Abstract: A sled assembly for an inspection robot includes a first portion having a first ultrasonic (UT) sensor structured to interrogate an inspection surface and a second portion having a second UT sensor structured to interrogate the inspection surface. The first portion includes a first UT sensor housing that includes a first plurality of UT sensors structured to interrogate the inspection surface, the first plurality of UT sensors including the first UT sensor, and the second portion includes a second UT sensor housing that includes a second plurality of UT sensors structured to interrogate the inspection surface, the second plurality of UT sensors including the second UT sensor. The first portion and the second portion move independently of each other.

Abstract: A system for inspecting a flange member includes an inspection assembly support ring having an inner arc portion and an outer inspection assembly mount portion. The inner arc portion has an inner diameter structured to mount on the flange member, and the outer inspection assembly mount portion is rotationally coupled to the inner arc portion with a plurality of bearings interposed therebetween. The system further includes an inspection assembly mounted on the outer inspection assembly mount portion, and the inspection assembly includes an ultrasonic (UT) sensor on a pivot arm. The UT sensor is structured to interrogate a tapered surface of the flange member and to acquire UT interrogation data therefrom.

Abstract: A sled assembly for an inspection robot includes a first portion having a first sensor mount at a first horizontal position, and a second offset portion having a second sensor mount at a second horizontal position. The first horizontal position and the second horizontal position are horizontally displaced by a selected horizontal distance. The first portion includes a first plurality of sensor mounts, and the first plurality of sensor mounts include the first sensor mount. Also, the first plurality of sensor mounts include a first horizontal distribution profile providing a horizontal displacement between adjacent ones of the first plurality of sensor mounts that is not greater than a selected inspection resolution.

Abstract: A method for inspecting an inspection surface using an inspection robot includes operating a first group of ultrasonic sensors with a first calibration set and operating a second group of ultrasonic sensors with a second calibration set. The first group of ultrasonic sensors is included in a first sled assembly of a payload, and the second group of ultrasonic sensors is included in a second sled assembly of the payload. The first group of ultrasonic sensors is at a first characteristic vertical position on the first sled assembly, and the second group of ultrasonic sensors is at a second characteristic vertical position on the second sled assembly. The first calibration set includes a same calibration as the second calibration set, and the second group of ultrasonic sensors provides inspection data that is redundant with inspection data provided by the first group of ultrasonic sensors.

Abstract: An inspection robot with a payload includes a first sled assembly including a first forward sensor mount group and a second rearward sensor mount group. The first forward sensor mount group is positioned at a first characteristic horizontal position, and the second rearward sensor mount group is positioned at a second characteristic horizontal position. The inspection robot with the payload also includes a second sled assembly comprising a third forward sensor mount group and a fourth rearward sensor mount group. The third forward sensor mount group is positioned at a third characteristic horizontal position, and the fourth rearward sensor mount group is positioned at a fourth characteristic horizontal position. The inspection robot with the payload also includes a payload mount. The first sled assembly is coupled to the payload mount at a first mounting position.

Abstract: A method for inspecting an inspection surface using an inspection robot includes inspecting the inspection surface with a first sled assembly, the first sled assembly including a first forward sensor mount group and a second rearward sensor mount group. The method also includes inspecting the inspection surface with a second sled assembly, the second sled assembly including a third forward sensor mount group and a fourth rearward sensor mount group, and interpreting a first calibration value for a plurality of sensors of the first forward sensor mount group and a plurality of sensors of the third forward sensor mount group. Furthermore, the method includes performing inspection operations based on the first calibration value and capturing inspection data based on the inspection operations.

Abstract: A differential pivoting mechanism for a payload for an inspection robot. The mechanism includes a first rotational pivot joint that pivotally couples to a first sensor housing to pivot the first sensor housing in a first degree of freedom in a plane substantially perpendicular to a direction of travel of the inspection robot along an inspection surface plane defined, at least in part, by the surface. A second rotational pivot joint that pivotally couples to a second sensor housing to pivot the second sensor housing in the first degree of freedom in the plane substantially perpendicular to the direction of travel. A differential pivot joint that pivotally couples to a sensor frame of the inspection robot to pivot the first sensor housing with the second sensor housing in a second degree of freedom in the plane substantially perpendicular to the direction of travel.

Abstract: A calibration block may include an engagement surface having a selected vertical extent along a vertical axis and a selected horizontal extent along a horizontal axis. The block may include a block depth trajectory comprising a variable depth of the block along the vertical axis, the depth of the block at each position along the vertical axis comprising an effective distance between the engagement surface and an opposing surface. The block may include an end face defining at least one vertical feature hole, where the at least one vertical feature hole comprises a plurality of vertical feature holes. Each one of the plurality of vertical feature holes may comprise an angular offset orientation with a vertical axis of the block, where the angular offset orientation comprises an angle between zero degrees and 45 degrees, inclusive. The block may include a side face defining at least one horizontal feature hole.

Abstract: A payload may perform inspection operations for an inspection surface. The payload may configure metadata for inspection data collected as a part of the inspection operations. The payload may upload inspection data in response to the inspection operations. The payload may perform at least one of analysis of the inspection data or validation of the inspection data utilizing the uploaded inspection data, where the performing at least one of analysis of the inspection data or validation of the inspection data comprises accessing a facility visualization and planning platform. The payload may provide a preliminary report in response to the analyzed and/or validated inspection data. The payload may review the preliminary report for data quality and/or data accuracy, and provide an approved report in response to the review. The payload may confirm the approved report for scope completion, and provide a confirmed final report.

Abstract: A method may collect inspection surface data at a first location proximate to an inspection surface of an asset. The method may transmit the inspection surface data to a second location distinct from the first location. The method may receive an inspection control parameter from the second location. The method may perform an inspection operation with an inspection robot having a phased array sensor, in response to the inspection control parameter, where the inspection control parameter comprises an inspection trajectory value.

