Portable multi-function inspection systems and methods

• US 8,242,445 B1
• Filed: 12/13/2010
• Issued: 08/14/2012
• Est. Priority Date: 09/29/2005
• Status: Active Grant

• Current Assignee: Teledyne FLIR LLC (Teledyne Technologies Incorporated)
• Original Assignee: FLIR Systems, Inc. (Teledyne Technologies Incorporated)
• Inventors: Scanlon, Tom, Woolaway, James T., Madding, Robert P.
• Primary Examiner(s): Porta, David
• Assistant Examiner(s): Green, Yara
• Application Number:
  US12/966,951
• Time in Patent Office: 610 Days
• Field of Search: 340/635, 340/588, 250/330, 250/338.1, 250/339.14, 250/339.03, 250/358.1, 250/33.14
• US Class Current: 250/330
• CPC Class Codes: G01J 5/02 Constructional details
• CPC Class Codes: G01J 5/025 Interfacing a pyrometer to an external device or network; User interface
• CPC Class Codes: G01J 5/026 Control of working procedures of a pyrometer, other than calibration; Bandwidth calculation; Gain control
• CPC Class Codes: G01J 5/0265 Handheld, portable ear thermometers G01J5/049
• CPC Class Codes: G01J 5/0275 Control or determination of height or distance or angle information for sensors or receivers
• CPC Class Codes: G01J 5/042 High-temperature environment G01J5/0007, G01J5/0044, G01J5/0088 and G01J5/004 take precedence
• CPC Class Codes: G01J 5/07 Arrangements for adjusting the solid angle of collected radiation, e.g. adjusting or orienting field of view, tracking position or encoding angular position optical collimating elements G01J5/0806
• CPC Class Codes: G01J 5/08 Optical arrangements
• CPC Class Codes: G01J 5/0893 Arrangements to attach devices to a pyrometer, i.e. attaching an optical interface; Spatial relative arrangement of optical elements, e.g. folded beam path G01J5/049 takes precedence
• CPC Class Codes: G01J 5/0896 using a light source, e.g. for illuminating a surface
• CPC Class Codes: G01R 31/308 using non-ionising electromagnetic radiation, e.g. optical radiation investigating or analysing materials by the use of optical means G01N21/00; image analysis G06T7/00

Abstract

In accordance with at least one embodiment of the present invention, a portable inspection system is disclosed to capture inspection data, such as for example an infrared image, sound information, and/or electrical measurement information. The inspection data may be securely recorded (e.g., with an encryption algorithm) along with associated information, which may include for example date, time, system settings, operator identification, and location.

Claims

1. An inspection system, comprising:

an infrared camera adapted to capture infrared image data, wherein the infrared camera comprises;

an infrared detector configured to receive thermal energy and generate the infrared image data;

a memory configured to store the infrared image data;

a display configured to display the infrared image data; and

a controller, coupled to the display, the memory, and the infrared detector, configured to control the infrared detector and process the infrared image data to store in the memory and/or to view on the display;

an extendable boom having a proximate end and a distal end;

a sensor unit, coupled to the distal end of the extendable boom, having one or more sensors adapted to provide sensor information, the sensor unit configured to wirelessly communicate with the infrared camera to provide the sensor information;

wherein the one or more sensors comprise an electrical measurement device, configured to measure an electrical parameter of an inspection target to provide as an electrical parameter value to the sensor unit to provide as the sensor information to the infrared camera, and an extendable boom microphone adapted to capture sound data from the inspection target to provide as the sensor information to the infrared camera, and wherein the infrared camera comprises;

an infrared camera microphone adapted to capture sound data from the inspection target; and

an audio processing unit adapted to analyze the sound data from the inspection target provided by the extendable boom microphone and the infrared camera microphone to determine a location of a gas leak associated with the inspection target and to provide visual cues based on the sound data to the display to direct the user of the inspection system to the gas leak.

2. The inspection system of claim 1, wherein the infrared camera comprises:

a laser rangefinder configured to provide a distance measurement between the infrared camera and the inspection target; and

wherein the controller is configured to receive the distance measurement and provide a safe distance indication based on the distance measurement for viewing on the display by the user of the inspection system, wherein the safe distance indication provides a color-coded warning for a degree of hazard to the user'"'"'s safety based on the distance measurement and safe distance values stored in the memory.

