Independent Drive Module Suspension for Hazardous Surface Inspection
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Solution Overview
Problem
Existing inspection systems for industrial surfaces face challenges such as hazardous environments, incomplete inspections, human error, and operational inefficiencies due to the need for shutdowns and stringent safety procedures, leading to inadequate coverage and resolution.
Innovation Solution
An inspection robot with modular drive assemblies and interchangeable payloads equipped with universal connectors for sensor configurations, capable of operating in hostile environments and generating interactive inspection maps for improved data collection and analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If personnel manually inspect industrial surfaces, then inspection can be performed with human judgment and adaptability, but personnel are exposed to hazards and inspections are incomplete due to safety procedures and confined spaces
Solution Approach 1:
The patent employs robotic systems with sensors (cameras, LIDAR, thermal imaging) that create digital copies and representations of industrial surfaces, allowing comprehensive inspection without human personnel entering hazardous areas. The robotic inspectors replicate human visual and tactile examination capabilities while eliminating exposure to dangerous environments.
Solution Approach 2:
The robotic inspection system acts as an intermediary between the inspector and the hazardous industrial environment. The robot traverses dangerous areas (high temperatures, confined spaces, toxic atmospheres) while transmitting data back to remote operators, thereby mediating the inspection process and protecting personnel from direct hazard exposure.
2Reliability
If industrial systems are shut down for inspection, then comprehensive inspection can be performed, but productivity is reduced and operational time is lost
Solution Approach 1:
The robotic inspection system enables continuous operation of industrial equipment during inspection. The robot can inspect moving machinery, rotating components, and operating processes without requiring shutdowns, maintaining continuous productive action while gathering comprehensive inspection data through multiple sensing modalities.
Solution Approach 2:
The system performs preliminary inspections during normal operation that can identify issues before they require system shutdown. By continuously monitoring and detecting anomalies during operational states, the robot enables proactive maintenance planning that minimizes disruptive shutdowns.
3Ease of operation
If stringent safety procedures are followed during manual inspection, then personnel safety is protected, but inspection efficiency is reduced and time is consumed
Solution Approach 1:
The robotic inspection system performs safety functions autonomously without requiring human personnel to follow complex safety procedures. The robot inherently handles its own safety requirements through programmed operational constraints, emergency stop capabilities, and automated hazard detection, eliminating the time-consuming safety briefings, lockout/tagout procedures, and continuous safety monitoring that would be required for human inspectors.
4Reliability
If manual inspection is performed in confined spaces, then inspection can be conducted, but coverage is incomplete and human error increases
Solution Approach 1:
The robotic inspection system employs dynamic positioning and multi-degree-of-freedom movement capabilities that allow it to navigate complex three-dimensional spaces and access all inspection areas uniformly. The robot can dynamically adjust its position, orientation, and sensor angles to achieve complete coverage of confined and irregular geometries, eliminating the incomplete coverage and positional limitations that constrain human inspectors in difficult-to-reach areas.
Data Source
AI summary
Inspection robots with independent drive module suspension are described. An example inspection robot may have a housing with a first connector on a first side of the housing, and a second connector on a second side of the housing. A first drive module, having at least one wheel and a first motor, may be operatively coupled to the first connector, and a second drive module, having at least one wheel and a first motor, may be operatively coupled to the second connector. The first and second drive modules may be coupled by a drive connector.