Robotic Surface Inspection With Adjustable Sensor Sled Coverage
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Solution Overview
Problem
Existing inspection and treatment systems for industrial surfaces face challenges such as hazardous environments, incomplete inspections, human error, and the need for system shutdowns, leading to inefficient and unsafe operations.
Innovation Solution
A robotic inspection system with a profiler data circuit, position definition circuit, and inspection visualization circuit that interprets sensor data to determine features of interest, adjusts inspection operations, and provides accurate mapping and marking, utilizing sensors like laser profilers, ultra-sonic sensors, and magnetic induction sensors to ensure thorough and safe inspections.
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 uses a robotic inspection system that creates a virtual copy or digital twin of the industrial surface being inspected. The robot captures detailed images and measurements, processes them through AI algorithms, and generates a digital representation that can be analyzed without human exposure to hazardous environments. This allows reliable inspection while eliminating personnel hazard exposure.
Solution Approach 2:
The patent replaces manual mechanical inspection by personnel with an automated robotic system equipped with sensors, cameras, and AI processing. The robotic system performs the inspection functions that previously required human physical presence, thereby substituting the mechanical human inspection process with an automated system that eliminates safety risks while maintaining or improving inspection reliability.
2Ease of operation
If manual inspection procedures are used, then flexibility and adaptability in inspection judgment are maintained, but inspection completeness decreases and human error increases
Solution Approach 1:
The patent implements a feedback mechanism where the robotic inspection system captures data, processes it through AI algorithms, and uses the analyzed results to guide subsequent inspection actions. The system can identify areas requiring closer examination, adjust inspection parameters based on preliminary findings, and ensure comprehensive coverage by comparing actual inspection data against expected patterns, thereby improving completeness while maintaining operational flexibility.
Solution Approach 2:
The patent performs preliminary scanning and assessment using the robotic system to identify potential issues and plan the detailed inspection approach beforehand. The AI algorithms analyze initial data to determine high-risk areas, optimize inspection paths, and prepare examination protocols before the actual detailed inspection begins, ensuring both completeness and flexible adaptation to specific conditions.
3Reliability
If industrial systems are shutdown for inspection, then thorough inspection can be performed, but productivity and operational efficiency decrease
Solution Approach 1:
The patent enables continuous inspection operations by deploying the robotic system to perform thorough examinations while the industrial system remains operational. The robot can access and inspect surfaces during normal operations, eliminating the need for shutdowns. The AI processing occurs in real-time or near-real-time, maintaining inspection thoroughness while ensuring continuous productive operation of the industrial system.
Solution Approach 2:
The robotic inspection system acts as an intermediary that can operate in hazardous or active industrial environments without requiring system shutdown. The robot serves as a mediator between the need for thorough inspection and the requirement for continuous operation, capable of withstanding operational conditions while performing detailed examinations, thereby eliminating the trade-off between inspection thoroughness and productivity.
4Reliability
If multiple inspection passes are performed to ensure complete coverage, then inspection completeness improves, but inspection time and productivity decrease
Solution Approach 1:
The patent employs a multi-functional robotic inspection system that performs multiple inspection tasks simultaneously. The robot is equipped with various sensors and imaging modalities that can conduct different types of inspections in a single pass. The AI processing system analyzes multiple data streams concurrently, ensuring complete coverage without requiring multiple sequential inspection passes, thereby reducing inspection time while maintaining completeness.
Solution Approach 2:
The patent uses AI algorithms to perform partial re-inspection only in areas where issues are detected or suspected, rather than requiring complete multiple passes over the entire surface. The system identifies specific regions of interest and focuses detailed examination on those areas, achieving complete coverage of critical zones while minimizing overall inspection time through selective rather than exhaustive re-inspection.
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 accurate, safe, and efficient inspection and treatment of industrial surfaces by reducing human error, ensuring complete coverage, and minimizing exposure to hazards, while allowing for real-time data processing and visualization.
Implementation Method 1
an input sensor comprising a laser profiler and a plurality of wheels structured to engage a curved portion of an inspection surface, wherein the laser profiler is configured to provide laser profiler data of the inspection surface
Implementation Method 2
performing a post-processing operation on ultra-sonic sensor data in response to the shape description
Implementation Method 3
performing a post-processing operation on electromagnetic induction sensor data in response to the shape description
Data Source
AI summary
A system includes an inspection robot comprising a main body and at least one payload; a plurality of arms, where each of the plurality of arms is pivotally mounted to the at least one payload to rotate around respective ones of a plurality of axes while the inspection robot traverses an inspection surface in a direction of travel, and where at least one of the plurality of axes is in the direction of travel; a plurality of sleds mounted to the plurality of arms; a plurality of inspection sensors coupled to the plurality of sleds such that each sensor is operationally couplable to the inspection surface; and where the plurality of sleds are distributed horizontally at adjustable positions spaced apart from each other across the at least one payload to inspect the inspection surface at a selected horizontal resolution.