3. The inspection system of claim 2, wherein the color-coded warning for a degree of hazard provides a first color to indicate a safe distance, a second color to indicate a minimum distance range, and a third color to indicate a less than safe minimum distance, and wherein the controller comprises a processor adapted to execute instructions stored in the memory.

4. The inspection system of claim 1, wherein the one or more sensors comprise a gas measurement device adapted to detect a presence and/or a concentration of at least one gas in a vicinity of the inspection target to provide as a gas measurement value to the sensor unit to provide as the sensor information to the infrared camera.

5. The inspection system of claim 4, wherein the electrical measurement device comprises a clamp meter, an amp meter, and/or a multimeter, wherein the gas measurement device comprises a solid-state chemical sensor, a photometric gas sensor, a chemical analysis unit, and/or a gas chromatography unit, wherein the extendable boom is couplable to the infrared camera, and wherein the proximate end is configured to be held by a user of the inspection system.

6. The inspection system of claim 5, wherein the infrared camera further comprises:

a target identification unit configured to obtain target identification information associated with the inspection target;

a position determination unit configured to obtain location and orientation information of the inspection system;

an operator identification unit configured to obtain user information associated with the user of the inspection system; and

wherein the controller is adapted to provide a cryptographic signature for the infrared image data along with the sensor information, the target identification information, the location and orientation information, and the user information.

7. The inspection system of claim 4, wherein a library of photometric and/or chromatographic detection profiles corresponding to various types of gases are stored in the memory to compare to the gas measurement value to identify the type of gas associated with the inspection target.

8. The inspection system of claim 1, wherein the memory is adapted to store at least one equation for performing computations based on temperature and electrical load measurements, and wherein the controller is adapted to execute the at least one equation and generate a result based on at least one temperature measurement derived from the infrared image data, at least one electrical load measurement performed by the electrical measurement device and stored in the memory, and a load correction factor.

9. The inspection system of claim 8, wherein the at least one equation comprises a first equation for determining a temperature estimate for a given electrical load and a second equation for determining an electrical load estimate for a given temperature.

10. The inspection system of claim 1, wherein the infrared camera is adapted to capture a first infrared image data of a target identifier associated with the inspection target, and wherein the controller is adapted to process the first infrared image data to extract target identifier information based on the target identifier.

11. The inspection system of claim 1, further comprising an infrared camera housing, wherein the infrared detector, the memory, the display, and the controller are within the housing, wherein the visual cues comprise pan and tilt pointing directions to a user of the inspection system, and wherein the audio processing unit is adapted to provide information based on the sound data to annotate one or more images of the infrared image data to store in the memory as to the location of the gas leak, and wherein the proximate end of the extendable boom is configured to be held by a user of the inspection system.

12. An inspection system, comprising:

an infrared camera adapted to capture infrared image data, wherein the infrared camera comprises;

an infrared detector configured to receive thermal energy and generate the infrared image data;

a memory configured to store the infrared image data;

a display configured to display the infrared image data; and

a controller, coupled to the display, the memory, and the infrared detector, configured to control the infrared detector and process the infrared image data to store in the memory and/or to view on the display,

a sensor unit having one or more sensors adapted to provide sensor information, the sensor unit configured to wirelessly communicate with the infrared camera to provide the sensor information for viewing on the display along with the infrared image data, and wherein the one or more sensors comprise a parameter measurement device configured to measure a parameter of an inspection target to provide as a parameter value to the sensor unit to provide as the sensor information to the infrared camera;

an extendable boom couplable to the infrared camera, the extendable boom having a proximate end and a distal end, wherein the proximate end is configured to be held by a user of the inspection system, and wherein the sensor unit is coupled to the distal end of the extendable boom;

wherein the one or more sensors comprise an extendable boom microphone adapted to capture sound data from the inspection target to provide as the sensor information to the infrared camera, and wherein the infrared camera comprises;

an infrared camera microphone adapted to capture sound data from the inspection target; and

an audio processing unit adapted to analyze the sound data from the inspection target provided by the extendable boom microphone and the infrared camera microphone to determine a location of a gas leak associated with the inspection target and to provide visual cues based on the sound data to the display to direct the user of the inspection system to the gas leak.

