TECHNICAL FIELD
The present disclosure generally relates to methods and systemsfor visual inspection
of structural elements and, more particularly, relates to method and system for
5 remote inspection of complex and uneven surfaces and non-destructive testing of
ferromagnetic structures.
BACKGROUND
10 The following description of the related art is intended to provide background
information pertaining to the field of the disclosure. This section may include certain
aspects of the art that may be related to various features of the present disclosure.
However, it should be appreciated that this section is used only to enhance the
understanding of the reader with respect to the present disclosure, and not as
15 admissions of the prior art.
As is generally known, ferromagnetic materials are preferred for construction of
complex structures in ships, bridges, oil rigs, refineries, wind turbines towers, power
transmission towers, and the like. Ferromagnetic materials are known to have long
operating life and additionally provide strength to the complex structures. At the
20 same time, ferromagnetic materials are susceptible to corrosion, fatigue, overload,
weathering, ageing thereby creating numerous defects in these structures such as
the thinning of steel plates, cracks, buckling, welding failure, and the like. If any of
these defects remain undetected, it may cause the sudden collapse of complete
structure or failure of strengthening members resulting in catastrophic events like
25 the sinking of ships, the collapse of bridges, failure of the wind turbine or power
transmission towers. To prevent such sudden failures, the continuous inspection and
maintenance of ferromagnetic structures and surfaces is required. The
conventionally available solutions involve inspection and maintenance either
manually or through remotely controlled vehicles with pre-installed cameras.
3
The conventionally available solutions include several limitations and problems. The
manual inspection and maintenance methods are primitive, prone to hazards, and
cannot be performed in inaccessible location like underwater conditions. The
remotely controlled vehicles used in the existing solutions also suffer from several
5 drawbacks. The vehicles used for inspection and monitoring suffers from several
stability issues in operating on complex and uneven ferromagnetic structures that
may include inability to operate on vertical surfaces and crossing 90-degree convex
bend, stability issues due to sticking of fine ferromagnetic particles on the wheels of
the vehicle, stability issues encountered while performing surface preparation and
10 non-destructive testing of the surface. The vehicle additionally suffers from
performance issues in underwater operation that may include issues with
waterproofing of the electronic components of the vehicle and thermal management
in the motor assembly used in the vehicle.
The currently known solutions are inefficient and include a plurality of limitations and
15 therefore, there is a need for improvement in this area of technology. In the light of
the aforementioned, there is a need for a method and a system for providing a
motorized electromagnetic vehicle to conduct surface preparation and nondestructive testing of complex and uneven ferromagnetic structures.
20 SUMMARY
This section is provided to introduce certain objects and aspects of the present
disclosure in a simplified form that are further described below in the detailed
description. This summary is not intended to identify the key features or the scope of
25 the claimed subject matter.
To overcome at least a few problems associated with the known solutions as provided
in the background section, an object of the present disclosure is to provide a novel
method and system for visual inspection and non-destructive testing of complex and
30 uneven ferromagnetic structures. Another object of the present disclosure is to
4
provide a motorized electromagnetic vehicle with a bi-wheel design consisting of a
magnetic front wheel assembly and a magnetic rear wheel assembly. It is yet another
object of the present disclosure to prevent sticking of metal particles to the magnetic
wheel assembly of the motorized electromagnetic vehicle. It is yet another object of
5 the present disclosure to ensure electromagnetic shielding of the electronic
components of the motorized electromagnetic vehicle. It is yet another object of the
present disclosure to provide a method for crossing convex 90-degree bend on
electromagnetic surfaces by the motorized electromagnetic vehicle. It is yet another
object of the present disclosure to conduct surface preparation and non-destructive
10 testing of complex and uneven ferromagnetic structures for the removal of thick
layers of rust and thin films of eroded paint by the robotic arm. It is yet another object
of the present disclosure to provide electromagnetic anchor arrangement to provide
stability to the motorized electromagnetic vehicle when conducting surface
preparation and non-destructive testing of complex and uneven ferromagnetic
15 structures.
To achieve the aforementioned objectives, the present disclosure provides a
motorized electromagnetic vehicle for the visual inspection of defects, surface
preparation, and non-destructive testing of ferromagnetic surfaces and structures.
20
A first aspect of the present invention relates to a motorized electromagnetic vehicle
for inspection of complex surfaces and non-destructive testing of ferromagnetic
structures. The motorized electromagnetic vehicle includes a magnetic wheel
assembly, a robotic arm manipulator, a tool assembly connected to the robotic arm
25 manipulator, an electromagnetic anchor arrangement, a chassis assembly comprising
at least one front chassis and at least one rear chassis, a segmentary joint, and a
steering assembly. Further, the motorized electromagnetic vehicle [100] designed to
cross a pre-defined angle range of the convex bend.
30 Another aspect of the present disclosure relates to a method for inspection and non-
5
destructive testing of complex and uneven ferromagnetic structures using a
motorized electromagnetic vehicle. The method comprises steering the motorized
electromagnetic vehicle for inspection and non-destructive testing of complex and
uneven ferromagnetic structure using a magnetic wheel assembly. The method
5 thereafter comprises holding the motorized electromagnetic vehicle on surface of the
complex and uneven ferromagnetic structure using an electromagnetic anchor
arrangement. The method thereafter comprises cleaning the surface of the complex
and uneven ferromagnetic structure for the non-destructive testing using a robotic
arm manipulator and a tool assembly. The method thereafter comprises performing
10 the non-destructive testing and inspection of the surface of the complex and uneven
ferromagnetic structure using the robotic arm manipulator, the tool assembly, and
at least one image recording system of the motorized electronic vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
15
The accompanying drawings, which are incorporated herein, and constitute a part of
this disclosure, illustrate exemplary embodiments of the disclosed methods and
systems in which like reference numerals refer to the same parts throughout the
different drawings. Components in the drawings are not necessarily to scale,
20 emphasis instead being placed upon clearly illustrating the principles of the present
disclosure. Some drawings may indicate the components using block diagrams and
may not represent the internal circuitry of each component. It will be appreciated by
those skilled in the art that disclosure of such drawings includes disclosure of
electrical components, electronic components, or circuitry commonly used to
25 implement such components.
FIG. 1 illustrates a schematic diagram of the motorized electromagnetic vehicle [100],
in accordance with exemplary embodiment of the present disclosure.
30 FIG. 1A illustrates a schematic diagram of the motorized electromagnetic vehicle
6
[100A], in accordance with exemplary embodiment of the present disclosure.
FIG. 2 illustrates a schematic diagram of the front and rear wheel assembly of the
motorized electromagnetic vehicle [200], in accordance with exemplary embodiment
5 of the present disclosure.
FIG. 2A illustrates a graphical representation of the variation in the magnetic field
strength as a function of thickness of steel used and as a function of air gap between
the components used in the motorized electromagnetic vehicle [200A], in accordance
10 with exemplary embodiment of the present disclosure.