Abstract: An inspection robot with a payload includes a first sled assembly including a first forward sensor mount group and a second rearward sensor mount group, the first forward sensor mount group at a first characteristic horizontal position and the second rearward sensor mount group at a second characteristic horizontal position. The inspection robot also includes a second sled assembly including a third forward sensor mount group and a fourth rearward sensor mount group, the third forward sensor mount group at a third characteristic horizontal position and the fourth rearward sensor mount group at a fourth characteristic horizontal position. The inspection robot also includes a payload mount and a means for inspecting an inspection surface at a selected inspection resolution. The first sled assembly is coupled to the payload mount at a first mounting position and the second sled assembly is coupled to the payload mount at a second mounting position.

Abstract: An inspection robot with a payload includes a first sled assembly comprising a first forward sensor mount group and a second rearward sensor mount group, a second sled assembly comprising a third forward sensor mount group and a fourth rearward sensor mount group, and a payload mount. The first sled assembly is coupled to the payload mount at a first mounting position. The inspection robot with the payload also includes a controller configured to interpret a first processing value for a plurality of sensors of the first forward sensor mount group, interpret a second processing value for a plurality of sensors of the second rearward sensor mount group, perform inspection operations based on the first processing value and the second processing value, and capture inspection data based on inspection operations.

Abstract: An example payload for an inspection robot having a mounting rail to inspect an inspection surface, the payload including a wedge element; and a probe holder, including: a mounting rail connection member structured to connect to the mounting rail; a wedge element holder structured to hold the wedge element; a spring-loaded member structured to connect to the mounting rail connection member and to provide a selected vertical force on the wedge element holder; and an extended member structured to connect to the spring-loaded member between a first end and a second end, and to connect to the wedge element holder at the second end.

Abstract: A payload may include a first sensor including a first linear phased array of ultrasonic (UT) elements. The payload may include a second sensor including a second linear phased array of UT elements. The payload may include a sensor holder having a body and including a bottom side structured to interface with the inspection surface, where the first sensor and the second sensor are each mounted on the body of the sensor holder such that the first linear phased array of UT elements is parallel to the second linear phased array of UT elements, and the second linear phased array of UT elements is inclined relative to the bottom side of the sensor holder.

Abstract: A payload may include a first swappable sensor package including at least one ultrasonic (UT) element. The payload may include a first wedge element having a unitary body and including a bottom side structured to interface with the inspection surface and a top side structured for the first swappable sensor package to be mounted directly thereon, where the first swappable sensor package is mounted directly on the unitary body of the first wedge element with at least one fastening mechanism such that the first swappable sensor package has an angle of 0 to 7 degrees, inclusive, relative to the bottom side of the first wedge element.

Abstract: Systems, methods, and apparatus for ultra-sonic inspection of a surface are described. An example system may include an inspection robot structured to move in a direction of travel on an inspection surface. The inspection robot may include a payload including a first ultrasonic (UT) phased array and a second UT phased array, the first UT phased array and the second UT phased array being arranged in a parallel configuration. The inspection robot may include a rastering device structured to move the payload in a direction of inspection, the direction of inspection being distinct from the direction of travel and the direction of inspection being distinct from the parallel configuration of the first UT phased array and the second UT phased array.

Abstract: A sled assembly for an inspection robot includes a first portion having a first sensor mount at a first horizontal position, and a second offset portion having a second sensor mount at a second horizontal position. The first horizontal position and the second horizontal position are horizontally displaced by a selected horizontal distance. The first portion includes a first plurality of sensor mounts, and the first plurality of sensor mounts include the first sensor mount. Also, the first plurality of sensor mounts include a first horizontal distribution profile providing a horizontal displacement between adjacent ones of the first plurality of sensor mounts that is not greater than a selected inspection resolution.

Abstract: A device may include a first portion having a first sensor mount, at a first horizontal position, the first sensor mount structured to accommodate a first inspection sensor and thereby interrogate an inspection surface. A device may include a second offset portion having a second sensor mount, at a second horizontal position, the second sensor mount structured to accommodate a second inspection sensor and thereby interrogate the inspection surface. The first horizontal position and the second horizontal position may be horizontally displaced by a selected horizontal distance.

Abstract: A payload for an inspection robot. The payload includes a payload coupler pivotally coupled to the inspection robot to pivot in a plane substantially parallel to a direction of travel of the inspection robot along an inspection surface plane; and a sensor frame pivotally coupled to the payload coupler to pivot in the plane substantially parallel to the direction of travel. The payload further includes: a first sensor housing including a first phased array ultra-sonic (UT) sensor aligned with the direction of travel. The first sensor housing is pivotally coupled to the sensor frame to pivot in a plane substantially perpendicular to the direction of travel. The payload further includes a second sensor housing comprising a second phased array UT sensor aligned with the direction of travel. The second sensor housing is pivotally coupled to the sensor frame to pivot in the plane substantially perpendicular to the direction of travel.

Abstract: A differential pivoting mechanism for a payload for an inspection robot. The mechanism includes a first rotational pivot joint that pivotally couples to a first sensor housing to pivot the first sensor housing in a first degree of freedom in a plane substantially perpendicular to a direction of travel of the inspection robot along an inspection surface plane defined, at least in part, by the surface. A second rotational pivot joint that pivotally couples to a second sensor housing to pivot the second sensor housing in the first degree of freedom in the plane substantially perpendicular to the direction of travel. A differential pivot joint that pivotally couples to a sensor frame of the inspection robot to pivot the first sensor housing with the second sensor housing in a second degree of freedom in the plane substantially perpendicular to the direction of travel.