Method and apparatus for automating an inspection process with training

• US 7,995,830 B2
• Filed: 02/17/2010
• Issued: 08/09/2011
• 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:
  US12/706,786
• Publication Number:
  US 20100165097A1
• Time in Patent Office: 538 Days
• Field of Search: 382/141, 382/159, 382/110, 348/84, 348/135, 348/E5.09, 348/125, 348/82, 348/E7.086, 348/E5.047, 348/E5.029, 156/64, 156/73.1, 250/332, 374/121, 374/124, 209/580
• 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. An inspection camera for conducting an equipment inspection process comprising:

a housing;

a lens mounted in an opening in the housing;

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

a microprocessor mounted in the housing and connected to the 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 to provide instruction to a camera operator in preparation for the equipment inspection process, for recording image data received by the microprocessor from the focal plane array, for storing image data from the microprocessor, for storing input from the input device, and for collecting operator validation information to assess an operator'"'"'s qualifications to perform at least one aspect of an inspection process including at least one validation question associated with the at least one aspect of the inspection process and requiring at least one correct answer to the at least one validation question to confirm that the operator is sufficiently knowledgeable about the at least one aspect of the inspection process; and

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

a power distribution system; and

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

2. The inspection camera of claim 1 wherein the focal plane array comprises an infrared focal plane array.

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

(a) loading the programmable camera with an operator proficiency application software routine to provide instruction to a camera operator in preparation for the equipment inspection process, where the operator proficiency application software routine describes equipment normal and abnormal thermal signatures;

(b) running the operator proficiency application software routine using media on-board the programmable camera to instruct the camera operator how to distinguish between normal and abnormal thermal signatures after entering a new survey location; and

(c) using the programmable camera to perform the equipment inspection process including capturing and recording images related to the normal and abnormal thermal signatures.

4. The method of claim 3 wherein the method comprises directing the equipment inspection process using a programmable infrared camera.

5. The method of claim 3 wherein:

step (a) further comprises loading the programmable camera with the operator proficiency application software routine to provide prompting the camera operator to log a fault condition in an operation category and a failure prediction category, and the method further comprises;

(d) running the operator proficiency software to prompt the camera operator to log the fault conditions in the operation category and the failure prediction category.

6. The method of claim 3 wherein:

step (a) further comprises loading the programmable camera with the operator proficiency application software routine to illustrate a location of a particular component in a system, and

step (b) further comprises running the operator proficiency application software routine to illustrate the location of the particular component in the system.

7. The method of claim 3 wherein:

step (a) further comprises loading the programmable camera with the operator proficiency application software routine to train the camera operator to distinguish between incipient failure and normal operation, and

step (b) further comprises running the operator proficiency application software routine to train the camera operator to distinguish between incipient failure and normal operation.

8. The method of claim 3 wherein:

step (a) further comprises loading the programmable camera with the operator proficiency application software routine to instruct the camera operator to assess and document operational conditions that either verify a normal operation or alert to an unexpected operation, and

step (b) further comprises running the operator proficiency application software routine to instruct the camera operator to assess and document operational conditions that either verify the normal operation or alert to the unexpected operation.

9. The method of claim 3 wherein:

step (a) further comprises loading the programmable camera with the operator proficiency application software comprising graphical and textual information to help the camera operator understand a type of equipment, and

step (b) further comprises running the operator proficiency application software routine to help the camera operator understand a type of equipment.

10. The method of claim 9 wherein the type of equipment is a lightning arrestor.

11. The method of claim 9 wherein the type of equipment is a load tap changer.

12. The method of claim 9 wherein the type of equipment is a transformer cooling system.

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

(a) loading the programmable camera with an operator proficiency application software routine to provide instruction to a camera operator in preparation for the equipment inspection process, wherein the operator proficiency application software routine comprises procedural instructions regarding how to set an operational mode of a piece of equipment for a thermal profile inspection;

(b) running the operator proficiency application software routine using media on-board the programmable camera to provide the procedural instructions to the camera operator; and

(c) using the programmable camera to perform the equipment inspection process including capturing and recording images according to the procedural instructions.

14. The method of claim 13 wherein the method comprises directing the equipment inspection process using a programmable infrared camera.

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

(a) loading the programmable camera with an operator proficiency application software routine to provide instruction to a camera operator in preparation for the equipment inspection process, wherein the operator proficiency application software routine comprises information for distinguishing between failure, operation, and design indicators;

(b) running the operator proficiency application software routine using media on-board the programmable camera to provide the information to the camera operator for distinguishing between equipment failure, operation and design indicators; and

(c) using the programmable camera to perform the equipment inspection process including capturing and recording images related to the failure, operation and design indicators.

16. The method of claim 15 wherein the method comprises directing the equipment inspection process using a programmable infrared camera.