System, method, and apparatus for inspecting a surface

Patent metadata

Field	Value
Publication number	US-12591239-B2
Application number	US-202418731490-A
Country	US
Kind code	B2
Filing date	Jun 3, 2024
Priority date	Dec 23, 2016
Publication date	Mar 31, 2026
Grant date	Mar 31, 2026

Abstract

A system includes an inspection robot comprising a main body and at least one payload; a plurality of arms, where each of the plurality of arms is pivotally mounted to the at least one payload to rotate around respective ones of a plurality of axes while the inspection robot traverses an inspection surface in a direction of travel, and where at least one of the plurality of axes is in the direction of travel; a plurality of sleds mounted to the plurality of arms; a plurality of inspection sensors coupled to the plurality of sleds such that each sensor is operationally couplable to the inspection surface; and where the plurality of sleds are distributed horizontally at adjustable positions spaced apart from each other across the at least one payload to inspect the inspection surface at a selected horizontal resolution.

First claim

What is claimed is:

1 . A system, comprising:
an inspection robot comprising a main body and at least one payload with a plurality of arms each pivotally mounted thereon to rotate around respective ones of a plurality of axes while the inspection robot traverses an inspection surface in a direction of travel, and wherein at least one of the plurality of axes is in the direction of travel; a plurality of sleds mounted to the plurality of arms; a plurality of inspection sensors coupled to the plurality of sleds such that each sensor is operationally couplable to the inspection surface; and wherein the plurality of sleds are distributed horizontally at adjustable horizontal positions spaced apart from each other across the at least one payload to inspect the inspection surface at a selected horizontal resolution.

2 . The system of claim 1 , wherein the at least one payload includes a plurality of payloads, and each payload is at a distinct horizontal inspection lane of the inspection surface.

3 . The system of claim 1 , wherein the horizontal distribution includes a spacing between each of the plurality of sleds to provide the selected horizontal resolution.

4 . The system of claim 3 , wherein the at least one payload includes a plurality of payloads, and each payload is at a distinct horizontal inspection lane of the inspection surface.

5 . The system of claim 1 , wherein the plurality of inspection sensors comprises a plurality of ultra-sonic (UT) sensors, the system further comprising a couplant chamber mounted to each of the plurality of sleds,
wherein the couplant chamber defines a delay line between the corresponding UT sensor and the inspection surface, and wherein the couplant chamber comprises a cone, the cone comprising a cone tip portion at an inspection surface end of the cone, and a sensor mounting end opposite the cone tip portion, and wherein the cone tip portion defines a couplant exit opening.

6 . The system of claim 5 further comprising a couplant entry for the couplant chamber, wherein the couplant entry is positioned between the cone tip portion and the sensor mounting end, and wherein the couplant entry is positioned at a vertically upper side of the cone in an intended orientation of the inspection robot on the inspection surface.

7 . The system of claim 1 , wherein the system further includes a biasing member providing a down force on each of the arms.

8 . The system of claim 1 , wherein:
the inspection robot further comprises a plurality of magnetic wheels configured to traverse a ferrous inspection surface.

9 . The system of claim 1 wherein the plurality of inspection sensors comprises a plurality of ultra-sonic (UT) sensors, the system further comprising a couplant chamber mounted to one of the plurality of sleds,
wherein the couplant chamber defines a delay line between the corresponding UT sensor and the inspection surface, and
wherein the couplant chamber comprises a cone, the cone comprising a cone tip portion at an inspection surface end of the cone, and a sensor mounting end opposite the cone tip portion, and wherein the cone tip portion defines a couplant exit opening;
a couplant entry for the couplant chamber, wherein the couplant entry is positioned between the cone tip portion and the sensor mounting end; and
wherein the couplant entry is positioned at a vertically upper side of the cone in an intended orientation of the inspection robot on the inspection surface.

10 . The system of claim 1 , wherein the at least one payload is horizontally moveable relative to the main body of the inspection robot.

11 . The system of claim 1 , wherein the plurality of sleds are respectively connected to the plurality of arms with a pivot connection that provides a pivotal degree of freedom.

12 . The system of claim 1 , wherein the plurality of arms are linearly spaced apart at the adjustable positions in a direction orthogonal to the direction of travel.

13 . A system, comprising:
an inspection robot comprising a main body and at least one payload with a plurality of arms mounted thereon; a plurality of sleds mounted to the plurality of arms; a plurality of inspection sensors coupled to the plurality of sleds such that each sensor of the plurality of inspection sensors is operationally couplable to an inspection surface; and the plurality of sleds distributed horizontally at adjustable horizontal positions spaced apart from each other across the at least one payload to inspect the inspection surface at a corresponding horizontal resolution.

14 . The system of claim 13 , wherein the at least one payload includes a plurality of payloads, and each payload is at a distinct horizontal inspection lane of the inspection surface.

15 . The system of claim 13 , wherein the system further includes a biasing member providing a down force on each of the arms.

16 . The system of claim 13 , wherein the plurality of inspection sensors comprises a plurality of ultra-sonic (UT) sensors.

17 . The system of claim 13 , wherein the plurality of sleds are respectively connected to the plurality of arms with a pivot connection that provides a pivotal degree of freedom.

18 . The system of claim 13 , wherein the at least one payload is horizontally moveable relative to the main body of the inspection robot.

19 . The system of claim 13 , wherein the plurality of sleds are distributed horizontally in a plane orthogonal to a direction of travel of the inspection robot.

Assignees

• Gecko Robotics Inc

Inventors

• Loosararian Mark
• Moore Joshua
• Gu Yizhu
• Low Kevin
• Bryner Edward
• Mackenzie Logan
• Miller Ian
• Chou Alvin
• Joslin Todd

Classifications

• G05B2219/45066

  Inspection robot · CPC title

• B25J9/1697

  Vision controlled systems · CPC title

• G05D1/24

  Arrangements for determining position or orientation · CPC title

• G05D1/223

  Command input arrangements on the remote controller, e.g. joysticks or touch screens · CPC title

• G05D1/246

  using environment maps, e.g. simultaneous localisation and mapping [SLAM] · CPC title