Nowadays, inspection process planning (IPP) for large volume metrology (LVM) attracts increasing attention in manufacturing and assembly industries such as aerospace and automotive, where large and complex assemblies and fabrications with complex surfaces are employed. Inspection is conventionally considered as a quality control manner. But there is changing shift to processes that are more related to the early design stage aiming to increase product performance and reduce costs by automation and elimination of rework. This is especially evident in the standardisation and implementation of Geometric Dimensioning and Tolerancing (GD&T) of new products and systems at the design stage. This study proposes a GD&T based systematic framework for the IPP of LVM systems within a digital environment. Orientating to solve the “what to measure” and “how to measure” problems in IPP, the prototype system has seven functional core modules including: tolerance feature analysis, instrument selection, inspection point selection, accessibility and visibility analysis, instrument setup and configuration, clustering analysis and measurement sequencing. An optimized inspection plan is output for the designer to evaluate the product design as well as for guiding the metrologist and process planner to conduct the inspection process. Heuristic rules, evolutionary algorithms and modern computational graphic techniques have been adopted to facilitate the supported functions. Coupled with state of art metrology systems, metrology and CAD software, the framework is able to work effectively and efficiently by means of incorporating international standards and industrial best practice. It is the first attempt to successfully minimise manual activities in the planning process for LVM systems, which results in improved efficiency, enhanced decision making and a better inspection plan overall. Two case studies have been conducted to validate the functionalities of the prototype system.

The 21st century demand for innovation is leading towards a revolution in the way products are perceived. This will have a major impact on manufacturing technologies as current product innovation is constrained by the available manufacturing processes, which function independently. One of the most significant developments is the emergence of hybrid manufacturing technologies integrating various individual manufacturing processes. Hybrid processes utilise the advantages of the independent processes whilst minimising their weaknesses as well as extending application areas. Despite the fact that the drawbacks of the individual processes have been significantly reduced, the application of state of the art hybrid technology has always been constrained by the capabilities of their constituent processes either from technical limitations or production costs. In particular, it is virtually impossible to machine complex parts due to limited cutting tool accessibility. By contrast, additive manufacturing (AM) techniques completely solve the tool accessibility issue, but this increased flexibility and automation is achieved by compromising on part accuracy and surface quality. Furthermore, the shape and size of raw materials have to be specific for each hybrid process. More importantly, process planning methods capable of effectively utilising manufacturing resources for hybrid processes are highly limited. In this research, a hybrid process, entitled iAtractive, combining additive, subtractive and inspection processes is proposed. An experimental methodology has been designed and implemented, by which a generative reactionary process planning algorithm (GRP2A) and feature-based decision-making logic (FDL) is developed. GRP2A enables a complex part to be accurately manufactured as one complete unit in the shortest production time possible. FDL provides a number of manufacturing strategies, allowing existing parts to be reused and transformed into final parts with additional features and functionalities. A series of case studies have been manufactured from zero and existing parts, demonstrating the efficacy of the iAtractive process and the developed GRP2A and FDL, which are based on a manual process. The major contribution to knowledge is the new vision for a hybrid process, which is not constrained by the capability of the individual processes and raw material in terms of shape and size. It has been demonstrated that the hybrid process together with GRP2A and FDL provides an effective solution to flexibly and accurately manufacture complex part geometries as well as remanufacture existing parts.