FIG. 3 illustrates a schematic diagram of the steering and segment rotary joint
assembly of the motorized electromagnetic vehicle [300], in accordance with
exemplary embodiment of the present disclosure.
15
FIG. 4 illustrates a schematic diagram of the electromagnetic anchor arrangement of
the motorized electromagnetic vehicle [400], in accordance with exemplary
embodiment of the present disclosure.
20 FIG. 5 illustrates a schematic diagram of the robotic manipulator and tool assembly
of the motorized electromagnetic vehicle [500], in accordance with exemplary
embodiment of the present disclosure.
FIG. 6 illustrates a line diagram of the method of crossing a 90-degree convex bend
25 when moving upwards from horizontal direction to vertical direction using the
motorized electromagnetic vehicle [600], in accordance with exemplary embodiment
of the present disclosure.
FIG. 6A illustrates a schematic diagram of the method of crossing a 90-degree convex
30 bend when moving upwards from horizontal direction to vertical direction using the
7
motorized electromagnetic vehicle [600A], in accordance with exemplary
embodiment of the present disclosure.
FIG. 7 illustrates a schematic diagram of the possible variations of the motorized
5 electromagnetic vehicle [700], in accordance with exemplary embodiment of the
present disclosure.
FIG. 8 illustrates a schematic diagram of the waterproof smart actuator for the
underwater operation of the motorized electromagnetic vehicle [800], in accordance
10 with exemplary embodiment of the present disclosure.
FIG. 9 illustrates an exemplary method flow diagram for inspection and nondestructive testing of complex and uneven ferromagnetic structures using a
motorized electromagnetic vehicle, in accordance with an embodiment of the
15 present disclosure.
The foregoing shall be more apparent from the following more detailed description
of the disclosure.
20 DETAILED DESCRIPTION
In the following description, for the purposes of explanation, various specific details
are set forth in order to provide a thorough understanding of embodiments of the
present disclosure. It will be apparent, however, that embodiments of the present
25 disclosure may be practiced without these specific details. Several features described
hereafter can each be used independently of one another or with any combination
of other features. An individual feature may not address any of the problems
discussed above or might address only some of the problems discussed above. Some
of the problems discussed above might not be fully addressed by any of the features
30 described herein.
8
Exemplary embodiments now will be described with reference to the accompanying
drawings. The invention may, however, be embodied in many different forms and
should not be construed as limited to the embodiments set forth herein; rather, these
5 embodiments are provided so that this invention will be thorough and complete, and
will fully convey its scope to those skilled in the art. The terminology used in the
detailed description of the exemplary embodiments illustrated in the accompanying
drawings is not intended to be limiting. In the drawings, like numbers refer to like
elements.
10
The specification may refer to “an”, “one” or “some” embodiment(s) in several
locations. This does not necessarily imply that each such reference is to the same
embodiment(s), or that the feature only applies to a single embodiment. Single
features of different embodiments may also be combined to provide other
15 embodiments.
As used herein, the singular forms “a”, “an” and “the” are intended to include the
plural forms as well, unless expressly stated otherwise. It will be further understood
that the terms “include”, “comprises”, “including” and/or “comprising” when used in
20 this specification, specify the presence of stated features, integers, steps, operations,
elements, and/or components, but do not preclude the presence or addition of one
or more other features, integers, steps, operations, elements, components, and/or
groups thereof. It will be understood that when an element is referred to as being
“connected” or “coupled” to another element, it can be directly connected or
25 coupled to the other element or intervening elements may be present. Furthermore,
“connected” or “coupled” as used herein may include wirelessly connected or
coupled. As used herein, the term “and/or” includes any and all combinations and
arrangements of one or more of the associated listed items.
30 Unless otherwise defined, all terms (including technical and scientific terms) used
9
herein have the same meaning as commonly understood by one of ordinary skill in
the art to which this invention pertains. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be interpreted as having a
meaning that is consistent with their meaning in the context of the relevant art and
5 will not be interpreted in an idealized or overly formal sense unless expressly so
defined herein.
The figures depict a simplified structure only showing some elements and functional
entities, all being logical units whose implementation may differ from what is shown.
10 The connections shown are logical connections; the actual physical connections may
be different.
In addition, all logical units described and depicted in the figures include the software
and/or hardware components required for the unit to function. Further, each unit
15 may comprise within itself one or more components, which are implicitly understood.
These components may be operatively coupled to each other and be configured to
communicate with each other to perform the function of the said unit. In the
following description, for the purposes of explanation, numerous specific details have
been set forth in order to provide a description of the invention. It will be apparent,
20 however, that the invention may be practiced without these specific details and
features.
As discussed in the background section, the known solutions fail to conduct the visual
inspection, surface preparation, and non-destructive testing of complex and uneven
25 ferromagnetic structures. The present disclosure provides a solution relating to a
motorized electromagnetic vehicle for the visual inspection and non-destructive
testing of complex and uneven ferromagnetic structures. More specifically, the
present disclosure provides a motorized electromagnetic vehicle with a magnetic
wheel assembly, electromagnetic anchor arrangement and robotic arm manipulator
30 connected to the tool assembly for the surface preparation and Non-Destructive
10
testing of complex and uneven ferromagnetic structures.
The present disclosure provides a motorized electromagnetic vehicle with a rubberlined magnetic wheel assembly to prevent the sticking of fine ferromagnetic particles
5 to the magnetic wheel assembly of motorized electromagnetic vehicle. Further, the
present disclosure provides a motorized electromagnetic vehicle with a tool assembly
that is provided with an electric impact needle descaler, a grinding wheel, and a Nondestructive Testing (NDT) Tool for enabling the removal of thick scales of rust and
thin layers of eroded paint from the surface of complex and uneven ferromagnetic
10 structures for the surface preparation.
FIG. 1 illustrates a schematic diagram of the motorized electromagnetic vehicle [100],
in accordance with exemplary embodiment of the present disclosure. FIG. 1A
illustrates a schematic diagram of the motorized electromagnetic vehicle [100A], in
15 accordance with exemplary embodiment of the present disclosure. In order to avoid
the duplicity of the information, the description of the FIG.1 and FIG.1A has been
explained in conjunction with each other. As shown in FIG. 1, the motorized
electromagnetic vehicle comprises at least one front wheel assembly [102], at least
one rear wheel assembly [104], at least one robotic manipulator [106], at least one
20 tool assembly [108], at least one electromagnetic anchor arrangement [110], at least
one front chassis [112], at least one rear chassis [114], at least one segment rotary
joint [116], and at least one steering assembly [118] that are operatively connected
to enable the visual inspection of complex and uneven ferromagnetic structures by
the motorized electromagnetic vehicle, wherein all the components are assumed to
25 be connected to each other unless otherwise indicated below. Also, in FIG. 1 only one
front wheel assembly, only one rear wheel assembly, only one robotic manipulator,
only one tool assembly, only one electromagnetic anchor arrangement, only one
front chassis, only one rear chassis, and only one segment rotary joint is shown,
however, the motorized electromagnetic vehicle may comprise multiple such units
30 and modules or the system may comprise any such numbers of said units and
11
modules, as may be required to implement the features of the present disclosure.
