laser welding arm

The robotic arm has 5-axis freedom and is capable of accomplishing high-precision welding requirements. The welding arm module includes an optional material nozzle and lazer head.

Robotic Arm Module

Four-bar mechanism

By incorporating a four-bar mechanism. The drone can adjust the height of the fly arm using only one linear stepper motor.

Fly Arm

Linear stepper motor

Control the propeller arms' movement for landing and flying.

Vacuum Mechanism

By incorporating a vacuum mechanism, the drone can attached to any flat surface. Its tripod feature makes sure the drone will not bob up and down.

Gripping Module

Vacuum Generator

Create vacuum

Servo Motor 1

Control tripod fixer rotate

Servo Motor 2

Control supporting arm rotate

Easy replacement

Two push buttons are placed on the side of the battery, helping Pilot readily to replace the battery.

Battery

Push to unlock

Easy replace

Lock Side

Slide in

Battery Indicator

Intuitive signal

3D Scanning

There are cameras as well as sensors on the top, bottom, left and right sides to recognize the surroundings in all directions for timely obstacle avoidance as well as environmental scanning.

Sensors

Filter tube & gas tube

The filler tube delivers additional material to the weld area for improved strength and durability, while the shielding gas tube supplies an inert gas to protect the weld pool from atmospheric contamination and ensure a clean, high-quality weld.

Inlet Details

shielding gas tube inlet

Filler inlet (optional)

Rotation

More freedom

The servo motors embedded in the drone ensure that the drone can rotate to adjust the optimal welding position when it is fixed in a particular position.