Dual Linear Phased Array Holders for Modular Robotic Inspection

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Solution Overview

Problem

Existing robotic inspection systems for industrial surfaces face challenges such as complexity in configuration, requiring multiple experts, increased operational risks, and safety hazards due to personnel exposure in hazardous environments, leading to incomplete inspections and high costs.

Innovation Solution

A system with a dual linear phased array of ultrasonic elements and a modular sensor sled design that allows for rapid configuration and separation of expert personnel, enabling automated inspection operations in hazardous environments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional robotic inspection systems are used, then inspection capability is provided, but system complexity increases and requires multiple experts

Engineering Contradiction:

Improveinspection capabilityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The inspection system is divided into modular sensor holders, each containing specific ultrasonic elements or arrays. These modular units can be independently configured and attached to the robotic platform, allowing the system to be adapted to different inspection needs without requiring complete system redesign or multiple expert configurations.

Inventive Principle:

Principle #1Segmentation

2Productivity

If traditional inspection systems are used, then inspection operations can be performed, but operational risks and safety hazards increase

Engineering Contradiction:

Improveinspection operationsVSAvoidoperational safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The sensor holders are designed with self-aligning and self-adjusting features that allow the robotic system to automatically perform inspection tasks without requiring constant human intervention or adjustment. The modular design enables automatic configuration based on pre-programmed parameters, reducing the need for personnel to be present in hazardous environments during operation.

Inventive Principle:

Principle #25Self-service

3Measurement precision

If traditional phased array ultrasonic inspection is used, then detailed surface inspection is achieved, but configuration complexity and time requirements increase

Engineering Contradiction:

Improveinspection resolutionVSAvoidconfiguration time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The sensor holders are pre-configured with specific phased array element arrangements and coupling geometries optimized for particular inspection tasks. This preliminary configuration allows the system to quickly deploy the appropriate inspection setup without requiring time-consuming on-site configuration, while still achieving high measurement precision through the pre-optimized sensor geometries.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If expert personnel are deployed for inspection operations, then proper inspection execution is ensured, but operational costs and attention burden increase

Engineering Contradiction:

Improveinspection qualityVSAvoidoperational efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system replaces the need for expert human operators with an automated robotic platform equipped with pre-configured sensor holders. The robotic system executes inspection operations autonomously based on pre-programmed sequences, eliminating the need for multiple experts to be present and reducing operational costs while maintaining inspection quality through consistent, repeatable automated operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 efficient, automated, and complete inspections of industrial surfaces with improved safety and reduced operational costs by allowing expert personnel to focus on high-value tasks while minimizing human exposure to hazards.

Implementation Method 1

a first sensor (11460) including a first linear phased array of ultrasonic (UT) elements and a second sensor (11465) including a second linear phased array of UT elements

Methodology Applied

Scientific EffectUltrasonic wave propagation: Ultrasound

Implementation Method 2

phased array ultrasonic (UT) inspection operations

Methodology Applied

Scientific EffectAcoustic reflection: Reflection

Data Source

PatentUS12442797B2Systems, methods, and apparatus for inspection of a surface using sensor holder with dual linear phased array of ultra-sonic elements

Publication Date: 2025.10.14 GECKO ROBOTICS INC

AI summary

An example payload for an inspection robot having a mounting rail to inspect an inspection surface, the payload including a wedge element; and a probe holder, including: a mounting rail connection member structured to connect to the mounting rail; a wedge element holder structured to hold the wedge element; a spring-loaded member structured to connect to the mounting rail connection member and to provide a selected vertical force on the wedge element holder; and an extended member structured to connect to the spring-loaded member between a first end and a second end, and to connect to the wedge element holder at the second end.