Automated 3D Scanning for Machine Component Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current inspection procedures for machine components, especially in the Oil & Gas industry, are largely manual and inefficient, requiring periodic disassembly and relying on human inspectors, which can lead to inaccuracies and increased downtime due to the lack of automated assessment tools.
Innovation Solution
An automated inspection apparatus comprising a computer unit, 3D scanner, and multiple sensors that create an annotated 3D model of the component, allowing for simulation and automatic determination of its serviceability and repairability based on predefined criteria, enabling remote inspection and reducing manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection procedures are used with human inspectors, then flexibility and adaptability in assessment are maintained, but inspection accuracy and efficiency deteriorate due to human error and time consumption
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical measurement system comprising a 3D scanner and multiple sensors. The system captures geometric data and surface characteristics automatically, eliminating human subjectivity and error. The computer processing unit analyzes the captured data objectively, providing precise measurements of component wear, deformation, and surface defects without human intervention.
Solution Approach 2:
The patent creates a digital 3D model (copy) of the physical machine component through scanning. This digital replica allows for repeated analysis, simulation, and assessment without physically handling or potentially damaging the original component. The annotated 3D model serves as a permanent record that can be reviewed multiple times for different assessment criteria.
2Reliability
If periodic inspection is performed to detect component wear and damage, then machine reliability is improved, but machine downtime increases due to disassembly and inspection procedures
Solution Approach 1:
The patent performs inspection actions before complete component failure occurs by detecting early signs of wear, deformation, and surface defects. The system identifies potential issues during routine inspections, allowing for proactive maintenance scheduling that minimizes downtime. By detecting problems early, the system prevents catastrophic failures that would require extensive disassembly and longer repair times.
Solution Approach 2:
The patent enables dynamic inspection capabilities where the system can quickly adapt to different component types and inspection criteria. The automated system can reconfigure measurement parameters and assessment standards based on the specific component being inspected, reducing the time required for each inspection cycle while maintaining comprehensive coverage of wear patterns and defects.
3Measurement precision
If comprehensive inspection phases including scanning and multiple sensor measurements are performed, then assessment accuracy is improved, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional inspection system where a single integrated platform performs multiple inspection tasks using different sensors and measurement techniques. The system can capture geometric data, surface roughness, coating thickness, and structural integrity within one unified workflow. This universal approach consolidates what would otherwise require multiple separate inspection devices into one coordinated system, managing complexity through integration rather than multiplication of separate systems.
Solution Approach 2:
The patent combines multiple inspection functions and data acquisition methods into a unified processing framework. The computer processing unit integrates data from various sensors (optical, tactile, thermal) and merges it with reference data from databases to produce a comprehensive assessment. By merging multiple data streams and analysis methods into a single coordinated process, the system achieves high assessment accuracy while managing complexity through centralized control and integrated software architecture.
Data Source
AI summary
An inspection apparatus to automatically determine the state of a serviced machine component through a plurality of inspection phases; the apparatus includes: a computer unit, a 3D scanner, a plurality of inspection sensors for performing a plurality of inspection phases on the component; the computer unit interacts with the scanner and the sensors in order to generate an annotated 3D model of the component; the computer unit is configured to perform simulation on the machine component so to determine a status of one or more regions of the machine component; furthermore, the computer unit may be provided with a checking engine for applying one or more criteria to the results of the simulation and automatically determine whether the component is serviceable and/or repairable and generate a status report accordingly.