Interactive Inspection Maps for Validating Robot Surface Coverage

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Solution Overview

Problem

Existing inspection systems for industrial surfaces face challenges in hazardous environments, requiring system shutdowns, reduced capacity, stringent safety procedures, and are prone to human error, incomplete inspections, and lack systematic coverage.

Innovation Solution

An inspection robot with modular drive assemblies, selective payloads, and universal connectors for sensors, capable of operating in hostile environments, generating interactive inspection maps, and providing improved environmental capabilities and reduced footprint for climbing inclined and vertical surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If personnel manually inspect industrial surfaces in hazardous environments, then inspection can be performed with simple equipment, but safety risks increase and inspections are prone to human error and incomplete coverage

Engineering Contradiction:

Improveinspection completenessVSAvoidpersonnel safety risks

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The inspection robot autonomously navigates and inspects industrial surfaces without requiring human operators to enter hazardous areas. The system performs self-directed inspection tasks, collecting data and generating reports automatically, thereby eliminating personnel exposure to safety risks while ensuring complete and consistent inspection coverage

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual human inspection with an automated robotic system equipped with sensors and navigation capabilities. This substitution eliminates the need for personnel to physically access hazardous environments while maintaining or improving inspection reliability through systematic and repeatable automated processes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If inspection systems are implemented in hazardous environments, then inspection coverage improves, but system complexity and operational disruption increase

Engineering Contradiction:

Improveinspection coverageVSAvoidsystem operational complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The inspection robot is designed as a multi-functional platform that can operate in various hazardous environments and perform different inspection tasks. By consolidating navigation, sensing, data processing, and reporting capabilities into a single universal system, the patent reduces overall system complexity compared to multiple specialized systems while maintaining comprehensive inspection coverage

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The robot autonomously performs navigation, obstacle avoidance, and inspection tasks without requiring complex external control systems or continuous human intervention. This self-service capability simplifies operational procedures while ensuring reliable and complete inspection coverage in hazardous environments

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If manual inspection procedures are used, then equipment and system costs are reduced, but inspection quality and systematic coverage deteriorate

Engineering Contradiction:

Improvesystem costVSAvoidinspection quality

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent replaces manual inspection methods with an automated robotic system equipped with precision sensors and systematic navigation. This substitution improves measurement precision and inspection quality through consistent, repeatable data collection while maintaining cost-effectiveness by eliminating the need for expensive safety equipment, training, and liability associated with human entry into hazardous environments

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12358141B2Systems, methods, and apparatus for providing interactive inspection map for inspection robot

Publication Date: 2025.07.15 GECKO ROBOTICS INC

AI summary

A system for providing an interactive inspection map of an inspection surface inspected by an inspection robot includes an inspection circuit structured to interpret inspection data of the inspection surface from the inspection robot and a user interaction circuit structured to interpret a user focus value from a user device. The user focus value includes an activation state value. The system further includes an inspection visualization circuit structured to provide the interactive inspection map to the user device in response to the user focus value. The interactive inspection map is based on the inspection data. Also, the system includes an inspection data validation circuit that determines an inspection data validity description of the inspection data. The inspection data validity description is provided as a display layer on the interactive inspection map to indicate whether the inspection data is valid.