Forward-Rearward Sensor Mount Groups for Robotic Inspection
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Solution Overview
Problem
Existing inspection and treatment systems for industrial surfaces face challenges in hazardous environments, requiring system shutdowns, safety procedures, incomplete inspections, and human error, while lacking systematic coverage and high resolution.
Innovation Solution
An inspection robot with modular drive assemblies, selective payloads, and sensor configurations for different surfaces, capable of operating in hostile environments, generating interactive inspection maps, and providing improved climbing capabilities with a reduced footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inspection systems are used in hazardous environments, then inspection can be performed, but system shutdowns and safety procedures are required which reduce productivity and increase inspection time
Solution Approach 1:
The inspection robot performs inspections autonomously without requiring human personnel entry into hazardous environments. The robot is equipped with integrated sensors, drive assemblies, and cooling systems that enable it to operate independently in hostile conditions, eliminating the need for safety shutdowns and procedures that would otherwise reduce productivity.
Solution Approach 2:
The patent replaces human inspection personnel with an automated robotic system. The robot uses electronic sensors, ultrasonic transducers, and automated control systems to perform inspections that would traditionally require human operators, thereby maintaining safety while improving productivity through continuous operation without safety interruptions.
2Measurement precision
If personnel enter inspection areas to conduct inspections, then inspection coverage can be achieved, but human error and judgment affect measurement precision and systematic coverage
Solution Approach 1:
The inspection robot incorporates multiple sensors including ultrasonic transducers, visual sensors, and LIDAR that provide continuous feedback about the inspection surface and robot position. This feedback enables automated control to maintain precise measurement resolution and ensure systematic coverage through programmable inspection paths, eliminating human judgment errors.
Solution Approach 2:
The robot creates digital copies of inspection data through multiple sensor arrays that capture surface characteristics, thickness variations, and geometric features. These digital representations provide objective, repeatable measurements that eliminate human error in interpreting inspection results and ensure consistent systematic coverage across the entire inspection area.
3Measurement precision
If inspection systems are designed for high resolution and complete coverage, then inspection quality improves, but device complexity increases
Solution Approach 1:
The inspection robot is divided into modular components including separate drive assemblies, sensor payloads, and processing units. Each module can be independently configured and optimized for specific inspection functions, allowing high resolution and complete coverage through coordinated module operation without requiring a single complex monolithic system.
Solution Approach 2:
The robot employs universal connectors and interchangeable payload modules that can be configured for different inspection scenarios. The same basic robot platform can accommodate various sensor combinations (ultrasonic, visual, LIDAR) and drive configurations, providing high resolution inspection capability across diverse applications without requiring separate specialized systems for each function.
4Ease of operation
If the inspection robot footprint is reduced for increased climbing capability, then mobility on inclined surfaces improves, but sensor mounting space is reduced
Solution Approach 1:
The robot extends its sensor mounting capability into the vertical dimension by positioning sensors on elevated platforms and using articulated arms that can reach various heights. This three-dimensional sensor distribution allows complete surface coverage and high resolution measurements while maintaining a compact horizontal footprint that enhances climbing capability on inclined surfaces.
Data Source
AI summary
An inspection robot with a payload includes a first sled assembly comprising a first forward sensor mount group and a second rearward sensor mount group, a second sled assembly comprising a third forward sensor mount group and a fourth rearward sensor mount group, and a payload mount. The first sled assembly is coupled to the payload mount at a first mounting position. The inspection robot with the payload also includes a controller configured to interpret a first processing value for a plurality of sensors of the first forward sensor mount group, interpret a second processing value for a plurality of sensors of the second rearward sensor mount group, perform inspection operations based on the first processing value and the second processing value, and capture inspection data based on inspection operations.