Method of automating a thermographic inspection process

• US 20050281456A1
• Filed: 06/18/2004
• Published: 12/22/2005
• Est. Priority Date: 06/18/2004
• Status: Active Grant

• Current Assignee: Computational Systems Incorporated (Emerson Electric Company)
• Original Assignee: CSI Technology Incorporated (Emerson Electric Company)
• Inventors: Garvey, Raymond E.
• Granted Patent: US 7,454,050 B2
• Time in Patent Office: Days
• US Class Current: 382/159
• CPC Class Codes: G01N 25/72 Investigating presence of flaws

Abstract

A process for using a hand-held infrared inspection system incorporating on-board training, on-board validation, on-board operator certification, on-board reporting information, or on-board survey instructions. Improved methods for automating area surveys are provided through exception-driven surveillance practices. Imbedded information enables less experienced operators to use more sophisticated devices more effectively. Validation or certification assures operator knowledge or ability. Multilevel classification of anomalies aids in automated analysis and report generation.

Claims

1. A method for directing an inspection process using a programmable infrared camera, the method comprising:

(a) loading the programmable infrared camera with an inspection training application software routine, where the inspection training application software routine describes at least one aspect of the inspection process, and

(b) running the inspection training application software routine to provide training information to an operator regarding how to perform at least one aspect of the inspection process.

2. The method of claim 1 for directing an inspection process using a programmable infrared camera, wherein the method further comprises:

(c) loading the programmable infrared camera with an operator validation application software routine where the operator validation application software routine includes at least one validation question associated with at least one aspect of the inspection process,

(d) running the operator validation application software routine to pose at least one validation question to the operator, and

(e) using the programmable infrared camera to indicate the operator'"'"'s response to at least one posed validation question.

3. The method of claim 1 for directing an inspection process using a programmable infrared camera, wherein the method further comprises:

(c) loading the programmable infrared camera with a survey results application software routine where the survey results application software routine defines findings for at least one aspect of the inspection process in terms of a plurality of dissimilar classifications and a plurality of grading levels for each classification, and

(d) running the survey results application software routine to assign at least one of the grading levels to at least one of the classifications of at least one of the findings.

4. The method of claim 1 for directing an inspection process using a programmable infrared camera, wherein the method further comprises:

(c) loading the programmable infrared camera with a survey template application software routine where the survey template application software routine describes at least one area survey parameter for conducting at least one aspect of the inspection process, and

(d) running the survey template application software routine to describe at least one area survey parameter to the operator.

5. The method of claim 1 for directing an inspection process using a programmable infrared camera where

(a) loading the inspection training application software routine comprises loading audio visual information to describe at least one aspect of an inspection process, and

(b) running the inspection training application software routine comprises running the inspection training application software routine to provide the audio visual information to the operator regarding how to perform at least one aspect of the inspection process.

6. The method of claim 1 for directing an inspection process using a programmable infrared camera where

(a) loading an inspection training application software routine comprises loading an inspection training application software routine comprising interactive features to describe at least one aspect of an inspection process, and

(b) running the inspection training application software routine comprises running the inspection training application software routine comprising interactive features to provide training information to an operator regarding how to perform at least one aspect of the inspection process.

7. The method of claim 1 for directing an inspection process using a programmable infrared camera where

(a) loading an inspection training application software routine comprises loading an inspection training application software routine comprising a procedural instruction to describe at least one aspect of an inspection process, and

(b) running the inspection training application software routine comprises running the inspection training application software routine comprising a procedural instruction to describe to the operator how to perform at least one aspect of the inspection process.

8. The method of claim 1 for directing an inspection process using a programmable infrared camera where

(a) loading an inspection training application software routine comprises loading an inspection training application software routine comprising a safety warning instruction that describes at least one aspect of an inspection process, and

(b) running the inspection training application software routine comprises running the inspection training application software routine comprising the safety warning instruction that describes to the operator how to perform at least one aspect of the inspection process.

