Robots for Inspection

Why Robots for inspection ?

• To answer this one must know the situations where

robot can work very well as compared to human being.
• The limitations of a human being can never become
hindrance for a industrial robot.
• The consistency a robot is far better than human
being.
• Robots are not subject to any emotions which can arise
due to any reasons like, weather, event, or any sort of
human behavior.
 Few situations or applications areas of
robots to think of ?

1. Arc welding and spot welding: think about

continuous welding, weld at difficult to access areas,
temperature, fatigue, operator safety are such
parameter which can easily affect the performance
of a human operator.
2. Painting
3. Inspection pressure and chemical vessels
4. Nuclear reactors
Note: All the students are advised to find few more
such examples
In Process inspection of a Car body
 In Process inspection of a Car body

• A robot can be assigned with the inspection task of

a car body:
1. To measure critical dimensions.
2. To find out any missing part or detail
3. To find out an welding defect
4. To check for any mis-orientation of parts
5. To check gap among sheet metal parts or profile
6. To detect presence of any unwanted material in the
sub-assembly
 What are the important outcome ?

1. Quick and accurate inspection

2. Check for geometric features
3. Can figure out defects easily
4. Data can be generated for SQC, like chart preparation
5. Can help in reduction of process variation
6. Reduction in the dependency of human operator i.e.
the same operator can be engaged with other task.
 What is an Inspection Robot ?

1. An inspection robot is a versatile machine equipped with

software, sensors, vision systems, and other advanced
technologies to interact with the surrounding
environments, gather data, and perform routine or
critical inspection tasks.
2. Inspection tasks are frequent in many industrial
environments (refineries, power plants, offshore
platforms, mining, or power stations), and their main
purpose, besides checking and monitoring, is to detect
malfunctions and errors.
 What is an Inspection Robot ?

3. Many of these environments present danger for humans.

The robots’ abilities to access hazardous or hard-to-
reach areas and their capacity for data collection and
analysis have positioned them as indispensable assets
across various sectors.
 what things must be taken in account

1. Type of robot
2. Sensors
3. Type of data collection
4. Data transfer technique
5. Type of inspection
6. Operating conditions like temperature , moisture,
vibrations , dusty atmosphere etc.
 Explain the bead and seam inspection for
a car body
1. A robotic system can check the bead and seams
present in the body of a car which is made up of sheet
metals.
2. Proper seams and joints are the key quality parameter in
the manufacturing of a car.
3. With the help of a vision sensors i.e. special cameras or
other types of sensors, sheet metal structure is inspected
w.r.t. to dimensions and any sort of gap or off set is
reported.
4. This inspection system can be a integrated part of car
body production line or assembly line.
 Types of robots used for inspection

1. Ground-based Robots:
• Ground-based inspection robots are designed to navigate
various terrains, from smooth warehouse floors to rugged
outdoor environments. These robots can be equipped with
wheels, tracks, or even legs, allowing them to traverse
obstacles and access confined spaces.
• Ground-based robots are commonly used for inspecting
pipelines, storage tanks, industrial machinery, and
infrastructure such as tunnels and sewers.
 Types of robots used for inspection

2. Aerial Drones:
• Aerial drones, also known as unmanned aerial vehicles
(UAVs) or quadcopters, are probably the ones everyone
thinks of when talking about robotic inspections.
• These lightweight, maneuverable devices are equipped with
high-resolution cameras, thermal imaging sensors, and
sometimes LiDAR technology.
• Aerial drones excel in inspecting large structures such as
bridges, power lines, and rooftops, offering a bird’s-eye view
of the area without the need for human intervention.
 Types of robots used for inspection

3. Underwater Robots (ROVs):

• Underwater robots are specifically designed to inspect
submerged structures and environments.
• These highly maneuverable robots are equipped with
cameras, sonar systems, and sometimes manipulator arms
to perform complex tasks and navigate challenging
environments precisely
 Types of robots used for inspection