13. The inspection system of claim 12, wherein the infrared camera comprises:

a laser rangefinder configured to provide a distance measurement between the infrared camera and the inspection target;

wherein the controller is configured to receive the distance measurement and provide a safe distance indication based on the distance measurement for viewing on the display by the user of the inspection system, wherein the safe distance indication provides a color-coded warning for a degree of hazard to the user'"'"'s safety based on the distance measurement and safe distance values stored in the memory; and

wherein the color-coded warning for a degree of hazard provides a first color to indicate a safe distance and at least a second color to indicate a minimum and/or less than safe minimum distance range.

14. The inspection system of claim 12, wherein the one or more sensors comprise:

an electrical measurement device configured to measure an electrical parameter of an inspection target to provide as an electrical parameter value to the sensor unit to provide as the sensor information to the infrared camera; and

a gas measurement device adapted to detect a presence and/or a concentration of at least one gas in a vicinity of the inspection target to provide as a gas measurement value to the sensor unit to provide as the sensor information to the infrared camera, wherein the electrical measurement device comprises a clamp meter, an amp meter, and/or a multimeter, and wherein the gas measurement device comprises a solid-state chemical sensor, a photometric gas sensor, a chemical analysis unit, and/or a gas chromatography unit.

15. The inspection system of claim 12, wherein the infrared camera further comprises:

a target identification unit configured to obtain target identification information associated with the inspection target;

a position determination unit configured to obtain location and orientation information of the inspection system;

an operator identification unit configured to obtain user information associated with the user of the inspection system; and

wherein the controller is adapted to provide a cryptographic signature for the infrared image data along with the sensor information, the target identification information, the location and orientation information, and the user information.

16. The inspection system of claim 12,

wherein the one or more sensors comprise an electrical measurement device configured to measure an electrical parameter of an inspection target to provide as an electrical parameter value to the sensor unit to provide as the sensor information to the infrared camera;

and

wherein the memory is adapted to store at least one equation for performing computations based on temperature and electrical load measurements, and wherein the controller is adapted to execute the at least one equation and generate a result based on at least one temperature measurement derived from the infrared image data, at least one electrical load measurement performed by the electrical measurement device and stored in the memory, and a load correction factor, and wherein the at least one equation comprises a first equation for determining a temperature estimate for a given electrical load and a second equation for determining an electrical load estimate for a given temperature.

17. A method of inspecting an inspection target with the inspection system of claim 12, wherein the inspection system is a portable inspection system, the method comprising:

capturing infrared image data of the inspection target with the portable inspection system;

processing the infrared image data within the portable inspection system;

storing the infrared image data within the memory of the portable inspection system;

displaying the infrared image data for viewing by a user on the display of the portable inspection system;

extending the boom of the portable inspection system towards the inspection target to capture, from a distal end of the boom, sensor information of the inspection target;

communicating wirelessly the sensor information;

receiving the sensor information; and

displaying the sensor information with the infrared image data for viewing by the user on the display of the portable inspection system.

18. The method of claim 17, comprising:

determining a distance measurement between the portable inspection system and the inspection target;

displaying the distance measurement with the infrared image data for viewing by the user of the portable inspection system; and

providing a color-coded warning for a degree of hazard to the user'"'"'s safety based on the distance measurement and safe distance values.

19. The method of claim 17, wherein the sensor information comprises an electrical measurement and/or a gas measurement based on a presence and/or a concentration of at least one gas in a vicinity of the inspection target.

20. The method of claim 17, wherein the sensor information comprises sound data from the inspection target, and wherein the method comprises displaying, based on the sound data, pointing cues to assist an operator of the portable inspection system to determine a location of a gas leak associated with the inspection target.

21. The method of claim 17, comprising:

storing at least one equation for performing computations based on temperature and electrical load measurements; and

calculating a result based on the at least one equation, at least one temperature measurement derived from the infrared image data, and at least one electrical load measurement from the sensor information.

