Method and apparatus for automating an inspection procedure

• US 7,706,596 B2
• Filed: 10/13/2008
• Issued: 04/27/2010
• 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.
• Primary Examiner(s): Chawan; Sheela C
• Application Number:
  US12/250,312
• Publication Number:
  US 20090097740A1
• Time in Patent Office: 561 Days
• Field of Search: 382/141, 382/143, 382/149, 382/152, 382/135, 382/168, 250/330, 250/332, 250/339.02, 250/339.14, 250/341.6, 250/358.1, 250/341.1, 356/51, 356/237.1, 356/256, 374/5, 374/10, 374/120, 374/121, 374/124, 374/137, 209/577, 348/86, 348/125, 348/135, 348/84, 348/E5.09, 348/E7.086, 348/E5.029, 348/E5.047, 700/95, 700/212
• US Class Current: 382/141
• 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 visible light camera, the method comprising

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

(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,

(c) where loading the programmable camera with a survey template application software routine comprises uploading at least a portion of the survey template application software routine from a software repository, and

(d) where 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 template application software routine using the wireless communication link.

2. The method of claim 1 comprising using a programmable combined visible light and infrared radiation camera.

3. The method of claim 1 comprising using a programmable combined visible light and infrared radiation camera having a single imaging array.

4. A method for directing an inspection process using a programmable visible light camera, the method comprising

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

(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, and

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

5. The method of claim 4 comprising using a programmable combined visible light and infrared radiation camera.

6. The method of claim 4 comprising using a programmable combined visible light and infrared radiation camera having a single imaging array.

7. A method for directing an inspection process using a programmable visible light camera, the method comprising

(a) loading the programmable 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, wherein the running step further comprises running the survey template application software routine to display a checklist.

8. The method of claim 7 comprising using a programmable combined visible light and infrared radiation camera.

9. The method of claim 7 comprising using a programmable combined visible light and infrared radiation camera having a single imaging array.

10. A method for directing an inspection process using a programmable visible light camera, the method comprising

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

(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, and

(c) uploading historical information to the programmable camera.

11. The method of claim 10 comprising using a programmable combined visible light and infrared radiation camera.

12. The method of claim 10 comprising using a programmable combined visible light and infrared radiation camera having a single imaging array.

13. A method for directing an inspection process using a programmable visible light camera, the method comprising

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

(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,

(c) running the survey template application software routine to prompt the operator to perform steps in a survey, and

(d) creating a record of that survey.

14. The method of claim 13 comprising using a programmable combined visible light and infrared radiation camera.

15. The method of claim 13 comprising using a programmable combined visible light and infrared radiation camera having a single imaging array.

16. A programmable camera for inspecting a process comprising:

an image array configured to receive electromagnetic radiation and produce image data;

an input device operatively connected to a microprocessor and configured to generate input data;

a data storage memory operatively connected to the microprocessor, the data storage memory configured for storing application software and for recording the image data and for storing the input data;

a display operatively connected to the microprocessor for displaying at least a portion of the image data, at least a portion of the application software, and at least a portion of the input;

a microprocessor operating system installed in the microprocessor for managing the flow of data between the microprocessor and (a) the image array, (b) the data storage memory, (c) the display, and (d) the input device under the direction of the application software; and

a wireless communication connection for uploading the application software from a software repository and the application software comprises a survey template application software routine that (a) describes at least one aspect of the inspection process and (b) provides instructions to an operator to inspect the vicinity of an area and (c) guides the operator through at least one aspect of the inspection process.

17. The programmable camera of claim 16 wherein the image array comprises a single imaging array for sensing infrared radiation and visible light.

18. A programmable camera for inspecting a process comprising:

an image array configured to receive electromagnetic radiation and produce image data;

an input device operatively connected to a microprocessor and configured to generate input data;

a data storage memory operatively connected to the microprocessor, the data storage memory configured for storing application software and for recording the image data and for storing the input data;

a display operatively connected to the microprocessor for displaying at least a portion of the image data, at least a portion of the application software, and at least a portion of the input;

a microprocessor operating system installed in the microprocessor for managing the flow of data between the microprocessor and (a) the image array, (b) the data storage memory, (c) the display, and (d) the input device under the direction of the application software; and

a global positioning system;

wherein the application software comprises a survey template application software routine that (a) describes at least one aspect of the inspection process and (b) provides instructions to an operator to inspect the vicinity of an area and (c) guides the operator through at least one aspect of the inspection process, and (d) identifies a location within the vicinity of the area using the global positioning system.

19. The programmable camera of claim 18 wherein the image array comprises a single imaging array for infrared radiation and visible light.

20. A programmable camera for inspecting a process comprising:

an image array configured to receive electromagnetic radiation and produce image data;

an input device operatively connected to a microprocessor and configured to generate input data;

a data storage memory operatively connected to the microprocessor, the data storage memory configured for storing application software and for recording the image data and for storing the input data;

a display operatively connected to the microprocessor for displaying at least a portion of the image data, at least a portion of the application software, and at least a portion of the input; and

a microprocessor operating system installed in the microprocessor for managing the flow of data between the microprocessor and (a) the image array, (b) the data storage memory, (c) the display, and (d) the input device under the direction of the application software;

wherein the application software comprises a survey template application software routine that (a) describes at least one aspect of the inspection process, and (b) provides instructions to an operator to inspect the vicinity of an area and (c) guides the operator through at least one aspect of the inspection process and (d) displays a checklist.

21. The programmable camera of claim 20 wherein the image array comprises a single imaging array for sensing infrared radiation and visible light.

22. A programmable camera for inspecting a process comprising:

an image array configured to receive electromagnetic radiation and produce image data;

an input device operatively connected to a microprocessor and configured to generate input data;

a data storage memory operatively connected to the microprocessor, the data storage memory configured for storing application software and for recording the image data and for storing the input data;

a display operatively connected to the microprocessor for displaying at least a portion of the image data, at least a portion of the application software, and at least a portion of the input;

a microprocessor operating system installed in the microprocessor for managing the flow of data between the microprocessor and (a) the image array, (b) the data storage memory, (c) the display, and (d) the input device under the direction of the application software; and

an interface for uploading information to the data storage memory;

wherein the application software comprises a survey template application software routine that (a) describes at least one aspect of the inspection process, and (b) provides instructions to an operator to inspect the vicinity of an area and (c) guides the operator through at least one aspect of the inspection process and (d) uploads historical information to the programmable camera.

23. The programmable camera of claim 22 wherein the image array comprises a single imaging array for sensing infrared radiation and visible light.

24. A programmable camera for inspecting a process comprising:

an image array configured to receive electromagnetic radiation and produce image data;

an input device operatively connected to a microprocessor and configured to generate input data;

a data storage memory operatively connected to the microprocessor, the data storage memory configured for storing application software and for recording the image data and for storing the input data;

a display operatively connected to the microprocessor for displaying at least a portion of the image data, at least a portion of the application software, and at least a portion of the input; and

a microprocessor operating system installed in the microprocessor for managing the flow of data between the microprocessor and (a) the image array, (b) the data storage memory, (c) the display, and (d) the input device under the direction of the application software;

wherein the application software comprises a survey template application software routine that (a) describes at least one aspect of the inspection process and (b) provides instructions to an operator to inspect the vicinity of an area and (c) guides the operator through at least one aspect of the inspection process and (d) prompts the operator to perform steps in a survey and (e) creates a report of the survey.

25. The programmable camera of claim 24 wherein the image array comprises a single imaging array for sensing infrared radiation and visible light.

26. The programmable camera of claim 24 wherein the application software further comprises instructions for an audible or visual safety warning provided to the operator.