Straight Hollow-Cylinder Inspection With 2D And 3D Surface Mapping
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Solution Overview
Problem
Existing methods for inspecting and measuring large caliber gun barrels are manual, time-consuming, prone to errors, and lack quantitative assessment of wear and surface defects, posing safety risks and affecting performance.
Innovation Solution
An AI-based robotic system with a crawling unit and inspection head, equipped with sensors and machine learning algorithms, automatically inspects and measures gun barrels, detecting and localizing defects, and estimating remaining useful life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual inspection using gun borescope is used, then visual examination of barrel surface is possible, but inspection process is time-consuming and error-prone
Solution Approach 1:
The patent replaces manual mechanical inspection operations with an automated robotic inspection system. The robotic crawler moves autonomously inside the barrel, carrying sensors that automatically capture images and measurements without human intervention, thereby eliminating the time-consuming manual manipulation of borescopes and gauges.
Solution Approach 2:
The robotic inspection system performs self-navigation and self-inspection within the barrel. The crawler autonomously moves along the barrel interior, activates sensors at appropriate positions, and collects data without requiring external manual control, making the inspection process self-sufficient and highly efficient.
2Measurement precision
If manual measurement with dial gauges is used, then dimensional variations can be measured, but measurement process is manual and data recording is time-consuming
Solution Approach 1:
The patent replaces manual dial gauge measurements with automated optical sensors and image processing systems. Cameras and laser scanners capture dimensional data automatically, and computer algorithms process the images to extract precise measurements, eliminating manual reading and recording operations while maintaining high measurement accuracy.
Solution Approach 2:
The system creates digital copies of the barrel interior through high-resolution imaging and 3D scanning. These digital models serve as accurate replicas that can be measured, analyzed, and archived without physical contact, enabling rapid repeated measurements and eliminating the need for manual data transcription.
3Loss of information
If visual inspection by operators is used, then qualitative assessment of erosion is possible, but quantitative assessment is not provided
Solution Approach 1:
The system creates comprehensive digital replicas of the barrel interior using multiple sensors including cameras, laser scanners, and depth sensors. These digital models capture both visual appearance and precise geometric information, providing complete quantitative data about erosion, pitting, and other defects that can be analyzed without loss of information.
Solution Approach 2:
The robotic inspection system integrates multiple sensing capabilities (visual imaging, laser ranging, depth measurement) into a single multi-functional platform. This universal system can perform both qualitative visual assessment and quantitative dimensional measurement simultaneously, eliminating the need for separate inspection methods while managing complexity through integration.
4Reliability
If automated robotic inspection is implemented, then inspection accuracy and repeatability are improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple inspection functions (visual imaging, dimensional measurement, depth sensing) into a single robotic platform. This multi-functional design achieves high reliability through consistent automated operation while managing complexity by combining functions in one unified system rather than using multiple separate devices.
Solution Approach 2:
The system incorporates real-time feedback through sensors that monitor the crawler's position, orientation, and sensor alignment. This feedback enables automatic adjustment and calibration during operation, ensuring consistent measurement accuracy and repeatability while reducing the need for complex manual calibration procedures.
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
Provides accurate, automated inspection and measurement, reducing human error and enhancing safety by quantitatively assessing barrel condition and predicting service life.
Implementation Method 1
an image acquisition unit, configured to provide 2D image data of an internal surface of the straight hollow cylindrical object
Implementation Method 2
a laser scanning unit, configured to provide 3D depth data of the internal surface of the straight hollow cylindrical object
Data Source
AI summary
Disclosed is an inspection and measurement system for hollow cylindrical objects (100) such as internal gun barrel surface of large caliber gun barrels (150). The system (100) comprises an inspection device (200,500) operatively connected to the controller (400). The controller (400) is configured to receive realtime 2D image and 3D laser scan data captured by the inspection device (200,500) to generate 2D and 3D maps of the internal surface of the hollow cylindrical object and provide a means of visualization and interpretation of inspection and measurement data.