4. Crawler Robots:
• Crawler robots are specialized inspection devices designed
to move along surfaces such as walls, ceilings, and vertical
structures.
• Equipped with grippers or suction cups, crawler robots can
adhere to various surfaces while carrying out inspections.
 What are the different technologies
which is promoting growth of robotic
inspection ?
• Most of the common technologies that enable inspections are:
• Advanced sensors include cameras, LiDAR (Light Detection and
Ranging), and thermal imaging systems: these sensors enable
them to capture detailed imagery, detect anomalies, and assess
the condition of equipment and infrastructure with precision and
accuracy.
• Autonomous navigation systems are another critical component
of inspection robots, allowing them to navigate complex
environments and perform inspections without human
intervention. These systems utilize advanced algorithms and
sensor data to navigate obstacles, follow predefined routes, and
adapt to changing conditions, ensuring efficient and thorough
inspections.
 What are the different technologies
which is promoting growth of robotic
inspection ?
• Remote control and monitoring capabilities enable
operators to oversee and control inspection robots from a
safe distance. This feature is particularly beneficial in
hazardous environments such as oil and gas, nuclear
facilities, and chemical plants, where human access may be
limited or dangerous.
• Furthermore, inspection robots are equipped
with sophisticated data analytics and reporting tools,
enabling them to analyze sensor data in real-time, identify
trends, and generate comprehensive reports.
• Other factors such teleoperations, wireless communication,
cloud capability , video compression technologies etc.
 What types of robots are used for
inspection based on the need of control ?

• Robots for inspection can be divided based on the

need for control by an operator. Hence, robot
control can be of three types:
• Full autonomy: The robot doesn’t require human
intervention to conduct everyday inspections.
• Supervised autonomy: The robot accomplishes short-term
tasks under supervision or under the request of human
supervision.
• Teleoperation: The robot is fully controlled by a human
operator who guides the robot in unknown environments.
 Key technology for robotic inspection

• Mobile platform- for movement

• Autonomous control: from simple to full autonomy
• Communication technology: from wired to wireless
• Charging technology
• Inspection technology: from standard sensors to vision
based and AI equipped algorithm
• Interaction mode :from manual control to Virtual reality
mode
 Key challenges for robotic inspection

• Type of inspection :contact type of non contact type

• Dedicated robot or versatile robot: single function or
multifunction
• Type of robot structure: cyldrical or articulated
• Integration of robot and inspection device
• Legal restrictions or guidelines
• Cost
• Mindset towards robotic inspection
 Application areas of robotic inspection

• Manufacturing : dimension and form inspection of parts,

orientation of sub-assembly and assemblies, profile
checking, surface roughness checking, NDT etc.
• Electrical Engineering: monitoring of power stations
• Chemical engineering: inspection and monitoring of
pressure vessels, reactors, processing stations. Gas leakage,
condition of pipes, joins, flanges.
• Pharmaceutical: checking of content in vials, packaging,
tablet making and its packaging.
• Civil and petrochemical Engineering: checking of storage
tanks, NDT, monitoring of rotating devices such as pumps
and compressors
 Application areas of robotic inspection

• Aerospace Engineering: inspection of structures for joining,

profile and defects, NDT, profile inspection
• Infrastructure: checking of structures, absence of critical
elements, presence of non standard practice etc.
 5 main advantages of using robotics for
infrastructure inspections:

• Ensuring the safety of the human

• Reducing the economic cost of the tasks
• Ease of access to complex spaces
• Reduction of human errors due to fatigue or
adverse conditions of the scenario
• Reduction of downtime as the robot can work in
shifts 24/7
 Types of robots for pipe inspection in
petrochemical industries

•Thickness Measuring Robot

•Diameter Robot
•Welding Pipe Robot
Let us see some example where robots
are doing monitoring and inspection
Robotic inspection- at electrical power
station
 Robotic inspection Electrical power
station-note

• By equipping the 5G gigabit gateway TG463 with

sensing devices such as laser radar, 5G wireless
networks, gas detectors, temperature and humidity
sensors, infrared thermal imaging cameras,
broadcasting voice systems, wide-angle dual-view
cameras, visible light cameras, and ultrasonic
radars, the robotic system becomes capable of
doing variety of inspection.
 Robotic inspection Electrical power
station-note

