Inspection Module for Vertical Structure Walls
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Solution Overview
Problem
Industrial infrastructure such as smoke stacks requires frequent shutdowns for inspection and repair, leading to significant downtime and reduced availability, especially in high-demand energy sectors where prolonged outages are costly and inefficient.
Innovation Solution
A modular inspection and repair system that includes a carrier with a controller, heat-resistant and insulated cover, rotational stabilizers, sensing and steering gyroscopes, laser range finder, and communication via radio transceiver, allowing for remote operation and data recording, enabling internal inspection and repair of vertical structures like smoke stacks without full shutdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manual inspection methods are used, then inspection can be performed, but the structure must be shut down for extended periods causing significant downtime
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated robotic inspection system equipped with sensors, cameras, and navigation capabilities. The robot can autonomously navigate the interior of smoke stacks and perform inspections without requiring human entry or shutdown of the structure, thereby eliminating downtime while maintaining inspection reliability
Solution Approach 2:
The inspection system is designed to operate independently without requiring shutdown or external support during inspection. The robot carries its own power source, navigation system, and inspection equipment, enabling it to perform complete inspections autonomously while the smoke stack remains in operation
2Productivity
If the smoke stack operates continuously, then availability is maintained, but inspection and repair cannot be performed
Solution Approach 1:
The patent replaces the need for human inspectors with an automated robotic system that can operate in the hot, hazardous environment of an operating smoke stack. The robot includes thermal insulation, heat-resistant materials, and autonomous navigation capabilities that enable it to perform inspections without shutdown, making inspection as easy as deploying the robot while maintaining full productivity
3Measurement precision
If manual inspection is performed, then problem areas can be detected, but the process requires extended shutdown periods
Solution Approach 1:
The patent employs advanced sensors including thermal cameras, ultrasonic sensors, and visual inspection systems mounted on the robot. These electronic measurement systems provide high-precision detection of structural defects, thermal anomalies, and material degradation instantly during continuous operation, eliminating the time-consuming nature of manual inspection while maintaining or improving detection accuracy
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 continuous operation of industrial structures during inspection and repair by providing remote, stable, and precise data collection and application of repair materials, reducing downtime and maintaining equipment availability.
Implementation Method 1
a sensing gyroscope configured to measure rotation of the modular around its longitudinal axis
Implementation Method 2
a steering gyroscope configured to effect rotation of the module around its longitudinal axis
Implementation Method 3
at least one laser range finder configured to determine the distance from the module to an internal side wall
Implementation Method 4
a cover that is comprised of a set of panels removably securable around the carrier and which is abrasion resistant and insulated against heat transfer
Data Source
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AI summary
The invention relates to an inspection and repair module for an internal side wall of a vertically erected structure, with the module including a carrier for supporting at least one data recording mechanism and being securable to a hoist, and for an inspection and repair module for an internal wall of a conduit with the module including propulsion means comprising a set of driven tracked wheels controllable by a controller carried by the carrier and configured to provide, within a conduit, longitudinal forward and reverse motion.