Intrinsically Safe Drone EMAT Wall Thickness Measurement
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Solution Overview
Problem
The inspection and measurement of hydrocarbon processing and transportation components, such as vessels and pipelines, are challenging due to remote and hazardous locations, which can lead to safety issues and increased costs, and existing methods may be affected by exterior coatings or layers, and require physical contact that poses ignition risks from static electricity.
Innovation Solution
An intrinsically safe unmanned aerial vehicle (UAV) equipped with an electromagnetic acoustic transducer (EMAT) that measures wall thickness without physical contact, using a proximity sensor to activate the EMAT and transmit measurements remotely, allowing for safe and accurate measurements through coatings and in hazardous environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical contact measurement methods are used, then measurement precision may be improved, but the risk of ignition from static electricity increases
Solution Approach 1:
The patent replaces mechanical contact-based thickness measurement with electromagnetic acoustic transducer (EMAT) technology that uses electromagnetic fields to generate and detect acoustic waves in the material. This substitution eliminates the need for physical contact between the measurement device and the component surface, thereby preventing static electricity generation while maintaining measurement capability through electromagnetic-acoustic coupling
Solution Approach 2:
The patent introduces electromagnetic fields and acoustic waves as intermediary carriers to transfer measurement information without direct physical contact. The EMAT uses electromagnetic energy to generate acoustic waves that propagate through the material, and the reflected waves carry thickness information back to the sensor, serving as a safe intermediary that avoids direct mechanical contact and associated ignition risks
2Reliability
If exterior coatings are present on components, then protection and corrosion resistance are improved, but measurement accuracy is degraded
Solution Approach 1:
The patent replaces mechanical contact measurement that is sensitive to surface coatings with electromagnetic acoustic transducer technology. The EMAT generates acoustic waves that propagate through the coating layer and into the base material, allowing the measurement system to penetrate the coating and measure the thickness of the underlying metal structure without being blocked or significantly affected by the exterior coating
Solution Approach 2:
The patent changes the measurement parameter from surface-level mechanical contact to electromagnetic-acoustic wave propagation through the material. By using acoustic waves with appropriate frequency and energy characteristics, the system can penetrate through coating layers and measure the thickness of the base material, effectively changing the measurement approach to accommodate the presence of protective coatings
3Measurement precision
If scaffolding is used for inspection, then measurement capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical scaffolding systems with an unmanned aerial vehicle (UAV) equipped with electromagnetic acoustic transducers. The UAV provides a mobile, flexible platform that can hover and position the EMAT sensors near the component surface without requiring fixed support structures, thereby eliminating the need for scaffolding while maintaining measurement capability
Solution Approach 2:
The patent transitions from static scaffolding structures to a dynamic unmanned aerial vehicle platform. The UAV can dynamically position itself, hover, and adjust its location in three-dimensional space to perform inspections of components in difficult-to-reach areas, providing the measurement capability previously requiring complex fixed scaffolding but with significantly reduced device complexity and setup requirements
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
Enables safe and accurate measurement of wall thickness in hazardous and remote locations without physical contact, reducing the risk of ignition and eliminating the need for surface cleaning or scaffolding, while allowing for the assessment of components with exterior coatings.
Implementation Method 1
an electromagnetic acoustic transducer (EMAT) that does not require physical contact with the wall of a structure to determine the wall thickness
Implementation Method 2
a proximity sensor coupled to the arm at the second end, the proximity sensor configured to activate the electromagnetic acoustic transducer in response to detection of the wall
Data Source
AI summary
Provided is an unmanned aerial vehicle for measuring the wall thickness of a structure. The unmanned aerial vehicle may be an intrinsically safe unmanned aerial vehicle and may include an arm having an electromagnetic acoustic transducer (EMAT) coupled to one end of the arm and a power and control assembly may be coupled to the other end of the arm as a counterweight. The power and control assembly may include an activation device for the EMAT, such as a proximity sensor. The EMAT may be coupled to a spring that compresses in response to a force normal to the wall being measured to prevent excessive force from being applied to the structure and the EMAT. Methods of measuring wall thickness using an unmanned aerial vehicle and a retrofit kit for an unmanned aerial vehicle are also provided.