Also, there may be one or more sub-units of said units and modules of the motorized
electromagnetic vehicle and the same is not shown in the FIG. 1 and the FIG. 1A for
the purpose of clarity.
5
In an example, the irregularities inspected and detected by the motorized
electromagnetic vehicle includes corrosion, fatigue, overload, weathering, ageing,
thinning of steel plates, cracks, buckling, welding failure, and the like on the complex
and uneven ferromagnetic structure.
10
In an exemplary embodiment, the segmentary joint connected to the at least one
front chassis and the at least one rear chassis provides flexibility to the motorized
electromagnetic vehicle to adapt to the uneven and complex surfaces. The at least
one front chassis and the at least one rear chassis of the motorized electromagnetic
15 vehicle are connected through the segmentary joint, where the angle between the
front chassis and the rear chassis may vary up to 180 degrees. The angle between the
front chassis and the rear chassis facilitates balance movement of the motorized
electromagnetic vehicle on the uneven and complex surfaces.
20 It should be noted that the motorized electromagnetic vehicle [100] is provided with
magnetic shielding to protect the electronic components in the motorized
electromagnetic vehicle from electromagnetic interference. The source of
electromagnetic interference is usually the electromagnetic field produced by the
magnetic wheel assembly [102], [104] along with other electromagnetic field
25 inducing components of the motorized electromagnetic vehicle. In an exemplary
embodiment, the motorized electromagnetic vehicle is provided with a plurality of
Mu-metal sheets as the lower covering to the front chassis [112] and the rear chassis
[114]. Mu-metal is a nickel-iron alloy and provides a path of least magnetic reluctance
to the electromagnetic field in the vicinity. The high relative permeability of the Mu30 metal is responsible for the ability to channelise electromagnetic field in the vicinity
12
and providing a path of least magnetic reluctance. The electromagnetic field interacts
with the Mu-metal sheets thereby protecting the electronic components of the
motorized electromagnetic vehicle. In an exemplary embodiment, the plurality of
components of the motorized electromagnetic vehicle protected from
5 electromagnetic interference include, but are not limited to, encoders, relays,
communication sensors, and the like. In another non-limiting embodiment, the
actuators in the robotic arm manipulator [106] are enclosed in a plurality of Mu-metal
sheets to protect the actuators from electromagnetic interference. In an example,
the plurality of Mu-metal sheets disclosed herein may be implemented as three (3)
10 layers of Mu-metal sheets.
FIG. 2 illustrates a schematic diagram of the front and rear wheel assembly of the
motorized electromagnetic vehicle [200], in accordance with exemplary embodiment
of the present disclosure. As shown in FIG. 2, the motorized electromagnetic vehicle
15 [200] comprises at least one magnetic front wheel assembly and at least one
magnetic rear wheel assembly provided with a smart actuator [242] and a plurality
of ball bearings [210]. The smart actuator [242] is attached to the aluminium shaft
[208] with the help of the plurality of bolts [202]. The plurality of ball bearings [210]
is positioned inside the bearing housing [212] with a plurality of circlips [214]. The
20 magnetic wheel assembly is provided with at least three ring magnets of neodymium
[216, 218, 220] placed in conjunction with a plurality of steel washers [222, 224].
Further, a thick rubber lining [204, 206] is fitted inside the grooves of the steel washer
[222, 224]. The magnetic wheel assembly is positioned on an aluminium shaft [208]
and located in a place with a plurality of circlips [230, 232]. The bearing housing [212]
25 that houses the plurality of ball bearings [210] is positioned on the aluminium shaft
[208] and fitted in with a plurality of circlips [226, 228, 230, 232]. The smart actuator
[242] of the magnetic wheel assembly is positioned with a motor side frame hold
[244] with a plurality of bolts [236] and the bearing housing is positioned with a
housing side frame hold [234] for enabling the motion of the motorized
30 electromagnetic vehicle on the surface of complex and uneven ferromagnetic
13
structures. The cross tie [238] is positioned firmly with the frame hold [244, 234] with
at least two bolts [240] to enable the steering movement of the motorized
electromagnetic vehicle.
5 In an exemplary embodiment of the present disclosure, the at least one smart
actuator [242] is connected with at least one processing unit (not shown in the FIG.
for the clarity purpose) to enable crossing of the pre-defined angle range of the
convex bend. The at least one processing unit is configured to deactivate the at least
one smart actuator [242] associated with the at least one rear wheel assembly [104]
10 in an event the at least one front wheel assembly [102] reaches to an edge of the
convex bend. The deactivation of the at least one smart actuator [242] starts a
crawling movement of the at least one rear wheel assembly [104] based on a forward
movement of the at least one front wheel assembly [102]. Next, the processing unit
is configured to enable crossing of the convex bend by the at least one front wheel
15 assembly [102] using the forward movement of the at least one front wheel assembly
[102]. Next, the processing unit is configured to re-activate the at least one smart
actuator [242] associated with the at least one rear wheel assembly [104]. Thereafter,
the processing unit is configured to enable crossing of the convex bend by the at least
one rear wheel assembly [104] to enable a complete crossing of the pre-defined angle
20 range of the convex bend by the motorized electromagnetic vehicle.
As used herein, a “processing unit” or “processor” includes one or more processors,
wherein processor refers to any logic circuitry for processing instructions. A processor
may be a general-purpose processor, a special-purpose processor, a conventional
25 processor, a digital signal processor, a plurality of microprocessors, one or more
microprocessors in association with a DSP core, a controller, a microcontroller,
Application Specific Integrated Circuits, Field Programmable Gate Array circuits, any
other type of integrated circuits, etc. The processor may perform signal coding data
processing, input/output processing, and/or any other functionality that enables the
30 working of the system according to the present disclosure. More specifically, the
14
processor or processing unit is a hardware processor. In an embodiment of the
present disclosure, the at least one processing unit is present inside the at least one
smart actuator. In another embodiment of the present disclosure, the at least one
processing unit may be present outside the at least one smart actuator and is
5 connected with the at least one smart actuator. In yet another embodiment, the at
least one processing unit may be present at any suitable position associated with the
motorized electromagnetic vehicle. In an embodiment, the at least one processing
unit includes a first processing unit connected with at least one first smart actuator
associated with at least one front wheel assembly. The at least one second processing
10 unit includes a second processing unit connected with at least one second smart
actuator associated with at least one rear wheel assembly. The at least one
processing unit is configured to enable and control the operations associated with
the at least one smart actuator.