9. The method of claim 1 for directing an inspection process using a programmable infrared camera where loading the camera with an inspection training application software routine comprises uploading at least a portion of the inspection training application software routine from a software repository prior to conducting an inspection.

10. The method of claim 9 for directing an inspection process further comprising automatically identifying and uploading at least a portion of the inspection training software routine.

11. A method for directing an inspection process using a programmable infrared camera, the method comprising:

(a) loading the programmable infrared camera with an operator validation application software routine where the operator validation application software routine comprises at least one validation question associated with at least one aspect of the inspection process, and

(b) running the operator validation application software routine to pose at least one validation question to the operator, and

(c) using the programmable infrared camera to indicate the operator'"'"'s response to at, least one posed validation question.

12. The method of claim 11 for directing an inspection process using a programmable infrared camera, wherein the method further comprises:

(d) loading the programmable infrared camera with a survey results application software routine where the survey results application software routine defines findings for at least one aspect of the inspection process in terms of a plurality of dissimilar classifications and a plurality of grading levels for each classification, and

(e) running the survey results application software routine to assign at least one of the grading levels to at least one of the classifications of at least one of the findings.

13. The method of claim 12 for directing an inspection process using a programmable infrared camera comprises using a programmable infrared camera with a wireless communication link, and further comprises communicating at least one of the grading levels assigned to at least one of the classifications of at least one of the findings to an external station using the wireless communication link.

14. The method of claim 11 for directing an inspection process using a programmable infrared camera wherein the method further comprises:

(d) loading the programmable infrared camera with a survey template application software routine where the survey template application software routine describes at least one area survey parameter for conducting at least one aspect of the inspection process, and

(e) running the survey template application software routine to describe at least one area survey parameter to the operator.

15. The method of claim 11 for directing an inspection process using a programmable infrared camera where

(a) loading an operator validation application software routine comprises loading an operator validation application software routine including a sufficient number of validation questions to certify the operator for at least one aspect of the inspection process based on the operator'"'"'s response, including a certification algorithm for determining whether the operator has correctly answered a sufficient number of the validation questions to be certified, and

(b) running the operator validation application software routine comprises running the operator validation application software routine to pose the sufficient number of validation questions to certify the operator for at least one aspect of the inspection process based on the operator'"'"'s response, and

(c) running the certification algorithm to determine whether the operator has answered a sufficient number of the validation questions to be certified.

16. The method of claim 11 for directing an inspection process using a programmable infrared camera where

(a) loading the operator validation application software routine comprises loading the operator validation application software routine including at least one validation question associated with a safety aspect of the inspection process, and

(b) running the operator validation application software routine comprises running the operator validation application software routine to pose the at least one validation question associated with a safety aspect of the inspection process to the operator, and

(c) using the programmable infrared camera to indicate the operator'"'"'s response to the at least one posed validation question comprises using the programmable infrared camera to indicate the operator'"'"'s response to the at least one posed validation question associated with a safety aspect of the inspection process.

17. The method of claim 11 for directing an inspection process using a programmable infrared camera where loading the camera with an operator validation application software routine comprises uploading at least a portion of the operator validation application software routine from a software repository prior to conducting an inspection.

18. The method of claim 17 for directing an inspection process using a programmable infrared camera further comprises using a programmable infrared camera with a wireless communication link and further comprises uploading at least a portion of the operator validation application software routine from a software repository using the wireless communication link prior to conducting an inspection.

19. The method of claim 11 for directing an inspection process using a programmable infrared camera comprises using a programmable infrared camera with a wireless communication link, and further comprises communicating the operator'"'"'s response to the at least one validation question to an external station using the wireless communication link.

20. The method of claim 11 for directing an inspection process further comprising:

(d) authorizing an inspection after acceptable validation information is received.

21. A method for directing an inspection process using a programmable camera, the method comprising

(a) loading the camera with a survey results application software routine where the survey results application software routine defines at least one finding for at least one aspect of the inspection process in terms of multi-vector representation of a plurality of dissimilar classifications and defines a plurality of grading levels for at least one classification, and

(b) running the survey results application software routine to assign at least one grading level to at least one of the classifications of at least one of the findings.

