Modular Inspection Robot Payloads for Curved Surface Coverage
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Solution Overview
Problem
Existing inspection systems for industrial surfaces face challenges such as hazardous environments, incomplete inspections, human error, and operational disruptions due to the need for shutdowns and stringent safety procedures, while also lacking systematic coverage and high-resolution data.
Innovation Solution
An inspection robot with modular drive assemblies and interchangeable payloads equipped with universal connectors for sensor configurations, capable of operating in hostile environments and generating interactive inspection maps for improved data collection and control, featuring a reduced footprint for enhanced mobility and environmental adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If personnel manually inspect industrial surfaces in hazardous environments, then inspection can be performed with human judgment and adaptability, but personnel are exposed to hazards and safety risks increase
Solution Approach 1:
The patent creates a robotic replica that copies human inspection capabilities by equipping it with sensors, cameras, and analytical tools that simulate human sensory and cognitive functions. The robot traverses hazardous surfaces and collects data that replaces the need for human personnel to physically enter dangerous zones, thereby eliminating personnel safety risks while maintaining inspection quality through automated sensing and analysis systems
Solution Approach 2:
The patent replaces the mechanical human inspection system with an automated robotic system. The robot uses motorized wheels, automated navigation, and electronic sensors to perform functions previously requiring human physical presence. This substitution eliminates exposure to harmful environmental factors while maintaining systematic and thorough inspection capabilities through programmed routines and automated data collection
2Stability of the object's composition
If the inspection robot has a larger footprint for stability, then the robot can maintain better balance on curved surfaces, but the horizontal range and mobility are reduced
Solution Approach 1:
The patent employs dynamic balance control where the robot's center of gravity and wheel configuration adjust in real-time based on surface curvature detection. The robotic system uses active control algorithms that modify wheel positions, rotation speeds, and body orientation dynamically as it traverses curved surfaces, allowing it to maintain stability without requiring a permanently large footprint that would limit its horizontal range and mobility
3Measurement precision
If multiple specialized inspection systems are used for different surfaces, then each system can be optimized for its specific surface type, but system complexity and operational downtime increase
Solution Approach 1:
The patent designs a universal robotic inspection platform that can adapt to multiple surface types through interchangeable payloads and adjustable sensor configurations. The robot carries a standardized interface that accepts different sensor arrays and inspection tools, allowing a single system to perform specialized inspections on various surfaces including curved, flat, and irregular geometries. This eliminates the need for multiple dedicated systems while maintaining measurement precision through payload-specific optimization
Solution Approach 2:
The patent divides the inspection system into modular components: a base robotic platform and separate interchangeable payloads. Each payload is optimized for specific inspection tasks or surface types, but can be quickly swapped on the same robot. This segmentation allows the system to maintain specialized inspection capabilities for different surfaces without requiring multiple complete systems, reducing overall complexity and operational downtime between inspections
Data Source
AI summary
Inspection robots and methods for inspection of curved surfaces are described. An example inspection robot may include a housing, and at least one drive module operative linked to the housing and including a wheel and motor. An example inspection robot may further include two sleds, each with a sensor, the sled connectable to a payload. An example payload may include multiple rail components with intervening connectors, the connectors are able to connect two rail components at a plurality of discrete engagement positions.