Mobile Laser Weld Inspection for Large Pipe Round Seams
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Solution Overview
Problem
Visual inspection of large pipe welds is costly, subjective, and inefficient due to human fatigue, requiring high personnel and lacking comprehensive documentation of three-dimensional weld conditions.
Innovation Solution
A mobile inspection device with a laser unit, control unit, and marking unit on a movable carriage that automates the inspection process, providing real-time evaluation and marking of defects on large pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual inspection by human inspectors is used, then inspection coverage can be achieved, but inspection cost increases and inspection speed decreases due to personnel requirements and human fatigue
Solution Approach 1:
The patent replaces the mechanical visual inspection system with an automated optical measurement system. A laser scanner mounted on a mobile carriage automatically scans the weld seam and captures three-dimensional data, eliminating the need for human inspectors to manually examine each weld while significantly increasing inspection speed and consistency
Solution Approach 2:
The inspection system performs self-evaluation by automatically analyzing the scanned weld geometry data against predefined quality criteria. The system independently identifies defects, generates inspection reports, and marks problematic areas without requiring continuous human intervention, thereby maintaining high inspection coverage while improving productivity
2Ease of operation
If visual inspection by human inspectors is used, then inspection can be performed, but subjectivity increases and measurement precision decreases due to different discrimination levels
Solution Approach 1:
The patent replaces subjective human visual assessment with an objective automated optical measurement system. The laser scanner consistently captures precise three-dimensional geometric data of the weld seam, and the evaluation algorithm objectively compares this data against quality standards, eliminating variability caused by different inspector discrimination levels while maintaining ease of operation
Solution Approach 2:
The system incorporates real-time feedback mechanisms where the scanned weld data is immediately analyzed and compared against target values. The system provides automated feedback on weld quality, highlighting deviations and defects with precise location information, thereby ensuring consistent measurement precision across all inspections
3Loss of information
If photos and inspection reports are used for documentation, then some record is created, but comprehensive three-dimensional documentation is lost
Solution Approach 1:
The patent transitions from two-dimensional photo documentation to comprehensive three-dimensional digital documentation. The laser scanner captures the complete three-dimensional geometry of the weld seam, including height profiles and width measurements, creating a digital twin that preserves all spatial information for accurate quality assessment and future reference
Solution Approach 2:
The system creates a digital copy of the weld seam through laser scanning, generating precise three-dimensional point cloud data that accurately represents the physical weld geometry. This digital copy serves as comprehensive documentation that can be stored, analyzed, and referenced without loss of information, replacing inadequate two-dimensional photos and text reports
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
Enhances inspection speed, reduces human error, and provides comprehensive documentation of weld quality, significantly reducing inspection time and personnel burden.
Implementation Method 1
The measuring unit is a laser unit with which the quality of the weld is measured
Implementation Method 2
the emitter emits at least one laser beam and the detector captures the reflected laser beam
Data Source
AI summary
A mobile inspection device for inspecting round welds of a large pipe includes at least one movable inspection carriage as a mobile base unit, wherein the inspection carriage has at least three wheels which are mounted on the base unit, at least one measuring unit for inspecting the weld, at least one transmitting and receiving unit, and at least one control unit. The inspection device also includes a marking unit. Also provided is a method for inspecting a round weld on a large pipe.