Structured Light Inspection Tool for Plastic Pipeline Defect Detection
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Solution Overview
Problem
Current inspection methods for plastic pipelines, particularly MDPE, face challenges due to their dielectric nature, making it difficult to detect internal defects and assess the integrity of weld joints, and existing technologies for detecting cross-bores between gas and sewer pipes are inefficient, especially in obstructed or water-filled environments.
Innovation Solution
A 3D imaging structured light-based inspection tool with a side-by-side SL sensor design for 360-degree unobstructed inspection, phase SL sensor for enhanced profile reconstruction, automatic calibration, and electronic stabilization, capable of projecting a multi-color or color-coded multi-ring pattern for seamless RGB integration, allowing insertion into small diameter pipelines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods (eddy current, ultrasound, EMAT) are used on plastic pipelines, then inspection capability is improved, but the dielectric nature of plastic walls prevents effective detection
Solution Approach 1:
The patent replaces electromagnetic-based inspection methods (eddy current, ultrasound, EMAT) with an optical-based structured light system. The projector-camera setup uses light projection and capture to create 3D surface profiles, eliminating the need for electromagnetic or acoustic coupling with the pipe wall, thus overcoming the dielectric barrier of plastic materials.
2Ease of operation
If visual inspection is used for weld joints, then ease of operation is improved, but reliability of defect detection deteriorates due to inability to detect subsurface defects
Solution Approach 1:
The patent transitions from 2D visual inspection to 3D surface profiling using structured light projection. By capturing the deformation of projected light patterns on the weld surface and reconstructing 3D profiles, the system reveals subsurface defects and bonding issues that are invisible to conventional visual inspection, while maintaining operational simplicity.
3Ease of operation
If LED-assisted cameras are used to detect cross-bores, then ease of operation is improved, but productivity deteriorates due to limited access in obstructed environments
Solution Approach 1:
The inspection tool is segmented into modular components: a projector unit, a camera unit, and a housing that can be inserted through existing pipe access points. This modular design allows the system to navigate obstructed environments more effectively than bulky camera systems, improving productivity in challenging inspection scenarios while maintaining ease of deployment.
4Measurement precision
If structured light projection is used for 3D imaging, then measurement precision is improved, but device complexity increases due to calibration and stabilization requirements
Solution Approach 1:
The system incorporates automatic calibration and electronic stabilization algorithms that perform self-correction during operation. The calibration process uses the known geometry of the projection system to automatically adjust parameters, while the stabilization algorithm compensates for vibrations and movements in real-time, reducing the need for manual intervention and complex external support systems.
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 reliable detection of surface deformations and material loss defects within plastic pipelines and effectively identifies cross-bores, improving the integrity assessment of weld joints and enhancing the efficiency of pipeline inspections.
Implementation Method 1
A 3D imaging structured light-based inspection tool
Implementation Method 2
projecting a multi-color or color-coded multi-ring pattern
Data Source
AI summary
An inspection tool includes a projector projecting a projected pattern on a cylindrical surface, a first camera generating a first image of the projected pattern and a controller generating a surface profile of the cylindrical surface based on the first image.