Autonomous Drone Corrosion Detection Under Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for inspecting insulated equipment for corrosion under insulation (CUI) are time-consuming and costly, making early detection difficult and leading to potential equipment damage and economic losses.
Innovation Solution
A system utilizing autonomous, modular unmanned vehicles with aerial and ground locomotion capabilities, equipped with infrared and pulsed eddy current modules, for non-destructive testing, which detects infrared waves and induces eddy currents to assess corrosion under insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional inspection methods are used to detect corrosion under insulation, then inspection accuracy can be maintained, but inspection time and cost increase significantly
Solution Approach 1:
The patent replaces mechanical stripping of insulation with non-contact infrared thermography and pulsed eddy current testing. The infrared detector captures thermal radiation patterns that indicate moisture accumulation, while PEC sensors detect electromagnetic responses from corrosion areas, eliminating the need for physical insulation removal and dramatically reducing inspection time.
Solution Approach 2:
The patent introduces an intermediary inspection system consisting of infrared detectors and PEC sensors that indirectly detect corrosion through thermal and electromagnetic signatures. This intermediary approach allows detection of subsurface corrosion without direct visual inspection, maintaining accuracy while avoiding time-consuming insulation removal.
2Reliability
If conventional inspection methods are used to detect corrosion under insulation, then reliable detection can be achieved, but equipment downtime and repair costs increase
Solution Approach 1:
The patent performs preliminary detection of corrosion using infrared and PEC methods before significant damage occurs. By detecting moisture accumulation and early-stage corrosion through thermal patterns and electromagnetic responses, the system enables proactive maintenance scheduling that minimizes equipment downtime and prevents catastrophic failures.
Solution Approach 2:
The patent replaces time-consuming mechanical inspection processes with rapid non-contact sensing. The infrared detector and PEC sensor can scan large areas of insulated equipment quickly, providing reliable corrosion detection data without requiring equipment shutdown or insulation removal, thus maintaining high equipment operational efficiency.
3Difficulty of detecting and measuring
If insulation and cladding are removed for inspection, then direct visualization of corrosion can be achieved, but inspection complexity and cost increase
Solution Approach 1:
The patent utilizes thermal radiation patterns detected by infrared sensors that create visual representations of temperature variations indicative of moisture and corrosion. The thermal imagery provides color-coded or grayscale visual differentiation of affected areas, making subsurface corrosion visible without physical insulation removal while simplifying the inspection process.
Solution Approach 2:
The patent substitutes mechanical insulation removal with electromagnetic and thermal sensing systems. The infrared detector captures thermal radiation, and PEC sensors measure electromagnetic responses, both providing direct visualization of corrosion conditions through non-contact measurement, thereby reducing inspection process complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables efficient and cost-effective detection of corrosion under insulation by quickly identifying susceptible areas and determining the presence of CUI, reducing downtime and repair costs while improving the accuracy of inspections.
Implementation Method 1
The infrared module includes an infrared detector configured to detect infrared waves emitted from the insulated equipment
Implementation Method 2
The PEC module includes at least one PEC sensor configured to induce an eddy current in the inner wall of the insulated equipment
Implementation Method 3
the PEC sensor configured to induce an eddy current in the inner wall of the insulated equipment
Data Source
AI summary
Methods and systems for inspecting insulated equipment for corrosion under insulation are provided. The system includes an autonomous unmanned vehicle having aerial and ground locomotive capabilities. The vehicle includes an infrared detector and a pulsed eddy current sensor. In the method, infrared waves emitted from the equipment are detected along the equipment with the infrared detector. Using the infrared detector, at least one image of an inner surface of the equipment is developed based on the detected infrared waves. At least one area that is susceptible to corrosion is determined based on the at least one image. The susceptible area is inspected with the pulsed eddy current sensor, which induces an eddy current in the inner wall of the equipment. Based on a rate of the decay in strength of the eddy current, it is determined whether corrosion exists at the susceptible area using a processor configured by code.