Tube Inspection Camera Assembly for High-Frame-Rate Imaging
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Solution Overview
Problem
Current camera systems for inspecting enclosed tube systems face issues with inadequate frame rate, poor image quality, limited battery life, cumbersome installation, and internal heat buildup, which restricts effective debris and defect identification and diagnosis.
Innovation Solution
A diagnostic camera apparatus with a camera housing, battery housing, and main housing designed for secure attachment to a moveable member, featuring improved lighting, a heat sink for thermal management, and detachable components for easy maintenance and installation, along with wireless communication for efficient image capture and data transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a generic low-cost camera is attached to a cable for inspection, then the system can identify debris or defects, but the frame rate is inadequate relative to the speed of movement
Solution Approach 1:
The patent changes the camera's operational parameters by providing it with adequate power supply (through improved battery capacity and electrical connection) and optimized lighting conditions (through multiple LEDs with diffusers), enabling the camera to operate at higher frame rates while maintaining image quality for debris and defect identification
2Illumination intensity
If a single un-diffused LED is used for illumination, then the camera can illuminate the enclosure, but the illumination is inconsistent and image quality is poor
Solution Approach 1:
The patent segments the illumination system into multiple LED light sources (at least three LEDs) positioned around the camera, with each LED having its own diffuser. This segmentation provides uniform illumination from multiple angles, eliminating shadows and inconsistent lighting, thereby improving image quality for debris and defect identification
Solution Approach 2:
The patent introduces diffusers as intermediary elements between the LED light sources and the enclosed space being inspected. These diffusers scatter and soften the light, creating uniform illumination that eliminates harsh shadows and improves overall image quality
3Volume of moving object
If small size coin cell batteries are used, then the camera can be compact, but the run time is limited and batteries are difficult to replace
Solution Approach 1:
The patent segments the power system into a removable battery assembly that can be independently accessed and replaced. The battery housing includes a removable cover that provides access to the battery, allowing quick replacement without tools or complex disassembly, thereby extending operational runtime while maintaining compact form factor
Solution Approach 2:
The patent makes the battery system dynamic by designing it as removable and replaceable rather than fixed. The electrical connection includes a removable electrical connector that engages with the battery assembly, allowing the battery to be quickly swapped during field operations to extend total operational duration
4Strength
If multiple parts, fasteners, and tools are used to secure the camera, then the camera can be firmly attached, but switching the unit is time-consuming and cumbersome
Solution Approach 1:
The patent segments the attachment system into a modular quick-connect interface. The electrical connection includes a removable connector that provides both electrical connectivity and mechanical attachment in a single integrated component, eliminating the need for multiple separate fasteners and tools
Solution Approach 2:
The patent merges the electrical connection and mechanical attachment functions into a single integrated removable connector. This unified interface provides firm attachment during operation while allowing rapid one-handed connection and disconnection, eliminating the time-consuming process of using multiple fasteners and tools
5Productivity
If the camera operates continuously, then inspection coverage increases, but internal heat builds up causing thermal shutdown
Solution Approach 1:
The patent extracts the heat generation issue by providing adequate power supply and thermal management that prevents excessive heat buildup in the first place, allowing continuous operation without thermal shutdown. The improved electrical connection and power management system efficiently delivers power while managing heat dissipation
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 apparatus provides high-quality images, extended battery life, rapid installation, and reduced thermal shutdowns, enabling more accurate and efficient inspection of enclosed tube systems with improved frame rates and longer operational run times.
Implementation Method 1
a heat sink for thermal management
Implementation Method 2
the main housing includes at least one light
Data Source
AI summary
The present disclosure relates in general to a diagnostic device for inspection of an enclosed tube system, and more particular, to obtain images or video of the interior of the enclosed tube system while the diagnostic device is attached to a moveable member and traveling through the enclosed tube system. A diagnostic apparatus including camera housing configured to include a camera assembly, battery housing configured to hold a battery assembly, and a main housing configured to be detachably secured to a moveable member, wherein the camera housing and battery assembly are secured to the main housing, and wherein the main housing includes at least one light.