Smart Robotics in Action: A Case Study of Automated Facility Inspection

Smart Robotics in Action: A Case Study of Automated Facility Inspection Systems

In recent years the emergence of "Smart Robotics" - advanced, AI-equipped robots - has gained attention as a promising solution to labor shortages affecting the industrial sectors. Companies are leveraging these robots, whose capabilities and performance have improved dramatically, to address workforce challenges and develop new operational strategies.

Robots equipped with AI are transforming how facilities conduct equipment inspections and monitoring through automated anomaly detection. By independently navigating facilities and evaluating equipment, these robots are taking over tasks traditionally performed by human inspectors, significantly reducing the number of person hours required. This combination of active sensing technology, real-time vibration analysis, and autonomous navigation is a breakthrough for organizations seeking to implement robotics-driven operational changes, especially those focused on automated facility inspections and digital transformation.

The Evolution of Robots and AI

This new generation of AI-powered "Smart Robotics," is being developed by a wide range of organizations, from major corporations to startups. With such a diverse and promising array of applications, the Smart Robotics market is projected to expand significantly, with particularly strong adoption in healthcare, automotive, and manufacturing sectors.

By integrating AI’s inferential capabilities - where the system predicts unknown outcomes based on learned data - robots are now able to make informed decisions and perform increasingly complex tasks with simple instructions. Additionally, breakthroughs in computer vision have enabled robots to detect and avoid obstacles more effectively, significantly improving their safety and utility.

NTT DATA aims to improve the operational efficiency and productivity of manufacturing enterprises facing labor shortages by introducing Smart Robotics to ease the burden on workers. By assigning specific tasks to robots, we reduce the need for dangerous or repetitive tasks to be performed by humans, allowing personnel to focus on tasks that require human expertise. Robots are also well-suited for hazardous or physically demanding tasks, which can take a toll on workers. Smart Robotics reduce the physical and mental strain on employees, enhance the work environment, and ultimately improve employee satisfaction.

NTT DATA's Case Studies

Our team at NTT DATA is pioneering the automation of facility inspections and anomaly detection through Smart Robotics. In manufacturing facilities, where regular equipment inspections are crucial, the scale of inspection requirements can be overwhelming. Also, inspecting areas that are high, low, or confined can pose significant safety risks.

We've developed a robotic system for facility inspections using active sensing in collaboration with Mitsubishi Chemical Corporation. This partnership combines Mitsubishi Chemical's expertise in factory anomaly detection with NTT DATA's robotics and computer vision capabilities.

Our solution employs a quadruped dog-like robot, chosen for its lightweight design, stable movement, and advanced sensing capabilities.

Technical Implementation

Figure 2: Interaction between Robot and PC

In the use case of pipeline inspection, a robot can autonomously access areas to detect abnormal vibrations. The system utilizes AR (Augmented Reality) markers with embedded ID and position information to guide the robot's navigation. The robot can patrol designated areas and adjust its position in real-time based on marker information. Analysis is performed using an on-board computer, allowing for immediate data processing and remote monitoring. The system is capable of processing information from multiple inspection targets simultaneously, maximizing efficiency during inspections.

The robot conducts a comprehensive vibration analysis along both horizontal and vertical axes, measuring amplitude and frequency data. Then, through advanced processing, it creates enhanced video footage that emphasizes pipe movements, making subtle vibrations more visible to operators who can then make informed decisions about maintenance needs.

Our testing program compared the performance characteristics of vibrating and non-vibrating pipes. When measuring horizontal movement, vibrating pipes demonstrated a peak-to-peak amplitude of 0.34mm, while stable pipes showed only 0.12mm of movement. Frequency analysis revealed consistent oscillations at 5.27Hz in vibrating pipes, providing clear differentiation from stable configurations. In vertical measurements, we observed a peak-to-peak amplitude of 0.25mm with a frequency of 6.15Hz. All these results were subsequently validated through comparison with traditional accelerometer measurements, confirming the accuracy of our robotic inspection system.

Figure 3: Inspection Area 1 - Vertical Pipes Analysis Results

Figure 3: Inspection Area 1 - Horizontal Pipes Analysis Results

Benefits of Robotic Inspection

The robotic inspection systems provide numerous advantages over traditional methods. Human-led inspections can require extensive time and effort, particularly when moving between inspection targets within a large facility and setting up the necessary equipment. Robots, however, can automatically adjust to targets, calculating vibration levels from video data without the need for complicated pre-setup procedures.

Although fixed sensors or cameras can also be used for facility inspections, they come with higher communication and maintenance costs, and limitations in where they can be installed. In contrast, robots, can be purpose built for navigating tight or hard-to-reach areas, making them a more cost-effective and versatile solution.

Robots also have the advantage of detecting events that might go unnoticed by human workers and provide a swift response. Detecting and visualizing small vibrations in pipelines, for example, can help identify potential issues that could lead to accidents or malfunctions. Indeed, by comparing current data with historical records, robots can identify unusual events early on and send emergency alerts to operators, including detailed information about the location and severity of the anomaly.

Future Developments

Our development roadmap includes significant enhancements to the current system. We are working to implement comprehensive remote operation capabilities with real-time video streaming, allowing operators to monitor facilities from safe, comfortable locations. This initiative includes integration with NTT's Innovative Optical and Wireless Network (IOWN) infrastructure to ensure reliable, high-speed data transmission.

We are also expanding the system's sensing capabilities through the integration of advanced equipment. High-speed cameras will enable more detailed vibration analysis, while directional microphones will add sound analysis to the robot's diagnostic capabilities. Additional sensors for thermal imaging and gas detection will further expand the range of anomalies the system can identify.

By leveraging Smart Robotics and AI technology, we're not only improving workplace safety and efficiency but also enabling more sophisticated monitoring and maintenance capabilities through manufacturing automation. We're proud to say that our ongoing collaboration with Mitsubishi Chemical and other industry partners continues to drive innovation in this field.