Inspection Robot Sensor Sled Layout for High-Resolution Surface Mapping
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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 potentially dangerous operations.
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
1Measurement precision
If personnel manually inspect industrial surfaces, then inspection flexibility is maintained, but inspection completeness and accuracy deteriorate due to human error and limited coverage
Solution Approach 1:
The inspection robot performs autonomous inspection operations without requiring human entry into hazardous environments. The robot autonomously navigates industrial surfaces, positions sensors, and collects inspection data, eliminating the need for personnel to manually conduct inspections while maintaining high accuracy through automated sensor systems.
Solution Approach 2:
The patent replaces manual mechanical inspection with an automated robotic system equipped with sensors. The robot uses sensor arrays (visual, ultrasonic, electromagnetic) to detect surface conditions, substituting human visual and physical inspection with automated sensing and data collection systems that provide more consistent and comprehensive coverage.
2Measurement precision
If inspection systems are designed for high resolution, then inspection quality improves, but device complexity and footprint increase
Solution Approach 1:
The inspection robot divides the sensor system into multiple independent sensor arrays (visual sensors, ultrasonic sensors, electromagnetic sensors) mounted on modular sleds. Each sensor type can be independently configured and positioned, allowing high-resolution inspection through coordinated sensing rather than requiring a single complex sensor system.
Solution Approach 2:
The patent achieves enhanced inspection resolution not by increasing sensor complexity in one dimension, but by adding multiple sensor types operating in different dimensions (visual, acoustic, electromagnetic). This multi-dimensional sensing approach provides comprehensive high-resolution data without proportionally increasing device complexity.
3Ease of operation
If robot footprint is reduced for better climbing capability, then mobility on inclined surfaces improves, but sensor mounting flexibility deteriorates
Solution Approach 1:
The robot divides the sensor mounting system into separate modular sleds that can be independently positioned on the robot body. This segmentation allows the compact robot chassis to maintain small footprint for climbing while providing flexible sensor placement options through the modular sled configuration, enabling adaptation to various inspection surfaces.
Solution Approach 2:
The sensor sleds are designed with adjustable positioning mechanisms that allow dynamic reconfiguration of sensor arrays relative to the robot body. This dynamic adaptability enables the compact robot to accommodate different sensor configurations for various inspection scenarios without increasing the base robot footprint, maintaining both climbing capability and inspection versatility.
4Adaptability or versatility
If inspection robot operates in hazardous environments, then inspection accessibility improves, but safety risks to personnel increase
Solution Approach 1:
The inspection robot is designed as a self-contained autonomous system that performs all inspection functions without human presence in hazardous environments. The robot autonomously navigates dangerous conditions (high voltage, toxic gases, confined spaces, high temperatures) and collects inspection data independently, eliminating the need for personnel exposure to harmful factors while maintaining full environmental capability.
Solution Approach 2:
The robot serves as an intermediary between inspection objectives and hazardous environments. Instead of personnel directly entering dangerous areas, the robot acts as a mediator that performs inspection functions in hazardous conditions while transmitting data back to safe control locations, thereby maintaining environmental adaptability while preventing harmful factor exposure to human operators.
Data Source
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 at a first characteristic horizontal position and the second rearward sensor mount group at a second characteristic horizontal position. The inspection robot also includes a second sled assembly including a third forward sensor mount group and a fourth rearward sensor mount group, the third forward sensor mount group at a third characteristic horizontal position and the fourth rearward sensor mount group at a fourth characteristic horizontal position. The inspection robot also includes a payload mount and a means for inspecting an inspection surface at a selected inspection resolution. The first sled assembly is coupled to the payload mount at a first mounting position and the second sled assembly is coupled to the payload mount at a second mounting position.