15 It should be noted that the smart actuator [242] is a brushless DC motor that
functions in combination with a 36:1 planetary gearbox and is provided with a
multiturn absolute encoder and integrated control electronics. It has the capability
to produce the peak torque of 70 NM at 60 RPM and is fitted in with an aluminium
shaft [208] by a plurality of bolts. In an example, the smart actuator includes a first
20 actuator connected with the front magnetic wheel assembly and a second actuator
connected with the rear wheel assembly. As illustrated in the figure, the magnetic
front wheel assembly and the magnetic rear wheel assembly are a combination of a
steel washer and three neodymium ring magnets [216, 218, 220]. In an example, the
steel washer of the magnetic wheel assembly is made with Material SS410. The
25 reason for using SS410 material in the steel washer is its ferromagnetic and corrosionresistant nature. In an exemplary embodiment, the magnetic wheel assembly is
provided with rubber lining on the outer circumference of the magnetic wheel
assembly to prevent the sticking of the fine ferromagnetic particles on the outer
circumference of the magnetic wheel assembly where it makes contact with the
30 complex and uneven ferromagnetic structures. If the fine ferromagnetic particles
15
come directly in between the magnetic wheel assembly wheel and the complex and
uneven ferromagnetic structures, the stability of the motorized electromagnetic
vehicle on the complex and uneven ferromagnetic structures is compromised which
may additionally lead to slipping of the motorized electromagnetic vehicle.
5
FIG. 2A illustrates a graphical representation of the variation in the magnetic field
strength as a function of thickness of steel used and as a function of air gap between
the components used in the motorized electromagnetic vehicle [200A], in accordance
with exemplary embodiment of the present disclosure. As shown in the figure, the
10 magnetic field strength emanating from a magnet varies approximately square of the
inverse of the distance from the magnets. In an exemplary embodiment, the
thickness of the washer on the magnetic wheel assembly is 27.02 mm. A 12.01 mm
wide and 7.77 mm deep groove is cut around the periphery of the steel washer and
a rubber lining is 9.02 mm thick and 12.01 mm wide is inserted in the groove so that
15 1.25 mm of rubber lining protrudes outside the washer. When the exemplary
magnetic wheel assembly is placed on a steel plate that has a thickness of more than
8 mm, the rubber lining compresses due to magnetic force between the steel washer
and the steel plate. The thickness of the rubber lining is reduced to around 0.6 mm
due to the compression. The nature of the magnetic field as illustrated in the
20 graphical representation as shown in FIG. 2A ensures that the magnetic field strength
on top of the rubber lining is negligible when compared to the magnetic field strength
at the top of steel washer of the magnetic wheel assembly. The difference in the
magnetic field strength at the top of rubber lining in comparison with the magnetic
field strength at the steel washer causes the sides of the steel washer to attract the
25 fine ferromagnetic particles. The present arrangement prevents slipping of the
motorized electromagnetic vehicle and provides stability in the operation on complex
and uneven ferromagnetic structures. Further, FIG. 200A-1 illustrates the fine
ferromagnetic particles sticking on the periphery of the magnetic wheel assembly
making it slippery, in the absence rubber lining on the magnetic wheel assembly. Also,
30 the FIG. 200A-2 depicts the situation when the motorized electromagnetic vehicle is
16
provided with a plurality of rubber lining on the magnetic wheel assembly. The figure
shows the fine ferromagnetic particles sticking on the side of the steel washer and
not over the plurality of rubber lining embedded in the grooves on the steel washer
of the magnetized wheel assembly.
5
FIG. 3 illustrates a schematic diagram of the Steering & Segment Rotary Joint
assembly of the motorized electromagnetic vehicle [300], in accordance with
exemplary embodiment of the present disclosure. As illustrated in the figure, the
steering shaft [302] is positioned with the cross tie [238] with at least two bolts and
10 is located inside the steering housing [314], supported by the upper steering housing
bearing [316] and the bottom steering housing bearing [318]. It is evident from the
figure that the plurality of ball bearings and the steering shaft are positioned with a
plurality of circlips [320, 322, 324, 326]. The pinion gear [304] of the steering and
segment rotary joint assembly of the motorized electromagnetic vehicle is fitted in
15 with the steering shaft [302] through the key slot that is provided on the steering
shaft and the pinion gear. The worm gear [306] of the steering and segment rotary
Joint assembly is supported at one end with a plurality of bearings positioned inside
the bearing housing [308], while the other end of the worm gear is operatively
connected to a smart actuator [310] that is positioned with the frame and with the
20 actuator mounting block [312]. It should be noted that the steering is driven by the
worm gear arrangement thereby enabling the movement of the motorized
electromagnetic vehicle. Further, as illustrated in the figure, the Segment rotary joint
is made of segment housing [328], a segment rotor [330], and a segment stopper
[332]. The segment housing [328] is attached to the rear frame [338] and the segment
25 rotor [330] is attached to the forward frame [336]. The segment stopper [332] is
attached to the segment housing [328] with a plurality of bolts [334]. The segment
stopper prevents the segment rotor from coming out of the segment housing.
Further, the fine clearance and the lubrication between the segment housing and the
segment rotor allow flexibility between the forward and the Aft frame.
30
17
As illustrated in the figure, the rotation of the steering shaft and the consequent
rotation of the magnetic wheel assembly is enabled by operating the smart actuator
with a remote control to turn the worm gear and pinion gear positioned with the
steering shaft to rotate the steering shaft. The worm gear mechanism keeps the
5 steering shaft locked in position while the smart actuator detects the position of the
steering shaft through its absolute multiturn encoder and displays the steering angle
in the control station down below. Also, the segment rotary joint is provided for
flexibility between the forward and rear frame. Due to unevenness on the surfaces
where the crawler works, both the magnetic wheels are not always present in the
10 same plane. Therefore, the segment rotary joint provides flexibility to adapt each
magnetic wheel and their respective plane as per terrain down below on which the
motorized electromagnetic vehicle functions.
FIG. 4 illustrates a schematic diagram of the electromagnetic anchor arrangement of
15 the motorized electromagnetic vehicle [400], in accordance with exemplary
embodiment of the present disclosure. As illustrated in the figure, the
electromagnetic anchor assembly includes at least two electromagnets [402, 404], a
plurality of chrome rods [406, 408], a plurality of linear bearings [410, 412], a lead
screw [414], positioned with a lead screw nut [416], a small pulley [420] working in
20 conjunction with a big pulley [422], at least one timing belt [426], at least one
actuator [428], and a plurality of bearings [430] fitted inside the bearing housing
[432]. The at least two electromagnets [402, 404] are positioned at the base of the
bottom fix plate [434] with the help of a plurality of bolts [436, 438]. The lower
section of the plurality of chrome rods [406, 408] is operatively connected to the base
25 of the bottom fix plate with a plurality of bolts [436, 438] while the upper section of
the plurality of chrome rods is welded to the top fix plate [440]. The plurality of ball
bearings [430] is positioned inside the ball bearing housing [432] with the help of a
circlip [442]. The ball bearing housing [432] as well as the linear Bearing [410, 412]
are fitted inside the linear Bearing housing [444, 446] with the help of a plurality of
30 circlips [448, 450, 452, 454] and are bolted to the top carriage plate [456]. The lead
18
screw nut [416] is bolted with an actuator shaft [460] and the combination of pulleys
[420, 422] is positioned inside the ball bearing housing [432] with the help of a
plurality of circlips. The actuator [428] is positioned with the aluminium shaft hub
[458] and the combination of a big pulley [422] and small pulley [420]. The system
5 further includes the forward frame [418] and the Aft frame [424].
