Ultrasonic Sensor Sled Calibration for Redundant Robot Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing inspection and treatment systems for industrial surfaces face challenges in hazardous environments, requiring shutdowns, safety procedures, and are prone to human error, incomplete inspections, and lack systematic coverage.
Innovation Solution
An inspection robot with modular drive assemblies, selective payloads, and sensor configurations for different surfaces, capable of operating in hostile environments, generating interactive inspection maps, and providing improved climbing capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If personnel manually inspect industrial surfaces, then inspection coverage can be complete, but safety hazards increase and human error is more likely
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated robotic inspection system. The robot performs inspection tasks autonomously in hazardous environments, eliminating the need for personnel to physically enter dangerous areas while maintaining complete inspection coverage through systematic automated scanning and data collection.
Solution Approach 2:
The inspection robot is designed to autonomously navigate inspection areas, position itself optimally for data collection, and execute inspection routines without continuous human intervention. The system self-manages its inspection process, collecting and processing data independently while ensuring comprehensive coverage of the inspected surface.
2Reliability
If inspection systems require shutdowns or reduced capacity for safety, then personnel safety improves, but productivity decreases
Solution Approach 1:
The robotic inspection system eliminates the need for shutdowns by operating autonomously during normal industrial operations. The robot can inspect surfaces while equipment remains operational, maintaining continuous productivity without compromising safety through manual personnel exposure.
Solution Approach 2:
The system performs inspection data collection continuously and stores results for later analysis. This allows inspection activities to be completed in advance or during low-risk periods, enabling comprehensive inspections without requiring shutdowns of critical industrial operations.
3Reliability
If stringent safety procedures are followed, then personnel safety improves, but inspection completeness and systematic coverage decrease
Solution Approach 1:
The automated robot system maintains systematic coverage and inspection completeness by following pre-programmed inspection paths and protocols. The robot consistently executes inspection routines with precise positioning and comprehensive data collection, eliminating the variability and omissions that occur in manual inspections even when safety procedures are stringent.
Solution Approach 2:
The inspection system incorporates real-time feedback mechanisms where the robot monitors its own position, inspection quality, and coverage status. This feedback enables the system to adjust its inspection path and parameters to ensure complete and systematic coverage while maintaining safety standards throughout the inspection process.
4Productivity
If personnel enter confined inspection spaces, then inspection coverage can be achieved, but human error and judgment errors increase
Solution Approach 1:
The robotic system provides consistent, repeatable inspection results by eliminating human judgment and error factors. The robot follows precise programmed paths, maintains consistent sensor positioning, and collects data objectively without the variability introduced by manual inspection, even in confined spaces.
Solution Approach 2:
The inspection robot creates digital copies and models of the inspected surfaces through systematic sensor data collection. These digital representations capture the inspection area completely and accurately, providing a permanent record that eliminates human error in documentation and analysis while maintaining full coverage of confined spaces.
Data Source
AI summary
A method for inspecting an inspection surface using an inspection robot includes operating a first group of ultrasonic sensors with a first calibration set and operating a second group of ultrasonic sensors with a second calibration set. The first group of ultrasonic sensors is included in a first sled assembly of a payload, and the second group of ultrasonic sensors is included in a second sled assembly of the payload. The first group of ultrasonic sensors is at a first characteristic vertical position on the first sled assembly, and the second group of ultrasonic sensors is at a second characteristic vertical position on the second sled assembly. The first calibration set includes a same calibration as the second calibration set, and the second group of ultrasonic sensors provides inspection data that is redundant with inspection data provided by the first group of ultrasonic sensors.