This thesis presents a real-time automated building progress monitoring solution for indoor environments using a mobile device. Such a system could prompt accurate and timely assessment of work progress that would allow managers to make adjustments and minimise both time and cost overrun when deviations from the schedule occur. Although many researchers have proposed approaches for progress monitoring in outdoor scenes, these cannot perform in real-time and shift into the complex interior environment. Research efforts for indoor environments are not fully automated and lead to errors in more complex scenes. Systems based on mobile devices could potentially enhance the inspection process and reduce the required time by allowing the inspector to acquire progress data by simply walking around the site. The main challenge of these systems is the tracking of the pose of the camera to achieve accurate alignment between the 3D design model and the real-world scene. Methods for estimating the user’s pose rely on a) tags on each target of interest, which require additional time and cost for installation and maintenance; b) pre-selected user locations, which restricts the user to those locations only; or c) GPS on the augmented reality headset, which only applies to outdoor inspections. Additionally, current mobile-based inspection systems do not perform any comparison between the captured as-built and the as-planned data. In this research, different marker-less Augmented Reality (AR) potential methods were implemented and tested for finding the most robust tracking solution. The Microsoft HoloLens was found to be the top performer for tracking the user’s pose and for overall user-experience. Next, a semi-automated method was developed for initially registering the 3D model to the real environment by exploiting information from detected floor and wall surfaces. Results showed that this method reduces the time of the initial registration by 58%. Having the 3D model aligned to the real environment and knowing the pose of the camera at every moment, an automated method was developed that exploits the captured as-built surface mesh data from the mobile device, compares it against the 3D design model and identifies in real-time whether an object has been built according to plan. Different parameters were tested for finding the optimum combination based on the current quality of mesh data. If quality of mesh data changes, then new parameters should be explored. Finally, the proposed solution was tested in real site conditions resulting in 76.6% precision, 100.0% recall, and 83.5% accuracy.

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Guided Wave Testing (GWT) is a relatively new development in non-destructive testing. Conventional Ultrasonic Testing (UT) methods are operated at high frequencies (MHz) and are capable of detecting very small (down to micrometre-scale) flaws within a range of millimetres from a transducer. GWT, however, is carried out at lower frequencies (kHz) and is capable of highlighting the position of volumetric structural detail and discontinuities, such as gross corrosion at a minimum of 9% of the cross-sectional area, tens of metres from a test location. Conventional ultrasonic testing relies on the transmission of bulk waves whereas GWT employs so-called ultrasonic guided waves (UGW). To simplify UGW inspections, several tests are conducted sequentially at a range of different excitation frequencies. The frequency bandwidth of each of these tests needs to be controlled to avoid complexities caused by the frequency dependent nature of the propagation of guided waves. This gives rise to the current GWT inspection procedure, where a number of different narrowband tests are conducted at several distinct frequencies. It is also found that different test circumstances (such as pipe coating or defect type) are inspected more easily with certain excitation frequencies than with others - and the optimum frequency can not always be predicted ahead of time. Thus, where time allows it is often beneficial to carry out a frequency sweep, whereby a large range of excitation frequencies are incrementally generated - for example, from 20 to 80kHz in 1kHz steps. This research proposes a novel approach to the existing pipeline inspection procedure by utilising the information contained within a broadband response. The overarching proposition given by this research is that the current collection procedure be entirely rewritten. This thesis will present ideas related to every area of the inspection procedure beginning with the tuning of excitation signals and concluding with recommendations on how tooling and excitation configuration can be modified to further optimise the technique for broadband excitation.

A principal forma de transporte de petróleo e derivados, entre outras substâncias, são os dutos, e um dos processos críticos relacionados é a sua inspeção periódica, que é necessária e obrigatória, de alto custo devido à sua complexidade, e que na maioria das vezes são realizadas manualmente, em procedimentos demorados, pouco confiáveis e insalubres devido ao meio e aos riscos a que o trabalhador é exposto. Este trabalho tem o objetivo de testar diversas aplicações e situações de um sistema de inspeção de dutos robótico desenvolvido. O interesse de observação foi a praticidade e facilidade de montagem e desmontagem do equipamento sobre a tubulação, a agilidade dos graus de liberdade propostos para o sistema, a flexibilidade do equipamento para utilização de diferentes métodos de inspeção, a rapidez e confiabilidade dos resultados de inspeção por ultrassom para varredura de espessuras em busca de corrosão generalizada interna de uma tubulação e a capacidade de precisão e resolução desta inspeção por ultrassom. Para abordar estes pontos, foram realizados uma série de testes, inicialmente para verificação do bom funcionamento dos graus de liberdade do sistema, e posteriormente com métodos diferenciados de inspeção, como testes para medição geométrica externa de uma tubulação, testes com sistemas de ultrassom embarcado em laboratório e em campo com diferentes malhas de inspeção e com um ou múltiplos cabeçotes, e para diferentes tubulações e formatos de redução de espessuras de parede na tubulação. / The main way for transporting petroleum and substances alike is through ducts, and one of the most critic processes involved is the periodic inspection, wich is necessary and mandatory, with a high cost due to its complexity, and, in most cases, done manually in long time consuming procedures and with little reliability and high risk for the workers involved. This work is intended to test various situations of a robotic inspection system developed. The observation interest was the practicity and easiness of assembling and disassembling the equipment on the pipes, the agility of degrees of freedom proposed for the system, the flexibility of the equipment for the use in different methods of inspection, the quickness and reliability of the results by ultrasound for scanning different thicknesses of a duct in search of "generalized internal corrosion" and the level of precision and resolution of this ultrasound scan. To approach this topics, a series of test were conducted, at first to check if the degrees of freedom of the system were working as intended and afterwards with different methods of inspection, such as external geometric measurements of the pipes, tests with onboard ultrasound systems in lab and on the field with different inspection grades and with one or multiple ultrasound sensors, and for different kinds of pipes and thickness reduction shapes of the pipe's walls.