The smart actuator is enabled to move the lead screw nut through the combination
of pulleys which is operatively connected by the timing belt. The lead screw and the
lead screw nut work in association to convert rotary motion into linear motion to be
10 transferred to the plurality of chrome rods through the top fix plate [446]. The linear
motion of the plurality of chrome rods enables the bottom fix plate [434] to move in
a linear motion with respect to the at least two electromagnets [402, 404] that are
positioned at the top to prevent obstruction when the motorized electromagnetic
vehicle moves across convex bends of 90 degrees. The motorized electromagnetic
15 vehicle is designed to enable the use of the robotic arm while it moves across convex
bends of 90 degrees on complex and uneven ferromagnetic structures, by lowering
electromagnets to enable it to come in contact with the steel plates to enable the
robotic arm to grip the steel plate firmly for the visual inspection and non-destructive
testing of ferromagnetic surfaces and structures. Further, the smart actuator is
20 enabled by its multiturn absolute encoder to store information related to the top
stowing position and bottom anchor position of the at least two electromagnets to
display the information in the control station of the motorized electromagnetic
vehicle.
25 FIG. 5 illustrates a schematic diagram of the robotic manipulator and tool assembly
of the motorized electromagnetic vehicle [500], in accordance with exemplary
embodiment of the present disclosure. As illustrated in the figure, the robotic
manipulator, is provided with joints and actuators to enable movement in different
directions to the allow the tool assembly connected to the robotic manipulator to
30 prepare and inspect the complex ferromagnetic surface, is mounted on an arm
19
mounting plate [502] and is ergonomically engineered to be lightweight and stiff at
the same time. This is mainly due to the extensive use of carbon filter composites and
3D printed parts. The robotic manipulator is connected to the tool assembly that may
include a plurality of surface preparation tools and a plurality of inspection tools. In
5 an example, the tool assembly includes surface preparation tools such as an electric
impact needle descaler [536], grinding tool [538], and the like. The tool assembly
further includes inspection tool that may include Ultrasonic Thickness (UT) gauge
[540], ultrasonic scanner, eddy current tester for crack detection, and the like.
10 As shown in the figure, the robotic manipulator consists of at least two high torque
actuators designed that may include a base actuator [506] and a shoulder actuator
[524] enabled to work in association with at least three low torque actuators that
may include an elbow actuator [516], an elbow joint [514], a wrist actuator [522] and
a tool positioning actuator [530]. The base actuator [506] of the robotic manipulator
15 & tool assembly is positioned inside the base stator housing [504] that is connected
with the arm mounting plate [502] with at least six studs [542]. The shoulder actuator
[524] of the robotic manipulator and tool assembly is positioned inside the shoulder
stator housing [508] that is connected to the rotor of the base actuator [506] by a
plurality of bolts. The shoulder actuator [524] is connected to the shoulder rotor
20 connector [510]. The twin fork-type design of the shoulder actuator connector is
enabled to stay connected to carbon fiber tubes [512, 526] that are operatively
positioned in connection with the elbow stator housing [518], with the wrist rotor
connecter [528], and with the tool positioning actuator housing [544]. The wrist
actuator Housing [520] of the robotic manipulator and tool assembly is connected to
25 the elbow actuator rotor. The robotic manipulator and tool assembly further consists
of a lower base plate [532] and an upper cover plate [534] composed of carbon fiber
composites and at least three tools that may include the electric needle descaler
[536], the grinding wheel [538] and the Ultrasonic Thickness (UT) gauge [540] that
are operatively connected to enable the surface preparation and non-destructive
30 testing.
20
The robotic arm manipulator and tool assembly is supported by a front and rear
Chassis that provides a framework of support to the robotic manipulator and tool
assembly of the motorized electromagnetic vehicle and is composed of non-magnetic
5 stainless-steel sheets of 6 mm in thickness that are welded together to provide the
framework of support to the robotic manipulator and tool assembly. The steel sheets
are cut in shape with high power laser cutting machine. Now, it is bent in shape with
a CNC bending machine. After all individual parts are ready, it is welded together to
build the complete frame in one piece.
10
For the surface preparation and non-destructive testing of complex and uneven
ferromagnetic structures, the motorized electromagnetic vehicle is enabled to move
to the specific location by positioning the electromagnetic anchor and switching on
the motorized electromagnetic vehicle for conducting the surface preparation and
15 non-destructive testing of that location of the surface of the complex and uneven
ferromagnetic structures. During the motion of the motorized electromagnetic
vehicle, the robotic manipulator and tool assembly is enabled to move in any
direction away from the starting position for conducting the surface preparation and
non-destructive testing of that location using the different tools.
20
After the execution of the surface preparation and non-destructive testing of that
location, the robotic manipulator and tool assembly is reinstated in the starting
position by disabling the electromagnets and dismounting the electromagnetic
anchor from its position. The motorized electromagnetic vehicle is now ready to
25 move in various locations. The motorized electromagnetic vehicle is equipped with
an image recording system. In an example, the image recording system may include
at least three monocular image recording systems and at least one stereo image
recording system enabled to conduct the visual inspection of defects in complex and
uneven ferromagnetic structures. The image recording system provides video feed in
30 real-time and video feed is recorded for the preparation of visual inspection reports
21
in the form of still images. If any defect like buckling, bend, or crack is found on the
structure, it can be saved in an image format and the details of the defect are
described. The stereo image recording system provides depth to the image and is
used for measuring the size of the defect that is recorded for future reference as well.
5
Further, the robotic manipulator and tool assembly of the motorized electromagnetic
vehicle is provided with a Light Detection and Ranging (LIDAR) tool to enable the
creation of a three-dimensional (3D) map of the area of operation for the efficient
detection of obstacles and to avoid the obstacles. With the help of the LIDAR, the
10 robotic manipulator and tool assembly can move in semi-autonomous or
autonomous mode. The motion of the motorized electromagnetic vehicle can be
controlled remotely by a long-range mesh router. For underwater application, it is
connected with a tether cable for communication while the steering & robotic
manipulator operation is controlled by a joystick that operates in connection with the
15 long-range mesh router to enable the remote-controlled movement of the motorized
electromagnetic vehicle across the surface of complex and uneven ferromagnetic
structures.
