Inspection Robot Sensor Fusion for Curved Surface Positioning
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Solution Overview
Problem
Existing inspection systems for industrial surfaces face challenges such as incomplete inspections, high risks to personnel, and inaccurate measurements due to hazardous environments and the need for shutdowns, especially when inspecting curved or irregular surfaces.
Innovation Solution
An inspection robot system utilizing sensor fusion and a combination of inertial measurement units (IMUs) and robot total stations (RTS) for precise positioning, allowing for improved distance information and range finding, enabling accurate mapping and inspection of industrial surfaces despite hazardous conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If personnel manually inspect industrial surfaces in hazardous environments, then inspection can be performed, but personnel safety risks increase and inspections may be incomplete or prone to human error
Solution Approach 1:
The patent uses laser scanning to create accurate digital copies (3D point clouds) of the inspection surface, allowing remote visualization and measurement without personnel physical presence in hazardous areas. This enables complete systematic inspection while eliminating personnel safety risks.
Solution Approach 2:
The patent replaces manual mechanical inspection with automated laser scanning and photogrammetry systems. The laser scanner and camera capture data automatically, eliminating human involvement in hazardous environments while providing complete and accurate inspection coverage.
2Adaptability or versatility
If an inspection robot pitches or moves on curved surfaces, then the robot can traverse obstacles and weld lines, but measurement accuracy decreases due to beam deviation from the inspection surface
Solution Approach 1:
The patent transitions from 2D planar measurement assumptions to 3D spatial measurement by incorporating robot pose data from IMUs and RTS. This allows the system to calculate accurate surface distances even when the robot is pitched or rotated, compensating for angular deviations through three-dimensional coordinate transformations.
Solution Approach 2:
The patent implements feedback by continuously monitoring robot position and orientation using IMUs and RTS, then using this information to compensate for beam deviation in real-time. The system feeds back the measured surface geometry to correct for any pitch or rotation effects on the laser beam direction.
3Measurement precision
If a single positioning system is used on the inspection robot, then the system is simpler, but positioning accuracy is insufficient for precise surface mapping
Solution Approach 1:
The patent merges multiple positioning systems (IMUs for inertial navigation, RTS for total station triangulation, and laser scanner data) into a unified sensor fusion framework. This combination provides redundant measurements and cross-validation, achieving high positioning accuracy while managing complexity through integrated processing.
Solution Approach 2:
The patent changes the parameters measured by different sensors to complement each other - IMUs provide acceleration and orientation data, RTS provides absolute position references, and the laser scanner provides surface geometry. By fusing these different parameter types, the system achieves superior positioning accuracy that no single sensor could provide alone.
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 accurate and systematic inspection data with reduced human error and safety risks, enabling efficient and complete inspections of complex industrial surfaces without requiring system shutdowns.
Implementation Method 1
Each sensor is configured to provide position data corresponding to a location of the robot on the surface. The position data from the sensors is combined to generate a description of the location of the robot on the surface. At least one of the first sensor or the second sensor includes an inertial measurement unit (IMU).
Implementation Method 2
At least one of the first sensor or the second sensor includes a robot total station (RTS).
Data Source
AI summary
An inspection robot positioning system includes a first position sensor configured to provide a first position value, a second position sensor configured to provide a second position value, and a controller configured to determine a position description for an inspection robot in response to the first position value and the second position value, the position description including a robot position value of the inspection robot on an inspection surface.