Rotating Pipeline Camera Assembly for Dead Zone-Free Inspection
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Solution Overview
Problem
Existing pipeline detectors face limitations in camera rotation angles, leading to incomplete detection in complex pipeline environments with numerous dead zones, affecting safety assessment and detection accuracy.
Innovation Solution
A pipeline detector with a camera assembly that includes a mounting shell, a rotatable mounting base, and a driving device comprising a driving motor and gears, allowing the camera to rotate flexibly and achieve all-round detection by inclining its optical axis relative to the rotation axis, along with a multi-layered waterproof and protective design to enhance durability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the camera is fixed in a conventional position on the pipeline detector, then the device structure is simple, but the camera rotation angle is limited and dead zones appear in detection
Solution Approach 1:
The camera is mounted on a rotatable mounting base that can dynamically adjust its orientation. The driving motor rotates the mounting base to change the camera's shooting direction, transforming the static camera setup into a dynamic one that adapts to different detection needs and eliminates dead zones.
Solution Approach 2:
The camera assembly is divided into separate functional modules: the mounting base for rotation, the camera for detection, and the driving motor for actuation. This segmentation allows independent optimization of each component and enables the complex rotation function without overwhelming the overall system design.
2Reliability
If the camera rotation mechanism is added to achieve all-round detection, then detection coverage is improved, but the device complexity increases
Solution Approach 1:
The mounting base serves multiple functions: it provides a rotating platform for the camera, houses the driving motor, contains the gear transmission mechanism, and offers structural support. This multi-functionality reduces the need for separate components and minimizes overall device complexity despite adding rotation capability.
Solution Approach 2:
The driving motor and gear mechanism are nested within the mounting base structure. The driving gear is sleeved on the motor output shaft, and the driven gear is integrated with the mounting base, creating a compact nested arrangement that reduces space requirements and structural complexity.
3Adaptability or versatility
If the camera optical axis is aligned with the rotation axis, then the structure is simple, but the camera cannot achieve flexible multi-dimensional adjustment in complicated pipeline environments
Solution Approach 1:
The camera optical axis is deliberately inclined at an angle relative to the rotation axis, breaking the symmetric alignment. This asymmetric configuration allows the camera to capture images at multiple angles during rotation, providing flexible multi-dimensional adjustment capability to adapt to complicated pipeline environments with elbows, branches, and diameter reductions.
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 all-round, dead zone-free detection in complex pipelines, improving detection accuracy and reliability while withstanding harsh environments, and extending equipment lifespan.
Implementation Method 1
a driving device for driving the mounting base for rotation; the driving device includes a driving motor fixedly disposed inside the mounting shell
Implementation Method 2
a driving gear sleeved on an output shaft of the driving motor, and a driven gear that is fixedly disposed on one side of the mounting base deviating from the camera and is engaged with the driving gear
Data Source
AI summary
Disclosed is a pipeline detector including a mounting rack, a host, and a wire coil enwound by a cable; one end of the cable is electrically connected to the host, and another end of the cable is connected with a camera assembly that includes a mounting shell, a mounting base rotatably disposed inside the mounting shell, a camera fixedly disposed on the mounting base, and a driving device driving the mounting base for rotation. The driving device includes a driving motor, a driving gear, and a driven gear; the cable is electrically connected to the camera; and a direction of optical axis of the camera is disposed in an inclined way relative to a direction of a rotation axis of the mounting base. According to the aforesaid technical solution, the camera can achieve all-round and dead zone-free detection in various complicated pipeline environments to improve detection accuracy and reliability.