Phased Array Inspection Robot for Hazardous Surface Scanning
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Solution Overview
Problem
Existing inspection systems for industrial surfaces face challenges such as the need for system shutdowns, hazardous personnel exposure, complex robot configuration, and the requirement for multiple experts, leading to increased operational risks and costs.
Innovation Solution
A modular robotic inspection system with a dual linear phased array payload that allows for rapid configuration, automated inspection operations, and separation of expert personnel, enabling safer and more efficient inspections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inspection systems are used, then inspection coverage is achieved, but system shutdowns are required and personnel are exposed to hazardous environments
Solution Approach 1:
An automated robotic inspection system serves as an intermediary between the inspector and the hazardous environment. The robot equipped with phased array ultrasonic sensors performs inspections in dangerous locations (high voltage areas, toxic gas zones, confined spaces) without requiring personnel exposure, thereby eliminating harmful factors while maintaining inspection reliability
Solution Approach 2:
The robotic inspection system performs self-navigation and self-inspection operations using automated phased array ultrasonic testing. The system independently traverses the inspection area, collects data, and generates reports without continuous human intervention, enabling safe operation in hazardous environments where personnel cannot be present
2Productivity
If manual inspection operations are performed, then inspection data is collected, but complex robot configuration and multiple expert personnel are required
Solution Approach 1:
The robotic inspection system incorporates automated configuration capabilities where the phased array ultrasonic testing system automatically configures inspection parameters, sensor settings, and data processing algorithms based on the specific application. This self-configuration eliminates the need for multiple expert personnel and reduces operational complexity while maintaining high inspection productivity
Solution Approach 2:
The phased array ultrasonic inspection system is designed with universal applicability across different industrial inspection scenarios. A single automated system can handle various inspection types (corrosion detection, wall thinning, crack detection) through software configuration rather than requiring different specialized equipment or expert personnel for each inspection type, thereby improving productivity while reducing complexity
3Measurement precision
If phased array ultrasonic inspection is performed, then inspection resolution is improved, but configuration complexity and operational expertise requirements increase
Solution Approach 1:
The automated robotic system performs self-calibration and self-configuration of the phased array ultrasonic elements. The system automatically adjusts excitation amplitudes, sequencing parameters, and beam steering settings based on the inspection requirements, eliminating the need for operators to manually configure complex phased array parameters while maintaining high measurement precision
Solution Approach 2:
The system incorporates real-time feedback mechanisms where inspection results are automatically analyzed and used to adjust phased array configuration parameters. The automated system monitors signal quality, adjusts element sequencing and excitation levels dynamically, and optimizes beam steering based on detected features, thereby maintaining high resolution while simplifying operation through closed-loop control
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
The system provides rapid and complete inspections of industrial surfaces, reducing operational risks and costs by allowing experts to focus on high-value tasks, while ensuring thorough and automated data collection in hazardous environments.
Implementation Method 1
a first sensor (11460) including a first linear phased array of ultrasonic (UT) elements, and a second sensor (11465) including a second linear phased array of UT elements
Data Source
AI summary
A method may collect inspection surface data at a first location proximate to an inspection surface of an asset. The method may transmit the inspection surface data to a second location distinct from the first location. The method may receive an inspection control parameter from the second location. The method may perform an inspection operation with an inspection robot having a phased array sensor, in response to the inspection control parameter, where the inspection control parameter comprises an inspection trajectory value.