• It can real-time monitor power station elements

such as circuit structures, breakers, isolating
switches, transformers, lightning arresters, lightning
rods, bus-bars and meters.
• This enables all-weather and automated intelligent
inspection, which can timely detect potential
hazards and eliminate the dangers of manual
inspections.
 Potential benefits

• accuracy of inspection
•Safety of human being
•Risk free operation
•Real time data transfer
•Remote operation
• any time robot can be deployed for inspection
•Can reduce accidents and downtime.
Robotic inspection- pipes
 Robotic inspection of pipes

•This is done in two cases (1) installation of new

pipe network (2) inspection of exiting pipe line.
•Internal surfaces of pipe can subject to corrosion or
damage to due to type and nature of fluid passing
through it.
•There can be problems at bands.
• conventional methods of trial and error for fault
detection can become too much costly.
 Robotic inspection of pipes-note

• Robot inspection cameras can navigate tight bends,

long distances, and uneven surfaces with ease.
• This allows for a more thorough inspection
compared to manual methods, which may be
limited by accessibility.
• Additionally, cameras provide high-definition video
and often come with features like pan, tilt, and
zoom capabilities and come equipped with high
illumination LEDs to provide a detailed view of the
pipe's interior.
 Robotic inspection of pipes-note

• Built for rugged conditions, the speed and

efficiency of robot crawlers often lead to quicker
inspections.
• This means less downtime for pipelines and faster
identification of problems.
• Early detection of issues allows for prompt repairs,
preventing potential damage and costly
emergencies.
 What types of robots are used for
inspection of pipes

1. Wheel driven type

2. Tracked/caterpillar type
3. Inchworm type
4. PIG type
5. Legged type
6. Screw drive type
• Robot pipe crawlers are a valuable tool for a wide
range of applications, including:
1. Municipal sewer line inspections
2. Industrial pipeline assessments
3. Building plumbing checks
4. Drainage system maintenance
Robotic inspection- In manufacturing
 Robotic inspection- In PCB making
industries

• As on todays printed circuit board are becoming

complex yet they have to be defect free, accurate
and less costly.
• Mounting of electronic component on a defective
PCB creates quality issues , loss of productivity
and profit both.
• Hence inspection of PCB is one of the critical
need of electronic industries.
 Robotic inspection- In PCB making
industries

• Major disadvantages of the human inspector:

1. Is affected by fatigue, time of day and day of the
week.
2. Cannot maintain long-term consistency.
3. Needs breaks and rest periods from the task.
4. Can be slower than a machine.
5. Inconsistency between different inspectors.
Robotic inspection- In a plant
Robotic inspection- In a petrochemical
plant
Robotic inspection- material movement
Robotic inspection- in a dark environment
 Additional Applications of Robots in
inspection

• Energy generation inspections. Inspections of oil drilling

facilities and gas pipelines are one of the most
commonly mentioned applications for robot inspection.
This category also encompasses robots monitoring
nuclear energy sites, robots inspecting electrical
substations, or making sure energy storage tanks are
intact.
• Civil engineering inspections: Inspections
of bridges, tunnels, sewer lines, and other civil
infrastructure
• Cave inspections: Cave robot inspections can reach out
harder-to-reach locations, test for air quality, or sample
materials for mining potential.
 Additional Applications of Robots in
inspection

• Underwater inspections. Whether at the bottom of the sea or inside

a liquid or gas storage tank, these robots inspect the integrity of
each structure better than a human could with just the naked eye.
• Hazmat issues. Whether the concern is chemical, biological,
radiological, or nuclear contamination, robots can be sent ahead to
help humans understand what hazards they face so they are
prepared and protected.
• Construction robots. Construction inspection robots are on the job
before work begins exploring the state of the foundation or hard-to-
reach crawl spaces. Sometimes they show up midway through the
project to check that real-world measurement matches the
blueprints. Regardless of what phase of construction they are
associated with, these robots help keep surprises to a minimum and
work on track.

9.LiDAR technology in inspection robots is used for:

a) Infrared thermal imaging
b) Detecting obstacles and creating 3D maps
c) Controlling autonomous movements
d) Data transmission