Robotic Shaft Inspection System with 3D Modeling
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Solution Overview
Problem
Current non-destructive inspection systems for ship drive shafts face challenges due to their lengthy and narrow diameter, requiring human access, leading to costly and time-consuming preparations, false sensor readings, and difficulties in removing and reapplying coatings, which can result in inefficient and inaccurate inspections.
Innovation Solution
A robotic system with a three-point contact configuration and a rotating arm for stable movement within the pipe, equipped with ultrasonic testing, visual inspection, and corrosion mapping capabilities, along with a preservative removal and application system, allowing for 360-degree imaging and 3D modeling, and an umbilical power and signal interface for efficient data transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If external inspection is used for drive shafts, then inspection can be performed without removing the shaft, but false sensor readings occur due to wrapping or external coatings
Solution Approach 1:
The inspection approach is inverted by moving from external inspection to internal inspection. The robotic system enters the shaft interior to perform inspections from the inside, eliminating the problem of external coatings and wrapping interfering with sensor readings while maintaining the benefit of not requiring shaft removal.
Solution Approach 2:
A robotic system serves as an intermediary between the inspection need and the shaft interior. The robot carries inspection equipment into the confined space, enabling internal inspection without human personnel needing to physically enter the shaft, thus solving both the accessibility problem and the measurement accuracy problem.
2Measurement precision
If human personnel are sent into shaft interior for inspection, then direct visual inspection is possible, but access is difficult due to confined space and preparation is time-consuming
Solution Approach 1:
The robotic system is self-sufficient, carrying its own power supply, inspection equipment, and navigation capabilities. It autonomously navigates the shaft interior and performs inspections without requiring human personnel to enter, eliminating the need for time-consuming preparation such as finding personnel small enough to fit and setting up access equipment.
Solution Approach 2:
Human mechanical entry and inspection is replaced with an automated robotic system. The robot substitutes for human personnel, performing visual and non-destructive inspections through electronic sensors and cameras while eliminating the need for human physical access preparation.
3Measurement precision
If shaft is removed for inspection, then complete internal examination is possible, but the process becomes costly and time-consuming
Solution Approach 1:
The robotic system acts as an intermediary that brings inspection capabilities into the shaft interior without requiring the shaft to be removed. The robot carries all necessary inspection equipment into the confined space, enabling complete internal examination while the shaft remains in place, thus avoiding the costly and time-consuming removal and reinstallation process.
4Reliability
If coatings are applied to shafts for protection, then corrosion resistance is improved, but sensor readings are impeded and additional removal/reapplication is required
Solution Approach 1:
The inspection location is inverted from external to internal, allowing inspection to be performed from the inside of the shaft where coatings do not interfere with sensor readings. This eliminates the need to remove protective coatings while maintaining both corrosion protection and measurement accuracy.
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
Enables precise, efficient, and accurate non-destructive inspections within confined spaces without human intervention, reducing preparation time and false defect detection, while allowing for the removal and reapplication of coatings as needed, improving inspection reliability and reducing costs.
Implementation Method 1
The NDI processes targeted for this robot are Ultrasonic Testing (UT), visual inspection and electronic corrosion mapping
Implementation Method 2
visual inspection, and corrosion mapping capabilities, along with a preservative removal and application system, allowing for 360-degree imaging and 3D modeling
Data Source
AI summary
A mobile automated pipe or shaft non-destructive inspection system with rotational inspection sensor assembly for 360 degree imaging or sensing and generation of three dimensional models or sensing imaging or depictions of the pipe or shaft, preservative removal/application system, mobile platform mounting, and control system as well as related methods.