Remote scanning and detection apparatus and method

• US 10,576,907 B2
• Filed: 06/29/2016
• Issued: 03/03/2020
• Est. Priority Date: 05/13/2014
• Status: Active Grant

• Current Assignee: GSE Technologies, LLC
• Original Assignee: GSE Technologies, LLC
• Inventors: Simula, Glen Raymond, Howard, Gary Bryan
• Primary Examiner(s): Kim, Hee-Yong
• Application Number:
  US15/196,826
• Publication Number:
  US 20160350907A1
• Time in Patent Office: 1,343 Days
• Field of Search: 348128
• CPC Class Codes: B60R 11/04 Mounting of cameras operative during drive; Arrangement of controls thereof relative to the vehicle
• CPC Class Codes: B60R 2011/004 outside the vehicle
• CPC Class Codes: G01N 21/8803 Visual inspection measuring projectors G01B9/08
• CPC Class Codes: G01N 21/8851 Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges G01N21/8806 and G01N21/93 - G01N21/95692 take precedence; optical measurement of dimensions G01B11/00; optical scanning G02B26/10; image transformation G06T3/00; computerised image enhancement G06T5/00; image processing per se for flaw detection G06T7/0002
• CPC Class Codes: G01N 25/72 Investigating presence of flaws
• CPC Class Codes: G01N 33/42 Road-making materials G01N33/38 takes precedence
• CPC Class Codes: G01S 13/885 for ground probing prospecting or detecting using electromagnetic waves G01V3/12
• CPC Class Codes: G01S 17/08 for measuring distance only indirect measurement G01S17/46; active triangulation systems G01S17/48
• CPC Class Codes: G01S 19/13 Receivers

Abstract

A surface scanning apparatus attached to a movable highway vehicle, mobile equipment or a drone (collectively, “platform”) that passes over a substrate, at least some of the features of which are to be sensed and characterized. The apparatus includes a variously adaptable, complete, and ready to operate packaged kit including configured sensor suites with components selected from the group consisting of a visual scanning sensor; an infra-red scanning sensor; a ground-penetrating radar unit; a laser range finder for sensing elevation of the apparatus above the substrate; a distance sensor for measuring displacement of the apparatus from a point of origin; a position sensing unit for determining a position of the apparatus; a simultaneous trigger mechanism; a structural boom assembly attached to the platform; and a processor for digitally processing measurements and signals collected by one or more of the group of components.

Claims

1. A surface and sub-surface scanning apparatus for scanning, scoping, inspecting, analyzing, locating and quantifying defects in or on numerous types of surfaces and other structure (collectively “

substrate”

), the apparatus being adapted to be attached to a movable highway vehicle, mobile equipment or a drone (collectively, “

platform”

) that passes over the substrate, wherein at least some of the surface and sub-surface features of the substrate are to be sensed and characterized, the apparatus including

a processor for receiving and processing measurements and signals from a variously adaptable, complete, and ready to operate scanning and scoping sensor head assembly including components a-e;

a. a vertically mounted visual scanning sensor with a high-definition visible band camera for capturing surface images of a planar or undulating portion of the substrate to be evaluated, wherein the high-definition visible band camera is positioned vertically above a portion of the substrate to be scanned;

b. a vertically mounted infra-red scanning sensor with a high-definition infra-red band camera for defining a defect'"'"'s sub-surface footprint or perimeter, wherein the infra-red scanning sensor is positioned vertically above the portion of the substrate to be scanned;

c. a 3-D ground-penetrating radar unit that is mounted at an angle between −

45 degrees, vertically or +45 degrees in relation to a normal line extending from the portion of the substrate to be characterized for defining sub-surface contours of a defect in wet or dry conditions so that together the infra-red band camera and 3-D ground-penetrating radar unit are adapted to characterize the density, dimensions, volume and shape of a defect field under observation, even under a opaque barrier such as Rebar;

d. a distance sensor for sensing distance of the apparatus from an object or from the substrate spaced apart from the apparatus, the distance sensor providing a reference signal to the processor for deriving calibration and correction factors related to height and data signals received and sent by the high-definition infra-red band camera and visible band camera;

e. a global positioning unit for determining the position of the apparatus, the global positioning unit enabling real-time recording of vehicle position, speed, and direction with respect to actual position coordinates and ensuring synergistic timing between image collection and geographic positioning, the apparatus further having