FIG. 6 illustrates a line diagram of the method of crossing a 90-degree convex bend
20 when moving upwards from horizontal direction to vertical direction using the
motorized electromagnetic vehicle [600], in accordance with exemplary embodiment
of the present disclosure. FIG. 6A illustrates a schematic diagram of the method of
crossing a 90-degree convex bend when moving upwards from horizontal direction
to vertical direction using the motorized electromagnetic vehicle [600A], in
25 accordance with exemplary embodiment of the present disclosure. In order to avoid
the duplicity of the information, the description of the FIG. 6 and FIG. 6A has been
explained in conjunction with each other.
In an exemplary embodiment, the method of crossing the 90-degree convex bend
30 from the lower plane [608] to the upper plane [604] by the motorized
22
electromagnetic vehicle is disclosed. The motorized electromagnetic vehicle on
reaching the edge [606] of the complex and uneven ferromagnetic structure disables
the smart actuator of the rear wheel [610] and the motorized electromagnetic vehicle
is propelled by the smart actuator of the front wheel [602] only. After crossing the
5 edge [606] by the front wheel, the smart actuator of the rear wheel [610] is enabled
again and the motorized electromagnetic vehicle is propelled by the combined use of
smart actuators associated with the front wheel [602] and rear wheel [610].
In another exemplary embodiment, the method of crossing the 90-degree convex
10 bend from the upper plane [604] to the lower plane [608] by the motorized
electromagnetic vehicle is disclosed. The motorized electromagnetic vehicle on
reaching the edge [606] of the complex and uneven ferromagnetic structure disables
the smart actuator in the front wheel [602] and the motorized electromagnetic
vehicle is propelled by the smart actuator of the rear wheel [602] only. After crossing
15 the edge [606], the smart actuator of the front wheel [602] is enabled again and the
motorized electromagnetic vehicle is propelled by the combined use of smart
actuators situated in the front wheel [602] and rear wheel [610].
FIG. 7 illustrates a schematic diagram of the possible variations of the motorized
20 electromagnetic vehicle [700], in accordance with exemplary embodiment of the
present disclosure. As illustrated in the figure, the framework of this version of the
motorized electromagnetic vehicle is supported with at least four castor wheels [702,
704] at the four corner positions. The four castor wheels at the corners with hard
suspension as illustrated in the present embodiment of the disclosure provides
25 stability to the motorized electromagnetic vehicle to use the robotic arm and to move
across convex bends of angles up to 90 degrees.
In an exemplary embodiment, the motorized electromagnetic vehicle is enabled for
underwater inspection. The motorized electromagnetic vehicle, the motor is made
30 waterproof by a mechanical seal and thermal management and is done by immersion
23
cooling of the motors and other electronic components. Further, 3M Novec 7300 or
Opteon SF10 is used for the elimination of excessive heat from the motor and
processors of the motorized electromagnetic vehicle, which then passes through the
radiator.
5
In another exemplary embodiment, the motorized electromagnetic vehicle, instead
of using only one steering gear, both the forward and the rear wheel assembly is
operatively coupled with twin steering gear [706,708] to enable greater
manoeuvrability and better lateral movement. Further, the several types of payloads
10 can be mounted on it like Electromagnetic Acoustic Transducer (EMAT) sensors,
welding holders, and the like.
FIG. 8 illustrates a schematic diagram of the waterproof smart actuator for the
underwater operation of the motorized electromagnetic vehicle [800], in accordance
15 with exemplary embodiment of the present disclosure. The figure shows the
underwater operation of the motorized electromagnetic vehicle for the underwater
inspection of the ships and the maritime structures. The smart actuators with
integrated electronics have been made waterproof for the underwater operation of
the motorized electromagnetic vehicle. These actuators have been tested at a
20 pressure of at least 10 bar which makes them suitable for operation up to 100 meters
deep in water for the visual inspection, surface preparation, and surface testing of
ferromagnetic structures underwater.
In an exemplary embodiment, as illustrated in the figure, the smart actuator is
25 housed in a steel casing [851], and the cable side of the smart actuator is sealed with
a cover plate [852] with an O-Ring [860] and a plurality of bolts [855]. The cover plate
is connected with a 9-pin male waterproof connector [853] for power and
communication as well as with a 9-pin female connector [854]. The sealing between
the rotary shaft [808] and the smart actuator [842] is done by using a mechanical seal
30 for which both the rotary and stationary faces are made of tungsten carbide (WC).
24
The use of tungsten carbide for both the faces ensures the durability of operation in
the marine environment. The mechanical seal is made of a stationary face [857]
which is sealed against the casing [851] using the O-Ring [858]. The rotary face [861]
is compressed against the stationary face [857] with a spring [856], that provides a
5 positive sealing.
In another exemplary embodiment, the motorized electromagnetic vehicle is capable
of underwater operation, where the smart actuator may be enclosed using at least
one of a plurality of sealing assembly. The sealing assembly protects the smart
10 actuator of the motorized electromagnetic vehicle from getting in contact with water
and thereby enabling underwater operation. In an example, the plurality of sealing
assembly includes but is not limited to mechanical sealing assembly like the one
illustrated in FIG. 8, oil-based sealing assembly, rubber-based sealing assembly, and
the like.
15
In an exemplary embodiment, for the thermal management of the motors and
electronics of the motorized electromagnetic vehicle, the casing [851] is filled with
the immersion cooling fluid Opteon SF10. Opteon SF10 has a boiling point of 110-
degree Celsius, liquid thermal conductivity of 0.077 W/m-K, and dielectric constant
20 of 5.48 at 1 kHz. These properties make it suitable for the immersion cooling as it can
safely be in contact with the electronics and the motor windings without triggering a
short circuit. In another exemplary embodiment, the at least one immersion cooling
fluid may be used for the thermal management in the motorized electromagnetic
vehicle. In an example, the at least one immersion fluid include but is not limited to
25 Opteon SF10, 3M Novec 7300, and the like.
By employing this arrangement, the successful waterproofing and thermal
management can be achieved for the underwater operation of the motorized
electromagnetic vehicle.
30
25
FIG. 9 illustrates an exemplary method flow diagram for inspection and nondestructive testing of complex and uneven ferromagnetic structures using a
motorized electromagnetic vehicle, in accordance with an embodiment of the
present disclosure. The method begins at step 902 with the need for inspection and
5 non-destructive testing of complex and uneven ferromagnetic structures.
