Inspection Robot Sensor Mount Layout for Complete Surface Coverage

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Solution Overview

Problem

Existing inspection and treatment systems for industrial surfaces face challenges such as hazardous environments, incomplete inspections, human error, and the need for system shutdowns, which result in inconvenient and unsafe operations.

Innovation Solution

An inspection robot with modular drive assemblies, selective payloads, and sensor configurations for different surfaces, capable of operating in hostile environments and generating interactive inspection maps, along with a sled assembly featuring offset sensor mounts for improved resolution and coverage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If personnel manually inspect industrial surfaces, then inspection flexibility is maintained, but safety hazards increase and inspection completeness decreases

Engineering Contradiction:

Improveinspection completenessVSAvoidpersonnel exposure to hazards

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces manual personnel inspection with an autonomous robotic inspection system. The robot performs inspection operations automatically, eliminating the need for personnel to physically enter hazardous environments while maintaining comprehensive inspection coverage through programmable inspection paths and multiple sensor modalities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The inspection robot is designed to autonomously navigate inspection areas, position itself optimally for inspection, and execute inspection routines without continuous human intervention. The system self-manages its inspection tasks, reducing dependency on personnel while ensuring complete coverage of inspection surfaces.

Inventive Principle:

Principle #25Self-service

2Reliability

If inspection systems require system shutdown, then inspection safety is improved, but productivity decreases

Engineering Contradiction:

Improveinspection safetyVSAvoidinspection availability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The robotic inspection system enables continuous inspection operations without requiring system shutdowns. The robot can operate during normal industrial operations, allowing inspection activities to continue uninterrupted and maintaining both safety and productivity simultaneously.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of operation

If inspection personnel enter confined spaces, then inspection access is achieved, but human error increases and safety procedures become more complex

Engineering Contradiction:

Improveinspection accessVSAvoidsafety procedures

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces personnel entry into confined spaces with an autonomous robot designed specifically for such environments. The robot navigates confined spaces without human intervention, eliminating the complexity of safety procedures like lockout/tagout and confined space entry permits while maintaining full access to inspection areas.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Measurement precision

If traditional sensor configurations are used, then device complexity is reduced, but measurement precision and inspection resolution decrease

Engineering Contradiction:

Improveinspection resolutionVSAvoidsensor configuration

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The inspection robot employs multiple separate sensor modules, each optimized for specific inspection tasks (e.g., ultrasonic testing, visual inspection, magnetic flux detection). These segmented sensor systems can be independently positioned and configured to achieve high-resolution inspection while maintaining manageable complexity through modular architecture.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent positions sensors at multiple spatial locations and orientations on the robot, utilizing three-dimensional sensor distribution to enhance inspection resolution. This multi-dimensional sensor arrangement provides comprehensive coverage and improved measurement precision compared to single-point sensor configurations.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20260063593A1Inspection robot with forward and rearward sensor mount groups

Publication Date: 2026.03.05 GECKO ROBOTICS INC

AI summary

An inspection robot with a payload includes a first sled assembly including a first forward sensor mount group and a second rearward sensor mount group. The first forward sensor mount group is positioned at a first characteristic horizontal position, and the second rearward sensor mount group is positioned at a second characteristic horizontal position. The inspection robot with the payload also includes a second sled assembly comprising a third forward sensor mount group and a fourth rearward sensor mount group. The third forward sensor mount group is positioned at a third characteristic horizontal position, and the fourth rearward sensor mount group is positioned at a fourth characteristic horizontal position. The inspection robot with the payload also includes a payload mount. The first sled assembly is coupled to the payload mount at a first mounting position.