22. The method of claim 21 for directing an inspection process using a programmable camera wherein the method further comprises:

(c) loading the camera with an inspection training application software routine, where the inspection training application software routine describes at least one aspect of an inspection process, and

(d) running the inspection training application software routine to provide training information to the operator regarding how to perform at least one aspect of the inspection process.

23. The method of claim 21 for directing an inspection process using a programmable camera wherein the method further comprises:

(c) loading the camera with an operator validation application software routine where the operator validation application software routine comprises at least one validation question associated with at least one aspect of the inspection process, and

(d) running the operator validation application software routine to pose at least one validation question to the operator and using the camera to indicate the operator'"'"'s response to at least one posed validation question.

24. The method of claim 23 for directing an inspection process using a programmable camera comprises using a programmable camera with a wireless communication link and further comprises wirelessly communicating the operator'"'"'s response to at least one posed validation question at least one of the operator'"'"'s responses to an external station.

25. The method of claim 21 for directing an inspection process using a programmable camera wherein the method further comprises

(c) loading the camera with a survey template application software routine where the survey template application software routine describes at least one area survey parameter for conducting at least one aspect of the inspection process, and

(d) running the survey template application software routine to describe at least one area survey parameter to the operator.

26. The method of claim 21 for directing an inspection process where loading the camera with survey results application software comprises loading survey results application software that defines at least one finding for at least one aspect of the inspection process in terms of multi-vector representation of a plurality of dissimilar classifications comprising “

failure,”

“

operation,” and

“

design.”

27. The method of claim 21 for directing an inspection process where loading the camera with a survey results application software routine comprises loading survey results application software that defines a plurality of grading levels comprising “

normal,”

“

alert,” and

“

fault.”

28. The method of claim 21 for directing an inspection process wherein loading the camera with a survey results application software routine comprises loading survey results application software that defines at least one finding for at least one aspect of the inspection process in terms of multi-dimensional representation that is at least in part numerical.

29. The method of claim 21 for directing an inspection process wherein loading the camera with a survey results application software routine comprises loading survey results application software that defines at least one finding for at least one aspect of the inspection process in terms of multi-vector representation that is at least in part graphical.

30. The method of claim 21 for directing an inspection process using a programmable camera further comprising

(c) loading the camera with a survey results application software routine comprises loading an algorithm for automatically recommending at least one follow-on step based upon assigning at least one grading level to at least one classification of at least one finding, and

(d) running the survey results application software routine comprises running the software routine algorithm and automatically recommending a follow-on step.

31. The method of claim 21 for directing an inspection process using a programmable camera where loading the camera with a survey results application software routine comprises uploading at least a portion of the survey results application software routine from a software repository prior to conducting an inspection.

32. The method of claim 31 for directing an inspection process directing an inspection process using a programmable camera comprises using a programmable camera with a wireless communication link and further comprises wirelessly uploading at least a portion of the survey results application software routine from a software repository prior to conducting an inspection.

33. The method of claim 21 for directing an inspection process using a programmable camera comprises using a programmable camera with a wireless communication link and further comprises wirelessly communicating at least one grading level assigned to at least one classification of at least one finding to an external station.

34. The method of claim 21 for directing an inspection process wherein the programmable camera is a programmable infrared camera.

46. The method of claim 21 further comprising:

(c) using the survey results application software routine to monitor the progression of a failure over time.

35. A method for directing an inspection process using a programmable infrared camera, the method comprising

(a) loading the programmable infrared camera with a survey template application software routine where the survey template application software routine describes at least one aspect of the inspection process, and

(b) running the survey template application software routine to instruct an operator to inspect the vicinity of an area and to guide the operator through the at least one aspect of the inspection process.