a structural boom assembly attached to the platform for securing and re-positioning the scanning and scoping head assembly in real time to achieve perpendicularity, the structural boom assembly also being attachable to the front, rear or side of the platform, a distal end of the structural boom assembly being adapted to move parallel to the X, Y, or Z axes, thus enabling the high-definition visible band camera and infra-red scanning sensor to scan perpendicularly in relation to the substrate and be mounted at a desired distance from the portion of the substrate to be scanned and achieve a desired field of view (FOV); and

a simultaneous trigger mechanism that communicates with the visual band camera, the infra-red band camera, and the 3-D ground-penetrating unit so that images are captured simultaneously and communicated to the processor,

the apparatus thereby providing improved accuracy, speedy on-site integration, and rapid processing of recorded scan data and high-definition visible band imagery, thus enabling an operator to identify material defects in concrete roadways, bridge decks, airport taxiways and runways, areas of delamination, previous patch repairs, spalling and other defects so that the operator can identify and reconcile defects and anomalies presented by the infrared camera data and the high-definition visible band imagery, so that the processor is adapted to provide accurate correlation and orientation of the recorded data with respect to global positioning system (GPS) coordinates and a time stamp.

2. The surface and sub-surface scanning apparatus of claim 1, wherein the platform is attached to a vehicle that operates at nominal highway speeds and preferably at a general magnitude of travel velocity of 50 miles per hour (80 kilometers per hour), whereby roadway lane and bridge closures, the re-routing of traffic onto alternate routes, the slowing of normal vehicle traffic, or otherwise significant interruptions to the normal and safe flow of traffic and vehicles are at least partially or entirely eliminated.

3. The surface and sub-surface scanning apparatus system of claim 1, wherein the distance sensor provides an accurate reference signal for calibration and correction factors related to the height and data signals received by either or both of the vehicle-mounted high-definition visible and infra-red band cameras.

4. The surface and sub-surface scanning apparatus of claim 1, wherein the processor includes a computer for receiving, storing and processing measurements and video data signals collected by the high-definition visible and infra-red band cameras.

5. The surface and sub-surface scanning apparatus system of claim 4, wherein the computer further includes a high-speed processor and software for integration of video data signals collected by the high-definition visible and infra-red band cameras.

6. The surface and sub-surface scanning apparatus system of claim 5, wherein the computer and high-speed processor further include a digital storage device whereby recorded data and signal outputs are stored.

7. The surface and sub-surface scanning apparatus system of claim 6, wherein the computer and high-speed processor further include digital software programs whereby the recorded data and signal outputs are further processed and formatted for output and analysis.

8. The surface and sub-surface scanning apparatus system of claim 7, further including at least one monitor for displaying the output so that the operator may visualize an internal structural condition of material below the substrate scanned, thus allowing the operator to identify and locate sub-surface structural defects and features apart from superficial or nonstructural defects of the scanned substrate.

9. The surface and sub-surface scanning apparatus system of claim 8, wherein the processor generates an output format consistent with quantitative data related to a calculated percentage of structural defects and their respectively defined physical locations with respect to GPS standards in accordance with customer-defined specifications, the transportation industry, and/or respective governing body standards.

10. A method for evaluating surface and sub-surface conditions of a substrate, the method comprising at least some of the steps of providing, not necessarily in the order listed

a processor for receiving and processing measurements and signals from the group of components (a.-e) of claim 1;

and

a structural boom assembly having a distal end that is movable about the X, Y, Z axes and a proximal end that is attachable to the front, rear or a side of a platform whereby the high-definition visible and infra-red cameras and the surface penetrating radar unit are remotely mounted on a platform at a desired distance from the surface to be scanned so as to encompass a desired field of view (FOV).

11. The surface and sub-surface scanning apparatus of claim 1, further including:

one or more heads for delivering a paint spray that are controlled by the processor so that as the platform moves, the platform can mark the substrate at or above the surface and sub-surface defective areas, thus dispensing with a need to mark manually.

12. The surface and sub-surface scanning apparatus of claim 1, where the components of the scanning and scoping sensor head assembly have six degrees of freedom that include displacement of the scanning and scoping sensor head assembly parallel to X, Y, and Z axes and roll, pitch and yaw motion.