Robotic Digital Thread Inspection for Accurate Pipe Connection Validation
Find Innovative SolutionsGenerate Solutions
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, which can lead to safety and operational issues.
Innovation Solution
A digital inspection assembly using integrated laser measurement, optical sensors, phased-array, and ultrasonic transducer technology, along with a robotic positioning system, to objectively measure and inspect pipe sections and threaded connections, reducing human subjectivity and error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional visual thread inspection methods are used, then the inspection process is simple and easy to implement, but the measurement precision and reliability deteriorate due to human subjectivity and environmental factors
Solution Approach 1:
The patent replaces the mechanical human visual inspection system with an automated optical measurement system. Digital cameras, lasers, and image processing algorithms objectively measure thread parameters without human subjectivity, eliminating environmental factors like lighting conditions and inspector fatigue that degrade measurement precision.
Solution Approach 2:
The patent creates digital copies of the physical thread structure through photogrammetry and optical scanning. Multiple digital images and laser measurements are captured and processed to generate virtual 3D models of threads, allowing precise measurement and analysis without physical contact, thereby improving measurement precision while maintaining relatively simple implementation.
2Reliability
If human inspectors perform visual inspection, then the deployment complexity is low, but the reliability and consistency of inspection results worsen due to human error and subjectivity
Solution Approach 1:
The inspection system performs self-validation through automated image processing and measurement algorithms. The system automatically captures images, processes them through standardized algorithms, and generates inspection results without requiring human judgment or interpretation, ensuring consistent and reliable results across different inspectors and environments.
Solution Approach 2:
The patent implements automated feedback loops where measurement results are immediately processed and compared against acceptance criteria. The system provides real-time feedback on thread quality, automatically flagging defects and generating reports, which eliminates the variability and delays associated with human inspection while improving reliability.
3Loss of information
If multiple measurement parameters are captured simultaneously, then the information completeness improves, but the device complexity and data processing requirements worsen
Solution Approach 1:
The patent merges multiple measurement functions into a single integrated inspection platform. Digital cameras, lasers, and image processing systems are combined to simultaneously capture geometric parameters, surface characteristics, and thread dimensions, eliminating information loss while managing complexity through integrated hardware and software architecture.
Solution Approach 2:
The inspection system is designed with multi-functionality to handle various thread types and measurement parameters using the same core platform. The universal system can inspect different thread profiles (NPT, BSP, API), measure multiple parameters (pitch, crest, root, angle), and generate comprehensive reports, reducing the need for multiple specialized devices.
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 digital inspection assembly provides accurate, repeatable, and objective measurements and inspections of pipe sections and threaded connections, improving safety and operational integrity while reducing costs and deployment complexity.
Implementation Method 1
at least one laser distance sensor utilizing time of flight to measure distance to the object
Implementation Method 2
phased-array and/or ultrasonic transducer ("UT") technology
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.