22. An inspection system, comprising:

an infrared camera adapted to capture infrared image data, wherein the infrared camera comprises;

an infrared detector configured to receive thermal energy and generate the infrared image data;

a memory configured to store the infrared image data;

a laser rangefinder configured to provide a distance measurement between the infrared camera and an inspection target;

a display configured to display the infrared image data; and

a controller, coupled to the display, the memory, and the infrared detector, configured to control the infrared detector and process the infrared image data to store in the memory and/or to view on the display; and

a sensor unit having one or more sensors adapted to provide sensor information, the sensor unit configured to wirelessly communicate with the infrared camera to provide the sensor information for viewing on the display along with the infrared image data, and wherein the one or more sensors comprise a parameter measurement device configured to measure a parameter of the inspection target to provide as a parameter value to the sensor unit to provide as the sensor information to the infrared camera;

wherein the controller is configured to receive the distance measurement and provide a safe distance indication based on the distance measurement for viewing on the display by the user of the inspection system, wherein the safe distance indication provides a color-coded warning for a degree of hazard to the user'"'"'s safety based on the distance measurement and safe distance values stored in the memory; and

wherein the color-coded warning for a degree of hazard provides a first color to indicate a safe distance and at least a second color to indicate a minimum and/or less than safe minimum distance range.

23. The inspection system of claim 22, wherein the one or more sensors comprise:

an electrical measurement device configured to measure an electrical parameter of an inspection target to provide as an electrical parameter value to the sensor unit to provide as the sensor information to the infrared camera; and

a gas measurement device adapted to detect a presence and/or a concentration of at least one gas in a vicinity of the inspection target to provide as a gas measurement value to the sensor unit to provide as the sensor information to the infrared camera, wherein the electrical measurement device comprises a clamp meter, an amp meter, and/or a multimeter, and wherein the gas measurement device comprises a solid-state chemical sensor, a photometric gas sensor, a chemical analysis unit, and/or a gas chromatography unit.

24. The inspection system of claim 23, wherein the memory is adapted to store at least one equation for performing computations based on temperature and electrical load measurements, and wherein the controller is adapted to execute the at least one equation and generate a result based on at least one temperature measurement derived from the infrared image data, at least one electrical load measurement performed by the electrical measurement device and stored in the memory, and a load correction factor, and wherein the at least one equation comprises a first equation for determining a temperature estimate for a given electrical load and a second equation for determining an electrical load estimate for a given temperature.

25. The inspection system of claim 22, wherein the one or more sensors comprise:

a target identification unit configured to obtain target identification information associated with the inspection target;

a position determination unit configured to obtain location and orientation information of the inspection system;

an operator identification unit configured to obtain user information associated with the user of the inspection system; and

wherein the controller is adapted to provide a cryptographic signature for the infrared image data along with the sensor information, the target identification information, the location and orientation information, and the user information.

26. The inspection system of claim 22, further comprising:

an extendable boom couplable to the infrared camera, the extendable boom having a proximate end and a distal end, wherein the proximate end is configured to be held by a user of the inspection system, and wherein the sensor unit is coupled to the distal end of the extendable boom;

wherein the one or more sensors comprise an extendable boom microphone adapted to capture sound data from the inspection target to provide as the sensor information to the infrared camera, and wherein the infrared camera comprises;

an infrared camera microphone adapted to capture sound data from the inspection target; and

an audio processing unit adapted to analyze the sound data from the inspection target provided by the extendable boom microphone and the infrared camera microphone to determine a location of a gas leak associated with the inspection target and to provide visual cues based on the sound data to the display to direct the user of the inspection system to the gas leak.

27. A method of inspecting an inspection target with the inspection system of claim 22, the method comprising:

capturing infrared image data of the inspection target with the inspection system;

processing the infrared image data within the inspection system;

storing the infrared image data within the memory of the inspection system; and

displaying the infrared image data for viewing by a user on the display of the inspection system.

28. The method of claim 27, further comprising:

determining a distance measurement between the portable inspection system and the inspection target; and

displaying the distance measurement and the safe distance indication along with the infrared image data for viewing by the user of the portable inspection system.

29. The method of claim 28, wherein the sensor information comprises an electrical measurement and/or a gas measurement based on a presence and/or a concentration of at least one gas in a vicinity of the inspection target.

30. The method of claim 27, wherein the sensor information comprises sound data from the inspection target, and wherein the method comprises displaying, based on the sound data, pointing cues to assist an operator of the portable inspection system to determine a location of a gas leak associated with the inspection target.