Modular Inspection Robot Wheel Positioning for Surface Adaptability

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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 operational inconveniences, requiring system shutdowns and personnel exposure, which result in low-resolution and unsystematic coverage.

Innovation Solution

A modular inspection robot with selectively coupled drive assemblies and universal connectors for payloads, equipped with diverse sensor configurations, capable of operating in hostile environments and generating interactive inspection maps, featuring a reduced footprint for improved climbing and horizontal range.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If personnel manually inspect industrial surfaces, then human judgment and flexibility are applied, but safety hazards increase and inspection completeness decreases

Engineering Contradiction:

Improveinspection completenessVSAvoidpersonnel safety hazards

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The inspection robot autonomously navigates and inspects industrial surfaces without requiring human personnel to enter hazardous environments. The system performs self-directed inspection tasks, collecting data and generating reports independently, thereby eliminating personnel exposure to safety hazards while maintaining inspection completeness through systematic 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 areas while maintaining or improving inspection quality through consistent, systematic data collection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If traditional inspection systems are used, then system shutdowns are required, but productivity decreases and operational impact increases

Engineering Contradiction:

Improveinspection efficiencyVSAvoidsystem shutdown duration

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The inspection robot enables continuous operation by performing inspections during normal system operation rather than requiring shutdowns. The robotic system can access and inspect surfaces while the industrial equipment remains operational, maintaining productivity while completing inspection tasks

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The robotic inspection system acts as an intermediary that can operate in hazardous or confined spaces without requiring the main system to shut down. It independently accesses inspection areas through specialized mechanisms while the primary system continues normal operation

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If fixed wheel configurations are used, then manufacturing simplicity is maintained, but adaptability to different surfaces decreases

Engineering Contradiction:

Improvesurface type adaptabilityVSAvoidwheel configuration complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The wheel assembly is divided into separable components including the wheel, motor, and mounting interface. This segmentation allows individual wheels to be independently replaced or reconfigured based on the specific surface requirements, providing adaptability without requiring complete system redesign

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wheel configuration transitions from static to dynamic through the ability to selectively couple and decouple different wheel assemblies. The system can adapt its wheel setup in response to different surface conditions, changing from a fixed to a flexible configuration as needed

Inventive Principle:

Principle #15Dynamics

4Ease of operation

If large footprint robots are used, then stability is improved, but climbing capability and horizontal range decrease

Engineering Contradiction:

Improveclimbing capabilityVSAvoidrobot stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The robotic system uses magnetic forces as a counterbalancing mechanism to maintain stability during climbing operations. The magnetic attraction between the robot and the surface provides stabilizing force that compensates for the reduced footprint, enabling vertical and inclined surface traversal without compromising stability

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Data Source

PatentUS12491732B2Inspection robots with flexible wheel/motor positioning

Publication Date: 2025.12.09 GECKO ROBOTICS INC

AI summary

Inspection robots with flexible wheel/motor positioning are described. An example inspection robot may have a housing having a first connector positioned on a first side of the housing, and a second connector positioned on a second side of the housing. A first drive module may include a wheel and a motor and be operatively coupled to the first connector. A second drive module may include a wheel and a second motor and be operatively coupled to the second connector, where the wheel may be interposed between the second connector and the second motor.