36. The method of claim 35 for directing an inspection process using a programmable infrared camera, wherein the method further comprises:

(c) loading the programmable infrared camera with a survey results application software routine where the survey results application software routine defines findings for at least one aspect of the inspection process in terms of a plurality of dissimilar classifications and a plurality of grading levels for each classification, and

(d) running the survey results application software routine to assign at least one of the grading levels to at least one of the classifications of at least one of the findings.

37. The method of claim 36 for directing an inspection process using a programmable infrared camera comprises using a programmable infrared camera with a wireless communication link and further comprises wirelessly communicating at least one of the classifications of at least one of the findings to an external station.

38. The method of claim 35 for directing an inspection process further comprising (c) providing exception identification information to the operator.

39. The method of claim 35 for directing an inspection process wherein step (a) further comprises loading the camera with a survey template application software routine that describes at least one area survey parameter comprising a graphical depiction of a component for conducting at least one aspect of the inspection process and step (b) further comprises running the survey template application software to describe the graphical depiction of the component to an operator.

40. The method of claim 35 for directing an inspection process using a programmable infrared camera where loading the camera with a survey template application software routine is accomplished by uploading at least a portion of the survey template application software routine from a software repository prior to conducting an inspection.

41. The method of claim 40 for directing an inspection process where using a programmable infrared camera comprises using a programmable infrared camera with a wireless communication link and further comprises wirelessly uploading at least a portion of the survey template application software routine using the wireless communication link.

42. The method of claim 40 for directing an inspection process using a programmable infrared camera where loading the camera with a survey template application software routine is accomplished by uploading at least a portion of the survey template application software routine from a software repository prior to conducting an inspection.

47. The method of claim 35 wherein:

the loading step further comprises loading the programmable infrared camera with a survey template application software routine where the survey template application software describes at least one survey parameter, and

the running step further comprises running the survey template application software to describe the at least one survey parameter to the operator.

48. The method of claim 47 wherein the at least one survey parameter comprises a location.

49. The method of claim 48 further comprising:

(c) identifying the location using either a visual method or a tagging system.

50. The method of claim 35 further comprising:

(c) identifying a location within the vicinity of the area using a global positioning system.

51. The method of claim 35 further comprising:

(c) obtaining and using multiple measurements over time to produce a trend.

52. The method of claim 35 further comprising:

(c) using the programmable infrared camera to associate and record observations or other data with at least one area survey parameter.

53. The method of claim 52 wherein the at least one area survey parameter comprises time.

54. The method of claim 35 wherein the running step further comprises running the survey template application software routine to display a checklist.

55. The method of claim 35 further comprising:

(c) receiving information during the inspection process and downloading the information.

56. The method of claim 35 further comprising:

(c) uploading historical information to the programmable infrared camera.

57. The method of claim 35 further comprising:

(c) running the survey template application software routine to prompt the operator to perform steps in an infrared survey; and

(d) creating a record of that survey.

58. The method of claim 35 further comprising:

(c) using the programmable infrared camera to document normal operational conditions in the vicinity of the area.

43. An infrared inspection camera for conducting an inspection process comprising:

a housing;

a lens mounted in an opening in the housing;

an infrared focal plane array mounted in the housing in a position to receive infrared radiation from the lens;

a microprocessor mounted in the housing and connected to the infrared focal play array for receiving image data from the focal plane array;

an input device operatively connected to the microprocessor to accept input data from an operator;

a data storage memory operatively connected to the microprocessor, the data storage memory for storing operator proficiency application software that provides training information, for recording image data received by the microprocessor from the infrared focal plane array, for storing image data from the microprocessor, and for storing input from the input device; and

a display operatively connected to the microprocessor for displaying the image data, the training information, and the input data to the operator;

a power distribution system; and

a microprocessor operating system installed in the microprocessor for managing the flow of data between the microprocessor and (a) the infrared focal plane array, (b) the data storage memory, (c) the display, and (d) the input device under the direction of the operator proficiency application software.

44. The infrared inspection camera of claim 43 wherein the operator proficiency application software collects validation information.

45. The infrared inspection camera of claim 43 wherein the operator proficiency application software collects certification information.