Robotic Digital Thread Inspection for Pipe Connection Accuracy
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Solution Overview
Problem
Conventional visual thread inspection methods for pipe sections and threaded connections are subjective, prone to human error, and inconsistent due to environmental factors, posing safety risks in operations.
Innovation Solution
An automated digital inspection assembly using integrated laser measurement and optical sensors, controlled by a robotic positioning device, to objectively verify threaded connection characteristics and measure attributes like length, diameter, and ovality, with synchronized dual-station inspection for enhanced accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional visual thread inspection methods are used, then inspection can be performed with simple equipment, but the inspection results are subjective and inconsistent due to human error and environmental factors
Solution Approach 1:
The patent replaces the mechanical visual inspection system with an optical measurement system. Digital cameras, laser scanners, and optical sensors capture images and measurements of threaded connections, eliminating human subjectivity. The system uses computer vision algorithms to automatically analyze the captured data, providing objective and consistent inspection results while maintaining relatively simple deployment.
2Reliability
If automated digital inspection systems are implemented, then inspection consistency and accuracy improve, but the device complexity and cost increase
Solution Approach 1:
The patent creates a multi-functional inspection system that can perform multiple inspection tasks using a single integrated platform. The system can inspect various types of threaded connections (API, NPT, BSPT), measure multiple parameters (thread profile, pitch, depth, ovality), and generate comprehensive inspection reports. This universal approach increases reliability while managing complexity through consolidation rather than requiring multiple specialized devices.
Solution Approach 2:
The patent uses digital imaging to create accurate copies of the physical threaded connections. Digital cameras and laser scanners capture high-resolution images and 3D point clouds that replicate the geometric features of the threads. These digital copies can be analyzed repeatedly without physical contact, improving reliability while keeping the physical inspection system relatively simple.
3Ease of operation
If manual visual inspection is used, then the equipment remains simple and portable, but human error and subjectivity affect inspection quality
Solution Approach 1:
The inspection system performs self-service through automated image capture and analysis. The digital camera automatically captures images of the threaded connection, and computer vision algorithms automatically measure and evaluate the thread geometry without requiring human interpretation. This self-service capability maintains ease of operation (simple setup and execution) while dramatically improving measurement precision through objective digital measurement.
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
Provides consistent, accurate, and repeatable inspections that reduce human error, ensuring compliance with OEM standards and enabling real-time data acquisition and reporting, suitable for mobile deployment in various locations.
Implementation Method 1
The sensor head can include a digital camera, a laser distance sensor, and/or one or more optical sensors
Implementation Method 2
The sensor head can include a digital camera, a laser distance sensor, and/or one or more optical sensors
Data Source
AI summary
A compact inspection assembly comprising digital sensors and/or laser measurement systems to measure and validate attributes of pipe and associated threaded connections. A custom designed end-effector sensor assembly is selectively attached to a robotic arm having software and control systems. An automated sensor assembly, selectively positioned relative to a pipe section, measures data regarding the pipe and associated threaded connections. The measured and recorded data can be inspected for defects and/or compared to predetermined standards (such as, for example, original equipment manufacturer and/or end user specifications or requirements) to verify pipe/connection compliance with desired standards.