UAV Thermal Flight Path Adjustment for Flare Stack Inspection

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Solution Overview

Problem

UAVs are susceptible to damage during inspections of high-temperature objects, such as flare stacks, which can be costly and risky for operators, and existing inspection methods are inefficient or dangerous for human inspectors.

Innovation Solution

A UAV flight system dynamically adjusts flight operations based on thermal sensor data to avoid thermal damage by deviating from initial flight plans and using thermal imaging to inspect obscured objects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a UAV performs inspection of high-temperature objects such as flare stacks, then inspection capability is improved, but thermal damage risk to the UAV increases

Engineering Contradiction:
Improveinspection capabilityVSAvoidthermal damage risk
Core Design Contradiction:
Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary thermal scanning of the inspection area before the main inspection flight to identify high-temperature zones. This advance detection allows the flight plan to be adjusted proactively, routing the UAV around thermal hazards before they become a threat to the aircraft.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The flight plan is made dynamic rather than static, allowing real-time modification based on thermal sensor data. The system continuously monitors thermal conditions and automatically adjusts the flight path during the inspection mission, enabling the UAV to adapt to changing thermal environments while maintaining inspection effectiveness.

Inventive Principle:
Principle #15Dynamics

2Productivity

If the UAV follows the initial flight plan, then inspection efficiency is improved, but exposure to thermal hazards increases

Engineering Contradiction:
Improveinspection efficiencyVSAvoidthermal hazard exposure
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system implements continuous feedback through thermal sensors that monitor the UAV's thermal environment in real-time. This feedback loop allows the system to detect thermal hazards during flight and automatically adjust the flight plan to avoid these zones, balancing inspection efficiency with safety by making data-driven routing decisions.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The system changes flight parameters such as altitude, speed, and position in response to thermal conditions. By dynamically adjusting these parameters based on thermal sensor data, the UAV can maintain productive inspection operations while avoiding thermal damage zones that would otherwise be encountered on a fixed flight path.

Inventive Principle:
Principle #35Parameter changes

3Measurement precision

If human inspectors are used for tall and dangerous structures, then detailed inspection is improved, but risk to human life increases

Engineering Contradiction:
Improveinspection detailVSAvoidhuman safety
Core Design Contradiction:
Measurement precisionVSReliability

Solution Approach 1:

The system uses thermal sensors and imaging equipment on the UAV to create thermal copies and visual records of the inspected structures. These thermal images and data sets provide detailed information about the target objects without requiring human inspectors to physically approach dangerous areas, thereby maintaining inspection quality while eliminating human risk.

Inventive Principle:
Principle #26Copying

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 system enables safe and effective inspection of high-temperature objects by automatically avoiding thermal hazards, allowing UAVs to collect detailed sensor data without risking damage or human life.

Implementation Method 1

the UAV can collect thermal sensor data and the flight system can automatically adjust the flight plan to avoid thermal damage to the UAV based on the thermal sensor data

Methodology Applied
Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS20250290754A1Dynamically Adjusting UAV Flight Operations Based On Thermal Sensor Data
Publication Date: 2025.09.18 SKYDIO INC
  • US20250290754A1 patent drawing
  • US20250290754A1 patent drawing
  • US20250290754A1 patent drawing

AI summary

In some implementations, a UAV flight system can dynamically adjust UAV flight operations based on thermal sensor data. For example, the flight system can determine an initial flight plan for inspecting a flare stack and configure a UAV to perform an aerial inspection of the flare stack. Once airborne, the UAV can collect thermal sensor data and the flight system can automatically adjust the flight plan to avoid thermal damage to the UAV based on the thermal sensor data.