At step 904, the method includes steering the motorized electromagnetic vehicle for
visual inspection and non-destructive testing of complex and uneven ferromagnetic
structure using a magnetic wheel assembly. In an example, the motorized
10 electromagnetic vehicle is controlled remotely using a remote-control station. The
remote-control station is connected to motorized electromagnetic vehicle using a
long-range mesh router for controlling in terrestrial operations. The remote-control
station is connected to motorized electromagnetic vehicle using a tether cable for
controlling underwater operations. The steering movement corresponds to the
15 translational movement of the motorized electromagnetic vehicle enabled using
smart actuators present in the magnetic wheel assembly.
At step 906, the method includes holding the motorized electromagnetic vehicle on
surface of the complex and uneven ferromagnetic structure using an electromagnetic
20 anchor arrangement. In an example, the motorized electromagnetic vehicle is firmly
secured to the complex and uneven ferromagnetic structure using an
electromagnetic anchor arrangement. The motorized electromagnetic vehicle is
thereby capable of performing inspection and non-destructive testing using tool
assembly without slipping or falling.
25
At step 908, the method includes cleaning the surface of the complex and uneven
ferromagnetic structure for the non-destructive testing using a robotic arm
manipulator and a tool assembly. In an example, the tool assembly includes surface
preparation tools such as an electric impact needle descaler, grinding tool, and the
30 like. The tool assembly further includes inspection tool that may include Ultrasonic
26
Thickness(UT) gauge, ultrasonic scanner, eddy current tester for crack detection, and
the like.
At step 910, the method includes performing the non-destructive testing and
5 inspection of the surface of the complex and uneven ferromagnetic structure using
the robotic arm manipulator, the tool assembly, and at least one image recording
system of the motorized electronic vehicle. In an example, the image recording
system includes at least three monocular image recording systems, at least one
stereo image recording system to record data associated with the inspection.
10
In accordance with an exemplary embodiment, the method further includes enabling
a movement of the motorized electromagnetic vehicle to cross a pre-defined angle
range of a convex bend. The method includes deactivating a smart actuator
associated with the at least one rear wheel assembly in an event the at least one front
15 wheel assembly reaches to an edge of the convex bend, wherein deactivation of the
smart actuator starts a crawling movement of the at least one rear wheel assembly
based on a forward movement of the at least one front wheel assembly. Next, the
method includes crossing the convex bend by the at least one front wheel assembly
using a forward movement of the at least one front wheel assembly. In an example,
20 the smart actuator associated with the front wheel assembly is used to enable the
movement of the motorized electromagnetic vehicle and to cross the convex bend.
Next, the method includes re-activating the smart actuator associated with the at
least one rear wheel assembly. Thereafter, the method includes crossing the convex
bend by the at least one rear wheel assembly to enable the crossing of the pre25 defined angle range of the convex bend by the motorized electromagnetic vehicle.
In accordance with an exemplary embodiment, the pre-defined angle range of the
convex bend corresponds to a range of at most 90 degrees. In an embodiment, the
pre-defined angle range of the convex bend may vary.
30
27
In accordance with an exemplary embodiment, the method further includes
embedding at least one layer of rubber lining on at least one magnetic front wheel
assembly and at least one magnetic rear wheel assembly of the magnetic wheel
assembly to prevent slippery movement of the motorized electromagnetic vehicle,
5 wherein the at least one layer of rubber lining prevents sticking of metal particles on
the magnetic wheel assembly.
The method terminates at step 912 after inspection and non-destructive testing of
complex and uneven ferromagnetic structures using a motorized electromagnetic
10 vehicle.
As is evident from the above disclosure, the present solution provides significant
technical advancement over the existing solutions by providing a method and system
for the visual inspection of complex and uneven ferromagnetic structures. The factors
providing the technical advancements in the present disclosure over the existing
15 solutions include but are not limited to:
 The motorized electromagnetic vehicle, as disclosed herein, is provided with
magnetic wheel assembly with a bi-wheel design implemented through a
front wheel assembly and a rear wheel assembly. The segmentary joint
connected to the at least one front chassis and the at least one rear chassis
20 provide flexibility to the motorized electromagnetic vehicle to adapt to the
uneven and complex surfaces. Further, the method related to crossing the
convex bend of at most 90 degrees through the alternate activation and
deactivation of the smart actuator associated with the at least one rear wheel
assembly enables the movement and crossing of the convex bends by the
25 motorized electromagnetic vehicle.
 The motorized electromagnetic vehicle, as disclosed herein, is provided with
a robotic arm manipulator and tool assembly to perform surface preparation
and non-destructive testing of the complex and uneven ferromagnetic
structures. The plurality of actuators provided in the robotic arm manipulator
28
allow the installation of multiple tools on the tool assembly at the same time.
 The motorized electromagnetic vehicle, as disclosed herein, is provided with
rubber lining embedded in the grooves provided on the washer of the
magnetic wheel assembly. The rubber lining prevents sticking of fine
5 ferromagnetic particles to the magnetic wheel assembly thereby enhancing
the stability of the motorized electromagnetic vehicle.
 The motorized electromagnetic vehicle, as disclosed herein, has underwater
operating capabilities and performs inspection to a depth of about 100 m in
water. Underwater operation capability is achieved by providing waterproof
10 mechanical sealing of electronic components. Additionally, smart actuator is
filled with the immersion cooling fluid like Opteon SF-10 for heat
management and elimination of excess heat from the smart actuators of the
motorized electromagnetic vehicle.
 The stability of the motorized electromagnetic vehicle, as disclosed herein, is
15 enhanced by providing electromagnetic anchor arrangement. The
electromagnetic anchor arrangement is used to provide grip to the motorized
electromagnetic vehicle on complex and uneven ferromagnetic structures.
The enhanced stability facilitates the movement of the robotic arm
manipulator and tool assembly without encountering the motorized
20 electromagnetic vehicle falling over.
 The present disclosure relies upon plurality of Mu-metal sheets as the
covering material for housing electronic components of the motorized
electromagnetic vehicle. The material is preferred herein due to the capability
to provide protection to the electronic components of the motorized
25 electromagnetic vehicle from electromagnetic interference. The application
of a plurality of Mu-metal sheets enhances the performance and the
durability of electronic components used in motorized electromagnetic
vehicles.
29
Therefore, as disclosed in the present disclosure, the present invention is helpful to
the user and hence an overall improved user experience is realized.
5 While considerable emphasis has been placed herein on the disclosed embodiments,
it will be appreciated that many embodiments can be made and that many changes
can be made to the embodiments without departing from the principles of the
present disclosure. These and other changes in the embodiments of the present
disclosure will be apparent to those skilled in the art, whereby it is to be understood
10 that the foregoing descriptive matter to be implemented is illustrative and nonlimiting.

We Claim:
1. A motorized electromagnetic vehicle [100] for inspection of complex surfaces
and non-destructive testing of ferromagnetic structures comprising:
- a magnetic wheel assembly [102], [104];
5 - a robotic arm manipulator [106];
- a tool assembly [108] connected to the robotic arm manipulator;
- an electromagnetic anchor arrangement [110];
- a chassis assembly comprising at least one front chassis [112] and at least
one rear chassis [114];
10 - a segmentary joint [116]; and
- a steering assembly [118],
wherein the motorized electromagnetic vehicle [100] is designed to cross a
pre-defined angle range of a convex bend.
2. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein
15 the magnetic wheel assembly comprises:
- at least one magnetic front wheel assembly [102];
- at least one magnetic rear wheel assembly [104];
- at least one smart actuator [242]; and
- a plurality of ball bearings [210],
20 wherein the at least one smart actuator [242] is connected with at least one
processing unit to enable the crossing of the pre-defined angle range of the
convex bend, wherein the at least one processing unit is configured to:
31
- deactivate the at least one smart actuator [242] associated with the at
least one rear wheel assembly [104] in an event the at least one front
wheel assembly [102] reaches to an edge of the convex bend, wherein
deactivation of the at least one smart actuator [242] starts a crawling
5 movement of the at least one rear wheel assembly [104] based on a
forward movement of the at least one front wheel assembly [102];
- enable crossing of the convex bend by the at least one front wheel
assembly [102] using the forward movement of the at least one front
wheel assembly [102];
10 - re-activate the at least one smart actuator [242] associated with the at
least one rear wheel assembly [104]; and
- enable crossing of the convex bend by the at least one rear wheel
assembly [104] for a complete crossing of the pre-defined angle range of
the convex bend by the motorized electromagnetic vehicle.
15
3. The motorized electromagnetic vehicle [100] as claimed in claim 2, wherein
the at least one magnetic front wheel assembly [102] and the at least one
magnetic rear wheel assembly [104] are embedded with at least one layer of
rubber lining to prevent slippery movement of the motorized electromagnetic
20 vehicle, wherein the at least one layer of rubber lining prevent sticking of
metal particles on the magnetic wheel assembly.
32
4. The motorized electronic vehicle [100] as claimed in claim 1, wherein the
segmentary joint [116] connected to the at least one front chassis [112] and
the at least one rear chassis [114] provide flexibility to the motorized
electromagnetic vehicle to adapt to the uneven and the complex surfaces.
5 5. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein
the pre-defined angle range of the convex bend corresponds to a range of at
most 90 degrees.
6. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein
the robotic arm manipulator [106] is connected to a plurality of surface
10 preparation tools and a plurality of inspection tools to conduct inspection and
non-destructive testing of the complex and uneven ferromagnetic structure.
7. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein
the motorized electromagnetic vehicle comprises a plurality of Mu metal
sheets positioned around the front chassis [112] and the rear chassis [114] to
15 prevent a plurality of components associated with the motorized
electromagnetic vehicle from magnetic interference.
8. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein
the robotic arm manipulator [106] comprises at least two high torque
actuator and at least three low torque actuator, wherein the high torque
20 actuator comprises a Base Actuator [506], a Shoulder Actuator [524], and the
low torque actuator comprises an Elbow Actuator [516], a Wrist Actuator
[522] and a Tool Positioning Actuator [530].
33
9. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein
the segment rotary joint [116] comprises:
- a segment housing [328] connected to a rear frame [338];
- a segment rotor [330] connected to a forward frame [336]; and
5 - a segment stopper [332] connected to the segment housing [328] with a
plurality of bolts [334].
10. The motorized electromagnetic vehicle [100] as claimed in claim 2, wherein
the at least one smart actuator [242] is enclosed using at least one of a
plurality of sealing assembly and at least one immersion cooling fluid to
10 enable underwater operation of the motorized electromagnetic vehicle.
11. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein
the electromagnetic anchor arrangement [110] comprises:
- at least two electromagnets [402, 404];
- a plurality of chrome rods [406, 408];
15 - a plurality of linear bearings [410, 412];
- a lead screw [414] positioned with a lead screw nut [416];
- a small pulley [420] coupled with a big pulley [422];
- at least one timing belt [426];
- at least one actuator [428]; and
20 - a plurality of bearings [430] fitted inside the bearing housing [432],
wherein the electromagnetic anchor arrangement [110] of the motorized
electromagnetic vehicle [100] facilitates holding the motorized
34
electromagnetic vehicle to the surface of the complex and uneven
ferromagnetic structure.
12. The motorized electromagnetic vehicle [100] as claimed in claim 1, wherein
the motorized electromagnetic vehicle is controlled remotely using a remote5 control station, wherein the remote-control station is connected with:
- a long-range mesh router for controlling the operation of the motorized
electromagnetic vehicle on terrestrial, and
- a tether cable for controlling underwater operations of the motorized
electromagnetic vehicle.
10 13. A method for inspection and non-destructive testing of complex and uneven
ferromagnetic structures using a motorized electromagnetic vehicle [100], the
method comprising:
- steering the motorized electromagnetic vehicle [100] for inspection and
non-destructive testing of complex and uneven ferromagnetic structure
15 using a magnetic wheel assembly [102], [104];
- holding the motorized electromagnetic vehicle on surface of the complex
and uneven ferromagnetic structure using an electromagnetic anchor
arrangement [110];
- cleaning the surface of the complex and uneven ferromagnetic structure
20 for the non-destructive testing using a robotic arm manipulator [106] and
a tool assembly [108]; and
35
- performing the non-destructive testing and inspection of the surface of
the complex and uneven ferromagnetic structure using the robotic arm
manipulator [106], the tool assembly [108], and at least one image
recording system of the motorized electronic vehicle.
5 14. The method as claimed in claim 13 further comprises enabling a movement
of the motorized electromagnetic vehicle [100] to cross a pre-defined angle
range of a convex bend, wherein the enabling the movement of the motorized
electromagnetic vehicle comprises:
- deactivating a smart actuator associated with the at least one rear wheel
10 assembly in an event the at least one front wheel assembly reaches to an
edge of the convex bend, wherein deactivation of the smart actuator
starts a crawling movement of the at least one rear wheel assembly based
on a forward movement of the at least one front wheel assembly;
- crossing the convex bend by the at least one front wheel assembly using
15 the forward movement of the at least one front wheel assembly; and
- re-activating the smart actuator associated with the at least one rear
wheel assembly; and
- crossing the convex bend by the at least one rear wheel assembly to
enable the crossing of the pre-defined angle range of the convex bend by
20 the motorized electromagnetic vehicle.
15. The method as claimed in claim 14, wherein the pre-defined angle range of
the convex bend corresponds to a range of at most 90 degrees.
36
16. The method as claimed in claim 13, wherein the method comprises
embedding at least one layer of rubber lining on at least one magnetic front
wheel assembly [102] and at least one magnetic rear wheel assembly [104] of
the magnetic wheel assembly, wherein the at least one layer of rubber lining
5 prevents slippery movement of the motorized electromagnetic vehicle by
preventing a sticking of metal particles on the magnetic wheel assembly.