Autonomous Multi-Sensor Inspection for 3D Asset Anomaly Detection
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Solution Overview
Problem
Conventional in-person inspections of manufactured articles and equipment are time-consuming, prone to human error, and inefficient in capturing and comparing data across different times and observers.
Innovation Solution
A system and method for autonomous inspection using an autonomous sensor apparatus equipped with multiple sensors that traverse a site to collect data, preprocess it, and compare it to pre-existing models to identify anomalies and communicate findings to operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If in-person inspections are performed by inspectors using various senses and specialized metrology equipment, then detailed observations can be obtained, but the inspection process becomes time-consuming and costly
Solution Approach 1:
The patent replaces the mechanical system of human inspectors physically traveling to locations with an autonomous mobile robot that navigates autonomously. The robot is equipped with multiple sensors (cameras, LIDAR, thermal sensors) that automatically capture inspection data without human intervention, thereby eliminating the time-consuming aspect of manual inspection while maintaining measurement precision through specialized sensor equipment.
Solution Approach 2:
The inspection system performs self-service through autonomous operation. The mobile robot independently navigates to inspection locations, captures data using its onboard sensors, and returns to the docking station without requiring human operators to physically traverse the site. This self-service capability significantly reduces inspection time while maintaining detailed observation accuracy.
2Loss of information
If inspectors manually record and organize observations from multiple objects and inspection points, then comprehensive data can be collected, but the process becomes cumbersome and time-consuming
Solution Approach 1:
The patent replaces the manual mechanical process of recording observations with automated digital capture systems. Multiple sensors on the mobile robot automatically record data from all inspection points, and the data is digitally stored and organized without human intervention. This eliminates the cumbersome manual recording process while ensuring comprehensive data collection through multi-sensor arrays.
Solution Approach 2:
The inspection system employs multiple types of sensors (visual cameras, LIDAR, thermal sensors) that can simultaneously capture different types of data from the same inspection location. This multi-functional approach ensures comprehensive data collection across multiple parameters while reducing the overall inspection time, as all data types are captured concurrently rather than sequentially.
3Adaptability or versatility
If physiological observations are used for inspection, then human inspectors can detect various characteristics, but the observations are prone to human error and cannot be precisely compared between different days and observers
Solution Approach 1:
The patent replaces physiological human observations with electronic sensor-based detection systems. The mobile robot uses cameras, LIDAR, and thermal sensors that provide objective, quantifiable measurements independent of human observers. This substitution eliminates human error and ensures consistent, repeatable measurements across different inspection days and locations, while maintaining the versatility to detect various physical characteristics through multiple sensor modalities.
4Measurement precision
If specialized metrology equipment is used to measure physical characteristics, then precise measurements can be obtained, but the data volume is limited to small areas on surfaces
Solution Approach 1:
The inspection system combines multiple types of sensors (visual cameras, LIDAR, thermal sensors) that can simultaneously measure different physical characteristics across large areas. This multi-functional sensor array overcomes the limitation of single-point metrology equipment by providing both precise measurements and broad coverage through parallel data collection from multiple sensor types positioned on the mobile robot.
Solution Approach 2:
The patent transitions from single-point surface measurements to three-dimensional spatial mapping using LIDAR and camera arrays. This dimensional expansion allows the system to capture precise measurements across the entire surface area of objects, not just small localized regions. The mobile robot's movement through three-dimensional space enables comprehensive coverage of large areas while maintaining measurement precision through coordinated multi-sensor data collection.
Data Source
AI summary
A method for performing an autonomous inspection. The method comprises traversing, by an autonomous sensor apparatus, a path through a site having three-dimensional objects located therein. The site includes three-dimensional objects located therein. The method comprises obtaining, by a plurality of sensors on-board the autonomous sensor apparatus, one or more data sets throughout the path. Each of the one or more data sets are associated with an attribute of one or more three-dimensional objects. The method comprises generating, by the first, second, or third processor, a working model from a collocated data set; and comparing, by the first, second, or third processor, the working model with one or more pre-existing models; to determine the presence and/or absence of anomalies. The presence and/or absence of anomalies are communicated as human-readable instructions.