Robotic Phased Array Inspection Reporting for Hazardous Surfaces
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Solution Overview
Problem
Existing inspection systems for industrial surfaces face challenges such as complexity, requiring multiple experts, increased operational risks, and high costs due to the need for manual configuration and exposure to hazardous environments, leading to incomplete inspections prone to human error.
Innovation Solution
A modular robotic inspection system with a dual linear phased array payload that allows for rapid configuration and confirmation of correct setup, enabling expert personnel to focus on high-value tasks, reducing operational risks and costs, and ensuring complete and safe inspections in hazardous environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection methods are used by personnel, then inspection can be performed, but the complexity increases requiring multiple experts, operational risks increase due to hazardous environment exposure, and costs increase
Solution Approach 1:
The inspection system performs self-configuration and self-validation through automated workflows. The system automatically configures phased array ultrasonic inspection parameters, validates sensor settings, and confirms proper setup without requiring multiple expert personnel, thereby reducing operational complexity while maintaining inspection reliability
Solution Approach 2:
The patent replaces manual mechanical inspection operations with an automated robotic inspection system equipped with phased array ultrasonic sensors. The robot autonomously navigates, positions sensors, and collects data, eliminating the need for human experts to physically enter hazardous environments, thus reducing both operational complexity and safety risks
2Ease of operation
If personnel enter hazardous environments for inspection, then direct inspection is possible, but safety risks increase and operational costs increase
Solution Approach 1:
The robotic inspection system acts as an intermediary between the inspector and the hazardous environment. The robot enters the hazardous area to perform inspections, while operators remain in safe locations controlling the system remotely, thereby eliminating direct human exposure to hazards while maintaining inspection accessibility
Solution Approach 2:
The patent substitutes human personnel with an automated robotic system for operations in hazardous environments. The robot performs all inspection tasks autonomously or semi-autonomously, completely eliminating the need for human entry into hazardous areas while maintaining full inspection capability
3Adaptability or versatility
If multiple experts are deployed for inspection operations, then comprehensive expertise is available, but operational risks increase and costs increase
Solution Approach 1:
The inspection system incorporates built-in expertise through automated configuration and validation workflows that encode expert knowledge. The system automatically determines appropriate inspection parameters, sensor settings, and procedures based on the specific application, eliminating the need to deploy multiple expert personnel while maintaining comprehensive technical capability
Solution Approach 2:
The robotic inspection system is designed with universal capabilities to perform multiple inspection tasks and adapt to different inspection scenarios through software configuration rather than requiring specialized personnel for each task type. The single system can handle various inspection requirements by loading appropriate inspection programs and parameters
4Measurement precision
If complex configuration procedures are used for phased array ultrasonic inspection, then inspection accuracy can be maintained, but setup time increases and human error increases
Solution Approach 1:
The system performs preliminary configuration and validation of inspection parameters before actual inspection begins. Automated workflows pre-configure phased array settings, validate sensor connections, and confirm proper setup in advance, ensuring inspection accuracy is maintained while significantly reducing on-site configuration time and potential for human error
Solution Approach 2:
The inspection system incorporates automated feedback mechanisms that validate configuration settings and provide real-time confirmation of proper setup. The system monitors inspection parameters, detects configuration errors, and automatically corrects or alerts operators to issues, thereby maintaining high inspection accuracy while reducing configuration time through automated verification rather than manual checking
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 with improved resolution and automation, reducing manual intervention and exposure to hazards, while maximizing sensor data collection and ensuring thorough coverage of complex industrial surfaces.
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 payload may perform inspection operations for an inspection surface. The payload may configure metadata for inspection data collected as a part of the inspection operations. The payload may upload inspection data in response to the inspection operations. The payload may perform at least one of analysis of the inspection data or validation of the inspection data utilizing the uploaded inspection data, where the performing at least one of analysis of the inspection data or validation of the inspection data comprises accessing a facility visualization and planning platform. The payload may provide a preliminary report in response to the analyzed and/or validated inspection data. The payload may review the preliminary report for data quality and/or data accuracy, and provide an approved report in response to the review. The payload may confirm the approved report for scope completion, and provide a confirmed final report.