Bridges are a vitally important part of modern infrastructure. Their condition needs to be monitored on a continuous basis in order to ensure their safety and functionality. Teams of engineers visually inspect more than half a million bridges per year in the US and the EU. There is clear evidence to suggest that they are not able to meet all bridge inspection guideline requirements. In addition, the format and storage of inspection reports varies considerably across authorities because of the lack of standardisation. The availability of a comprehensive and open digital representation of the data involved in and required for bridge inspection is an indispensable necessity for exploiting the full potential of modern digital technologies like big data exploration, artificial intelligence and database technologies. A thorough understanding of bridge inspection information requirements for reinforced concrete bridges is needed as basis for overcoming the stated problem. This work starts with a bridge inspection guideline analysis, from which an information model and a candidate binding to Industry Foundation Classes (IFC) is developed. The resulting bridge model can fully store inspection information in a standardised way which makes it easily shareable and comparable between users and standards. Then, two inspection stages for locating and classifying visual concrete defects are devised, implemented and benchmarked to support the bridge inspection process: In a first stage, healthy concrete surfaces are located and disregarded for further inspection. In a second hierarchical classification stage, each of the remaining potentially unhealthy surface areas is classified into a specific defect type in accordance with bridge inspection guidelines. The first stage achieves a search space reduction for a subsequent defect type classification of over 90% with a risk of missing a defect patch of less than 10%. The second stage identifies the correct defect type to a potentially unhealthy surface area with a probability of 85%. A prototypical implementation serves as a proof of concept. This work closes the gap between requirements arising from established inspection guidelines, the demand for holistic data models which has recently become known as "digital twin", and methods for automatically identifying and measuring specific defect classes on small scale images. It is of great significance for bridge inspectors, bridge owners and authorities as they now have more suitable data models at hand to store, view and manage maintenance information on bridges including defect location and defect types which are being retrieved automatically. With these developments, a foundation is available for a complete revision of bridge inspection processes on a modern, digital basis.

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abstract: This thesis presents the design and testing of a soft robotic device for water utility pipeline inspection. The preliminary findings of this new approach to conventional methods of pipe inspection demonstrate that a soft inflatable robot can successfully traverse the interior space of a range of diameter pipes using pneumatic and without the need to adjust rigid, mechanical components. The robot utilizes inflatable soft actuators with an adjustable radius which, when pressurized, can provide a radial force, effectively anchoring the device in place. Additional soft inflatable actuators translate forces along the center axis of the device which creates forward locomotion when used in conjunction with the radial actuation. Furthermore, a bio-inspired control algorithm for locomotion allows the robot to maneuver through a pipe by mimicking the peristaltic gait of an inchworm. This thesis provides an examination and evaluation of the structure and behavior of the inflatable actuators through computational modeling of the material and design, as well as the experimental data of the forces and displacements generated by the actuators. The theoretical results are contrasted with/against experimental data utilizing a physical prototype of the soft robot. The design is anticipated to enable compliant robots to conform to the space offered to them and overcome occlusions from accumulated solids found in pipes. The intent of the device is to be used for inspecting existing pipelines owned and operated by Salt River Project, a Phoenix-area water and electricity utility provider. / Dissertation/Thesis / Masters Thesis Engineering 2019